PC60-7 Shop Manual (WM)

YEBM200600
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PC60-7
omat
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MACHNE MODEL
PC60-7
.com
SERIAL NUMBER
DBK0001 and up
PC60-7B DBKB0001 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.
• PC60-7 mount the 4D102-1 and 4D95LE-2 engine.

For details of the engine, see the 102 Series 95-2 Engine Shop Manual.
• For the PC60-7 for Norway (serial No. 55720 and up), the parts
which different from the standard model have been put together
and added as Section 50. For the common parts, see this manual.
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YEBM200600
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komat
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MACHINE MODEL SERIAL NUMBER

PC60-7 DBK0001 and up
PC60-7B DBKB0001 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.
• PC60-7 mount the 4D102-1 and 4D95LE-2 engine.

For details of the engine, see the 102 and 95-2 Series Engine Shop Manual.
• For the PC60-7 for Norway (Serial No. 55720 and up), the parts which different from the
standard model have been put together and added as Section 50. For the common parts, see
this manual.
© 2002
All Rights Reserved 00-1
Printed in P. R. China 06-03 ⑨
SAFETY SAFETY NOTICE
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
50 OTHER SPECIFICATION ............................................................................................ 50-1

PC60-7 (For Norway)
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90 OTHERS .................................................................................................................................. 90-1
00-2 PC60-7
③
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the ○ Page to be newly added Add
table below
● Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously

revised or made additions.
LIST OF REVISED PAGES

Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision Mark Page Revision
number number number number number
• 00-1 ⑨ 10-3 10-43 ③ 10-85 10-119
00-2 ③ 10-4 10-44 ③ 10-86 ⑧ 10-120
• 00-2-1 ⑨ 10-5 10-45 ③ 10-87 10-121
• 00-2-2 ⑨ 10-6 10-46 ③ 10-88 10-122
• 00-2-3 ⑨ 10-7 ⑧ 10-47 10-89 ③ 10-123
00-3 10-7-1 ⑧ 10-48 ③ 10-89-1 ⑧ 10-124
00-4 10-8 10-49 ③ 10-89-2 ⑧ 10-125
00-5 10-9 10-50 ③ 10-89-3 ⑧ 10-126
00-6 10-10 10-51 10-89-4 ⑧ 10-127
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00-7 10-11 10-52 10-89-5 ⑧ 10-128
00-8 10-12 10-53 ③ 10-89-6 ⑧ 10-129
00-9 10-13 ③ 10-54 10-89-7 ⑧ 10-130
00-10 10-14 ③ 10-56 ③ 10-89-8 ⑧ 10-131
00-11 10-15 10-57 ③ 10-90 ③ 10-132
00-12 10-16 10-58 10-90-1 ③ 10-133
00-13 10-17 10-59 10-90-2 ③ 10-134
00-14 10-18 10-60 10-91 ③ 10-135
00-15 10-20 ③ 10-61 10-92 ③ 10-136 ③
00-16 10-21 10-62 10-93 10-137
00-17 10-22 10-63 10-94 ③ 10-138
00-18 10-23 10-64 10-95 ③ 10-139
00-19 10-24 10-65 10-96 10-140 ③
00-20 10-25 10-66 • 10-97 ⑨ 10-141
00-21 10-26 10-67 10-98 10-142
00-22 10-27 10-68 • 10-100 ⑨ 10-143
10-28 10-69 10-101 10-144
01-1 10-29 10-70 10-102 10-145
01-2 10-30 ③ 10-71 10-103 10-146
01-4 ③ 10-32 10-72 10-104 ③
• 01-5 ⑨ 10-33 10-73 10-105 20-1 ⑤
01-5-1 ③ 10-34 10-74 10-106 ③ 20-2 ⑤
• 01-5-2 ⑨ 10-35 10-75 10-107 ③ 20-2-1 ⑤
• 01-6 ⑨ 10-36 10-76 ③ 10-108 ③ 20-3 ⑤
01-7 10-37 ③ 10-77 10-109 ③ 20-4 ⑥
01-8 ③ 10-38 10-78 ③ 10-110 ③ 20-5 ①
01-9 10-39 10-79 10-112 ③ 20-6 ①
10-40 ③ 10-80 ③ 10-113 20-7 ①
10-1 10-41 ③ 10-81 10-114 20-8 ①
• 10-2 ⑨ 10-42 ③ 10-82 ③ 10-116 20-9 ①
• 10-2-1 ⑨ 10-42-1 ③ 10-83 • 10-117 ⑨ 20-10 ⑤
ο 10-2-2 ⑨ 10-42-2 ③ 10-84 ③ 10-118 20-11 ⑤
PC60-7 00-2-1
⑨
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
20-12 ⑤ 20-206 ① 20-309 ① 20-412 ① 30-37 ④
20-101 ⑤ 20-207 ① 20-310 ① 20-413 ① 30-37-1 ④
20-102 ⑤ 20-208 ① 20-311 ① 20-414 ① 30-37-2 ④
20-103 ⑤ 20-209 ① 20-312 ① 20-451 ① 30-37-3 ④
20-104 ⑤ 20-210 ① 20-313 ① 20-452 ① 30-37-4 ④
20-105 ⑤ 20-211 ① 20-314 ① 20-453 ① 30-38 ④
20-106 ⑤ 20-212 ① 20-315 ① 20-454 ① 30-39 ②
20-107 ⑤ 20-213 ⑤ 20-316 ① 20-456 ① 30-40 ④
20-108 ⑤ 20-214 ① 20-317 ① 20-457 ① 30-40-1 ④
20-109 ⑤ 20-215 ⑤ 20-318 ① 20-458 ① 30-40-2 ④
20-109-1 ⑤ 20-216 ⑤ 20-319 ① 20-459 ① 30-41 ②
20-109-2 ⑤ 20-216-1 ⑤ 20-320 ① 30-42 ②
20-109-3 ⑤ 20-216-2 ⑤ 20-321 ① 30-1 ⑥ 30-43 ②
20-109-4 ⑤ 20-216-3 ⑤ 20-322 ① 30-2 ⑥ 30-44 ②
20-109-5 ⑤ 20-216-4 ⑤ 20-323 ① 30-3 ② 30-45 ②
20-109-6 ⑤ 20-216-5 ⑤ 20-324 ① 30-4 ② 30-46 ②
20-109-7 ⑤ 20-217 ① 20-351 ① 30-5 ② 30-46-2 ⑥
20-109-8 ⑤ 20-218 ① 20-352 ① 30-6 ② 30-46-3 ⑥
20-109-9 ⑤ 20-219 ① 20-353 ① 30-7 ② 30-46-4 ⑥
20-109-10 ⑤ 20-220 ① 20-354 ⑤ 30-8 ⑥ 30-46-5 ⑥
20-109-11 ⑤ 20-221 ① 20-355 ① 30-8-1 ⑥ 30-46-6 ⑥
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20-109-12 ⑤ 20-222 ① 20-356 ① 30-9 ② 30-46-7 ⑥
20-109-13 ⑤ 20-223 ① 20-357 ① 30-10 ② 30-46-8 ⑥
20-110 ① 20-224 ① 20-358 ① 30-11 ② 30-46-9 ⑥
20-111 ① 20-225 ① 20-359 ① 30-11-1 ⑥ 30-46-10 ⑥
20-112 ① 20-226 ① 20-360 ① 30-11-2 ⑥ 30-46-11 ⑥
20-113 ① 20-227 ① 20-361 ① 30-11-3 ⑥ 30-46-12 ⑥
20-114 ① 20-228 ① 20-362 ① 30-11-4 ⑥ 30-46-13 ⑥
20-115 ① 20-229 ① 20-363 ① 30-11-5 ⑥ 30-46-14 ⑥
20-116 ① 20-230 ① 20-364 ① 30-12 ④ 30-46-15 ⑥
20-117 ① 20-231 ① 20-365 ① 30-13 ④ 30-46-16 ⑥
20-118 ① 20-251 ⑤ 20-366 ① 30-14 ④ 30-46-17 ⑥
20-119 ① 20-252 ⑤ 20-367 ① 30-15 ② 30-46-18 ⑥
20-120 ① 20-253 ⑤ 20-368 ① 30-16 ④ 30-46-19 ⑥
20-121 ⑦ 20-254 ① 20-369 ① 30-17 ② 30-46-20 ⑥
20-121-1 ① 20-255 ① 20-370 ① 30-18 ④ 30-46-21 ⑥
20-122 ① 20-256 ① 20-371 ① 30-19 ④ 30-46-22 ⑥
20-123 ① 20-258 ① 20-372 ① 30-20 ④ 30-46-23 ⑥
20-124 ① 20-259 ① 20-373 ① 30-21 ④ 30-46-24 ⑥
20-125 ① 20-260 ① 20-374 ① 30-22 ④ 30-46-25 ⑥
20-126 ① 20-261 ⑤ 20-375 ① 30-23 ② 30-46-26 ⑥
20-127 ① 20-262 ① 20-376 ① 30-24 ② 30-46-27 ⑥
20-128 ① 20-263 ① 20-401 ① 30-25 ② 30-46-28 ⑥
20-129 ① 20-264 ① 20-402 ⑤ 30-26 ② 30-46-29 ⑥
20-130 ① 20-265 ① 20-402-1 ⑤ 30-27 ② 30-46-30 ⑥
20-131 ① 20-266 ① 20-403 ① 30-28 ② 30-46-31 ⑥
20-132 ① 20-301 ① 20-404 ① 30-29 ② 30-46-32 ⑥
20-133 ① 20-302 ① 20-405 ⑤ 30-30 ② 30-46-33 ⑥
20-134 ① 20-303 ① 20-406 ① 30-31 ④ 30-46-34 ⑥
20-201 ⑤ 20-304 ① 20-407 ⑤ 30-32 ② 30-46-35 ⑥
20-202 ① 20-305 ① 20-408 ① 30-33 ② 30-46-36 ⑥
20-203 ① 20-306 ① 20-409 ① 30-34 ② 30-46-37 ⑥
20-204 ① 20-307 ① 20-410 ① 30-35 ② 30-46-38 ⑥
20-205 ① 20-308 ① 20-411 ① 30-36 ② 30-46-39 ⑥
00-2-2 PC60-7
⑨
30-46-40 ⑥ 30-67 ② 30-121 ② 50-9 ③ 90-13
30-46-41 ⑥ 30-68 ② 30-122 ④ 50-10 ③ 90-15
30-46-42 ⑥ 30-69 ② 30-122-1 ④ 50-11 ③ 90-17
30-46-43 ⑥ 30-70 ② 30-123 ② 50-12 ③ 90-19 ③
30-46-44 ⑥ 30-71 ② 30-124 ② 50-13 ③ 90-21 ③
30-46-45 ⑥ 30-72 ④ 50-14 ③ 90-23 ③
30-46-46 ⑥ 30-73 ④ 40-1 50-15 ③ 90-201 ⑤
30-46-47 ⑥ 30-73-1 ④ 40-2 ⑧ 50-16 ③
30-46-48 ⑥ 30-73-2 ④ 40-2-1 ⑧ 50-17 ③
30-46-49 ⑥ 30-74 ② 40-3 50-18 ③
30-46-50 ⑥ 30-75 ② 40-4 50-19 ③
30-46-51 ⑥ 30-76 ② 40-5 50-20 ③
30-46-52 ⑥ 30-78 ② 40-6 ③ 50-21 ③
30-46-53 ⑥ 30-79 ② 40-7 ③ 50-22 ③
30-46-54 ⑥ 30-80 ② 40-8 50-23 ③
30-46-55 ⑥ 30-81 ② 40-9 ③ 50-24 ③
30-46-56 ⑥ 30-82 ② 40-10 50-25 ③
30-46-57 ⑥ 30-83 ② 40-11 ③ 50-26 ③
30-46-58 ⑥ 30-84 ② 40-12 50-27 ③
30-46-59 ⑥ 30-85 ② 40-13 50-28 ③
30-46-60 ⑥ 30-86 ② 40-14 50-29 ③
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30-46-61 ⑥ 30-87 ② 40-15 50-30 ③
30-47 ② 30-88 ② 40-16 50-31 ③
30-47-1 ⑥ 30-89 ② 40-17 50-32 ③
30-47-2 ⑥ 30-90 ② 40-18 50-33 ③
30-47-3 ⑥ 30-91 ② 40-19 50-34 ③
30-47-4 ⑥ 30-92 ② 40-20 50-35 ③
30-47-5 ⑥ 30-94 ② 40-21 50-36 ③
30-47-6 ⑥ 30-95 ② 40-22 ③ 50-37 ③
30-47-7 ⑥ 30-96 ② 40-23 ③ 50-38 ③
30-47-8 ⑥ 30-97 ② 40-24 ③ 50-39 ③
30-47-9 ⑥ 30-98 ② 40-25 ③ 50-41 ③
30-47-10 ⑥ 30-99 ② 40-26 ⑧ 50-42 ③
30-48 ② 30-100 ② 40-26-1 ⑧ 50-43 ③
30-49 ② 30-101 ② 40-27 ③ 50-44 ③
30-50 ② 30-102 ② 40-28 ③ 50-45 ③
30-51 ② 30-103 ② 40-28-1 ③ 50-46 ③
30-52 ② 30-104 ② 40-28-2 ③ 50-47 ③
30-53 ② 30-105 ② • 40-29 ⑨ 50-48 ③
30-54 ④ 30-106 ② 40-30 ③ 50-49 ③
30-55 ④ 30-107 ② 40-31 50-50 ③
30-55-1 ④ 30-108 ② 40-32 50-51 ③
30-55-2 ④ 30-109 ② 40-33 50-52 ③
30-56 ② 30-110 ② 40-34 50-53 ③
30-57 ② 30-111 ② 40-35 50-54 ③
30-58 ② 30-112 ② 40-36
30-59 ② 30-113 ② 90-1 ③
30-60 ② 30-114 ② 50-1 ③ 90-3
30-61 ② 30-115 ② 50-3 ③ 90-5 ③
30-62 ② 30-116 ② 50-4 ③ 90-5-2 ③
30-63 ② 30-117 ② 50-5 ③ 90-5-4 ③
30-64 ② 30-118 ② 50-6 ③ 90-7
30-65 ② 30-119 ② 50-7 ③ 90-9
30-66 ② 30-120 ② 50-8 ③ 90-11
PC60-7 00-2-3
⑨
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00-2-4 PC60-7
⑨
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 is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous 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 the
Mistakes in operation are extremely dangerous. tools and parts in their correct places. Always
Read the Operation and Maintenance Manual keep the work area clean and make sure that
carefully BEFORE operating the machine. there is no dirt or oil on the floor. Smoke only in
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the areas provided for smoking. Never smoke
1. Before carrying out any greasing or repairs,
while working.
read all the precautions given on the decals
which are fixed to the machine.
PREPARATIONS FOR WORK
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing.
the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper,
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 safety
trained, experienced welder carry out the work. pin or use blocks to prevent the work
When carrying out welding work, always wear equipment from falling. In addition, be sure to
welding gloves, apron, hand shield, cap other lock all the control levers and hang warning
clothes suited for welding work. signs on them.
4. When carrying out any operation with two or 9. When disassembling or assembling, support
more workers, always agree on the operating the machine with blocks, jacks or stands
procedure before starting. Always inform your before starting work.
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps
compartment. when getting on or off the machine. Never
5. Keep all tools in good condition and learn the jump on or off the machine. If it is impossible to
correct way to use them. use the handrails, ladders or steps, use a
stand to provide safe footing.
00-3
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out. • When installing hoses and wires, be sure
that they will not be damaged by contact
Before disconnecting or removing components
with other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make
12. The water and oil in the circuits are hot when
sure that they are not twisted. Damaged tubes
the engine is stopped, so be careful not to get
are dangerous, so be extremely careful when
burned.
installing tubes for high pressure circuits. Also,
Wait for the oil and water to cool before carry-
check that connecting parts are correctly
ing out any work on the oil or water circuits.
installed.
13. Before starting work, remove the leads from
21. When assembling or installing parts, always
the battery. Always remove the lead from the
use the specified tightening torques. When
negative (-) terminal first.
installing protective parts such as guards, or
14. When raising heavy components, use a hoist parts which vibrate violently or rotate at high
or crane. speed, be particularly careful to check that
Check that the wire rope, chains and hooks they are installed correctly.
are free from damage.
22. When aligning two holes, never insert your
Always use lifting equipment which has ample
fingers or hand. Be careful not to get your
capacity.
fingers caught in a hole.
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Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to pre- 23. When measuring hydraulic pressure, check
vent the component from hitting any other part. that the measuring tool is correctly assembled
Do not work with any part still raised by the before taking any measurements.
hoist or crane.
24. Take care when removing or installing the
15. When removing covers which are under tracks of track-type machines.
internal pressure or under pressure from a When removing the track, the track separates
spring, always leave two bolts in position on suddenly, so never let anyone stand at either
opposite sides. Slowly release the pressure, end of the track.
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 minimum of
gasoline when washing electrical parts.
00-4
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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
maintenance standards.
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.
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Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each
component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
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 REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark (①②

Shop manuals are issued as a guide to carrying ③….) is recorded on the bottom of the pages.
out repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Electrical volume: Each issued as Revised pages are shown in the LIST OF
Attachments volume: one volume to REVISED PAGES next to the CONTENTS page.
cover all models
These various volumes are designed to avoid SYMBOLS

duplicating the same information. Therefore, to
deal with all repairs for any model , it is necessary So that the shop manual can be of ample practical
that chassis, engine, electrical and attachment use, important safety and quality portions are
volumes be available. marked with the following symbols.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will Symbol Item Remarks
be sent to KOMATSU distributors. Get the most
Special safety precautions
up-to-date information before you start any work.
Safety are necessary when per-
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forming the work.
FILING METHOD Special technical precau-

1. See the page number on the bottom of the tions or other precautions
page. File the pages in correct order. Caution for preserving standards
2. Following examples show how to read the are necessary when per-
page number.1 forming the work.
Example 1 (Chassis volume): Weight of parts of sys-
tems. Caution necessary
10 - 3 Weight when selecting hoisting
wire, or when working pos-
ture is important, etc.
Item number (10. Structure and
Function) Places that require special
Tightening
Consecutive page number for attention for the tightening
torque
each item torque during assembly.
Places to be coated with
Example 2 (Engine volume): Coat adhesives and lubricants,
etc.
12 - 5 Places where oil, water or
Oil, water fuel must be added, and
Unit number (1. Engine) the capacity.
Item number (2. Testing and Places where oil or water
Adjusting) Drain must be drained, and
Consecutive page number for quantity to be drained.
each item.
3. Additional pages: Additional pages are indicated

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
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause
Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting,
with a hoist, etc. In the DISASSEMBLY and a serious accident can result. Hooks have
AND ASSEMBLY section, every part maximum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part 3) Do not sling a heavy load with one rope alone,
causing interference with the part to be but sling with two or more ropes symmetrically
removed. wound onto the load.
Slinging with one rope may cause turning
WIRE ROPES of the load during hoisting, untwisting of
1) Use adequate ropes depending on the the rope, or slipping of the rope from its
weight of parts to be hoisted, referring to original winding position on the load,
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the table below: which can result in a dangerous accident.
Wire ropes
(Standard “Z” or “S” twist ropes 4) Do not sling a heavy load with ropes forming a
without galvanizing) wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
10 9.8 1.0 shows the variation of allowable load kN {kg}
11.5 13.7 1.4 when hoisting is made with two ropes, each of
12.5 15.7 1.6 which is allowed to sling up to 9.8 kN {1000 kg}
14 21.6 2.2 vertically, at various hanging angles.
16 27.5 2.8 When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be

onesixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydr-
aulic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure
from tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
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★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it

out. (See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it
in mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion and 1) Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention ring
ring (1) contacts contact surface a of the hexagonal (1) contacts contact surface a of the hexagonal
portion at the male end portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to 2) Hold in the condition in Step 1), and push until
the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
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3) Hold in the condition in Steps 1) and 2), and pull out 3) Hold in the condition in Steps 1) and 2), and pull out
whole body (2) to disconnect it. whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention ring
ring (1) contacts contact surface a of the hexagonal (1) contacts contact surface a of the hexagonal
portion at the male end to connect it. portion at the male end to connect it.
Connection
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 Komatsu code Part No. Q’ty Container Main applications, featuresr
x Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
x Used in places requiring an imme-
diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1 B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oethlene and vinyl chloride),
rubber, metal and non-metal.
x Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g
container x Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: x Used as adhesive or sealant for
790-129-9060
1 kg metal, glass and plastic.
(Set of
Hardenin
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LT-3 adhesive and Can
g
hardening
agent:
agent)
Adhesives 500 g
Polyethylene x Used as sealant for machined
LT-4 790-129-9040 250 g holes.
container
Holtz x Used as heat-resisting sealant for

790-126-9120 75 g Tube repairing engine.
MH 705
x Quick hardening type adhesive

Three bond Polyethylene x Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container x Used mainly for adhesion of met-
als, rubbers, plastics and woods.
x Quick hardening type adhesive
x Quick cure type (max. strength af-
Aron-alpha Polyethylene
790-129-9130 2g ter 30 minutes)
201 container
x Used mainly for adhesion of rub-
bers, plastics and metals.
x Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc x Used at joint portions subject to
648-50 container
high temperatures.
x Used as adhesive or sealant for
LG-1 790-129-9010 200 g Tube gaskets and packing of power train
case, etc.
x Used as sealant for various
threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can
x Used as sealant for tapered plugs,
Gasket
elbows, nipples of hydraulic piping.
sealant
x Features: Silicon based, resist-
ance to heat, cold
x Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
x mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, featuresr
x Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube x Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives
thermostat housing, etc.
Three bond x Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
x Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can tion (to prevent from squeaking).
Molybdenum
x Used to prevent seizure or scuf-
disulphide
fling of the thread when press fit-
lubricant
LM-P 09940-00040 200 g Tube ting or shrink fitting.
x Used as lubricant for linkage,
bearings, etc.
SYG2-400LI x General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA x Used for normal temperature, light
Grease SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
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SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g x Used for places with heavy load
disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUET

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 of bolt Width across flats
mm mm Nm kgm
6 10 13.2±1.4 1.35±0.15
8 13 31±3 3.2±0.3
10 17 66±7 6.7±0.7
12 19 113±10 11.5±1
14 22 177±19 18±2
16 24 279±30 28.5±3
18 27 382±39 39±4
20 30 549±59 56±6
22 32 745±83 76±8.5
24 36 927±103 94.5±10.5
27 41 1320±140 135±15
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30 46 1720±190 175±20
33 50 2210±240 225±25
36 55 2750±290 280±30
39 60 3290±340 335±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85±1.95 0.8±0.2
8 13 18.6±4.9 1.9±0.5
10 14 40.2±5.9 4.1±0.6
12 27 82.35±7.85 8.4±0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given
in the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5±4.9 2.5±0.5
18 24 49±19.6 5±2
22 27 78.5±19.6 8±2
24 32 137.3±29.4 14±3
30 36 176.5±29.4 18±3
33 41 196.1±49 20±5
36 46 245.2±49 25±5
42 55 294.2±49 30±5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in
the table below.
mm mm Nm kgm
10 14 65.7±6.8 6.7±0.7
12 17 112±9.8 11.5±1
16 22 279±29 28.5±3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Nm kgm
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03,04
05,06
10,12
.com 14
20
24
33
Varies depending
on type of
connector.
34.3±4.9
93.1±9.8
142.1±19.6
421.4±58.8
3.5±0.5
9.5±1
14.5±2
43±6
14 42 877.1±132.3 89.5±13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Norminal No.
mm mm Nm kgm
08 08 14 7.35±1.47 0.75±0.15
10 10 17 11.27±1.47 1.15±0.15
12 12 19 17.64±1.96 1.8±0.2
14 14 22 22.54±1.96 2.3±0.2
16 16 24 29.4±4.9 3±0.5
18 18 27 39.2±4.9 4±0.5
20 20 30 49±4.9 5±0.5
24 24 32 68.6±9.8 7±1
30 30 32 107.8±14.7 11±1.5
33 33 n 127.4±19.6 13±2
36 36 36 151.9±24.5 15.5±2.5
42 42 n 210.7±29.4 21.5±3
52 52 n 323.4±44.1 33±4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

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

mm Nm kgm
6 10±2 1.02±0.20
8 24±4 2.45±0.41
10 43±6 4.38±0.61
12 77±12 7.85±1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (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±2 1.02±0.20
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10 12±2 1.22±0.20
12 24±4 2.45±0.41
14 36±5 3.67±0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

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

mm Nm kgm
1 / 16 3±1 0.31±0.10
1/8 8±2 0.81±0.20
1/4 12±2 1.22±0.20
3/8 15±2 1.53±0.41
1/2 24±4 2.45±0.41
3/4 36±5 3.67±0.51
1 60±9 6.12±0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Current
Norminal Dia. of Cross Cable O.D.
Number of rating Applicable circuit
number strands section (mm)
strands (A)
2 2
(mm ) (mm )
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
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60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
Classi- Charging Ground Starting Lighting Instrument Signal Other
ty
fication
Code W B B R Y G L
Pri-
1
mary
Color White Black Black Red Yellow Green Blue
Code WR － BW RW YR GW LW
2
Color White & Red － White & Black Red & White Rellow & Red Green & Whit Blue & White
Code WB － BY RB YB GR LR
3
Color White & Black － Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL － BR RY YG GY LY
Auxi-
4
liary Yellow & Green &
Color White & Blue － Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG －－ RG YL GB LB
5
Color White & Green －－ Red & Green Yellow & Blue Green & Black Blue & Black
Code －－－ RL YW GL －
6
Color －－－ 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
• 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 ○ A , then draw a horizontal
line from○ A.
(2) Locate the number 5 in the row across the top, take this as ○ B , then draw a perpendicular line
down from○ B .
(3) Take the point where the two lines cross as○ C . This point ○ C gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 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
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point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
00-16
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00-17
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00-18
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00-19
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00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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.
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00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh)
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00-22
01 GENERAL
Dimension ...................................................01- 2
Specifications ..............................................01- 4
Weight Table ...............................................01- 8
Table of oil and coolant capacities..............01- 10
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E20107
01-1
GENERAL DIMENSION
DIMENSION
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※The values marked * are for blade specification only.
E20107
WORKING RANGE
※The values marked * are

for shovel operations.
01-2
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PC60-7 01-3
（2）
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC60-7
Machine model
Standard specification Blade specification
Serial Number 52374 - 57999 52374 - 57999
Bucket capacity m3 0.25 0.25
Operating weight kg 6,200 6,700
Max. digging depth mm 4,100 4,100

Max. vertical wall depth mm 3,505 3,505
Working ranges
Max. digging reach mm 6,360 6,360

Max. reach at ground level mm 6,220 6,200
Max. digging height mm 7,150 7,150
Max. dumping height mm 5,015 5,015
Performance
Max. lifting height of blade mm — 410

Max. lowering depth of blade mm — 270
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Max. digging force
Swing speed
Swing max. slope angle
kN {kg}
rpm
deg.
47 {4,800}
12
20
47 {4,800)
12
20
Travel speed Km/h Lo 2.8 H i 4.5 Lo 2.8 Hi 4.5
Gradeability deg. 35 35
2
Ground pressure kPa {kg/cm } 29.42 {0.30} 30.40 {0.31}
(standard shoe width: 450 mm)
Overall length (for transport) mm 6,080 6,080

Overall width mm 2,225 2,280
Overall width of track mm 2,150 2,150
Overall height (for transport) mm 2,590 2,590
Overall height (to top of cab) mm 2,590 2,590
Ground clearance, counterweight mm 750 750
Dimensions
Min. ground clearance mm 350 350

Tail swing radius mm 1,750 1,750
Min. swing radius of work equipment mm 1,750 1,750
Height of work equipment at min. mm 5,460 5,460

swing radius
Length of track on ground mm 2,130 2,130
Track gauge mm 1,700 1,700
Height of machine cab mm 1,750 1,750
Blade width x height mm — 2,260 x 470
01-4 PC60-7
③
PC60-7
Machine model
Serial Number 52374 - 57999 52374 - 57999
Model 4D102E-1
Type 4-cycle, water-cooled, in-line, vertical, direct injection
No. of cylinders-bore x stroke mm 4 - 102 x 120
Piston displacement l {cc} 3.92 {3,920}
Flywheel horsepower kW/rpm {HP/rpm} 40.5/1,750 {54.2/1,750}

Performance
Max. torque Nm/rpm {kgm/rpm} 245/1,200 {25/1,200}

Enging
Max. speed at no load rpm 1,950
Min. speed at no load rpm 950
Min. fuel consumption g/kWh {g/HPh} 230 {172}
Starting motor 24V, 4.5kW
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Alternator 24V, 25A
Battery 12V, 70Ah x 2
Radiator core type CF 19-4

Undercarriage
Carrier roller (each side) 1
Track roller (each side) 5
Track shoe Assembly-type triple grouser, 38 (each side)
Type x No. Variable displacement piston type x 1

Hydraulic
pump
Discharge amount l/min 155

2
Set pressure MPa {kg/cm } 24.5 {250}
Control
Type x no. 7-spool type x 1 8-spool type x 1

valve
Hydraulic equipment
Control method Hydraulic assist type Hydraulic assist type
Travel motor Fixed capacity piston type

Hydraulic
(with brake valve, parking brake) x 2

motor
Swing motor Fixed capacity piston type

Hydraulic cylinder Double-acting piston
Hydraulic tank Box-shaped, open
Hydraulic filter Tank return side
Hydraulic cooler Air cooled
PC60-7 01-5
⑨
SPECIFICATIONS
PC60-7
Machine model
Serial Number 58001 and up 58001 and up
3
Bucket capacity m 0.25 0.25
Operating weight kg 6,200 6,700
Max. digging depth mm 4,100 4,100

Max. vertical wall depth mm 3,505 3,505
Working ranges
Max. digging reach mm 6,360 6,360

Max. reach at ground level mm 6,220 6,200
Max. digging height mm 7,150 7,150
Max. dumping height mm 5,015 5,015
Performance
Max. lifting height of blade mm — 410

Max. lowering depth of blade mm — 270
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Max. digging force
Swing speed
Swing max. slope angle
kN {kg}
rpm
deg.
47 {4,800}
12
20
47 {4,800}
12
20
Travel speed Km/h Lo 2.8 Hi 4.5 Lo 2.8 H i 4.5
Gradeability deg 35 35
2
Ground pressure kPa {kg/cm } 29.42 {0.30} 30.40 {0.31 }
Overall length (for transport) mm 6,080 6,080

Overall width mm 2,225 2,280
Overall width of track mm 2,150 2,150
Overall height (for transport) mm 2,590 2,590
Overall height (to top of cab) mm 2,590 2,590
Ground clearance, counterweight mm 750 750
Dimensions
Min. ground clearance mm 350 350

Tail swing radius mm 1,750 1,750
Min. swing radius of work equipment mm 1,750 1,750
Height of work equipment at min. mm 5,460 5,460

swing radius
Length of track on ground mm 2,130 2,130
Track gauge mm 1,700 1,700
Height of machine cab mm 1,750 1,750
Blade width x height mm — 2,260 x 470
01-5-1 PC60-7
③
PC60-7
Machine model
Model 4D95LE-2
No. of cylinders-bore x stroke mm 4 - 95 x 115

Performance

Enging
Min. speed at no load rpm 1,050
Min. fuel consumption g/kWh {g/HPh) 224 {165}
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Alternator 24V, 25A
Radiator core type CF 19-3

Undercarriage

Hydraulic
pump
Discharge amount l/min 155

2
Set pressure MPa {kg/cm ) 24.5 {250}
Control
Type x no. 7-spool type x 1 8-spool type x 1

valve
Hydraulic equipment
Control method Hydraulic assist type Hydraulic assist type

Hydraulic

motor

Hydraulic cooler Air cooled
PC60-7 01-5-2
⑨
GENERAL WEIGHT TABLE
WEIGHT TABLE
These weights are for reference when handling or transporting components.
Unit: kg
PC60-7
Machine model

Engine assembly (excl. water, oil) 382 382
PTO (coupling) assembly 6 6
Radiator, oil cooler assembly 31 (※ 36) 31 (※ 36)
Revolving frame 638 638
Operator's cab 260 260
Operator's seat 20 20
Fuel tank (excl. fuel) 50 50
Hydraulic tank (excl. hydraulic oil) 58 58
Counterweight 685 (※※715) 685 (※※715)
Hydraulic pump assembly 57 57
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7-spool control valve 43 —
8-spool control valve (with blade) — 48
Swing circle assembly 99 99
Swing machinery assembly 43 43
Swing motor assembly 22 22
Center swivel joint 13 16
Track frame assembly 1,200 1,342
x Track frame 613 735
x Idler 55 x 2 55 x 2
x Idler cushion 40 x 2 40 x 2
x Carrier roller 4x2 4x2
x Track roller 14 x 2 14 x 2
x Travel motor 90 x 2 90 x 2
x Sprocket 25 x 2 25 x 2
Track shoe assembly
x Standard triple shoe (450 mm) 400 x 2 400 x 2
x Wide triple shoe (600 mm) 480 x 2 480 x 2
x Swamp shoe (700 mm) 590 x 2 590 x 2
x Rubber shoe (450 mm) 366 x 2 366 x 2
(※ ): Serial Number 59775 and up

(※※): Serial Number 58001 and up
01-6 PC60-7
⑨
Unit: kg
PC60-7
Machine model
Boom assembly 410 410

Arm assembly 160 160
Link assembly 55 55
Bucket assembly 210 210
Blade assembly — 360
Boom cylinder assembly 90 90
Arm cylinder assembly 72 72
Bucket cylinder assembly 51 51
Blade cylinder assembly — 44
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PC60-7 01-7
GENERAL TABLE OF OIL AND COOLANT CAPACITIES
TABLE OF OIL AND COOLANT CAPACITIES
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01-8 PC60-7
③
FUEL, OIL
• Select the fuel and oil according to the ambi-
ent temperature as shown in the table.
★ The specified oil capacity indicates the total
amount of oil including the oil in the piping for
each component; the refill capacity indicates
the amount of oil added when the oil is
changed for normal inspection and mainten-
ance.
★ When starting the engine in ambient tempera-
tures of below 0°C, even if the daytime tem-
perature rises to 10°C, always use SAE 10W
or SAE 10W-30.
Note 1: For hydraulic oil H046-HM, use the oil rec-
ommended by Komatsu.
See the Operation and Maintenance
Manual for details of the procedure for
changing the oil.
Note 2: There are two types of automatic greasing
cartridges available: the standard type
(NLGI No. 2) and the cold area type (NLGI
No. 0).
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When changing the automatic greasing
cartridge from the standard type to the
cold area type, or from the cold area type
E20107
to the standard type, please see the Op-

eration and Maintenance Manual.
Note 3: If the cold area type grease (NLGI No. 0)
is used in warm areas, some grease will
drip from the ends of the work equipment
pins, but there is no problem in the lubri-
cating performance.
ANTI-FREEZE
Komatsu genuine Super Coolant (AF-ACL) is
added at a proportion of 30% to the cooling water,
so there is no need to change the density for
temperatures down to -10°C.
If the temperature goes below -10°C adjust the
density according to the table below.
Below -10°C -15°C -20°C -25°C

Proportion
30% 36% 41% 46%
of anti-freeze
Proportion
70% 64% 59% 54%
of water
★ Use tap water for the coolant.
01-9
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01-10 PC60-7
③
10 STRUCTURE AND FUNCTION
Radiator, oil cooler ....................................10- 2

PTO (coupling) ..........................................10- 3
Engine control ...........................................10- 4
Power train diagram ..................................10- 5
Swing circle ...............................................10- 6
Swing machinery.......................................10- 7
Track frame ...............................................10- 8
Idler cushion ..............................................10- 9
Hydraulic piping drawing...........................10- 10
Hydraulic circuit diagram...........................10- 11
Hydraulic tank ...........................................10- 12
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Hydraulic pump .........................................10- 13
Control valve .............................................10- 40
Self-pressure reducing valve ....................10- 51
CLSS .........................................................10- 56
Swing motor ..............................................10- 86
Center swivel joint .....................................10- 90
Travel motor ..............................................10- 92
Valve control..............................................10- 98
Work equipment, swing PPC valve ..........10-100
Travel PPC valve.......................................10-104
Service PPC valve ....................................10-108
Solenoid valve...........................................10-112
Hydraulic cylinder......................................10-114
Work equipment........................................10-116
Work equipment pin automatic
greasing system ....................................10-117
Electrical allocation diagram (1/2) ............10-130
Electrical allocation diagram (2/2) ............10-131
Electrical circuit diagram ...........................10-132
Electrical control system ...........................10-134
Machine monitor system ...........................10-142
PC60-7 10-1
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
RADIATOR, OIL COOLER

Serial No. : 52374 - 57999
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1. Fan guard Specifications Oil cooler

2. Radiator inlet hose Radiator • Core type: CFT-1
3. Drain valve • Core type: CF19-4 • Heat dissipation area
4. Radiator outlet hose • Heat dissipation area : 6.26 m2
5. Oil cooler inlet : 21.63 m2 • Fin pitch: 4.0/2
6. Oil cooler outlet • Fin pitch: 3.5/2 • Oil capcity: 2.1 l
7. Oil cooler • Water capcity: 6.2 l
8. Radiator
9. Shroud
10. Reserve tank
10-2 PC60-7
⑨
Serial No.: 58001 - 59774
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2. Radiator inlet hose Radiator • Core type: CFT-1
8. Radiator
9. Shroud
10. Reserve tank
PC60-7 10-2-1
⑨
Serial No.: 59775 and up
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2. Radiator inlet hose Radiator • Core type: AL-CF40
8. Radiator
9. Shroud
10. Reserve tank
10-2-2 PC60-7
⑨
STRUCTURE AND FUNCTION PTO (COUPLING)
PTO (COUPLING)
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E20107
1. Drain plug 5. Pump case

2. Shaft 6. Breather/oil filler plug
3. Coupling 7. Cage
4. Flywheel 8. Level plug
10-3
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
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E20107
1. Fuel control dial Outline

2. Starting switch • The engine can be stopped and started sim-
3. Starting motor ply by using the starting switch.
4. Stop lever • The engine stop solenoid has a fail-safe
5. Battery mechanism which acts to drive the fuel injec-
6. Fuel injection pump tion pump stop lever to the RUN position when
7. Governor lever the starting switch is turned ON, so if there is
any abnormality in the electrical system, the
engine stops.
10-4
STRUCTURE AND FUNCTION POWER TRAIN DIAGRAM
POWER TRAIN DIAGRAM
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E20107
1. Idler 7. Hydraulic pump

2. Center swivel joint 8. Engine
3. Control valve 9. Swing motor
4. Swing brake solenoid valve 10. Swing machinery
5. Travel speed solenoid valve 11. Swing circle
6. Travel motor
10-5
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
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E20107
1. Swing circle outer race Specifications

2. Ball 76
Reduction ratio: = 7.60
3. Swing circle inner race 10
4. Plug Amount of grease: 5 l (G2-LI)
5. Grease nipple.
S. Inner race, outer race zone position
10-6
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
Serial No. : 52374 – 59570
Serial No. : 55720 – 59570 (For Norway)
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1. Swing pinion (number of teeth : 10) Specification

2. Case Reduction ratio: (22 + 68)/22 × (19 + 68)/19 = 18.73
3. No. 2 planetary carrier Swing reduction ratio : 18.73 × 7.60 = 142.363
4. No. 2 sun gear (number of teeth : 19) Swing speed : 12 rpm
5. Ring gear (number of teeth : 68) Lubricating oil : SAE30-CD
6. No. 1 planetary carrier Lubricating oil amount : 1.5 l
7. No. 1 sun gear (number of teeth : 22)
8. Swing motor
9. Level gauge
10. No. 1 planetary gear (number of teeth : 23)
12. Drain plug
13. Swing circle (number of teeth : 76)
PC60-7 10-7
⑧
Serial No. : 59571 and up

Serial No. : 59571 and up (For Norway)
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1. Swing pinion (number of teeth : 10) Specification

2. Case Reduction ratio : (22 + 68)/22 × (19 + 68)/19 = 18.73
3. No. 2 planetary carrier Swing reduction ratio : 18.73 × 7.60 = 142.363
4. No. 2 sun gear (number of teeth : 19) Swing speed : 12 rpm
5. Ring gear (number of teeth : 68) Lubricating oil : SAE30-CD
6. No. 1 planetary carrier Lubricating oil amount: 1.5 l
7. No. 1 sun gear (number of teeth : 22)
8. Swing motor
9. Level gauge
12. Drain plug
13. Swing circle (number of teeth : 76)
10-7-1 PC60-7
⑧
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PC60-7 01-5-2
⑨
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
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1. Idler 6. Track roller

2. Track frame 7. Track shoe
3. Carrier roller 8. Idler cushion
4. Travel motor 9. Idler guard
5. Sprocket
10-8 PC60-7
STRUCTURE AND FUNCTION IDLER CUSHION
IDLER CUSHION
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E20107
1. Yoke Specifications
2. Rod (piston) Amount of grease: 120 cc
3. Front support (cylinder)
4. Recoil spring
5. Wear ring
6. Packing
7. Rear support
8. Lubricator
9. Drain plug
10-9
★ The sketch shows the blade specification machine.
10-10
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Hydraulic tank
6. R.H. travel motor
7. Hydraulic pump
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8. Control valve
k
9. Oil cooler
10. L.H. travel motor

11. L.H. work equipment PPC valve
12. R.H. work equipment PPC valve
13. Center swivel joint
14. Travel PPC valve
★ For details of this page, see page 90-3.
15. Blade cylinder

(blade specification machine)
16. PPC lock solenoid valve
17. Swing lock solenoid valve
HYDRAULIC PIPING DRAWING
omat
18. Travel speed solenoid valve
s
19. Mode selection solenoid valve
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E20107
om
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

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E20107
10-11
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
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E20107
1. Return filter Specifications

2. Safety valve Tank capacity: 71 l
3. Cap Amount of oil inside tank: 57 l
4. Vacuum valve Cracking pressure of pressure valve:
5. Pressure valve 0.04±0.01 MPa {0.39±0.15 kg/cm2}
6. Sight gauge Cracking pressure of vacuum valve:
7. Suction strainer 0 - 0.05 MPa {0 - 0.46 kg/cm2}
8. Drain plug Actuating pressure of safety valve:
0.10±0.02 MPa (1.05±0.2 kg/cm2)
10-12
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
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PA : Pump discharge PDA : Pump air bleed port

PA2 : LS pressure inlet port PLS : LS pressure inlet port
PA3 : Drain port PM : L mode selection pilot port
PD1 : Pump drain PS : Pump suction
1. Main pump
PC60-7 10-13
③
1. MAIN PUMP
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PA : Pump discharge ★ The main pump consists of one unit formed by

PA2 : LS pressure inlet port the pump, servo piston, PC valve, and LS valve.
PA3 : Drain port The explanation in STRUCTURE AND FUNC-
PDA : Pump air bleed port TION is divided into two parts: the pump and PC
PD1 : Pump drain valve + LS valve.
PLS : LS pressure inlet port
PM : L mode selection pilot port
PS : Pump suction
10-14 PC60-7
③
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E20107
1. Shaft 6. Piston
2. Cradle 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. Spring
5. Shoe 10. Servo piston
10-15
Function
• The engine rotation and torque transmitted to
the pump shaft is converted into hydraulic
energy, and pressurized oil is discharged ac-
cording to the load.
• It is possible to change the discharge amount
by changing the swash plate angle.
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E20107
Structure • Piston (6) carries out relative movement in the
• Cylinder block (7) is supported to shaft (1) by axial direction inside each cylinder chamber of
spline a, and shaft (1) is supported by the front cylinder block (7).
and rear bearings. • Cylinder block (7) seals the pressure oil to
• The tip of piston (6) is a concave ball, and valve plate (8) and carries out relative rota-
shoe (5) is caulked to it to form one unit. tion. This surface is designed so that the oil
Piston (6) and shoe (5) form a spherical bear- pressure balance is maintained at a suitable
ing. level.
• Rocker cam (4) has flat surface A, and shoe The oil inside each cylinder chamber of cylin-
(5) is always pressed against this surface der block (7) is sucked in and discharged
while sliding in a circular movement. through valve plate (8).
Rocker cam (4) brings high pressure oil at
cylindrical surface B with cradle (2), which is
secured to the case, and forms a static
pressure bearing when it slides.
10-16
Operation
1) Operation of pump
i) Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat sur-
face A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4)
and the axial direction of cylinder block (7)
changes. Angle α is called the swash plate
angle.
ii) Center line X of rocker cam (4) maintains

swash plate angle a in relation to the axial
direction of cylinder block (7), and flat
surface A moves as a cam in relation to
shoe (5).
In this way, piston (6) slides on the inside
of cylinder block (7), so a difference be-
tween volume E and F is created inside
cylinder block (7). The suction and dis-
charge is carried out by this difference F -
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E.
In other words, when cylinder block (7)
rotates and the volume of chamber E be-
comes smaller, the oil is discharged dur-
E20107
ing that stroke.

At the same time, the volume of chamber F
becomes larger, and as the volume
becomes larger, oil is sucked in.
(The diagram shows chamber F at the end
of the suction process and chamber E at
the end of the discharge process.)
iii) If center line X of rocker cam (4) is in line

with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does
not carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
iv) In other words, there is a proportional re-

lationship between swash plate angle α
and the pump discharge amount.
10-17
2) Control of discharge amount

• If swash plate angle α becomes larger, the dif-
ference in volumes E and f becomes larger
and discharge amount Q increases.
Swash plate angle α is changed by servo pis-
ton (10).
• Servo piston (10) moves in a reciprocal move-
ment () according to the command from the
PC and LS valve.
• This straight line movement is transmitted to
rocker cam (4), and rocker cam (4), which is
supported by the cylindrical surface to cradle
(2), moves in a rotating motion on the cylin-
drical surface in the ( ) direction.
• With servo piston (10), the area receiving the
pressure is different at the top and bottom, so
main pump discharge pressure (self pressure)
PP is always connected to the pressure
chamber at the small diameter piston end (top).
Output pressure Pen of the LS valve is brought
to the pressure chamber at the large diam-
eter piston end (bottom).
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The relationship in the size of pressure PP at
the small diameter piston end and pressure
Pen at the large diameter piston end, and the
E20107
ratio between the pressure-receiving area at
the small diameter piston end and the large
diameter piston end controls the movement of
servo piston (10).
10-18
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10-19
2. PC VALVE, LS VALVE, SERVO PISTON
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PA2 : LS pump pressure port PC valve LS valve

PA3 : Drain port 4. Piston 12. Plug
PLS : Control valve LS pressure inlet port 5. Spring 13. Sleeve
PM : Mode selection solenoid pressure inlet port 6. Seat 14. Spring
PP : Main pump pressure port 7. Spring 15. Piston
8. Piston
Servo piston 9. Sleeve
1. Servo piston 10. Piston
2. Lever 11. Plug
3. Spring
10-20 PC60-7
③
LS valve
Function
• The LS valve controls the pump discharge
amount according to the amount of move-
ment of the control lever, that is the oil flow
demanded by the actuator.
• The LS valve detects the oil flow demanded by
the actuator from the differential pressure
∆PLS between input pressure Pa2 of the con-
trol valve (downstream pressure of self-pres-
sure reducing valve) (Note 1) and control
valve outlet pressure PLS, and controls main
pump discharge amount Q.
(Pa2 is called the LS pump pressure, PLS is
called the LS pressure, and ∆PLS is called the
LS differential pressure.)
• In other words, the pressure loss (= LS dif-
ferential pressure ∆PLS) generated by the flow
of oil from the pump passing through opening
area of the control valve spool is detected.
By controlling pump discharge amount Q so
that this pressure loss remains constant, a
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pump discharge amount is supplied in
accordance with the demands of the control
valve by controlling pump discharge amount
E20107
Q.
• Main pump discharge pressure PP, LS pump
pressure Pa2, and LS pressure PLS are
brought to the LS valve.
The relationship between pump discharge
amount Q and LS differential pressure ∆PLS
changes as shown in the diagram on the right.
Note 1: Previously, the pump discharge pres-

sure and control valve outlet port
pressure were brought to both sides of
the LS valve as the LS differential
pressure /PLS.
However, the LS differential pressure
changes according to the differential
pressure at the self pressure reduc-
ing valve, so it is necessary to bring
the self pressure reducing valve
downstream pressure = control valve
inlet port pressure and control valve
outlet port pressure to the LS valve.
10-21
Operation
1. When control valve is at HOLD position
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E20107
10-22
• The LS pressure PLS is brought from the con-

trol valve outlet port to spring chamber a of the
LS valve. LS pump pressure Pa2 at the control
valve inlet port is brought to chamber b at the
tip of the sleeve on the opposite side.
• The position of piston (15) is determined by the
size of pump pressure Pa2 and the combined
force of LS pressure PLS + force of spring
(14).
• Before the engine is started, servo piston (1) is
pushed down (direction of minimum swash
plate angle) by spring (3).
• After the engine is started, if all the control
valves are at the neutral position, no pressure
oil flows to the control valve outlet port, so LS
pressure PLS is 0 MPa {0 kg/cm2}.
(Spring chamber a is connected to the drain
circuit through the control valve spool.)
At the same time, LS pump pressure Pa2 is
held at the unload pressure of approx. 2.7 MPa
{27 kg/cm2}.
• For this reason, piston (15) is pushed to the
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right (), port c and port d are interconnected,
and pump pressure PP is brought from port d
to chamber X at the large diameter end of
E20107
servo piston (1).

• Pump pressure PP is always supplied to cham-
ber Y at the small diameter end of servo pis-
ton (1), but the force applied to the large di-
ameter end of servo piston (1) is greater be-
cause of the difference in area at both ends of
the piston, so servo piston (1) moves up in the
direction of the minimum swash plate angle
().
10-23
2. When opening area of control valve is maximum (lever operated fully)
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E20107
10-24
• When the control lever is operated fully, that is,

when the area of opening of the control valve
becomes larger, the difference between LS
pump pressure Pa2 and LS pressure PLS (LS
differential pressure ∆PLS) becomes smaller.
• LS pressure PLS brought to spring chamber a
of the LS valve becomes close to LS pump
pressure Pa2, and piston (15) is pushed to the
left () by the combined force of LS pressure
PLS + force of spring (14). This closes port c
and interconnects port d and port e.
• As a result, the pressurized oil acting on cham-
ber X at the large diameter end of servo pis-
ton (1) flows from port d to port e and is con-
nected to port f of the PC valve.
• At this point, port f of the PC valve is drained
inside the pump case through the inside of the
piston, so the pressure in chamber X at the
large diameter end of servo piston (1) also
becomes the drain pressure.
• Because of this, servo piston (1) is moved
down in the direction of the maximum swash
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plate angle () by pump pressure PP acting on
chamber Y at the small diameter end of the
piston.
E20107
10-25
3. When opening area of control valve is small (small movement of lever)
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E20107
10-26
• When the control lever is operated in small

movements, or when it is operated to the
HOLD position (in other words, when the area
of opening of the control valve becomes
smaller), the difference between LS pump
pressure Pa2 and LS pressure PLS (in other,
words, LS pressure ∆PLS) becomes larger.
• When this happens, the movement is the
same as for [1. When control valve is at HOLD
position]: LS pump pressure Pa2 pushes pis-
ton (14) to the right (), so servo piston (1) is
moved up in the direction of the minimum
swash plate angle ().
In other words, the basic LS set differential
pressure of the LS valve is taken as 1.96 MPa
{20 kg/cm2}. In the range from the neutral po-
sition of the control valve to the small area of
opening of the control valve (fine control), in
the area where the LS differential pressure
∆PLS is more than 1.96 MPa {20 kg/cm2}, the
pump swash plate angle moves in the mini-
mum direction.
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If the area of opening of the control valve is
further increased, and LS differential pressure
∆PLS goes below 1.96 MPa {20 kg/cm2}, the
E20107
pump swash plate angle is moved in the maxi-

mum direction.
10-27
4. When pump flow is amount demanded by control valve
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E20107
10-28
• Let us take the area receiving the pressure at

the large diameter end of servo piston as A1,
the area receiving the pressure at the small
diameter end as A2, the pressure acting on the
large piston diameter end as Pen, and the
pressure acting on the small piston diameter
end as PP.
• When the flow of oil from the pump reaches
the flow demanded by the control valve, LS
pump pressure Pa2 acting on port b of the LS
valve and the combined force of LS pressure
PLS + force of spring (14) acting on spring
chamber a are balanced, so piston (15) stops
at almost the central position.
• As a result, port c, port d, and port e open
approximately the same amount, so the pump
pressure flows from port c to port d. Part flows
from port e to the tank case and is drained, so
the pressure is reduced by approx.1/2 and
flows to chamber X at the large diameter end
of servo piston (1).
• At this point, the relationship between the
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area receiving the pressure at both ends of
piston (1) is A2 : A1 = 1 : 2, so the pressure
applied to both ends of servo piston (1) be-
comes PP : Pen = 2 : 1. This makes the force
acting on both ends of servo piston (1) 1 : 1, so
servo piston (1) stops in that position and the
pump discharge amount is balanced with the
oil flow demanded by the control valve.
• The force of the spring is adjusted so that Pa2
- PLS = ∆PLS ≒ 1.96 MPa {20 kg/cm2} at the
point where piston (15) is balanced.
• In other words, when the area of opening of
control valve is 1/2, the pump swash plate
angle is also 1/2, and when the area of open-
ing of control valve is 1/4, the pump swash
plate angle is also 1/4. LS differential pressure
∆PLS is always held at 1.96 MPa {20 kg/cm2},
so the pump discharge amount is in ac-
cordance with the area of opening of the con-
trol valve.
• For example, after balancing at an area of
opening 1/4 of the control valve, if the system
is operated to 3/4 of the area of opening of the
control valve, LS differential pressure ∆PLS
will drop momentarily.
As a result, the LS valve is actuated and the
pump discharge amount is increased, but
when the pump swash plate angle rises to 3/4,
the LS differential pressure ∆PLS rises to 1.96
MPa {20 kg/cm2}, so it is balanced in this posi-
tion.
PC60-7 10-29
PC valve
Function
• When discharge pressure PP becomes higher,
the area of opening of the control valve be-
comes larger, and even if the LS valve tries to
increase pump discharge amount Q, the PC
valve carries out control to prevent any in-
crease above fixed discharge amount Q to
match discharge pressure PP. It carries out
approximate horsepower control to prevent the
hydraulic horsepower absorbed by the pump
from exceeding the engine horsepower.
• In other words, if the load during operations
becomes larger and pump discharge pressure
PP rises, pump discharge amount Q is re-
duced; and if pump discharge pressure PP
goes down, pump discharge amount Q is in-
creased.
• The relationship between pump discharge
pressure PP and pump discharge amount Q is
as shown in the diagram on the right.
Normally, it is set to the pump absorption
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torque for the standard mode, but if the mode
selector solenoid valve signal is input, the
pump absorption horsepower is reduced by
approx. 20% as shown by the curve for the
light load mode.
10-30 PC60-7
③
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PC60-7 10-31
Operation
1. When actuator load is large (pump discharge pressure PP is high)
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E20107
10-32
• When the load on the actuator becomes high

and pump discharge pressure PP rises, pis-
ton (8) is pushed to the left () because of the
relationship between the cross-sectional area
of piston portions S1 and S2 (S1 > S2).
• As a result, port f and port g are intercon-
nected, pump pressure PP flows from port g to
port f, and at the same time, port f and the
drain circuit are shut off.
• If the LS valve takes action to increase the
pump discharge amount, spool (15) of the LS
valve is moved to the left () and port d and
port e are interconnected.
• As a result, pump pressure PP from port f of
the PC valve flows from port e of the LS valve
to port d, enters chamber X at the large diam-
eter end of servo piston (1), and stops the
movement of servo piston (1).
• If pump discharge pressure PP rises further,
piston (8) moves to the left () and servo pis-
ton (1) moves up in the direction of the mini-
mum swash plate angle () because of the
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pressure in chamber X at the large diameter
end.
• When servo piston (1) moves up (), piston (4)
E20107
is moved to the right () through lever (2).

