‘SEBM020B0303 SIO IMCA\INTOAL La KOMATSU PW60-3 MACHINE MODEL SERIAL No. PW60-3 2001 and up10 20 40 60 70 80 CONTENTS ENGINE 11 STRUCTURE AND FUNCTION 12. TESTING AND ADJUSTING 13 DISASSEMBLY AND ASSEMBLY POWER TRAIN 21 STRUCTURE AND FUNCTION 22 TESTING AND ADJUSTING 23 DISASSEMBLY AND ASSEMBLY 24 MAINTENANCE STANDARD STEERING AND BRAKE SYSTEM 41 STRUCTURE AND FUNCTION 42. TESTING AND ADJUSTING 43 DISASSEMBLY AND ASSEMBLY 44 MAINTENANCE STANDARD. HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION . 62 TESTING AND ADJUSTING 63 DISASSEMBLY AND ASSEMBLY 64 MAINTENANCE STANDARD ‘WORK EQUIPMENT 71 STRUCTURE AND FUNCTION 73 DISASSEMBLY AND ASSEMBLY 74 MAINTENANCE STANDARD ELECTRICAL SYSTEM 81 STRUCTURE AND FUNCTION 82 TESTING AND ADJUSTING No. of page Pweo-3 214 22-1 23-1 24-1 att 42-1 43-1 44-1 61-1 62-1 63-1 64-1 MA 73-1 74-1The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below. vis | inteaion Jaton equied © |e tobenemiy wed | aa e to be replaced Replace Po tote ote vce Pages having no marks are those previously revised or ‘made additions LIST OF REVISED PAGES work pase Teme | ata wage TENT ark page Temeot| ata rape THTeot Lark Page Time of + 01 3 a1 8 a4 292 ne? 2 2 2 8 28 2282 + oa 8 3 2 a6 ar 4 2082 + 22 3 wee a? a2 4 na? + 2a 3 ws 8 a8 228 2 0: 3 we 8 a9 ar 2 m2 2 0. 4 m7 8 2110 a2 2 0. 5 we 2 aut ma 2 zt 0. 6 m9 8 ma na 2 22 0-7 1102 aaa as 2 243 o0- 8 ie aia ne 2 24 o0- 9 2 avis a7 2 268 ov-10 ne 2 aise me 2 24-6 ee aa mo 2 27 is 2 asa mio 2 24-8 ne ie 2 ais9 mi 2 12 war 2 2120 ie at 13 wre 2 aa nasa 2 a2 wa 92 ne na 2 ana ns na 2 an zis? ane we? 228 nie 2 ans. a) na 2 225 ni 2 ane 2204 13082 2126 mia 2 a7 ws 4 ava nig 2 ane wat 2128 na 2 “0 Rs 4 at 2129 na 2 4110 ze 4 a2 21.00 na 2 aut we a3 aa nase aua2 Pweo-3, 00-2-1 owork Pane EMH T ack pose TM" mark rane TMNT tak pose TEMES tank wage Timect anas ait waa eras e220 anne a2 0 |e as 8 6138 e2 | ans as) |e we 8 e136 e228 an0 aa a7 e137 e2 | aur as | ae e130 e220 | ne ae ane e140 6231 ane erat e222 s120 Br 2 ont ei4e e220 ea a2 sa eras 638 ee aa 2 o3 eras 2 a3 ee og ona 6148 ee a2 a re e146 e237 128 sae 9 |e ore 2 evar e298 4128 e738 on? e143 es 27 an oe e430 a128 1a 4 ere er wa 129 ae 2 6110 2 | sea 120 ae 2 enti ea sat + a0 8 era ea er oo en 3 foe an 8 eis ea 2 4 sn 3 |e ae ersa as 1 2 2 ayoa1 3 12 ors er ee 2 a2 2 |e aw 3 erie a8 es 2 eae 3 |e as evr es) 6 2 ower 2 |e ats 3 ere eo a7 2 a9 sa 3 er18 en ee 2 ana +9 6120 er wo 2 aa er) erat eis 12 saga 2002 oz ew ene ee wae ev23 es our? aa san 3 orze ere en 2 ava san 4 e128 wr eae ea wa e126 ee ens 2 Saat 3 a2? evar s ew 2 ana a2 6128 6220 ea? a2 6129 e221 es 2 6120 a2 | e192 at erat 23 e207 ane oa em ear ans e139 es 2 2 002-2 Pwe60-3Time of Mork Pose Timect | stark Pape Time of Time of Mark Page Lo Mark Page Mark Page 22 ar 4 em 2 2.2 eas 2 eo 4 aa 1 as 1 Pet ereree) na na at 13.2 133 m4 2 76 726 ma. m2 ma m4 aa a Pweo-3 0-2-3 5A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- Quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols A and “4 cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. are used to mark safety pre- A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual carefully BEFORE operating the machine 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. « Always wear safety glasses when hitting parts with a hammer. «Always wear safety glasses when grinding parts with a grinder, etc 3.f welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep alll tools in good condition and learn the correct way to use them. 6 Decide a place in the repair workshop to keep tools and removed parts. Always keep, the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for ‘smoking. Never smoke while working, PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders ‘or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned, Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first 14.When raising heavy components, use 2 hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil ‘on the floor can cause you to slip, or can even start fires 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19, Be sure to assemble all parts again in their original places Replace any damaged parts with new parts. + When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits, Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the trackFOREWORD. This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or ‘assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD. This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows Chassis volum Engine volume: Issued for every machine mode! Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume ‘These various volumes are designed to avoid du- plicating the seme information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready DISTRIBUTION AND UPDATING Any adgitions, amendments or other changes will be sent to KOMATSU distributers, Get the most up- to-date information before you start any work FILING METHOD 1. See the page number on the bottom of the page File the pages in correct order. 2. Following examples show how to read the page number Example 1 (Chassis volume}: 21-3 Unit number (2. Power train) Item number (1. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume) 42-410 Unit number (1. Engine) Item nurnber 2. Testing and Adjusting! Group No. (4. Fuel system) Consecutive page No. Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen () and number after the page number. File as in the example. 00-6 REVISED EDITION MARK (@@ 2: When a manual is revised, an edition mark is recorded on the bottom outside comer of the pages. REVISIONS Rovised pages ate shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are ‘marked with the following symbols. Symbol | Item Remarks ———J Safety Special soety precautions are A hevessary when performing the fork Extra special safety precautions “a are necessary when performing, * the work because itis under internal pressure. Special technical precautions or other precautions for Ke | Caution | preserving standards are necessary when performing the work Weight of parts or systems . Coton necascorr when . Oil cooler installation face: Liquid gasket (LG-7) 2. Installoil filter (1). (See Pa) >. Oilfilter seat face: Grease G2-LI REMOVAL OF FAN AND FAN PULLEY ASSEMBLY Remove the fan guard. Loosen mounting bolt (1), the mount bolt, and nut (2) of the adjustment plate, then remove the fan belt. (See PS, P6) 3. Remove the mounting bolt, then remove fan and fan pulley (3). (See P6) vo INSTALLATION OF FAN AND FAN PULLEY ASSEMBLY 1. Install fan and pulley (3) with bolts. (See P6) 2. Fit fan belt in pulley groove. (See PS) Adjust the fan belt tension. For details, see 12 TESTING AND ADJUST- ING, Adjusting fan belt tension. 3. Install the fan guard. Pweo-3PW60-3 13-3REMOVAL OF FUEL INJECTION PUMP ASSEMBLY Remove step and disconnect intake hose (1) (See P1) Disconnect fuel control rod (2). (See P2) Disconnect fuel injection pipe (3). (See P2) Disconnect fuel hose (4). (See P3) Disconnect fuel hose (6). (See P3) Disconnect lubrication tube (6). (See P3) Remove bracket (7). (See P4) Remove mounting bolts and nuts, then remove fuel injection pump assembly (8). (See PS) exes aen INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY % Turn the crankshaft in the normal direction and align the “1.4” mark on the crankshaft with the pointer. At this time, if there is no match mark on the pump drive gear, turn the crankshaft one more revolution 1. Fix the drive gear with a bolt (Thread dia, = 8 mm, Pitch = 1.0 mm, Length = 35 mm) 2. Fit an O-ring, then install fuel injection pump as- sembly (8), (See P5) % Insert a pin (0.D.: 45 mm! into the hole for confirming the fuel injection timing, and con- firm that the pin fits smoothly into the nail plate hole. 3. Install bracket (7), (See P4) 4, Fit gasket and connect lubrication tube (6). (See P3) 5. Fitgasket and connect fuel hose (6), (4). (See PS) 6. Connect fuel injection pipe (3). (See P2) FEE) Sleeve nut 23 + 0.2 kgm 7. Connect fuel control rod (2). (See P2) + Bend the cotter pin securely. 