As a result, springs (5) and (7) are moved in
the direction of compression and piston (8) is
pushed back to the right.
• When piston (8) is pushed back to the right
and port f and port g are shut off, servo piston
(1) stops moving up ().
• The position where servo piston (1) stops is
higher (closer to the minimum swash plate
angle ) than when the pump discharge pres-
sure is low.
10-33
2. When actuator load becomes smaller (pump discharge pressure PP drops)
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E20107
10-34
• When the load on the actuator becomes

smaller and pump discharge pressure PP
drops, piston (8) is pushed to the right () by
the force of springs (5) and (7).
• As a result, port g and port f are shut off, and
at the same time, port f is connected to the
drain circuit.
• When this happens, if the LS valve is acting to
increase the pump discharge pressure, the
limit of the PC valve disappears, so the pres-
surized oil in chamber X at the large diameter
end of servo piston (1) passes from port d of
the LS valve to port e, and flows from port f of
the PC valve to the drain circuit as explained in
the section on the LS valve.
• For this reason, servo piston (1) is moved
down in the direction of the maximum swash
plate angle () by the pressure in chamber Y
at the small diameter end.
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E20107
10-35
3. When mode selector solenoid valve signal pressure is input
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E20107
10-36
When mode selector solenoid valve signal

pressure is input
• When the mode selector solenoid valve is
turned ON and signal pressure PM is input to
port PM, it acts on piston (10) and piston (10)
pushes piston (8) to the left ().
• As a result, springs (5) and (7) are com-
pressed and the spring load is increased, so
the pump absorption torque is reduced by
approx. 20%.
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PC60-7 10-37
③
4. Action of spring
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10-38 PC60-7
• The spring load of springs (5) and (7) in the PC

valve is changed by the swash plate angle.
• When servo piston (1) moves, lever (2) moves,
and piston (5) moves to the right or left
according to the direction of rotation of lever
(2).
• If piston (4) moves to the right (), spring (5)
and spring (7) are compressed. If it moves
further to the right (), spring (5) contacts seat
(6), so only spring (7) functions as a spring.
In other words, the spring load is changed by
piston (5) extending or contracting springs (5)
and (7).
• The pump absorption torque curve, which
shows the relationship between pump dis-
charge pressure PP and discharge amount Q,
is a bent curve as shown in the diagram on the
right because springs (5) and (7) have dif-
ferent spring loads.
• In addition, if mode selection solenoid valve
signal pressure PM is input, even if it changes,
springs (5) and (7) are pushed from the right
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through piston (8), so the spring load changes.
The position where spring (8) stops, in other
words, the pump absorption torque, is de-
termined by the position where the force of
springs (5) and (7) is in balance with pump
pressure PP + mode selection pressure PM
acting on piston (8).
• In other words, if pump discharge pressure PP
increases, pump discharge amount Q is
reduced; and if pump discharge pressure PP
goes down, pump discharge amount Q is in-
creased.
• The pump absorption torque, which shows the
relationship between pump discharge pressure
PP and pump discharge amount Q, moves in
parallel from a to b as shown in the diagram on
the right according to the increase in each
signal pressure.
PC60-7 10-39
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
Outline TSW : to swing motor
The following five types of control valve are used. TC : to oil cooler
• 6-spool valve (standard ) TB : to tank
• 7-spool valve (standard + 1 service valve) LS : to pump LS valve
• 8-spool valve (standard + 2 service valve) PP : from PPC shuttle valve
• 8-spool valve TS : to tank
(blade specification + 1 service valve) PA1 : from left swing PPC valve
• 9-spool valve PB1 : from right swing PPC valve
(blade specification + 2 service valve) PA2 : from L.H. travel FORWARD PPC valve
PB2 : from L.H. travel REVERSE PPC valve
★ Each service valve is an add-on type where PA3 : from R.H. travel FORWARD PPC valve
PB3 : from R.H. travel REVERSE PPC valve
one valve each can be added, so it is possible
PA4 : from boom RAISE PPC valve
to add valves or remove valves if necessary.
PB4 : from boom LOWER PPC valve
An explanation is given of the external appear-
PA5 : from arm OUT PPC valve
ance for all types.
PB5 : from arm IN PPC valve
Only an explanation of the 8-spool valve (blade
PA6 : from bucket DUMP PPC valve
specification + 1 service valve) is given for the
PB6 : from bucket CURL PPC valve
cross section.
PA7 : from blade RAISE PPC valve
★ The cross-sectional structure of the service
PB7 : from blade LOWER PPC valve
valve is the same as the structure for the stan- PA8 : from service 1 PPC valve
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dard bucket valve, so see the bucket valve for PB8 : from service 1 PPC valve
details. PA9 : from service 2 PPC valve
PB9 : from service 2 PPC valve
Names, name of ports
(common for all external view diagrams)
1. No. 1 service valve
P : from main pump

A1 : to swing motor MB
B1 : to swing motor MA
A2 : to L.H. travel motor A
B2 : to L.H. travel motor B
A3 : to R.H. travel motor B
B3 : to R.H. travel motor A
A4 : to boom cylinder bottom
B4 : to boom cylinder head
A5 : to arm cylinder head
B5 : to arm cylinder bottom
A6 : to bucket cylinder head
B6 : to bucket cylinder bottom
A7 : to attachment 1
B7 : to attachment 1
10-40 PC60-7
③
EXTERNAL VIEW
6-spool valve (standard)
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PC60-7 10-41
③
7-spool valve (standard + 1 service valve)
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10-42 PC60-7
③
8-spool valve (standard + 2 service valve)

8-spool valve (blade specification + 1 service valve)
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PC60-7 10-42-1
③
9-spool valve blade specification 2 service valve
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10-42-2 PC60-7
③
CROSS SECTION
★ The cross section shows the 8-spool valve
(brade specification + 1 service valve).
The cross-sectional structure of the 8-spool
valve service valve is the same as the struc-
ture of the bucket valve, so see it.
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1. Suction valve (L.H. travel A) 9. Suction valve (service B)

2. Suction valve (R.H. travel A) 10. Suction valve (blade bottom)
3. Suction valve (boom bottom) 11. Suction valve (bucket bottom)
4. Suction valve (arm head) 12. Suction valve (arm bottom)
5. Suction valve (bucket head) 13. Suction valve (boom head)
6. Plug (blade head) 14. Suction valve (R.H. travel B)
7. Suction valve (service A) 15. Suction valve (L.H. travel B)
8. Safety valve 16. Cooler bypass valve
PC60-7 10-43
③
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1. Main relief valve 6. Spool (arm)

2. Spool (swing) 7. Spool (bucket)
3. Spool (L.H. travel) 8. Spool (blade)
4. Spool (R.H. travel) 9. Spool (service)
5. Spool (boom)
10-44 PC60-7
③
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1. Swing pump pressure 8. Pressure compensation 15. Pressure compensation

circuit orifice valve F (blade) valve R (boom)
2. Pressure compensation 9. Pressure compensation 16. Pressure compensation
valve F (swing) valve F (service) valve R (R.H. travel)
3. Pressure compensation 10. Pump pressure detection 17. Pressure compensation
valve F (L.H. travel) plug valve R (L.H. travel)
4. Pressure compensation 11. Pressure compensation 18. Pressure compensation
valve F (R.H. travel) valve (service) valve R (swing)
5. Pressure compensation 12. Pressure compensation 19. LS select valve
valve F (boom) valve (blade) ★ F: Flow control valve
6. Pressure compensation 13. Pressure compensation R: Reducing valve
valve F (arm) valve R (bucket)
7. Pressure compensation 14. Pressure compensation
valve F (bucket) valve R (arm)
PC60-7 10-45
③
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1. Check valve (service)

2. Check valve (blade ,B side only)
3. Check valve (bucket)
4. Check valve (arm)
5. Check valve (boom)
10-46 PC60-7
③
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L.H., R.H. travel valve Boom valve

1. Suction valve (A) 6. Suction valve (bottom)
2. Suction valve (B) 7. Suction valve (head)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F
PC60-7 10-47
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1. Main relief valve Swing valve

2. Lift check valve 4. Spool
3. LS select valve 5. Pressure compensation valve R
6. Pressure compensation valve F
10-48 PC60-7
③
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Arm valve Bucket valve (service valve)

1. Suction valve (head) 6. Suction valve (head)
2. Suction valve (bottom) 7. Suction valve (bottom)
3. Spool 8. Spool
4. Pressure compensation valve R 9. Pressure compensation valve R
5. Pressure compensation valve F 10. Pressure compensation valve F
PC60-7 10-49
③
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1. Pump pressure detection plug BLADE VALVE

2. Safety valve 8. Suction valve (bottom)
3. Pressure release plug 9. Spool
4. LS bypass plug 10. Pressure compensation valve R
5. Swing pressure compensation valve F 11. Pressure compensation valve F
6. Swing pressure compensation valve R
7. Unload valve
10-50 PC60-7
③
STRUCTURE AND FUNCTION SELF-PRESSURE REDUCING VALVE
SELF-PRESSURE REDUCING VALVE
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E20107
a. Port P1 (from main pump)

b. Port PC (to main pump)
c. Port Pr
(supplies oil to electromagnetic valve, PPC
valve, EPC valve, etc.)
d. Port T (to hydraulic tank)
10-51
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E20107
1. Valve (reducing valve) 7. Poppet

2. Valve (sequence valve) 8. Spring (reducing valve pilot)
3. Spring (sequence valve large) 9. Spring (reducing valve main)
4. Spring (sequence valve small) 10. Spring (safety valve)
5. Plate 11. Ball
6. Screw
10-52
Operation
1. Engine stopped
• Poppet (7) is pushed against the seat by spring
(8): Pr → T closed
• Valve (1) is pushed against the plug by spring
(9): P1 → Pr open
• Valve (2) is pushed by spring (3) and spring
(4): P1 → P2 closed
2. (1) At HOLD
(2) When load (pressure P2) is low (opera-
tions where work equipment moves un-
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der own weight, such as boom LOWER,
arm IN)
Note: When pressure P2 (load pressure) is
lower than self-pressure reducing valve
output pressure (pressure Pr)
Valve (2) is subjected to force from spring (3),
spring (4), and pressure Pr (0 kg/cm2 when
engine is stopped) in the direction to close the
circuit between port P1 → P2. However, if
hydraulic oil flows in from port P1 (pressure
P1), (force of spring (3) and spring (4) + area ø
d of valve (2) x pressure Pr) are balanced, and
the opening between P1 and P2 is adjusted in
order to maintain pressure P1 and pressure Pr
at the above set value.
• If pressure Pr goes above the set pressure,
poppet (7) opens and hydraulic oil flows from
port Pr → spool (1) orifice → poppet (7) open-
ing → tank circuit.
As a result, a difference in pressure is gener-
ated on both sides of spool (1) orifice, so spool
(1) moves in the direction to close the open-
ing between P1 → Pr, and pressure Pr is main-
tained at the certain pressure by which pres-
sure P1 is reduced
(set pressure) by the amount of this opening.
PC60-7 10-53
③
3. When load pressure (pressure P2) is high

When load pressure (pressure P2) is increased
and pump discharge amount is increased by
operation such as digging
Pressure P1 also increases (pressure P1) >
(spring (3) and area d of valve (2) × pressure
Pr), and valve (2) moves to the end of its
stroke.
As a result, the amount of opening between
P1 → P2 increases, so the passage resistance
becomes smaller and the horsepower loss of
the engine is reduced.
• If pressure Pr goes above the set pressure,

poppet (7) opens and hydraulic oil flows from
port Pr → spool (1) orifice → poppet (7) open-
ing → tank circuit.
As a result, a difference in pressure is gener-
ated on both sides of spool (1) orifice, so spool
(1) moves in the direction to close the open-
ing between P1 → Pr. Pressure Pr is main-
tained at the certain pressure by which pres-
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sure P1 is reduced (set pressure) by the
amount of this opening.
4. When abnormally high pressure is generated

If pressure Pr of the self-pressure reducing
valve becomes abnormally high, ball (11)
pushes against the force of spring (10) and
separates from the seat. Hydraulic oil flows
from output port Pr → T, and pressure Pr is
lowered to protect the equipment (PPC valve,
electromagnetic valve, and other equipment
using the pressure oil from port Pr) from ab-
normal high pressure.
10-54 PC60-7
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PC60-7 10-55
③
STRUCTURE AND FUNCTION CLSS
CLSS
1. OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing • The CLSS consists of a variable capacity single
System, and has the following features. piston pump, control valve, and actuators.
1) Fine control not influenced by load • The pump body consists of the main pump, the
2) Control enabling digging even with fine PC valve and LS valve.
control
3) Ease of compound operation ensured by
flow divider function using area of open-
ing of spool during compound operations
4) Energy saving using variable pump con-
trol
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10-56 PC60-7
③
2. BASIC PRINCIPLE
1) Control of pump swash plate angle • If LS differential pressure ∆PLS becomes
• The pump swash plate angle (pump discharge lower than the set pressure of the LS valve,
amount) is controlled so that LS differential the pump swash plate becomes larger; if it
pressure ∆PLS (the difference between pump becomes higher than the set pressure of the
pressure PP and control valve outlet port LS LS valve, the pump swash plate becomes
pressure PLS ) (load pressure of actuator) is smaller.
constant. ★ For details of the operation, see HYDRAULIC
(LS pressure ∆PLS = Pump discharge pres- PUMP.
sure PP - LS pressure PLS)
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PC60-7 10-57
③
2) Pressure compensation control

• A pressure compensation valve is installed to downstream (outlet port) of the notch in the
the inlet port side of the control valve spool to spool of each valve.
balance the load. In this way, the flow of oil from the pump is
When two actuators are operated together, divided in proportion to the area of openings
this valve acts to make pressure difference S1 and S2 of each valve.
∆P between the upstream (inlet port) and
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10-58 PC60-7
3. OPERATION FOR EACH FUNCTION

AND VALUE 1. Unload valve
Hydraulic circuit diagram and name of values (LS pressure + 2.6 MPa {27 kg/cm2})
2. Safety valve
(27.5 MPa {280 kg/cm2})
3. Pressure compensation valve
4. Suction valve
5. Main relief valve
(24.5 MPa {250 kg/cm2})
6. Lift check valve
(cracking pressure:
0.13 MPa {1.3 kg/cm2})
7. Cooler bypass valve
(cracking pressure:
0.81 MPa {8.3 kg/cm2})
8. LS select valve
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E20107
10-59
1) Unload valve
Function
1. When the control valve is at HOLD, pump dis- When this happens, pump discharge pressure
charge amount Q discharged by the minimum PP is set at 2.6 MPa {27 kg/cm2} by spring (2)
swash plate angle is released to the tank inside the valve. (LS pressure PLS: 0 MPa {0
circuit. kg/cm2})
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E20107
Operation
When control valve is at HOLD
• Pump discharge pressure PP is acting on the • In this way, pump discharge pressure PP is set
left end of spool (1) and LS pressure PLS is to 2.6 MPa {27 kg/cm2}.
acting on the right end.
• When the control valve is at HOLD, LS pres-
sure PLS is not generated, so only pump dis-
charge pressure PP has any effect, and PP is
set only by the load of spring (2).
• As pump discharge pressure PP rises and
reaches the load of spring (2) (2.6 MPa {27 kg/
cm2}), spool (1) is moved to the right (). The
oil in pump circuit is then connected to tank
circuit T through the drill hole in sleeve (2).
10-60
2. During fine control of the control valve, when When the difference in pressure between
the demand flow for the actuator is within the pump discharge pressure PP and LS pressure
amount discharged by the minimum swash PLS reaches the load of spring (2) (2.6 MPa
plate angle of the pump, pump discharge {27 kg/cm2}), the unload valve opens, so LS
pressure PP is set to LS pressure PLS + 2.6 differential pressure ∆PLS becomes 2.6 MPa
MPa {27 kg/cm2}. {27 kg/cm2}.
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E20107
Operation
During fine control of control valve
• When fine control is carried out on the control • In other words, pump discharge pressure PP
valve, LS pressure PLS is generated and acts is set to a pressure equal to the spring force
on the right end of spool (1). (2.6 MPa {27 kg/cm2}) + LS pressure PLS,
When this happens, the area of the opening of and LS differential pressure ∆PLS becomes
the control valve spool is small, so there is a 2.6 MPa {27 kg/cm2}.
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 (2) (2.6 MPa
{27 kg/cm2}), spool (1) moves to the right (),
and pump circuit PP and tank circuit T are con-
nected.
10-61
3. When the control valve is being operated and out to tank circuit T is cut off, and all of pump
the demand flow for the actuator becomes discharge amount Q flows to the actuator
greater than the pump discharge from the circuit.
minimum swash plate angle, the flow of the oil
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Operation E20107
Control valve operated
• When the control valve is operated to a larger • As a result, pump circuit PP and tank circuit T
stroke, LS pressure PLS is generated and acts are shut off, and all the pump discharge
on the right end of spool (1). amount Q flows to the actuator circuit.
When this happens, the area of the opening
of the control valve spool is large, so the dif-
ference between LS pressure PLS and pump
discharge pressure PP is small.
• For this reason, the difference in pressure be-
tween pump discharge pressure PP and LS
pressure PLS does not reach the load of
spring (2) (2.6 MPa {27 kg/cm2}), so spool (1)
is pushed to the left () by spring (2).
10-62
2) Introduction of LS pressure
Function
• The LS pressure is the actuator load pressure circuit PLS.
at the outlet port end of the control valve. In addition, orifice C is installed midway be-
• With the control valve, it reduces pump pres- tween pump circuit PP and reducing valve (3),
sure PP at reducing valve (3) of the pressure and it acts as a damper.
compensation valve to the same pressure as • With the travel valve, actuator circuit pres-
actuation pressure A, and sends it to the LS sure A is taken directly to the LS circuit PLS.
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E20107
Operation
1. Main control valve (boom, arm, bucket, swing)
• When spool (1) is operated, pump pressure • The area at both ends of reducing valve (3) is
PP flows from flow control valve (2) and notch the same (SA = SLS), and actuator circuit pres-
a in the spool through bridge passage b to sure PA (= A) acts on the SA end. The reduced
actuator circuit A. pump pressure PP acts on SLS at the other
• At the same time, reducing valve (3) also end.
moves to the right (), so pump pressure PP • As a result, reducing valve (3) is balanced at a
brought from orifice c has its pressure re- position where actuator circuit pressure PA and
duced by the pressure loss at notch d. It goes the pressure of spring chamber PLS1 are the
to LS circuit PLS, and then goes to spring same. Pump pressure PP reduced at notch d
chamber PLS1. becomes actuator circuit pressure A and is
• When this happens, LS circuit PLS is con- taken to LS circuit PLS.
nected to tank circuit T from LS bypass plug
(4) (see the section on the LS bypass plug).
10-63
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E20107
2. Travel valve
• When spool (1) is operated, pump pressure
PP flows from flow control valve (2) and notch
a in the spool through bridge passage b to
actuator circuit A.
• At the same time, reducing valve (3) is moved
to the right () by actuator circuit pressure
PA, and notch c and notch d are intercon-
nected respectively with travel junction circuit e
and LS circuit PLS.
• As a result, actuator circuit pressure PA (= A)
passes from notch c through notch d and goes
to LS circuit PLS.
★ The travel circuit is different from the work
equipment circuit: actuator circuit pressure PA
goes directly to LS circuit PLS.
10-64
3) LS bypass plug
Outline
1. This releases the residual pressure of LS pres- it creates a pressure loss in the throttled flow
sure PLS. of the spool or shuttle valve, and increases the
2. This makes the speed of the rise in pressure of stability by lowering the effective LS dif-
LS pressure PLS more gentle. ferential pressure.
In addition, with this discarded throttled flow,
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E20107
Operation
• The pressurized oil for LS circuit PLS passes
from clearance filter a (formed by the clear-
ance between LS bypass plug (1) and the
valve body) through orifice b and flows to the
tank circuit.
10-65
4) Pressure compensation valve

Function
• During compound operations, if the load (When this happens, the other actuator being
pressure becomes lower than the other ac- used for compound operation (right side) is at
tuator and the oil flow is about to increase, a higher load than the actuator on this side (left
compensation is received. side).)
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E20107
Operation
• If the load pressure of the other actuator (right are balanced in position where the difference
side) becomes higher during compound op- in pressure between PLS and PA acting on
erations, the oil flow in actuator circuit A on both ends of reducing valve (2) and the pres-
this side (left side) tries to increase. sure loss between PP and PPA on both sides
• If this happens, the LS pressure PLS of the of flow control valve (2) are the same.
other actuator acts on spring chamber PLS1, • In this way, the pressure difference between
and reducing valve (1) and flow control valve upstream pressure PPA and downstream
(2) are pushed to the left (). pressure PA of both spools used during com-
• Flow control valve (2) throttles the area of pound operations is the same, so the pump
opening between pump circuit PP and spool flow is divided in proportion to the area of
upstream PPA, and pressure loss is generated opening of notch a of each spool.
between PP and PPA.
• Flow control valve (2) and reducing valve (1)
10-66
5) Area ratio of pressure compensation valve

Function
• The pressure compensation valve determines S1: Area of flow control valve (2)
the compensation characteristics by carrying - area of piston (3)
out fine adjustment of the area ratio (S2/S1) S2: Area of reducing valve (1)
between area S2 of reducing valve (1) and - area of piston (3)
area S1 of flow compensation valve (2) to
match the characteristics of each actuator.
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E20107
Area ratio (S2:S1) and compensation

characteristics
• When ratio is 1.00:
[pump pressure PP - spool notch upstream Ratio of Ratio of
Valve Valve
pressure PPB]≒[LS circuit pressure PLS - ac- area area
tuator circuit pressure PA (= A)] and oil flow is Service 0.98 L.H. travel 1.00
divided in proportion to area of opening of Bucket 0.98 R.H. travel 1.00
spool. Arm 0.96 Swing 0.98
• When ratio is more than 1.00:
Boom 0.96 Blade 1.00
PP - PPB > PLS - PA (= A) and oil flow is di-
vided in a proportion less than area of open-
ing of spool.
• When ratio is less than 1.00:
PP - PPB < PLS - PA (= A) and oil flow is di-
vided in a proportion more than area of open-
ing of spool.
10-67
6) L.H., R.H. travel junction circuit

Function
• To compensate for any difference in the oil eling in a straight line, so there is no travel
flow in the left and right travel circuits when deviation.
traveling in a straight line, the junction cir- • When steering the machine, the difference in
cuit opens when the left and right travel the load pressure returns the reducing valve of
spools are operated. the travel valve on the inside of the turn, so the
In this way, the flow of oil to the left and right junction circuit is closed and the machine can
travel motors is almost the same when trav- be steered.
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E20107
Operation
When traveling in a straight line
• When left and right travel spools (1) are oper-
ated, the pump discharge flows from pump
circuit PP and circuit PA to actuator circuit A.
• When traveling in a straight line, to make ac-
tuator circuit PA equal, left and right reducing
valves (2) are pushed to the right () by the
same amount, and notch a and the travel junc-
tion 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
difference is compensated to prevent any
deviation in travel.
10-68
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E20107
Steering when traveling

• When traveling in a straight line, if left travel • Damper b is provided in the circuit to dampen
spool (left 1) is returned to the neutral posi- any excessive characteristics in the opening or
tion and steering is operated, a difference closing of the travel junction circuit if the spool
(right A > left A) is generated in the load pres- is operated suddenly.
sure of left and right travel actuator circuits PA,
and LS pressure PLS becomes the same
pressure as right A (the side with the high load
pressure).
• As a result, flow control valve (3) on the left
travel side is pushed to the left () by LS cir-
cuit PLS, that is, right travel load pressure right
A, so the opening of the left notch a is closed,
the left and right travel circuits are shut off, and
it becomes possible to operate the steering
when traveling.
10-69
7) Travel LS bypass circuit

Function
• When the travel and another actuator are op- the drop in the travel speed to the minimum.
erated at the same time, the amount of oil • When the travel is operated independently or
discarded by the throttle in LS circuit PLS in- any other actuator is operated indepen-
creases and the pressure compensation pre- dently, the bypass circuit is closed.
cision of the travel circuit is relaxed to keep
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E20107
Operation
Normal operation
• When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom cir-
cuit pressure A1.
• At the same time, LS circuit pressure PLS also
goes to spring chamber PLS1 of reducing
valve (2) of the travel valve.
• The travel spool is not being operated, so
travel actuator circuit PA is closed, and check
valve (4) inside flow control valve (3) is also
closed.
• As a result, when the boom is operated inde-
pendently, the travel LS bypass circuit is
closed.
10-70
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E20107
Travel + other actuator operated

• When boom spool (1) is operated, LS circuit • For this reason, LS circuit pressure PLS
PLS becomes the same pressure as boom cir- (which is the same pressure as boom circuit
cuit pressure A1. pressure A1), flows to travel circuit A2 to re-
• With the actuator circuit pressure, the boom duce the pressure.
RAISE pressure is normally higher than the
travel pressure (A1 > A2), so the pressure of
spring chamber PLS1 inside reducing valve (2)
of the travel valve is higher than travel circuit
pressure PA.
• As a result, reducing valve (2) moves to the
left, LS pressure of spring chamber PLS1 goes
from orifice a and pushes check valve (4) open,
so oil flows from passage b and passage c to
travel circuit PA.
10-71
8) Boom regeneration circuit

Function
1. When the boom is being lowered, if bottom sends the return oil flow at the bottom end to
pressure A of cylinder (1) is higher than head the head end to increase the cylinder speed by
pressure B, and there is hydraulic drift, this that amount.
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E20107
Operation
• If there is hydraulic drift when lowering the
boom, pressure A at the bottom end of boom
cylinder (1) becomes higher than pressure B
at the head end.
• When this happens, part of the return oil at the
bottom end passes through regeneration
passage a of boom spool (1), pushes check
valve (3) open, and flows to the head end.
• As a result, the boom lowering speed is in-
creased.
10-72
2. When lowering the boom, if head pressure B process, check valve (3) closes and shuts off
of cylinder (1) is greater than bottom pressure the circuit between the head and bottom ends.
A, and the work equipment is in the digging
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E20107
Operation
• When the boom is lowered, if the work equip-
ment is in the digging process, pressure B at
the head end of cylinder (1) becomes higher
than pressure A at the bottom end.
• When this happens, check valve (3) is closed
by spring (4) and pressure B at the head end,
so the circuit between the head circuit and bot-
tom circuit is shut off.
10-73
9) LS select valve
Function
• When the swing + boom RAISE are operated ing into LS circuit PLS. In this way, it pre-
together, this valve ensures the high pressure vents the boom RAISE speed from drop-
which is generated when driving the swing, ping.
and prevents swing LS pressure a from flow-
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E20107
Operation
Normal operation
• Normally, except when boom RAISE is oper-
ated, the pilot pressure does not act on pilot
port BP.
• In this condition, pump pressure PP pushes
valve (1) open and goes to reducing valve (4)
of the swing valve. When the swing is oper-
ated, LS pressure PLS is generated in accor-
dance with the load pressure and flows to the
pump LS valve.
10-74
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Swing + boom RAISE at same time

• When the swing + boom RAISE are operated • As a result, swing LS pressure PLS is not gen-
at the same time, the signal pressure from the erated, so only the boom RAISE LS pressure
boom RAISE PPC circuit is sent to into pilot goes to the pump LS valve, and the pump
port BP. discharge amount is controlled by the boom
• When this pilot pressure BP acts on piston (2) RAISE LS pressure.
and becomes stronger than spring (3), piston • The size of pilot pressure BP is determined by
(2) is pushed fully to the left (). Valve (1) the amount the control lever is operated.
closes, and pump pressure PP stops flowing to
reducing valve (4) of the swing valve.
PC60-7 10-75
4. Operation of system as a whole

1) When all control valves are at HOLD 12. L.H. travel valve
• Pump discharge amount Q all flows from un- 12A. Spool
load valve (6) to tank (1). 12B. Pressure compensation valve
• None of the spools (each spool A) is being (flow control valve)
operated, so the LS pressure PLS is not gen- 12C.Pressure compensation valve
erated. (reducing valve)
At the same time, the LS pressure PLS is con- 13. Swing valve
nected to the tank circuit by LS bypass plug (6), 13A. Spool
so it is the tank pressure. 13B. Pressure compensation valve
• In this condition, LS differential pressure ∆PLS (flow control valve)
becomes the unload pressure-tank pressure, 13C.Pressure compensation valve
and becomes higher than the LS set pressure (reducing valve)
of LS valve (4), so main pump (2) is set to the 14. LS select valve
minimum swash plate angle. 15. Unload valve
1. Hydraulic tank 18. Lift check valve
19. Swing pump pressure circuit orifice
Hydraulic pump 20. Central safety valve
2. Main pump
3. PC valve Actuator
21. Bucket cylinder
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4. LS valve
5. Servo piston 22. Arm cylinder
23. Boom cylinder
Control valve 24. L.H. travel motor
6. LS bypass plug 25. R.H. travel motor
7. Pump pressure detection plug & LS damper 26. Swing motor
8. Bucket valve
8A. Spool
8B. Pressure compensation valve Self-pressure reducing valve
(flow control valve) 27. Sequence valve
8C. Pressure compensation valve 28. Reducing valve
(reducing valve)
8D. Check valve ★ The suction valve is not shown.
9. Arm valve
9A. Spool
9B. Pressure compensation valve
(flow control valve)
9C. Pressure compensation valve
(reducing valve)
9D. Check valve
10. Boom valve
10A. Spool
10C.Pressure compensation valve
(reducing valve)
10D.Check valve
11. R.H. travel valve
11A. Spool
(reducing valve)
10-76 PC60-7
③
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PC60-7 10-77
2) When swing is operated individually

• When swing spool (13A) is operated, pump 10B. Pressure compensation valve
discharge amount Q flows to swing motor (26). (flow control valve)
At the same time, LS pressure PLS is 10C.Pressure compensation valve
generated and unload valve (15) closes. (reducing valve)
LS pressure PLS becomes the load pressure 10D.Check valve
of swing motor (26). 11. R.H. travel valve
• In the swing circuit, the difference between 11A. Spool
pump discharge pressure PP and LS pressure 11B. Pressure compensation valve
PLS, in other words, LS differential pressure (flow control valve)
∆PLS, becomes the same as the LS set pres- 11C. Pressure compensation valve
sure of LS valve (4). (reducing valve)
• As a result, the swash plate angle of main 12. L.H. travel valve
pump (2) is kept at a point midway between 12A. Spool
the minimum and maximum angles, and the 12B. Pressure compensation valve
main pump discharges the oil flow demanded (flow control valve)
by the swing circuit (approx. 50%). 12C.Pressure compensation valve
When the swing is operated independently, (reducing valve)
pump discharge amount Q does not become 13. Swing valve
100%. 13A. Spool
• With swing pressure compensation valves 13B. Pressure compensation valve
(13B) and (13C), the pump pressure PP passes (flow control valve)
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from LS select valve (14), goes through ori-
fice (19), and flows to the left end of flow con- (reducing valve)
trol valve (13B), so it moves fully to the right. 14. LS select valve
15. Unload valve
1. Hydraulic tank 17. Cooler bypass valve
18. Lift check valve
Hydraulic pump 19. Swing pump pressure circuit orifice
2. Main pump 20. Central safety valve
3. PC valve
4. LS valve Actuator
5. Servo piston 21. Bucket cylinder
22. Arm cylinder
Control valve 23. Boom cylinder
6. LS bypass plug 24. L.H. travel motor
7. Pump pressure detection plug & LS damper 25. R.H. travel motor
8. Bucket valve 26. Swing motor
8A. Spool
8B. Pressure compensation valve Self-pressure reducing valve
(flow control valve) 27. Sequence valve
8C. Pressure compensation valve 28. Reducing valve
(reducing valve)
9. Arm valve
9A. Spool
(reducing valve)
9D. Check valve
10. Boom valve
10A. Spool
10-78 PC60-7
③
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PC60-7 10-79
3) When left and right travel are operated at

same time
• When left and right travel spools (11A) and 10C.Pressure compensation valve
(12A) are operated, pump discharge amount Q (reducing valve)
flows to left and right travel motors (24) and 10D.Check valve
(25), and at the same time, LS pressure PLS is 11. R. H. travel valve
generated and unload valve (15) closes. 11A. Spool
• When this happens, reducing valves (11C) and 11B. Pressure compensation valve
(12C) of the left and right travel valves move to (flow control valve)
the right, the travel junction circuit is inter- 11C. Pressure compensation valve
connected, and this prevents any deviation in (reducing valve)
travel. 12. L.H. travel valve
• When left and right travel spools (11A) and 12A. Spool
(12A) are 100% open, if pump discharge 12B. Pressure compensation valve
amount Q is almost 100%, the pressure is set (flow control valve)
so that it becomes the same as the LS set dif- 12C.Pressure compensation valve
ferential pressure, and main pump (1) is kept (reducing valve)
at the maximum swash plate angle. 13. Swing valve
• If left and right travel spools (11A) and (12A) 13A. Spool
are less than 100% open, pump discharge 13B. Pressure compensation valve
amount Q is controlled in accordance with the (flow control valve)
area of opening of the spool by LS differential 13C.Pressure compensation valve
(reducing valve)
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pressure ∆PLS.
14. LS select valve
15. Unload valve
1. Hydraulic tank 16. Main relief valve
Hydraulic pump 18. Lift check valve
2. Main pump 19. Swing pump pressure circuit orifice
3. PC valve 20. Central safety valve
4. LS valve
5. Servo piston Actuator
21. Bucket cylinder
Control valve 22. Arm cylinder
6. LS bypass plug 23. Boom cylinder
7. Pump pressure detection plug & LS damper 24. L.H. travel motor
8. Bucket valve 25. R.H. travel motor
8A. Spool 26. Swing motor
(flow control valve) Self-pressure reducing valve
8C. Pressure compensation valve 27. Sequence valve
(reducing valve) 28. Reducing valve
8D. Check valve
9. Arm valve ★ The suction valve is not shown.
9A. Spool
(reducing valve)
9D. Check valve
10. Boom valve
10A. Spool
10-80 PC60-7
③
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PC60-7 10-81
4) Boom + arm operated at same time

• If boom spool (10A) is operated to RAISE and 9B. Pressure compensation valve
arm spool (9A) is operated at the same time to (flow control valve)
OUT, pump discharge amount Q flows to each 9C. Pressure compensation valve
cylinder (23) and (22). (reducing valve)
• When this happens, the load pressure of 9D. Check valve
boom cylinder (23) is greater than the load 10. Boom valve
pressure of arm cylinder (22), so the oil tries 10A. Spool
to flow to arm cylinder (22) where the load 10B. Pressure compensation valve
pressure is low. However, the pressure on the (flow control valve)
upstream side of arm spool (9A) is com- 10C.Pressure compensation valve
pensated by pressure compensation valves (reducing valve)
(9B) and (9C), which receive the load pressure 10D.Check valve
of the boom (= maximum LS pressure PLS). 11. R.H. travel valve
• In this way, the pressure difference between 11A. Spool
the upstream pressure and downstream pres- 11B. Pressure compensation valve
sure of boom spool (10A) and arm spool (9A) (flow control valve)
becomes equal, so the flow of oil from main 11C. Pressure compensation valve
pump (2) is divided in proportion to the area of (reducing valve)
opening of each spool. 12. L.H. travel valve
• If the area of opening of boom spool (10A) and 12A. Spool
arm spool (9A) is 100%, even if pump dis- 12B. Pressure compensation valve
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charge amount Q becomes 100%, LS differ-
ential pressure ∆PLS is set so that it does not 12C.Pressure compensation valve
reach the LS valve set differential pressure, so (reducing valve)
main pump (1) is held at the maximum swash 13. Swing valve
plate angle. 13A. Spool
• If the area of opening of boom spool (10A) 13B. Pressure compensation valve
and arm spool (9A) is less than 100%, pump (flow control valve)
discharge amount Q is controlled in accor- 13C.Pressure compensation valve
dance with the area of opening of the spools (reducing valve)
14. LS select valve
by LS differential pressure ∆PLS.
15. Unload valve
1. Hydraulic tank
19. Swing pump pressure circuit orifice
Hydraulic pump
20. Central safety valve
2. Main pump
3. PC valve
Actuator
4. LS valve
21. Bucket cylinder
5. Servo piston
22. Arm cylinder
23. Boom cylinder
Control valve
6. LS bypass plug
7. Pump pressure detection plug & LS damper
26. Swing motor
8. Bucket valve
8A. Spool
Self-pressure reducing valve
27. Sequence valve
28. Reducing valve
(reducing valve)
9. Arm valve
9A. Spool
10-82 PC60-7
③
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PC60-7 10-83
5) Boom RAISE + swing used at same time

• When boom spool (10A) is operated to RAISE 8C. Pressure compensation valve
and swing spool (13A) is operated at the same (reducing valve)
time, pump discharge amount Q flows to boom 8D. Check valve
cylinder (23) and swing motor (26). 9. Arm valve
• When this happens, LS select valve (14) is ac- 9A. Spool
tuated, and pump circuit PP and swing reduc- 9B. Pressure compensation valve
ing valve (13C) circuit are shut off, so the (flow control valve)
swing LS pressure is not generated and LS 9C. Pressure compensation valve
differential pressure ∆PLS becomes the load (reducing valve)
pressure of boom cylinder (23). 9D. Check valve .
• In addition, when swing pressure compensa- 10. Boom valve
tion valves (13B) and (13C) move to a certain 10A. Spool
position, the pump pressure PP introduction 10B. Pressure compensation valve
passage is shut off. As a result, they cannot (flow control valve)
move to the end of their stroke, and they are 10C.Pressure compensation valve
held at the position where the passage be- (reducing valve)
tween pump circuit PP and spool (13A) is 10D.Check valve
throttled. 11. R.H. travel valve
In other words, swing pressure compensation 11A. Spool
valves (13B) and (13C) do not operate to re- 11B. Pressure compensation valve
ceive compensation when the swing motor (flow control valve)
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load becomes small in normal swing opera-
tion; they are held at the position to receive (reducing valve)
compensation from the start of the swing. 12. L.H. travel valve
• If the area of opening of boom spool (10A) and 12A. Spool
swing spool (13A) is 100%, even if pump 12B. Pressure compensation valve
discharge amount Q becomes 100%, LS dif- (flow control valve)
ferential pressure ∆PLS is set so that it does 12C.Pressure compensation valve
not reach the LS valve set differential pres- (reducing valve)
sure, so main pump (1) is held at the maxi- 13. Swing valve
mum swash plate angle. 13A. Spool
• If the area of opening of boom spool (10A) and
swing spool (13A) is less than 100%, pump
discharge amount Q is controlled in ac-
(reducing valve)
cordance with the area of opening of the
14. LS select valve
spools by LS differential pressure ∆PLS.
15. Unload valve
1. Hydraulic tank 17. Cooler bypass valve
Hydraulic pump 19. Swing pump pressure circuit orifice
2. Main pump 20. Central safety valve
3. PC valve
Actuator
4. LS valve
21. Bucket cylinder
5. Servo piston
22. Arm cylinder
23. Boom cylinder
Control valve
6. LS bypass plug
7. Pump pressure detection plug & LS damper
26. Swing motor
8. Bucket valve
8A. Spool
Self-pressure reducing valve
27. Sequence valve
28. Reducing valve
★ The suction valve is not shown.
10-84 PC60-7
③
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PC60-7 10-85
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
Serial No. : 52374 – 59570
LMF40AB-2
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a. Port T (to tank) Specifications

b. Port B (from swing lock solenoid valve Model : LMF40AB-2
c. Port MA (from control valve) Motor capacity :40.8 cc/rev
d. Port MB (from control valve) Rated speed :1838 rpm
e. Port S (from lift check valve) Safety valve set pressure: 20.5 MPa {209 kg/cm2}
Suction valve cracking pressure:
Max. 0.03 MPa {0.3 kg/cm2}
Brake release pressure:
1.81±0.25 MPa {18.5±2.5 kg/cm2}
10-86 PC60-7
⑧
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E20107
1. Output shaft 8. Valve plate

2. Case 9. End cover
3. Thrust plate 10. Brake spring
4. Shoe 11. Brake piston
5. Piston 12. Disc
6. Center spring 13. Plate
7. Cylinder 14. Suction-safety valve
10-87
SUCTION-SAFETY VALVE
Function
• When the swing is stopped, the outlet port
circuit of the motor is closed by the control
valve, but the motor continues to be turned by
the inertia of the swing. As a result, the
pressure at the outlet port of the motor be-
comes abnormally high and there is danger
that the motor will be damaged.
• The safety valve is installed to prevent this
problem. It acts to release the abnormally
high pressure oil from the outlet port of the
motor to port S, and also functions as a swing
brake.
• The suction valve supplies an amount of oil
equivalent to the amount of oil released by
the safety valve. It sends this oil from port S to
the inlet port of the motor to prevent any
cavitation.
Operation
1. When starting swing
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• If the swing control lever is operated to swing
to the left, the pressurized oil from the pump
passes through the control valve and is sup-
E20107
plied to port MA.
• When this happens, the pressure at port MA
rises and the starting force is generated in the
motor, so the motor starts to turn.
The oil from the outlet port of the motor flows
from port MB through the control valve and
returns to the tank.
2. When stopping swing
• When the swing control lever is returned to the
neutral position, no more pressurized oil is
supplied from the pump to port MA.
At the same time, the oil from the outlet port of
the motor returns from the control valve to the
tank, and the circuit is closed.
• The pressure at port MB rises, and rotating
resistance to the motor is generated, so the
brake starts to take effect.
If the pressure at port MB rises to the set pres-
sure of safety valve (1), safety valve (1) opens
and releases the pressurized oil at port MB to
port S.
• No pressurized oil is supplied at port MA, but
the swing continues, so negative force is gen-
erated.
When this negative pressure drops to the set
pressure of suction valve (2), suction valve (2)
opens and oil is supplied from port S to pre-
vent cavitation.
10-88
SWING BRAKE
Operation
1. Swing brake solenoid valve de-energized
• If the swing brake solenoid valve is de-ener-
gized, the flow of pressurized oil from the main
pump is shut off, and port B is connected to
the tank circuit.
• As a result, brake piston (11) is pushed down
() by brake spring (10), pushes disc (12) and
plate (13) together, and the brake is applied.
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2. Swing brake solenoid valve energized
• When the swing brake solenoid valve is ener-
gized, the valve is switched, and pressurized
oil from the main pump enters port B and
flows to brake chamber a of brake piston (11).
• The pressurized oil entering chamber a over-
comes brake spring (10) and pushes brake
piston (11) up ().
• As a result, disc (12) and plate (13) are sepa-
rated and the brake is released.
PC60-7 10-89
③

Serial No.: 59571 and up (For Norway)
LMF40AB-2 (without reverse rotation prevention valve)
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B : From swing brake solenoid valve Specifications

MA : From swing control valve Model : LMF40AB-2
MB : From swing control valve Motor capacity :40.8 cc/rev
S : From tank Safety valve set pressure: 20.5 MPa {209 kg/cm2}
T : To tank Check valve cracking pressure:
Max. 0.03 MPa {0.3 kg/cm2}
1. Plate
10-89-1 PC60-7
⑧
LMF40ABE-2 (with reverse rotation prevention valve)
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B : From swing brake solenoid valve Specifications

MA : From swing control valve Model : LMF40ABE-2
MB : From swing control valve Motor capacity : 40.8 cc/rev
S : From tank Safety valve set pressure: 20.5 MPa {209 kg/cm2}
T : To tank Check valve cracking pressure:
1. Reverse rotation prevention valve Max. 0.03 MPa {0.3 kg/cm2}
PC60-7 10-89-2
⑧
★ The drawing shows the motor without reverse

rotation prevention valve.
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1. Output shaft 9. Brake spring

2. Case 10. Brake piston
3. Thrust plate 11. Plate
4. Shoe 12. Disc
5. Piston 13. Center spring
6. Cylinder block 14. Check valve spring
7. Valve plate 15. Check valve
8. End cover 16. Relief valve
10-89-3 PC60-7
⑧
SAFETY VALVE PORTION
1. Outline
The safety valve portion consists of a check
valve and relief valve.
2. Function
• When the swing is stopped, the output cir-
cuit of the motor is closed by the control valve,
but the motor continues to rotate because of
inertia. For this reason, the pressure at the
output side of the motor becomes abnormally
high, and this will damage the motor. To
prevent this, the oil causing the abnormal
hydraulic pressure is allowed to escape from
the outlet port (high-pressure side) of the
motor to port S, thereby preventing damage
to the motor.
3. Operation
1) When starting swing
• When the swing control lever is operated to left
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swing, the pressurized oil from the pump
passes through the control valve and is sup-
plied to port MA. Because of this, the pres-
sure at port MA rises, starting torque is gen-
erated in the motor, and the motor starts to
rotate.
The oil from the outlet port of the motor passes
from port MB through the control valve and
returns to the tank.
2) When stopping swing
• When the swing control lever is returned to
neutral, no pressurized oil is supplied from the
pump to port MA.
The return circuit to the tank is closed by the
control valve, so the pressure of the oil from
the outlet port of the motor increases at port
MB. Resistance to the rotation of the motor is
created, and the brake starts to take effect.
• The pressure at port MB rises to the set pres-
sure of relief valve B, and in this way, a high
braking torque acts on the motor, and the
motor stops.
• When relief valve B is being actuated, the re-
lief oil from relief valve B and the oil from port
S pass through check valve CA and are sup-
plied to port MA. This prevents cavitation from
occurring at port MA.
PC60-7 10-89-4
⑧
OPERATION OF SWING BRAKE

1) When swing brake solenoid valve is de-ener-
gized
If the swing brake solenoid valve is de-ener-
gized, the flow of pressurized oil from the self-
pressure reducing valve is shut off, and port B
is connected to the tank circuit.
As a result, brake piston (10) is pushed down
by brake spring (9), pushes disc (12) and plate
(11) together, and the brake is applied.
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2) When swing brake solenoid valve is energized
When the swing brake solenoid valve is ener-
gized, the valve is switched, and pressurized
oil from the self-pressure reducing valve en-
ters port B and flows to brake chamber a.
The pressurized oil entering chamber a over-
comes brake spring (9) and pushes brake pis-
ton (10) up. As a result, disc (12) and plate (11)
are separated and the brake is released.
10-89-5 PC60-7
⑧
REVERS ROTATION PREVENTION VALVE
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MA : Port 1. Valve body

MB : Port 2. Spool (MA end)
T1 :Port 3. Spring (MA end)
T2 :Port 4. Plug (MA end)
5. Spool (MB end)
6. Spring (MB end)
7. Plug (MB end)
PC60-7 10-89-6
⑧
EFFECT EXPLANATION DRAWING
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10-89-7 PC60-7
⑧
Function
• This valve reduces the swing back generated
in the swing body by the inertia of the swing
body, the backlash and rigidity of the machin-
ery system, and the compression of the hy-
draulic oil when the swing is stopped.
• This is effective in preventing spillage of the
load when stopping the swing and reducing
the cycle time (the positioning ability is good
and it is possible to move swiftly to the next
job).
1. When brake pressure is being generated at

port MB
Operation
• Pressure MB passes through the notch and
goes to chamber d, spool (5) compresses
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spring (6) according to the difference in area
D1 > D2, moves to the left, and MB → e is
connected.
• When this happens, pressure MA is below the
set pressure of spring (3), so spool (2) does
not move. For this reason, the pressure oil is
closed, and the braking force is ensured.
2. After motor stops Operation

• The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
• When this happens, reversal pressure is gen-
erated at port MA. Pressure MA goes to cham-
ber a, compresses spring (3), spool (2) moves
to the right, and MA → b is connected.
• At the same time, b → f is connected through
the drill hole in spool (5), so the reversal pres-
sure at port MA is bypassed to port T to pre-
vent the 2nd reversal.
PC60-7 10-89-8
⑧
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

Serial No.: 52374 - 57999
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A1. From main control valve port A2 D1. From main control valve port A3 1. Cover
A2. To L.H. travel motor port A D2. To R.H. travel motor port B. 2. Body
B1. From main control valve port B2 G1. From travel speed solenoid valve 3. Slipper seal
B2. To L.H. travel motor port B G2. To L.H. and R.H. travel motor port C 4. O-ring
C1. From main control valve port B3 T1. To tank. 5. Shaft
C2. To R.H. travel motor port A T2. To L.H. and R.H. travel motor port D
10-90 PC60-7
③
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A1. From main control valve port A2 D1. From main control valve port A3 1. Cover
A2. To L.H. travel motor port A D2. To R.H. travel motor port B. 2. Body
B1. From main control valve port B2 G1. From travel speed solenoid valve 3. Slipper seal
B2. To L.H. travel motor port B G2. To L.H. and R.H. travel motor port C 4. O-ring
C1. From main control valve port B3 DR1. To tank. 5. Shaft
C2. To R.H. travel motor port A DR2. To L.H. and R.H. travel motor port D
PC60-7 10-90-1
③
BLADE SPECIFICATION MACHINE

Serial No. : 52374 - 57999
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A1. From main control valve port A2 E1. From blade control valve port A 1. Cover
A2. To L.H. travel motor port A E2. To blade cylinder bottom. 2. Body
B1. From main control valve port B2 F1. From blade control valve port B 3. Slipper seal
B2. To L.H. travel motor port B F2. To blade cylinder head. 4. O-ring
C1. From main control valve port B3 G1. From travel speed solenoid valve 5. Shaft
C2. To R.H. travel motor port A G2. To L.H. and R.H. travel motor port C
D1. From main control valve port A3 T1. To tank.
D2. To R.H. travel motor port B T2. To L.H. and R.H. travel motor port D
10-90-2 PC60-7
③
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A1. From main control valve port A2 E1. From blade control valve port A 1. Cover
A2. To L.H. travel motor port A E2. To blade cylinder bottom. 2. Body
B1. From main control valve port B2 F1. From blade control valve port B 3. Slipper seal
B2. To L.H. travel motor port B F2. To blade cylinder head. 4. O-ring
C1. From main control valve port B3 G1. From travel speed solenoid valve 5. Shaft
C2. To R.H. travel motor port A G2. To L.H. and R.H. travel motor port C
D1. From main control valve port A3 DR1. To tank.
D2. To R.H. travel motor port B DR2. To L.H. and R.H. travel motor port D
PC60-7 10-91
③
STRUCTURE AND FUNCTION TRAVEL MOTOR
TRAVEL MOTOR
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a. Port C1 (to tank). Specification

b. Port A (from control valve) Model: GM09VL
c. Port D (from travel speed solenoid valve)
d. Port B (from control valve) Hydraulic motor
e. Port C2 (to tank) Motor capacity : Lo 39.8 cc/rev
Hi 25.1 cc/rev
Rated speed : Lo 1785 rpm
Hi 2773 rpm
Brake release pressure: 0.45 MPa {4.6 kg/cm2}
Travel speed switching pressure:
1.96 - 6.86 MPa {20 - 70 kg/cm2}
Final drive
Reduction ratio : 62.4
Speed : Lo 28.6 rpm
Hi 44.4 rpm
10-92 PC60-7
③
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1. Check valve 11. Swash plate 21. Drain plug

2. Check valve spring 12. Floating seal 22. Center shaft
3. Counterbalance valve 13. RV gear 23. Regulator piston
4. Return spring 14. RV gear 24. Case
5. End cap 15. Crankshaft 25. Spindle
6. Spring 16. Driven gear 26. Piston
7. Regulator valve 17. Cover 27. Cylinder
8. Brake piston 18. Drive gear 28. Brake spring
9. Plate 19. Shaft 29. Valve plate
10. Disc 20. Coupling 30. Check valve
PC60-7 10-93
OPERATION OF MOTOR
1) At low speed (motor swash plate angle at maximum)
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• The travel speed solenoid valve is deener- • As a result, swash plate (11) is pushed in the
gized, so the pilot pressure oil from the self maximum swash plate angle direction by the
pressure reducing valve does not flow to port main pressure inside cylinder chamber P, the
D. motor capacity becomes the maximum, and
• For this reason, regulator valve (6) is pushed the system is set to low speed.
fully to the left () by spring (7).
• Because of this, it pushes check valve (32),
and the main pressure oil from the control
valve going to end cover (5) is shut off by
regulator valve (6).
• At the same time, the pressurized oil at cham-
ber a of regulator piston (23) passes through
passage b in regulator valve (6) and is drained
to the motor case.
10-94 PC60-7
③
2. At high speed (motor swash plate angle at minimum)
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• When the travel speed solenoid valve is ener-

gized, the pilot pressure oil from the self pres-
sure reducing valve flows to port D, and
pushes regulator valve (6) to the right ().
• Because of this, the main pressure oil from
the control valve passes through passage b
in regulator valve (6), enters regulator piston
(23) at the bottom, and pushes regulator pis-
ton (23) to the left ().
• As a result, swash plate (11) is pushed in the
minimum swash plate angle direction, the
motor capacity becomes the minimum, and
the system is set to high speed.
PC60-7 10-95
③
OPERATION OF PARKING BRAKE

1. When starting to travel
• When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool (3), opens the circuit to
the parking brake, pushes open check valve
(31), and flows into chamber a of brake pis-
ton (8).
• It overcomes the force of spring (28), and
pushes piston (8) to the left ().
• When this happens, the force pushing plate
(26) and disc (27) together is lost, so plate (26)
and disc (27) separate and the brake is re-
leased.
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2. When stopping travel
• When the travel lever is placed in hold, coun-
terbalance valve spool (3) returns to the hold
position and the circuit to the parking brake is
closed.
• The pressurized oil in chamber a of brake pis-
ton (8) is drained to the case from the orifice in
the check valve, and brake piston (8) is
pushed to the right () by spring (28).
• As a result, plate (26) and disc (27) are pushed
together, and the brake is applied.
10-96 PC60-7
OPERATION OF BRAKE-VALVE
Function
• When traveling downhill, the weight of the
machine makes it try to travel faster than the
speed of the motor.
• As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and there is danger that the ma-
chine will run away.
• To prevent this, this valve acts to make the
machine travel according to the engine speed
(pump discharge amount).
Operation when pressure oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port PA. It pushes open check valve (2a)
and flows from motor inlet port MA to motor
outlet port MB.
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• However, the motor outlet port is closed by
check valve (2b) and spool (3), so the pres-
sure at the supply side rises.
• The pressurized oil at the supply side flows
from orifice E1 in spool (3) to chamber S1.
When the pressure in chamber S1 goes
above the spool switching pressure, spool
(19) is pushed to the right ().
• As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate.
Operation of brake when traveling downhill

• If the machine tries to run away when travel-
ing downhill, the motor will turn under no load,
so the pressure at the motor inlet port will
drop, and the pressure in chamber S1
through orifice E1 will also drop.
• When the pressure in chamber S1 drops be-
low the spool switching pressure, spool (3) is
returned to the left () by spring (4), and
outlet port MB is throttled.
• As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents the
machine from running away.
PC60-7 10-97
⑨
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
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1. Travel PPC valve 8. Hydraulic pump A : Boom LOWER H : Swing right