8. Connect intake hose (1) and install step. (See P1) ‘%* Refer to TESTING AN ADJUSTING and confirm the fuel injection timing. 13-4 REMOVAL OF WATER PUMP ASSEMBLY 1. Loosen drain valve and drain the cooling water. Be careful not to loosen the drain valve too much, Otherwise, the drain vaive will get out of place. ‘+ If the coolant contains antifreeze, dispose of it carefully 2. Disconnect radiator inlet hose (1). (See P6) 3. Remove fan and fan puley. For details, see 13 REMOVAL OF FAN AND FAN PULLEY. 4. Disconnect water temperature gauge wiring (2) (See P7) 5. Disconnect heater hose (3). (See P7} 6. Disconnect radiator outlet hose (4). See P7) 7. Remove water pump assembly (5). (See P8) INSTALLATION OF WATER PUMP ASSEMBLY 1. Fita gasket and O-ring, set water pump assembly (6) in its mounting position, then tighten the bolts. (See P8) 2. Connect radiator outlet hose (4). (See P7) 3. Connect heater hose (3), then connect water temperature sensor wiring (2). (‘See P7) 4, Install the fan and fan pulley, For details, see 13 INSTALLATION OF FAN AND FAN PULLEY. 5. Install radiator inlet hose (1). (See P6) 6. Tighten the radiator drain vaive, then add water through the filler to the specified level + Start the engine to circulate the water through the piping, then check the water level again Pweo-3Pw60-3 13-5 2REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. Remove step (1). (See P1) 2. Disconnect fuel injection tube (2) from nozzle holder assembly. (See P1) 3. Disconnect spill hose (3), (See P2) 4, Remove nozzle holder assemly (4). (See P3) + After removing the nozzle holder, put a blind plug into the holder mounting hole to prevent the entry of foreign matter. INSTALLATION OF NOZZLE HOLDER ASSEMBLY Make sure that thore is no dust or foreign matter on the nozzle holder assembly mounting surface. 1. Fit gasket and install nozzle holder assembly (4). (See P3) 3} Mounting bolt: 4.5 + 0.5 kgm 2. Connect spill hose (3). (See P2) 3. Connect fuel injection pipe (2). (See P1) GED Sleeve nut: 2.25 + 0.25 kgm 4. Install step (1). (See P1) 13-6 Pweo-3Pweo-3REMOVAL OF CYLINDER HEAD ASSEMBLY 1. Water pump assembly Remove water pump assembly. For details, see 13 REMOVAL OF WATER PUMP ASSEMBLY. 2. Fuel filter assembly Remove fuel filter assembly (1) from cylinder head. (See P1) 3. Air cleaner hose and wiring 1) Disconnect air cleaner hose (2). (See P1) 2) Disconnect electrical intake air heater wiring (3). (See P2) 4. Fuel injection tube Disconnect fuel injection tube (4). (See P1) 5. Spill hose Disconnect spill hose. 6. Nozzle holder assembly Remove clamp (6), then remove nozzie holder as- sembly (6). (See P3) 7. Mutfler assembly 1) Disconnect drain tube (7), (See Pa) 2) Remove muffler assembly from exhaust manifold, 8. Cylinder head cover Remove cylinder head cover. 9. Rocker arm assembly 1) Loosen locknut, then turn back adjustment screw 2 or 3 turns. 2} Remove rocker arm assembly (8). (See PS) 10. Push rod Remove push rod (9). (See P6) 11. Cylinder head assembly Remove cylinder head mounting bolts, then litt, off cylinder head assembly (10). (See P7) kg) Cylinder head assembly: 28 kg Pweo-3Pwe0-3. 13-9INSTALLATION OF CYLINDER HEAD ASSEMBLY 4. Adjustment of valve clearance + Adjust the clearance between the valve and rocker arm to the following values using tool Special toot ene penne; Part Marne oy Intoke valve Exhaust valve ‘A| 785-100-1370 | Fesler gauge 1 Dae am som When cola 1. Cylinder head assembly 1) Check that cylinder head mounting surtace and inside of cylinder are free from dust + For details of adjusting valve clearance, see Install head gasket on cylinder head. 12 TESTING AND ADJUSTING VALVE + Install gasket with TOP mark facing up. CLEARANCE. 2) Raise cylinder head assembly (101, align 5. Cylinder head cover with dowel pin, and install. (See P1) Fit O-ring on cylinder head cover, then position 3) Tighten cylinder head mounting bolts. (See con cylinder block. Ft) =] Mounting nut: 1.05 + 0.15 kgm 7s Mounting bott ‘Anti-friction compound LM-P) 6. Muffler assembly 1). Fit gasket and install muffler assembly to the =) ne ‘exhaust manifold. = Cynder head ae 2) Connect drain tube (7). (See P5) ore 7. Nozzle holder assembly a | % Moke sure that there is no dust or foreign tan matter on nozzle holder assembly mounting Taser Ch Pyare] Fit gasket and install nozzle holder assembly (6), Install push rod (9). ‘See P2) then install clamp (6) (See P6) 32 Clamp mounting bolt: 4.5 + 0.5 kgm 8. Spill hose Connect spill hose. 9. Fuel injection tube Connect fuel injection tube (4). (See P8) GED Sleeve nut: 2.3 + 0.2 kgm 10. Wiring and air cleaner hose 1) Connect electrical intake air heater wiring (3). (See P7) 2) Connect air cleaner hose (2). (See P8) 3. Rocker arm assembly 1) Align rocker arm assembly (8) with stud bolt 44, Fuel filter assembly and position. (See P3) Install fuel filter assembly (1) to cylinder head. 2). Check that ball of adjustment serew is fitted (See P8) in push rod, then tighten nuts and bolts. GI Mounting bolts: 2.5 * 05 kom 12. Water pump assemby 13-10 2 Install water pump assembly. For details, see 13 INSTALLATION OF WATER PUMP ASSEMBLY. Pweo-3PW60-3 13-11 2REMOVAL OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 1. Loosen the radiator drain vaive and drain the coolant. ‘If the coolant contains antifreeze, dispose of it carefully. 2. Disconnect radiator inlet hose (1). (See P1) 3. Disconnect sub-tank hose (2). (See P1) 4. Disconnect intake hose (3). (See P1) 5. Disconnect radiator outlet hose (4). (See P2) 6. Disconnect oil cooler inlet hose (5). (See P3) 7. Disconnect oil cooler outlet hose (6) (See P4) 8. Sling radiator and oil cooler assembly (7), then remove, (See P5) [ie") Radiator and oll cooler assembly: 45 kg INSTALLATION OF RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY 1. Sling radiator and oil cooler assembly (7), then install. (See P5) 2. Connect oil cooler outlet hose (6). (See P4) 3. Connect oil cooler inlet hose (5). (See P3) 4. Connect radiator outlet hose (4). (See P2) 5. Connect intake hose (3). (See P1) 6. Connect sub-tank hose (2). (See P1) 7. Connect radiator inlet hose (1). (See P1) 8. Tighten the radiator drain valve, then add water through the filler to the specified level * Start the engine to circulate the water through the piping, then check the water level again. + Check the hydraulic oil level at the same time. 13-12 Pwe0-3 2Pweo-3 13-13 2REMOVAL OF ENGINE AND HYDRAULIC PUMP ASSEMBLY “AM Lower work equipment to the ground. After stop- ping engine, operate work equipment contro! lever several times to release the pressure re- raining in piping. Then, slowly loosen hydraulic tank filler cap to relieve the internal pressure from hydraulic tank. Bi disconnect the tead from the negative ( terminal ofthe battery Draining water 1) Loosen drain valve and drain the cooling water % Be careful not to loosen the drain valve too much. Otherwise, the drain valve will get out of place. % If the coolant contains antifreeze, dispose of it carefully 2. Hydraulic oil drain Remove the drain plug to drain the oil from the tank. eee Hydraulic oil: approx 88 & 3. Radiator inlet hose Remove radiator inlet hose (1). (See P1) 4. Fanpulley Remove fan pulley assembly. For details, see REMOVAL OF FAN PULLEY ASSEMBLY. 5. Heater hose, spill hose Disconnect heater hose (2) and spill hose (3) (See P2) 6. Water temperature sensor wiring Disconnect water temperature sensor wiring (4) (See P2) 7. Radiator outlet hose Disconnect radiator oulet hose (6). ‘See P2) 8. Intake hose Disconnect intake hose (6). (See P2) 9. Alternator 1) Disconnect wiring (7). (See P3) 2) Remove adjustment plate (8). (See P3) 10. Vacuum pump piping Disconnect piping (9). (See P32) 13-14 2 11, Steering pump piping 1) Disconnect outlet hose (10). (See P4) 2) Remove inlet hose (11). (See P4] 12. Tachometer cable Disconnect tachometer cable (12). (See P5) 13, Fuel hose Disconnect fuel hose (13), (See PS) + Fitblind plug because the fuel will gush out. 14, Fuel connect cable Disconnect fuel control cable (14). (See P6) 16, Intake air heater wiring Disconnect wiring (16). (See P6) il temperature sensor wiring Disconnect oil temperature sensor wiring (16) (See P7) 17. Pump piping Disconnect the pump piping and hose from the pump assembly. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY. Pweo-3PW60-3 13-15 2Disconnect ground wiring (17). (See P1) 19, Rear mounting bolt Remove mounting bolts (18). (See P1) 20. Front mounting bolt Remove mounting bolt 19). (See P2) 21. Sling engine and hydraulic pump assembly (20) horizontally and dismount it by gradually lifting it (See P3) [ks] Engine and hydraulic pump assembly 450 kg ‘When raising the engine and main pump as- sembly, be careful of the position of the center of gravity, and check that all wiring ‘and piping has been removed before starting 13-16 Pweo-3 213-17, Pweo-3INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY 1. Engine assembly Sling engine assembly (20) into position, attach 2 cushion, align with the mounting bolts, then lower the engine (See P1) 2. Front mounting bolt Tighten mounting bolts (19). (See P2) <== Mounting bolt: 28.5 + 30 kgm 3. Rear mounting bolts Tighten mounting bolts (18). (See P3) 4. Engine ground Connect ground wiring (17). (See P3) 5. Pump piping Connect the pump piping to the pump assembly. For details, see INSTALLATION OF HYDRAULIC PUMP ASSEMBLY. 6. Oil temperature sensor wiring Connect oil temperature sensor wiring (16), (See Pa} 13-18 7. Intake air heater wiring Connect intake air heater wiring (15). (See P5) 8. Fuel control cable Connect fuel control cable (14). (See P6) ‘Bend the cotter pin securely 9. Fuel hose Connect fuel hose (13). (See P6) 10. Tachometer cable Connect tachometer cable (12). (See P6) 11. Steering pump piping 1) Fit O-ring, then install inlet hose (11). (See P7) 2) Connect outlet hose (10). (See P7) 12. Vacuum pump piping Fit gasket, then instal piping (9), (See P7) 13, Alternator 1) install adjustment plate (8). (See P8) 2) Connect wiring (7). (See P8) Pweo-3Pt Ey earl Pweo-3 13-1914. Intake hose Connect intake hose (6). (See P1) 15. Radiator outlet hose Connect radiator outiet hose (6). (See P1) 16. Water temperature sensor wiring Connect water temperature sensor wiring (4). (See Pt) 17. Heater hose, spill hose Connect spill hose (3) and heater hose (2). (See Pa) 18. Fan pulley assembly Install fan pulley assembly. For details, see INSTALLATION OF FAN PULLEY ASSEMBLY. 19, Radiator inlet hose Install radiator inlet hose (1). (See P1) 20. Add oil Tighten the tank drain plug and add oil through the filler. 21. Add oil Tighten the radiator drain valve and add water through filer to the specified level * Start the engine to circulate the cooling water and oil through the piping, then check the levels again. Hydraulic oll tank: 88 & 22. Connect the lead to the negative (—) terminal of battery. 13-20 2 Pweo-3Pw60-3 13-21 2REMOVAL OF PTO ASSEMBLY 1. Remove the main pump assembry. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY. 2. Remove drain plug then drain oil from PTO case. 3. Remove muffer (1) together with the bracket. (See P1) 4. Screw eyeboit 1) (Thread dia. = 12 mm, Pitch = 1.75 mm) into the main pump installation hole ‘and remove PTO assembly (2). (See P2) INSTALLATION OF PTO ASSEMBLY 1. Using eyebolt 1) (Thread dia, = 12 mm, Pitch 1.75 mm, install PTO assembly (2). (See F1 2) >. PTO case mounting face: Liquid gasket (LG-8) 7 Apply thread tightener to mounting bolts marked = 2. Add engine oil through oil filler of the PTO case, remove level plug, and add oil until ol flows out, of the level hole, (al PTO case: approx.0.9 3. Fit @ gasket and install muffler assembly (1) together with the bracket. (See P1) 4. Install the main pump assembly For details, see INSTALLATION OF HYDRAULIC PUMP ASSEMBLY. 13-22 DISASSEMBLY OF PTO ASSEMLY 1, Remove snap ring (1), then remove shaft and bearing assembly (2), (See P3, F2) 2. Remove snap ring (3), receive the inner race of bearing (4), then push out shaft (5) with a press. (See F3) ASSEMBLY OF PTO ASSEMBLY 1. Press fit bearing (4) into shaft (6), then install snap ring (3). (See P3) ‘+ Install the bearing seal so that the seal faces the engine. (So that it faces the opposite) 2. Assemble shaft-bearing assembly (2) to case (6), then install snap ring (1). (See F2, P3) Pweo-313-23 Pweo-3POWER TRAIN 21 STRUCTURE AND FUNCTION Pwe0.3 Power train Travel system Schematic of power train Hydraulic circuit diagram Travel motor Center swivel joint Transmission Solenoid valve for forward-reverse selection Forward-reverse selector lever Travel PPC valve High-low speed selection contro! Swing system. Schematic of swing system Hydraulic circuit diagram ‘Swing motor and brake valve assembly Swing mechanical brake Swing machinery Swing circle 21 21 20 21 21-6 4 2145 2147 21418 21419 21.20 2121 - 2122 21.23 21.24 21.29 2131 21-82 21-1POWER TRAIN OUTLINE The mechanical motive force from engine (1) is convert: ed to hydraulic motive force by hydraulic pumps (4), (5) and (6) This hydraulic motive force is divided by the two control valves (2) and (3) and is sent to swing motor (71, travel motor (11), and the hydraulic cylinders, where it is again converted to mechanical motive force. ‘The swing motor is a 1-pump circuit, and the travel motor is a 2-pump merged circuit, ‘When travel PPC valve (12) is operated, the hydraulic motive force from charging pump (6) acts on the travel control valve to cerry out hydraulic assist 21-2 Engine LH. Sspool control valve R.H. 5:spoo! control valve Front main pump Rear main pump Charging pump ‘Swing motor Center swivel joint Transmission Solenoid valve Travel motor ‘Travel PPC valve Swing machinery Swing circle Front wheel Front axle Rear axle Rear wheel Pw60.3TRAVEL SYSTEM 1. Front whee! 9. LH. 5-spo0! control valve 2. Front axle 10. R.H. 5-sp00! control valve 3, Front drive shaft 11. Oil cooler 4, Travel motor 12, Rear axle 5. Transmission 13. Rear whee! 6. Center swivel joint 14. Solenoid valve 7. Hydraulic tank 18, Rear drive shaft 8. Hydraulic pump 16. Travel PPC valve Pweo-3 21-3SCHEMATIC OF POWER TRAIN 1, Travel PPC valve 12. LH. spool control valve 2, Solenoid valve 12s, Main relief valve 3. Engine 12. Travel control valve 4, Front main pump 13. RL. S-spoo! control valve 5, Rear main pump 1a, Main relief valve 6. Charging pump 1b. Travel control valve 7. Hydraulic oil filter 14, Center swivel joint 8, Hydraulic tank 15. Travel motor assembly 9. Check valve 18a, Brake valve 10. Check valve 18b, Safety valve 11, Oil cooler 15c. Suction valve 18d. Travel motor 21-4 Pwo.HYDRAULC CIRCUIT DIAGRAM 21-5 Pw60-3TRAVEL MOTOR 1. Air bleeding plug 2, Port PA: From travel control valve 2. Brake valve b. Port PB: From travel control valve 3. Suction valve © Port T : To hydraulic tank 4, Travel motor 21-6 PW60-31. TRAVEL MOTOR 1 Section AA. 1. Housing 5. Cylinder block Type : KMFO90 2. Case 6 Piston Theoretical displacement: 87.8ce/rev 3. Output shaft 7. Valve plate Rated rpm 1,976 rpm 4. Center ball 8 Center shaft (at 173 min}1) Explanation of axial piston motor Principle © A dise shat is carried on bearings so that the disc i free to rotate. If force F is applied diagonally to this disc, the force F is divided into the components of force, F, (force perpendicular to the disc) and F, (circumferential force of the disc). F, pushes the dise in its axial direction and F; rotates the disc clockwise, © If force Fis applied to the disc, the force F is similarly divided into the components, F\’ and F,', Fy’ rotates the dise counterclockwise. Structure ‘© Seven pistons (6) of axial piston motor are provided fon one cylinder block (5), parallel to cylindrical plane. Gylinder block (6) rotates