2. L.H. travel control lever 9. Control valve B : Boom RAISE I : Blade RAISE
3. R.H. travel control lever 10. L.H. work equipment C : Bucket CURL J : Blade LOWER
4. R.H. work equipment control lever D : Bucket DUMP K : Travel FORWARD
PPC valve 11. L.H. work equipment E : Arm OUT L : Travel REVERSE
5. R.H. work equipment PPC valve F : Arm IN M : Safety lock ON
control lever 12. Safety lock lever G : Swing left N : Safety lock OFF
6. Blade control lever
10-98 PC60-7
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PC60-7 10-99
⑨
STRUCTURE AND FUNCTION WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
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※1: Serial No. 55940 and up
a. Port P (from self pressure reducing valve) d. Port P4 (L.H.: Left swing / R.H.: Bucket DUMP)
b. Port T (to tank). e. Port P1 (L.H.: Arm OUT/ R.H.: Boom LOWER)
c. Port P2 (L.H.: Arm IN / R.H.: Boom RAISE) f. Port P3 (L.H.: Right swing / R.H.: Bucket CURL)
10-100 PC60-7
⑨
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E20107
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
10-101
Operation
1) At hold
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in
spool (1). (Fig. 1)
2) Fine control (hold → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
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pushed by metering spring (2) and moves
down.
When this happens, fine control hole f is shut
E20107
off from drain chamber D. At almost the same
time, it is connected to pump pressure cham-
ber PP, and the pilot pressure from port PPPC
of the main valve is sent through fine control
hole f and goes from port P1 to port A.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut off
from pump pressure chamber PP. At almost
the same time, it is connected to drain cham-
ber D, so the pressure at port P1 escapes.
As a result, spring (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port P1.
The relationship of the positions of spool (1)
and body (10) (fine control hole f is in the
middle between drain chamber D and pump
pressure chamber PP) does not change until
retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control lever,
so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a position where the pressure of
chamber A (same as pressure at port P1) and
the force of the return spring of the control
valve spool are balanced. (Fig. 2)
10-102
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed down by metering spring
(2), so fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP, so
the pressure at port P1 supplies the pump
pressure until the pressure recovers to a pres-
sure equivalent to the position of the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f'
of the valve on the side that is not moving. It
passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3)
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4) At full stroke
Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1). Fine control hole f
is shut off from drain chamber D and is con-
nected to pump pressure chamber PP. There-
fore, the pilot pressure oil from port PPPC of
the main valve passes through fine control
hole f and flows from port P1 to chamber A to
push the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f' and flows to
drain chamber D. (Fig. 4)
PC60-7 10-103
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
TRAVEL PPC VALVE
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a. Port P (from self pressure reducing valve)

b. Port T (to tank)
c. Port P1 (L.H. FORWARD)
d. Port P3 (R.H. FORWARD)
e. Port P2 (L.H. REVERSE)
f. Port P4 (R.H. REVERSE)
10-104 PC60-7
③
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1. Piston 5. Valve
2. Plate 6. Metering spring
3. Collar 7. Centering spring
4. Body 8. Bolt
PC60-7 10-105
Operation
1) At hold
spool (1). (Fig. 1)

When piston (4) starts to be pushed by disc
down.
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ber PP, and the pilot pressure of the self pres-
sure reducing valve is sent through fine con-
trol hole f and goes from port P1 to port A.
As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure of port P1.
middle between drain chamber D and pump
pressure chamber PP) does not change until
retainer (9) contacts spool (1).
10-106 PC60-7
③

When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
chamber D flows in from fine control hole f' of
the valve on the side that is not moving. It
passes through port P2 and goes to chamber
B to charge the oil. (Fig. 3)
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4) At full stroke
Disc (5) pushes down piston (4), and retainer
is shut off from drain chamber D and is con-
fore, the pilot pressure oil from the self pres-
sure reducing valve passes through fine con-
trol hole f and flows from port P1 to chamber A
to push the control valve spool.
PC60-7 10-107
③
STRUCTURE AND FUNCTION SERVICE PPC VALVE
SERVICE PPC VALVE
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a. Port T (to tank) 1. Spool

b. Port P (from self pressure reducing valve) 2. Metering spring
c. Port P1. 3. Centering spring
d. Port P2 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
10-108 PC60-7
③
Operation
1) At hold
spool (1). (Fig. 1)

When piston (4) starts to be pushed by lever
down.
ber PP, and the pilot pressure of the self pres-
sure reducing valve is sent through fine con-
trol hole f and goes from port P1 to port A.
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As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure of port P1.
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (7) contacts spool (1).
PC60-7 10-109
③

When lever (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
chamber D flows in from fine control hole f' of
the valve on the side that is not moving. It
passes through port P2 and goes to chamber
B to charge the oil. (Fig. 3)
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4) At full stroke
Lever (5) pushes down piston (4), and retainer
is shut off from drain chamber D, and is con-
fore, the pilot pressure oil from the self pres-
sure reducing valve passes through fine con-
trol hole f and flows from port P1 to chamber A
to push the control valve spool.
10-110 PC60-7
③
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10-111
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
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a. Port T (to tank). 1. PPC safety lock solenoid valve

b. Port P (from self pressure reducing valve) 2. Swing brake solenoid valve
c. Port T1 (from PPC valve). 3. Travel speed solenoid valve
d. Port T2 (from LS select valve). 4. Mode selection solenoid valve
e. Port A1 (to PPC valve). 5. Block
f. Port A2 (to swing motor).
g. Port A3 (to L.H., R.H. travel motor)
h. Port A4 (to pump PC valve)
10-112 PC60-7
③
STRUCTURE AND FUNCTION SOLENOID VALVE
1. Nut
2. Plunger
3. Coil
4. Connector
5. Push pin
6. Spring
7. Spool
8. Block
Operation
When solenoid is deenergized
• The signal current does not flow from the con-
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troller, so coil (3) is deenergized.
• For this reason, spool (7) is pushed to the left
() by spring (6).
E20107
• As a result, port A closes and the pressurized

oil from the control pump does not flow to the
actuator.
At the same time, the oil from the actuator
flows from port B to port C, and is then drained
to the tank.
When solenoid is energized

• When the signal current flows to the solenoid
valve, coil (3) is energized, and propulsion
force is generated to move plunger (2) to the
right ().
• For this reason, spool (7) is pushed to the right
() by push pin (5).
• As a result, the pressurized oil from the con-
trol pump flows from port A to port B, and then
flows to the actuator.
At the same time, port C is closed, and this
stops the oil from flowing to the tank.
10-113
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BLADE CYLINDER
1. Head bushing 6. Cylinder

2. Piston rod 7. Piston ring
3. Cylinder head 8. Wear ring
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4. Wear ring 9. Piston nut
5. Rod packing 10. Bottom bushing
E20107
Specification Unit: mm
Cylinder
Item Boom Arm Bucket Blade
Inside diameter of cylinder 115 100 90 120

Outside diameter of piston rod 65 60 55 70
Stroke 840 865 710 130
Max. stroke 2,150 2,193 1,765 679
Min. stroke 1,310 1,328 1,055 549
Width across flats of piston nut 70 65 60 80
10-114
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10-115
STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
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E20107
1. Bucket
2. Bucket cylinder
3. Arm
4. Arm cylinder
5. Boom
6. Boom cylinder
7. Blade cylinder
8. Blade
10-116
STRUCTURE AND FUNCTION WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM

Serial No. : 52374 - 57999 (Standard)
Serial No. : 58001 and up (If equipped)
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1. Flow divider valve (①,②,③,④,⑤) • Automatic greasing points

2. R.H. work equipment control lever
No. Greasing point
(boom RAISE)
3. Flow divider valve (⑥,⑦,⑧) ① Arm, bucket connecting pin
4. Monitor panel ② Arm, link connecting pin
5. Hydraulic pump
6. Grease cartridge ③ Bucket cylinder foot pin
7. Controller ④ Boom, arm connecting pin
8. Electric grease pump
⑤ Arm cylinder rod pin
9. Boom RAISE oil pressure switch
10. Flow divider valve (⑨) ⑥ Arm cylinder foot pin
⑦ Boom cylinder rod pin
⑧ Boom cylinder foot pin
⑨ Boom foot pin
PC60-7 10-117
⑨
1. SYSTEM DIAGRAM
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10-118 PC60-7
2. OPERATION OF SYSTEM
• The automatic greasing system adds the • The amount of grease for each work equip-
hours of operation of the equipment, and ment pin is set according to the load on the
every time the total reaches 5 hours, it car- pin.
ries out greasing.
• The boom RAISE oil pressure switch signal is
used to detect operation of the work equip-
ment.
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E20107
10-119
3. COMPONENTS OF SYSTEM
1) Controller
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E20107
1. Connector Input/output signals

2. Controller
3. Fuse CN-P44
No. Name of signal Input/output
Specification
Model: LC2MP 1 Power source +24V —
2 GND —
3 — —
4 Abnormality signal Output
5 Boom RAISE signal Input
6 Starting switch ON signal Input
10-120
2) Electric grease pump
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E20107
1. Motor Specification
2． Grease cartridge Model: LD05CP
3. Air bleed plug
4. Pump
5． Pressure switch
6. Connector
10-121
Operation
1. Greasing, pressurizing
• When motor (1) rotates in the normal direc-
tion, eccentric shaft (2) rotates counterclock-
wise and pump piston (4) is operated in a re-
ciprocal movement by link plate (3).
• During the return stroke () of pump piston
(4), the grease inside cartridge (5) is sucked
in, and on the discharge stroke (), check
valve (6) is pushed open and the grease is
pushed out to discharge port P.
• Pressure release spool (7) is moved to the
right () by pin (8) of eccentric shaft (2) and
pressure release hook (9). This shuts off dis-
charge port P and return passage T, so the
pressurized condition is maintained.
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E20107
• When the pressure inside the pump rises and
goes above the set pressure, indicator (10) is
pushed to the left (), pressure switch (11) is
switched ON, and motor (1) stops.
• When the pressure goes down again and pres-
sure switch (11) is turned OFF, motor (1) starts
again and the pressurized condition is main-
tained.
10-122
• If abnormal pressure is generated in the cir-

cuit at discharge port P end, safety valve (12)
opens and releases the pressure to return cir-
cuit T to protect the equipment from damage.
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E20107
2) Release of pressure, waiting for work

• When the greasing is completed, motor (1)
rotates in reverse, and eccentric shaft (2) ro-
tates clockwise.
• Pressure release spool (7) is moved to the left
() by pin (8) of eccentric shaft (2) and pres-
sure release hook (9).
• As a result, discharge port P and return cir-
cuit T are interconnected, and the pressure in
the circuit is released to cartridge (5).
• When this happens, pump piston (4) moves in
a reciprocal motion, but the discharged
grease flows to return circuit T, so the pres-
sure does not rise.
• When the pressure in the circuit drops, indi-
cator (10) is pushed back, and pressure switch
(11) is turned OFF, motor (1) stops.
If pressure switch (11) is not turned off, the
controller automatically rotates motor (1) in the
opposite direction to release the pressure.
10-123
3) Flow divider valve

Type installed to revolving frame
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E20107
a. From electric grease pump

b. To boom cylinder foot pin ⑧
10-124
Type installed to boom
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E20107

b. To left boom foot pin ⑨
c. To right boom foot pin ⑨
d. To arm cylinder foot pin ⑥
e. To boom cylinder rod end pin ⑦
f. To arm flow divider valve
10-125
Type installed to arm
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E20107
a. From boom flow divider valve

b. To bucket cylinder foot pin ③
c. To arm, link connecting pin ②
d. To arm, bucket connecting pin ①
e. To boom, arm connecting pin ④
f. To arm cylinder rod end pin ⑤
10-126
Structure A. Discharge port

B. Discharge port
C. Measurement chamber
D. Piston chamber
E. Oil passage.
F. Supply port
1. Measurement piston
2. Head
3. Body
4. Spring
5. Spring retainer
6. Pilot piston
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E20107
Operation
1) Supply
• When grease from the pump is supplied to
supply port F, the pressure at supply port F
rises and pilot piston (6) is pushed up.
• As a result, oil passage E opens and the
grease enters piston chamber D of measure-
ment piston (1) from oil passage E.
10-127
• Measurement piston (1) is pushed down by

the grease in piston chamber D, and the
grease in measurement chamber C is dis-
charged to the work equipment pins from
discharge ports A and B.
• At the end of this stroke, pilot piston (6) is
pushed back down by measurement piston (1),
and supply port F and oil passage E are
closed.
• In this way, the measurement and discharge
process for one cycle is completed.
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2) Resetting
• When the pump enters the pressure release
mode, measurement piston (1) is pushed back
up by spring (4).
• When this happens, the grease in piston
chamber D passes from oil passage E through
the inside of pilot piston (6), and enters mea-
surement chamber C to reset the system to
the initial stage in preparation for the next
time of actuation.
10-128
3) Boom RAISE oil pressure switch
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1. Plug Specifications
2. Switch Structure of contact : N.O. contact
3. Connector Actuation (ON) pressure :
0.5±0.1 MPa {5.0±1.0 kg/cm2}
Resetting (OFF) pressure :
0.3±0.05 MPa {3.0±0.5 kg/cm2}
10-129
STRUCTURE AND FUNCTION ELECTRICAL ALLOCATION DIAGRAM
ELECTRICAL ALLOCATION DIAGRAM (1/2)

INSIDE CAB
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1. Alarm buzzer 7. Starting switch 13. Travel speed switch

2. Swing holding brake 8. Fuse box (standard specification machine)
controller 9. Swing lock prolix switch 14. PPC lock limit switch
3. Horn switch 10. Radio 15. Travel boost switch
4. Speaker 11. Wiper switch (blade specification machine)
5. Monitor panel 12. Swina lock switch 16. Heater
6. Fuel control dial 17. One-touch slow-down switch
18. Glow resistance
10-130
E20107
19. Front lamp

20. Working lamp
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21. Fuel level sensor
k
24. Swing brake solenoid valve
26. Room lamp

27. Antenna
28. Engine oil pressure sensor
29. Engine stop solenoid
30. Glow plug
31. Starting motor
omat
32. Window washer
s
33. Coolant temperature sensor
34. Air conditioner compressor (option)
35. Alternator
36. Battery relay
37. Fusible link
38. Battery
40. Automatic greasing controller
upar
ELECTRICAL ALLOCATION DIAGRAM (2/2)
42. Swing oil pressure switch
tsbook
.c 43.
44.
45.
Air conditioner unit
Wiper motor
Horn
10-131
ELECTRICAL ALLOCATION DIAGRAM
om
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM

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10-132
AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM
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E20107
10-133
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM

TOTAL SYSTEM DIAGRAM
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10-134
1. Pump control function
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Function
• To reduce the drop in engine speed when the
engine is running at low speed, this system
controls the speed by automatically lowering
the pump absorption torque when the engine
is running at low speed.
PC60-7 10-135
Operation
Fuel control
dial set en- Mode Actuation
gine speed
Mode selector solenoid
valve is turned ON and
signal pressure is sent to
Below TCC valve to reduce pump
Light load
1,400 rpm absorption torque by
approx. 15% from normal
in order to prevent any
drop in engine speed.
Mode selection solenoid
valve is turned OFF and
Above signal pressure does not
Normal
1,400 rpm flow to TCC valve, so pump
absorption torque is set to
normal (100%).
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10-136 PC60-7
③
2. Swing lock, swing holding brake function
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Function
• This machine is equipped with a swing lock
and swing holding brake function.
10-137
Operation
1) Swing lock, swing holding brake function
• The swing lock (manual) can be locked at • Swing lock switch and swing lock, swing holding brake
any desired position, and the swing Lock Lock
Function Actuation
holding brake (automatic) is intercon- switch lamp
nected with the swing, so it prevents any Swing brake is applied approx.
hydraulic drift after the swing is stopped. 4 seconds after swing lever is
Swing
returned to neutral. When
OFF OFF holding
swing lever is operated, brake
brake
is released and swing opera-
tions can be carried out freely.
When swing lock is actuated,
swing is fixed in position. Even
Swing if swing lever is operated,
ON ON
lock swing lock is not canceled and
swing operations cannot be
carried out.
2) Swing lock prolix function
• If any abnormality occurs in the controller, ON OFF
Swing lock
and the swing holding brake is not ac- prolix switch
(when there is abnor- (when controller is
tuated normally or the swing cannot be, mality in controller) normal)
operated, the swing lock prolix switch can Swing lock
ON OFF ON OFF
switch
be operated to cancel the swing lock and
Swing
allow the swing to be operated. Swing Swing Swing
holding
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• Even if the swing lock prolix switch is Swing brake lock lock lock
brake
actuated released actuated
turned ON, if the swing lock switch is still actuated
ON, the swing lock is not canceled.
E20107
• When the swing lock is canceled, the
swing has only a hydraulic brake operated
by the safety valve, so if the swing is
stopped on a slope, there may be hydrau-
lic drift of the swing.
10-138
3. Travel speed selection function
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Function Operation
• This machine is equipped with a travel speed Travel Travel
Travel Travel Travel
selection function. speed boost
switch pedal speed motor speed
• The standard specification machine is eq- (standard (blade solenoid swash (km/h)
uipped with a travel speed switch to switch specifica specifica valve plate
angle
between high and low speeds; the blade speci- - tion) - tion)
fication machine is equipped with a travel Low
LOW Released OFF Max. speed
boost pedal (low speed when released, high
(2.8)
speed when depressed). High
HIGH Depressed ON Min. speed
Travel speed se- Standard speci- Blade specifica- (4.5)
lection method fication machine tion machine
Panel switch ○ ×
Boost switch × ○
PC60-7 10-139
4. One-touch slow-down function
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Function Operation
• When the machine is out of action for a short
time, such as when waiting for work or
waiting for a dump truck, if the One-touch
slow-down switch at the top of the left lever
is pressed, and the engine speed will drop
immediately to the deceleration speed to
reduce fuel consumption and noise.
• When starting work again, press the switch
again to restore the engine speed immedi-
ately to the set speed.
10-140 PC60-7
③
5. System components
1) Swing holding brake controller
1. Controller
2. Connector
Input/output signals
CN-C1
Input/
No Name of signal
output
1 Power source +24V -
2 GND
3 Oil pressure switch Input
4 Solenoid valve Output
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2) Swing oil pressure switch

★ Same as boom RAISE oil pressure switch
in "Work equipment pin automatic greas-
ing system".

Swing brake solenoid valve
Travel speed solenoid valve
★ For details, see SOLENOID VALVE.
10-141
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
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Function
• The machine monitor system is a system that
uses sensors installed at various parts of the
machine to observe the condition of the ma-
chine. It then processes this information and
displays it on a panel to inform the operator of
the condition of the machine.
• The panel display can be broadly divided into
the following:
1. The monitor portion, which issues a warn-
ing when any abnormality is found in the
machine.
2. The pilot portion, which displays the op-
eration and the condition of the machine
3. The gauge portion, which always displays
the condition of the machine
• Switches for electrical attachments are also
installed inside the monitor panel.
10-142
1. MONITOR PANEL
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Outline Input/output signals

• The monitor panel has a monitor display CN-P1 (monitor panel)
function and switches for electrical compo- Input/ Input/
No Name of signal No Name of signal
nents. Output output
• It has a built-in CPU (Central Processing Unit) 1 Power source +24V － 9 Engine oil pressure Input
which processes the data and outputs the 2 Power source +24V － 10 Charge level Input
display. 3 GND － 11 Automatic greasing Input
• A liquid crystal display is used for the gauge 4 GND － 12 Swing lock Input
display; lamps are used for the monitor dis-
5 Starting signal Input 13 Preheating Input
play.
6 Coolant temperature Input 14 －－
7 Fuel level Input 15 Buzzer Output
8 －－ 16 Night lighting Input
CN-P2 (light switch) CN-P3 (heater switch)

Input/ Input/
output output
2 Working lamp Output 2 Heater Hi Output
3 Night lighting Output 3 Heater Lo Output
4 +24V － 4 GND －
10-143
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1. Service meter 7. Heater switch
2. Coolant temperature gauge 8. Preheating pilot lamp
3. Fuel level gauge 9. Automatic greasing caution lamp
E20107
4. Light switch 10. Swing lock pilot lamp
5. One-touch slow-down pilot lamp 11. Charge caution lamp
6. Fuel control dial 12. Engine oil pressure caution lamp
Display
category
Symbol Display item Display range Display method
Engine oil Below When the starting switch is turned ON with the engine
pressure
2
49kPa {0.5 kg/cm } running, the display is as follows:
CAUTION
Normal : OFF
When there is Abnormal : ON (buzzer sounds if abnormality occurs
Charge amount
defective charging when engine is running)
Automatic When there is Normal : OFF
greasing abnormality Abnormal : ON
One lamp lights up to show the temperature
Coolant
When the lamp at the highest level (right) lights
temperature
Gauges
up, the segment flashes and the buzzer sounds

One lamp lights up to show the level
Fuel level When the lamp at the lowest level (left) lights up,
the segment flashes
When the starting switch is at HEAT, lamp is ON (30 sec); and
Preheating When preheating after this it flashes for 10 sec., then goes OFF to indicate
completion of preheating
Pilot
When swing is
Swing lock Lights up when swing lock switch is ON
locked
One-touch decel Lo-idling Lights up when one-touch decel switch is ON
Lo: Heater fan Lo

Heater switch －
Hi: Heater fan Hi
Switch
1. Monitor panel lights up

Light switch －
2. Monitor panel, head light and work lamp light up
10-144
2. SENSOR
• The signals from the sensors are input directly to the monitor panel.
• The contact type sensors are always connected at one end to the chassis ground.
Category of display Type of sensor Sensor method When normal When abnormal
Caution Engine oil pressure Contact OFF (open) ON (closed)
Coolant temperature Resistance －－
Gauges
Fuel level Resistance －－
1) Engine oil pressure sensor
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
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2) Coolant temperature sensor
1. Connector
2. Plug
3. Thermistor
10-145
3) Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistance
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10-146
20 TESTING AND ADJUSTING
Standard value table for engine Adjusting PC valve .......................................20-111

related parts ................................................. 20-2 Measuring LS differential pressure and
Standard value table for chassis adjusting LS valve.................................... 20-112
related parts ................................................. 20-3 Testing hydraulic pressure in the control
Standard value table for electrical circuit........................................................ 20-113
related parts ............................................... 20-12 Testing outlet pressure of solenoid
Tools for testing, adjusting and valve......................................................... 20-114
troubleshooting ........................................ 20-101 Measuring PPC valve output pressure........ 20-115
Measuring engine speed ............................. 20-102 Adjusting work equipment and swing
Measuring exhaust gas color ...................... 20-104 PPC valve ................................................ 20-115
Adjusting valve clearance............................ 20-105 Testing travel deviation ................................ 20-116
Measuring compression pressure ............... 20-107 Measuring oil leakage.................................. 20-117
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Measuring blowby pressure ........................ 20-109 Releasing remaining pressure in hydraulic
Testing and adjusting fuel injection circuit........................................................ 20-119
timing ....................................................20-109-2 Checking of clearance of swing circle
Measuring engine oil pressure ................. 20-109-7 bearing ..................................................... 20-120
Testing and adjusting alternator Checking and adjusting of track shoe
belt tension............................................ 20-109-9 tension...................................................... 20-121
Adjusting engine stop solenoid linkage Testing wear of sproket.............................20-121-1
................................................................20-109-10 Bleeding air.................................................. 20-122
Adjusting fuel control linkage .................20-109-12 Automatic greasing controller...................... 20-124
Testing and adjusting of hydraulic Troubleshooting ........................................... 20-201
pressure in work equipment,
swing and travel circuits........................... 20-110
★ Note the following when making judgments using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the ma-
chine from the factory and is given for reference. 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.
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.
When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
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.
Be careful not to get caught in the fan, fan belt or other rotating parts.
PC60-7 20-1
⑤
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Machine model PC60-7
Seriaol Number 52374 -57999
Engine 4D102E-1
Item Measurement conditions Unit Standard value Permissible value
High idling 1,950±50 —
Engine speed Low idling rpm 950±50 —
Rated speed 1,750 —
At sudden acceleration Max. 4.0 7.0

Bosch
Exhaust gas color
index
At high idling Max. 2.0 3.0
Intake valve 0.25 —
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Valve clearance mm
Exhaust valve 0.51 —
(normal temperature)
Oil temperature: Min. 2.41 Min. 1.01

40 - 60°C MPa {Min. 24.6} {Min. 10.3}
Compression pressure 2
(engine speed: 250 rpm) {kg/cm } (Differentiol pressure
(SAE 15W-40 oil) between cylinders)
(Coolant temperature:
Max. 803.6 3,400
Blowby pressure operating range) Pa
{Max. 82} {347}
(Orifice dia.: 5.613mm) At rated output {mmH2O}
(Ref.) (Ref.)
(SAE 15W-40 oil)
operating range)
At high idling MPa 0.34 - 0.52 2.1

Oil pressure 2
(SAE 15W-40) {kg/cm } {3.5 - 5.3} {21}
At low idling Min. 0.1 0.07

(SAE 15W-40) {Min. 1.0} {0.7}
Whole speed range

Oil temperature °C 80 - 110 120
(inside oil pan)
Before top dead center ( 0)

Fuel injection timing 15±1 15±1
(B.T.D.C.) deg
Deflection when pressed

Belt tension
with finger force of mm 6 - 10 —
(air compressor)
approx. 58.8N {6kg}.
20-2 PC60-7
⑤
Machine model PC60-7
Seriaol Number 58001 and up
Engine 4D95LE-2
Item Measurement conditions Unit Standard value Permissible value
High idling 2,250±60 —

+80
Engine speed Low idling rpm 1,050+0 —
Rated speed 2,100 —
At sudden acceleration Max. 5.0 Max. 7.0

Bosch
Exhaust gas color
index
At high idling Max. 1.0 Max. 2.0
Intake valve 0.35 —

Valve clearance mm
Exhaust valve 0.50 —
(normal temperature)
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Compression pressure
Oil temperature:
40 - 60°C
(engine speed:
320 - 360 rpm)
MPa
2
{kg/cm }
Min. 2.94
{Min. 30}
Min. 2.06
(Min. 21)
(SAE 15W-40 oil)
Max. 490 Nax. 980
Blowby pressure operating range) Pa
{Max. 50} {Max. 100}
(Orifice dia.: 5.613mm) At rated output {mmH2O}
(Ref.) (Ref.)
(SAE 15W-40 oil)
operating range)
At high idling 0.34 - 0.59 Min. 0.25

(SAE30) {3.5-6.0} {Min. 2.5}
At high idling MPa 0.29 - 0.54 Min. 0.21

Oil pressure 2
(SAE 10W) {kg/cm } {3.0 - 5.5} {Min. 2.1}
At low idling Min. 0.1 Min. 0.08

(SAE30) {Min. 1.0} {Min. 0.8}
At low idling Min. 0.08 Min. 0.07

(SAE10W) (Min. 0.8) {Min. 0.7}
Whole speed range

Oil temperature °C 80 - 110 120
(inside oil pan)
Before top dead center (°)

Fuel injection timing 12±0.75 —
(B.T.D.C.) deg
Deflection when pressed

Belt tension
with finger force of mm 6 - 10 —
(air compressor)
approx. 58.8N{6kg}.
PC60-7 20-2-1
⑤
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20-2 PC60-7
⑤
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
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PC60-7 20-3
⑤
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20-4 PC60-7
⑥
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E20107
20-5
①
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20-6
①
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20-7
①
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E20107
20-8
①
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PC60-7 20-9
①
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20-10 PC60-7
⑤
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PC60-7 20-11
⑤
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
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20-12 PC60-7
⑤
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Inspection/adjustment item Symbol Part No. Part Name Remarks
1 799-203-8001 Mufti-tachometer Digital display

Engine speed A L: 60 - 2,000 rpm
2 795-790-2500 Adapter assembly H: 60 - 19,999 rpm
Coolant and oil tempera-
B 799-101-1502 Digital thermometer -99.9 – 1,299 °C
ture
Pressure gauge : 2.5{2.5}, 5.9{60},
799-101-5002 Hydraulic tester 2
39.2{400}, 58.8{600} MPa{kg/cm }
1
Pressure gauge :
790-261-1203 Digital hydraulic tester 2
68.6 MPa {700 kg/cm }
2
2 799-401-2320 Hydraulic gauge 0.98 MPa {10 kg/cm }
Both male and female
x 790-261-1311
14 x 1.5 (female PT1/8)
3 Adapter Both male and female
x 790-261-1321
Hydraulic oil pressure C 18 x 1.5 (female PT1/8)
x 790-261-1331
22 x 1.5 (female PT1/8)
4 799-401-2701 Differential pressure gauge
x 790-261-1360 Adapter
14 x 1.5 (female PT1/8)
5 x 790-261-1370 Nut For 14 x 1.5 blind
x 07003-31419 Gasket For blind
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Compression pressure D
1
2
3
795-502-1590
x 790-553-1110
x 795-553-1110
Compression gauge
Adapter
0 – 6.9 MPa {0 – 70 kg/cm }
Kit No.: 795-502-1205
2
Blowby pressure E 799-201-1504 Blowby checker 0 – 4,900 Pa {0 – 500mmH2O}

Commercialy
Valve clearance F Feeler gauge
available
1 799-201-9000 Handy smoke checker Discoloration 0 – 79%
(with standard color samples)
Exhaust gas color G Commercialy
2 Smoke meter (Discoloration x 1/10 Bosch
available index)
79A-264-0021 0 – 294 N {0 – 30 kg}
Operating force H Push-pull scale
79A-264-0091 0 – 490 N {0 – 50 kg}
Commercialy
Stroke, hydraulic drift I Scale
available
Commercialy
Work equipment speed J Stop watch
available
Voltage and resistance
K 79A-264-0211 Tester
value measurement
1 799-601-2600 T -adapter box
Sensor harness diagnosis L
2 799-601-7000 Adapter assembly
Air breeding from the auto 1 21T-38-11390 Nipple

M
lubricator piping 2 07020-00000 Fitting
1 795-799-1130 Gear Cranking tool
Valve clearance / 2 795-102-2102 Spring pusher
O
Fuel injection timing
Commercialy
3 Dial guage
available
Measurement of wear on
P 790-607-1031 Wear gauge
sprocket tooth
PC60-7 20-101
⑤
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

When installing or removing a measuring
equipment, be careful not to touch any high
temperature parts.
★ Measure the engine speed under the following
conditions.
• Coolant temperature: Within operating range
• Hydraulic oil temperature : 45 – 55 °C
Serial No. : 52374 - 57999
1. Remove the fan gurad (1).
2. Remove the cap (2) for speed pick-up port.
3. Install the adapter assembly (A2) to the revolu-

tion taking off port and install the sensor ① for
the tachometer. Then connect to the tachometer
body (A1).
4. Start the engine, and measure the engine speed
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when it is set to the conditions for measure-
ment.
When measuring the engine speed, be careful

not to touch any rotating parts or high tem-
perature parts.
1) Measurement of the low-idling and high-
idling speed:
Measure the engine speeds when the fuel
lever is set to the low-idling and high-idling.
2) Measurement of, the speed at the pump re-
lief:
Measure the engine speeds at it full capacity
when each pump is relieved.
20-102 PC60-7
⑤
TESTING AND ADJUSTING MEASURING ENGINE SPEED
1. Remove the fan gurad (1).
2. Install sensor ① of tachometer A1, then connect

A1 to the tachometer.
3. Start the engine, and measure the engine speed

when it is set to the conditions for measurement.
Since the fun guard is kept removed during

measurement of the engine speed, never stand
near the fan (rotary part). Take care not to catch
the tachometer cable in the fan.
1) Measurement of the low-idling and high- idling

speed:
Measure the engine speeds when the fuel
lever is set to the low-idling and high-idling.
2) Measurement of the speed at the pump re-
lief:
Measure the engine speeds at it full capacity
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when each pump is relieved.
PC60-7 20-103
⑤
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

• When measuring in the field when there is no air
or power supply, use smoker checker G1; when
recording official data, use smoke meter G2.
★ Raise the coolant temperature to the operating
range before measuring.
When removing or installing the measuring
equipment, be careful not to touch any high
temperature part.
1. Measuring with handy smoke checker G1

1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the
exhaust pipe, accelerate the engine sud-
denly, and at the same time operate the
handle of tool G1 to catch the exhaust gas on
the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
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2. Measuring with smoke meter G2
1) Insert probe into the outlet port of exhaust
pipe, then tighten the clip to secure it to the
exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
★ The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V out-
let.
★ When connecting the port, check first that
the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump, then
fit the filter paper.
★ Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (10 sheets or more) inside the filter pa-
per holder, and read the indicated value.
20-104 PC60-7
⑤
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Serial No. : 52374 - 57999
1. Remove the cylinder head cover.
2. Set cranking tool O to the flywheel.
3. Rotate the crankshaft in the normal direction to a

point where timing pin (1) enters the hole in the
gear.
★ Push pin (1) in lightly while cranking.
★ The position where the pin enters the hole is
the No. 1 top dead center.
4. At this position, adjust the clearance of the valves

marked ● in the valve arrangement chart. At the
same time, make match marks on the crankshaft
pulley and timing gear case, then remove timing
pin (1).
5. Next, rotate the crankshaft one turn (360°) in the

normal direction, align the match marks made in
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Step 4 accurately, then adjust the valve clearance
of the remaining valves marked ○.
★ To adjust the valve clearance, loosen locknut
(4), then insert feeler gauge F between rocker
arm (6) and valve stem (5), and turn adjust-
ment screw (3) until the clearance is a sliding fit.
Then tighten locknut (4) to hold the ad-
justment screw in position.
Locknut:
24±4 Nm {2.45±0.41 kgm}
★ Firing order: 1 - 3 - 4 - 2
★ valve clearance
Intake side.......................... 0.25 mm
Exhaust side....................... 0.51 mm
PC60-7 20-105
⑤
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
2. Turn the crankshaft forward and match "1.4TOP"

line (1) on the crank pulley to pointer (2).
3. When cylinder No. 1 is at the compression top

dead center, adjust the valves as indicated by ●
in the valve position table. Turn the crankshaft
forward by 360 degrees, then adjust the valves as
indicated by ○ in the valve position table.
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4. Insert tool F between rocker lever (3) and valve
stem (4), and turn adjustment screw (5) so that tool
F will move lightly, then tighten locknut (6).
Locknut : 44.1±4.9 Nm {4 .5±0.5 kgm}
★ The valve clearance may be adjusted accord-
ing to the following procedure; Bring cylinder
No. 1 to the compression top dead center and
adjust the valve clearance of cylinder No.1.
Then, turn the crankshaft by 180 degrees and
adjust the valve clearance of each cylinder
according to the firing order.
• Firing order: 1 - 2 - 4 - 3
★ After tightening the locknut, check the valve
clearance again.
20-106 PC60-7
⑤
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
Serial No. : 52374 – 57999
While measuring the compression pressure, take

care not to touch the exhaust manifold, etc. to get
burnt and not to catch your clothes in the fan or
fan belt.
1. Adjust the valve clearance accurately. For de-

tails, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine until the oil temperature is

40 - 60°C.
3. Remove the nozzle holder assembly of the cylin-

der to be measured. For details, see REMOVAL
OF NOZZLE ASSEMBLY
4. Install adapter D2 to the nozzle holder mounting

part, then connect compression gauge D1.
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5. Install multi-tachometers A1 and A2.
★ See MEASURING ENGINE SPEED.
6. Disconnect engine stop solenoid terminals (M3,

M37).
7. Rotate the engine with the starting motor and

measure the compression pressure.
★ Read the compression pressure when the
pointer of the compression gauge stops.
★ When measuring the compression pressure,
measure the engine speed and check that it is
in the range of the measuring condition.
★ After measuring the compression pressure,
install the nozzle holder assembly. For de-
tails, see INSTALLATION OF NOZZLE ASSEM-
BLY.
PC60-7 20-107
⑤
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
While measuring the compression pressure, take

care not to touch the exhaust manifold, etc. to
get burnt or catch your clothes in the fan or fan
belt.
1. Adjust the valve clearance accurately. For de-

tails, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine until the oil temperature is

40 - 60°C.
3. Remove nozzle holder assembly (1) of the cylin-

der to be measured.
4. Install adapter D3 to the nozzle holder mounting

part, then connect compression gauge D1.
5. Install multi-tachometer A1.

★ See MEASURING ENGINE SPEED.
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6. Disconnect engine stop solenoid terminals (M3,
M37) (2) and fix the governor lever of the injec-
tion pump to the non-injection position, then ro-
tate the engine with the starting motor and mea-
sure the compression pressure.
★ Read the compression pressure when the pointer

of the compression gauge stops.
★ After measuring the compression pressure, install
the nozzle holder assembly.
20-108 PC60-7
⑤
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
MEASURING BLOWBY PRESSURE

Serial No. : 52374 - 57999
★ Raise the coolant temperature to the operating

range before measuring the blowby pressure.
1. Install the blowby checker to the tip of engine

breather hose (1).
2. Run the engine at the rated output and measure

the blow-by pressure.
When measuring the blowby pressure, be

careful not to touch any high temperature
parts or rotating parts.
★ The blowby should be measured with the en-

gine running at rated output.
• If it is inpossible to check at rated output, mea-
sure at high idling. In this case, the blowby
value will be about 80% of the value at rated
output.
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★ Blowby varies greatly according to the condi-
tion of the engine. Therefore, if the blowby
value is considered abnormal, check for prob-
lems connected with defective blowby, such as
excessive oil consumption, defective exhaust
gas color, and prematurely dirty or de-
teriorated oil.
PC60-7 20-109
⑤
TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE
Serial No. :58001 and up
1. Remove cylinder head cover (1).
2. Install plug E to breather tube (2).
3. Install cylinder head cover (1), then install blowby

checker E to the oil filler.
4. Run the engine at the rated output and measure

the blow-by pressure.
Do not touch a hot part or a rotary part dur-
ing measurement.
★ The regular blow-by pressure is measured
while the engine is running at the rated out-
put.
• An approximate value can be obtained in the
field by performing relief operation.
• If rated-output operation or relief operation
cannot be performed, measure the blow-by
pressure while the engine is running at high
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idling. In this case, the measure blow-by pres-
sure is about 80% of that measured at the
rated output.
★ The blow-by pressure may vary largely with
the condition of the engine. If the measured
blow-by pressure is judged abnormal, check
for high oil consumption, bad exhaust gas
color, deterioration or dirtiness of oil, etc.
which are related to improper blow-by pres-
sure.
★ After finishing measurement, remove plug E
without fail.
20-109-1 PC60-7
⑤
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Serial No. : 52374 - 57999
1. Testing
1) Using cranking tool O, rotate the crankshaft
in the normal direction to a point where tim-
ing pin (1) enters the hole in the gear.
2) Remove plug (2), turn over timing pin (3), and
check that timing pin (3) meshes with timing
pin pointer (4) at the injection pump end.
2. Adjusting
• If timing pin does not mesh
1) Remove the injection pump.
For details, see REMOVAL OF FUEL INJEC-
TION PUMP
2) Rotate the camshaft of the injection pump to
align timing pin (3) with timing pin pointer (4).
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3) Install the injection pump.
For details, see INSTALLATION OF FUEL IN-
JECTION PUMP
PC60-7 20-109-2
⑤
Adjustmentby use of match marks

★ Apply this method usually.
(When installing the fuel injection pump to the
original engine without repairing it, when check-
ing only the injection timing, etc.)
1. Bring cylinder No. 1 to the compression top dead

center.
1) Turn the crankshaft forward and match
"1.4TOP" line (1) on the crank pulley to pointer
(2).
2) Check that cylinder No. 1 is at the compres-
sion top dead center by the following method.
If the following condition is not obtained, turn
the crankshaft one more turn.
★ If the fuel injection pump is removed:
Check that "C" is seen at the tooth tip of
idler gear (3).
★ If the fuel injection pump is installed to the
engine: Remove the head cover and check
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that both air intake valve and exhaust valve
of cylinder No. 1 are closed (both air intake
valve and exhaust valve of cylinder No. 1
have the valve clearance).
2. Remove front cover (4) of the fuel injection pump.
3. Install the fuel injection pump holder and drive gear

as one unit to the engine.
4. Insert the timing check pin 4.0 - 4.5 mm in diam-

eter and 80 mm in length in hole "a" of the front
gear cover and match it to the hole of the drive
gear.
★ Check that the timing check pin enters straight
and the hole of the fuel injection pump holder is
aligned with the mounting hole of the front gear
cover (in which the mounting bolt will be
inserted).
★ If the holes are deviated from each other, re-
move the fuel injection pump and check its
engagement with the drive gear.
5. Remove the timing check pin and tighten each bolt.
20-109-3 PC60-7
⑤
Adjustment by use of match marks

(When installing a repaired or replaced fuel injection
pump, when checking after disassembling or replac-
ing the gear train)
2. Bring cylinder No. 1 to the compression top dead

center.
1) Turn the crankshaft forward and match injec-
tion timing line (1) on the crank pulley to pointer
(2).
2) Check that both air intake valve and exhaust
valve of cylinder No. 1 have the valve clear-
ance.
★ If either or both of the valves do not have
the valve clearance, turn the crankshaft
one more turn.
3. Remove snap ring (3) from the front end of the

rocker shaft, then remove air intake rocker arm (4)
of cylinder No. 1.
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4. Using spring pusher O2, compress the valve
spring and remove valve cotter (5).
5. Loosen spring pusher O2 and remove spring seat

(6) and valve spring (7).
6. Turn the stem of air intake valve (8) with the fin-
gers while it is in contact with the top of piston (9)
to fit it securely.
PC60-7 20-109-4
⑤
7. Apply dial gauge 03 to the valve stem end and turn

the crankshaft forward. Set the dial gauge to 0
when its pointer starts turning in reverse.
8. Turn the crankshaft about 45° degrees in reverse

from the compression top dead center of cylinder
No. 1.
9. Turn the crankshaft forward so that the dial gauge

indicates standard dimension "a". This dimension
is equivalent to BTDC 12±0.75°.
★ Standard dimension: 1.69±0.22 mm
★ Be sure to adjust the above dimension by turn-
ing the crankshaft forward.
10. Disconnect fuel injection pipe (10) of cylinder No.1.
11. Remove delivery valve holder (11), and remove

delivery valve (12) and spring (13) from its inside.
Then, install delivery valve holder (11) again.
12. Set the fuel injection lever to the FULL position.
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13. Loosen the nut at the oblong hole of the injec-
tion pump mounting flange, then loosen the in-
jection pump mounting bolts (14).
14. Turning the injection pump outward and operating

the priming pump, move the injection pump toward
the cylinder block little by little and stop when the
fuel stops flowing out of the delivery valve holder.
★ If the injection pump is slanted out, the injec-

tion timing is delayed. If the former is slanted
toward the cylinder block, the latter is ad-
vanced.
15. Tighten injection pump mounting bolts (14) al-

ternately.
16. Tighten the nut at the oblong hole of the injec-tion

pump mounting flange.
17. Turn the crankshaft forward and check that the

dial gauge indicates 0±0.22 mm when cylinder.
No. 1 is at the top dead center (when the pointer
of the dial gauge starts moving in reverse). If the
pointer of the dial gauge is out of this range, re-
peat the above steps from 7.
20-109-5 PC60-7
⑤
18. Remove the delivery valve holder (11) and install

delivery valve (12) and spring (13) to it, then in-
stall delivery valve holder (14) again.
★ Replace the O-ring and copper gasket of the
delivery valve.
Tighten the delivery valve 3 times to secure it.
(If it is not tightened sufficiently, the gas-ket
may be broken.)
Delivery valve holder:
32.4±2.0 Nm {3.3±0.2 kgm}
19. Connect fuel injection pipe (3).

Sleeve nut:
23.5±1.0 Nm {2.4±0.1 kgm}
20. Install valve spring (7) and valve seat (6).
21. Compress the valve spring with spring pusher O2

and install valve cotter (5).
22. Install air intake rocker arm (4) of cylinder No. 1,

then install snap ring (3).
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★ Install the snap ring securely.
23. Install the cylinder head cover.

Cylinder head cover mounting bolt:
8.8±1.0 Nm {0.9±0.1 kgm}
PC60-7 20-109-6
⑤
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

★ Measure the engine oil pressure under the fol-
lowing conditions.
• Coolant temperature: Within operating range
Serial No. : 52374 - 7999
1. Remove engine oil pressure sensor (1), then in-

stall the adapter of oil pressure gauge kit C1 and
oil pressure gauge C2 (1.0 MPa {10 kg/cm2}).
2. Start the engine, and measure the oil pressure with

the engine at low idling and high idling.
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20-109-7 PC60-7
⑤
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
1. Remove engine oil pressure sensor (1), then in-

stall the nipple and oil pressure gauge C2 (1.0
MPa {10 kg/cm2} of oil pressure gauge kit C1.
2. Start the engine and measure the oil pressure at

Iow idling and high idling.
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PC60-7 20-109-8
⑤
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
Testing
• Press the intermediate point of the belt between
the alternator and fan pulley with force of about
58.8 N {6 kg}, and check that the belt is deflected
by 6-10mm.
Adjusting
1. Remove the cover from the side of the alternator.
2. Loosen belt tension adjustment bolt (1) and al-

ternator mounting nut (2).
3. Move alternator toward the front of the machine

body with a bar, then tighten belt tension adjust-
ment bolt (1).
4. Tighten mountino nut (2).
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20-109-9 PC60-7
⑤
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
ADJUSTING ENGINE STOP SOLENOID LINKAGE

Seeial No.: 52374 - 57999
Testing
1. Turn ON the starting switch and check that lever
(5) can move toward rod (4) (it has some play) at
this time.
★ Since the clearance cannot be checked visu-
ally check it by feeling with the hand.
(Reference) Clearance "a" between lever (5) and
stopper (6): 1 - 2 mm
★ If the above clearance is too large, the engine
output may not be heightened to the full level. If
the former is eliminated, the solenoid may
burn.
Adjusting
1. Loosen mounting bolt (7) of solenoid (1).
2. Move solenoid (1) in the direction of the arrow (A)
to the end.
★ The hole of bracket (8) is oblong.
3. Turn ON the starting switch to operate solenoid (1).
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4. Move solenoid (1) in the direction of the arrow (B)
by the hand until lever (5) comes in contact with
stopper (6).
★ Since clearance "a" cannot be checked visu-
ally, move the solenoid to check the clearance
by feeling with the hand.
★ If solenoid (1) is moved forcibly in the direc-
tion of the arrow (B) after lever (5) comes in
contact with stopper (6), the solenoid may
burn.
5. After lever (5) comes in contact with stopper (6),
move solenoid (1) by 1 - 2 mm in the direction of
the arrow (A).
★ Since clearance "a" cannot be checked visu-
ally, check it by the moving distance of the
solenoid.
6. Tighten mounting bolt (7) of solenoid (1).
7. Operate the solenoid several times and check that
linkage (2) - (4) do not interfere with another part
and the solenoid is not heated abnormally.
8. If the parts between solenoid (1) and linkage (4)
have been disassembled, assemble them into a
sub-assembly in advance, then install the sub-
assembly to the engine.
1) When installing the above sub-assembly, ad-
just distance "a" between both ends of the rod
to the following value.
★ a : 163 mm
★ Screwing depth b on solenoid side: 15 mm
★ Screwing depth c on lever side: 15 mm
PC60-7 20-109-10
⑤
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID LINKAGE
★ If the fuel injection pump or engine stop solenoid

has been replaced, adjust the engine stop linkage
according to the following procedure.
1. If the engine stop solenoid has been replaced,

install the used rod to the new solenoid. (Keep rod
nuts (4) and (5) loosened.)
Threads of rod (all threaded part):
Liquid adhesive (LT-2)
★ Do not apply adhesive to the part of 5 mm from

each end, however.
2. Turn ON the starting switch to operate the sole-

noid without connecting the injection pump stop
lever and rod.
3. Push stop lever (1) toward the operation side and

connect rod (2).
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4. Adjust the length of rod (2) by turning it until stop
lever (1) comes in contact with the internal stop-
per on the operation side.
5. Tighten nut (3) and install the cotter pin.
6. Loosen the rod by 1/2 - 1 turn to lengthen it (by 1 -

2 mm) to make play between stop lever (1) and
stopper on the operation side.
7. Tighten locknuts (4) and (5).

★ Tighten these nuts securely so that rod (2) will
not turn.
8. Check that the engine starts and stops normally

and the solenoid is not heated abnormally.
20-109-11 PC60-7
⑤
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL

LINKAGE
★ If the fuel injection pump, servo motor, and cable
have been replaced, or if the engine speed is not
the specified value, adjust as follows.
Serial No. : 52374 - 57999
1. Adjusting control linkage

1) If the parts have been replaced, connect the
cable securely to the fuel injection pump gov-
ernor lever.
★ Connect to the bottom hole of the fuel in-
jection pump governor lever.
2) Turn the starting switch to the ON position
and the fuel control dial to the FULL position.
3) Put fuel injection pump governor lever (1) in
contact with the FULL stopper.
4) In the above condition, pull cable (2) with a
force of approx. 98 N {approx.10 kg}, and tem-
porarily tighten nuts (3) and (4).
★ Tighten nuts with the cable pulled to re-
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move any play.
5) Loosen nut (3) 2 turns and tighten nut (4) 2
turns, then tighten both nuts.
6) Start the engine and check that it is running at
the specified speed.
2. Adjusting engine stall prevention switch

★ This should be actuated when the speed goes
below 1400 rpm.
1) Turn the starting switch to the ON position and
the fuel control dial to LOW.
2) Adjust bracket (7) so that the clearance be-
tween the tip of limit switch (5) and plate (6) is
3 - 4 mm.
★ The hole in bracket (7) is an oblong hole.
3) Check that limit switch (5) is not at the end of
its stroke when the fuel control dial is turned to
FULL.
PC60-7 20-109-12
⑤
1. Adjusting control linkage

1) If any part has been replaced, connect the
cable to the injection pump governor lever
securely.
★ Connect the cable to the lowest hole of
injection pump governor lever.
2) Turn ON the starting switch and set the fuel
control dial to the FULL position.
3) Bring injection pump governor lever (1) to
stopper (2) on the FULL side.
4) Pulling cable (3) with force of about 98 N {10
kg} under the above condition, tighten nuts (4)
and (5) temporarily.
★ Tighten the nuts while pulling the cable to
eliminate play.
5) Return nut (4) by 2 turns and tighten nut (5) by
2 turns to retighten them.
6) Start the engine and check that it runs at the
specified speed.
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2. Adjusting engine stall preventing switch
★ This switch operates when the engine speed
lowers below 1400 rpm.
1) Turn ON the starting switch and set the fuel
control dial to the LOW position.
2) Adjust the clearance between the end of limit
switch (6) and plate (7) to 3 - 4 mm by moving
bracket (8).
★ The hole of bracket (8) is oblong.
3) Set the fuel control dial to the FULL position,
and check that limit switch (6) is not at the
stroke end at this time.
20-109-13 PC60-7
⑤
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PC60-7 20-109-14
⑤
TESTING AND ADJUSTING OF HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS
TESTING AND ADJUSTING OF

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING
AND TRAVEL CIRCUITS
1. Measuring
★ Hydraulic oil temperature at measurement:
45 - 55 °C
Place the work equipment of the ground and

stop the engine. Slowly loosen the oil filler cap
on the hydraulic oil tank to release the
pressure in the tank, and set the safety lock
lever to the lock position.
• Remove the pressure detection plug (1)
(10mm, P=1.25) from the circuit to be mea-
sured, and connect the oil pressure gauge C1
(58.8 MPa {600kg/cm2}).
• Measuring of unload pressure

Measure the hydraulic oil pressure with the en-
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gine at the full speed and the control lever at
NEUTRAL.
• Measuring of pump relief pressure

Measure the hydraulic oil pressure when each
actuator is relieved with the engine at the full
speed.
★ However, since the set pressure of the swing
motor safety valve is lower than the main relief
pressure, this measurement actually measure
the relief pressure of the safety valve.
Furthermore the travel motor is not equipped
with a safety valve.
20-110 PC60-7
①
TESTING AND ADJUSTING ADJUSTING PC VALVE
2. Adjusting main relief valve

Loosen the lock nut (1) and turn the adjustment
screw (2) to adjust.
★ Turn the adjustment screw:
• CLOCKWISE to increase the pressure;
• COUNTERCLOCKWISE to decrease the
pressure.
★ Adjusting amount for one turn of the adjust-
ment screw: 12.5 MPa {128 kg/cm2}
Lock nut: 39.2±4.5 Nm {4.5±0.5 kgm}
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E20107
ADJUSTING PC VALVE
★ In case the engine speed lowers as a load be-
comes larger, or in case the work equipment speed
is slow even though the engine speed, pump
discharge pressure and LS differential pressure
are normal, adjust the PC valve according to the
following procedure.
1. Loosen the lock nut (1). For the cases of slow

speed, turn the sleeve (2) clockwise, and for the
cases of lowering of engine speed, turn the sleeve
counterclockwise.
★ Clockwise rotation of the sleeve "increases"
the suction torque of the pump, and coun-
terclockwise rotation "decreases" the suction
torque.
★ Rotation range of the screw shall be within"
180°. for both clockwise and counterclock-
wise".
2. After adjustment finished, tighten the lock nut.