together with ‘output shaft (3} when the pistons reciprocate. © Seven pistons (6) are installed on disc-like spherical joints. Cylinder block (5) is slanted against output shaft (3) © Fixed valve plate (7) is in contact with the end of the cylinder block (6) © The angle of inclination of eylinder block (5) can be controlled, Therefore, the torque of motor can be varied by changing the angle of inclination of evlinder block (5). Funetion © When oil flows into the LH. ports and out of the R.H. ports in valve plate (7), the oil pressure is applied to the rear sides of pistons (6) leading to the LH, ports, and output shaft (3) rotates clockwise In this ease, pistons (6) rotate clockwise together with eylinder block (S} at the same speed as output shaft (3), while sliding in cylinder block (10), ‘Then, when piston (6) reaches the uppermost point this piston cylinder connects to the ports on the ‘outlet side in valve plate (7). © When pistons (6) reach the outlet ports, the pressure ‘on the pistons back sides is relieved, eliminating the force on outpur shaft (3). Then pistons (6) are rotated by output shaft (3) and allowed to slide though cylinder block (5). The oil on the pistons back sides is drained to the tank, The above men tioned movements are followed by all sever pistons (6) and output shaft (3) rotates clockwise. If the oll inlet and outlet ports are used in the reverse way, the above movements are made oppositely, ‘causing output shaft (2) to rotate counterclockwise, 21-8 208F 142 208F 1434 208F 1444 Pw60.32, TRAVEL BRAKE VALVE Section 6 The brake valve consists of the counterbalance valve and ‘the safety valve. Rated tow 173 min Safety vate set pressure: 55°90 kg/m? at 1940/in) Spool switching pressure: 6.1 kg/em* 10. M. 12. Section D-D Spool switching spring Counter balance valve spoo! Housing Check vaive spring Check valve Adjustment screw Lock nut Sleeve Safety valve poppet spring Safety valve poppet Safety valve main valve spring Safety valve main valve 21-91) Counterbalance valve Function When driving the machine downhill, the whee! rotates more quickly than the revolution of travel motor due to its own weight, thus tending to accelerate motors. However, with the employment of the counter balance valve, load is applied to the motor so that the machine will travel in confirmity with the engine speed. Operation When oil starts flowing: When the travel control lever is changed either to F" or “R, oll from the main pump enters the Pa port via the travel control valve, and pushes check valve Cy When the hydraulic pressure applied to check valve Cy is inereased, check valve (C;) is moved and oil flows to motor outlet port (MB) via motor inlet port (MAJ, and then to the opposing side of the spool. However, the outlet {Pe port) is closed with chock valve (C2); therefore, the oil flow stops. ‘As.a result, the travel motors do not rotate. And the oil pressure is further increased, the oil pressure in chamber (E1} at the right of spool, increases. When the oil pressure is boosted to spool switching pressure, spool moves to the left, allowing the oto flow out from D3 of spool (1) to PB port. The oil Finally returns to the hy: draulic tank, In this way, the travel motor starts rotating, When the machine is traveling downhill Due to its own weight, the travel motor rotates Quickly than the revolution of motor normally with the oil. Therefore, the oil pressure on the inlet side (Ma) of the motor decreases. When the oil pressure in chamber (E,) decreases to less than spool switching pressure, spool moves to the right, thus blocking the oil from flowing out from D3 ‘of spool, As a result, the oil pressure on the outlet side (Ma) of the motor rises. As this oil pressure works as a resistance to the motor, the machine is prevented from travelling at a speed higher than the engine speed. As it is clear from the above, the machine cannot travel at a higher speed other than that conforms to the regulated engine speed. 21-10 Cr) PA2). Safety valve Function When stopping the machine or driving downhill, the circuit for motor outlet port is closed or throt. tled by the counterbalance valve, but the motor trys to rotate by inertia so that the ail pressure on the outlet side of the motor rises. And this may damage the motor and piping. So the oil pressure ‘on the motor outlet side relieves to the motor inlet side Operation © When stopping the machine or driving downhill, the circuit for motor outlet port (A) is closed or throttled by the counterbalance valve, but the oll pressure of motor outlet port (A) rises by the inertia of motor. ‘© When the pressure in chamber A reaches the safety valve spring force (set pressure}, open poppet (10). This allows the oil in chamber A to flow into chamber C through chamber B. © When the pressure in chamber B drops, a differnece in pressure between chamber A and chamber B is ‘generated by orifice a of main valve (11). Main valve (11) is pushed open by the pressure in chamber A, land the pressure in chamber A drops. Pwe0-3 21-113, SUCTION VALVE jamnl Section AA FUNCTION 1 © When travel operation is stopped, the outlet circuit 2 of the travel motor is closed by the counter balance 3 valve. However, the travel motor keep running by the force of inertia, causing the pressure in the a travel motor outlet circuit to go too high. This b ‘causes damage to the travel motor. To prevent such « damage, this excessively high pressure oil of the motor outlet side must be relieved co the motor inlet side (low pressure side) 21-12 Valve body Suction valve Valve spring From port MA From port MB From port TOPERATION At constant travel When the machine starts traveling, or during constant travel, the pressure of chamber A from the travel motor ort MA is higher than the pressure of chamber B from ‘the tank, 50 the suction valve is kept closed. Travel stopped ‘When travel is stopped, the travel control valve stops the Pressurized oil from the pump to chamber A, but the ‘motor continues to turn because of inertia, so the oil at chamber A is sucked out, and the pressure at chamber A drops. When the pressure at portion A drops further, and it becomes lower than the pressure of chamber B, the pressure differnece (differential pressure) between chamber A and chamber B opens the suction valve, and oil is supplied to chamber A to make up the difference, Pwe0.3 From travel motor From tank mae 21-13CENTER Port C Port A Port D Port J Port D Port 8 Port B Port E Port J 21-14 SWIVEL JOINT From blade control valve port A From LH. and R.M. travel control valve Ta blade cylinder head side Ta suspension lock selector valve From blade control valve port By From L.H. and R.H. travel control valve To travel motor port A To steering cylinder bottom side To tank Bee Port H Port F Port F Port G Port & Portc Port A Port H Port G Cover Plate Body Siipper seal Dust seal Shaft Section 8-8 From parking brake solenoid valve From steering valve port R To steering cylinder head side From suspension lock solenoid valve From steering valve port To blade cylinder bottom side To travel motor port B To parking brake cylinder To suspension lock valveTRANSMISSION Section D-0 Oil lover plug Breather Oil drain plug Cage High speed drive gear Input shaft (Low speed drive gear) Cover Case Low speed driven gear Output shaft (< Ld “CET Section CC " 12, 13, 14. 15. 16. 7. 18. 19, 20. Section €£ Rear coupling Shifter fork shaft Inner race Shifting (dog) gear Shifting fork Gear (coupling internal gear) High speed driven gear Bearing Front coupling Cage 21-1520 19 Wo 18 15 M82 Reduction ratio Transmission | Axle reduction | Total reduction reduction ratio, Hor speed a Low a 2.667 21-16SOLENOID VALVE FOR FORWARD-REVERSE SELECTION FUNCTION ‘This solenoid valve for the forward-reverse selection is installed between the travel PPC valve and the travel control valve and serves to change the direc: tion of oil to flow into a control port of the travel control valve. Consequently the direction of travel can be controlled by depressing the travel ac: celeration pedal or by shifting the forward-reverse selector lever provided on the steering column in the proper position, PW60:3 1 2 3. 4 5. 6 Solenoid assembly Push rod Core Valve body Spool Core Push rod Solenoid assembly ). Return spring Spring retainer Spring retainer Return spring 21-17FORWARD-REVERSE SELECTOR LEVER FUNCTION ©The forward-reverse selector lover is installed on the steering column, Changing this lever actuates solenoid valve for forward:-reverse selection. 21-18 Band Screw Lever Knob Spring Base 10, " 12 Cover Insulater Body Action plate Push rod Lever master Pwe0.3TRAVEL PPC VALVE FUNCTION ‘An amount of prossurized oil equivalent to the amount of movement of the travel pedal is supplied from the charging pump to the pilot case of the ‘travel control valve. This moves the spool of the travel control valve to the desired position and controls the travel speed Pweo.3 Section AA Piston a. To hydraulic tank Collar b. From charging pump Retainer ©. To solenoid valve Spring for Forward-Reverse Centering spring selection Fine control hole Valve Body 21-19HIGH-LOW SPEED SELECTION CONTROL OUTLINE ‘The High: Low speed selection is carried out manually by ‘operating High-Low speed selection lever (3) on the left side inside the operator's compartment. This movement is transmitted to brake swivel joint (2), passes through the hollow inside of center swivel joint (1) and acts mechanically to directly switch the shifter fork shaft of transmission (4) 21-20 Center swivel joint Brake swivel joint High-Low speed selection lever Transmission Pwe0-3SWING SYSTEM Swing circle ‘Swing machinery 3. Swing motor Hydraulic tank LH. 5.spool control valve 5. Hydraulic pump Oil cooler Pw60-3 21-21SCHEMATIC OF SWING SYSTEM 1. Engine 8. Hydraulic ol fitter 2. Front main pump 8. Hydraulic tank 3. Rear main pump. 10. LH. 5:spoo! control valve 4, Charging pump 10a. Main relief valve 5. Cheek valve 10b, Swing control valve 6. Cheek valve 11, Swing motor assembly 7. Oil cooler 11a, Brake valve 1b. Swing motor 21-22 naeHYDRAULIC CIRCUIT DIAGRAM Pwe03 21-23SWING MOTOR AND BRAKE VALVE ASSEMBLY e-| | Hi Type KMF40A8.2 Theoretical displacement: 40.2 ce/rev. Port $: To hydraulic tank Port MA: From swing control valve Port T: To hydraulic tank Port MB: From swing control valve 21-24 Pw60-31, SWING MOTOR Housing Case Genter shaft Valve plate Piston Cylinder block Center ball Output shaft Pw603 Section AA 21-252. SWING BRAKE VALVE 1 Uau 3 , Section 86 sestion CC Adjustment screw 1 2. Lock nut 3. Sleeve 4. Safety valve spring 5. Piston 21-26 Safety valve Housing Check valve ‘Check valve spring The swing brake valve consists ofthe check valve and the satety valve, 2 Seting pressure: 225 °S kafem? (at 119 min)Function © When swing operation is stopped, the outlet circuit of the swing motor is closed by the swing controt valve. However, the swing motor keeps running by the force of inertia causing the pressure in the swing motor outlet circuit to go too high. This causes damage to the swing motor, To prevent such damage, this excessively high pressure oll of the motor outlet side must be relieved to the motor inlet side (low pressure side). Operation 1. When operating the swing control lever from ‘Neutral to “SWING RIGHT’ Compared with a counterbalance valve type (e- ‘uipped to traveling circuit), the safety valve type does not allow the pressure to be trapped in the Outlet circuit when swinging is slowed down. Consequently, no rattle occurs during deceleration, resulting in improved control of swinging, I . Mounting bott Gasket sealant iLG-1) G23) Mounting bolt: 11.25 + 1.25 kgm 2) Install cage (18) temporarily. (See P4) 2) Gear, dog gear 3) 1) install spacer (16) to shaft (12). (See P5, P6) 2) Assemble gear (15), dog gear (14) and gear (13), (See P5, P6) 3) Remove cage (18), then fit O-ring and tight- ‘en cage fully. (See P4) >= Mounting bolt: Gasket sealant (LG-1) =) Mounting bolt: 6.75 * 0.75 kgm 7. Cage, coupling 1). Fit O-ring and install cage (9). (See P8) ~~ Mounting bolt: Gasket sealant (LG-1) =] Mounting bolt: 6.75 + 0.75 kgm 2) Install couplig (8). (See P7) ~~ Oilseat: Grease (G2-LI {<. Mounting bolt: Gasket sealant LG-1) 3 Mounting bolt: 6.78 + 0.75 kgm 23-16 2 Parking brake Install brake shoe assembly (7). (See PS} 32) Mounting bolt: 18 + 2 kgm Check that ther the brake lining Install brake drum (6). (See P10) 32) Mounting bolt: 11.25 + 1.25 kam is no oll or grease stuck 10 Cover, shifting fork Install shifting fork (5) to shaft (4), tighten Jock bolt (3), then secure with wire, (See Pi) Ox Lock bolt: Thread tightener (L-2) GD Lock bolt: 4.75 * 0.25 kgm Install pin (2) together with spring. (See P11) Fit gasket, align position of pin, then install cover (1). (See P12) 7 Gasket: Gasket sealant (LG-1) ~~ Mounting bolt: Gasket sealant LG-1) = Mounting bolt: 6.75 = 0.75 kgm Pweo-3Pwe0-3 23-17 2REMOVAL OF SWING MOTOR ASSEMBLY “AE Lower the work equipment to the ground and slowly remove the cap of the hydraulic oil tank to release the air from the tank, 1. Disconnect hoses (1) and (2). (See P1) 2. Remove bracket (3). (See P1) 3. Sling swing motor assembly (4), then remove. (See P2) f ta) Swing motor assembly: 35 kg INSTALLATION OF SWING MOTOR ASSEMBLY 1. Fit O-ring and install swing motor assembly (4), (See P2) 2. Install bracket (3), (See P1) 3. Connect hoses (2) and (1). (See P1) 23-18 REMOVAL OF SWING MACHINERY ASSEMBLY “AS Lower work equipment completely to ground * and stop engine. Operate control lever several times to release remaining oil pressure in hydrau- lic piping. Then remove oil filler cap slowly to release remaining oll pressure in hydraulic tank 1, Remove swing motor assembly. For details, see REMOVAL OF SWING MOTOR ASSEMBLY 2. Disconnect hoses (1). (See P3} 3. Remove tube (2) and disconnect hoses (3). (See Pay 4, Disconnect hose (4). (See P5) 5. Using eye bolt (1) (Thread dia, = 14 mm, Pitch 2.0 mm), sling swing machinery assembly (5), then remove. (See P8) 2) Swing machinery INSTALLATION OF SWING MACHINERY ASSEMBLY 1. Using eyebolt 1) (Thread dia. = 14 mm, Pitch = 2.0 mm), raise swing machinery assembly (6), align pinion and inside teeth of swing circle, and dowel pin, then install. (See P6) 2. Connect hose (4). (See PS) 3. Fit O-ring and connect hoses (3), then install tube (2). (See P4) 4. Connect hoses (1). (See P3) 5. Install swing motor assembly. For details, see INSTALLATION OF SWING MOTOR ASSEMBLY. %* Start the engine to circulate the oil through the piping, then add oil to the specified level in the ‘machinery case and hydraulic oil tank. Pweo-3DISASSEMBLY OF SWING MACHINERY ASSEMBLY 3) Remove smail pinion gear (10) and bearing (11) from case (9). (See PS) 1. Cover 1) Remove the mounting bolts. % Two bolts are installed on the lower side of the swing motor installation side. 2) Using three extraction bolts 1 (Thread dia = 12 mm, Pitch = 1.75 mm, remove cover (1). (See P1) % Pullout the driven gear at the same time. 3} Disassembe the cover as follows. 3. Ring gear Remove snap ring (2) and remove bear: Remove ring gear (12). (See P6) ing (3). (See P2) ii) Remove gear (4). (See 3) 4. Large pinion gear * Punch out the gear from the side 1) Remove bolts (15), then remove holder (16). from which the bearing was (See P7, P8) removed, 2) Remove large pinion gear (17). (See P8) 2. Case, small pinion gear 5. Carrier assembly 1) Remove the mounting bolts, 1). Receiving on case (8), use a press to push + One bolts installed from the bottom. out carrier assembly (21). (See P9) 2) Prying between case (8) and case (3) + Pullout on the bearing inner race side remove case (9). (See P4) ‘Extraction force for carrier assembly % Be careful not to scratch the cases, ‘Approx. 