Lock nut:
100.45±12.25 Nm {10.25±1.25 kgm}
20-111
①
TESTING AND ADJUSTING MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
MEASURING LS DIFFERENTIAL PRESSURE

AND ADJUSTING LS VALVE
1. Measuring LS differential pressure
1) Measurement using a differential pressure
gauge
i) Remove the plug (1) and (2) (PT 1/8),
and install the oil pressure measure-
ment plug C1.
Then connect to the defferential pressure
gauge C4.
★ Connection of differential pressure
gauge:
High pressure side: connect to plug (1)
High pressure side: connect to plug (2)
ii) Measure the LS differential pressure ac-
cording to the conditions shown in Table 1.
Table 1
Differential
Work Fuel
Operation pressure
mode lever 2
MPa {kg/cm }
2.5 - 3.9
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S Full Lever at NEUTRAL
{25 - 40}
Vehicle speed : Hi 2.1±0.1
S Full
Travel idling (lever full) {21.5±1}
E20107
※ Travel idling at one side
2) Measurement using a hydraulic pressure

gauge
★ Use a same gauge.
i) Remove the plug (1) and (2) (PT 1/8), and
install the oil pressure measurement plug.
ii) Install the oil pressure gauge C1 (39.2 MPa
{400 kg/cm2}) to the pump discharge
pressure measurement plug.
★ Reading of the gauge shall be 9.8
MPa {10 kg/cm2} step.
(If a pressure gauge of 39.2 MPa {400
kg/cm2} is not available, one of 58.8
MPa {600 kg/cm2} may be used.)
iii) Measure the pump discharge pressure
according to the conditions shown in
Table 1.
★ Read the indicator needle at a right
angle to the scale accurately.
iv) Remove the oil pressure gauge C1 and
install it to the LS pressure measure-
ment plug.
v) Measure the LS pressure according to the
conditions shown in Table 1.
★ Read the indicator needle at a right
angle to the scale accurately.
(Pump discharge pressure) - (LS pres-
sure) = LS differential pressure
20-112
①
TESTING AND ADJUSTING TESTING HYDRAULIC PRESSURE IN THE CONTROL CIRCUIT
2. Adjusting of the LS valve

If the values obtained during the measurement of
the differential pressure according to the foregoing
conditions are not in the "standard value range",
adjust the LS valve according to the following
procedure.
1) Loosen the lock nut (2) and turn the screw (3)
to adjust.
• Turn the screw:
CLOCKWISE to increase the differential
pressure;
COUNTERCLOCKWISE to decrease the
pressure.
• Adjusting amount for one turn of the screw:
1.29 MPa {13.2 kg/cm2}
2) After the adjustment finished, tighten the lock
nut (2).
Lock nut:
0.56±0.07 Nm {5.75±0.75 kgm}
(Caution) Make sure to adjust the LS valve with
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measuring the differential pressure.
E20107
TESTING HYDRAULIC
PRESSURE IN THE CONTROL
CIRCUIT
1. Measuring
45 - 55 °C
1) Remove the pressure detection plug (1) (PT
1/8) and install the hydraulic pressure gauge
C1 (5.9 MPa {60 kg/cm2}).
2) Start the engine and measure with the en-
gine at the full speed.
20-113
①
TESTING AND ADJUSTING TESTING OUTLET PRESSURE OF SOLENOID VALVE
TESTING OUTLET PRESSURE OF SOLENOID VALVE

Measuring
45 - 55 °C
1. Disconnect the output hose (2) of the solenoid

valve, and install the hydraulic pressure gauge C1
(5.9 MPa {60 kg/cm2}) with using the adapter C3
contained in the pressure gauge kit.
2. Measure the outlet pressure of the solenoid valve
according to the conditions shown in Table 1.
Table 1
Operation Oil pressure
Solenoid name Measurement conditions Operating condition 2 Remarks
of solenoid MPa{kg/cm )
Swing or work equipment 2.9±0.5

Brake canceled ON
lever operated {30±5}
Swing parking
1
brake All levers except travel at
0
NEUTRAL (5 sec. after Brake actuated OFF
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(0)
returning to NEUTRAL)
Travel speed select at Hi Motor swash
2.9±0.5
x Engine running Travel speed Hi ON plate angle at
{30±5}
Travel speed x Travel lever operated minimum
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2
select Motor swash
Travel speed select at Lo, 0
Travel speed Lo OFF plate angle at
or engine at full speed (0)
maximum
Oil pressure
Safety lock lever at RUN 2.8 - 2.9
applied on PPC ON
side (29 - 30)
PPC oil pressure valve circuit
3
lock Oil pressure not
Safety lock lever at LOCK 0
applied on PPC OFF
side (0)
valve circuit
Oil pressure
0
Fuel control lever full applied on mode OFF
(0)
select circuit
4 Mode select
Oil pressure not
2.9±0.5
Fuel control lever slow applied on mode ON
{30±5}
select circuit
※ Operation of solenoid valve

ON: Continuous (oil pressure generated)
OFF : Not continuous (oil pressure : 0)
20-114
①
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING ADJUSTING OF WORK EQUIPMENT AND SWING PPC VALVE
MEASURING PPC VALVE OUTPUT

PRESSURE
★ Hydraulic oil temperature when measuring:
45 - 55 °C
1. Measuring PPC valve output pressure

1) Disconnect the hose (1) of the circuit to be
measured.
2) Install adapter C3 between the hose and elbow.
3) Install oil pressure gauge C1 (5.9 MPa {60
kg/cm2}) to adapter C3.
4) Run the engine at high idling, operate the
control lever of the circuit to be measured, and
measure the oil pressure.
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E20107
ADJUSTING OF WORK
EQUIPMENT AND SWING PPC
VALVE
★ If there is excessive play in the work equipment or
swing lever, adjust as follows.
Place the work equipment on the ground and stop

the engine. Slowly loosen the oil-filler cap of the
hydraulic oil tank to release the pressure inside
the tank.
1. Remove the PPC valve.

2. Remove the boot (1).
3. Loosen the lock nut (2), and adjust the amount of
play of the lever by adjusting the position of the
disk (3).
★ Play of the lever: 0.5 - 3mm
(at the point 200mm away from the rotation
center of the lever)
★ When the lock nut (2) tightened, the amount of
play of the lever will decrease. So, adjust
considering the amount of decrease.
4. Fix the disk (3) and tighten the lock nut (2) with a
specified torque.
Lock nut:
112.7±14.7 Nm {11.5±1.5 kgm}
20-115
①
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

1. Set the machine in the travel posture.
★ For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45°.
2. Travel for 10 m, then measure the deviation when

traveling for the next 20 m.
★ Measure with the engine at high idling.
★ Install the hydraulic pressure gauge and
measure the pump discharge pressure at the
same time.
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E20107
20-116
①
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

★ Hydraulic oil temperature when measuring:
45 - 55 °C
1. Work equipment cylinder
★ If the hydraulic drift of the work equipment is
outside the standard value, measure the
leakage inside the cylinder as follows, and
judge if the cause of the hydraulic drift is in the
cylinder or in the control valve.
• If the leakage is within the standard value ,
the problem is in the control valve.
• If the leakage is greater than the standard
value, the problem is in the cylinder.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2) Disconnect piping (1) at the head end, then
block the piping at the chassis end with a blind
plug.
Be careful not to disconnect the piping at

the bottom end.
3) Start the engine and apply the relief pres-
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sure to the bottom end of the cylinder with
the engine at high idling.
4) Continue this condition for 30 seconds, then
E20107
measure the oil leakage for the next one

minute.
20-117
①
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
2. Swing motor
1) Disconnect the drain hose (1) of the swing
motor and the drain hose (2) of the swivel joint,
and fit a blind cap at the hose end.
2) Attach a vinyl hose to the elbow side of the
motor and receive leaking oil with a mea-
suring cylinder.
3) Turn the swing lock switch ON.
4) Start the engine and operate the swing relief
with the engine at high idling.
5) After keeping this condition for 30 seconds,
minute.
★ After the first measurement, swing by 180° and
repeat the measurement.
3. Travel motor
1) Disconnect the drain hose (3) of the travel
motor, and fit a blind cap on the hose end.
2) Attach a vinyl hose to the elbow side, and
receive oil with a measuring cylinder.
3) Fit the block ① under the track shoe grouser.
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Or, fit the block ② between the sprocket and
the frame to lock the track shoe.
4) Start the engine and operate the swing relief
E20107
with the engine at high idling.
Incorrect lever operation possibly causes an
accident, therefore, give and confirm signals
properly.
5) After keeping this condition for 30 seconds,

minute.
★ This measurement shall be repeated several
times with running the motor slightly (change
the relative positions between the valve plate
and cylinder, and piston and cylinder.).
20-118
①
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE

IN HYDRAULIC CIRCUIT
★ No accumulator is installed, so the pressure re-
maining in the piping between the control valve
and the hydraulic cylinder or swing motor cannot
be released by operating the control levers.
Therefore, when removing the above piping, be
careful of the following points.
1. Run the engine at low idling, operate the hydraulic

cylinders so that they are not relieved at the end of
the stroke, lower the work equipment to the ground,
then stop the engine.
★ If the engine is stopped with the cylinder re-
lieved at the end of the stroke, wait for 5 -10
minutes before starting the operation.
2. When removing the piping, gradually loosen the

sleeve nut of the piping to slowly release the
pressure remaining in the piping. Remove piping
when the oil stops spurting out.
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E20107
20-119
①
TESTING AND ADJUSTING CHECKING OF CLEARANCE OF SWING CIRCLE BEARING
CHECKING OF CLEARANCE OF
SWING CIRCLE BEARING
Procedure of checking clearance of swing
circle bearing mounted on machine
1. Fix a magnet-type dial gauge to the outer (or in-
ner) circle of the swing circle, and attach the probe
to the end surface of the inner (or outer) circle.
Set the dial gauge at the front or rear.
2. Extend the work equipment to the maximum reach,

and set the tip of the bucket to the same height as
the bottom of the revolving frame.
At this time, the front of the upper structure will tilt
down and the rear will rise.
3. Set the dial gauge to the zero point
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E20107
4. Set the arm more or less at right angle to the
ground surface, and lower the boom until the front
of the machine comes off the ground.
At this time, the upper structure will tilt back, so the
front will rise and the rear will go down.
5. Read the value on the dial gauge at this point.

The value is the clearance of the swing circle
bearing.
While measuring, never put your hand or foot
under the under-carriage.
6. Restore the condition in Step 2, and check that the

dial gauge has returned to the zero point. If it has
not returned to the zero point, repeat Steps 2 to 5.
20-120
①
TESTING AND ADJUSTING CHECKIING AND ADJUSTING OF TRACK SHOE TENSION
CHECKING AND ADJUSTING

OF TRACK SHOE TENSION
Checking Adjusting
1. Run the engine at low idling and move the ★ If the standard track shoe tension is abnormal,
machine forward by the length of track on the adjust according to the following procedure.
ground and stop slowly.
1. When tension is too high
2. Place straight-edge (3) over idler (1) and 1) Loosen valve (1) gradually to discharge
carrier roller (2). grease.
Do not loosen the valve more than 1
3. Measure the maximum distance between the turn since the internal high-pressure
top of the track and the underside of the grease may spout out.
straight-edge.
★ If the grease is not discharged suffi-
• If the standard slack (a) is in the following
ciently, move the machine slowly for-
range, the shoe tension is normal.
ward and in reverse.
Standard slack 2) To check that the track shoe tension is
Specification
(a) normal, run the engine at low idling and
Road liner, steel shoe 10-30 mm move the machine forward by the length of
Rubber shoe 1-3 mm track on the ground and stop slowly.
3) Test the track shoe tension again. If it is
still abnormal, adjust it again.
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1) Supply grease through grease fitting (2).
★ If the track shoe tension is not tensed
well, move the machine slowly forward
and in reverse.
Grease fitting: Grease (G2-LI)
2) To check that the track shoe tension is nor-
mal, run the engine at low idling and move
the machine forward by the length of track
on the ground and stop slowly.
3) Test the track shoe tension again. If it is
still abnormal, adjust again.
PC60-7 20-121
⑦
TESTING AND ADJUSTING TESTING WEAR OF SPROCKET
TESTING WEAR OF SPROCKET
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1. Remove the track shoe assembly.
★ See DISASSEMBLY AND ASSEMBLY, Re-
movel of road liner (Rubber pad) assembly
or Removal of steel shoe assembly.
2. Align wear gauge P with the sprocket.

★ Align the datum line, the align the sprocket
wave pattern and wear gauge wave pattern.
3. Judge the wear of the sprocket.

★ If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
★ If the sprocket wave pattern has reached
the wear limit line, replace the sprocket
with a new part.
20-121-1 PC60-7
⑤
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PC60-7 01-5-2
⑨
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
Bleeding Bleeding Bleeding air
Start Start
Nature of work air from air from from travel
engine operations
pump cylinder motor
x Replace hydraulic oil
○ ○ ○ ○ ○
x Clean strainer (Note1)
x Replace return filter element ○ ○
x Replace, repair pump

○ ○ ○ ○
x Remove suction piping
x Replace, repair control valve ○ ○ ○
x Replace cylinder
○ ○ ○
x Remove cylinder piping
x Replace swing motor
○ ○ ○
x Remove swing motor piping
x Replace travel motor, swivel
○ ○ ○
x Remove travel motor, swivel piping
Note 1: Bleed the air from the travel motors only when the oil inside the motor case has been drained.
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1. Bleeding air from pump
1) Loosen air bleed plug (1) and air bleeder
(2), and check that oil oozes out from the
plug.
2) When oil oozes out, tighten plug(1) and air
bleeder (2).
Plug:
17.64±1.96 Nm {1.8±0.2 kgm}
★ Precautions when starting the engine

After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
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, then raise
and lower the boom 4 - 5 times in
succession.
★ Operate the piston rod to approx. 100
mm before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
20-122 PC60-7
①
TESTING AND ADJUSTING BLEEDING AIR
3) Run the engine at high idling 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 and bucket cylinders.
★ When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.
3. Bleeding air from travel motor

1) Disconnect motor drain hose (3).
2) Run the engine at low idling and check that
oil oozes out from the nipple.
3) If oil oozes out, connect hose (3).
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E20107
20-123
①
TESTING AND ADJUSTING AUTOMATIC GREASING CONTROLLER
AUTOMATIC GREASING CONTROLLER

Display on the panel and special functions
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E20107
1. Display at starting switch ON 3. Display at auto-greasing operation
Self diagnosis of the controller is carried out When the auto-greasing interval set in the
with all LEDs lighting up for a short time pe- auto-greasing setting mode has elapsed, and
riod and the lamp . at right bottom corner of when the "START" switch is pressed, display
the 7-segment LED flashing. After the self- on the control panel will change as shown be-
analysis, auto repressurization is carried out, low.
and normal display will appear on the panel.
2. Display at normal operation

The power LED lights up, and the lamp . at
the bottom right corner of the 7-segment LED
flashes.
Pressure
Pump operating Pump depressurising
maintaining
7-segment
LED
Power LED ON ON ON
Greasing LED ON Flash (slow) Flash (quick)
20-124
①
4. Error code indication

When a trouble occurs, the alarm LED starts to
blink, and the 7-segment LED automatically
changes to display an error code to require
remedy by an operator.
1) Actual display
Ex.: Pump pressurization failure (required
pressure not obtained within the
greasing period)
2) To erase the error code, and to resume the

pump operation and timer-count of the
greasing interval, perform the following
procedure.
i) When the 7-segment LED displays "ab-
normal pressure" indication:
Press the [RESET/ESC] button
once, and "small dot" will be dis-
played.)
ii) When the 7-segment LED displays "ab-
normal setting" indication:
Press and hold the [RESET/ESC]
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switch for more than 5 seconds
and release the button. Display
shows "0" for about 2 seconds,
E20107
and the "small dot flashing" on

the display.
5. Auto-greasing setting function

In case the work equipment is used in a remark-
able severe condition, or it is used for longer
period in a construction site where grease flows
out excessively, such as rivers and streams, if
more frequent greasing than the original setting
interval is required, change the setting values
on the controller to shorten the greasing inter-
val.
Note 1) Make sure to explain users that
shorter greasing interval will shorten
the service life of the grease cartridge
comparing with the standard of 500
hours because grease consumption
per hour increases.
Note 2) If there is no more necessity to
shortening the greasing interval,
restore the original setting values
(a=6, b=6, c=0) on the controller.
20-125
①
Procedures to change the setting values of the

greasing controller
1. To enter into the auto-greasing setting mode:

1) Confirm the display on the 7-segment LED
on the controller.
i) When "small dot flashing" displayed on
the 7-segment LED, go to section 2)
below.
ii) If "abnormal pressure indication" dis-
played on the 7-segment LED, refer
the section "4-2)-i)" of the error code
indication, and make the LED display
"small dot flashing", then go to section
2) below.
iii) If "abnormal setting indication" dis-
played on the 7-segment LED, refer
the section "4-2)-ii)" of the error code
indication, and make the LED display
"small dot flashing", then go to section
2) below.
2) Operation
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Push V and Z switchs simultaneously.
• When the auto-greasing setting mode
is, called, the display changes as
E20107
shown in the right, and "a" at the
7-segment LED and the setting LED
flash.
★ "a" indicates the setting item.
3) To select a setting item:

Press the Z switch.
★ As the Z switch is pressed, the setting
item changes (a: Greasing interval, b:
Greasing time, c).
20-126
①
4) To determine a setting item, push the V

switch while the intended setting item is
flashing.
★ When the V switch is pushed, the set-
ting item and code No. flash alternately.
★ Figure displayed immediately after
pressing the V switch is the presently
stored code No.
5) To select a code No., press the Z switch.

• The code No. increases as the Z
switch is pressed.
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6) To store the code No., press the [SET]
switch while desired code No. is flashing.
★ By pressing the [SET] switch, the 7-seg-
E20107
ment LED returns to the status described

in the section 1), and setting of the next
item is enabled.
Setting of code No. in item [a] finished
To item [b]
Setting of code No. in item [b] finished
To item [c]
Setting of code No. in item [c] finished
To item [a]
2. To continue the setting:

Repeat the procedures from 2) to 6) in the
same manner.
3. To terminate the auto-greasing setting

mode:
Press the [ESC] switch.
★ When the setting item (alphabet) only is
flashing
…… Press the [ESC] switch once.
When the setting item (alphabet) and code
No. (number) are flashing alternately
…… Press the [ESCI switch twice.
Press and hold the [ESC] switch for 5 seconds.
★ When the switch is released after held for 5
seconds, "0" will flash on the 7-segment
LED to indicate the controller has been re-
set.
20-127
①
List of auto-greasing setting codes
Setting item Code No.
No. Item 0 1 2 3 4 5 6 7 8 9
a Greasing interval (hr.) 1 1.5 2 3 4 5 6 8
b Greasing time (min.) 2 3 5 7 10 15 20 25
c
8
Note 1. Fields marked with a oblique line are not available.
2. Code No. setting shall be done to each item.
3. Original setting values of the auto-greasing controller at the time of shipping from the factory
are a=6, b=6 and c=0.
4. Item "c" must be always set to "0". If other value is set to this item, auto-greasing may not be
carried out during operation.
★ If other value than "0" is mistakenly set in this item, reset the value.
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E20107
20-128
①
AIR BLEEDING FROM EACH COMPONENT OF AUTO-GREASING SYSTEM
Work procedure and bleeding procedure

Air bleeding procedure
Air bleeding item 1 2 3 4
Initial grease
Air bleeding Air bleeding
filling into main
Work details from auto- from greasing Operation
greaser piping
greasing pump lateral piping
and distributor.
x Replacement, repair of auto-greasing
○ ○ ○
pump
x Replacement of auto-greasing piping
○ ○ ○
x Replacement of auto-greasing distributor
x Removal of auto-greasing piping
x Removal of auto-greasing distributor ○ ○
x In cold district, when grease is changed

○ ○ ○ ○
from G2-LI to G0-LI
x Thermal contraction of grease due to
change in temperature ○ ○
1. Initial grease filling into main greaser

piping and distributor.
1) Disconnect the hose (1) under the pump,
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and remove the boom cylinder bottom dis-
tributor plug (2) and the arm distributor
plug (3).
E20107
2) Fix the tools M1 and M2 to the arm distribu-

tor plug section, fill the grease, and confirm
that new grease comes out of the hose end
under the pump and the boom cylinder bot-
tom distributor plug.
★ Discharge foreign matters and residual
air completely.
Greasing piping
: Grease (G2-LI) (standard type)
: Grease (G0-LI) (cold area type)
20-129
①
3) Connect the hose (1) under the pump, and

fix the boom cylinder bottom distributor
plug (2) and the arm distributor plug (3).
Plug (2), (3):
1.76±0.19 Nm {0.18±0.02 kgm}
Plug (2), (3) : Liquid gasket (LG-5)
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E20107
2. Air bleeding from auto-greasing pump
1) Remove the air bleeding screw (1). (Allen
key size: 5m m)
2) Turn ON the starting switch and push the
[START] switch to run the pump.
★ Discharge residual air in the pump to-
gether with grease.
★ Accumulated timer-count in the greas-
ing interval timer is reset, and timer will
start counting after greasing is com-
pleted.
3) After confirming that only grease comes
out of the air bleeding screw (1), turn OFF
the starting switch to stop the pump.
4) Tighten the air bleeding screw (1).
Air bleeding screw:
2.94±0.98 Nm {0.3±0.1 kgm}
20-130
①
3. Air bleeding from greasing lateral piping

1) Push the (START) switch on the greasing
controller to run the pump.
2) Confirm that one series of greasing process

(pressurization → pressure holding → de-
pressurization) has been completed and the
operation is in the wait mode (small dot
flashing).
With the standard setting of the setting

item b on the controller (greasing time =
6), it will take about 15 minutes after
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pressing the [START] switch.
3) Fill the grease with a grease gun into the

E20107
air bleeding plug of each distributor, and

confirm that the grease comes out of the
work equipment pins or clearance at the
bearing sections.
20-131
①
Confirmation method of depressurizing spool

indicator
1. The position of the depressurizing spool indica-

tor (1) can be visually checked by removing the
screw (3), cap (2) and rubber packing (4) at the
side of the pump.
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E20107
2. During depressurizing process and waiting
process, the depressurizing spool indicator is
coming out from the pump body by approx.
7.5mm.
3. During the pressurizing process and pressure

holding process, the depressurizing spool indi-
cator is stored in the pump body without any
protrusion.
20-132
①
Replacement of controller fuse
• Replacement of the controller fuse shall be

carried out according to the following
procedure.
1. Remove the rubber cap (1) with a screwdriver

or similar tool.
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E20107
2. Remove the fuse (2) with long-nose pliers,

etc., and replace with a new fuse.
★ Fuse: Blade type ATC-10
3. Fix the rubber cap.
20-133
①
Confirmation procedure for discharge amount

from distributor
1. On the discharge amount adjusting caps on
each distributor, figures are embossed which
indicate the discharge amount.
2. Correspondence of discharge amount and
figures on the cap is as shown in the table
below.
Figure embossed on
the discharge amount 1 2 3 4 5 6
adjusting cap
Discharge amount of
0.15 0.25 0.35 0.45 0.55 0.65
distributor (cc)
Quintuple distributor for arm

Adjusting
A B C D E
cap
Embossed
1 4 6 2 1
figure
Discharge
0.25 0.45 0.65 0.25 0.15
amount (cc)
Bucket
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Greasing Arm/ Arm/ Arm/ Arm
cylinde
objective link bucket boom cylinder
r
piston joint joint joint rod end
foot
E20107
4-spool distributor for boom
Adjusting cap F G H I
Embossed
3 3 1 1
figure
Discharge
0.35 0.35 0.15 0.15
amount (cc)
Arm Boom
Greasing Boom Boom
cylinder cylinder
objective piston foot foot
foot rod end
Distributor for boom cylinder foot
Adjusting cap J
Embossed figure 1
Discharge amount (cc) 0.35
Greasing objective piston Boom cylinder bottom
20-134
①
TROUBLESHOOTING
Points to remember when troubleshooting ......................................................................................... 20-202

Sequence of events in troubleshooting............................................................................................... 20-203
Points to remember when carrying out maintenance ......................................................................... 20-204
Checks before troubleshooting ........................................................................................................... 20-212
Connector types and mounting locations............................................................................................ 20-213
Connection table for connector pin numbers ...................................................................................... 20-217
Method of using judgement table ........................................................................................................ 20-227
Method of using troubleshooting charts .............................................................................................. 20-228
Failure modes and judgement table.................................................................................................... 20-230
Troubleshooting of electrical system (E mode)................................................................................... 20-251
Troubleshooting of engine (S mode)................................................................................................... 20-301
Troubleshooting of hydraulic and mechanical system (H mode)........................................................ 20-351
Troubleshooting of machine monitor system (M mode)...................................................................... 20-401
Troubleshooting of auto-greasing system (D mode)........................................................................... 20-451
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PC60-7 20-201
⑤
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
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.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
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 or cap from a location which is under pressure from oil, water, 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 swiftly, and
to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and
function. 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.
1. When carrying out troubleshooting, do not 2) Check checking items before starting.
hurry to disassemble the components. 3) Check other checking items.
If components are disassembled immediately 4) Other maintenance items can be checked
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any failure occurs: externally, so check any item that is
· Parts that have no connection with the considered to be necessary.
failure or other unnecessary parts will be 4. Confirming failure.
disassembled. Confirm the extent of the failure yourself, and
· It will become impossible to find the cause judge whether to handle it as a real failure or
of the failure. as a problem with the method of operation,
It will also cause a waste of manhours, parts, etc.
or oil or grease, and at the same time, will ★ When operating the machine to re-enact
also lose the confidence of the user or the troubleshooting symptoms, do not
operator. carry out any investigation or measurement
For this reason, when carrying out that may make the problem worse.
troubleshooting, it is necessary to carry out 5. Troubleshooting
through prior investigation and to carry out Use the results of the investigation and
troubleshooting in accordance with the fixed inspection in Items 2 - 4 to narrow down the
procedure. causes of failure, then use the
2. Points to ask user or operator troubleshooting flowchart to locate the
1) Have any other problems occured apart position of the failure exactly.
from the problem that had been reported? ★ The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were 2) Start from the most likely points.
there problems with the machine condition 3) Investigate other related parts or
this? information.
4) Under what conditions did the failure 6. Measures to remove root cause of failure
occur? Even if the failure is repaired, if the root
5) Had any repairs been carried out before cause of the failure is not repaired, the same
the failure? failure will occur again.
When were these repairs carried out? To prevent this, always investigate why the
6) Has the same kind of failure occurred problem occureed. Then, remove the root
before? cause.
3. Check before troubleshooting
1) Were there abnormal symptoms about the
machine?
20-202 PC60-7
①
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
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20-203
①
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and
"Handling hydraulic equipment" (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one
component to another component, connectors
used for connecting and disconnecting one wire
from another wire, and protectors or tubes used for
protecting the wiring.
Compared 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
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deformation or damage. For this reason, it is
necessary to be extremely careful when handling
wiring harnesses.
Main failures occurring in wiring harness
E20107
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 connector, or because one
or both of the connectors is deformed or the
position is not correctly aligned, or because there
is corrosion or oxidization of the contact surfaces.
② Defective crimping or soldering of connectors

The pins of the male and female connectors are in
contact at the crimped terminal or soldered portion,
but if there is excessive force brought to bear on
the wiring, the plating at the joint will peel and
cause improper connection or breakage.
20-204
①
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 crimping of the connector may separate,
or the soldering may be damaged, or the wiring
may be broken.
④ High-pressure water entering connector

The connector is designed to make it difficult for
water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
As already said, the connector is designed to
prevent water from entering, but at the same time,
if water does enter, it is difficult for it to be drained.
Therefore, if water should get into the connector,
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the pins will be shortcircuited by the water, so if
any water gets in, immediately dry the connector or
take other appropriate action before passing
electricity through it.
⑤ Oil or dirt stuck to connector

E20107
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 stuck to the connector, wipe
it off with a dry cloth or blow it dry with compressed
air and spray it with a contact restorer.
★ When wiping the mating portion of the, be
careful not to use excessive force or deform the
pins.
★ If there is oil or water in the compressed air, the
contacts will become even dirtier, so remove
the oil and water from the compressed air
completely before cleaning with compressed
air.
20-205
①
2) Removing, installing, and drying connectors

and wiring harnesses
y Disconnecting connectors
① Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then
hold the male and female connectors in each
hand and pull apart. For connectors which
have a lock stopper, press down the stopper
with your thumb and pull the connectors apart.
★ Never pull with one hand.
② When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the clip.
★ If the connector is twisted up and down or to
the left or right, the housing may break.
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E20107
③ Action to take after removing connectors
After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or water
from getting in the connector portion.
★ If the machine is left disassembled for along
time, it is particularly easy for improper
contact to occur, so always cover the
connector.
20-206
①
y Connecting connectors
① Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating portion).
2) Check tact there is no deformation,
defective contact, corrosion or damage to
the connector pins.
3) Check that there is no damage or breakage
to the outside of the connector.
★ 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 wiring with a dryer, but be
careful not to make it too hot as this will
cause short circuits.
★ If there is any damage or breakage, replace
the connector.
② Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
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For connectors with lock stopper, push in the
connector until the stopper clicks into position.
③ Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wiring
harness is misaligned, or the clamp is out of
E20107
position, adjust it to its correct position.

★ If the connector cannot be corrected easily,
remove the clamp and adjust the position.
④ If the connector clamp has been removed, be

sure to return it to its original position. Check
also that there are no loose clamps.
20-207
①
y 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.
★ If the connector is blown dry with
compressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the
compressed air before blowing with air.
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② Dry the inside of the connector with a dryer. If
water gets inside the connector, use a dryer to
dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used in
E20107
order 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 connector.

After drying, leave the wiring harness
disconnected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector, blow
it with contact restorer and reassemble.
20-208
①
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 handling 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 a
vinyl bag.
Never touch the connector contacts with your
hand.
⑤ During rainy weather, do not leave the control
box in a place where it is exposed to rain.
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⑥ Do not place the control 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 arc welding
When carrying out arc welding on the body,
E20107
disconnect all wiring harness connectors

connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no change
in the reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.
20-209
①
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to be
particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, 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. It is 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 performance should be
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confirmed with special test equipment.
E20107
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 entering.
If the opening is left open or is blocked with a rag,
there is danger of dirt entering or 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 oil. 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 filter out the dirt that has
collected during storage, so this is an even more
effective method.
20-210
①
5) Change hydraulic oil when the temperature 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. (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 oil.
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: primary flushing
is carried out with flushing oil, and secondary flushing
is carried out with the specified hvdraulic oil.
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E20107
7) Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry 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 3µ) particles that the filter built into the
hydraulic equipment cannot remove, so it is an
extremely effective device.
20-211
①
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Remedy
standard
1. Check fuel level — Add fuel
2. Check for dirt or water in fuel — Clean, drain

Lubricating oil, cooling water
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
5. Check swing machinery oil level — Add oil
6. Check engine oil level (level of oil in oil pan) — Add oil
7. Check cooling water level — Add water
8. Check condition of dust indicator — Clean or replace
9. Check hydraulic oil filter Replace
— Tighten or replace
1. Check for loose or corroded battery terminal
equipments
Electrical
Tighten or replace
E20107
2. Check for loose or corroded alternator terminals —
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Tighten or replace
3. Check for loose or corroded starting motor terminals —
Mechanical equipments
1. Check for abnormal noise or smell — Repair

Hydraulic,
2. Check for oil leakage — Repair
3. Bleed air from system — Bleed air
1. Check battery voltage (engine stopped) 20-30V Replace
2. Check level of battery electrolyte — Add or replace
3. Check for discolored, burnt, or bare wiring — Replace

Electrical components
4. Check for missing wiring clamps, hanging wire — Repair
5. Checks for getting wet onto wiring Disconnect

(check carefully getting wet at connectors — connector and dry
and terminals connection
—
6. Check for broken or corroded fuse Replace
After running
7. Check alternator voltage for few min.
(engine running at over half throttlf) Replace
27.5-29.5 V
8. Noise when battery relay is operated
— —
(switch starting switch from ON to OFF)
20-212
①
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

★ Address column in the table indicates the addresses in the connector location diagram (3D drawing).
Serial No. : 52374 – 57999

Connector
Connector
Connector
Connector
Address
Address
Mounting location Mounting location
No. of
No. of
type
type
pins
pins
No.
No.
C1 M 4 Engine starting relay A-3 M16 1 Horn —
D1 KES1 2 Diode — M17 M 6 Wiper motor, intermediate B-1
D2 KES1 2 Diode — M18 M 3 Wiper switch E-2
D8 KES1 2 Diode — M19 M 2 Wiper switch F-2
D11 KES1 2 Diode — M21 PA 9 Radio E-1
DA1 4 Diode (Solenoid) — M22 1 Horn switch A-4
M23 1 Speaker A-5
DA2 4 Diode (Solenoid) —
M24 1 Speaker A-6
E11 1 Heater relay in P-9
M25 1 Horn switch A-5
E12 1 Heater relay coil —
M26 M 6 Air conditioner unit (option) P-1
E13 1 Heater relay out —
M27 1 Room tamp L-7
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E14 1 Ribbon heater —
M28 KES1 2 Window washer Q-8
FB1 6 Fuse box F-7 M29 M 2 Speed selection switch (for STD) D-1
H1 S 16 Intermediate A-2 M30 M 2 Optional power source —
H2 L 2 Intermediate A-2 M31 KES0 4 Wiper motor L-5
H3 S 8 Intermediate A-2 M32 1 Decceleration switch D-1
K5 X 4 Fuel control motor relay A-4 M33 1 Decceleration switch D-1
K6 SWP 4 Fuel control motor relay F-6 M34 X 1 Air compressor (option) —
K7 SWP 4 Fuel control motor F-7 Air conditioner condenser
M35 X 2
(option)
—
K33 2 Deceleration indicator —
K34 2 Deceleration indicator — M37 1 Engine stop solenoid —
Travel boost pedal switch (for
K35 M 2 Fuel control motor relay — M40 1 C-1
blade)
M1 1 B-terminal of starting motor O-9 Travel boost pedal switch (for
M41 1 C-1
M2 1 C-terminal of starting motor O-9 blade)
M3 1 Engine stop solenoid Q-9 M75 X 2 Sefty relay (S, R-terminal) O-1
M4 S 16 Intermediate B-2 M76 1 Sefty relay B-terminal —
M5 1 R-terminal of alternator P-2 M78 1 Optional power source —
M8 1 Light L-6 M79 1 Optional power source —
M9 M 1 Working lamp K-9 P1 AMP040 16 Monitor panel A-8
M10 M 1 Working lamp, intermediate L-7 P2 KES1 4 Monitor panel B-8
M11 L 2 Fusible link R-8 P3 KES1 4 Monitor panel C-8
M12 KES1 3 Car heater F-5 P4 M 2 Buzzer A-3

P5 1 Fuel sensor L-6
M14 L 2 Fusible link R-8
P6 1 Fuel sensor L-6
M15 L 2 Fusible link R-8 P7 X 2 Water temperature sensor P-9
PC60-7 20-213
⑤
Connector
Connector
Connector
Connector
Address
Address
No. of
No. of
type
type
pins
pins
No.
No.
P13 1 Engine oil pressure switch Q-8
P44 SWP 6 Auto-greasing controller R-3
S1 X 2 Swing pressure switch Q-2
S2 X 2 Swing pressure switch R-3
S4 X 2 Boom RAISE pressure switch R-3
S12 1 PPC hydraulic lock switch —
PPC hydraulic lock switch,
S14 M 2 F-2
intermediate
S15 1 Fuel lever limit switch Q-9
S18 1 Fuel lever limit switch P-9
Tl 1 Battery relay, B-terminal R-6
T2 1 Ground to revolving frame S-5
T4 1 Alternator, B-terminal Q-2
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T5 1 Ground to cab C-7
T6 1 Starting switch (B) C-8
1 Starting switch (BR) C-8
T8 1 Starting switch (ACC) C-8
T9 1 Starting switch (C) C-8
T10 1 Starting switch (R1) C-8
T16 1 Battery relay, BR-terminal R-6
T17 1 Battery relay, M-terminal R-6
T18 1 Battery relay, E-terminal R-7
V1 X 2 PPC hydraulic lock solenoid N-9
V3 X 2 Mode selection solenoid M-9
V4 X 2 Swing holding brake solenoid N-9
V5 X 2 Speed selection solenoid N-9
X3 1 Swing lock prolix switch F-6
X5 M 4 Swing lock switch E-1
BR (1) (Battery relay, M-terminal) —
RB (1) (Battery relay, B-terminal) —
20-214 PC60-7
①
Serial No. : 52374 - 57999
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PC60-7 20-215
⑤
Serial No. : 52374 – 57999
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20-216 PC60-7
⑤
TESTING AND ADJUSTING CONNECTOR TYPES AND MOUNTING LOCATIONS
★ Address column in the table indicates the addresses in the connector location diagram (3D drawing).

Connector
Connector
Connector
Connector
Address
Address
No. of
No. of
type
type
pins
pins
No.
No.
C1 M 4 Engine starting relay A-3 M18 M 3 Wiper switch E-2
D1 KES1 2 Diode — M19 M 2 Wiper switch F-2
D2 KES1 2 Diode — M21 PA 9 Radio E-1
D5 KES1 2 Diode — M22 1 Horn switch A-4
D8 KES1 2 Diode —
M23 1 Speaker A-5
D11 KES1 2 Diode —
M24 1 Speaker A-6
D18 KES1 2 Diode —
M26 M 6 Air conditioner unit (option) —
DA1 090 3 Diode (Solenoid) —
M27 1 Room lamp M-1
DA2 KES1 2 Diode (Solenoid) —
M28 KES1 2 Window washer O-9
E12 X 1 Glow plug O-9
FB1 6 Fuse box F-7 M29 M 2 Speed selection switch (for STD) D-1
A-2 M30 M 2 Optional power source —
H1 S 16 Intermediate
N-2
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M31 KES1 4 Wiper motor M-1
A-2
H2 L 2 Intermediate M32 1 Decceleration switch D-1
N-1
A-2 M33 1 Decceleration switch D-1
H3 S 8 Intermediate
P-3
M34 X 1 Air compressor (option) O-9
K5 X 4 Fuel control motor relay A-4
M35 X 2 Air conditioner condenser(option) —
K6 SWP 6 Fuel control motor relay F-6
K7 SWP 6 Fuel control motor F-7 M37 1 Engine stop solenoid N-9
Travel boost pedal switch (tor
K33 M 2 Deceleration indicator — M40 1 C-1
blade)
K35 M 2 Fuel control motor relay —
M75 X 2 Sefty relay (S, R-terminal) Q-5
M1 1 B-terminal of starting motor P-9
M76 1 Sefty relay B-terminal Q-3
M2 1 C-terminal of starting motor P-8
M77 1 Sefty relay C-terminal Q-5
M3 1 Engine stop solenoid N-9
M78 1 Optional power source —
B-2
M4 S 16 Intermediate
O-2 P1 AMP040 16 Monitor panel A-8
M5 1 R-terminal of alternator Q-6 P2 KES1 4 Monitor panel B-8
M8 1 Light G-8 P3 KES1 4 Monitor panel C-8
M9 M 1 Working lamp I-9
P4 M 2 Buzzer A-3
M10 M 1 Working lamp, intermediate I-9
P5 1 Fuel sensor J-9
M11 L 2 Fusible link P-8
P6 1 Fuel sensor K-9
M12 KES1 3 Car heater F-5
P7 X 2 Water temperature sensor O-9
M14 L 2 Fusible link Q-8 P13 1 Engine oil pressure switch Q-5
M15 L 2 Fusible link Q-8 P44 SWP 6 Auto-greasing controller Q-4
M16 1 Horn — S1 X 2 Swing pressure switch Q-4
B-1 S2 X 2 Swing pressure switch Q-4
M17 M 6 Wiper motor, intermediate
P-2
PC60-7 20-216-1
⑤
Connector
Connector
Connector
Connector
Address
Address
No. of
No. of
type
type
pins
pins
No.
No.
S4 X 2 Boom RAISE pressure switch Q-5
S14 M 2 F-2
intermediate
T1 1 Battery relay, B-terminal Q-7
T2 1 Ground to revolving frame —
T4 1 Alternator, B-terminal Q-6
T5 1 Ground to cab Q-3
T6 1 Starting switch {B} D-8
T7 1 Starting switch (BR) D-8
T8 1 Starting switch (ACC) D-8
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T9 1 Starting switch (C) D-8
T10 1 Starting switch (R1) D-8
T11 1 Starting switch (R2) D-8
T12 1 Glow signal —
T13 1 Glow signal —
T16 1 Battery relay, BR-terminal Q-7
T17 1 Battery relay, M-terminal Q-6
T18 1 Battery relay, E-terminal Q-7
V1 X 2 PPC hydraulic lock solenoid M-9
V3 X 2 Mode selection solenoid N-9
V4 X 2 Swing holding brake solenoid M-9
V5 X 2 Speed selection solenoid M-9
X5 M 4 Swing lock switch E-1
20-216-2 PC60-7
⑤
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PC60-7 20-216-3
⑤
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20-216-4 PC60-7
⑤
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PC60-7 20-216-5
⑤
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20-216-6 PC60-7
⑤
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ 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.
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E20107
20-217
①
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20-218
①
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20-219
①
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20-220
①
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20-221
①
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20-222
①
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20-223
①
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20-224
①
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20-225
①
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20-226
①
TESTING AND ADJUSTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This jjudgement table is a tool to determine if the problem with the machine is caused by an abnormality in
the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then
used to decide which troubleshooting table (E-OO, H-OO) matches the symptoms.
★ The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the
monitor system (M-OO).
(See the contents for troubleshooting of the monitor system)
Troubleshooting of travel, work equipment and swing device
(PPC Hydraulic pressure lock, swing brake, power mode, travel speed)
FAILURE MODES AND JUDGMENT TABLE
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E20107
[Procedure 1]
Locate the failure mode.
Ask the operator questions and try to re-enact the failure (check the failure symptoms on the actual
machine). Use this information to locate the appropriate failure symptom from Failure Modes No. 1 -No. 26
in the Judgement Table.
[Procedure 2]
Judge if the failure is in the electrical system, or in the hydraulic or mechanical system.
1) Connect a T-adapter or socket between the wiring harness and connector for solenoids marked with a
O in the Judgement Table, then follow the troubleshooting procedures and measure the voltage for
each to check if it is the normal voltage.
2) Is the voltage the same as in the table (when normal)?
Voltage is same as in table (when normal) → go to appropriate troubleshooting (H-OO) for hydraulic
or mechanical system.
If voltage is different from table (when normal) → go to appropriate troubleshooting (E-OO) for
electrical system.
[Procedure 3]
Carry out appropriate troubleshooting (YES/NO troubleshooting).
20-227
①
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
E-OO Troubleshooting of electrical system
H-OO Troubleshooting of hydraulic, mechanical system
M-OO 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 example, a)), so 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))
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3) Method of following troubleshooting chart
· Check or measure the item inside
or the NO line to go to the next
, and according to the answer follow either the YES line
(Note: The number written at the top right corner of the
is an index number; it does not indicate the order to follow.)
E20107
· Following the YES 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))
· Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the 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 answer to the
question is NO, follow the NO line.
· Below the 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 equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order from Item 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 ★. (See Example (4))
The precautions marked ★ are not given in the , but must always be followed when carrying
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 appearinq in
the troubleshooting flow chart for each failure mode (problem).
20-228
①
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
①
E-6 Power mode cannot be changed
②
a) Work equipment speed is slow
When engine speed is middle and higher
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E20107
④
★ Before carrying out this troubleshooting, check for engagement failure at relating connectors.
★ Before proceeding to the next step, make sure to restore removed connectors.
★ When the fuse 2 is not blown out.
20-229
①
TESTING AND ADJUSTING FAILURE MODES AND JUDGMENT TABLE
FAILURE MODES AND JUDGMENT TABLE
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E20107
20-230
①
TESTING AND ADJUSTING FAILURE MODES AND JUDGMENT TABLE
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E20107
20-231
①
TROUBLESHOOTING AUTO-GREASING CONTROLLER
AUTO-GREASING PUMP
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20-232
①
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
E-1 Work equipment does not move even when the PPC hydraulic pressure lock lever is set to
the DRIVE side ........................................................................................................................ 20-252
E-2 Work equipment does move even if the PPC hydraulic pressure lock lever is at the LOCK
position....................................................................................................................................... 20-253
E-3 Does not swing ......................................................................................................................... 20-254
E-4 Swing brake does not work ...................................................................................................... 20-258
E-5 Travel speed cannot be switched ............................................................................................. 20-260
a) Cannot be switched to Hi .................................................................................................... 20-260
b) Cannot be switched to Lo ................................................................................................... 20-260
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E-6 Power mode cannot be changed .............................................................................................. 20-261
a) Work equipment speed is slow when engine speed is middle and higher ......................... 20-261
b) Excessive engine speed drop at engine speed middle and lower ..................................... 20-261
E-7 Engine does not start ................................................................................................................ 20-262
a) Starter does not work............................................................................................................ 20-262
b) Engine stop solenoid does not work ................................................................................... 20-264
E-8 Engine does not stop ................................................................................................................ 20-265
E-9 Wiper does not work ................................................................................................................. 20-266
PC60-7 20-251
⑤
TROUBLESHOOTING E-1
E-1 Work equipment does not move even when the PPC hydraulic
pressure lock lever is set to the DRIVE side
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E-1 Related electric circuit diagram
20-252 PC60-7
⑤
TROUBLESHOOTING E-2
E-2 Work equipment does move even if the PPC hydraulic pressure
lock lever is at the LOCK position.
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PC60-7 20-253
⑤
TROUBLESHOOTING E-3
E-3 Does not swing

★ Carry out this troubleshooting with both swing lock switch and swing prolix switch being [OFF].
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20-254 PC60-7
①
TROUBLESHOOTING E-3
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E20107
20-255
①
TROUBLESHOOTING E-3
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E20107
20-256
①
TROUBLESHOOTING E-3
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20-257
①
TROUBLESHOOTING E-4
E-4 Swing brake does not work

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E20107
20-258
①
TROUBLESHOOTING E-4
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E20107
20-259
①
TROUBLESHOOTING E-5
E-5 Travel speed cannot be switched

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E20107
E-5 Related electrical circuit diagram
20-260
①
TROUBLESHOOTING E-6
E-6 Power mode cannot be changed

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PC60-7 20-261
⑤
TROUBLESHOOTING E-7
E-7 Engine does not start

a) Starter does not work
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E-7 a) Related electrical circuit diagram
20-262 PC60-7
①
TROUBLESHOOTING E-7
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E20107
20-263
①
TROUBLESHOOTING E-7
b) Engine stop solenoid does not work
E-7 b) Related electrical circuit diagram
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E20107
20-264 PC60-7
①
TROUBLESHOOTING E-8
E-8 Engine does not stop

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E20107
20-265
①
TROUBLESHOOTING E-9
E-9 Wiper does not work

★ Before carrying out this troubleshooting, check for engagement failure at relating connectors
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E20107
20-266
①
TROUBLESHOOTING OF ENGINE (S MODE)
Method of using troubleshooting chart................................................................................................. 20-302

S-1 Starting performance is poor (Starting always takes time) ..................................................... 20-306
S-2 Engine does not start .............................................................................................................. 20-308
(1) Engine does not turn....................................................................................................... 20-308
(2) Engine turns no but exhaust smoke comes out (Fuel is not being injected) ................. 20-309
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............... 20-310
S-3 Engine does not pick up smoothly (Follow-up is poor)........................................................... 20-311
S-4 Engine stops during operations .............................................................................................. 20-312
S-5 Engine does not rotate smoothly (Hunting) ............................................................................ 20-313
S-6 Engine lacks output (or lacks power)...................................................................................... 20-314
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................. 20-315
S-8 Oil consumption is excessive (or exhaust gas is blue)........................................................... 20-316
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S-9 Oil becomes contaminated quickly ......................................................................................... 20-317
S-10 Fuel consumption is excessive ............................................................................................... 20-318
E20107
S-11 Oil is in cooling water, or water spurts back, or water level goes down ................................. 20-319
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ..................................................... 20-320
S-13 Oil level rises (Water, fuel in oil) ............................................................................................. 20-321
S-14 Water temperature becomes too high (Overheating) ............................................................. 20-322
S-15 Abnormal noise is made ......................................................................................................... 20-323
S-16 Vibration is excessive ............................................................................................................. 20-324
20-301
①
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart is divided into three
sections: questions, check items, and trouble-
shooting. The questions and check items are used
to pinpoint high probability causes that can be
located from the failure symptoms or simple
inspection without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections ○ A +○ B in the chart on the right cor-
responds to the items where answers can be
obtained from the user. The items in ○ B are
items that can be obtained from the user, de-
pending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under ○ C
in the chart on the right correspond to this.
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The serviceman narrows down the causes from
information ○ A that he has obtained from the
user and the results of ○ C , that he has obtained
E20107
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-302
①
The basic method of using the troubleshooting

chart is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are
marked with ○, and of these, causes that have a
high probability are marked with ◎.
Check each of the [Questions] and [Check items]
in turn, and marked the ○ or ◎ in the chart for
items where the problem appeared. The vertical
column (Causes) that has the highest number of
points is the most probable cause, so start
troubleshooting for that item to make final
confirmation of the cause.
※1. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and
mark the Cause column with △ to use as
reference for locating the cause of the
failure. However, do not use this when
making calculations to narrow down the
causes.
※2. Use the A in the Cause column as refer-
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ence for [Degree of use (Operated for long
period)] in the [Questions] section as
reference. As a rule, do not use it when
E20107
calculating the points for locating the cause,

but it can be included if necessary to
determine the order for troubleshooting.
20-303
①
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
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20-304
①
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E20107
20-305
①
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

Possible causes of the engine not starting though ex-
haust gas being discharged.
• Electrical system is defective.
• Fuel supply is insufficient.
• Air intake is insufficient.
• Fuel selection is improper.
(Under the ambient temperature of -10°C or lower,
use ASTM D975 No.1
★ Battery charaina rate
Charging rate
Ambient 100% 90% 80% 75% 70%
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
• A battery can be used if the specific gravity shows

70% or higher charging rate shown in the above
table.
• In cold weather, 75% or higher charging rate is required.
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E20107
20-306
①
TROUBLESHOOTING S-1
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E20107
20-307
①
TROUBLESHOOTING S-2
S-2 Engine does not start

(1) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized
★ If internal parts of the engine are seized, carry

out troubleshooting for "Engine stops during
operations”.
• Defective electrical system

• Failure in power train
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E20107
20-308
①
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes

out (Fuel is not being injected)
General causes why engine turns but no exhaust smoke

comes out
• Supply of fuel impossible

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
★ Standards for use of fuel
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E20107
20-309
①
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected)
General causes why exhaust smoke comes out but

engine not start
• Lack of rotating force due to defective electri-

cal system
• Insufficient supply of fuel
• Improper selection of fuel and oil
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E20107
20-310
①
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly

• Improper condition of fuel injction
• Improper fuel used
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E20107
20-311
①
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations
• Seized parts inside engine

• Overheating
★ If there is overheating and the engine stops,

carry out troubleshooting for overheating.
• Failure in power train
★ If the engine stops because of a failure in

the power train, carry out troubleshooting for
the chassis.
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E20107
20-312
①
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly
• Air in fuel system

• Defective governor mechanism
• Defective electric governor mechanism
(engine with electric governor)
★ If hunting stops when electric governor rod

is disconnected, carry out troubleshooting
for the chassis.
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E20107
20-313
①
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output

• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overtaking
★ If there is overheating and lack of output,

carry out troubleshooting for overheating.
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E20107
20-314
①
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black

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E20107
20-315
①
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
★ Do not run the engine at idling for more than 20
minutes continuously. (Both low and high idling)
General causes why oil consumption is excessive
• Abnormal combustion of oil

• External leakage of oil
• Wear of lubrication system
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E20107
20-316
①
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
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E20107
20-317
①
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive
• Leakage of fuel
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E20107
20-318
①
S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
General causes why oil is in cooling water
• Internal leakage in lubrication system

• Internal leakage in cooling system
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E20107
20-319
①
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
★ Standards for engine oil selection
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E20107
20-320
①
S-13 Oil level rises (Water, fuel in oil)

★ If there is oil in the cooling water, carry out trouble-
shooting for "Oil is in cooling water".
General causes why oil level rises
• Water in oil (milky white)

• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
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E20107
20-321
①
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes too
high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
★ Carry out troubleshooting for chassis.
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E20107
20-322
①
S-15 Abnormal noise is made

★ Judge if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made
• Abnormality due to defective parts

• Abnormal combustion
• Air sucked in from intake system
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E20107
20-323
①
S-16 Vibration is excessive

★ If there is abnormal noise together with the vi-
bration, carry out troubleshooting also for "Ab-
normal noise is made".
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)

• Improper alignment
• Abnormal combustion
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E20107
20-324
①
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
Troubleshooting flow charts for each failure mode
All work equipments, travel, swing
H-1 Speeds of all work equipments, swing and travel are slow or lack of power ..................... 20-352
H-2 Excessive drop in engine speed, or engine stalls............................................................... 20-354
H-3 All work equipments, travel and swing do not move........................................................... 20-355
H-4 Abnormal sound is generated (around the pump) .............................................................. 20-355
H-5 Fine control ability is poor, or response is poor .................................................................. 20-356
Work equipment
H-6 Boom movement is slow or lacks of power......................................................................... 20-356
H-7 Arm movement is slow or lacks of power ........................................................................... 20-358
H-8 Bucket movement is slow or lacks of power ....................................................................... 20-360
H-9 Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal) ....................................................................................... 20-361
H-10 Excessive hydraulic drift (boom, arm, bucket) .................................................................... 20-361
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H-11 Excessive time lag (engine at low speed)........................................................................... 20-362
Compound operations
H-12 In compound operations, work equipments, movement of one with
E20107
larger load is slow................................................................................................................ 20-362

H-13 In swing + boom RAISE operation, boom RAISE movement is slow................................. 20-363
H-14 In travel + swing operation, travel speed drop is excessive ............................................... 20-363
H15 In travel + work equipment (boom RAISE) operation, travel speed drop is excessive ...... 20-363
Travel system
H-16 Vehicle curves unintentionally during travel........................................................................ 20-364
H-17 Travel deviation is larger at starting .................................................................................... 20-364
H-18 Travel speed is low, or lacks of power................................................................................ 20-364
H-19 Steering operation is difficult............................................................................................... 20-367
H-20 Travel speed cannot be switched ....................................................................................... 20-368
H-21 Travel does not work (one side only) .................................................................................. 20-368
Swing system
H-22 Does not swing (both sides, one side only) ........................................................................ 20-369
H-23 Swing acceleration is poor .................................................................................................. 20-370
H-24 Excessive overrun when stopping swing (both sides, one side only)................................. 20-372
H-25 Excessive shock when stopping swing (one direction only)............................................... 20-373
H-26 Excessive abnormal noise when stopping swing (one direction only) ............................... 20-373
H-27 Excessive hydraulic drift of swing (when the swing brake is released or activated) .......... 20-374
H-28 Swing speed is faster than the specified speed.................................................................. 20-375
H-29 Blade speed is slow, or lack of power................................................................................. 20-375
H-30 Blade does not move .......................................................................................................... 20-376
H-31 Excessive hydraulic drift of the blade.................................................................................. 20-376
20-351
①
TROUBLESHOOTING H-1
H-1 Speeds of all work equipments, swing and travel are slow or lack
of power.
★ Before starting this troubleshooting, make sure that the main pump does not make any abnormal
sound.
(If abnormal sound is made, carry out troubleshooting described in H-4.)
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E20107
20-352
①
TROUBLESHOOTING H-1
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PC60-7 20-353
①
TROUBLESHOOTING H-2
H-2 Excessive drop in engine speed, or engine stalls

★ Confirm that the main relief pressure is normal.
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※ If the engine speed is still lower than the speed shown in
Table 1 even after the PC valve is replaced with a new one,
carry out the troubleshooting in the section (S).
If the engine speed is higher than that value, it can be judged
that the PC valve is defective (replace).
Table 1
Engine speed at
Model Serial No. Condition
arm relief
52374 - 57999 Min. 1,650 rpm x Engine at high idling
x Swing lock switch ON
x With the arm dump at the stroke end, shift
PC60
the lever to the full side gradually, and
58001 and up Min. 2,000 rpm read the value where the engine speed
drop is largest.
20-354 PC60-7
⑤
TROUBLESHOOTING H-3, H-4
H-3 All work equipments, travel and swing do not move
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H-4 Abnormal sound is generated (around the pump)
20-355
①
H-5 Fine control ability is poor, or response is poor
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H-6 Boom movement is slow or lacks of power
E20107
★ When the travel and swing speeds are normal.
20-356
①
TROUBLESHOOTING H-6
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E20107
20-357
①
TROUBLESHOOTING H-7
H-7 Arm movement is slow or lacks of power
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E20107
20-358
①
TROUBLESHOOTING H-7
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E20107
20-359
①
TROUBLESHOOTING H-8
H-8 Bucket movement is slow or lacks of power
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E20107
20-360
①
H-9 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
★ When the boom, arm or bucket is operated independently.
H-10 Excessive hydraulic drift (boom, arm, bucket)
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※ Because the safety valve and the suction valve commonly
serve for the boom, arm and bucket, if excessive hydraulic
E20107
drift occurs equally for boom, arm and bucket, it can be

judged that the cause is defective safety valve or suction
valve.
20-361
①
H-11 Excessive time lag (engine at low speed)
★ When the speeds of the work equipments are normal.
Engine at low idling (sec)