18 tons 23-20 PW60-3 2Pweo-3 23-21 22). Disassemble the carrier assembly as follows. Using puller 2), remove inner race (25). (SeeP1) 1) Drive spring pin (26) into the shaft. (See P2) ii Pull out shaft (27) and remove it, (See P3) ivi Remove thrust washer (28), gear (29), bearing (30), and spring pin (26). (See PA) 23-22 2 ASSEMBLY OF SWING MACHINERY ASSEMBLY Preparatory work ‘© Clean each part and correct any burrs, © Apply engine oil to the bearings and sliding por- tions before assembling, 1. Carrier assembly 1) Assemble the carrier assembly as follows |) Install bearing (31) (0.0.: 47 mm) to car- rier (21). (See P5) ii) Assemble bearing (30) to gear (29), put thrust washers (28) on both sides, then set carrier (21) in place, (See PS) Be sure to align the shaft holes. iid’ Align the pin holes, then install shaft (27). (See P6) 'v)_ Install spring pin (26). (See P7) VW) Install inner race (25) by shrink fitting. (See P7) + Shrink fitting temperature: 100°C for approx. 30 min, Pwe0-3% vara poaraia P3 . ri) B o a 30 ol a ms Ft | Lj | ——! 20282016 PS ~ 31— ri P6 20272136 P7 23-23, 22) 3) 2. Large pi ” 2) 23-24 2 Install the following parts to the case. Press fit bearing (24) (0.0. 150 mm) {nto case (8), then install snap ring (22), (See P1, P2) ji) Install oil seal (2) (0D. 3) 7 Ollseallip: Grease G2-LI 110 mm). (See Assemble the carrier assembly as follows. i) Support the inner race of the bearing in- stalled to case (8) with large pinion gear (17), (See Pa} i) Set the spline of carrier assembly (21) in alignment with the pinion gear, then press fit into position. (See P4) ion gear Install large pinion gear (17), an O-ring, and. holder (16). (See PS) Tighten bolt (15). (See P6) Ga Bolt: 282 + 3.2kgm 3. Ring gear Fit an O-ring and install ring gear (12). (See P7) 4 Case 1) install bearing (7) (0.0: 130 mm) to case (9). See Pa) 2}, Fit an O-ring, align @ bearing with the inner race of the carrier, then install case (9). [See P9} 5. Pinion gear 1) Install bearing (11) (LD: 35 mm} to small pinion gear (10). (See P10} >. Bearing: Grease (G2-L0 Pweo-3ozeaiaa PW60-3 23-25 22} Install small pinion gear (10). ‘See P1) 6. Cover 1) Insta the following parts to the cover ') Install bearing (5) (0.0. 72 mm). (See P2) i Instalidriven gear (4). (See P3) 2) Apply liquid gasket, align the gear with the bearing inner race of the carrier, then install cover {1}. (See Pa) Case: Liquid gasket (LG-6) 3) Tighten the mounting bolts. ‘Three bolts are installed from below. 321 Mounting bolts (12 mm: 118 + tkgm 7. Bearing 1) Align bearing (3) with the small pinion gear 2nd installit. (See P5) 7 Bearing: Grease (G2-Ui) 2). install snap ring (2). (See PS) 23-26 PW60-3 223-27, 2 Pwe0-3REMOVAL OF SWING CIRCLE ASSEMBLY 1. Remove the work equipment assembly For details, see REMOVAL OF WORK EQUIP- MENT ASSEMBLY, 2. Disconnect the upper piping and links of the swivel joint. For details, see REMOVAL OF SWIVEL JOINT ASSEMBLY. 3. Disconnect link (1) at swivel joint end. (See P1) 4. Remove bracket {2) and mounting bolt, then leaving in position temporarily. (See P2) 5. Remove mounting bolts, then pull swing motor assembly (3} out from swing machinery assem- bly. (See P2) 4 The revolving frame can not swing because the brake valve is built into the swing motor, therefore it is necessary to remove the swing motor assembly. 6. Leaving 2 or 3 mounting bolts in position at front ‘and rear, remove mounting bolts of revolving, frame. (See P3, Pa) 7. Hook a hanging tool at the counterweight and boom foot, then temporarily sling revolving frame assembly (4). (See P5) Rotate the revolving frame when removing the mounting bolts. 8. Using lever block, adjust the balance at front and rear, remove the remaining mounting bolts, then remove the revolving frame assembiy tg) Revolving frame assembly: 2,600 kg 8. Remove mounting bolts, then remove swing circle assembly (5). (See P6) ko) Swing circle assembly: 100 kg 23-28 z INSTALLATION OF SWING CIRCLE ASSEMBLY Set swing circle assembly (6) in the mounting po- sition, then tighten the mounting bolts. * To install, turn the “S” mark on the circle to face the LH. side of the frame. (See P6) 7 Mounting bolts: Adhesive {LT-2) =) Mounting bolts: 28.6 + 3.5 kgm 2. Apply grease (G2-L into the swing circle to the inner gear. + Grease amount: approx. ¢ 3, Hook a hanging tool to the counterweight and boom foot, sling revolving frame assemby (4) then adjust the balance in front and rear with lever block. (See P5) 4. Set the revolving frame assembly in alignment with the dowel pin of the swing circle, then tight- 0 the mounting bolts 7 Mounting bolts: Adhesive (LT-2) S32) Mounting bolts: 28.5 + 3.5 kgm ‘* Rotate the revolving frame when tightening the mounting bolts 5. Fit O-ring and install swing motor assembly (3) to the swing machinery assembly. (See P2) 6. Connect ink (1) at swivel oint end, (See P1) Bend the cotter pin securely. 7. Connect the upper piping and links to the swivel joint, For details, see INSTALLATION OF SWIVEL JOINT ASSEMBLY. ‘* Bend the cotter pin securely. Install the work equipment. For details, see IN- STALLATION OF WORK EQUIPMENT ASSEM- BLY. Pweo-3Pw60-3 23-29 2POWER TRAIN 24 MAINTENANCE STANDARD Travel brake valve valve Transmissi Swing circle Swing motor 24-1 OTRAVEL BRAKE VALVE 5 8 2 swnne-c 7 Section 9-0 Unite Ne check er citer Rene —— per Sanaa sine Pepa i : | A nene re Frentengm | iaains | innaind | Feee | ngeated 30 Toe" | eee | "oad? | wea | ose t Froace st2085 60g 16a9 2 | erect vate pring staxo8 | 208 | 02K | o16%0 2 | rarening ora torstety wave 12:2 kam 1 | arieing ora or ts 2a: oangr 5 | Temeningtocue fr bot 68:07 kan Titon 6 | Timening rae for bo 680.7 kgm 2 | Tarening tore frog 20:3 kgm 24-2 Pw0-3TRAVEL SUCTION VALVE om & a al Unit mm check tem crea reeay Sandrd ze length | Installed T Ins = Fr lostalted ‘Suction valve spring SOR | “eng == vem, | TgRuR | etace zsx10 Lowe | - | oz “aeriog oaue or tg B+ thom omen Tein trae fo ue 0b kgm 24-3TRANSMISSION 7 2 = 1 4 si 8 6 op i=in eh ote a oANLD c 5 _—Units mm No. Cheek ier criteria Remedy —— Standard eteorance Clearance limit 1 | Backiaen netween high-speed gears — z 0.184 — 0.468 2. | Aacklash between low-speed gears 0.170 - 0.469 3. | Axial play of input shot bearing 042-147 4 | Axil play of output shaft bearing 0271.22 | Tolerance Standord Standard | Clearance ‘ioe clearance | limit 5, | Ciaance been siting fork at and Replace a -0050 +0027 | 0089- “oo “0 0.077 L Standord size | Repaie ii ee Free length installed | Installed | Free | insta 6 | 0. ° OD. “Tength | "toad | length | "toad aa | sak9 7_| Tightening toraue for input shaft mut 25 + 25 kgm ihten 1g | Tigheaning torque for shifting fork ete Pwe03 24-5SWING MACHINERY a 1 10 § 6 8 4 Unit: mm Stand eran tarace imi ons 04a ] o7 2 | Baskin betncon 2nd pinion 012-027 | 06 Repiace 5 [Baa inne le pen oe and swing circle: a 20 5 | sue pinion ava pov 25-075 dius : fpeiy Wear of output shaft collar surtace 4 | hardehrome © | comaesing with sil set 5 iN 089 9 on7 | sees replace 7 | Tightening torque of saing machinery maunting bolt kgm (Width across Hats) 24 «3 | Tiomtening toque of swing pinion mat 25s 3hym Tien 3 | ighenne ean af oe mourn ae wo | igre ous of ees Se 24-6 Pw60-3SWING CIRCLE ection BS s Aa Section AA Units No. chock tom Ccritaria Remedy Standaed clearance Clearance tim 1 | Bearing axial clearance | reviace 0040.20 0s 2 | ggrernstoraue fr outer race Zissanee Toh 3 | fighting ora for inner race eee ‘Grease must not be ely contaminated or fouled in white, . = 4 | Grease (reese capacity) 5.00) ReplaceSWING MOTOR Standard size T Repair limit ee ee + | check vate spin Free torah | instaied | tnstaied |g Unsatlea | a¥ damage 24-8 Pw60-3STEERING AND BRAKE SYSTEM 41 STRUCTURE AND FUNCTION Steering system Steering pump Schematic of steering system Hydraulic cireuit diagram ‘Steering valve and main relief valve Steering main relief valve Steering valve Steering cylinder Axle Differential gear Final drive Drive shatt Whee! Brake system Schematic of brake system Hydraulie circuit diagram Brake master cylinder Hydromaster Brake swivel joint Brake lock valve Parking brake selector solenoid valve 4134 Whee! brake 41.35 Parking brake 41.36 Parking brake cylinder 41.37 ‘Suspension system 41.38 ‘Schematic of suspension system... 