Time lag
Boom Max. 3.9
Arm Max. 1.0
Bucket Max. 1.0
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H-12 In compound operations, work equipments, movement of one with
larger load is slow
E20107
★ Engine at full speed
Table 1
Cause Remedy
Malfunction of the pres- Replace (Replace the pressure compen-
sure compensation valve sation valve of the smaller load side)
(※Replace as the valve stack assembly.)
Combination of compound operations Larger load side

1 Boom raise + Arm in Boom raise
2 Boom raise + Arm out Arm out
3 Boom raise + Bucket curl Boom raise
4 Arm out + Bucket curl Arm out
5 Boom lower + Arm out Arm out
20-362
①
TROUBLESHOOTING H-13, H-14, H-15
H-13 In swing + boom RAISE operation, boom RAISE movement is slow
★ When the machine works normally in independent operations of swing and boom UP.
H-14 In travel + swing operation, travel speed drop is excessive

★ When the machine works normally in independent operations of swing and travel.
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E20107
H-15 In travel + work equipment (boom RAISE) operation, travel speed

drop is excessive
★ When the machine works normally in independent operations of the work equipment (boom UP) and
travel.
20-363
①
TROUBLESHOOTING H-16
H-16 Vehicle curves unintentionally during travel
★ When the speeds of the work equipment and swing are normal
a) Curves to the same side in both forward and backward travel
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E20107
20-364
①
b) Curving side is different for forward and reverse travel
Fig. 1 Location of defective swivel joint packings and direction of travel deviation
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E20107
20-365
①
H-17 Travel deviation is larger at starting
★ When the travel speed is normal

(However, in case the travel deviation occurs also in normal travel, carry out the troubleshooting in the
section H-16 "Vehicle curves unintentionally during travel" first.)
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E20107
H-18 Travel speed is low, or lacks of power
★ When travel deviation does not occur. (In case the travel deviation occurs also, carry out the trouble-
shooting in the section H-16 "Vehicle curves unintentionally during travel" first.)
★ When the work equipment speed is normal.
20-366
①
H-19 Steering operation is difficult
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E20107
20-367
①
H-20 Travel speed cannot be switched
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H-21 Travel does not work (one side only)
E20107
20-368
①
H-22 Does not swing (both sides, one side only)
a) Does not swing to either left or right
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E20107
b) Does not swing in one direction
20-369
①
H-23 Swing acceleration is poor
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E20107
※ When there is not an adapter to block the
circuit.
Hose of the PPC valve exchange hose of
swing for hose of arm (in and out) or boom
(raise), and then operate reverse.
20-370
①
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E20107
20-371
①
H-24 Excessive overrun when stopping swing (both sides, one side only)
a) One direction only
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E20107
b) Both directions
Table 1
Cause Remedy
Defective swing motor Repair or replace
20-372
①
TROUBLESHOOTING H-25, H26
H-25 Excessive shock when stopping swing (one direction only)
H-26 Excessive abnormal noise when stopping swing (one direction
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only)
E20107
20-373
①
H-27 Excessive hydraulic drift of swing

(when the swing brake is relased or activated)
a) When the swing brake is released
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E20107
b) When the swing brake is activated
20-374
①
TROUBLESHOOTING H-28, H29
H-28 Swing speed is faster than the specified speed
H-29 Blade speed is slow, or lack of power
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★ When the work equipment, travel and swing speeds are normal.
E20107
20-375
①
H-30 Blade does not move
★ When the blade is operated independently
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E20107
H-31 Excessive hydraulic drift of the blade
20-376
①
TROUBLESHOOTING OF MACHINE MONITOR
SYSTEM (M MODE)
Electric circuit diagram of the machine monitor system................................................................... 20-402

M-1 No indicator lamp lights up when the starting switch is turned ON
(3-second self-check is not carried out either).................................................................... 20-403
M-2 All the lamps remain lighting-up after 3-second self-check completed after
the starting switch turned ON.............................................................................................. 20-403
M-3 Some lamps do not light up during self-check (all lamps lights up for 3 seconds)
upon starting switch ON ...................................................................................................... 20-404
a) All gauge lamps do not light up (caution lamp does light up)....................................... 20-404
b) Swing lock, auto-greasing failure or preheat does not light up
(all gauge lamps light up).............................................................................................. 20-404
c) Charge caution lamp does not light up ......................................................................... 20-404
d) Engine oil pressure caution lamp does not light up...................................................... 20-404
M-4 When turning ON the power (before engine starting), charge caution lamp
does not light up .................................................................................................................. 20-405
M-5 When turning ON the power (before engine starting), engine oil pressure
caution lamp does not light up ............................................................................................ 20-405
M-6 At preheating, preheating indicator does not light up ......................................................... 20-406
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M-7 Though the switch is operated, swing lock does not light up ............................................. 20-406
M-8 While engine running, engine oil pressure caution lamp lights up
(engine oil pressure is normal)............................................................................................ 20-407
M-9 Charge caution lamp lights up while engine running .......................................................... 20-407
M-10 Abnormality in engine water temperature gauge................................................................ 20-408
a) Indicator remains in the lowest level (white range) and does not rise
after engine started. ...................................................................................................... 20-408
b) Level rises immediately after starting the engine.
Indicator goes in the red range though overheat does not occur................................. 20-408
c) Engine water temperature gauge lamp goes off........................................................... 20-408
M-11 Abnormality in fuel gauge.................................................................................................... 20-409
a) All segments of the fuel gauge go off ........................................................................... 20-409
b) Fuel gauge indicates FULL though the level is low ...................................................... 20-409
c) Fuel gauge does not indicate FULL though the tank is full .......................................... 20-409
M-12 Malfunction of the buzzer .................................................................................................... 20-411
a) Buzzer does not sound ................................................................................................. 20-411
b) Buzzer does not stop sounding .................................................................................... 20-411
M-13 Service meter does not work while the engine is running .................................................. 20-412
a) When the charge caution lamp does not light up ......................................................... 20-412
b) When the charge caution lamp lights up, refer to the item M-9.................................... 20-412
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing controller is normal)................ 20-412
M-15 Illumination does not light up............................................................................................... 20-413
a) Illumination at gauge section does not light up............................................................. 20-413
b) Illumination at the service meter section does not light up
(Service meter itself do work normally)......................................................................... 20-413
M-16 Heater does not work .......................................................................................................... 20-414
a) Both Hi and Lo do not work........................................................................................... 20-414
b) Lo only does not work ................................................................................................... 20-414
c) Hi only does not work.................................................................................................... 20-414
PC60-7 20-401
①
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR

SYSTEM
Serial No. : 52374 - 57999
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20-402 PC60-7
⑤
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PC60-7 20-402-1
⑤
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E20107
20-2 PC60-7
⑤
TROUBLESHOOTING M-1, M-2

(3-second self-check is not carried out either)
M-1 Related electrical circuit
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E20107
M-2 All the lamps remain lighting-up after 3-second self-check com-
pleted after the starting switch turned ON
★ Check the fuse before this troubleshooting.
20-403
①
TROUBLESHOOTING M-3
M-3 Some lamps do not light up during self-check (all lamps lights up
for 3 seconds) upon starting switch ON
a) All gauge lamps do not light up

(caution lamp does light up)
b) Swing lock, auto-greasing failure or preheat does not

light up (all gauge lamps light up)
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E20107
c) Charge caution lamp does not light up
d) Engine oil pressure caution lamp does not light up
20-404
①
M-4 When turning ON the power (before engine starting), charge cau-
tion lamp does not light up
★ Before carrying out this troubleshooting, check for en-
gagement failure at relating connectors.
★ Before proceeding to the next step, make sure to restore
removed connectors.
★ Check for the breaking wire in the bulb (lamp) before this
troubleshooting.
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M-5 When turning ON the power (before engine starting), engine oil
pressure caution lamp does not light up.
removed connectors.
★ Check for the breaking wire in the bulb (lamp) before this
troubleshooting.
M-5 Related electrical circuit diagrar
PC60-7 20-405
⑤
M-6 At preheating, preheating indicator does not light up

removed connectors.
★ If the lamp does not light up also during the self-check
upon power ON, refer to M-2.
M-6 Related electrical circuit diagram
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M-7 Though the switch is operated, swing lock does not light up
removed connectors.
20-406 PC60-7
①
(engine oil pressure is normal)
removed connectors.
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M-9 Charge caution lamp lights up while engine running
removed connectors.
PC60-7 20-407
⑤
TROUBLESHOOTING M-10
M-10 Abnormality in engine water temperature gauge

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20-408 PC60-7
①
M-11 Abnormality in fuel gauge

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E20107
20-409
①
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E20107
20-410
①
M-12 Malfunction of the buzzer
a) Buzzer does not sound
b) Buzzer does not stop sounding
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E20107
M12 Related electrical circuit diagram
20-411
①
M-13 Service meter does not work while the engine is running
removed connectors.
a) When the charge caution lamp does not light up
b) When the charge caution lamp lights up, refer to the item M-9.
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E20107
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing control-
ler is normal)
removed connectors.
20-412
①
M-15 Illumination does not light up
* Before carrying out this troubleshooting, check for engagement failure at relating connectors.
* Before proceeding to the next step, make sure to restore removed connectors.
a) Illumination at gauge section does not light up.
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E20107
b) Illumination at the service meter section does not light up (Service meter itself do work normally)
20-413
①
M-16 Heater does not work

removed connectors.
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E20107
M-16 Related electric circuit diagram
20-414
①
TROUBLESHOOTING OF AUTO-GREASING
SYSTEM (D MODE)
D-1 [Alternate blinking of [E] and [a]] Abnormality in pump pressurization is displayed................... 20-452
D-2 [Alternate blinking of [E] and [b]] Abnormality in depressurization is displayed.
[Alternate blinking of [E] and [c]] Abnormality in pressure detection is displayed...................... 20-454
D-3 [Alternate blinking of [E] and [0]] Abnormality in controller setting is displayed ....................... 20-454
D-4 Abnormal sound is generated from the work equipment pin, though no abnormality
is displayed on the monitor panel and greasing controller......................................................... 20-456
D-5 All LEDs on the greasing controller goes off .............................................................................. 20-458
D-6 Pump does not run even though the start-up switch is pressed ................................................ 20-458
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E20107
20-451
①
TROUBLESHOOTING D-1
D-1 [Alternate blinking of [E] and [a]] Abnormality in pump pressuriza-

tion is displayed
★ When disconnecting the connector for troubleshooting during this abnormality is occurring, if
[E] and [a] do not blink alternately any more when the start-up switch is turned ON after
reconnecting the connector, the problem has been corrected.
★ In case the starting switch is turned OFF once after the trouble occurred, turn ON the starting switch
and the start-up switch, and confirm that [E] and [a] blink alternately (if not, the trouble has been
corrected).
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E20107
20-452
①
TROUBLESHOOTING D-1
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E20107
20-453
①
TROUBLESHOOTING D-2, D-3
D-2 [Alternate blinking of [E] and [b]] Abnormality in depressurization

is displayed.
[Alternate blinking of [E] and [c]] Abnormality in pressure detection
is displayed.
★ When disconnecting the connector for troubleshooting during this abnormality is occurring, if
this error code is not displayed when the connector is reconnected, the problem has been
corrected.
and confirm the error code (if the error code is not displayed, the trouble has been corrected).
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E20107
D-3 [Alternate blinking of [E] and [0]] Abnormality in controller setting
is displayed
and confirm that alternate blinking of [E] and [0] is displayed (if not displayed, the trouble has been
corrected).
20-454
①
TROUBLESHOOTING D-1
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E20107
20-455
①
TROUBLESHOOTING D-4
D-4 Abnormal sound is generated from the work equipment pin,

though no abnormality is displayed on the monitor panel and
greasing controller.
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E20107
20-456
①
TROUBLESHOOTING D-4
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E20107
20-457
①
D-5 All LEDs on the greasing controller goes off
★ When a T-adapter is inserted after disconnecting a connector, or when the connector is replaced
after disconnecting the T-adapter for troubleshooting during the trouble is occurring, if all LEDs
light up for a short period and the lamp at the bottom right of the 7-segment LED blinks, the
trouble has been corrected.
and confirm that all LEDs and the lamp at bottom right of the 7-segment LED go off. (if all LEDs light up
for a short period and the lamp at the bottom right of the 7-segment LED blinks, the trouble has
been corrected.)
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E20107
D-6 Pump does not run even though the start-up switch is pressed.
★ When a connector is replaced after disconnecting it for the troubleshooting during the trouble
is occurring, if the pump starts to work when the start-up switch is pressed, the trouble has
been corrected.
and confirm that the pump does not work. (if the pump does work, the trouble has been corrected.)
20-458
①
TROUBLESHOOTING D-1, 2, 3, 4, 5, 6 RELATED ELECTRICAL CIRCUIT DIAGRAM
D-1, 2, 3, 4, 5, 6 Related electrical circuit diagram
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E20107
20-459
①
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20-460
①
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ............... 30- 3 SWING MOTOR, SWING MACHINERY

PRECAUTIONS WHEN CARRYING Removal and Installation ......................... 30- 47
OUT OPERATION ................................... 30- 4 SWING MOTOR
SPECIAL TOOL LIST............................... 30- 6 Disassembly............................................ 30-47-1
SKETCHES OF SPECIAL TOOLS .......... 30- 9 Assembly ................................................ 30-47-5
*STARTING MOTOR SWING MACHINERY
Removal and Installation ....................... 30- 12 Disassembly............................................ 30- 48
*ALTERNATOR Assembly ................................................ 30- 51
Removal and Installation ....................... 30- 13 REVOLVING FRAME
*FUEL INJECTION PUMP Removal .................................................. 30- 54
Removal ................................................ 30- 14 Installation ............................................... 30- 55
Installation ............................................. 30- 16 SWING CIRCLE
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*WATER PUMP Removal and Installation ......................... 30- 56
Removal and Installation ....................... 30- 18 IDLER, RECOIL SPRING
*NOZZLE HOLDER Removal and Installation ......................... 30- 57
Removal and Installation ....................... 30- 19 RECOIL SPRING
*THERMOSTAT Disassembly............................................ 30- 58
Removal and Installation ....................... 30- 20 Assembly ................................................ 30- 59
*ENGINE OIL COOLER CORE IDLER
Removal ................................................ 30- 21 Disassembly............................................ 30- 60
Installation ............................................. 30- 22 Assembly ................................................ 30- 61
CYLINDER HEAD TRACK ROLLER
Removal ................................................ 30- 23 Removal and Installation ......................... 30- 63
Installation ............................................. 30- 28 Disassembly............................................ 30- 64
ENGINE, MAIN PUMP Assembly ................................................ 30- 66
Removal ................................................ 30- 31 CARRIER ROLLER
Installation ............................................. 30- 37 Removal and Installation ......................... 30- 68
RADIATOR, HYDRAULIC COOLER TRACK SHOE
Removal ................................................ 30- 38 Removal and Installation ......................... 30- 69
Installation ............................................. 30- 40 HYDRAULIC TANK
FUEL TANK Removal .................................................. 30- 70
Removal and Installation ....................... 30- 41 Installation ............................................... 30- 71
CENTER SWIVEL JOINT MAIN PUMP
Removal ................................................ 30- 42 Removal .................................................. 30- 72
Installation ............................................. 30- 43 Installation ............................................... 30- 73
Disassembly and assembly................... 30- 44 MAIN PUMP INPUT SHAFT OIL SEAL
SPROCKET Removal and Installation ......................... 30- 74
Removal and Installation ....................... 30- 45
TRAVEL MOTOR
Removal and Installation ....................... 30- 46
Disassembly and assembly................... 30-46-2
The items marked with * shall be applied to only machines, serial Nos.
52374 - 57999 (with 4D102E-1 engines)
PC60-7 30-1
⑥
METHOD OF USING MANUAL PRECAUTIONS WHEN CARRYING OUT OPERATION
CONTROL VALVE COUNTERWEIGHT

Removal.................................................. 30- 75 Removal and Installation..........................30- 122
Installation............................................... 30- 76 MONITOR
Disassembly ........................................... 30- 78 Removal and Installation..........................30- 123
Assembly ................................................ 30- 82 SWING CONTROLLER
MAIN RELIEF VALVE Removal and Installation..........................30-123
Disassembly and assembly .................... 30- 86 AUTO-GREASING CONTROLLER
SOLENOID VALVE Removal and Installation..........................30- 124
Removal and Installation......................... 30- 87 AUTO-GREASING PUMP
WORK EQUIPMENT LEFT SIDE PPC VALVE Removal and Installation..........................30- 124
(POR ARM, SWING CONTROL)
Removal and Installation......................... 30- 88
WORK EQUIPMENT RIGHT SIDE PPC VALVE
(POR BOOM, BUCKET CONTROL)
WORK EQUIPMENT PPC VALVE
(FOR BOOM, ARM, BUCKET, SWING CONTROL
PPC VALVE)
Disassembly ........................................... 30- 90
Assembly ................................................ 30- 91
TRAVEL PPC VALVE
Disassembly and assembly .................... 30- 94
BOOM CYLINDER
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Removal.................................................. 30- 96
Installation............................................... 30- 97
ARM CYLINDER
Removal.................................................. 30- 98
Installation............................................... 30- 99
BUCKET CYLINDER
Removal.................................................. 30- 100
Installation............................................... 30- 101
BLADE CYLINDER
Removal.................................................. 30- 102
Installation............................................... 30- 103
HYDRAULIC CYLINDER
Disassembly ........................................... 30- 104
Assembly ................................................ 30- 107
WORK EQUIPMENT
Removal.................................................. 30- 110
Installation............................................... 30- 111
BUCKET
Removal.................................................. 30- 112
Installation............................................... 30- 113
ARM
Removal.................................................. 30- 114
Installation............................................... 30- 115
BUCKET•ARM
Removal.................................................. 30- 116
Installation............................................... 30- 117
BOOM
Removal.................................................. 30- 118
Installation............................................... 30- 119
BLADE
OPERATOR’S CAB
30-2 PC60-7
⑥
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 ※ 1,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○○○○ASSEMBLY .............Title of operation
...............................................................Precautions related to safety when carrying out the

operation
1. ×××× (1) . ......................................Step in operation
★............................................................Technique or important point to remember when re
moving ××××(1).
2. △△△△ (2) ..........................................※ 1 Indicates that a technique is listed for use during
installation
3. □□□□ assembly (3)
.....................................................See Lubricant and Coolant Table

INSTALLATION OF○○○○ASSEMBLY .....Title of operation
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• Carry out installation in the reverse order to removal.
※ 1...................................................Technique used during installation
E20107
★ ..................................................... Technique or important point to remember when

installing △△△△(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) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
(2) The tools marked ☆ in the SPECIAL TOOLS LIST are not available as an assembly.
(3) Items listed as 79○T-○○○○-○○○○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.
PC60-7 30-3
②
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 removal 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 installing.
• 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
E20107
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
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1) Hoses and tubes using sleeve nuts
Nominal 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)
10 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 Flange (hose end) peeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions (mm)
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 PC60-7
②
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.
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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.
E20107
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

• 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.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• 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.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-5
②
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79○T-○○○-○○○○cannot be supplied (they are items to be locally
manufactured).
★ Necessity:■....... Cannot be substituted, should always be installed (used)

●....... 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 ○ in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
New/
Nece- Ske- Nature of work,
Component Symbol Part No. Part Name ssity
Q’ty re-
tch
model remarks
Disassembly, assembly
Removal, installation of
of swing machinery A 796-226-1110 Push tool ■ 1 ○
E20107
collar
assembly
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1 791-685-8005 Compressor B ■ 1
Disassembly, assembly 2 790-201-2860 Spacer ■ 1 ○

B
of recoil spring assembly 3 790-101-1600 Cylinder ■ 1
4 790-101-1102 Pump ■ 1
791-616-1030 Remover & installer ■ 1
C 790-101-1102 Pump ■ 1
track shoe assembly
790-105-1100 Cylinder ■ 1
1 796-732-1311 Stopper ■ 1
D 1 796T-297-1110 Push tool ● 1 ○ Replacement of oil seal
hydraulic pump assembly 2
2 790-201-2730 Spacer ■ 1 ○ for pump shaft
1 790-502-1003 Cylinder repair stand ■ 1
1
2 790-101-1102 Pump ■ 1
Arm,
1 790-330-1100 Multi-wrench ■ 1
bucket Removal,
2 installation of
Boom, cylinder head
2 790-102-3802 Wrench assembly ■ 1
blade
of hydraulic cylinder E Socket (width
790-302-1340 ■ 1 Blade
assembly 1 across flats: 80)
2 Socket (width
790-102-1320 ■ 1 Boom Removal,
across flats: 70)
3 installation of
Socket (width
790-302-1290 ■ 1 Bucket piston nut
across flats: 60)
Socket (width
790-302-1320 ■ 1 Arm
across flats: 65)
Expansion of
4 790-720-1000 Expander ● 1 All
piston ring
30-6
③
New/
Nature of work Symbol Part No. Part Name ssity
Q’ty re-
tch
model remarks
796-720-1670 Ring ● 1
Blade
07281-01279 Clamp ● 1
766-720-1660 Ring ● 1 Boom, Installation of
5
07281-01159 Clamp ● 1 arm piston ring
796-720-1650 Ring ● 1
Bucket
07281-01029 Clamp ● 1
790-201-1702 Push tool KIT ■ 1
790-201-1811 • Push tool 1
Blade
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1702 Push tool KIT ■ 1
790-201-1781 • Push tool 1
Arm
790-101-5021 • Grip 1
01010-50816 • Bolt 1 Press fitting of
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6
790-201-1702 Push tool KIT ■ 1 coiled bushing
790-201-1771 • Push tool 1

Bucket
Disassembly, assembly of 790-101-5021 • Grip 1
hydraulic cylinder E
assembly 01010-50816 • Bolt 1
790-201-1702 Push tool KIT ■ 1
790-201-1791 • Push tool 1
Boom
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool KIT ■ 1
790-201-1620 • Plate 1
Blade
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool KIT ■ 1
790-201-1610 • Plate 1 Insertion of dust
7 Boom
790-101-5021 • Grip 1 seal
01010-50816 • Bolt 1
790-201-1500 Push tool KIT ■ 1
790-201-1580 • Plate 1
Bucket
790-101-5021 • Grip 1
01010-50816 • Bolt 1
PC60-7 30-7
②
New/
Q’ty re-
tch
model remarks
790-201-1500 Push tool KIT ■ 1
Disassembly, assembly of 790-201-1590 • Plate 1 Insertion of dust
hydraulic cylinder E 7 Arm
790-101-5021 • Grip 1 seal
assembly
01010-50816 • Bolt 1
1 790-441-1802 Remover ■ 1
Removal, installation of 1-1 790-441-1810 • Sleeve 1 ○

work equipment assembly
1-2 792-900-1530 • Screw 1
1-3 01803-13034 • Nut 1 Pulling out of boom foot
F
1-4 01643-33080 • Washer 1 pin
Removal, installation of 1-5 796-900-1240 • Adapter 1

boom assembly 2 790-101-4000 Puller (50 ton long) 1
3 790-101-1102 Pump 1
Removal, installation of Wench (angle Tightening of cylinder head
1 790-331-1110 ■ 1
engine cylinder head G tightening wrench) bolt
assembly 2 795-799-1130 Gear ■ 1 Barring
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Removal, installation of 1 795-799-1390 Puller ■ 1 Removal of drive gear
fuel injection pump H
assembly 2 795-799-1130 Gear ■ 1 Barring
J 795-799-1170 Puller ■ 1 Pulling out of nozzle holder
nozzle holder assembly
1 790-501-5200 Unit repair stand 1
2 790-901-2110 Bracket 1 Disassembly, assembly of
1
3 790-901-1371 Plate 1 ○ motor
4 790-901-1390 Plate 1 ○
2 799-301-1600 Oil leak tester KIT 1 Pulling out brake piston
1 01017-31400 Bolt 1
2 01580-01411 Nut 1
3 3 796T-266-1120 Washer 1 ○
cylinder block spring
Disassembly, assembly of
P 4 01643-31445 Washer 1
swing motor
5 01643-32060 Washer 1
1 796T-266-1110 Push tool 1 ○
4 Press fitting of oil seal
2 790-201-2720 Spacer 1 ○
1 790-101-5081 Plate 1 Press fitting Push tool
of main kit No.
5 2 790-101-5021 Grip 1
bearing outer 790-101-
3 01010-50816 Bolt 1 race 5001
Press fitting of main bearing

6 796-126-1140 Push tool 1 ○
inner race
30-8 PC60-7
⑥
New/
Q’ty re-
tch
model remarks
Press fitting of sub bearing
7 796-126-1130 Push tool 1 ○
inner race
P 1 01435-00816 Bolt 1
of swing motor Measurement of turning
8 Commercially
2 Torque wrench 1 torque of drive shaft
available
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PC60-7 30-8-1
⑥
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30-10 PC60-7
⑥
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A. Push tool
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E20107
B2. Spacer
30-9
②
D2-1. Push tool
E20107
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D2-2. Spacer
30-10
②
F1-1. Sleeve
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PC60-7 30-11
②
P1-3. Plate
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30-11-1 PC60-7
⑥
P1-4. Plate
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PC60-7 30-11-2
⑥
P3-3. Washer
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P4-1. Push tool
30-11-3 PC60-7
⑥
P4-2. Spacer
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P6. Push tool
PC60-7 30-11-4
⑥
P7. Push tool
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30-11-5 PC60-7
⑥
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PC60-7 30-11-4
⑥
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING MOTOR ASSEMBLY

Serial No. : 52374 – 57999
Disconnect the cable from the negative (-)

terminal of the battery.
1. Open engine hood.
2. Remove stating motor side cover (1).
3. Disconnect 4 wirings (2).
4. Remove 2 mounting bolts (3).
5. Remove starting motor assembly (4). ※ 1
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INSTALLATION OF STARTING
MOTOR ASSEMBLY
Serial No. : 52374 - 57999
• Carry out installation in the reverse order to

removal.
※ 1
Starting motor assembly mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
30-12 PC60-7
④
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY

Serial No. : 52374 – 57999

2. Remove fan guard (1), then remove fan (2)

and move towards radiator.
3. Disconnect 2 wires (3).

★ Before disconnecting the wiring, fit tags to
distinguish the mounting position.
4. Remove clamp (4) of heater hose.
5. Using wrench ① , raise tensioner (5) and

remove fan belt (6).
Be extremely careful not to get your
fingers caught when removing the belt.
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6. Remove alternator mounting bolt (7) and
spacer (8). ※ 1
7. Remove mounting bolt (9) of alternator

mounting plate, then remove alternator
assembly (10). ※ 1
INSTALLATION OF ALTERNA-
TOR ASSEMBLY
Serial No. : 52374 - 57999

removal.
※ 1
Alternator assembly mounting bolt (7), (9)
: 43 ± 8 Nm {4.38 ± 0.61 kgm}
PC60-7 30-13
④
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION PUMP

ASSEMBLY
Serial No. : 52374 – 57999

2. Remove washer tank (1) together with bracket,

and move towards main pump.
3. Remove oil filter assembly (2) together with

bracket, then move towards main pump. ※ 1
4. Remove intake hose cover (3), then remove

intake hose (4).
5. Remove fan guard (5).

★ Clamp (6) of the fuel control cable is also
tightened with one of the fan guard
mounting bolts.
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6. Disconnect fuel control cable (7), then remove
together with bracket (8), and move towards
radiator.
★ When disconnecting, check the position of
the lever mount hole.
7. Disconnect 2 wires (10) of engine stop

solenoid assembly (9), and remove together
with bracket (11).
★ The (+) and (-) terminals of the 3 solenoid
terminals are used.
★ Spacers (12) are used on two of the
bracket mounting bolts. ※ 2
8. Disconnect fuel inlet hose (13) and return hose

(14).
★ Fuel will flow out when the hoses are
disconnected, so insert wooden plugs in
the hoses to prevent the fuel from leaking.
9. Remove lubrication tube (15).
10. Disconnect spill hose (16), then disconnect 2

tubes (17) between fuel injection pump and
fuel filter block. ※ 3
11. Disconnect delivery tube (8) ※ 4
30-14 PC60-7
④
12. Using tool H2, rotate engine in normal direction,

and push No. 1 cylinder compression top dead
center positioning pin (19) into gear.
★ Push the pin lightly against the gear and
rotate the engine slowly.
★ After determining the TDC position, check
if the meshing of the timing pin has come
out.
13. Remove bracket (20) at bottom of injection

pump and bracket (21) at governor end.
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14. Rotate cap (22) and remove, then remove
washer (23) and nut (24).
★ Be extremely careful not to drop the nut
and washer inside the case when
removing.
15. Using tool H1, pull drive gear of fuel injection

pump, and loosen from shaft.
PC60-7 30-15
②
16. Remove 4 nuts (25), then remove fuel injection

pump assembly (26). ※ 5
NSTALLATION OF FUEL INJEC-

TION PUMP ASSEMBLY
Serial No. : 52374 - 57999

removal.
※ 1
★ Coat one of the 3 mounting bolts (marked
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※ in the diagram on the right) of the oil
filter assembly bracket with gasket sealant.
Oil filter assembly bracket mounting bolt:
Gasket sealant (LG-7)
※ 2
• Length of mounting spacer (12)
L1=12.0 mm, L2=44.5 mm
※ 3
Tube eye joint (17)
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
※ 4
Delivery tube sleeve nut (18)
43 ± 6 Nm {4.38 ± 0.61 kgm}
※ 5
• Install the fuel injection pump assembly as
follows.
1) Check that the No. 1 cylinder is at compres-
sion top dead center.
★ For details, see Removal Step 12.
2) Remove plug (27), then remove timing pin
(28).
3) Reverse the position of timing pin (28),
align the groove of the timing pin with
pointer (29) inside the pump, then tempor-
arily tighten plug (27).
★ If the tooth of pointer (29) cannot be
aligned with the timing pin hole, rotate
the shaft of the fuel injection pump to
align the pointer tooth.
30-16 PC60-7
④
4) Align pump camshaft with pump drive gear

and install fuel injection pump assembly
(26), then tighten nut (25).
Nut (25) :
43 ± 6 Nm {4.38 ± 4.61 kgm}
5) Assemble washer (24), and tighten nut (23)

temporarily.
★ Be extremely careful not to drop the
nut and washer inside the case when
installing.
Temporary tightening of nut (23):
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
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★ This is not the final torque value.
★ To prevent damage to the timing pin,
be careful not to tighten the nut to more
than the above tightening torque.
6) Remove meshing of engine timing pin (19).
7) Remove plug (27), reverse position of

timing pin (28), then assemble and install
plug to fuel injection pump.
(27) : 14.7 Nm {1.5 kgrn}
8) Tighten drive nut (23) of fuel injection

pump fully.
Nut (23) :
95 ± 10 Nm {9.7 ± 1.02 kgm}
9) For remaining installation, carry out in

reverse order to removal.
PC60-7 30-17
②
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
Serial No. : 52374 - 57999
1. Drain coolant.
3. Remove fan guard (1), then remove fan (2),

and move towards radiator.
4. Using wrench ① , raise tensioner (3), then

5. Remove tensioner (3). ※ 1
6. Remove water pump assembly (5). ※ 2
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INSTALLATION OF WATER
PUMP ASSEMBLY
Serial No. : 52374 – 57999

removal.
※ 1
Tensioner mounting bolt:
43 ± 6 Nm {4.38 ± 0.61 kgm}
※ 2
Water pump assembly mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
• Refilling with water

Add water through the water filler to the
specified level.
Run the engine to circulate the water through
the system. Then check the water level again.
30-18 PC60-7
④
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDERASSEMBLY
Serial No. : 52374 - 57999
2. Disconnect delivery tube (1) at nozzle holder

assembly end. ※ 1
3. Remove spill tube (2). ※ 2
4. Remove nozzle holder assembly (3). ※ 3

★ If it is difficult to remove the nozzle holder
assembly, use tool J to remove it.
★ Be careful not to let dirt or dust get into the
nozzle holder assembly mount.
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INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
Serial No. : 52374 - 57999

removal.
※ 1
Delivery tube sleeve nut
30 ± 5 Nm {3.06 ± 0.51 kgm}
※ 2
Joint bolt: 8 ± 2 Nm {0.81 ± 0.20 kgm}
※ 3
Nozzle holder assembly
60 ± 9 Nm {6.12 ± 0.92 kgm}
Nozzle holder assembly thread portion:

Seizure prevention compound (Moly-
coat 1000)
★ When assembling the nozzle holder, clean
the nozzle holder mount, and check that
there is no dirt or dust inside the sleeve
before assembling. Tighten the mounting
bolts gradually in turn and be careful not to
tighten unevenly.
PC60-7 30-19
④
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT ASSEMBLY

Serial No. : 52374 - 57999
1. Drain coolant.
2. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.
3. Disconnect radiator inlet hose (1).
4. Disconnect bypass hose (2).
5. Remove alternator bracket (3). ※ 1
6. Remove thermostat housing (4). ※ 2
7. Remove thermostat (5).
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INSTALLATION OF THERMO-
STAT ASSEMBLY
Serial No. : 52374 – 57999

removal.
※ 1
Alternator bracket mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
※ 2
Thermostat housing mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

Add water through water filler to the specified
level.
★ Run the engine to circulate the water
through the system.
Then check the water level again.
30-20 PC60-7
④
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
REMOVAL OF ENGINE OIL

COOLER CORE ASSEMBLY
Serial No.: 52374 - 57999
1. Drain coolant.
2. Remove engine hood assembly.
3. Remove alternator assembly.

For details, see REMOVAL OF ALTERNATOR
ASSEMBLY.
4. Remove muffler drain pipe (1).
5. Remove fire prevention cover (2).
6. Remove 4 nuts (4) of exhaust manifold pipe

(3).
7. Remove muffler (5) together with exhaust

manifold pipe (3).
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8. Remove intermediate clamp (6) of heater
hose.
9. Remove exhaust manifold (7).
10. Disconnect 2 oil filter hoses (8) and remove

hose clamps (3 places).
★ Remove the clamps at 3 places: 1 on the
left side of the engine and 2 under the
engine.
PC60-7 30-21
④
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER CORE
11. Remove engine oil cooler assembly (9)

together with oil filter hose (8). ※ 1
12. Remove cooler core (10) from engine oil

cooler assembly (9).
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INSTALLATION OF ENGINE OIL
COOLER CORE ASSEMBLY
Serial No. : 52374 - 57999

removal.
※ 1
Oil cooler assembly mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
30-22 PC60-7
④
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
1. Drain coolant.
2. Open engine hood assembly (1).
4. Remove fire prevention cover (3).
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E20107
5. Remove 4 nuts (5) of exhaust manifold pipe (4),

then remove muffler (6) together with exhaust
manifold pipe. ※ 1
6. Remove intake hose (7).
7. Remove water temperature sensor connector

from oil filter assembly bracket (8), then
remove oil filter assembly (8) together with
bracket, and move towards counterweight.
※ 2
30-23
②
9. Remove fan (11) and move towards radiator.
E20107
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10. Using wrench ①, raise tensioner (12), then
11. Remove radiator inlet hose (14).
12. Remove intermediate clamp, and disconnect

heater hose (15) and electrical intake air
heater wiring (16).
30-24 PC60-7
②
13. Remove tensioner (17) together with bracket

(18). ※ 3
14. Remove 3 mounting bolts of alternator holder

bracket (19), then move alternator assembly
towards partition plate.
15. Remove exhaust manifold (20). ※ 4
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E20107
16. Disconnect water temperature sensor connector

(21).
17. Remove clamps (22) and (23) (2 places), then

remove delivery tube (24). ※ 5
18. Disconnect engine stop solenoid mounting

bracket (25) from head.
19. Remove spill hose (26) and tube (27) between

injection pump and fuel filter block. ※ 6
20. Remove intermediate clamp (28), then remove

tube (29) between fuel supply pump and fuel
filter block. ※ 7
30-25
②
21. Remove intake commector (30). ※ 8
22. Remove fuel filter assembly (31).
23. Remove intermediate clamp (33), (34) for spill

tube (32).
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E20107
24. Remove spill tube (35).
25. Remove nozzle holder assembly (36). ※ 9
26. Remove head cover (37). ※10
27. Remove rocker arm assembly (38). ※11

★ Loosen the locknut and turn the adjustment
screw back 2 - 3 turns.
30-26
②
28. Remove push rod (39).
29. Remove cylinder head mounting bolts in order

shown in diagram on right. ※12
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E20107
30. Lift off cylinder head assembly (40).

Cylinder head assembly: 36 kg
31. Remove cylinder head gasket (41). ※13
30-27
②
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
※ 1
Exhaust manifold pipe mounting nut (5)
37 - 49 Nm {3.8 - 5 kgm}
※ 2
★ Coat one of the 3 mounting bolts (marked
※ in the diagram on the right) of the oil
filter assembly bracket with gasket sealant.
Oil filter assembly bracket mounting bolt:
※ 3
Tensioner bracket (18) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
※ 4
★ Tighten the mounting bolts in the order (1)
- (8) shown in the diagram on the right.
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Exhaust manifold (20) mounting bolt:
E20107
43 ± 6 Nm {4.38 ± 0.61 kgm}
※ 5
Delivery tube (24) sleeve nut
Fuel injection pump end:
43 ± 6 Nm {4.38 + 0.61 kgm}
Nozzle holder end:
30 ± 5 Nm {3.06 ± 0.51 kgm}
※ 6
Joint bolt for tube (27)
29.4 ± 4.9 Nm {4.38 ± 0.61 kgm}
※ 7
Joint bolt for tube (29)
29.4 ± 4.9 Nm {4.38 ± 0.61 kgm}
※ 8
Intake connector (30) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
※ 9
Lock nut for nozzle holder assembly (36):
60 ± 9 Nm {6.12 ± 0.92 kgm}
Nozzle holder assembly thread portion:
Seizure prevention compound (Moly-
coat 1000)
30-28
②
※10
Head cover (37) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
※11 ※12 ※13

• Install the rocker arm assembly and cylin-
der head assembly as follows.
★ Check that there is no dirt or dust on the
cylinder mount surface or inside the
cylinder.
1. Set cylinder head gasket (41) to cylinder block.

★ Check that the gasket is aligned with the
holes in the block.
2. Raise cylinder head assembly (40) and set to
cylinder block.
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3. Assemble push rod (39).
E20107
Add engine oil to the push rod socket

portion.
4. Fit rocker arm assembly (38), and tighten

mounting bolts by hand.
★ Check that the ball portion of the
adjustment screw is fitted securely in the
socket portion of the push rod.
Put engine oil on the seat surface and
thread of the 8 mm and 12 mm
diameter mounting bolts.
30-29
②
5. Tighten cylinder head mounting bolts in order

shown in diagram.
Put engine oil (SAE15W-40) on the
seat and thread of the mounting bolts.
Cylinder head mounting bolt:
1) 1st step: Tighten ail bolts in order ① -

to 90 ± 5 Nm {9.18 ± 0.51 kgm}.
★ Check in the same order that all the
bolts are tightened to 90 ± 5 Nm {9.18
± 0.51 kgm}.
2) 2nd step:For the long bolts (③ ⑥ ),
tighten further in order ③ -
to 120 ± 5 Nm {12.24 ± 0.51
kgm}.
★ Check that the long bolts in Step (2)
are tightened to 120 ± 5 Nm {12.24 ±
0.51 kgm}.
3) 3rd step: i) When using tool G-1
• Using angle tightening wrench
(tool G-1), tighten bolts a further
90° in order ① - .
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ii) When not using tool G-1
E20107
• Make match marks with a felt
pen on bolt head, then tighten
bolt a further 90°.
6. Tighten rocker arm assembly mounting bolts

(diameter: 8 mm).
Rocker arm mounting bolt (diameter: 8

mm) : 24 ± 3 Nm {2.45 ± 0.31 kgm}
7. Adjust valve clearance.

Adjusting valve clearance.

Add water to the specified level, and run the
engine to circulate the water through the
system. Then check the water level again.
30-30
②
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
REMOVAL OF ENGINE, MAIN PUMP

ASSEMBLY
Serial No. : 52374 – 57999
Lower the work equipment completely to the

ground and stop the engine. Then loosen the
oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Remove hydraulic tank strainer, then use tool

D1 to stop oil.
★ When not using tool D1, remove the drain
plug, and drain the oil from the hydraulic
tank and piping.
Hydraulic tank: Approx. 68 l
2. Drain coolant.
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3. Remove engine hood (1).
4. Disconnect hose (2) from reservoir tank.
5. Disconnect hose (3) of window washer tank

and wiring (4).
PC60-7 30-31
④
6. Remove counterweight assembly (5).

For details, see REMOVAL OF COUNTERW-
EIGHT ASSEMBLY
7. Remove undercover under engine and under-

cover under pump.
8. Remove muffler cover (6) and partition plate

(7).
9. Remove starting motor side cover.
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10. Remove cover (8) at intake hose portion, then
remove intake hose (9) and intermediate
clamp (10).
11. Disconnect ground connection (11) from pump.
30-32 PC60-7
②
12. Disconnect suction tube (12), LS pressure inlet

hose (13), and LS pump pressure inlet hose
(14).
13. Disconnect main pump outlet hose (15), drain

hose (16), mode selector pilot pressure hose
(17), and blade sensing pilot pressure hose
(18).
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E20107
14. Disconnect fuel control cable (19) together

with bracket (20).
15. Disconnect 2 stop solenoid wires (21), water

temperature sensor connector (22), and engine
oil pressure sensor wiring (23), then remove
intermediate clamps (24) (2 places).
16. Disconnect fuel supply hose (25), fuel return

hose (26), and spill hose (27).
30-33
②
18. Remove fan (29), and move towards radiator.
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E20107
19. Using wrench ① , raise tensioner (30) and
20. Disconnect electrical intake air heater wiring

(32) and heater hose (33), then remove
intermediate clamp (1 place).
21. Remove radiator inlet hose (34).
30-34
②
22. Remove 2 alternator wires (35), then remove

alternator assembly (36).
23. Remove alternator mounting bracket (37).
24. Remove radiator outlet hose (38).
25. Disconnect heater hose (39), then remove

heater hose mounting elbow (40).
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26. Disconnect 3 starting motor terminal C wiring
E20107
(41). ※ 1
27.Disconnect starting motor terminal B wiring (42)

and wiring connector (43). ※ 2
30-35
②
28. Sling engine and main pump assembly, and

loosen engine mount bolts (44).
29. Remove mount bolts, then raise engine and

main pump assembly (45) slowly, and lift off.
※ 3
★ When removing the engine and main
pump assembly, check that all the wiring
and piping has been disconnected, and be
careful not to hit any other parts when
lifting off.
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Engine, main pump assembly: 465 kg
E20107
30-36
②
INSTALLATION OF ENGINE, MAIN

PUMP ASSEMBLY
Serial No. : 52374 - 57999

removal.
※ 1
Starting motor assembly, terminal C
mounting nut (dia.: 5mm):
2.5 - 3.0 Nm {0.25 - 0.31 kgm}
※ 2
Starting motor assembly, terminal B
mounting nut (dia.: 10mm):
15.7 -19.6 Nm {1.6 - 2.0 kgm}
※ 3
★ Set the engine mount rubber as shown in
the diagram on the right, then install. the
engine and main pump assembly.
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Engine mount mounting bolt:
277 ± 31.9 Nrn {28.25 ± 3.25 kgm}
Refilling with water

level.
• Refilling with oil (hydraulic tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
Hydraulic tank: 68 l (SAE10W-CD)
• Bleeding air.
Bleed the air from the fuel system.
Bleeding air.
PC60-7 30-37
④
REMOVAL OF ENGINE, MAIN

PUMP ASSEMBLY


D1 to stop oil.
tank and piping.
2. Drain coolant.
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3. Remove engine side cover.
4. Remove two heat insulation panels (1), then

re-move muffler (2).
5. Disconnect air intake hose (3).
6. Disconnect following hoses from main pump.

• Drain hoses (4) and (5)
• Mode selector solenoid pressure input
hose (6)
• Main pump discharge hose (7)
• LS pump pressure input hose (8)
• LS pressure input hose (9)
• Suction tube (10)
If oil is stopped with tool D1 and drain
hoses (4) and (5) are disconnected, oil
flows out. Accordingly, prepare plugs
(07376-50628) in advance.
30-37-1 PC60-7
④
7. Disconnect ground wire (11) from main pump.
8. Disconnect two wires (12) from alternator.
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9. Disconnect wire (13) from engine oil pressure
switch.
★ Disconnect wire damp (14).
10. Remove mounting bolt of heater relay (15).

★ Move the heater relay and engine harness
aside.
11. Disconnect glow plug wring connector (E12)

(16).
12. Disconnect air compressor wiring connector

(M34) (17).
13. Disconnect water temperature sensor wiring

connector (P7) (18).
PC60-7 30-37-2
④
14 Disconnect two engine stop solenoid wires

(19).
15 Remove fuel control lever limit switch (20) and

bracket as one unit.
16 Disconnect two starting motor wires (21).
17. Disconnect fuel control cable (22). ※ 1

★ Before disconnecting this cable, check its
fitting dimension.
18. Disconnect fuel feed hose (23), fuel return

hose (24), and spill hose (25). ※ 2
★ If the fuel feed hose is disconnected, fuel
flows out. Accordingly, prepare a wooden
plug, etc. in advance.
19. Disconnect two heater hoses (26).
20 Disconnect radiator inlet hose (27) and outlet

hose (28).
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22 Remove air conditioner compressor assembly

(OP) from engine assembly according to
* When removing compressor assembly after
releasing refrigerant (R134a):
1) Using tool X, release all refrigerant (R
134a).
2) Disconnect two air conditioner pipes
(31) from air conditioner compressor
assembly (30).
* When removing compressor assembly with-
out releasing refrigerant (R134a):
1) Loosen two lock bolts (32) and one
mounting bolt (33) of the air conditioner
compressor to remove air conditioner
compressor belt (34).
2) Remove air conditioner compressor
assembly (30) and air conditioner piping
together, then secure them out of
engine with ropes, etc.
30-37-3 PC60-7
④
23. Sling engine and main pump assembly

temporarily and remove four engine mounting
bolts (35).
24. Lift off engine and main pump assembly (36).

★ Check that the all wiring and piping have
been disconnected and the assembly will
not interfere with the machine body and
radiator.
Engine and main pump assembly:
370 kg
INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
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removal.
※ 1
★ Adjust the fuel control cable. For details,
see TESTING AND ADJUSTING, Adjusting
fuel control cable.
※ 2
Fuel hose joint bolt:
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}

level.

Add oil through oil filler to the specified level.
• Bleeding air.
Bleed the air from the fuel system.
Bleeding air.
• Charging air conditioner with gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
PC60-7 30-37-4
④
DISASSEMBLY AND ASSEMBLY RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR, HYDRAULIC

COOLER ASSEMBLY
Serial No.: 52374 - 57999


D1 to stop oil.
tank and piping.
Hydraulic tank : Approx. 68 l
2. Drain coolant.
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3. Remove engine hood.
4. Remove counterweight assembly.

EIGHT ASSEMBLY.
5. Remove cover (1) at intake hose portion. Then

remove intake hose (2) and intermediate
clamp (3).
6. Remove 3 fuse connectors (4) from air cleaner

bracket, then remove battery relay assembly
(5).
7. Remove air cleaner bracket (6).
30-38 PC60-7
④
8. Remove frame (7).
9. Disconnect hydraulic cooler inlet hose (8) and

outlet hose (9).
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★ Clamp (11) of the fuel control cable is also
mounting bolts.
11. Remove fan (12), then move it towards

radiater.
PC60-7 30-39
②
12. Disconnect radiator inlet hose (13) and outlet

hose (14).
13. Sling radiator and hydraulic cooler assembly

(15), then remove mounting bolts, and lift off
radiator and hydraulic cooler assembly (15).
★ When raising the radiator and hydraulic
cooler assembly, be extremely careful not
to damage the core, and stop to remove
the fan during the removal operation.
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INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY
Serial No. : 52374 - 57999

removal.

Add water through the water filler to the
specified level.

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.
30-40 PC60-7
④
REMOVAL OF RADIATOR, HYDRAULIC

COOLER ASSEMBLY


D1 to stop oil.
★ When not using tool D1, remove the drain,
and drain the oil from the hydraulic tank
and piping.
2. Drain coolant.
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EIGHT ASSEMBLY.
5. Remove 3 fuse connectors (4) from air cleaner

bracket, then remove battery relay assembly
(5).
6. Remove air cleaner bracket (6).
7. Remove frame (7).
PC60-7 30-40-1
④
8. Disconnect hydraulic cooler inlet hose (8) and

outlet hose (9).

★ Clamp of the fuel control cable is also
mounting bolts.
10. Remove fan (12), then move it towards

radiater.
11. Disconnect radiator inlet hose and outlet hose.
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12 Sling radiator and hydraulic cooler assembly
(15), then remove mounting bolts, and lift off
radiator and hydraulic cooler assembly (15).
★ When raising the radiator and hydraulic
cooler assembly, be extremely careful not
to damage the core, and stop to remove
the fan during the removal operation
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY

removal.

Add water through the water filler to the speci-
fied level.

again.
30-40-2 PC60-7
④
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY

★ Turn the chassis 45° to the right and lower the

work equipment completely to the ground.
1. Drain fuel.
Fuel tank: Approx. 130 l (when full)
3. Remove handrail (1).
4. Remove right side cover (2).
5. Disconnect 2 fuel level sensor wiring connectors

(3).
6. Disconnect fuel return hoses (4).
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7. Disconnect fuel return hose (5) at fuel tank
end.
8. Disconnect fuel supply hose (6).