41.40 Hydraulic circuit diagram 41.40 Suspension lock valve . at Suspension lock eylinder 41.43 Pwe03 41-1STEERING SYSTEM Steering eylinder Center swivel joint Steering wheel Hydraulic tank Steering pump Steering valve 41-2 Pwe0sSTEERING PUMP Oucherae Drive gear Bracket Gear case Cover Driven gear Bushing Side plate Oil seat Section AA Type = LALS ‘Theoretical displacement : 8.5 c.c./rev. Max. delivery pressure: 175 kg/em? ‘Max. pump speed £3,500 rpm. A1-3SCHEMATIC OF STEERING SYSTEM Hydraulic tank Steering pump Steering main relief valve Steering wheel Steering valve Hand pump Center swivel joint Steering cylinder 41-4HYDRAULIC CIRCUIT DIAGRAMSTEERING VALVE AND MAIN RELIEF VALVE a 1 9 w 2 i 18 3 " 4 a 9 20 5 B 6 ui ? 15 Section 8 16 section AA a: Port T: To hydraulic tank 4, Snap ing 11. Sleeve bs Port P: From steering pump 2. Needle bearing 12. Spool Port L: To steering cylinder bottom side 3. Center pin 13. Check valve ball 6: Port A: To steering eyiinder head side 4. Deive shatt 14, Check valve seat 5. Valve body 18, Plate 6 Goroier 16. Spacer 7. Lower cover 17, Set screw 8 Bushing 18. Check valve seat 9. Main relief valve 19. Check valve ball 10. Center spring 20, Retainer 41-6 Pweo-3STEERING MAIN RELIEF VALVE Section CC FUNCTION © The steering main relief valve is installed in the circuit between the steering pump and the steering valve. If any abnormal pressure is generated while the steering is being used, the oil sent from the pump is relieved by this valve to prevent damage to the steering pump or other parts. OPERATION © Chamber A forms a pump circuit and chamber C is In the tank drain circuit. Chamber 8 is filled with oll delivered through an orifice a in the valve body. A baallis in the valve seat. (Fig. 1) © If the oi pressure in chambers A and & goes up to a preset pressure, the ball opens, causing the pressurized oil in chamber B to flow to chamber C. Consequently, the oil pressure in chamber B drops, (Fig. 2) © If the pressure in chamber B drops, a pressure ifference is generated between chambers A and B due to an orifice in the main valve. Then, the main valve is pushed open by the pressure in chamber A, causing the oil in chamber A to flow from the ‘chamber. (Fig. 3) 1. Main valve spring 2. Adjustment screw 3. Ball 4. Spring 5. Main valve setting pressure: 1402 kglom* (at 27.0 nin From steering valve To steering vale jars Totank Fromsteering BUMP Fig. 1 From searing valve To steering valve Totank Fromsteering PUMP Fig. 2 From storing valve To steering valve To tank Fromsteering pume Fig. 9 41-7STEERING VALVE OPERATION 1) Steering wheet not being turned © When the steering wheel is not being used, center pin (3) is held by center spring (10) in the center of the oblong hole of spool (12). The spool and sleave do not move. © For this reason, the ports in the sleeve leading 10 the cylinder and hand pump, and the vertical Groove in the spool are shut off. The small holes at the bottom of the spool and sleeve (two holes each at twelve points around the circumference) are connected, © The oil sent from the pump passes from the inlet Port of the valve through the sleeve and spool It then flows inside the spool and passes through the oblong hole in the spool and through the spring mount, flows to the valve outlet port and is drained to the tank, 41-8 2o0F048 Vertiea groove Small Roles ‘pions hole 208P009 Port for stering ‘ylinde head Sait oes Port for steering antes 20BP010 Pwe0.32) ‘Steering wheel turned (steering to left) wy me ge fy q When the steering wheel is turned to the left, spool (12) which is connected by the spline of the Steering shaft turns to the left. However, sleeve (11) and the spool are interconnected by center spring (10}, so the spool compresses the center spring (10). As a result, there is a difference in the angle of rotation of the spoo! and the sleeve, This difference is corresponds to the amount by which the center spring is compressed, Because of this difference, the vertical grooves cut into the spool are connected to the ports in the sleeve, The hand pump port of the sleeve is connected to the bottom of the steering cylinder (turning to left), and the head of the steering cylinder (turning to right) is connected to the valve outlet port by the vertical grooves in the spool (See P41-12) 200F 050 The oil sent from the pump flows into the hand pump from the valve inlet port and returns again to the sleeve, from the vertical grooves in the spool, it flows to the post in the sleeve leading to the head of the steering cylinder. The oil at the bottom of the steering cylinder flows from the ort in the sleeve, through the vertical grooves in the spool and is drained to the tank, When this happens, the pressure oil from the hand, Pump rotates it in the opposite direction like @ motor and this makes the steering wheel lighter. When the steering wheel is stopped, the difference in rotation of the sleeve and spool is returned to the same condition as when the steering wheel is ‘not being turned, Ao3) Operation when pump breaks down (Steering to right) © If there is any failure in the pump or engine, or when the machine is being towed, it is dangerous cof the steering cannet be operated normally © For this reason, a hand pump is built into the bottom of the steering valve. During normal oper ation, this hand pump acts simply as a flow control It takes its rotating force from the pressure cit but if the blow of pressure oil stops, center pin (3) hits the end face of the oblong hole in spool {12}. As a result, the turning force of the steering whee! ‘acts as the drive force for the hand pump, 41-10 zo0rosal Ourieiniet pore When this happens, a difference in rotation between the spoot and sleeve (11) occurs and the vertical grooves of the spool are connected to the ports of the sleeve, When the steering wheel is turned, the hand pump also turns, Oil is then sucked directly from the tank passing through check valve (19) which is installed between the inlet and outlet ports of the valve, It enters the suction side of the hand pump and is then sent from the detivery side to the bottom of the steering eylindor. The hand pump is similar to a trochoid pump, but at the root of the teeth of the stator, there are ports which act to suck in and force out pressure oiCONNECTIONS BETWEEN HAND PUMP AND SLEEVE AtFo1O The connections between the sleeve and the suction and drain ports of the hand pump, which are joined by the sleeve, are as shown in the above diagram, If the steering wheel is turned to the right, ports a,¢,¢, 9, i and k are connected to the pump by the vertical grooves of the spool, ports b, d, f, h, j and! are con. ected in the same way to the head of the steering cylinder. In the situation shown in Fig. 1, ports 1, 2 and 3 are the hand pump delivery ports. They are connected with ports J, b and d, so oil is sont to the cylinder, [At the same, ports 5, 8 and 7 are connected, so oil flows in from the pump, If the steering wheel is turned 90°, from the position, the condition changes to that in Fig. 2. In this case ports 1, 2 and 3 are the suction ports and are connected with ports J, k and a, Ports §, 6 and 7 are the delivery ports and are connected with ports d, f and h, Pweo-3 2080! | 208012 41-11(© In this way, the ports of the hand pump acting as delivery ports are connected to ports wnich are connected to the steering cylinder. The ports of the hand pump ecting as suction ports are connected te the pump circuit, © if there is any failure in the pump or engine, the suction and delivery of the hand pump is carried out forcibly, So the steering wheel can be turned to send oil to the steering cylinder COMPARISON OF