E20107
9. Remove mounting bolts, and lift off fuel tank

assembly (7). ※ 1
Fuel tank assembly: 55 kg
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
※ 1
Thread of fuel tank mounting bolt:
Thread tightener (LT-2)
Fuel tank mounting bolt:
176.5 ± 19.6 Nm {18 ± 2 kgm}
• Refilling with oil (fuel tank)
Fuel tank: Approx. 130 l (when full)
30-41
②
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
oil filler cap of the hydraulic tank slowly to
release the pressure inside the hydraulic
tank.
★ Mark all the piping with tags to prevent mistake

the in the mounting position when installing.
1. Disconnect 2 travel moter drain hoses (1) .
2. Remove elbow (2).
3. Disconnect 4 right and left travel motor inlet

and outlet hoses (3).
4. Disconnect 2 blade hoses (4).
5. Disconnect 2 travel motor speed selector
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hoses (5).
6. Disconnect upper side drain hose (6) of swivel

joint.
E20107
7. Disconnect hoses (7) between control valve
and swivel joint.
8. Remove swivel joint stopper bracket (8).
9. Remove swivel joint mounting bolts (bottom),

then raise center swivel joint assembly, and lift
off center swivel joint assembly (9). ※ 1
30-42
②
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
removal.
※ 1
Thread of swivel joint mounting bolt:
Swivel joint mounting bolt:
110.25 ± 12.26 Nm (11.25 ± 1.25 kgm)

★ Add oil through the oil filler to the specified
through the system. Then check the oil
level again.
• Bleeding air
★ Bleed the air from the travel motor.
Bleeding air.
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E20107
30-43
②
DISASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY
1. Remove cover (1).
2. Remove snap ring (2).
3. Using tool ②, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4. Remove snap ring (6), then remove oil seal (7)

and slipper seal (8).
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E20107
ASSEMBLY OF CENTER SWIVEL
ASSEMBLY
1. Assemble slipper seal (8) to swivel shaft (5).
2. Using push tool ①, press fit oil seal (7) to

swivel rotor (4), then install snap ring (6).
Lip of oil seal : Grease (G2-LI)
3. Set swivel shaft (5) to block, and using push

tool, tap swivel rotor (4) with a plastic hammer
to install.
★ Be extremely careful not to damage the lip
of the oil seal and slipper seal when installing
the rotor.
4. Install ring (3) and secure with snap rind (2).
5. Fit O-ring and install cover (1).
30-44
②
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Swing work equipment 90° and jack up

machine with work equipment, then set block
① between track frame and track shoe.
3. Remove mounting bolts, and pull out sprocket

(1) slightly. ※ 1
4. Set eyebolt and nut to mounting bolt hole, and

lift off sprocket (1).
Sprocket: 25 kg
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INSTALLATION OF SPROCKET
removal.
※ 1
Thread of sprocket mounting bolt:
E20107

Sprocket mounting bolt:
205.8 ± 19.6Nm (21 ± 2 kgm)
30-45
②
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REMOVAL OF TRAVEL MOTOR ASSEMBLY

1. Remove sprocket.
For details, see REMOVAL OF SPROCKET.

2. Remove cover (1). ※ 1
3. Disconnect 4 travel motor hoses (2), then

remove 4 nipples, and lift off travel motor
assembly (3). ※ 2
★ Install blinds plug in the disconnected
hoses.
★ Be extremely careful not to damage the
nipple seal surface of the hose mount.
Travel motor assembly: 95 kg
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INSTALLATION OF TRAVEL
E20107
MOTOR ASSEMBLY
removal.
※ 1
Thread of cover mounting bolt:
Cover mounting bolt:
65.7 ± 6.9 Nm {6.7 ± 0.7kgm}
※ 2
Thread of travel motor mounting bolt:
Travel motor mounting bolt
276.85 ± 31.85 Nm {8.25 ± 3.25 kgm}
★ Bleed the air from the travel motor (hydraulic

tank).
Bleeding air from travel motor.

level.
30-46
②
DISASSEMBLY AND ASSEMBLY SPROCKET
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30-47
②
DISASSEMBLY, ASSEMBLY OF TRAVEL MOTOR

GM09VL2
CONTENTS
Safety ............................................................................................................................................... 30-46-3

Sectional drawing, single view drawing, and parts list
Sectional drawing of assembly.................................................................................................. 30-46-4
Single view disassembly drawing of reduction gear assembly.................................................. 30-46-6
Single view disassembly drawing of hydraulic motor assembly ................................................ 30-46-7
Parts list .................................................................................................................................... 30-46-8
Tools................................................................................................................................................. 30-46-9
Tightening torque ........................................................................................................................... 30-46-15
Weight Table................................................................................................................................... 30-46-15
Disassembly................................................................................................................................... 30-46-16
Maintenance standard table ........................................................................................................... 30-46-36
Assembly........................................................................................................................................ 30-46-38
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Dimensions table of clearance adjustment parts ............................................................................ 30-46-60
Performance confirmation test ....................................................................................................... 30-46-61
30-46-2 PC60-7
⑥
SAFETY
TYPES AND MEANING OF WARNING TERMS
• The four warning terms shown in the following table are used in the maintenance manual according to
the degree of expected danger (or the scale of an expected accident).
• Understand the meaning of these warning terms and observe the instructions given together with
these terms.
WARNING TERM MEANING

This term means that there is an imminent danger and is used when neglecting the given
procedure or instruction can cause death or serious injury.
DANGER
This term means that there is a latent danger and is used when neglecting the given
procedure or instruction can cause death or serious injury.
WARNING
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CAUTION
com This term means that there is a latent danger and is used when neglecting the given
procedure or instruction can cause injury of medium or light degree or damage of
equipment or devices.
This symbol is used to draw the reader's attention or emphasize some information.
The terms of Danger and Warning do not appear in this maintenance manual, however.
PC60-7 30-46-3
⑥
SECTIONAL DRAWING, SINGLE VIEW DRAWING, AND PARTS

LIST
SECTIONAL DRAWING OF ASSEMBLY
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30-46-4 PC60-7
⑥
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PC60-7 30-46-5
⑥
SINGLE VIEW DISASSEMBLY DRAWING OF REDUCTION GEAR ASSEMBLY
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30-46-6 PC60-7
⑥
SINGLE VIEW DISASSEMBLY DRAWING OF HYDRAULIC MOTOR ASSEMBLY
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PC60-7 30-46-7
⑥
PARTS LIST
Symbol Part named Q’ty Symbol Part named Q’ty
REDUCTION GEAR ASSEMBLY 1 HYDRAULIC MOTOR 1
1 Hub 1 Rear flange kit 1

101 • Rear flange 1
123 • Spool 1
Spindle kit 1
144 • Hexagon socket head plug 3
• Spindle assembly 1
152 • Plug 2
2 • • Spindle 1
154 • Hexagon socket head plug 6
3 • • Hold flange 1
174 • O-ring 2
19 • Reamer bolt 3
178 • Orifice 1
37 • Expande 1 179 • Filter 1
199 • Nameplat 1
RV gear assembly 1
• RV gear kit 1 102 Shaft 1
4 • • RV gear A 1 103 Swash plate 1
5 • • RV gear B 1 104 Cylinder block 1
9 Crankshaft 3
12 • Spacer 6 Piston kit 1
22 • Tapered roller bearing 6 • Piston assembly 9
23 • Needle roller bearinIng 6 105 • • Piston 1
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106 • • Shoe 1
6 Input gear 1
107 Retainer plate 1
Spur gear kit 1 108 Thrust ball 1
7 • Spur gear 3 109 Timing plate 1
110 Washer 2
8 Cover 1 112 Piston 1
113 Spring 8
114 Spring 1
F seal kit 1
115 Friction plate 2
10 • Distance piece 1
116 Mating plate 2
31 • Floating seal 1
121 Plug 1
124 Plug 2
11 Collar 1
125 Spring retainer 2
14 Distance piece 3 126 Plug 2
15 Coupling 1 127 Valve 2
16 Shaft 1 128 Spring 2
17 Pin 24 130 Spring 2
18 Ring 1 132 Oil seal 1
135 O-ring 1
20 Snap ring 136 O-ring 2
t: Above 1.90 up to 1.95 3 137 O-ring 2
↓<At interval of 0.05> 139 O-ring 1
t: Above 2.45 up to 2.50 141 Parallel pin 2
142 Parallel pin 2
21 Ball bearing 2 143 Hexagon socket head bolt 8
24 C-type snap for shaft 1 145 THS snap ring 1
25 C-type snap for shaft 3 149 Deep groove ball bearing 1
26 Steel ball 1 150 Deep groove ball bearing 1
27 O-ring 2 151 Roller 3
28 O-ring 1 153 Thrust plate 1
29 O-ring 1
Piston assembly 1
30 O-ring 1
161 • Piston 1
33 Hexagon socket head plug 3
162 • Shoe 1
30-46-8 PC60-7
⑥
TOOLS
1. Standard tools
Applicable parts
(Index No. in structural/ Name Type/Standard Q’ty
disassembly drawing)
126, 143, 121, 152, 33 Torque wrench Nominal size: 1800, dial type 1
19, 124, 160 Torque wrench Nominal size: 5600, dial type 1
33 Hexagon wrench Nominal size: 8 1
126 Hexagon socket Nominal size: 10, insertion angle: 12.7 1
143 Hexagon socket Nominal size: 8, insertion angle: 12.7 1
124,160 Socket Nominal size: 36, insertion angle: 12.7 1
19 Socket Nominal size: 27, insertion angle: 12.7 1
124,160 Adapter Insertion angle: 12.7 x 19.05 1
124,160 Spanner Round strong spanner 36 1
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1, 165, 21, 11, 132
8, 10, 102, 112
24, 25
Hammer
Plastic hammer
Snap ring pliers
Nominal size: 12
L = Approx. 300
For shaft
1
1
1
20, 145 Snap ring pliers For hole
1 Center punch φ9.5 x 100 1
21 Pin punch φ4 x 150 1
1, 2 for slinging products Sling Hook, wire rope 1 set
Cleaning of products and parts Washing brush 1
Cleaning of products and parts Wire brush 1
Draining of lubricating oil Container Vat for general use 3
and hydraulic oil
Steel ball receiver W450 × D300 × H20
For match marks Paint marker White oil paint 1
17 Wire netting basket 2 pcs.
11 Rubber mat 1
149 Leather gloves 1 pair
Supply of oil Jug For hydraulic oil and lubricating oil 2
33 Sealing tape 1
PC60-7 30-46-9
⑥
2. Devices
Applicable parts
Disassembly, assembly of Work table for general 1 set
products use
Cleaning of products and parts Cleaning tank For rough cleaning and finish cleaning 1 set
104, 149 Press work table Capacity of press: Min. 1.96 kN {200 kg} 1 set
149 Heating tank Heating ability: Min. 100°C 1 set

Capacity: 500 x 500 x 500
1 Electric drill Portable electric drill
1
(Max. drill diameter: φ10)
1 Drill φ2 1
161, 162, 163 for drying cleaned Compressed air Pressure: 294 - 490 kPa {3 - 5 kg/cm2}
products and parts
Lathe 1 set
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3. Measuring toolsom
Applicable parts
For adjustment of thickness of Thickness gauge Measurement range: 0.04 - 0.3 mm 2
snap ring (20)
For adjustment of thickness of Outside micrometer Measurement range: 0 - 25 mm 1

snap ring (20) Min. division: 0.01
For adjustment of preload on ball Unit-type depth Measurement range: 0 - 25 mm 1

bearing (21) micrometer Min. division: 0.01
30-46-10 PC60-7
⑥
4. Manufactured tools
1) Work table for travel motor
• A work table used to carry out disassem-
bly and assembly work of the travel
motor easily and safely.
2) Clamp
• A clamp used to fix spindle (2) and hub
(1).
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3) Holder (I)
• A holder used to insert spring (114),
washer (110), and snap ring (145) in
cylinder block (104).
• A holder used to remove spring (114)
from cylinder block (104).
4) Holder (II)
• A holder used to remove deep groove
ball bearing (149) from shaft (102).
PC60-7 30-46-11
⑥
5) Holder (III)
• A holder used to press fit oil seal (132)
to the oil seal hole of spindle (2).
6) Holder (IV)
• A holder used to set the RV gear
assembly securely. Apply this holder to
the outer race of tapered roller bearing
(22) of crankshaft (9) of the RV gear
assembly and hit it lightly with a hammer
to set the RV gear assembly.
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7) Jig to adjust preload on main bearing
• A jig used to press fit ball bearing (21)
to hub (1).
• A jig used to measure the axial
clearance of ball bearing (21).
8) Steel rod (I)

• A steel rod used to take ring (18) out of
hub (1).
30-46-12 PC60-7
⑥
9) Eyebolt for PT
• An eyebolt used together with wires
and a crane to take cover (8) out of
hub (1).
10) Long eyebolt

• An eyebolt used to sling the travel
motor, spindle (2), and hub (1).
Use A
Hub M14
Spindle M16
Travel motor M14
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11) Spatula
• A spatula used to remove timing plate
(109) from rear flange (101).
12) Pin punch

• A punch used to remove the outer race
and collar (11) of ball bearing (21).
PC60-7 30-46-13
⑥
13) Pointed punch

• A punch used to remove ring (165) in
the pilot valve.
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30-46-14 PC60-7
⑥
TIGHTENING TORQUE
Applicable part Bolt/Nut to be used Width across Tightening torque

(Structural drawing) Name Nominal size flats (mm) (Nm {kgm})
19 Reamer bolt M20 P2.5 27 41.16 {4.2}

33 Hexagon socket head plug PT3/8 8 3.92 {0.4}
124 Plug M30 P1.5 36 35.28 {3.6}
126 Plug M24 P1.5 10 12.74 {1.3}
143 Hexagon socket head bolt M10 P1.5 8 5.78 {0.59}
144 Hexagon socket head plug PT1/8 5 1.23 {0.125}
121 Plug M20 26 5.88 {0.6}
152 Plug PF1/4 6 2.94 {0.3}
154 Hexagon socket head plug GDL-1/16-S 4 0.98 {0.1}
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WEIGHT TABL
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Applicable part
Name Weight (kg)
(Structural drawing)
Travel motor assembly Approx. 90
1 Hub 21.75
2 Spindle 26.65
101 Rear flange assembly 11.85
PC60-7 30-46-15
⑥
DISASSEMBLY
1. Preparation
• Before disassembling the travel motor,
prepare the following items.
1) Preparation of work table
• Prepare a work table for disassembling
the travel motor.
• The work table must be so strong that
the internal parts of the travel motor
can be disassembled and assembled
on it and its top must be so wide that
those parts can be arranged on it and
will not move or fall during the work.
• Spread a rubber or vinyl sheet over the
work table.
2) Preparation of tools and materials
Prepare the tools and materials shown in
the tool section.
2. General precautions for work

★ Since the disassembled internal parts are
coated with hydraulic oil, the are slippery.
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Take care not to let them slip down to hurt
you or themselves.
★ Combustible liquid such as kerosene is
used to clean the parts. Handle it very
carefully since it can cause a fire and a
burn on you.
1) Before disassembling the travel motor, con-
sider the inspection items, characteristics of
the detected trouble, etc. and then work
according to the given disassembly procedure.
2) Since the parts are made very precisely,
handle them carefully. Take care not to hit
them against each other or drop them.
3) If a firmly fitted part is removed by hitting or
prying it, it may have burrs or may be
broken. As a result, it cannot be installed
any more and the performance may be
lowered by it. Work on such a part patiently.
4) If the travel motor is left disassembled
partly or perfectly, its parts may be rusted
by moisture and dust. Accordingly, if it is
obliged to interrupt the work, take
rust-preventive measures and protect the
parts from dust.
5) When disassembling, make match marks
on the mating faces of the parts.
6) Arrange the removed parts well so that
they will not be damaged or lost.
7) Replace each seal once the travel motor is
disassembled, as a rule. Accordingly,
prepare the all replacement seals before
disassembling.
30-46-16 PC60-7
⑥
3. Cleaning of travel motor

1) Tighten eyebolts into the mounting screw
holes of spindle (2).
Install the 2 eyebolts symmetrically
into the mounting screw holes of the
spindle.
2) Install wires to the eyebolts and sling the

travel motor and carry into the cleaning
tank.
3) Clean each part of the travel motor with a
washing brush.
Since the space between hub (1) and
(2) (in which the floating seal is
installed) is filled with soil and sand,
clean it very carefully.
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4. Installation of travel motor
1) Install the travel motor to the worktable.
Matching the screw holes of hub (1)
to those of the worktable, insert the
travel motor in the mounting hole of
the worktable carefully.
2) Fix the travel motor to the worktable with

two hexagon socket head bolts.
PC60-7 30-46-17
⑥
5. Draining lubricating oil

1) Turn over the travel motor.
2) Loosen hexagon socket head plugs (33) (3
pieces).
If the hexagon socket head plugs (33)
are removed, oil flows out when the
travel motor is turned over. According-
ly, loosen them to the degree that they
can be loosened with the fingers.

4) Remove hexagon socket head plugs (33)
(3 pieces) from cover (8) and drain the
lubricating oil.
When draining the lubricating oil,
place a container under the worktable.
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6. Removal of cover
2) Make match marks on the mating faces of
hub (1) and cover (8) with an oil paint
marker.
3) Find out the closed gap of ring (18) and

make a punch hole for drilling at a point on
outside of the hub about 20 mm inside
from the end of ring (18).
30-46-18 PC60-7
⑥
4) Make a hole 2 mm in diameter with an

electric drill from outside of hub (1) toward
ring (18).
Apply the drill to the punch hole and
make the hole straight until the ring is
pushed by the ring and raised from
the cover. Wipe off the metal chips
made by drilling so that they will not
stick to the parts to be disassembled.
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5) Insert the steel bar in the hole to push out
ring (18).
At this time, the tip of ring (18) is
pushed out above cover (8).
6) Hold the tip of ring (18) pushed up above

cover (8) with the hands and remove ring
(18) from the ring groove of hub (1).
PC60-7 30-46-19
⑥
7) Tighten the eyebolts for PT into the screw

holes for hexagon socket head plugs (33)
of cover (8). (2 places)
8) Install hooks and wires to the eyebolts for

PT and lift off cover (8) with a crane.
If cover (8) cannot be removed easily
because of the resistance of O-ring
(29), hit its rim lightly with a plastic
hammer when lifting it up.
9) Remove O-ring (29) from cover (8).

Do not reuse removed O-ring (29).
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7. Removal of input gear
1) Remove C-type shaft snap rings (24) from
shaft (16).
2) Remove input gear (6) from shaft (16).
3) Remove shaft (16) from coupling (15).
4) Remove steel ball (26) from shaft (16).
5) Remove coupling (15) from shaft (102).
30-46-20 PC60-7
⑥
8. Removal of rear flange

The following work is executed to
remove the plugs easily when the
inside of the rear flange needs to be
disassembled. At this time, loosen
the plugs to the degree that they can
be removed with the fingers.
If the inside of the rear flange does
not need to be disassembled, do not
loosen the plugs.
2) Loosen plugs (124) (2 pieces).
3) Loosen plugs (126) (2 pieces).
This work is executed to remove the
plugs easily when the inside of the
rear flange needs to be disassembled.
If the inside of the rear flange does
not need to be disassembled, do not
loosen the plugs.
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4) Remove hexagon socket head bolts (143)
(8 pieces).
5) Remove rear flange (101) from spindle (2).

Hold the rear flange with both hands
and lift up straight carefully to remove.
If it is pried forcibly or hit to remove,
timing plate (109) may fall and may
be broken.
6) Remove springs (13) (8 pieces).
PC60-7 30-46-21
⑥
7) Remove parallel pin (142) from spindle (2).
8) Remove O-ring (30) from spindle (2).

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9. Disassembly of rear flange
1) Place rear flange (101) with the mating
face for spindle (2) up.
2) Remove timing plate (109) from rear flange
(101).
The timing plate may be fitted to the
mating face of the rear flange
because of oil and may not be
removed easily. In this case, insert a
spatula in the cast groove on the
mating face of the rear flange and
raise off the timing plate. If a sharp
tool such as a screwdriver is inserted
between the mating faces, the mating
faces will be damaged and oil will
leak. Accordingly, do not use such a
sharp tool.
3) Remove parallel pin (141) from rear flange

(101).
30-46-22 PC60-7
⑥
4) Remove deep groove ball bearing (150)

from rear flange (101).
10. Disassembly of brake valve in rear flange

1) Remove plugs (124) (2 pieces) from rear
flange (101).
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2) Take 2 spring retainers (125) and 2 springs
(128) out of rear flange (101).
3) Take spool (123) out of rear flange (101).
Slant rear flange (101) with either
plug port down, and spool (123) slips
down. Hold the tip of the spool and
take it out.
4) Take plugs (126) (2 pieces) out of rear

flange (101).
PC60-7 30-46-23
⑥
5) Take 2 springs (130) and 2 valves (127)

out of rear flange (101).
6) Remove O-rings (136) from plugs (124).

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7) Remove O-ring (137) from plug (126).
11. Disassembly of pilot valve in rear flange

1) Insert the pointed punch in the cut of ring
(165) and hit it with a hammer to take out
ring (165).
30-46-24 PC60-7
⑥
2) Lift up rear flange (101) with the hole of the

removed ring down, and stopper (164),
spring (166), and valve (163) can be
removed from the rear flange.
Remove ring (165) only when the
pilot valve needs to be replaced.
If ring (165) is removed, the hole is
scratched. Accordingly, repair the
hole carefully after removing the ring.
Do not reuse the removed ring (165).
★ If the above parts cannot be remo-
ved by lifting the rear flange with
the holed own, apply compressed
air gradually to the 2nd-speed
selector port.
If the compressed air is applied
suddenly, the parts may jump out
and may hurt you. Apply it
gradually and carefully.
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12. Removal of plug
1) Remove plug (152) only when it is required
to do so. If malfunction is caused by dirt,
etc., remove this plug and clean the oil port
thoroughly. At this time, take care not to let
steel ball (168) fall.
2) Remove O-ring (174) from plug (152).
13. Disassembly of parking brake unit

★ If compressed air is applied suddenly,
piston (112) may jump out of spindle (2)
and may hurt you. Accordingly, place a
protective cover, etc. over piston (112).
1) Apply compressed air to the tube hole for
the parking brake on spindle (2) to take
piston (112) out of spindle (2).
2) Take O-rings (135) and (139) out of piston
(112).
Do not reuse removed O-rings (135)
and (139).
PC60-7 30-46-25
⑥
14. Disassembly of hydraulic, motor

If the travel motor is laid on its side, the oil
flows out. Accordingly, place a container
under the travel motor.
1) Turn the travel motor by 90 degrees.

2) Drain the oil from the travel motor.
3) Hold cylinder block (104) with the hands
and turn it to both directions by 2 - 3 turns
to separate shoe (106) from thrust plate
(153).
★ If cylinder block (104) is pulled out
without performing the above action,
shoe (106) is left on swash plate (103)
and the parts sticking to cylinder block
(104) (piston, shoe, etc.) come off
cylinder block (104) and fall in spindle
(2).
4) Pull cylinder block (104) out of shaft (102).
At this time, friction plate (115) and
mating plate (116) are removed
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together with cylinder block (104).
5) Remove friction plate (115) and mating
plate (116) from removed cylinder block
(104).
6) Remove the piston assembly [piston (105)
and shoe (106)] and retainer plate (107)
from cylinder block (104).
At this time, hold retainer plate (107)
with both hands and remove it
together with the above parts.
Piston (105) and shoe (106) are
made in one unity by drawing them at
the spherical part of the piston. It is
impossible to separate piston (105)
and shoe (106) from each other
without damaging shoe (106). If
either or both of them need to be
replaced, replace them as a set
(hereinafter, referred to as the piston
assembly) and replace the 9 sets
(hereinafter, referred to as the piston
kit).
7) Pull piston assemblies (105) and (106) (9
assemblies) out of retainer plate (107).
30-46-26 PC60-7
⑥
8) Take thrust ball (108) out of cylinder block

(104).
9) Take rollers (151) (3 pieces) out of cylinder

block (104).
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15. Removal of springs in cylinder block
1) Place cylinder block (104) on the press
work table.
When removing the springs align
holder (I) with the washer to prevent
damage of the cylinder block caused
by contact. Cover the cylinder block
with a vinyl sheet for protection.
Remove the springs only when they
need to be replaced.
2) Place holder (I) on washer (110). Securing
holder (I) with the press, remove round
R-type snap ring (145) from the snap ring
groove of cylinder block (104) with snap
ring pliers.
3) Release the press gradually until the
spring force is lost.
★ If the press is released suddenly, the
spring may jump out to hurt you.
Accordingly, release the press slowly.
PC60-7 30-46-27
⑥
4) Take round R-type snap ring (145), washer

(110), spring (114), and washer (110) out of
16. Pulling out shaft

1) Remove swash plate (103) from shaft
(102).
When removing the swash plate,
pivot (176) may stick to it. Take care.
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2) Pull shaft (102) out of spindle (2). At this
time, deep groove ball bearing (149) is
removed together with the shaft.
The shaft can be pulled out easily by
hitting its end on the reduction gear
side lightly with a plastic hammer. If it
is hit strongly, it may jump out,
however.
3) Remove thrust plate (153) from swash

plate (103).
Swash plate (103) may not be
removed easily because of the oil on
its mating face. In this case, insert a
spatula between the swash plate and
thrust plate and raise it lightly, and
the swash plate is removed easily.
30-46-28 PC60-7
⑥
4) Take 2 pivots (176) and 2 parallel pins (177)

out of spindle (2).
★ At the following step, the 2nd-speed
selector piston assembly may jump out
and hurt you because of compressed
air. Accordingly, put a protective cover
over the 2nd-speed selector piston
assembly.
5) Supply compressed air to the passage of
spindle (2) to take the 2nd-speed selector
piston assembly (piston and shoe) and
spring (185) out of spindle (2).
• Piston (161)
Piston assembly
• Shoe (162)
Compressed air:
0.29 - 0.49 MPa {3 - 5 kg/cm2}
Piston (161) and shoe (162) are made
in one unity by drawing them at the
spherical part of the piston. It is
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impossible to separate piston (161)
and shoe (162) from each other
without damaging piston (161). If either
or both of them need to be replaced,
replace them as a set (hereinafter,
referred to as the piston assembly).
17. Removal of deep groove ball bearing

Remove the deep groove ball bearing
only when it needs to be removed.
1) Place holder (II) on the press work stand
and put shaft (102) in it.
2) Push the shaft end with the press to
remove deep groove ball bearing (149)
from the shaft.
Do not reuse the deep groove ball
bearing.
18. Removal of spur gears

★ When the snap ring is removed, it
may come off the pliers nose and fly
out. Take care.
2) Remove C-type shaft snap rings (25) (3
pieces) from crankshafts (9).
PC60-7 30-46-29
⑥
3) Remove spur gears (7) (3 pieces) from

crankshafts (9).
4) Remove distance pieces (14) (3 pieces)

from crankshafts (9).
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19. Removal of hold flange
2) Set clamps (2 pieces) to hub (1) and
spindle (2) to secure them. At this time, set
the clamps symmetrically.
If hold flange (3) is removed without
setting the clamps, hub (1) and
spindle (2) separate from each other
and spindle (2) will fall from the work
table. Be sure to use the clamps.
4) Remove snap rings (20) (3 pieces) from

hold flange (3).
30-46-30 PC60-7
⑥
5) Make match marks on snap ring (20) and

hold flange (3) with an oil paint marker.
Make these marks so that the snap
ring and hold flange will be installed
to the original positions.
6) Loosen reamer bolts (19) (3 pieces).

The threaded parts of the reamer
bolts (19) are coated with adhesive.
When the reamer bolts are loosened,
if the adhesive sticks to their reaming
parts, they may be seized and may
not be removed easily. Accordingly,
loosen the reamer bolts as slowly as
possible. If they become heavy, do
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not loosen them forcibly but tighten
them again, then loosen slowly.
The tightening torque of these
reamer bolts is 411.6 ± 63.7 Nm {42 ±
6.5 kgm}. Since the threaded parts
are coated with adhesive, larger
torque than 411.6 ± 63.7 Nm {42 ±
6.5 kgm} is required to loosen them,
however.
7) Remove hold flange (3) from spindle (2).
8) Make match marks on hold flange (3) and
spindle (2) with an oil paint marker.
Make these marks so that hold flange
(3) will be installed to the position of
spindle (2) before disassembly.
The 3 holes on spindle (2) for
installing reamer bolts (19) have been
made simultaneously. When spindle
(2) or flange (3) needs to be replaced,
replace both of them as an assembly.
(Hereinafter, this assemble will be
referred to as the spindle assembly.)
PC60-7 30-46-31
⑥
20. Removal of clamps

2) Remove the clamps (2 pieces).
21. Removal of spindle

1) Tighten 2 eyebolts symmetrically into the
mounting screw holes of spindle (2).
2) Install hooks to the eyebolts and sling them

with a crane to remove spindle (2) from
hub (1).
At this time, floating seal (31), outer race of
tapered roller bearing (22), and oil seal are
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removed, too.
3) Remove distance piece (10) from hub (1).
4) Remove O-ring (28) from hub (1).

30-46-32 PC60-7
⑥
22. Removal of ball bearing, RV gear assembly,

and pin
1) Hit the end of pin (17) with pin punch ②
and hammer ① to remove ball bearing
(21) from hub (1).
At this time, RV gear assembly [RV gear A
(4), RV gear B (5), crankshaft (9), tapered
roller bearing (22), needle roller bearing
(23), and spacer (12) ] and pin (17) are
removed, too.
When removing ball bearing (21), hit
3 – 4 points on the periphery of the
pin end lightly so that the bearing will
not be slanted.
If the outer race of ball bearing (21) is

removed from hub (1), ball bearing
(21), RV gear assembly and pin (17)
fall from hub (1). Accordingly, place a
container and a rubber mat on it
under the work table to protect the
falling parts.
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2) Remove ball bearing (21), RV gear
assembly, and pin (17) which fell from the
hub. RV gear A (4) and RV gear B (5) of
the RV gear assembly can be separated
from crankshaft (9).
Remove tapered roller bearing (22),
needle roller bearing (23), and spacer
(12) from crankshaft (9) only when
they need to be replaced.
23. Removal of ball bearing and collar

2) Hit the end of collar (11) with pin punch ④
and hammer ③ from the cover (8) side of
hub (1) to remove ball bearing (21) and
collar (11) from hub (1).
If ball bearing (21) and collar (11) are
removed, they fall from hub (1).
Accordingly, place a rubber mat
under the work to protect those parts.
PC60-7 30-46-33
⑥
24. Removal of spindle parts

1) Remove oil seal (132) from spindle (2).
Never reuse removed oil seal (132).
2) Take floating seal (31) out of spindle (2).
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3) Take outer races (3 pieces) of tapered
roller bearings (22).
The outer races of tapered roller
bearings (22) may stick to the spindle
and may not be taken out easily
because of the lubricating oil films. In
this case, hit the center of the
mounting hole of the spindle (2)
lightly with an aluminum bar, and the
oil films are broken and the outer
races can be taken out easily.
25. Disassembly of hold flange parts

1) Take the outer races of tapered roller
bearings (22) out of hold flange (3).
30-46-34 PC60-7
⑥
26. Rough cleaning of parts

1) Classify the parts into hub (1), spindle (2),
hold flange (3), rear flange (101), and the
other parts (hereinafter, referred to as the
internal parts).
2) Put the hub, spindle, cover, and rear flange
in the cleaning tank and clean them.
Clean these parts and remove soil
and sand from them carefully.
★ Kerosene is combustible. Take care of
fire extremely.
3) Put the internal parts and kerosene in the
rough cleaning container and clean them.
If dirty parts are washed in water
soon after they are put in kerosene,
they may be scratched. Accordingly,
leave them in kerosene until the dirt
and grease become loose and float.
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27. Finish cleaning
1) Put the parts and kerosene in the finish
cleaning container and clean them
carefully to their inside, turning them
slowly.
2) Wipe kerosene off the parts with clean
cloths.
Dry the inside of hub (1), spindle (2),
and hold flange (3) by blowing
compressed air against them in a
clean and dry place. After drying
them, apply hydraulic oil to them.
Dry the inside of rear flange (101),
hydraulic motor parts, and RV gear
assembly naturally in a clean and dry
place. After drying them, apply
hydraulic oil to them.
If pins (17) (24 pieces) are handled,
roughly they may scratch each other
and may be lost. Accordingly, handle
them very carefully.
PC60-7 30-46-35
⑥
MAINTENANCE STANDARD TABLE

Disassemble and inspect the GM motor according to the following standard. Handle its parts carefully. In
particular, take care not to damage the moving parts and sliding parts.
1) Seals
Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they are
free from damage.
2) Maintenance standard for worn parts)
i) Replace all the parts which have visible extreme damages.
ii) Replace the parts which have the following trouble (phenomenon).
Standard value Allowable value

Part No. Part name Trouble
(Standard dimension) (Criterion)
Spindle kit
(2) Spindle • Part surface has visible serious

damage.
(3) Hold flange • Part surface is scuffed or worn
easily.
(19) Reamer bolt
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RV gear assembly
(4) RV gear (A) • RV gear tooth surface is worn

(5) RV gear (B) unevenly.
(9) Crankshaft • When crankshaft (9) is revolved,
(22) Tapered roller bearing each part does not move
(23) Needle roller bearing smoothly.
10 Distance piece • Sliding surface has flaw.
• Sliding surface is worn abnor-
mally.
20 Snap ring • Periphery or end faces are worn
abnormally.
21 Ball bearing • There is bruise.
• Surface is flaked.
• Surface is worn unevenly.
Rear flange kit
(101) Rear flange • Moving part against spool (123)

has flaw.
• Clearance between rear flange
and spool is large. Clearance Clearance
• Contact face against valve (127) 12-1 µ 23 µ
has flaw.
• Depth to contact face against
valve (127) is large.
(123) Spool • Outside surface has flaw.
• Outside surface is worn unevenly.
30-46-36 PC60-7
⑥
Standard value Allowable value

Part No. Part name Trouble
(Standard dimension) (Criterion)
102 Shaft • Contact face against oil seal (132)
is worn.
• Spline is worn.
153 Thrust plate • Thrust plate is seized.
104 Cylinder block • Spline is worn.
• Inside of bore is worn remarkably.
• Sliding surface against timing plate
(109) is scratched and worn
unevenly.
Piston assembly
(105) Piston • There is axial clearance between

piston (105) and shoe (106).
Clearance: Clearance:
(106) Shoe • Shoe is worn abnormally.
0.05 mm 0.15 mm
• Shoe is worn unevenly.
107 Retainer plate • Periphery and end faces are worn
unevenly.
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108 Thrust ball • Spherical sliding parts against
retainer plate (107) is worn
unevenly.
109 Timing plate • Sliding surface is seized and worn
unevenly.
115 Friction plate • Both end faces are worn unevenly. Braking torque: Braking torque:
116 Mating plate • Specified torque is not produced. 82.38 Nm (8.4 kgm) 82.38 Nm (8.4 kgm)
• Plate is seized.
127 Valve • Seat surface has flaw.
149 Deep groove ball • There is bruise.
bearing • Surface is flaked.
150 Deep groove ball • Surface is worn unevenly.
bearing
163 Valve • Outside surface has flaw.
PC60-7 30-46-37
⑥
ASSEMBLY
• Carry out assembly in the reverse order to 3. Assembly procedure
disassembly, as a rule.
If any part is replaced before assembling,
1. Preparation the preload on the ball bearing and
Prepare a worktable, tools, and materials for thickness of the snap ring may need to
disassembling, similarly to preparation for be adjusted. Accordingly, see if any of the
disassembly. following part has been replaced before
2. General precautions for work assembling.
1) Observe the same general precautions 1) Replacement parts which require ad just-
with disassembly. ment of preload on ball bearing Hub (1),
2) Remove all metal chips and foreign matter spindle (2), collar (11), hold flange (3), ball
from the all parts and check that any part bearing (21)
does not have a burr, bruise, etc. before 2) Replacement parts which require adjust-
assembling. If there is any burr or bruise, ment of thickness of snap ring
remove it with an oilstone. Spindle (2), hold flange (3), crankshaft (9),
3) Replace the O-rings, oil seals, and floating spacer (12), tapered roller bearing (22),
seal with new ones. snap ring (20)
4) Replace the reamer bolts with new ones, If any of the above part is replaced before
as a rule. If it is obliged to reuse one, assembling, be sure to use only the
remove all adhesive from it with a brush. If adjusted parts. If a part which has not
bolt seat has any flaw, remove it with an been adjusted is used, the travel motor
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oilstone and then degrease the reamer will malfunction and cause breakage soon.
bolt. Accordingly, observe this precaution.
5) Since the reamer bolt holes of spindle (2)
and threaded parts of reamer bolts (19) are
to be coated with adhesive when they are
assembled, degrease them.
6) When fitting the O-rings, oil seals, and
floating seals, take care not to damage
them. (Apply a little amount of grease to
their surface so that they will fit smoothly.)
7) When installing the hydraulic motor parts
and moving or sliding parts of the valves,
be sure to apply clean hydraulic oil (NAS
Standard Grade 9 or higher) to them.
8) When assembling, do not put on cloth
gloves. (If they are used, a fiber can cause
malfunction.)
9) Tighten each bolt or plug to the torque
shown in the torque table.
10) After finishing the assembly work, plug the
all ports to prevent dirt from entering them.
30-46-38 PC60-7
⑥
4. Reassembly of hub assembly

1) Check that any of hub (1), spindle (2), hold
flange (3), collar (11), and ball bearings (21)
(2 pieces) has not been replaced with new
one.
If any of the above parts has not been
replaced, go to the next step. If any of
the above parts has been replaced,
adjust the preload on the ball bearing
before going to the next step.
2) Tighten 2 eyebolts symmetrically into the
screw holes of hub (1).
3) Install hooks and wires to the eyebolts and
sling and install hub (1) to the worktable
with a crane.
Matching the screw holes of hub (1)
to those of the worktable, insert the
hub in the mounting hole of the
worktable carefully.
4) Fix hub (1) to the worktable with hexagon
socket head bolts.
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5) Install collar (11) to hub (1).
6) Insert ball bearing (21) in hub (1).

Apply a pin punch to the rim of ball
bearing (21) and hit it lightly with a
hammer all round to fit the bearing
little by little.
PC60-7 30-46-39
⑥
7) Apply grease to O-ring (28) and fit O-ring

(28) to the O-ring groove of hub (1).
8) Install distance piece (10) to hub (1).

If distance piece (10) is difficult to
insert, hit it lightly with a plastic
hammer. If the distance piece is
inserted suddenly, O-ring (28) may
be broken to cause oil leakage. Take
care.
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5. Reassembly of spindle assembly
1) Apply grease to the O-ring of floating seal
(31) and then fit floating seal (31) to the
floating seal groove of spindle (2).
Remove the O-ring from the floating
seal and apply grease thinly all round
the O-ring.
Fit the O-ring to the groove of the
spindle correctly and set the floating
seal so that it will be parallel with the
groove face of spindle.
2) Install 2 eyebolts symmetrically to spindle
(2).
sling spindle (2) with the crane and insert it
in hub (1) slowly.
30-46-40 PC60-7
⑥
4) Fix hub (1) and spindle (2) with the clamps.

At this time, install the clamps symmetri-
cally.
6) Fit outer races (3 pieces) of tapered roller

bearings (22) to the respective outer race
holes in spindle (2).
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7) Installation of RV gear assembly
i) Insert RV gear A (4) in hub (1).
ii) Fit crankshafts (9) (3 pieces) to the

respective outer race holes for tapered
roller bearings (22) in spindle (2).
At this time, tapered roller bearings
(22), needle roller bearings (23),
and spacers (12) must be installed
to the crankshafts.
PC60-7 30-46-41
⑥
iii) Insert RV gear B (5) in hub (1).

Since the phases of RV gear A (4)
and RV gear B (5) are matched,
set the punch holes on the ends of
those gears at the same position.
8) Insert pins (17) (24 pieces) between the

pin spaces of hub (1) and tooth spaces of
the gear.
Apply lubricating oil to pins (17)
before inserting them.
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9) Insert ball bearing (21) in hub (1).
Apply pin punch ② to the rim of ball
bearing (21) and hit it lightly with
hammer ① all round to fit the
bearing little by little.
6. Installation of hold flange

1) Fit hold flange (3) to the inner race of ball
bearing (21) in hub (1).
When fitting hold flange (3) to ball
bearing (21), set the match marks on
spindle (2) and crankshaft (9) to the
positions before disassembly.
If hold flange (3) does not enter the in-
ter race of ball bearing (21) smoothly,
hit it evenly and lightly with a plastic
hammer.
30-46-42 PC60-7
⑥
7. Tightening of reamer bolts

1) Apply anti-seizure lubricating oil to the
reaming parts of reamer bolts (19) and
apply adhesive to the threaded parts of the
reamer bolts.
2) Tighten reamer bolts (19) (3 pieces) until
hold flange (3) is press fitted to ball bearing
(21) perfectly.
If reamer bolts (19) are stained with
oil grease, degrease, clean, and dry
in air for 10 minutes and then apply
adhesive to their threaded parts.
3) Tighten reamer bolts (19) (3 pieces) to the
specified torque.
Reamer bolts (19):
411.6 ± 63.7 Nm {42 ± 6.5 kgm}
Tighten 3 reamer bolts (19) evenly
little by little. If only 1 or 2 of them are
tightened first, hold flange (3) will
slant and ball bearing (21) will not be
fitted accurately in hold flange (3) and
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can cause seizure of reamer bolts
(19).
If the seats of 3 reamer bolts (19) are
not fitted accurately to the surface of
the hold flange, inspect and remove
the cause.
5) Remove the clamps (2 pieces).
7) Fit the outer race of tapered roller bearing

(22) to hold flange (3).
8. Fitting of snap rings

1) Check that any of spindle (2), hold flange
(3), crankshaft (9), tapered roller bearing
(22), spacer (12), and snap rings (20) has
not been replaced with new one.
If any of the above parts has not been
replaced, go to the next step. If any of
the above parts has been replaced,
adjust the axial clearance of tapered
roller bearing (22) before going to the
next step.
PC60-7 30-46-43
⑥
When replacing only snap rings (20),

select the same ones as the used
ones or similar ones from 12 types.
2) Fit snap rings (20) to the snap ring holes in
hold flange (3).
Fit 3 snap rings (20) to the positions
before disassembly, matching them
to the match marks on hold flange (3).
When using new snap rings (20),
select ones having the thickness
selected in the previous process.
3) Install distance pieces (14) (3 pieces) to crank
shaft (9).
9. Installation of spur gears

1) Install spur gears (7) (3 pieces) to crankshaft
(9).
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Install spur gears (7) (3 pieces) to
crankshaft (9), matching their match
marks (punch holes) as shown in the
figure below.
2) Install C-type shaft snap rings (25) (3

pieces) to the snap ring grooves of
crankshaft (9).
30-46-44 PC60-7
⑥
10. Press fitting of oil seal

2) Apply lithium grease to the lip of the oil

seal and press fit oil seal (132) to the oil
seal hole of spindle (2) with holder (III) and
a hammer.
11. Installation of shaft

1) Put deep groove ball bearing (149) in a
heating tank and heat it at 100 ± 10°C for
10 minutes and then insert it in shaft (102).
Put on leather gloves to insert the
bearing and take care not to get
burnt.
Insert deep groove ball bearing (149)
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until it is fitted to the flange of shaft
(102).
2) Fit parallel pins (177) (2 pieces 9 to the pin

3) Apply lithium grease as paste to pivots
(176) (2 pieces) and fit them to parallel
pins (177) of spindle (2).
4) Install piston assembly [piston (161) and
shoe (162) ] to spindle (2).
6) Fit shaft (102) to spindle (2).

Fit shaft (102) to spindle (2) slowly,
taking care that it will not damage the
lip of oil seal (132) fitted in spindle (2).
If the lip is damaged, oil will leak and
the travel motor will be broken soon.
PC60-7 30-46-45
⑥
7) Apply molybdenum disulfide grease to

thrust plate (153) and install it to swash
plate (103).
8) Install swash plate (103) to spindle (2).

Apply grease to mating faces of
swash plate (103) and spindle (2).
When installing swash plate (103) to
spindle (2), match its steel ball holes
to steel balls (167) (2 pieces) fitted to
spindle (2).
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12. Reassembly of cylinder block
1) Insert washer (110), spring (114), washer
(110), and round R-type snap ring (145) in
cylinder block (104) in order.
2) Place cylinder block (104) on the press
work table.
3) Place holder (I) on washer (110). Securing

it with the press, install round R-type snap
ring (145) to the snap ring groove of
cylinder block (104) with snap ring pliers.
Cover cylinder block (104) with a
vinyl sheet to protect its contact face
against timing plate (109).
30-46-46 PC60-7
⑥
13. Reassembly of hydraulic motor parts

1) Fit rollers (151) (3 pieces) to the hole of
2) Place thrust ball (108) on cylinder block
(104).
3) Fit 9 piston assemblies to retainer plate
(107).
After fitting the piston assemblies, soak
all of them in hydraulic oil.
4) Install 9 piston assemblies to cylinder block

(104).
Match retainer plate (107) to the
spherical part of thrust ball (108).
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5) Install cylinder block (104) to shaft (102).
When installing cylinder block (104),
match its spline hole to the spline part
of shaft (102).
After installing the cylinder block,
revolve it by hand to check that it has
no play. If it has any play, inspect it.
14. Assembly of parking brake assembly

1) Install friction plate (115) and mating plate
(116) alternately to the peripheral groove of
cylinder block (104). At this time, install the
friction plate first, then the mating plate.
Before installing friction plate (115),
soak it in hydraulic oil.
PC60-7 30-46-47
⑥
2) Fit O-rings (135) and (139) to the O-ring

grooves of piston (112). At this time, apply
grease thinly to O-rings (135) and (139).
4) Install piston (112) in spindle (2).

If piston (112) does not enter spindle
(2) smoothly because of the resistance
of O-rings (135) and (139), hit its end
lightly with a plastic hammer.
When installing piston (112), take
care not to damage the O-rings.
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15. Reassembly of brake valve parts in rear
flange
1) Install O-rings (137) (2 pieces) to plugs
(126) (2 pieces).
Apply grease to O-rings (137).
2) Install valve (127) and spring (130) to each

plug (126). At this time, apply grease to the
spring to lower the spring force and
connect the valve, spring, and plug by
utilizing the adhesion of the grease.
3) Insert each plug (126), to which valve

(127) and spring (130) are installed, in
rear flange (101).
30-46-48 PC60-7
⑥
When inserting each plug (126),

place rear flange (101) on the work
table with the plug mounting screw
hole up and align the plug with the
screw hole.
Protect the O-ring and prevent
removal of spring (130) from valve
(127) caused by contact of the inside
wall of the rear flange and valve.
If spring (130) comes off valve (127),
the valve will not fit to the seat of rear
flange (101) and oil leak.
4) After inserting plugs (126) (2 pieces),

tighten them into rear flange (101)
temporarily with a hexagon wrench.
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5) Insert spool (123) in rear flange (101).
When inserting the spool, apply
hydraulic oil to it.
★ When installing the spool, align it with
the hole of the rear flange so that its
outside surface and the inside surface
of the rear flange will not be damaged.
★ If the hole of the rear flange and outside
surface of the spool are damaged by
contact, internal leakage will occur after
assembly and the performance of the
travel motor will lower.
6) Fit O-rings (136) to plugs (124).

Apply grease to O-rings (136).
PC60-7 30-46-49
⑥
7) Install spring retainers (125) and springs

(128) to plugs (124).
8) Install plugs (124) (2 pieces) to rear flange

(101).
When installing each plug to the rear
flange, take care not to deform the
spring.
9) Tighten plugs (124) (2 pieces) into rear

flange (101) temporarily with a spanner.
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16. Reassembly of rear flange parts
1) Installation of pilot valve in rear flange
i) Place the rear flange with the mating
face against spindle (2) up.
ii) Insert valve (163) in rear flange (101).
iii) Fit spring (166) to valve (163) and

place stopper (164) over them.
30-46-50 PC60-7
⑥
iv) Bend new ring (165) a little and put it in

rear flange (101) from above stopper
(164) and insert it in the ring groove.
Be sure to fit ring (165) to the ring
groove of rear flange (101).
If ring (165) is not fitted to the ring,
groove valve (163) does not operated
stably and high speed and low speed
cannot be selected normally.
Be sure to use new ring (165).
2) Apply hydraulic oil to deep groove ball
bearing (150) and fit it to rear flange (101).
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3) Fit parallel pins (141) (2 pieces) to the pin
holes of rear flange (101).
4) Apply grease to the mating face of timing

plate (109) against rear flange (101).
5) Install timing plate (109) to rear flange
(101), using parallel pins (141) as guides.
Install timing plate (109) until it fits to
rear flange (101).
The timing plate must be fitted so that
it will not fall from the rear flange
when it is installed to spindle (2).
PC60-7 30-46-51
⑥
17. Connection of rear flange and spindle

1) Fit O-rings (30) and (27) to the O-ring
grooves of spindle (2).
When fitting O-ring (30), do not apply
grease to it. If grease is applied at
this time, it may ooze out through the
joint of the rear flange and spindle
while travel motor is operating. Since
the grease oozing out can be
mistaken for oil leakage, do not apply
grease to O-ring (30).
2) Fit parallel pins (142) (2 pieces) to spindle

(2).
3) Supply hydraulic oil of 0.55 liters into

spindle (2).
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4) Install rear flange (101) to spindle (2),
matching its pin holes to parallel pins (142)
(2 pieces) fitted to spindle (2).
When installing rear flange (101) to
spindle (2), install springs (113) (8
pieces) to the rear flange. At this time,
apply grease to springs (113) to
prevent them from coming off the rear
flange.
5) Tighten hexagon socket head bolts (143)

(8 pieces) into spindle (2) to the specified
torque.
Hexagon socket head bolts (143):
57.82 ± 9.8 Nm {5.9 ± 1.0 kgm}
30-46-52 PC60-7
⑥
6) Tighten plugs (124) to the specified torque.

Plugs (124):
352.8 ± 39.2 Nm {36 ± 4 kgm}
7) Tighten plugs (126) to the specified torque.

Plugs (126):
127.4 ± 14.7 Nm {13 ± 1.5 kgm}
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18. Reassembly of input gear
2) Install coupling (15) to shaft (102).
3) Install shaft (16) to coupling (15).
4) Install input gear (6) to shaft (16).
Fit input gear (6) to shaft (102),
meshing it with 3 spur gears (7). If it
does not mesh, inspect.
5) Install C-type shaft snap rings (24) to the

snap ring grooves of shaft (16).
6) Fit steel ball (26) to the steel ball hole of

shaft (16).
Apply grease to steel ball (26) so that
it will not fall when cover (8) is
installed.
PC60-7 30-46-53
⑥
19. Reassembly of cover

1) Supply lubricating oil of 1.7 liters into hub
(1).
2) Fit O-ring (29) to the O-ring groove of

cover (8).
Apply grease to O-ring (29).
3) Install cover (8) to hub (1).

Mach them match marks of cover (8)
and hub (1) to install them to the
positions before disassembly.
Install cover (8) by hitting its periphery
lightly with a plastic hammer. If it is
installed suddenly by hitting it strongly,
the O-ring will be broken and
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lubricating oil will leak.
4) Fit ring (18) to the ring groove of hub (1).
5) Wind sealing tape onto hexagon socket

head plugs (33) (2 pieces) and tighten
them into cover (8) to specified torque.
Hexagon socket head plugs (33):
392 ± 14.7 Nm {4 ± 1.5 kgm}
Wind the sealing tape onto each
hexagon socket head plug (33) at
least 2 turns. Tighten each hexagon
socket head plug (33) until the number
of threads projected from the end of
cover (8) becomes ±1.
30-46-54 PC60-7
⑥
20. Removal of travel motor

1) Turn over travel motor.
2) Remove the travel motor mounting bolts

from the work table.
3) Tighten eyebolts (2 pieces) into the screw

Install 2 eyebolts symmetrically to the
screw holes of spindle (2).
remove the travel motor from the work
table with the crane.
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PC60-7 30-46-55
⑥
21. Adjustment of preload on ball bearing

A proper preload must be applied to ball
bearing (21) to secure a proper life span.
If any part which affects the preload is
replaced, assemble the parts temporarily
and check the preload according to the
If the GM motor is assembled without
checking the preload, it will malfunction
and will be broken soon.
• Parts which affect preload on ball bearing
Hub (1), spindle (2), hold flange (3), ball
bearing (21), collar (11)
• If any of the above parts is not replaced,
skip this process and go to 6.1.
• The following are the procedures for
checking and adjust the preload.
Adjustment procedure for preload on ball

bearing
1) Install the main bearing preload adjustment
jig ⑥ to spindle (2) and tighten the special
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nut ⑦ to press fit ball bearing (21) to hub
(1).
Special nut ⑦: 39.2 Nm {4 kg m}
2) Measure depth "A" with depth micrometer

⑤ through the measurement hole of the
main bearing preload adjustment jig.
3) Since dimension "B" of main bearing
preload adjustment jig ⑥ is known, obtain
clearance "C" by the following formula.
A: Measured value
"C" = "A" - "B" B: Dimension of jig
C: Standard dimension
30-46-56 PC60-7
⑥
4) Obtain dimension "D" of hold flange (3).
5) Adjust hold flange (3) by the following

methods, depending on the measurement
in 2) - 4) above.
Dimension "C" is the standard dimension
of the hold flange.
i) When the measured dimension of hold
flange (3) is smaller than the standard
dimension
Cut face E of hold flange (3) with a
lathe, etc. to the standard dimension.)
ii) When the measured dimension of hold
flange is within the tolerance of the
standard dimension
Use the hold flange as it is.
iii) When measured dimension D of hold
flange (3) is larger than the standard
dimension
Replace the spindle assembly with
new one.
New hold flange (3) has an adjustment
allowance.
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Since the hold flange and spindle
are used together, they are made
in an assembly. Accordingly, it is
impossible to replace only the
hold flange. Replace both hold
flange and spindle together. The
assembly of the hold flange and
spindle is called the spindle
assembly.
• When replacing the spindle assem-
bly, execute the disassembly and
assembly procedures again.
6) Remove the main bearing preload adjust-

ment jig ⑥ from spindle (2).
7) After adjusting the hold flange according to

above steps i), ii), and iii), go to 6.1.
PC60-7 30-46-57
⑥
22. Adjustment of axial clearance of tapered

roller bearing
If any of the following parts is replaced,
the axial clearance of tapered roller
bearing (22) must be adjusted to a proper
level by adjusting the thickness of snap
ring (20). If the GM motor is assembled
without adjusting the axial clearance of
the tapered roller bearing, it will
malfunction and will be broken soon.
• Spindle (2), hold flange (3), crankshaft
(9), spacer (12), snap ring (20), tapered
roller bearing (22)
• If any of the above parts is not
replaced, go to 8 without adjusting the
snap ring thickness.
• The following is the method of adjusting
axial clearance of the tapered roller
bearing.
1) Lightly hit the outer race of tapered roller
bearing (22) installed to crankshaft (9) with
a hammer and holder (IV).
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This action is required to insert the RV
gear assembly in spindle (2) securely.
2) Fit thinnest snap ring (20) to the snap ring
groove in hold flange (3).
3) Lightly hit the periphery of snap ring (20)
with the hammer and holder (IV).
Check that the RV gear assembly is
insecurely in spindle (2).
30-46-58 PC60-7
⑥
4) Insert a thickness gauge between snap

ring (20) and tapered roller bearing (22) to
measure the clearance.
5) Measurement of snap ring thickness

• Set thickness of snap ring (Max.)
Max. = (Thickness of thickness gauge)
+ (Thickness of snap ring fitted at
present)
• Set thickness of snap ring (Min.)
Min. = (Thickness of thickness gauge)
+ (Thickness of snap ring fitted at
present) - (0.05 mm)
6) After the snap ring thickness is decided,

select one from the 12 types and install it
to the hold flange.
(See 23. Dimensions table of clearance
adjustment parts.)
7) After installing the snap ring having the
decided thickness, go to 8.2.
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PC60-7 30-46-59
⑥
DIMENSIONS TABLE OF CLEARANCE ADJUSTMENT PARTS
GM Model
No. GM09VL2
Part name
1 Snap ring (20) Type symbol Dimensiont

A Above 1.90 up to 1.95
B Above 1.95 up to 2.00
C Above 2.00 up to 2.05
D Above 2.05 up to 2.10
E Above 2.10 up to 2.15
F Above 2.15 up to 2.20
G Above 2.20 up to 2.25
H Above 2.25 up to 2.30
I Above 2.30 up to 2.35
J Above 2.35 up to 2.40
K Above 2.40 up to 2.45
L Above 2.45 up to 2.50
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30-46-60 PC60-7
⑥
PERFORMANCE CONFIRMATION TEST

After maintaining the GM motor, test its performance according to the following procedure.
1. Necessary measuring instruments
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PC60-7 30-46-61
⑥
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30-46-62 PC60-7
⑥
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY
REMOVAL OF SWING MOTOR,

SWING MACHINERY ASSEMBLY
An accumulator is not installed, so loosen the
sleeve nut of the hose slowly and check that
no oil spurts out before removing.
1. Disconnect swing motor suction hoses (1).
2. Disconnect 2 swing motor main port hoses (2).
3. Disconnect swing motor brake pressure

release hose (3).
4. Disconnect 2 swing motor drain hoses (4).
5. Disconnect 3 hoses (5) between control valve

and swivel joint.
6. Remove mounting bolts, then sling swing
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machinery and swing motor assembly (6), and
use forcing screw ① to remove. ※ 1
★ When removing the swing machinery and
swing motor assembly, lift off slowly and be
careful not to damage the wiring or piping.
Swing machinery and swing motor
assembly : 70 kg
INSTALLATION OF SWING MO-

TOR, SWING MACHINERY AS-
SEMBLY
removal.
※ 1
Swing machinery case mating surface:
Swing machinery and swing motor
assembly mounting bolt:
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
level again.
• Bleeding air
★ Bleed the air from the swing motor.
Bleeding air.
PC60-7 30-47
②
DISASSEMBLY AND ASSEMBLY SWING MOTOR
DISASSEMBLY OF SWING
MOTOR ASSEMBLY
LMF40AB-2 WITH BRAKE
1. Swing motor assembly

Set swing motor assembly (1) to tool P1.
2. End cover
1) Loosen plug (2).
2) Remove end cover (3).
★ The valve plate may be sticking to the
end cover. Take care not to drop the
valve.
3) Remove outer race (4) and spacer (5).
4) Remove plug (2), spring (6), and relief
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valve (7).
3. Brake spring
Remove brake spring (8).
4. Valve plate
Remove valve plate (9).
★ When reusing the valve plate, keep it,
taking care not to damage its contact
surface against the cylinder block.
5. Brake piston
Supply compressed air with tool P2 to remove
brake piston (10).
★ Air pressure: 0.39 MPa {4 kg/cm2}
If the air pressure is too high, the brake
piston jumps out. Take care.
30-47-1 PC60-7
⑥
6. Shaft and cylinder block assembly

Remove shaft and cylinder block assembly (11)
from motor case (12).
7. Plate and disc

Remove plate (13) and disc (14).
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8. Sub bearing
Remove sub-bearing (15) with puller ①.
★ Take care not to apply force to the bearing
holder.
★ When reusing the cylinder block, cover the
contact surface against the valve plate with
gasket paper, etc. to protect it from being
damaged.
9. Cylinder block and piston assembly

1) Remove cylinder block and piston
assembly (16) from shaft assembly (17).
★ The cylinder block and piston
assembly may come off separately.
Take care not to drop them.
PC60-7 30-47-2
⑥
2) Disassembly of cylinder block and piston

assembly
Pull piston assembly (19) out of cylinder
block (18) and remove retainer guide (20)
and preload pins (21).
★ When the cylinder block and piston
assembly is removed from the shaft
assembly or when the piston assembly
is pulled out of the cylinder block, the
preload pins may come off and fall.
Take care not to miss the preload pins.
3) Disassembly of piston assembly

Pull piston (23) out of retainer shoe (22).
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4) Disassembly of cylinder block
i) Set tool P3 to cylinder block (18).
ii) Fix the bolt of tool P3 with a wrench,
etc. and tighten the nut to compress
the spring and remove snap ring (24).
iii) Loosen then nut of tool P3 gradually to
release spring (25) and then remove
tool P3.
iv) Remove spacer (26), spring (25), and
spacer (26) from cylinder block (18).
10. Shaft assembly

1) Remove thrust plate (27) and spacer (28)
from shaft assembly (17).
30-47-3 PC60-7
⑥
2) Remove bearing (30) from shaft (29) with

push tool (2).
11. Plate
Remove plate (13) from motor case (12).
★ When the shaft and cylinder block
assembly are removed from the motor
case, the plate can be removed.
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12. Oil seal and outer race
1) Remove snap ring (31) from motor case 12
and then remove oil seal (32).
2) Remove outer race (33).
13. When the above disassembly work is not

necessary and only the oil seal needs to be
replaced, replace the oil seal according to
the following procedure.
1) Remove snap ring (31).
2) Push out oil seat (32) with bar ⑦ (the end
of which may be hit with a hammer) to the
core and then pry out the oil seal.
★ Hit the central part between outside
and inside of the oil seal and pry out 2
places opposite to each other such as
A and B in the figure at right.
★ Take care not to damage the shaft
case.
PC60-7 30-47-4
⑥
ASSEMBLY OF SWING MOTOR

ASSEMBLY
LMF40AB-2 WITH BRAKE
Clean the all parts and remove burrs, etc. from

them. Coat their sliding surfaces with engine oil
(EO10-CD) before installing.
Be sure to check the following parts before
installing.
i) Contact of the cylinder block and valve plate
(See the section of contact check procedure.)
ii) Contact of the valve plate and end cover (See
the section of contact check procedure.)
1. Motor case
1) Press fit outer race (33) with tool P5.
2) Set tool P1 to motor case (12).
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2. Shaft assembly
1) Press fit bearing (30) to shaft (29) with tool
P6 to form them into shaft assembly (17).
★ Press the end of the bearing inner race
with tool P6 until the bearing fits to the
shaft end.
★ Press fitting load:
1,834 - 7,119 N {187 - 726 kg}
Press fitting surface of bearing:
Lubricating oil (EO10-CD)
2) Install shaft assembly (17) to motor case

(12).
3) Install thrust plate (27) and spacer (28).
★ After installing thrust plate (27) to the
motor case, turn it to the right and left
to check that it is installed accurately.
30-47-5 PC60-7
⑥
3. Cylinder block and piston assembly

1) Assembly of cylinder block
i) Install spacer (26), spring (25), and
spacer (26) to cylinder block (18).
ii) Set tool P3 to cylinder block (18).
iii) Fix the bolt of tool P3 with a wrench,
etc. and install the nut to compress
spring (25) and install snap ring (24).
★ Check that the snap ring is fixed to
the groove securely.
iv) Remove tool P3.
2) Assembly of piston assembly

Install piston (23) to retainer shoe (22).
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3) Assembly of cylinder block and piston
assembly
i) Install 3 preload pins (21) to cylinder
block (18).
★ Apply grease (G2-LI) to the
preload pins to prevent them from
coming out.
ii) Install retainer guide (20) to cylinder
block (18) and then install piston
assembly (19) to form them into cylinder
block and piston assembly (16).
★ match the splines of the cylinder
block and retainer guide to each
other.
4) Install cylinder block and piston assembly

(16) to motor case (12).
★ Take care sufficiently that the preload
pins will not fall.
PC60-7 30-47-6
⑥
4. Plate, disc, and piston

1) Install plate (13) and disc (14) in order.
★ Do not clean the disc with trichloroethyl-
ene or denatured alcohol or blow air
strongly against it.
Disc surface:
2) Fit the O-ring and install brake piston (10).
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5. Adjustment of shaft end play
1) Set hydraulic jack ③ under the bottom
end of the shaft and press fit sub-bearing
(15) with tool P7 and puller ④.
★ Press the end of the sub bearing inner
race with tool P7 until the bearing fits to
the shaft end.
★ Press fitting load:
1,412 - 5,237 N {144 - 534 kg}
(May be increased to 9.8 kN {1,000 kg}.)
Press fitting surface of bearing:
2) Install spacer (5) and outer race (4) to end

cover (3).
★ Install the spacer which has been
removed.
3) Install valve plate (9) to end cover (3),
matching it to the dowel pin.
★ Check that the valve plate does not
interfere with the bearing and pin.
★ When installing the valve plate, do not
give an impact to it. (If an impact is
given, the sliding surface may be
damaged and distorted.)
30-47-7 PC60-7
⑥
4) Install end cover (3) horizontally to motor

case (12).
★ Take care sufficiently that the valve
plate will not fall.
★ Do not install the spring and O-ring of
the parking brake.
Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
5) Push the shaft end with puller ⑤ to shift

the shaft toward the end cover.
★ Pushing out load:
981 - 1,079 N {100 -110 kg}
6) Install an eyebolt to the shaft end and pull
up the shaft and measure the end play with
dial gauge ⑥.
★ End play: 0.05 - 0.25 mm
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7) If the end play is out of the standard range,
adjust it according to the following procedure.
i) Remove the end cover.
ii) Remove the valve plate and outer race.
iii) Select a proper spacer from the following
table.
Thickness (mm) Spacer to be used
1.6 70S-7T-12260
1.7 70S-7T-12270
1.8 70S-7T-12360
1.9 70S-77-12370
2.0 70S-7T-12380
2.1 70S-7T-12390
2.2 70S-7T-12460
iv) Install the selected spacer and assemble

the parts again according to steps 5-2) -
5-6) and measure the end play.
v) After adjusting the end play, remove
the end cover.
6. End cover assembly

1) Install relief valve (7) and spring (6) in
order and then fit the O-ring and tighten
plug (2) temporarily.
PC60-7 30-47-8
⑥
2) Install brake spring (8).
3) Fit the O-ring to the motor case and install

end cover (3) horizontally, matching it to
the dowel pin.
★ Take care sufficiently that the brake
spring and valve plate will not fall.
★ Check that end cover does not
interfere with the pin.
★ Take care sufficiently that the O-ring is
not caught in the motor case and end
cover.
Mating face of motor case:
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Gasket sealant
[LG-7 or LG-5 (LOCTITE 572/575)]
Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
4) Tighten plug (2).
Plug (2):
166.7 ± 19.6 Nm {17 ± 2 kgm}
7. Measurement of turning torque of swing

motor assembly
Set tool P8 to the motor shaft and release the
brake and then revolve the shaft at the speed
of 3- 5 sec/turn and measure its turning torque.
★ The turning torque must not fluctuate while
the shaft is revolved.
• Fluctuation of turning torque: 0 - 1.96
Nm {0 - 0.2 kgm}
• Turning torque: 10.8 - 16.7 Nm {1.1 -
1.7 kgm}
• Brake releasing pressure: 2.94 ± 0.29
MPa {30 ± 3 kg/cm2}
8. Oil seal
1) Check that there are not burrs and sharp
edges at the corners of the shaft.
2) Press fit oil seal (32) with tool P4.
★ Clean the oil seal lip.
Oil seal lip end (all round):
Grease (G2-LI-S)
3) Install snap ring (31).
30-47-9 PC60-7
⑥
CONTACT CHECK OF CYLINDER BLOCK,

VALVE PLATE, AND END COVER
1. Contact check of cylinder block and valve
plate
★ This check is not necessary when both of
the cylinder block and valve plate are
spares (new).
★ Perform this check when either of the
cylinder block or valve plate is a spare or is
repaired.
★ If the contact is improper, correct it by
lapping the parts on a surface plate.
1) Make a centering tool for the cylinder block
and valve plate.
★ This tool may be made of a soft
material such as plastic, Bakelite, etc.
2) Degrease the parts to be checked.
★ Do not wipe the parts with a cloth.
3) Set the tool and apply check paint to the
cylinder block.
★ Apply the paint thinly.
4) Press the valve plate with force of 39.2 -
49.0N {4 - 5 kg} against the cylinder block
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and turn it by 90 degrees and then return it
to its original position. Repeat this motion 2
- 3 times.
5) Remove the valve plate and transfer the
contact surface onto a tape and check it.
★ The standard contact area is as
follows.
Sealing part a
Valve platec. Min. 80%
Cylinder blocke. Min. 80%
★ For the details of the work procedure, see
the guide to parts judgment.
2. Valve plate and end cap
1) Remove all oil and grease from the parts to
be checked.
★ Do not wipe with a cloth.
2) Paint the end cap with inspection paint,
then put the valve plate on top.
★ Coat thinly with paint.
3) Push the valve plate with a force of 39.2 -
49.0 N {4 - 5 kg} against the end cap, turn
the valve plate 90°, then turn it back to the
original position. Repeat this process 2 or
3 times.
4) Remove the valve plate, transfer the
contact surface to a tape, and check the
contact surface.
★ The contact of the mating surface of
the valve plate and end cap must cover
at least 80% without any variation.
★ If the contact is defective, use a
surface plate and correct by lapping.
PC60-7 30-47-10
⑥
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY OF SWING MACHINERY

ASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery.
Swing machinery case: Approx. 1.5 l

Remove swing motor assembly (1).
3. No. 1 sun gear, No. 1 carrier assembly

1) Remove No. 1 sun gear (2).
2) Remove No. 1 carrier (3).
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3) Disassemble No. 1 carrier assembly as
follows.
i) Remove snap ring (4), then remove
thrust washer (5), gear (6), bearing (7),
and thrust washer (8).
ii) Knock in pin (9) and knock out shaft

(10).
★ After removing the shaft, remove
pin (9).
iii) Remove thrust washer (11) from carrier
(12).
30-48 PC60-7
②
4. No.2 sun gear

Remove No.2 sun gear (13).
5. Ring gear
Remove ring gear (14).
6. No. 2 carrier assembly

1) Remove No. 2 carrier assembly (15).
2) Disassemble No. 2 carrier assembly as fol-

lows.
i) Remove snap ring (16), then remove
thrust washer (17), gear (18), bearing
(19), and thrust washer (20).
ii) Knock in pin (21), and knock out shaft
(22).
★ After removing the shaft, remove
pin (21).
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iii) Remove thrust washer (23) from
carrier (24).
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7. Collar
1) Set shaft and case assembly to press,
push bearing (25) with push tool A.
★ Operate the press gradually and press
fit the bearing to a point where the split
collar can be removed.
2) Remove split collar (26).
8. Shaft assembly
1) Set block ① to shaft and case assembly
(27), then using push tool ②, remove shaft
assembly (28) with press.
2) Remove bearing (25).
30-49
②
3) Set shaft assembly to press, then using

push tool ③ , remove bearing (29) and
collar (30) from shaft (31).
9. Dust seal, oil seal, bearing outer race

1) Remove dust seal (32) and oil seal (33)
from case (34).
E20107
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2) Using puller ④ , remove bearing outer
races (35) and (36) from case (34).
30-50
②
ASSEMBLY OF SWING MACHINERY

ASSEMBLY
★ Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with
engine oil before installing.
1. Oil seal
Using push tool ⑤, press fit oil seal (33) to
case (34).
★ Replace the oil seal with a new part.
Lip oil seal: Grease (G2-LI)
2. Bearing outer races

Using push tool, press fit outer races (35) and
(36) to case (34).
3. Shaft assembly
1) Install collar (30) to shaft (31).
2) Using push tool ⑥, press fit bearing (29)

with press.
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E20107
3) Set case assembly (37) to shaft assembly

(28).
4) Using push tool ⑦, press fit bearing (25)

with a press to a point where split collar
enters.
★ Press-fitting force : Max. 11.76 kN
{1200kg}
★ Press fit the bearing slowly while rotating
the case.
5) Install split collars (26).
6) Using push tool ⑧, press fit shaft (31) with

press until split collar (26) is fixed in
position.
7) Screw bolt (10mm, P=1.5mm) into case,

then using push- pull scale ⑧, measure
tangential force in direction of rotation.
★ Tangential force: Max. 147 N {15 kg}
★ The tangential force is the maximum
force at the start of rotation.
30-51
②
4. Dust seal
Using push tool ⑩, press fit dust seal (32).
★ Replace the dust seal with a new part.

1) Assemble No. 2 carrier assembly as
follows.
i) Install thrust washer (23) to carrier
(24).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
to install shaft (22).
E20107
iii) Insert pin (21).
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★ After inserting the pin, caulk the pin
portion of the carrier.
★ Check that the stepped difference
between the shaft and carrier is
less than 0.2 mm.
iv) Assemble thrust washer (20), bearing
(19), gear (18), and thrust washer (17),
then install snap ring (16).
2) Install No. 2 carrier assembly (15) to shaft

and case assembly.
6. Ring gear
Install ring gear (14).
Ring gear mating surface:

Gasket sealant (LG-4 or LG-6)
7. No. 2 sun gear

Install No. 2 sun gear (15).
30-52
②

1) Assemble No. 1 carrier assembly as
follows.
i) Install thrust washer (11) to carrier
(12).
ii) Align position of pin holes of shaft and
carrier, then tap with a plastic hammer
to install shaft (10).
iii) Insert pin (9).
★ After inserting the pin, caulk the pin
portion of the carrier.
★ Check that the stepped difference
between the shaft and carrier is
less than 0.2 mm.
iv) Assemble thrust washer (8), bearing

(7), gear (6), and thrust washer (5),
then in-stall snap ring (4).
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2) Install No. 1 carrier assembly (3).
3) Install No. 1 sun gear (2).

Install swing motor assembly (1).
Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
Motor mating surface:
Gasket sealant (LG-4 or LG-6)
10. Refilling with oil, adding grease

Tighten drain plug and add engine oil through
oil filler.
Swing machinery case: Approx. 1.5 l

Swing machinery case:
Grease (G2-L1) Approx. 110 cc
PC60-7 30-53
②
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING FRAME

ASSEMBLY
Serial No. : 52374 – 57999

1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.

For details, see REMOVAL OF COUNTER-
WEIGHT ASSEMBLY.
3. Disconnect grease tube (1).
4. Disconnect boom cylinder hose (2).
5. Sling boom cylinder assembly (3), then remove

lock plate (4), and remove pin (5).
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6. Remove boom cylinder assembly (3).
Boom cylinder assembly: 105 kg
7. Remove cover (6) at intake hose end, then

remove intake hose (7) and clamp (8).
8. Remove oil filter assembly (9) together with

bracket, and move to a point where there is no
interference with lifting tool.
9. Disconnect all hoses (10) between control

valve and swivel joint, and drain hose (11).
30-54 PC60-7
④
11. Raise block ① set between wire and frame,

then sling, taking care that wire does not
contact engine.
12. Remove mounting bolts, then lift off revolving

frame assembly (14). ※ 1
★ Leave 2 mounting bolts each at the front
and rear, use a lever block to adjust the
balance of the revolving frame assembly to
the front and rear, and left and right, then
remove the remaining bolts, and lift off.
When removing the revolving frame assem-

bly, be careful not to hit the center swivel
joint assembly.
Revolving frame assembly: 2300 kg
INSTALLATION OF REVOLVI
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NGFRAME ASSEMBLY
com
Serial No. : 52374 - 57999

removal.
※ 1
Mating surface of swing circle:
Thread of revolving frame mounting bolt
: Thread tightener (LT-2)
Revolving frame mounting bolt:
277.5 ± 32.4 Nm (28.3 ± 3.3 kgm)

level again.
• Bleeding air
Bleeding air.
PC60-7 30-55
④
REMOVAL OF REVOLVING
FRAME ASSEMBLY

1. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.

EIGHT ASSEMBLY.
4. Disconnect boom cylinder hose (2).
5. Sling boom cylinder assembly (3), then remove

lock plate (4), and remove pin (5).
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6. Remove boom cylinder assembly (3).
7. Disconnect all hoses (10) between control

valve and swivel joint and drain hose (11).
9. Raise block ①, set between wire and frame,

then sling, taking care that wire does not
contact engine.
30-55-1 PC60-7
④
10. Remove mounting bolts, then lift off revolving

frame assembly (14). ※ 1
★ Leave 2 mounting bolts each at the front
and rear, use a lever block to adjust the
balance of the revolving frame assembly to
the front and rear, and left and right, then
remove the remaining bolts, and lift off.
When removing the revolving frame
assembly, be careful not to hit the center
swivel joint assembly.
Revolving frame assembly: 2300 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
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removal.
※ 1
Mating surface of swing circle:
Thread of revolving frame mounting bolt
: Thread tightener (LT-2)
Revolving frame mounting bolt:
277.5 ± 32.4 Nm (28.3 ± 3.3 kgm)

level again.
• Bleeding air
Bleeding air.
PC60-7 30-55-2
④
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE ASSEMBLY

1. Remove revolving frame assembly.
For details, see REMOVAL OF REVOLVING
FRAME ASSEMBLY
2. Lift off swing circle assembly (1). ※ 1

Swing circle assembly: 110 kg
INSTALLATION OF SWING
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CIRCLE ASSEMBLY
• .com
Carry out installation in the reverse order to
removal.
※ 1
★ Set the soft zone S mark on the inside ring of
the inner race on the left side of the chassis as
shown in the diagram, then install to the track
frame.
Surface of circle teeth :
Grease (G2-LI)
Mounting bolt: Thread tightener (LT-2)
Mounting bolt
276.85 ± 31.85 Nm {28.25 ± 3.25 kgm}
30-56 PC60-7
②
DISASSEMBLY AND ASSEMBLY IDLER, RECOIL SPRING
REMOVAL OF IDLER, RECOIL

SPRING ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Sling idler and recoil spring assembly (1), and

pullout to the front to remove.
Idler, recoil spring assembly: 95 kg
3. Disconnect recoil spring assembly (3) from

idler assembly (2). ※ 1
Idler assembly: 60 kg
Recoil spring assembly: 35 kg
INSTALLATION OF IDLER, RE-

COIL SPRING ASSEMBLY
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removal.
E20107
※ 1
Thread of recoil spring assembly mount-
ing bolt: Thread tightener (LT -2)
30-57
②
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
E20107
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1. Remove lock plate (1), then remove seat (2)
and lubricator (3).
2. Remove yoke piston assembly (5) from recoil

spring assembly (4).
3. Disassembly of recoil spring assembly

1) Set recoil spring assembly (4) to tool B.
The recoil spring is under large install-
ed load, so be sure to set the tool
properly. Failure to do this is dangerous.
★ Installed load of spring:
42.63 kN {4,350 kg}
2) Apply hydraulic pressure slowly to compress
spring, then remove nut (6).
★ Compress the spring to a point where
the nut becomes loose.
★ Release the hydraulic pressure slowly
to remove the spring tension.
★ Remove pilot (8) and cylinder (9)
from(7).
★ Remove O-ring (10) from cylinder.
4. Disassembly of yoke piston assembly

1) Remove wear ring (12) from yoke piston
(11).
2) Remove snap ring (13), then remove
U-packing (14).
30-58
②
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY OF RECOIL SPRING ASSEMBLY

1. Assembly of yoke piston assembly
1) Assemble U-packing (14) to yoke piston
(11), and secure with snap ring (13).
2) Assemble wear ring (12).
2. Assembly of recoil spring assembly

1) Install O-ring (10) to cylinder (9).
2) Assemble cylinder (9) and pilot (8) to
spring (7), and set to tool B.
3) Apply hydraulic pressure slowly to compress
spring, and tighten nut (6) so that installed
length of spring is dimension "a".
★ Installed length "a" of spring : 322 mm
Thread of nut:
Anti-friction compound (LM-P)
4) Remove recoil spring assembly (4) from

tool B.
3. Fill inside of cylinder with a minimum of 120 cc

of grease.
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4. Assemble yoke piston assembly (5) to recoil

spring assembly (4).
E20107
Yoke piston sliding portion wear ring:

Grease (G2-LI)
5. Fit lubricator (3) and seat (2), and secure with

lock plate (1).
★ Install the valve so that the direction of the
fitting is to the outside.
30-59
②
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER ASSEMBLY

1. Remove dowel pin (1), then remove support
(2).
2. Remove floating seal (3) from support (2) and

idler (4).
3. Pull out idler (4) from shaft (5) and support

assembly (5).
★ It is filled with approx. 90 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
4. Remove floating seal (6) (on opposite side)

from idler (4) and shaft (5) and support
assembly (7).
5. Remove dowel pin (8), then remove support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
E20107
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30-60
②
ASSEMBLY OF IDLER ASSEMBLY

1. Press fit bushings (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5)

with dowel pin (8).
3. Install floating seal (6) to idler (4) and shaft (5)

and support assembly (7).
★ Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
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dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
E20107
4. Assemble shaft (5) and support assembly (7)

to idler (4).
5. Add oil between shaft (5) and idler (4).
Oil: 60 cc (SAE30CD)
30-61
②
6. Install floating seal (3) to idler (4) and support

(2).
★ Coat the sliding surface of the floating seal
with oil, and be careful not to let any dirt or
dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
7. Install O-ring, then install support (2) with

dowel pin (1).
E20107
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30-62
②
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
REMOVAL OF TRACK ROLLER ASSEMBLY

1. Lower work equipment to ground, then loosen
lubricator (1), and relieve track tension. ※ 1
The adjustment cylinder is under extremely
high pressure, so never loosen the lubricator
more than one turn. If the grease does not
come out easily, move the machine backwards
and forwards.
2. Remove mounting bolts of track roller, then

swing work equipment 90°, jack up machine
with work equipment, and remove track roller
assembly (2) towards outside of machine. ※ 2
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E20107
INSTALLATION OF TRACK
ROLLER ASSEMBLY
removal.
※ 1
★ Adjust the track shoe tension.
Testing and adjusting track shoe tension.
※ 2
Thread of track roller assembly mounting
bolt: Thread tightener (LT-2)
★ Position the plug on the outside of the
chassis, then set the track roller assembly
to the mounting position.
★ Operate the work equipment control levers
to lower the machine gradually, and tighten
the mounting bolts partially.
★ Operate the work equipment control levers
to lower the machine completely to the
ground, then tighten the mounting bolts
fully.
30-63
②
DISASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Remove pin (1), then remove collar (2).
2. Remove floating seal (3) from collar (2) and

roller (4).
3. Pull out roller (4) from shaft (5).

★ It is filled with 75 - 85 cc. of oil, so drain the
oil at this point or lay a cloth to prevent the
area from becoming dirty.
E20107
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30-64
②
4. Remove floating seal (6) (on opposite side)

from roller (4) and shaft (5).
5. Remove bushings (7) and (8) from roller (4).
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E20107
30-65
②
ASSEMBLY OF TRACK ROLLER ASSEMBLY

1. Using push tool ①, press fit bushings (9) and
(10) to roller (4).
2. Assemble collar (8) to shaft (5), and install pin

(7).
3. Install floating seal (6) to shaft (5).

★ When assembling the floating seal, clean
the contact surface of O-ring (6c) and
floating seal (6a), remove all grease and oil,
and dry it. Make sure that no dirt or dust
sticks to the contact surface of the floating
seal.
4. Install floating seals (6) and (3) to roller (4).

★ For details of the precautions when
installing floating seals (6b) and (6d), and
(3b) and (3d), see the precautions marked
★ for Step 3.
E20107
5. Assemble shaft (5) to roller (4).
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6. Turn over roller (4) and shaft (5) assembly.
7. Add oil between shaft (5) and idler (4).
Oil: 75 - 85cc (SAE30CD)
8. Install floating seal (3) to collar (2).

★ For details of the precautions when
installing floating seals (3a) and (3c), see
the precautions marked for ★ for Step 3.
30-66
②
9. Assemble collar (2) to shaft (5), and install pin

(1).
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E20107
30-67
②
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Lower work equipment, then loosen lubricator
(1), and relieve track tension. ※ 1

high pressure. Never loosen the lubricator
come out, move the machine backwards and
forwards.
2. Using hydraulic jack ①, push up track to a

position where carrier roller assembly can be
removed, then remove carrier roller assembly
(2). ※ 2
E20107
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INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
※ 1
★ Adjust the track tension.
Testing and adjusting track tension.
※ 2
Thread of carrier roller assembly mounting
bolt: Thread tightener (LT-2)
30-68
②
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Lower work equipment, then loosen lubricator
(1), and relieve track tension. ※ 1
high pressure. Never loosen the lubricator
come out, move the machine backwards
and forwards.
2. Move machine forward so that position of

master pin is at front of idler, and set block ①
in position.
3. Using tool C, pull out master pin. ※ 2
4. Remove tool C, and pull out temporary pin,

and remove dust seal, then drive machine in
reverse to lay out track (2). ※ 3
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E20107
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
※ 1
★ Adjust the track tension.
Testing and adjusting track tension.
※ 2
★ Use tool C and press fit the master pin so that
the protrusion dimension "a" from the master
pin is the same at both ends of master pin.
※ 3
★ When assembling the dust seal, coat the
bushing contact surface with grease (G2-LI).
30-69
②
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain oil from hydraulic tank.

3. Remove handrail (1).
4. Remove right side cover (2).
5. Remove rubber hose clamp (3).
6. Remove hose clamp (4), then disconnect hose
E20107
(5).
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7. Disconnect hoses (6), (7), (8), and (9).
★ Make match marks before disconnecting.
8. Lift off hydraulic tank assembly (10). ※ 1

Hydraulic tank assembly: 70 kg
30-70
②
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
removal.
※ 1
Thread of hydraulic tank mounting bolt:
Hydraulic tank mounting bolt:

176.5 ± 19.6 Nm {18 ± 2 kgm}

again.
Hydraulic tank: 68 l (SAE1OWCD)
• Bleeding air
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Bleeding air from hydraulic tank.
Bleed the air.
PC60-7 30-71
②
REMOVAL OF MAIN PUMP

ASSEMBLY
Serial No. : 52374 – 57999

1. Remove the hydraulic tank strainer, and using

tool D1, stop the oil.
★ When not using tool D1, remove the
drain, and drain the oil from the hydraulic
tank and inside the system.
2. Remove engine hood, then remove undercover

under pump.
3. Remove engine safty lever bracket (1).
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5. Remove muffler cover (3) and muffler assembly

(4) togather with exhaust manifold cnnector (5)
6. Disconnect main pump suction tube (6).
7. Disconnect main pump outlet hose (7).
8. Disconnect main pump drain hose (8).
9. Disconnect power mode select pilot pressure

hose (9).
10. Disconnect LS pressure input hose (10).
11. Disconnect LS pump pressure input hose (11).
12. Disconnect blade sennsing pilot pressure hose

(12).
30-72 PC60-7
④
13. Disconnect ground cable (13).
14. Sling main pump assembly (14), and using

forcing screws ① to remove main pump
assembly. ※ 1
Main pump assembly: 56 kg
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INSTALLATION OF MAIN PUMP
ASSEMBLY
Serial No.: 52374 – 57999

removal.
※ 1
Mating surface of pump case:
• Refilling with oil (PTO gear case)

Add engine oil through the oil filler to the
specified level.
PTO gear case: 0.35 l (SAE30CD)

Add oil through the oil filler to the specified level.
Hydraulic tank: 68 l (SAE10WCD)
• Bleeding air
Bleed the air from main pump.
Bleeding air.
PC60-7 30-73
④
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

ASSEMBLY

1. Remove the hydraulic tank strainer, and using

tool D1, stop the oil.
★ When not using tool D1, remove the
drain plug, and drain the oil from the
hydraulic tank and inside the system.
2. Drain cooling water.
3. Remove engine side cover.
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4. Remove two heat insulation panels (1), then
remove muffler (2).
5. Disconnect air intake hose (3).
6. Disconnect following hoses from main pump.

• Drain hoses (4) and (5)
• Mode selector solenoid pressure input
hose (6)
• Main pump discharge hose (7)
• LS pump pressure input hose (8)
• LS pressure input hose (9)
• Suction tube (10)
If oil is stopped with tool D1 and drain
hoses (4) and (5) are disconnected, oil
flows out. Accordingly, prepare plugs
(07376-50628) inadvance.
30-73-1 PC60-7
④
DISASSEMBLY AND ASSEMBLY MAIN PUMP
7. Disconnect ground wire (11) from main pump.
8. Sling main pump assembly (14), and using

forcing screws ① to remove main pump
assembly. ※ 1
Main pump assembly: 60 kg

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removal.
※ 1
Mating surface of pump case:
• Refilling with oil (PTO gear case)

Add engine oil through the oil filler to the
specified level.
PTO gear case: 0.35 l (SAE30CD)

again.
Hydraulic tank: 68 l (SAE10WCD)
• Bleeding air
Bleed the air from main pump.
Bleeding air.
PC60-7 30-73-2
④
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP IN-

PUT SHAFT OIL SEAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP
ASSEMBLY.
2. Remove PTO assembly (1). ※ 1
3. Remove snap ring (2), then remove spacer (3).
4. Lever up oil seal (4) with a screwdriver to

remove. ※ 2
★ When removing the oil seal, be extremely
careful not to damage the shaft.
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INPUT SHAFT OIL SEAL
removal.
※ 1
Mounting bolt: Thread tightener (LT-2)
PTO bearing cage mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
※ 2
Lip of oil seal : Grease (G2-LI)
Coat the outside circumference of the
oil seal thinly with grease (G2-LI), then
press fit.
★ Use tool D2 to press fit oil seal (4).
30-74 PC60-7
②
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL VALVE

ASSEMBLY
★ Make match marks before removing the
hoses.
1. Disconnect hoses (1), (2) and (3).

★ Disconnect 8 hoses (2) and (3).
2. Disconnect hoses (4) and (5) between valve

and each actuator in order from top.
★ The order of the hoses from the top is as
follows: blade, bucket, arm, boom, R.H.
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travel, L.H. travel, swing.
E20107
3. Disconnect hoses (6), (7), and (8).
4. Remove clamp (9).
5. Disconnect hoses (10), (11), (12) and (13).
6. Remove U-bolt mounting bracket (14) for

securing oil cooler inlet hose.
30-75
②
7. Sling control valve assembly (15), then remove

4mounting bolts of control valve mounting
bracket, and lift off control valve assembly
together with bracket.
Control valve assembly: 60 kg
INSTALLATION OF CONTROL
VALVE ASSEMBLY
removal.
E20107
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level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
• Bleeding air
★ Bleed the air from the circuit between the
valve and the hydraulic cylinder.
Bleeding air.
30-76 PC60-7
②
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30-77
②
DISASSEMBLY OF CONTROL VALVE ASSEMBLY

★ The set pressure of the safety valve cannot be 1) Remove case (5), then remove spring (6)
adjusted when it is installed on the machine, and retainer (7).
so do not disassemble. 2) Remove plugs（8）and（11）from spool (14)，
★ Except for the R．H，and L．H．travel，the spools then remove spring (9)and valve (10).
and pressure compensation valves are not ★ Plug (8) is for the RAISE valve and
interchangeable，so always mark them before plug (11) is for the LOWER valve.
removing them.
★ Loosen the plug with the spool still assembled 5. Arm control valve
in the valve body. 1) Remove case (5), then remove spring (6)
and retainer (7)．
1. Remove main relief valve assembly (1), safety 2) Remove plug (8) from spool（15），then
valve assembly (2), LS select valve assembly remove spring (9)and valve（10）．
(3), and unload valve assembly (4).
6. Bucket control valve
2. Swing control valve 1) Remove case (5), then remove spring (6)
1) Remove case (5), then remove spring (6) and retainer (7).
and retainer (7). 2) Remove plug (8) from spool (16).
2) Remove plug (8) from spool (12), then
remove spring (9)and valve (10)． 7. Blade control valve
E20107
1) Remove case (5), then remove spring (6)
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3. Travel control valve and retainer (7)。
1) Remove case (5), then remove spring (6) 2) Remove plug (8) from spool (17), then
and retainer (7)． remove spring (9) and valve (10).
2) Remove spool（13）．
4. Boom control valve
30-78
②
8. Pressure compensation valve 5) For bucket

1) For swing i) Remove plug (18), then remove valve
i) Remove plug (18), then remove valve (32), spring (20), and valve (33).
(19), spring (20), and valve (21). ii) Remove piston (34) from valve (33).
ii) Remove piston (22) from valve (21). 6) For blade
2) For travel i) Remove plug (18), then remove valve
i) Remove plug (18), then remove valve (35), spring (20), and valve (36).
(23), spring (20), and valve (24). ii) Remove piston (37) from valve (36).
ii) Remove orifice (25) from valve (23).
3) For boom 9. Remove suction valve (38).
i) Remove plug (18), then remove valve
(26), spring (20), and valve (27). 10. Remove plug (39), then remove spring (40)
ii) Remove piston (28) from valve (27). and check valve (41).
4) For arm
i) Remove plug (18), then remove valve 11. Remove plug (43) from body (42), then
(29), spring (20), and valve (30). re-move springs (44) and (45) and poppet
ii) Remove piston (31) from valve (30). (46).
★ The springs are different so be careful to
distinguish them.
12. Remove plugs (47) and (48).
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E20107
30-79
②
E20107
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30-80
②
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E20107
30-81
②
ASSEMBLY OF CONTROL VALVE ASSEMBLY

★ Except for the R.H. and L.H. travel, the spools 5) For travel
and pressure compensation valves are not i) Assemble orifice (25) in valve (23).
interchangeable, so always mark them before ii) Assemble valve (23), spring (20), and
disassembling them. valve (24) in body, then fit O-ring and
install plug (18).
• Before assembling coat the sliding surface 6) For swing
with engine oil. i) Assemble piston (22) in valve (21).
ii) Assemble valve (21), spring (20), and
1. Fit O-ring and backup ring and install plugs valve (19) in body, then fit O-ring and
(47) and (48). install plug (18).
Plug : 39.2 ± 4.9 Nm {4 ± 0.5 kgm}
2. Assemble poppet (46) and springs (45) and

(44) to body (42), then fit O-ring and install
plug (43).
Plug : 127.4 ± 19.6 Nm {13 ± 2 kgm}
3. Assemble check valve (41) and spring (40) to

body, then fit O-ring and install plug (35).
E20107
Plug: 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
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4. Fit O-ring and install suction valve (38).
Plug: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
5. Pressure compensation valve

1) For blade
i) Assemble piston (37) in valve (36).
valve (35) in body, then fit O-ring and
install plug (18).
Plug:
139.65 ± 22.05 Nm {14.25 ± 2.25 kgm}
2) For bucket
install plug (18).
3) For arm
install plug (18).
4) For boom
install plug (18).
30-82
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E20107
30-83
6. Blade control valve 3) Assemble retainer (7) and spring (6), then
1) Assemble spool (17) in body. fit O-ring and install case (5).
2) Assemble valve (10) and spring (9), then fit
O-ring and install plug (8). 10. Travel control valve
Plug: 1) Assemble spool (13) in body.
17.15 ± 2.45 Nm {1.75 ± 0.25 kgm} 2) Assemble retainer (7) and spring (6), then
fit O-ring and install case (5).
3) Assemble retainer (7) and spring (6), then
fit O-ring and install case (5). 11. Swing control valve
1) Assemble spool (12) in body.
Case mounting bolt: 2) Assemble valve (10) and spring (9), then fit
11.27 ± 1.47 Nm {1.15 ± 0.15 kgm} O-ring and install plug (8).
★ The tightening torques are the same fit O-ring and install case (5).
for all the valves, so refer to the
tightening torque for the blade valve 12. Fit O-ring and install unload valve assembly
when tightening the other valves. (4).
Unload valve:
7. Bucket control valve
166.6 ± 19.6 Nm {17 ± 2 kgm}
1) Assemble spool (16) in body, then fit
O-ring and install plug (8).
13. Fit O-ring and install LS select valve assembly
E20107
(3).
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LS select valve:
8. Arm control valve 127.4 ± 19.6 Nm {13 ± 2 kgm}
2) Assemble valve (10) and spring (9), then fit 14. Fit O-ring and install safety valve assembly (2).
O-ring and install plug (8). Safety and suction valve:
3) Assemble retainer (7) and spring (6), then 98 ± 9.8 Nm {10 ± 1 kgm}
15. Fit O-ring and install main relief valve
9. Boom control valve assembly (1).
Main relief valve:
2) Assemble valve (10) and spring (9), then fit
O-ring and install plugs (11) and (8). 53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
★ Plug (8) is for the RAISE valve and plug
(11) is for the LOWER valve.
30-84
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E20107
30-85
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY

1. Loosen nut (1), and pull out adjustment screw
(2), then remove spring (3) and poppet (4).
★ Before loosening nut (1), measure the
protrusion dimension of adjustment screw
(2) from the end face of the nut.
2. Remove snap ring (6) from sleeve (5), then

re-move valve (7) and spring (8).
3. Remove backup ring (9) from sleeve (5).
ASSEMBLY OF MAIN RELIEF

VALVE ASSEMBLY
1. Assemble backup ring (9) and O-ring to sleeve
(5).
2. Assemble spring (8) to valve (7), and assemble
E20107
in sleeve (5), then install snap ring (6).
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3. Assemble poppet (4) and spring (3) in sleeve
(5).
4. Screw adjustment screw (2) into sleeve (5),

adjust so that protrusion dimension from end
face of locknut (1) is the same as when it was
disassembled, then secure with locknut (1).
Locknut : 68.6 ± 9.8 Nm {7 ± 1 kgm}
★ Check and adjust the relief pressure.

Testing and adjusting pressure in work
equipment , travel, swing circuits.
30-86
②
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID
VALVE ASSEMBLY
2. Remove 4 solenoid wiring connectors (1) from

clip, then disconnect. ※ 1
★ Record the connection number and the
connecting position of the wiring.
3. Disconnect 9 hoses (2).

★ Mark the connecting position of the hoses
with tags before disconnecting.
4. Remove mounting bolts (3), then remove

solenoid valve assembly (4).
When removing solenoid valve as individual

part
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Remove nut (5), then remove solenoid valve
(6). ※ 2
E20107
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
removal.
※ 1
Check the connector number, then connect.
※ 2
Mounting nut (5):
4.9 ± 0.1 Nm {0.5 ± 0.1 kgm}
Solenoid valve as individual part (6):

39.2 ± 9.8 Nm {4 ± 1 kgm}
30-87
②
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT LEFT SIDE PPC VALVE
REMOVAL OF WORK EQUIP-

MENT LEFT SIDE PPC VALVE
ASSEMBLY
(FOR ARM, SWING CONTROL)
in-side the hydraulic tank.
1. Remove boot (2) from cover (1), raise to top,

then remove lever (3).
★ Check the direction of the lever.
2. Disconnect clamp (4).

★ Remove the mounting bolts and move to
wards rear.
E20107
4. Remove mounting bolts of PPC valve
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assembly (5), then raise PPC valve assembly,
and disconnect 6 hoses (6). ※ 1
5. Remove PPC valve assembly (5). ※ 2
INSTALLATION OF WORK
EQUIPMENT LEFT SIDE PPC
VALVE ASSEMBLY
(FOR ARM, SWING CONTROL)
removal.
※ 1
Hose joint bolt:
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
※ 2
★ If there is excessive play in the control
levers, adjust the PPC valve. For details,
see TESTING AND ADJUSTING, Adjusting
PPC valve.
30-88
②
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT RIGHT SIDE PPC VALVE

MENT RIGHT SIDE PPC VALVE
ASSEMBLY
(FOR BOOM, BUCKET CON-
TROL)

then disconnect wiring of horn, and remove
lever (3).
★ Move cover (1) up.
2. Disconnect wiring clamp.
3. Remove mounting bolts of PPC valve assembly
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(5), then raise PPC valve assembly, and
disconnect 6 hoses (4). ※ 1
4. Remove PPC valve assembly (5). ※ 2

E20107
EQUIPMENT RIGHT SIDE PPC
VALVE ASSEMBLY
(FOR BOOM, BUCKET CON-
TROL)
removal.
※ 1
Hose joint bolt:
39.2 ± 4.9 Nm {4.0 ± 0.5kgm}
※ 2
★ If there is excessive play in the control le-
vers, adjust the PPC valve. For details, see
TESTING AND ADJUSTING, Adjusting
PPC valve.
30-89
②
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
(FOR BOOM, ARM, BUCKET,
SWING CONTROL PPC VALVE)
1. Remove nut (1), then remove disc (2) and boot
(3).
2. Remove bolts, then remove plate (5).

★ Do not remove joint (4) unless it is to be
re-placed.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), and remove retainer (9),

springs (10) and (11), and shim (12).
★ Spring (10) consists of a set of two types of
springs with different installed loads, so
E20107
check the mounting position (oil port) and
mark with tags to prevent mistakes when
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installing.
5. Pullout valve (13) from body (14).
30-90
②
ASSEMBLY OF WORK EQUIP-

MENT PPC VALVE ASSEMBLY
(FOR BOOM, ARM, BUCKET,
SWING CONTROL PPC VALVE)
1. Assembly valve (13) to body (14). 7. Assemble boot (3) and disc (2), and tighten
with nut (1).
2. Assemble shim (12) and spring (11) to valve Nut: 112.7 ± 14.7 Nm {11.5 ± 1.5 kgm}
(13).
★ When assembling spring (11), set the end ★ After assembling the disc, adjust the height
with the small coil diameter (inside diameter) of the disc.
at shim (12) end. For details, see TESTING AND ADJUSTING,
Adjusting PPC valve.
3. Assemble spring (10), retainer (9), and piston
(8).
★ The number of loops in the coil for
spring(10) is different for each of the
hydraulic ports below, so be careful when
installing.
Position of port Free length of spring
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P1, P2 44.4 m m
P3, P4 42.4 mm
★ The position of each port is marked on the

bottom of the valve body.
E20107
Piston : Grease (G2-LI)

★ When assembling piston (8), coat the
out-side of the piston and the inside of the
hole in the body with grease.
4. Fit O-ring to collar (7) and assemble in body

(14), then install seal (6).
5. Install plate (5).

Mounting bolt
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (4)

Sliding portion of joint: Grease (G2-LI)
Female thread of body:
★ Coat two places on the female thread with

one drop each of Loctite as shown in the
diagram.
Joint : 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
★ Keep strictly to the joint tightening torque.
30-91
②
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove floor mat.
2. Remove bottom cover.
3. Remove levers (1). ※ 1
4. Remove cover (2). ※ 2
5. Remove covers (3), then remove springs (4).
6. Disconnect 6 PPC hoses (5), and remove

travel PPC valve assembly (6). ※ 3
E20107
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INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
removal.
※ 1
★ Adjust the travel lever.
Adjusting travel lever.
※ 2
Cover mounting bolt:
19.6 ± 1.96 Nm {2.0 ± 0.2 kgm}
※ 3
Hose mounting joint bolt (width across
flats: 30mm):
39.2 ± 4.9 Nm {4.0 ± 0.5 kgm}
Hose mounting joint bolt (width across

flats: 22mm):
29.4 ± 4.9 Nm {3.0 ± 0.5 kgm}
30-92
②
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30-93
②
DISASSEMBLY OF TRAVEL
PPC VALVE ASSEMBLY
1. Remove cover and cam assembly (1), then
remove shims (2).
★ Check the number and thickness of shims
(2) for each mounting position, and keep in
a safe place.
2. Remove plate (3).
3. Remove seal (4) and collar (5).
4. Pull out piston (6), and remove retainer (7),

springs (8) and (9), and shims (10).
★ Check the number and thickness of shims
(10) for each mounting position, and keep
in a safe place.
5. Pull out valve (11) from body (12).
E20107
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ASSEMBLY OF TRAVEL PPC
VALVE ASSEMBLY
1. Assemble valve (11) in body (12).
2. Assemble shims (10) and spring (9) to valve

(11).
★ Assemble the same number and thickness
of shims (10) as was removed during
disassembly.
Standard shim thickness: 0.3 mm
★ Spring (9) is not symmetrical at the top and
bottom, so assemble with the small coil
diameter (inside diameter) at the shim end.
3. Assemble spring (8), retainer (7), and piston

(6).
Outside circumference of piston, body
hole:
Grease (G2-LI)
4. Fit O-ring to collar (5) and assemble in body

(11), then install seal (4).
5. Assemble plate (3)
6. Fit cover and cam assembly (1) and assemble

shims (2), then tighten with bolt.
Sliding portion of shaft, connecting
portion of lever and piston : Grease
(G2-LI)
30-94
②
★ Assemble the same number and thickness

of shims (2) as was removed during
disassembly.
Standard shim thickness: 1.6 mm
Mounting bolt (a):
27.93 ± 3.43 Nm {2.85 ± 0.35 kgm}
Mounting bolt (b):
30.87 ± 3.43 Nm {3.15 ± 0.35 kgm}
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E20107
30-95
②
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ASSEMBLY
Extend the arm and bucket fully, lower the
work equip ment completely to the ground,
and put the safety lock lever in the LOCK
position.
2. Sling boom cylinder assembly (2), and remove

lock plate, then remove head pin (3). ※ 1
★ There are shims installed, so check the
number and thickness, and keep in a safe
place.
3. Start engine, and retract piston rod, then tie

piston rod with wire to prevent it from coming
out.
★ Set stand under the cylinder assembly, and
E20107
adjust the position for slinging the cylinder
assembly.
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4. Disconnect left and right hoses (5).
6. Remove plate, and remove bottom pin (6),

then remove boom cylinder assembly (2). ※ 2
place.
30-96
②
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM CYL-

INDER ASSEMBLY
removal.
※ 1
Inside surface of bushing when
assembling pin:
Greasing after assembling pin:
Grease (LM-G)
When aligning the position of the pin hole,
never insert your fingers in the pin hole.
★ Adjust the shim thickness so that the
clearance between cylinder rod (7) and
plate (8) is below 1 mm.
★ Standard shim thickness : 1.0 mm
※ 2
Inside surface of bushing when assem-
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bling pin:
Grease (LM-G)
E20107

clearance between cylinder bottom (9) and
bracket (10) is below 1 mm.
★ Standard shim thickness:
1.0 mm, 2.0 mm
• Bleeding air
★ Bleed the air from the cylinder.
Bleeding air from hydraulic cylinder.

level.
30-97
②
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
Curl the bucket and arm in, lower them onto
a block, then set the safety lock to the LOCK
position.
1. Sling arm cylinder assembly.
3. Remove lock plate, then remove head pin (2).

※ 1
place.

out.
E20107
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7. Raise arm cylinder assembly, remove plate,

then remove bottom pin (5), and remove arm
cylinder assembly (6).
place.
Arm cylinder assembly : 80 kg
30-98
②
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM CYLIN-

DER ASSEMBLY
removal.
※ 1
bling pin:
Grease (LM-G)

★ Standard shim thickness: 1.0 mm
※ 2
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bling pin:
E20107
Grease (LM-G)

clearance between cylinder bottom (10)
and bracket (9) is below 1 mm.
• Bleeding air

level.
30-99
②
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET CYLIN-

DER ASSEMBLY
Extend the bucket cylinder piston rod approx.
20 mm, lower the work equipment completely
to the ground, then set the safety lock lever
to the LOCK position.
1. Set block ① under arm top.
2. Set blocks ② and ③ between link and arm.
3. Sling bucket cylinder assembly.
4. Remove lock bolt (1). ※ 1
5. Remove lock plate, then remove head pin (2),

and tie piston rod with wire to prevent it from
coming out. ※ 2
E20107
If pin (2) comes out, link (7) will fall, so be
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careful that block ② does not come out.
number and thickness, and keep in a
safe place.

8. Raise bucket cylinder assembly, remove plate,

then remove bottom pin (5), and remove
bucket cylinder assembly (6). ※ 3
place.
Bucket cylinder assembly: 60 kg
30-100
②
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
removal.
※ 1
★ When tightening the locknut, tighten so
that the clearance between the plate and
nut is 0.5 - 1.5 mm.
※ 2
bling pin:
Grease after assembling pin:
Grease (LM-G)
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clearance between link (8) and link (7) is
below 1mm.
1.0 mm, 2.0 mm
※ 3
E20107

bling pin:
Grease (LM-G)
clearance between cylinder bottom (10)
and bracket (9) is below 1 mm.
• Bleeding air
For details, see TESTING ADN ADJUSTING,

level.
30-101
②
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
REMOVAL OF BLADE CYLINDER

ASSEMBLY
Swing the work equipment 45°, lower the
work equipment to the ground, then lower the
blade to the ground, and stop the engine.
Operate the blade control lever 2 - 3 times to
release the remaining pressure in the
hydraulic piping.
Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank, then set
the safety lock lever to the LOCK position.
1. Remove blade cylinder protection cover.
2. Sling blade cylinder assembly (1), and remove

head mounting pin (2). ※ 1
place.
E20107
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out.

4. Disconnect hoses (3).
5. Remove bottom pin (4), and lift off blade

cylinder assembly (1). ※ 2

place.
Blade cylinder assembly: 50 kg
30-102
②
INSTALLATION OF BLADE CYL-

INDER ASSEMBLY
removal.
※ 1 ※ 2
★ Assemble the shims securely to their
original position.
• Bleeding air

level.
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E20107
30-103
②
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Cylinder assembly
1) Set cylinder assembly (1) in tool E1.
2) Using hydraulic pump or power wrench,
loosen head assembly (2) with tool E2.
3) Pull out piston rod assembly (3).
★ Place a container under the cylinder to
catch the oil.
2. Piston rod assembly

1) Set piston rod assembly (3) in tool E1.
loosen nut (4) with tool E3.
★ Width across flats of nut:
E20107
unit: mm
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Cylinder Boom Arm Bucket Blade
Width across
70 65 60 80
flats of nut
3) Remove piston assembly (5) and retainer

(6).
• Retainer (6) is used for the boom and
arm cylinders only.
4) Remove plunger (7).
• Boom and arm cylinder only
5) Remove collar (8) and head assembly (9).
30-104
②
6) Remove cap (12), pull out 9 balls (10), then

remove plunger (11).
• Arm cylinder only
Boom, arm, bucket cylinder

3. Disassembly of piston assembly
1) Remove wear ring (13).
2) Remove piston ring (14).
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E20107
30-105
②
4. Disassembly of cylinder head assembly Boom, arm, bucket cylinder

1) Remove O-ring and backup ring (15).
2) Remove O-ring (17).
3) Remove snap ring (18), then remove dust
seal (19).
4) Remove rod packing (20).
5) Remove buffer ring (21).
6) Remove bushing (22).
Blade cylinder
E20107
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30-106
②
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
★ Be careful not to damage the packings, dust
seals, and O-rings.
★ Do not try to force the backup ring into position.
Warm it in warm water (50 - 60°C) before fitting
it
1. Assembly of cylinder head assembly
1) Using tool E6, press fit bushing (22).
2) Assemble buffer ring (21).
3) Assemble rod packing (20).
4) Using tool E7, install dust seal (19), and

se-cure with snap ring (18).
5) Install backup ring (15) and O-ring.
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6) Install O-ring (17).
E20107
2. Assembly of piston assembly
1) Using tool E4, expand piston ring (14).

★ Set the piston ring on the tool E4, and
turn the handle 8 - 10 times to expand
the ring.
2) Set tool E5 in position, and compress

piston ring (14).
3) Assemble wear ring (13).

★ Be careful not to open the end gap of
the ring too wide.
Ring groove: Grease (G2-L1)
30-107
②
3. Piston rod assembly

1) Set plunger (11) to piston rod, assemble 9
balls (10), then secure with cap (12).
★ Check that there is a slight play at the
tip of the plunger.
• Arm cylinder only
2) Assemble head assembly (9).
3) Fit O-ring and backup ring, and assemble

collar (8).
4) Assemble plunger (7).

5) Assemble retainer (6).

• Boom and arm cylinders only
6) Assemble piston assembly (5).
E20107
7) Set piston rod assembly (2) to tool E1.
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8) Using tool E3, tighten nut (4).
Nut: Thread tightener (LT 2)
Nut:
Cylinder Tightening torque
Boom 2597 ± 259.7 Nm {265 ± 26.5 kgm}
Arm 2646 ± 264.6 Nm {270 ± 27 kgm}
Bucket 2156 ± 215.6 N m {220 ± 22 kgm}
Blade 3969 ± 399.9 Nm {405 ± 40.5 kgm}
4. Cylinder assembly
1) Set cylinder to tool E1.
2) Install piston rod assembly (3).
★ Push the piston rod in fully.
30-108
②

tighten head assembly (2) with tool E2.
Head assembly
Cylinder Tightening torque
Boom 960.4 ± 96.04 Nm {98 ± 9.8 kg m)
Arm 784 ± 78.4Nm {80 ± 8 kgm}
1st step: Tighten to 1176 - 1372 Nm
{120 - 140 kgm}
2nd step: Loosen to 0 Nm {0 kgm}

Bucket
3rd step: Tighten to 392 Nm {40 kg}.
4th step: Angle tightening

(distance of turning 3.5 - 4.5 mm)
Blade 980.0 ± 98.0 Nm {100 ± 10 kgm}
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E20107
30-109
②
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

MENT ASSEMBLY
Extend the arm and bucket fully, lower the
work equipment completely to the ground,
and set the safety lock lever to the LOCK
position.
2. Sling boom cylinder assembly (2), remove lock

plate, then remove head pin (3). ※ 1
place.
3. Lower boom cylinder assembly onto stand.

E20107
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4. Disconnect hoses (4) and (5), and secure to
valve with rope.
★ Install blind plugs at the male end and in
the disconnected hoses.
5. Disconnect wiring connector (6) for working

lamp.
6. Disconnect grease hose (7).
7. Raise work equipment assembly, remove plate,

then remove foot pin (8) using tool F, and
remove work equipment assembly (9).
place.
Work equipment assembly: 1000 kg
30-110
②
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
EQUIPMENT ASSEMBLY
removal.
※ 1
bling pin:

Grease (LM-G)
※ 2
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bling pin:

E20107
Grease (LM-G)

clearance between boom (12) and bracket
(13) is below 1 mm.
0.5 mm, 1.0 mm
• Bleeding air

level.
30-111
②
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET ASSEM-

BLY
Set the back of the bucket facing down, lower
the work equipment completely to the ground,
and set the safety lock lever to the LOCK
position.
1. Remove rings (1) and (2).
2. Pull out pin (3), and remove connecting pin (4)

between link and bucket. ※ 1
number and thickness, and keep in a safe.

out.
4. Pull out pin (5), and remove plate (6), then
E20107
remove connecting pin (7) between arm and
bucket. ※ 2
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place.
5. After raising work equipment, swing to discon-

nect bucket assembly (8).
Bucket assembly: 215 kg
30-112
②
DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION OF BUCKET AS-

SEMBLY
removal.
※ 1
bling pin:
Grease (LM-G)
clearance between bucket boss (9) and
link (10) is below 1 mm.
★ Standard shim thickness : 1.0, 1.6, 3.2 mm
※ 2
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bling pin, inside surface, end face of
spacer (12): Anti-friction compound
(LM-P)
E20107
Grease (LM-G)
★ Insert the O-ring at the end face of the
bucket boss securely.
clearance between arm top (11) and
spacer (12) is below 0.5 mm.
30-113
②
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY

1. Remove bucket assembly.
For details, see REMOVAL OF BUCKET ASSE-
MBLY.
2. Secure front link to arm with wire.
3. Pull in arm so that it is easy to remove pin at

arm cylinder head, then lower arm and bucket
cylinder assembly (1) on to block ①.
Set the safety lock lever to the LOCK
position.
4. Set block ② between arm cylinder and boom.
6. Remove lock plate, then remove arm cylinder

head pin (3). ※ 1
E20107
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place.

out.
An accumulator is not installed, so loosen
the sleeve nut of the hose slowly and
check that no oil spurts out before
removing.

10. Remove plate, then remove connecting pin (6)

between arm and boom. ※ 2
place.
11. After raising boom, swing to remove arm and

bucket cylinder assembly (1).
Arm, bucket cylinder assembly (including

link): 240 kg
30-114
②
DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION OF ARM ASSEMBLY

removal.
※ 1
assembling pin:
Grease (LM-G)

bracket(8) is below 1 mm.
※ 2
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assembling pin:
Grease (LM-G)
E20107

clearance between boom top (9) and arm
bottom (10) is below 0.5 mm.
0.5 mm,1.0 mm
• Bleeding air

level.
30-115
②
DISASSEMBLY AND ASSEMBLY BUCKET • ARM
REMOVAL OF BUCKET • ARM

ASSEMBLY
Curl the bucket and arm in, lower them onto
a block, then set the safety lock to the LOCK
position.

pressure inside the hydraulic tank.
1. Set block ② between arm cylinder and boom.
3. Remove lock plate, then remove arm cylinder

head pin (2).
place.
E20107
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out.

removing.