TROCHOID PUMP AND HAND PUMP IN STEERING VALVE © Trochoid pump ( t The intet port and outlet port are divided, As the shaft turns, the situation changes from position 2 to position 6 in the diagram. tn this way. oil is sucked in from the inlet port and delivered from the outiet port. © Hand pump in steering pump In addition, adjustment of the oil flow to match the angle by which the steering wheel is turned is, also carried out by the hand pump. The oil from the pump always passes through the hand pump, For every 1/7 turn of the steering wheel, the inner teeth of the hand pump gear advance one position, so the oil flow is adjusted by this movement In this way, the oil delivery is directly proportional ‘to the amount the steering wheel is turned, Even if there is any failure in the pump or engine, the hand pump acts in exactly the same way, 30 the oil delivery remains the same as under nomal conditions, 8 aieors In the case of the hand pump, there are inlet and outlet ports at the root of the inner teeth of the stator. As the shaft turns, situation changes as shown in the diagram, In positions 2 and 3 the steering pump and the ports are connected, so ois sucked in, The shaft turns further, and in positions 5 and 6, the steering cylinder and the port are connected, so oif is sont to the cylinder. This same action occurs at each port 41-12 Pwe60-3FUNCTION OF CENTER SPRING © Center spring (9) consists of three layers of leaf springs crossed to form an X shape. The springs are assembled in spool (11) and sleeve (10) as shown in the diagram on the right. When the steering wheel is turned, the spring is compressed and a difference in rotation arises between the spool and the sleeve Because of this, the ports in the spool and sleeve are connected and oil is sent to the eylinder, When the turning of the steering wheel is stopped, the hand pump also stops turning so no more ail is sent to the cylinder. If this happens, the oil pressure will rise and be relieved through the main relief valve. To Prevent this, the difference in angle of rotation of the sleeve and spool is removed by the action of the center spring, so the situation is the same as when the steering whee! is not being turned, 41-13STEERING CYLINDER Bushing Cylinder head Rod packing Piston rod Cylinder Distance betwaen ‘mounting pine thin | Mow Stroke 320 Cevinde 1D 50 2 6. Head side tube 7, Piston 8, Piston ring 9. Wearing 10. Piston nut Piston nue 25 s40 | 970 Al-14 Pw60.3AXLE FRONT AXLE 1 2 3, 4 6. 6. 2. 8, Tie rod Differential gear Knuele arm Brake Whee! hub Final drive Axle housing King pin 41-15REAR AXLE Differential gear Brake Whee! hub Final drive Axle housing 1 2 3 4 5. 41-16 Pwe0-3DIFFERENTIAL GEAR Support cap Differential gear housing Ditferential pinion Cross joint Bevel gear Adjustment ring Differential side gear Adjustment screw Bevel pinion Differential case STRUCTURE The differential consists of bevel pinion (9) sup. ported in the tapered roller bearing in differential ‘case (10), differential gear housing (2) supported in the tapered roller bearing and fixed with cap in the differential case, bevel gear (5) bolted to housing (2), cross joint (4) supported in housings (2) and (10), and differential side gear (7) trans rmitting power to pinion (3) and the axle shaft on the spider. Input coupling FUNCTION The differential is installed in the center of the axle housing and performs the following functions. 1) It reduces the speed of the motive force trans- mitted from the transfer through the drive shaft by one stage, using bevel pinion (9) and bevel gear (5), It also converts it and turns it at right angles to the right and left 2) When the direction of travel of the machine is changed, for example, when turning left, the wheels on the left side, If this to rotate faster then the wheels on the left side. If this does not happen, the machine cannot turn smoothly to the left, The differential acts according to the difference in the resistance from the road surface to the tires, It automatically changes the speed on the right and loft sides to enable the machine to be turned smoothly to the left. 41-17FINAL DRIVE 41-18 Universal joint Spindle Wheel hub ‘Sun gear shaft ‘Sun gear . Planetery carrier Planetary pinion 10 n 12, 13 14 Ring gear Dise Caliper Knuckle arm Axie housing Axle shaft King pinDRIVE SHAFT OUTLINE © The motive force from the engine passes through the travel motor and transmission. Part of this motive force passes through rear drive shaft and goes to the rear axle; the rest of the motive force passes through front drive shaft and is sent to the front axle, © In addition to transmitting the motive force, the drive shafts have the following purposes, When there is shock from the road surface during traveling, or when there is shock during operations, the axle in front and behind the engine and trans- mission change position, To allow the motive force to be transmitted with- ‘out damage to parts of the machine when there is shock or when the components move position, the drive shafts have a universal joint and a sliding joint, This allows them to handle changes in angle and length, Pwe0.3 Flange Cross joint Sleeve Shaft 41-19WHEEL 1. Rim 2. Tire 3. Tube 4. Side ring 5. Disc Size 7.50-20-12PR Tire inflation pressure: 5.0 kg/em* © A pair of tires are installed that lett and right tire tread pattorn face inversely, 41-20 PW60-3BRAKE SYSTEM Center swivel joint Brake swivel joint Parking brake solenoid valve Charging pump Vacuum pump Brake lock valve Hydromaster Pweo-3 4 10, " 12, 13, 14, Serial No. 2539 and up 10 ut 12 Rear wheel brake Brake master cylinder Brake oll tank Parking brake cylinder Parking brake Brake pedal Front wheel brake 41-21 3SCHEMATIC OF BRAKE SYSTEM 1, Brake pedal 8, Front wheel brake 2. Brake mastor cylinder 9, Rear wheel brake 3. Brake oil tank 10. Charging pump 4, Hydromaster 11, Parking brake solenoid valve 5. Vacuum pump 12, Center swivel joint 8. Brake swivel joint 13. Parking brake eylinder 7. Brake lock valve 14, Parking brake 4l 322 Pwe60-3HYDRAULIC CIRCUIT DIAGRAM 41-23,BRAKE MASTER CYLINDER Push rod © Max, stroke: 35mm Boot © Remaining pressure: 0 kg/em* Piston stopper © Setting pressure: 30 kglem* Body Piston Piston cup Return spring 41-24 Pwe0.3OPERATION 1. Brake ope 3 If the brake pedal is gradually depressed, push rod (1) is pushed and piston (6) starts to move to the right, When the lip of piston cup (6) blocks oil escape hole a, the cil inside cylinder chamber A is sent to the wheel cylinder. (Fig mn 2. Brake released Hf the pressure on the brake pedal is oradually released, the hydraulic pressure drops. When the pedal starts to move back to its original position, the oil sent to the wheel cylinder is returned by the force of the Hydromaster to the master cylinder, and it flows into cylinder chamber A. (Fig. 2) If the brake pedal is suddenly released, return spring (7) acts, so the return speed of piston (5) is faster than the flow speed of the brake oil returning from the wheel cylinder. This starts 10 create negative pressure in cylinder chamber A, So a clearance is formed at piston cup (6) and the oil in chamber B flows into cylinder chamber A. (Fig. 3) When the piston is completely returned, and piston cup (6) opens oll escape hole a, the extra oll sent to the wheel cylinder is returned through oil escape hole a and goes back to the brake oil tank. (Fig, 4) Pw60:3 F559 de From brake oi sank Fig. > To brake ol tank 41-25HYDROMASTER FUNCTION. © The hydraulic pressure from the master cylinder actuates relief valve (4} of the Hydromaster. Using the difference in pressure between the atmospheric pressure and the vacuum formed by the vacuum ump, the hydraulic force from the master eytincier is boosted and sent to each whee! cylinder In other words, this booster device gives a large braking force for only a small operating effort of the brake pedal. 41-26 Power evlinder Power piston