7. Remove lock plate, then remove connecting

pin (5) between arm and boom.
8. After raising boom, swing to remove bucket

and arm assembly (6).
place.
Bucket, arm assembly : 450 kg
30-116
②
DISASSEMBLY AND ASSEMBLY BUCKET • ARM
INSTALLATION OF BUCKET •
ARM ASSEMBLY
removal.
※ 1
bling pin:
Grease (LM-G)

※ 2
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bling pin:
E20107
Grease (LM-G)

clearance between boom (9) and arm
bottom (10) is below 0.5 mm.
0.5 mm, 1.0 mm
• Bleeding air

level.
Run the engine to curculate the oil through
30-117
②
DISASSEMBLY AND ASSEMBLY BOOM
REMOVAL OF BOOM ASSEMBLY

1. Remove bucket and arm assembly.
For details, see REMOVAL OF BUCKET, ARM
ASSEMBLY.
2. Lower boom assembly completely to ground,

and set safety lock lever to LOCK position.
4. Sling boom cylinder assembly (2), and remove

lock plate then remove head pin (3). ※ 1
place.
5. Lower boom cylinder assembly onto stand.

removing.
E20107
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6. Disconnect hoses (4) and (5), and secure to
valve with rope.
7. Disconnect wiring connector (6) for working

lamp.
9. Raise boom assembly and remove plate, then

remove foot pin (8) using tool F.
10. Lift off boom assembly (9).

place.
Boom assembly (with arm cylinder):

445 kg
30-118
②
DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION OF BOOM AS-

SEMBLY
removal.
※ 1
bling pin:
Grease (LM-G)

※ 2
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bling pin:
E20107
Grease (LM-G)

clearance between boom (12) and bracket
(13) is below 1 mm.
0.5 mm,1.0 mm
• Bleeding air

level.
30-119
②
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE ASSEMBLY

Swing the work equipment 45°, lower the
work equipment to the ground, then lower the
blade to the ground, and stop the engine.
Operate the blade control lever 2 - 3 times to
release the remaining pressure in the
hydraulic piping.
pressure inside the hydraulic tank, then set
the safety lock lever to the LOCK position.
1. Remove blade cylinder protection cover.
2. Sling blade cylinder assembly (1), and remove

bottom pin (2). ※ 1
★ Start the engine, retract the blade cylinder
rod, then lower it onto a block.
place.
E20107
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3. Sling blade assembly, and remove left and
right pins (3). ※ 2
place.
4. Remove blade assembly (4).

Blade assembly: 350 kg
INSTALLATION OF BLADE AS-

SEMBLY
removal.
※ 1
★ Insert the shims securely.
※ 2
★ Assemble the shims securely to their
original position.
30-120
②
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
REMOVAL OF OPERATOR'S
CAB ASSEMBLY
1. Remove floor mat.
2. Disconnect speaker wiring (1), room lamp

wiring (2), antenna wiring (3), and washer
hose (4).
★ Fit tags to mark the male and female ends
of the connectors to prevent mistakes
when connecting.
3. Disconnect wiper motor wiring connector (5).
4. Remove 9 cab mounting bolts.

★ Check the position of the chassis ground
connection.
5. Lift off operator's cab assembly (6).
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Operator's cab assembly: 250 kg
INSTALLATION OF OPERATOR'S
CAB ASSEMBLY
removal.
PC60-7 30-121
②
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
Serial No. : 52374 – 57999
2. Remove cover (1) at intake hose side.
3. Disconnect reservoir tank hose (2).
4. Disconnect window washer tank hose (3) and

connector (4).
5. Set eyebolts ① to counterweight assembly

(5), and sling.
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6. Remove 4 mounting bolts (4), then lift off coun-
terweight assembly (5). ※ 1
Counterweight assembly: 650 kg
INSTALLATION OF COUNTER-
WEIGHT ASSEMBLY
Serial No. : 52374 – 57999

removal.
※ 1
Thread of counterweight mounting bolt:
Counterweight mounting bolt:
549.2 ± 58.8 Nm {56 ± 6 kgm}
★ When installing the counterweight, adjust

so that the clearance and stepped
difference is uniform on the left and right.
30-122 PC60-7
②
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
2. Disconnect reservoir tank hose (1).
3. Remove air intake hose (2).

★ Disconnect clamp (3).
5. Remove window washer tank (5) from bracket.
6. Set eyebolts ① to counterweight assembly

(6), and sling.
7. Remove mounting bolts, then lift off counter-

weight assembly (6). ※ 1
Counterweight assembly: 715 kg
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INSTALLATION OF COUNTER-
WEIGHT ASSEMBLY

removal.
※ 1
Thread of counterweight mounting bolt:
Thread tightener (LT 2)
Counterweight mounting bolt:
549.2 ± 58.8 Nm {56 ± 6 kgm}
★ When installing the counterweight, adjust

so that the clearance and stepped
difference is uniform on the left and right.
PC60-7 30-122-1
④
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30-124 PC60-7
②
MONITOR
DISASSEMBLY AND ASSEMBLY SWING CONTROLLER
REMOVAL OF MONITOR AS-

SEMBLY

then remove lever (3).
2. Disconnect horn wiring.
3. Remove cover (1), and disconnect 3 connectors

(4).
4. Remove monitor assembly (5) from cover (1).

※ 1
INSTALLATION OF MONITOR
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removal.
Mounting nut of monitor assembly:

8.33 ± 0.49 Nm {0.85 ± 0.05 kgm}
E20107
REMOVAL OF SWING CON-

TROLLER ASSEMBLY
1. Tip operator's seat over to front, then disconnect

wiring connector (1) under operator's seat.
2. Remove mounting bolts, then remove

controller assembly (2).
INSTALLATION OF SWING
CONTROLLER ASSEMBLY
removal.
30-123
②
AUTO-GREASING CONTROLLER
DISASSEMBLY AND ASSEMBLY AUTO-GREASING PUMP
REMOVAL OF AUTO-GREASING
CONTROLLER ASSEMBLY
2. Disconnect 3 wiring connectors (1).

★ Fit tags to mark the male and female ends
the connectors to prevent mistakes when
connecting.
3. Remove 2 mounting bolts, then remove

INSTALLATION OF AUTO-
GREASING CONTROLLER AS-
SEMBLY
E20107
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removal.
PUMP ASSEMBLY
• Disconnect the cable from the negative (-)
2. Remove 2 wiring connectors (1), and disconnect

hose (2). ※ 1
3. Remove 2 mounting bolts, then remove pump

assembly (3).
INSTALLATION OF AUTO-
GREASING PUMP ASSEMBLY
removal.
※ 1
★ Bleeding air inside circuit
For details, see Bleeding air from auto-
greasing device.
30-124
②
40 MAINTENANCE STANDARD
Swing machinery .......................................... 40- 2

Swing circle .................................................. 40- 3
Track frame .................................................. 40- 4
Idler .............................................................. 40- 5
Track roller ................................................... 40- 6
Carrier roller ................................................. 40- 7
Track shoe .................................................... 40- 8
Hydraulic pump ............................................ 40-11
Control valve ................................................ 40-12
Self-pressure reducing valve .......................40-24
Swing motor ................................................... 40-26
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Center swivel joint ........................................ 40-27
Work equipment, swing PPC valve .............. 40-29
Travel PPC valve ......................................... 40-30
Service PPC valve ....................................... 40-31
Work equipment ........................................... 40-32
Hydraulic cylinder ......................................... 40-36
PC60-7 40-1
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
Serial No. : 52374 – 59570
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Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 Standard clearance Clearance limit

1 sun gear and No. 1
planetary gear 0.11-0.31 0.6
Backlash between No. 1

2 planetary gear and ring 0.12-0.40 0.6
gear
3 planetary carrier and No. 2 0.13-0.31 —
sun gear Replace
gear
5 sun gear and No. 2 0.11-0.31 0.6
planetary gear
Backlash between swing
6 pinion and swing circle 0.22-0.85 2.0
gear
Wear of swing pinion shaft Standard size Tolerance Repair limit
7 surface contacting with oil Repair hard
0
seal 65 64.8 chrome
-0.074
plating or
Wear of swing pinion collar
-0.043 replace
8 surface contacting with 125 124.8
dust seal -0.106
40-2 PC60-7
⑧

Serial No. : 59571 and up (For Norway)
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Unit: mm
Backlash between No. 1 Standard clearance Clearance limit

1 sun gear and No. 1
planetary gear 0.11-0.31 0.6

gear
3 planetary carrier and No. 2 0.13-0.31 —
sun gear Replace
gear
5 sun gear and No. 2 0.11-0.31 0.6
planetary gear
Backlash between swing
6 pinion and swing circle 0.22-0.40 2.0
gear
Wear of swing pinion shaft Standard size Tolerance Repair limit
7 surface contacting with oil Repair hard
0
seal 65 64.8 chrome
-0.074
plating or
Wear of swing pinion col-
-0.043 replace
8 lar surface contacting with 125 124.8
dust seal -0.106
PC60-7 40-2-1
⑧
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40-2-2 PC60-7
⑧
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
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E20107
Unit: mm
Standard clearance Clearance limit

Clearance of bearing in
1 Replace
axial direction
0.04 - 0.20 0.5
40-3
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
E20107
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Unit: mm
Standard size Repair limit

Rebuild
Vertical width of idler Track frame 74 78
1
guide
Rebuild or
Idler 73 69
replace
Track frame 158 162 Rebuild

Horizontal width of idler
2
guide Rebuild or
Idler 156 152
replace
3 Recoil spring Free length Installed load Installed load Free length Installed load Replace
47.4 N
410 323
(4837 kg)
40-4
MAINTENANCE STANDARD IDLER
IDLER
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Unit: mm

Outside diameter
1
Of protrusion of idler
460 452
Outside diameter of tread

2 415 407
of idler
Rebuild or
3 Width of protrusion of idler 43 37 replace
4 Overall width of idler 100 92
5 Width of tread of idler 28.5 32
Standard Tolerance Standard Clearance

Clearance between shaft size Shaft Hole clearance limit
6
and bushing -0.250 +0.062 0250- Replace
44 1.5 bushing
-0.074 0 0.352
7 Play of idler in axial direction Repair limit :1.5
Thickness of idler tread Standard size Repair limit Rebuild or

8
(thickness at tread surface) 12 8 replace
PC60-7 40-5
③
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
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Check item Criteria
Unit: mm
Remedy
Outside diameter of Standard size Repair limit

1 flange
(outside) 149 —
Outside diameter of Rebuild or
2 120 113 replace
tread
3 Width of tread 30 33.5
4 Width of flange 12 7

size clearance limit
Clearance between Shaft Hole
5
shaft and bushing
-0.250 +0.075 0.225-
38 1.5
-0.270 -0.025 0.345
Standard Tolerance Standard Interference Replace

size interference limit bushing
Interference between Shaft Hole
6
roller and bushing
+0.117 +0.300 0.057-
48 —
-0.087 0 0.117

7 Side clearance of roller
0.38-0.73 1.5
Thickness of track roller Standard size Repair limit Rebuild or

8
tread replace
36 32.5
40-6 PC60-7
③
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
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Unit: mm
Standard size Repair limit Rebuild or

1 Outside diameter of tread
replace
82 78
2 Width of tread 100 — Replace

Thickness of carrier roller
3 Rebuild or replace
tread
10 8
PC60-7 40-7
③
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRIPLE SHOE, SWAMP SHOE
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40-8 PC60-7
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
1 Link pitch
154.25 157.25
Turn or replace
Outside diameter of
2 41.2 37.2
bushing
Triple 20 12 It is possible to
Height of carry out lug
3
grouser welding
Swamp
or rebuilding until
repair limit has
4 Height of link 74 70 been reached.
Standard Tolerance Standard Interference
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size Shaft Hole interference limit
Interference between
5
bushing and link If it exceeds
+0.314 +0.062 0.214- interference
41 —
+0.274 +0 0.314 limit, replace
Interference between +0.150 -0.198 0.198-
6 24 —
regular pin and link +0 -0.250 0.400
If it is less than
Interference between +0.020 -0.198 0.178-
7 24 — interference limit,
master pin and link -0.020 -0.250 0.270 replace with oversize
8 Protrusion of bushing 3.0 Adjust
Tightening torque of Default : 118±20 Nm

9 Tighten
shoe bolt {12±2 kgm, additional tightening: 90±10°}

Triple
Thickness grouser 26 18 Weld lug or
10 shoe
of grouser rebuild
Swamp
14 4
shoe
Thickness of link
Rebuild or
11 (bushing press-fitting 20 16
replace
portion)
Turn or
12 Thickness of bushing 8.4 4.4 (Heavy)
replace
PC60-7 40-9
③
MAINTENANCE STANDARD RUBBER SHOE
RUBBER SHOE
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Unit: mm

1 Wear of lug height
30 5
2 Wear of roller guard 101 81 Replace

Wear of meshing portion
3 3 -2
of sprocket
4 Wear of roller tread height 28.5 23.5
40-10 PC60-7
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
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PC60-7 40-11
③
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
6-SPOOL OIL PRESSURE ASSIST TYPE (STANDARD SPECIFICATION)
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40-12 PC60-7
7-SPOOL OIL PRESSURE ASSIST TYPE (STANDARD + 1 SERVICE VALVE)
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E20107
40-13
(STANDARD SPECIFICATION)
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E20107
Unit: mm
Free length Installed Installed Installed Replace
Cooler bypass Free length spring if
1 x OD length load load
valve spring damaged or
231.4 N 185.3 N deformed
50.2 x 21.6 33 —
{23.6 kg} {18.9 kg}
40-14
④
(STANDARD + 1 SERVICE VALVE)
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E20107
Unit: mm

Cooler bypass Free length spring if
valve spring damaged or
50.2 x 21.6 33 —
{23.6 kg} {18.9 kg}
40-15
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E20107
Unit: mm
Free length Installed Installed Installed
Spool return spring Free length
(work equipment, travel)
34.3 N 27.4 N Replace
41.1 x 19.3 40.5 — spring if
{3.5 kg} {2.8 kg}
damaged or
Spool return spring 61.7 N 49 N deformed
2 42.3 x 19.2 40.5 —
(swing) {6.3 kg} {5 kg}
Spool return spring 54.9 N 44 N

3 42.3 x 19.2 40.5 —
(boom, arm) (5.6 kg) {4.5 kg}
40-16
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E20107
Unit: mm
Spool return spring Free length
(work equipment, travel)
41.1 x 19.3 40.5 — spring if
{3.5 kg} {2.8 kg}
damaged or
Spool return spring 61.7 N 49 N deformed
2 42.3 x 19.2 40.5 —
(swing) {6.3 kg} {5 kg}
Spool return spring 54.9 N 44 N

3 42.3 x 19.2 40.5 —
(boom, arm) {5.6 kg} {4.5 kg}
40-17
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E20107
Unit: mm
Pressure compensation Free length
valve spring
13.7 N 11 N Replace
28 x 14.4 14.5 — spring if
{1.4 kg} {1.12 kg}
damaged or
Pressure compensation 56 N 44.7 N deformed
2 33.4 x 14.4 21.5 —
valve spring {5.7 kg} {4.56 kg}
Pressure compensation 27.7 N 22.2 N

3 30.85 x 5.2 20 —
40-18
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E20107
Unit: mm
Pressure compensation Free length
valve spring
13.7 N 11 N Replace
28 x 14.4 14.5 — spring if
{1.4 kg} {1.12 kg}
damaged or
Pressure compensation 56 N 44.7 N deformed
2 33.4 x 14.4 21.5 —
Pressure compensation 27.7 N 22.2 N

3 30.85 x 5.2 20 —
40-19
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E20107
Unit: mm

Free length spring if
1 Check valve spring x OD length load load
damaged or
27.2 x 6.9 22 —
{0.4 kg} {0.32 kg}
40-20
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Unit: mm
Free length spring if
1 Check valve spring x OD length load load
damaged or
27.2 x 6.9 22 —
{0.4 kg} {0.32 kg}
PC60-7 40-21
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Unit: mm
Lift check valve Free length spring if
spring damaged or
36.3 N 29 N deformed
55.7 x 22.3 44.9 —
{3.7 kg} {2.96 kg}
40-22 PC60-7
③
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PC60-7 40-23
③
MAINTENANCE STANDARD SELF-PRESSURE REDUCING VALVE
SELF-PRESSURE REDUCING VALVE
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40-24 PC60-7
③
MAINTENANCE STANDARD SELF-PRESSURE REDUCING VALVE
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Unit: mm
Spring Free length
(reducing valve main)
19.6 N 17.7 N
19.2 x 7.2 16.1 —
{2 kg} {1.8 kg}
Spring 20.6 N 18.6 N Replace

2 16.5 x 7.2 12.7 — spring if
(reducing valve pilot) {2.1 kg} {1.9 kg}
damaged or
Spring 316.5 N 294.4 N deformed
3 71 x 18 52 —
(sequence valve large) {32.3 kg} {30 kg}
Spring 149.9 N 133.3 N

4 63 x 10 54 —
(sequence valve small) {15.3 kg} {13.6 kg}
61.7 N 58.8 N
5 Spring (safety valve) 16.1 x 7.8 13.4 —
{6.3 kg} {6 kg}
PC60-7 40-25
③
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
Serial No. : 52374 – 59570
LMF40AB-2
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Unit: mm
spring damaged or
31.6 x 6.5 21.4 —
{0.35 kg} {0.28 kg}
40-26 PC60-7
⑧
Serial No. : 59571 and up ★ The drawing shows the motor without reverse
Serial No. : 59571 and up (For Norway) rotation prevention valve.
LMF40AB-2
LMF40ABE-2
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Unit: mm
spring damaged or
33.0 x 13.8 23.0 —
{0.13 kg} {0.10 kg}
PC60-7 40-26-1
⑧
MAINTENANCE STANDARD SWING MOTOR
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40-2 PC60-7
⑧
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

Serial No. : 52374 - 57999
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Unit: mm
Standard size Standard clearance Clearance limit
Clearance between
1 Replace
rotor and shaft
60 0.056 - 0.105 0.111
PC60-7 40-27
③
MAINTENANCE STANDARD CENTER SWIVEL JOINT
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Unit: mm
Clearance between
1 Replace
rotor and shaft
60 0.056 - 0.105 0.111
40-28 PC60-7
③
BLADE SPECIFICATION MACHINE

Serial No. : 52374 - 57999
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Unit: mm
Clearance between
1 Replace
rotor and shaft
70 0.056 - 0.105 0.111
PC60-7 40-28-1
③
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Unit: mm
Clearance between
1 Replace
rotor and shaft
70 0.056 - 0.105 0.111
40-28-2 PC60-7
③
MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
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Unit: mm
Centering spring Free length
(for P3, P4)
44.4 x 15.5 34 — spring if
{3 kg} {2.4 kg}
damaged or
Centering spring 39.0 N 31.0 N deformed
2 47.9 x 15.5 34 —
(for P1, P2) {4 kg} {3.2 kg}
17.0 N 14.0 N
3 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.4 kg}
PC60-7 40-29
⑨
MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
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Unit: mm
Free length
1 Centering spring x OD length load load Replace
spring if
108 N 86 N damaged or
48.1 x 15.5 32.5 —
{11 kg} {8.8 kg} deformed
17 N 14 N
{1.7 kg} {1.4 kg}
40-30 PC60-7
③
MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
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E20107
Unit: mm
Free length
1 Centering spring x OD length load load Replace
spring if
124.5 N 100.0 N damaged or
33.6 x 15.3 28.4 —
{12.7 kg} {10.2 kg} deformed
16.7 N 13.7 N
{1.7 kg} {1.4 kg}
40-31
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
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E20107
40-32
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E20107
Unit: mm

Clearance between
size Shaft Hole clearance limit
bushing and mounting
1
pin of revolving frame
and boom -0.030 +0.174 0.130-
65 1.0
-0.100 +0.100 0.274
Clearance between
-0.030 +0.174 0.130-
2 bushing and mounting 60 1.0
-0.100 +0.100 0.274
pin of boom and arm
Clearance between
-0.225 -0.062 0.105-
-0.285 -0.120 0.223
pin of boom and arm
Clearance between
-0.225 -0.062 0.105- Replace
-0.285 -0.120 0.223
pin of boom and arm
Clearance between
-0.225 +0.149 0.325-
-0.285 +0.100 0.434
pin of boom and arm
Clearance between
-0.030 +0.173 0.130-
-0.100 +0.100 0.273
pin of boom and arm
Clearance between
bushing and mounting
-0.225 +0.142 0.105-
7 pin of track frame and 50 1.0
-0.287 +0.080 0.229
blade (blade specification
machine)
40-33
DIMENSIONS OF WORK EQUIPMENT
1. Arm
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Unit: mm E20107
NO. PC60-7 NO. PC60-7
1 ø 60 11 395.1
2 70 12 342
3 220 13 312.2
4 ø 60 14 1,066.9
5 142.4 15 ø 50
6 218.8 16 200
7 458.6 17 ø 50
8 1,635.3 18 211
9 1,678.4 Min. 1,055
19
10 252.9 Max. 1,765
40-34
2. Bucket
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E20107
Unit: mm
NO. PC60-7 NO. PC60-7
1 309.8 12 71
2 38.6 13 296
3 97.1 14 ø 18
4 312.2 15 ø 100
5 1,057.2 16 ø 115
6 143.7 17 95
7 — 18 75
8 60° 19 60
9 ø 50 20 60
10 200 21 211
11 40 22 24
40-35
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
* The diagram shows the boom cylinder
Boom :961±96.1Nm{98±9.8 kgm} Boom :2.60±0.26NM{265±26.51kgm}(Width across flats:70mm)

Arm :785±78.5Nm{80±8.0kgm} Arm :2.65±0.26Nm{270±27kgm} (Width across flats:65mm)
Bucket:See below Bucket:2.16±0.22Nm{220±22kgm} (Width across flats:60mm)
Blade :981±98.0Nm{100±10.0kgm} Blade :3.97±0.40Nm{405±40.5kgm} (Width across flats:80mm)
Bucket cylinder
Order for tightening head
1) Tighten to a tightening torque of 1270±98.10 Nm {130±10 kgm}.
2) Loosen to a tightening torque of 0.00 Nm {0 kgm}.
3) Tighten to a tightening torque of 392.0 Nm {40 kgm}.
4) Tighten cylinder head by additional angle. (Tighten 3.5 - 4.5 mm)
Unit: mm
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Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
-0.030 +0.250 0.085-

Boom 65 0.426
-0.070 +0.055 0.326
Clearance
between -0.030 +0.151 0.024- Replace
1 Arm 60 0.327
piston rod and -0.076 +0.006 0.227 bushing
bushing
-0.030 +0.151 0.024-
Bucket 55 0.327
-0.076 +0.006 0.227
E20107
-0.030 +0.271 0.105-
Blade 50 0.675
-0.104 +0.075 0.375
-0.030 +0.174 0.130-

Boom 50 1.0
-0.100 +0.100 0.274
Clearance -0.030 +0.174 0.130-
between Arm 60 1.0
-0.100 +0.100 0.274
2 piston rod
support shaft -0.030 +0.174 0.130-
Bucket 50 1.0
and bushing -0.100 +0.100 0.274
-0.030 +0.174 0.130-

Blade 70 1.0
-0.104 +0.100 0.278 Replace pin
and bushing
-0.030 +0.174 0.130-
Boom 65 1.0
-0.100 +0.100 0.274
Clearance
between 0.030 +0.174 0.130-
Arm 55 1.0
cylinder -0.100 +0.100 0.274
3
bottom
-0.030 +0.142 0.130-
support shaft Bucket 50 1.0
-0.100 +0.080 0.274
and bushing
-0.030 +0.174 0.130-
Blade 70 1.0
-0.104 +0.100 0.278
40-36
50 OTHER SPECIFICATION
PC60-7 (For Norway)..................................... 50- 3
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PC60-7 50-1
③
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50-2 PC60-7
③
PC60-7 (For Norway)
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MACHINE MODEL SERIAL NUMBER
PC60-7 55720 and up (For Norway)
· This section contains only information related to the Norway specification. For
other information, see the PC60-7 Shop Manual.
PC60-7 50-3
③
CONTENTS
GENERAL
Dimension...........................................................................................................................................50- 5
Specifications .................................................................................................................................. 50- 7
Weight table........................................................................................................................................50- 9
Table of oil and coolant capacity .................................................................................................... 50-11

Word equipment pin automatic grasing system (OPT) ................................................................... 50-13
Electrical allocation diagram ........................................................................................................... 50-26
Electric circuit diagram ................................................................................................................... 50-30
Machine monitor system ................................................................................................................. 50-32

Connector types and mounting locations ....................................................................................... 50-35
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TROUBLESHOOTING
Troubleshooting of machine monitor system ................................................................................. 50-41

Auto-greasing controller (OPT) ....................................................................................................... 50-54
Auto-Greasing pump (OPT) ............................................................................................................. 50-54
50-4 PC60-7
③
GENERAL GENERAL
GENERAL
DIMENSION
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★ The vallues maked ※ are for blade specification only.
SVPO5835
PC60-7 50-5
③
GENERAL GENERAL
WORKING RANGE
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★ The vallues maked ※ are for shovel operations
50-6
③
SPECIFICATIONS
PC60-7
Machine model
Blade specification
Serial Number 55720 and up

3
Bucket capacity m 0.25
Operating weight kg 6,700
Max. digging depth mm 4,100

Max. vertical wall depth mm 3,505
Working ranges
Max. digging reach mm 6,360

Max. reach at ground level mm 6,200
Max. digging height mm 7,150
Max. dumping height mm 5,015
Performance
Max. lifting height of blade mm 410

Max. lowering depth of blade mm 270
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Max. digging force kN {kg} 47 {4,800}
Swing speed rpm 12
Swing max. slope angle deg. 20
Travel speed Km/h Lo 2.8 Hi 4.5
Gradeability deg 35
2
Ground pressure kPa {kg/cm } 30.40 {0.31}
Overall length (for transport) mm 6,080

Overall width mm 2,280
Overall width of track mm 2,150
Overall height (for transport) mm 2,765
Overall height (to top of cab) mm 2,765
Ground clearance, counterweight mm 750
Dimensions
Min. ground clearance mm 350

Tail swing radius mm 1,750
Min. swing radius of work equipment mm 1,750
Height of work equipment at min. swing radius mm 5,460
Length of track on ground mm 2,130
Track gauge mm 1,700
Height of machine cab mm 1,750
Blade width x height mm 2,260 x 470
PC60-7 50-7
③
PC60-7
Machine model
Blade specification
Model 4D102
No. of cylinders-bore x stroke mm 4 -102 x 120

Performance

Engine

Min. speed at no load rpm 950
Min. fuel consumption g/kWh {g/HPh} 230{172}
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Alternator 24V, 35A
Radiator core type CWX-4

Undercarrlage

Hydraulic

pump
Discharge amount l / min 155

2
Set pressure MPa {kg/cm } 24.5{250}
Control
Type x no. 8-spool type x 1

Valve
Hydraulic equlpment
Control method Hydraulic assist type

Hydraulic
Motor


Hydraulic cooler Air cooled (CFT-1)
50-8 PC60-7
③
WEIGHT TABLE
These weights are for reference when handling or transporting components.
Unit: kg
PC60-7
Machine model
Blade specification
Engine assembly (excl. water, oil) 382
PTO (coupling) assembly 6
Radiator, oil cooler assembly 31
Revolving frame 638
Operator's cab 260
Operator's seat 20
Fuel tank (excl. fuel) 50
Hydraulic tank (excl. hydraulic oil) 58
Counterweight 685
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Hydraulic pump assembly
7-spool control valve
8-spool control valve (with blade)

57
48
Swing circle assembly 99
Swing machinery assembly 43
Swing motor assembly 22
Center swivel joint 16
Track frame assembly 1,342

· Track frame 735
· Idler 55x2
· Idler cushion 40x2
· Carrier roller 4x2
· Track roller 14x2
· Travel motor 90x2
· Sprocket 25x2
Track shoe assembly

· Standard triple shoe (450 mm) 400x2
· Wide triple shoe (600 mm) 480x2
· Swamp shoe (700 mm) 590x2
· Rubber shoe (450 mm) 366 x 2
PC60-7 50-9
③
Unit: kg
PC60-7
Machine model
Blade specification

Boom assembly 410
Arm assembly 160
Link assembly 55
Bucket assembly 210
Blade assembly 360
Boom cylinder assembly 90
Arm cylinder assembly 72
Bucket cylinder assembly 51
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Blade cylinder assembly 44
50-10 PC60-7
③
TABLE OF OIL AND COOLANT CAPACITIES
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PC60-7 50-11
③
FUEL, OIL
· Select the fuel and oil according to the ambi-

ent temperature as shown in the table.
★ The specified oil capacity indicates the total
amount of oil including the oil in the piping for
each component; the refill capacity indicates
the amount of oil added when the oil is
changed for normal inspection and mainte-
nance.
★ When starting the engine in ambient
temperatures of below 0ºC, even if the dayti-
me temperature rises to 10ºC, always use
SAE10W or SAE 10W-30.
Note1: For hydraulic oil H046-HM, use the oil
recommended by Komatsu.
See the Operation and Maintenance
Manual for details of the procedure for
changing the oil.
Note2: There are two types of automatic greasing
cartridges available: the standard type
(NLGI. No.2) and the cold area type (NLGI.
No.0).
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When changing the automatic greasing
cartridge from the standard type to the
clod area type, or from the cold area type
to the standard type, please see the
Operation and Maintenance Manual.
Note3: If the cold area type grease (NLGI No. 0)
is used in warm areas, some grease will
drip from the ends of the work equipment,
pins, but there is no problem in the
lubricating performance.
ANTI-FREEZE
Komatsu genuine Super Coolant (AF-ACL) is
added at a proportion of 30% to the cooling water,
so there is no need to change the density for
temperatures down to -10ºC.
If the temperature goes below -10ºC, adjust the
density according to the table below.
Below -10ºC -15ºC -20ºC -25ºC

Proportion
of anti-freeze 30% 36% 41% 46%
Proportion
of water 70% 64% 59% 54%
★ Use tap water for the coolant.
50-12 PC60-7
③

WORK EQUIPMENT PIN AUTOMATIC GREASING SYSTEM
(OPT)
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1. Flow divider valve (①,②,③,④,⑤) · Automatic greasing points

2. R.H. work equipment control lever No. Greasing point
(boom RAISE) ① Arm, bucket connecting pin
3. Flow divider valve (⑥,⑦,⑧)
② Arm, link connecting pin
4. Monitor panel
5. Hydraulic pump ③ Bucket cylinder foot pin
6. Grease cartridge ④ Boom, arm connecting pin
7. Controller ⑤ Arm cylinder rod pin
⑥ Arm cylinder foot pin
10. Flow divider valve (⑨) ⑦ Boom cylinder rod pin
⑧ Boom cylinder foot pin
⑨ Boom foot pin
PC60-7 50-13
③
1. SYSTEM DIAGRAM
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50-14 PC60-7
③
2. OPERATION OF SYSTEM
· The automatic greasing system adds the hours · The amount of grease for each work equipment
of operation of the equipment, and every time pin is set according to the load on the pin.
the total reaches 5 hours, it carries out
greasing.
· The boom RAISE oil pressure switch signal is
used to detect operation of the work equipment.
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PC60-7 50-15
③
3. MPONENTS OF SYSTEM
1) Controller
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1. Connector Input/output signals

2. Controller
3. Fuse CN-P44
No. Name of signal Input/output
Specification 1 Power source +24V
Model: LC2MP
2 GND
3 —
4 Abnormality signal Output
r Boom RAISE signal Input
6 Starting switch ON signal Input
50-16 PC60-7
③
2) Electric grease pump
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1. Motor Specification
2. Grease cartridge Model: LD05CP
3. Air bleed plug
4. Pump
5. Pressure switch
6. Connector
PC60-7 50-17
③
Operation
1) Greasing, pressurizing
· When motor (1) rotates in the normal
direction, eccentric shaft (2) rotates counte-
rclockwise and pump piston (4) is operated
in a reciprocal movement by link plate (3).
· During the return stroke (←) of pump piston
(4), the grease inside cartridge (5) is sucked
in, and on the discharge stroke ( ), check
valve (6) is pushed open and the grease is
pushed out to discharge port P.
· Pressure release spool (7) is moved to the
right ( ) by pin (8) of eccentric shaft (2) and
pressure release hook (9). This shuts off
discharge port P and return passage T, so
the pressurized condition is maintained.
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· When the pressure inside the pump rises
and goes above the set pressure, indicator
(10) is pushed to the left (← ), pressure
switch (11) is switched ON, and motor (1)
stops.
· When the pressure goes down again and
pres-sure switch (11) is turned OFF, motor
(1) starts again and the pressurized
condition is maintained.
50-18 PC60-7
③
· If abnormal pressure is generated in the

circuit at discharge port P end, safety valve
(12) opens and releases the pressure to
return circuit T to protect the equipment from
damage.
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2) Release of pressure, waiting for work
· When the greasing is completed, motor (1)
rotates in reverse, and eccentric shaft (2)
rotates clockwise.
· Pressure release spool (7) is moved to the
left ( ) by pin (8) of eccentric shaft (2) and
pressure release hook (9).
· As a result, discharge port P and return circuit
T are interconnected, and the pressure in
the circuit is released to cartridge (5).
· When this happens, pump piston (4) moves
in a reciprocal motion, but the discharged
grease flows to return circuit T, so the
pressure does not rise.
· When the pressure in the circuit drops,
indicator (10) is pushed back, and pressure
switch (11) is turned OFF, motor (1) stops.
If pressure switch (11) is not turned off, the
controller automatically rotates motor (1) in the
opposite direction to release the pressure.
PC60-7 50-19
③
3) Flow divider valve

Type installed to revolving frame
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b. To boom cylinder foot pin⑧
50-20 PC60-7
③
Type installed to boom
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b. To left boom foot pin ⑨
c. To right boom foot pin ⑨
d. To arm cylinder foot pin ⑥
e. To boom cylinder rod end pin ⑦
f. To arm flow divider valve
PC60-7 50-21
③
Type installed to arm
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a. From boom flow divider valve

b. To bucket cylinder foot pin ③
c. To arm, link connecting pin ②
d. To arm, bucket connecting pin ①
e. To boom, arm connecting pin ④
f. To arm cylinder rod end pin ⑤
50-22 PC60-7
③
Structure
A. Discharge port
B. Discharge port
C. Measurement chamber
D. Piston chamber
E. Oil passage
F. Supply port
1. Measurement piston
2. Head
3. Body
4. Spring
5. Spring retainer
6. Pilot piston
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Operation
1) Supply
· When grease from the pump is supplied to
supply port F, the pressure at supply port F
rises and pilot piston (6) is pushed up.
· As a result, oil passage E opens and thegrease
enters piston chamber D of measure-ment
piston (1) from oil passage E.
PC60-7 50-23
③
· Measurement piston (1) is pushed down by the

grease in piston chamber D, and the grease in
measurement chamber C is discharged to the
work equipment pins from discharge ports A
and B.
· At the end of this stroke, pilot piston (6) is
pushed back down by measurement piston (1),
and supply port F and oil passage E are closed.
· In this way, the measurement and discharge
process for one cycle is completed.
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2) Resetting
· When the pump enters the pressure release
mode, measurement piston (1) is pushed back
up by spring (4).
· When this happens, the grease in piston
chamber D passes from oil passage E through
the inside of pilot piston (6), and enters
measurement chamber C to reset the system to
the initial stage in preparation for the next time
of actuation.
50-24 PC60-7
③
3) Boom RAISE oil pressure switch
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1. Plug Specifications
2. Switch Structure of contact : N.O. contact
3. Connector Actuation (ON) pressure :
0.5±0.1 MPa {5.0±1.0 kg/cm2}
Resetting (OFF) pressure :
0.3±0.05 MPa {3.0±0.5 kg/cm2}
PC60-7 50-25
③
ELECTRICAL ALLOCATION DIAGRAM (1 / 2)
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50-26 PC60-7
③
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PC60-7 50-27
③
(1/2)
INSIDE CAB
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50-28 PC60-7
③
1. Front lamp
2. Working lamp
5.Travel speed solenoid valve
6. Swing brake solenoid valve
8. Additional light (Front)
9. Room lamp
10. Additional light (Rear)
11. Starting motor
12. Antenna
13. Glow plug
16. Window washer
18. Alternator
19. Fusible link
20. Battery relay
21. Battery
22. Electric grease pump (OPT)
23. Automatic greasing controller (OPT)
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26. Heater unit
27. Additional light relay
28. Wiper motor
29. Horn
30. Horn switch
31. Speaker
32. Monitor panel
33. Fuel control dial
34. Starting switch
35. Fuse box
36. Swing lock prolix switch
37. Additional light switch
38. Radio
39. Wiper switch
40. Swing lock switch
41. PPC lock limit switch
42. Travel boost switch
43. One-touch slow-down switch
44. Glow resistance
45. Alarm buzzer
46. Swing holding brake controller
PC60-7 50-29
③
ELECTRIC CIRCUIT DIAGRAM

PC60-7 Serial No. 55720 and up for Norway.
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50-30 PC60-7
③
HEATER ER ELECTRIC CIRCUIT DIAGRAM
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PC60-7 50-31
③
MACHINE MONITOR SYSTEM
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Function
· The machine monitor system is a system
that uses sensors installed at various parts
of the machine to observe the condition of
the ma-chine. It then processes this
information and displays it on a panel to
inform the operator of the condition of the
machine.
· The panel display can be broadly divided
into the following:
1. The monitor portion, which issues a
warning when any abnormality is
found in the.
2. The pilot portion, which displays the
operation and the condition of the
machine
3. The gauge portion, which always
displays the condition of the machine
· Switches for electrical attachments are
also installed inside the monitor panel.
50-32 PC60-7
③
1. MONITOR PANEL
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Outline Input/output signals
· The monitor panel has a monitor display CN-P1 (monitor panel)
function and switches for electrical compo- Input/ Input/
nents. output output
Power source Engine oil
· It has a built-in CPU (Central Processing Unit) 1
+24V
- 9
pressure
Input
which processes the data and outputs the Power source
display. 2 - 10 Charge level Input
+24V
· A liquid crystal display is used for the gauge 3 GND - 11
Automatic
Input
display; lamps are used for the monitor greasing
display. 4 GND - 12 Swing lock Input
5 Starting signal Input 13 Preheating Input
Coolant
6 Input 14 - -
temperature
7 Fuel level Input 15 Buzzer Output
8 - - 16 Night lighting Input
CN-P2 (light switch) CN-P3 (heater switch)

Input/ Input/
output output
2 Working lamp Output 2 Heater Hi Output
3 Night lighting Output 3 Heater Lo Output
4 +24V - 4 GND -
PC60-7 50-33
③
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1. Service meter 7. Heater switch (x-1)
2. Coolant temperature gauge 8. Preheating pilot lamp
3. Fuel level gauge 9. Automatic greasing caution lamp (x2)
4. Light switch 10. Swing lock pilot lamp
5. One-touch slow-down pilot lamp 11. Charge caution lamp
6. Fuel control dial 12. Engine oil pressure caution lamp
※ 1: The switch is installed, but it cannot be used.

※ 2: Works only on machines equipped with the automatic greasing system (Option).
50-34 PC60-7
③
STRUCTURE AND FUNCTION TESTING AND ADJUSTING

CONNECTOR TYPES AND MOUNTING LOCATIONS
★ Address column in the table indicates the addresses in the connector location diagram (3D drawinq).
Connector
Connector
Connector
Connector
Address
Address
No. of
No. of
type
type
pins
pins
No.
No.
C1 M 4 Engine starting relay A-3 M12 KES1 3 — —
D1 KES1 2 Diode — M14 L 2 Fusible link Q-5
D2 KES1 2 Diode — M15 L 2 Fusible link Q-5
D8 KES1 2 Diode — M16 1 Horn —
D11 KES1 2 Diode — M17 M 6 Wiper motor, intermediate Q-2
DA1 4 Diode (Solenoid) — M18 M 3 Wiper switch E-2
DA2 Diode (Solenoid) M19 M 2 Wiper switch F-2
4 —
M21 PA 9 Radio E-1
E11 1 Heater relay in P-8
E12 1 Heater relay coil —
M23 1 Speaker A-5
E13 1 Heater relay out —
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M24 1 Speaker A-6
E14 1 Ribbon heater —
FB1 6 Fuse box F-7 M26 M 6 Heater unit P-3
H1 S 16 Intermediate N-1 M27 1 Room lamp Q-9
H2 L 2 Intermediate N-1 M28 KES1 2 Window washer Q-8
H3 S 8 Intermediate N-2 M29 M 2 Speed selection switch (for STD) D-1
K5 X 4 Fuel control motor relay A-4 M30 M 2 Optional power source —
K6 SWP 4 Fuel control motor relay F-6 M31 KES0 4 Wiper motor M-1
K7 SWP 4 Fuel control motor F-7 M32 1 Decceleration switch D-1
K33 2 Deceleration indicator — M33 1 Decceleration switch D-1
K34 2 Deceleration indicator — M34 X 1 — —
K35 M 2 Fuel control motor relay — M35 X 2 — —
K101 — 1 Additional light (Right front) M-9 M37 1 Engine stop solenoid —
K102 — 1 Additional light (Left front) N-9 Travel boost pedal switch (for
M40 1 C-1
K103 Additinoal light (Rear) blade)
— 1 N-9
M1 1 B-terminal of starting motor P-2 Travel boost pedal switch (for
M41 1 C-1
blade)
M2 1 C-terminal of starting motor P-3
M66 — 6 Wiper motor intermediate Q-2
M3 1 Engine stop solenoid Q-8
M67 — 2 Additional light switch F-4
M4 S 16 Intermediate N-2
M68 — 6 Additional light relay P-3
M5 1 R, E-terminal of alternator Q-7 M69 — 1 Additional light intermediate Q-3
M8 1 Light M-1 M75 X 2 Sefty relay (S, R-terminal) P-2
M9 M 1 Working lamp K-9 M76 1 Sefty relay B-terminal —
M10 M 1 Working lamp, intermediate M-9 M78 1 Optional power source —
M11 L 2 Fusible link Q-5 M79 1 Optional power source —
PC60-7 50-35
③
Connector
Connector
Connector
Connector
Address
Address
No. of
No. of
type
type
pins
pins
No.
No.
P1 AMP040 16 Monitor panel A-8 X3 — 1 Swing lock prolix switch F-6
P2 KES1 4 Monitor panel B-8 X4 — 1 Swing lock prolix switch F-6
P3 KES1 4 Monitor panel C-8 X5 M 4 Swing lock switch E-1
P4 M 2 Buzzer K-4 BR — (1) (Battery relay, M-terminal) Q-6
P5 1 Fuel sensor M-9 RB — (1) (Battery relay, B-terminal) Q-6
P6 1 Fuel sensor M-9

P7 X 2 Water temperature sensor P-8
P13 1 Engine oil pressure switch Q-8
P44 SWP 6 Auto-greasing controller (OPT) R-3
S4 X 2 Boom RAISE pressure switch Q-4
S12 — 1 PPC hydraulic lock switch —
S13 — 1 PPC hydraulic lock switch —
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S14 M 2 F-2
intermediate
S15 — 1 Fuel lever limit switch P-8
S18 — 1 Fuel lever limit switch P-8
Tl — 1 Battery relay, B-terminal Q-6
T2 — 1 Ground to revolving frame Q-6
T4 — 1 Alternator, B-terminal Q-8
T5 — 1 Ground to cab P-9
T6 — 1 Starting switch (B) C-8
T7 — 1 Starting switch (BR) C-8
T8 — 1 Starting switch (ACC) C-8
T9 — 1 Starting switch (C) C-8
T10 — 1 Starting switch (R1) C-8
T16 — 1 Battery relay, BR-terminal Q-6
T17 — 1 Battery relay, M-terminal Q-6
T18 1 Battery relay, E-terminal Q-7
V1 X 2 PPC hydraulic lock solenoid Q-9
V3 X 2 Mode selection solenoid O-9
V4 X 2 Swing holding brake solenoid O-9
V5 X 2 Speed selection solenoid O-9
50-36 PC60-7
③
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PC60-7 50-37
③
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50-38 PC60-7
③
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PC60-7 50-39
③
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50-40
TROUBLESHOOTING
TROUBLESHOOTING OF MACHINE MONITOR

SYSTEM (M MODE)
Electric circuit diagram of the machine monitor system.........................................................................20-40

(3-second self-check is not carried out either)...................................................................... 20-41
M-2 All the lamps remain lighting-up after 3-second self-check completed after
the starting switch turned ON................................................................................................ 20-41
M-3 Some lamps do not light up during self-check (all lamps lights up for 3 seconds)
upon starting switch ON ........................................................................................................20-42
a) All gauge lamps do not light up (caution lamp does light up)........................................... 20-42
b) Swing lock, auto-greasing failure or preheat does not light up
(all gauge lamps light up).................................................................................................. 20-42
c) Charge caution lamp does not light up ........................................................................... 20-42
d) Engine oil pressure caution lamp does not light up.......................................................... 20-42
M-4 When turning ON the power (before engine starting), charge caution lamp
does not light up.................................................................................................................... 20-43
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M-5 When turning ON the power (before engine starting), engine oil pressure
caution lamp does not light up. ............................................................................................. 20-43
M-6 At preheating, preheating indicator does not light up .......................................................... 20-44
M-7 Though the switch is operated, swing lock does not light up ...............................................20-44
(engine oil pressure is normal).............................................................................................. 20-45
M-9 Charge caution lamp lights up while engine running ........................................................... 20-45
M-10 Abnormality in engine water temperature gauge ................................................................20-46
a) Indicator remains in the lowest level (white range) and does not rise
after engine started. ..........................................................................................................20-46
b) Level rises immediately after starting the engine.
Indicator goes in the red range though overheat does not occur..................................... 20-46
c) Engine water temperature gauge lamp goes off............................................................... 20-46
M-11 Abnormality in fuel gauge ..................................................................................................... 20-47
a) All segments of the fuel gauge go off ............................................................................... 20-47
b) Fuel gauge indicates FULL though the level is low .......................................................... 20-47
c) Fuel gauge does not indicate FULL though the tank is full ..............................................20-47
M-12 Malfunction of the buzzer...................................................................................................... 20-49
a) Buzzer does not sound ..................................................................................................... 20-49
b) Buzzer does not stop sounding ........................................................................................20-49
M-13 Service meter does not work while the engine is running .................................................... 20-50
a) When the charge caution lamp does not light up ............................................................. 20-50
b) When the charge caution lamp lights up, refer to the item M-9........................................ 20-50
M-14 Auto-greasing abnormality alarm lights up (Auto-greasing controller is normal) ................. 20-50
M-15 Illumination does not light up ................................................................................................ 20-51
a) Illumination at gauge section does not light up. ............................................................... 20-51
(Service meter itself do work normally)............................................................................. 20-51
PC60-7 50-41
③
ELECTRIC CIRCUIT DIAGRAM OF THE MACHINE MONITOR

SYSTEM
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50-42 PC60-7
③
TROUBLESHOOTING M-1,M-2

(3-second self-check is not carried out either)
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M-2 All the lamps remain lighting-up after 3-second self-check com-
pleted after the starting switch turned ON
PC60-7 50-43
③
TROUBLESHOOTING M-3
M-3 Some lamps do not light up during self-check (all lamps lights up3
seconds) upon starting switch ON
a) All gauge lamps do not light up

(caution lamp does light up)
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50-44 PC60-7
③
M-4 When turning ON the power (before engine starting), charge caution
lamp does not light up
★ Before carrying out this troubleshooting, check for
engagement failure at relating connectors.
★ Before proceeding to the next step, make sure to
restore removed connectors.
★ Check for the breaking wire in the bulb (lamp) before
this troubleshooting.
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M-5 When turning ON the power (before engine starting), engine oil
pressure caution lamp does not light up.
★ Before carrying out this troubleshooting, check
for engagement failure at relating connectors.
★ Before proceeding to the next step, make sure
to restore removed connectors.
★ Check for the breaking wire in the bulb (lamp)
before this troubleshooting.
PC60-7 50-45
③
M-6 At preheating, preheating indicator does not light up

★ Before carrying out this troubleshooting, check for engage-
ment failure at relating connectors.
removed connectors.
★ If the lamp does not light up also during the self-check upon
power ON, refer to M-2.
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Though the switch is operated, swing lock does not light up
removed connectors.
50-46 PC60-7
③
M-8 While engine running, engine oil pressure caution lamp lights
up(engine oil pressure is normal)
★ Before carrying out this troubleshooting, check for engage-
ment failure at relating connectors.
removed connectors.
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M-9 Charge caution lamp lights up while engine running
removed connectors.
PC60-7 50-47
③
M-10 Abnormality in engine water temperature gauge

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50-48 PC60-7
③
M-11 Abnormality in fuel gauge

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PC60-7 50-49
③
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50-50 PC60-7
③
M-12 Malfunction of the buzzer

a) Buzzer does not sound
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b) Buzzer does not stop sounding
M12 Related electrical circuit diagram
PC60-7 50-51
③
M-13 Service meter does not work while the engine is running
removed connectors.
a) When the charge caution lamp does not light up
b) When the charge caution lamp fights up, refer to the item M-9.
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M-14 Auto-greasing abnormality alarm lights up (Auto-greasing control-
ler is normal)
removed connectors.
50-52 PC60-7
③
M-15 Illumination does not light up

a) Illumination at gauge section does not light up.
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(Service meter itself do work normally)
PC60-7 50-53
③
TROUBLESHOOTING AUTO-GREASING CONTROLLER
AUTO-GREASING PUMP

CONTROLLER ASSEMBLY (OPT)
2. Disconnect 3 wiring connectors (1).

★ Fit tags to mark the male and female
ends of the connectors to prevent
mistakes when connecting.
3. Remove 2 mounting bolts, then remove

INSTALLATION OF
AUTO-GREASING
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CONTROLLER ASSEMBLY (OPT)
· Carry out installation in the reverse order to
removal.
PUMP ASSEMBLY (OPT)
1． Open engine hood.
2． Remove 2 wiring connectors (1), and

disconnect hose (2). ※ 1
3． Remove 2 mounting bolts, then remove pump

assembly (3).
INSTALLATION OF
AUTO-GREASING PUMP
ASSEMBLY(OPT)
· Carry out installation in the reverse order to
removal.
※ 1
★ Bleeding air inside circuit
For details, see Bleeding air from auto-
greasing device.
50-54 PC60-7
③
OTHERS
90 OTHERS
Hydraulic piping drawing................................90- 3

Hydraulic circuit diagram ...............................90- 5
Overall system diagram (1/5) ........................90- 7
Overall system diagram (2/5) ........................90- 9
Overall system diagram (3/5) ........................ 90-11
Electrical allocation diagram.......................... 90-17
Electric circuit diagram
Serial No. : 52374 – 57999 ....................... 90-19
Serial No. :58001 and up .......................... 90-21
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Electric circuit diagram
(PC60-7 Serial No. 55720 and up
for Norway)................................................ 90-23
Connector types and mounting locations ....90-201
PC60-7 90-1
④
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OTHERS HYDRAULIC PIPING DRAWING

★ The sketch shows the blade specification machine
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Hydraulic tank
6. R.H.travel motor
7. Hydraulic pump
8. Control valve
9. Oil cooler
10. L.H.travel motor
11. L.H.work equipment PPC valve
12. R.H.work equipment PPC valve
15. Blade cylinder
17. Swing lock solenoid valve
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E20107
90-3
Serial No.:52374-57999
1. Hydraulic tank
2. Hydraulic filter
3. Strainer
4. Breather
5. Hydraulic pump
6. Control valve
6A. Safety valve
6B. Main relief valve
6C. Unload valve
6D. LS select valve
6E. Pressure compensation valve
6F. Swing spool
6G. Pressure compensation valve
6H. L.H.travel spool
6I. R.H.travel spool
6J. Pressure compensation valve
6K. Boom spool
6L. Arm spool
6M. Bucket spool
6N. Blade spool
7. Self-pressure reducing valve
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8. Boom cylinder
9. Arm cylinder
10. Bucket cylinder
11. Blade cylinder
13. Travel motor(L.H.)
14. Travel motor(R.H.)
15. Swing motor
16. R.H.PPC valve
17. L.H.PPC valve
19. PPC shuttle valve
20. Solenoid valve
21. Oil cooler
PC60-7 90-5
③
STANDARD SPECIFICATION
Serial No.:58001and up
SOLENOID VALVE
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LS PRESSURE
DETECTION
CAP
SAFETY VALVE
SETTING PRESSVRE
0.038±0.015MPa
{0.39±0.15kg/cm2}
CHECK VALVE
CRACKING PRESSVRE
0.-0.0045MPa
{0-0.046kg/cm2}
PC60-7 90-5-2
③
STANDARD SPECIFICATION PUMP PRESSURE
Serial No.:58001and up DETECTION PORT
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LS PRESSURE
DETECTION
CAP
SAFETY VALVE
SETTING PRESSVRE
0.038±0.015MPa
{0.39±0.15kg/cm2}
CHECK VALVE
CRACKING PRESSVRE
0.-0.0045MPa
{0-0.046kg/cm2}
PC60-7 90-5-4
③
OTHERS OVERALL SYSTEM DIAGRAM
OVERALL SYSTEM DIAGRAM(1/5)

WHEN ALL CONTROL VALVES ARE AT HOLD
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E20107
90-7

WHEN SWING IS OPERATED INDEPENDENTLY
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E20107
90-9

WHEN LEFT AND RIGHT TRAVEL ARE OPERATED AT SAME TIME
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E20107
90-11

WHEN BOOM + ARM ARE OPERATED AT SAME TIME
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E20107
90-13

WHEN BOOM RAISE + SWING ARE OPERATED AT SAME TIME
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E20107
90-15
OTHERS ELECTRICAL ALLOCATION DIAGRAM
ELECTRICAL ALLOCATION DIAGRAM
19. Front lamp

20. Working lamp
24. Swing speed solenoid valve
26. Room lamp
27. Antenna
30. Glow plug
31. Starting motor
32. Window washer
34. Air conditioner compressor (option)
35. Alternator
36. Battery relay
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37. Fusible link
38. Battery
40. Automatic greasing controller
E20107
41. Boom RAISF oil pressure switch

43. Air conditioner unit
44. Wiper motor
45. Horn
90-17
ELECTLIC CIRCUIT DIAGRAM
Serial No.:52374-57999
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PC60-7 90-19
③
Serial No.:58001 and up
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PC60-7 90-21
③
PC60-7 Serial No.:55720 and up for Norway
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PC60-7 90-23
③
OTHERS CONNECTOR TYPES AND MOUNTING LOCATLONS
CONNECTOR TYPES AND MOUNTING LOCATLONS

Serial No.:52374-57999
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PC60-7 90-201
③
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SHOP MANUAL
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PC60-7
© 2002
All Rights Reserved
9 Printed in P. R. China 06-03

PC60-7 Shop Manual (WM)

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PC60-7 Shop Manual (WM)

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YEBM200600

• This shop manual may contain attachments and optional

• PC60-7 mount the 4D102-1 and 4D95LE-2 engine.

MACHINE MODEL SERIAL NUMBER

• PC60-7 mount the 4D102-1 and 4D95LE-2 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

50 OTHER SPECIFICATION ............................................................................................ 50-1

Pages having no marks are those previously

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark (①②

Chassis volume: Issued for every machine model REVISIONS

These various volumes are designed to avoid SYMBOLS

DISTRIBUTION AND UPDATING

FILING METHOD Special technical precau-

3. Additional pages: Additional pages are indicated

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release Type 1

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it

2) After inserting the hose in the mating adapter

x Used to prevent rubber gaskets,

Holtz x Used as heat-resisting sealant for

x Quick hardening type adhesive

x Ftures: Silicon based, quick hard-

Three bond x Used as heat-resisting sealant for

x Used as lubricant for sliding por-

STANDARD TIGHTENING TORQUET

Thread diameter of bolt Width across flats

Thread diameter of bolt Width across flats

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Thread diameter Tightening torque

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Thread diameter Tightening torque

ELECTRIC WIRE CODE

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting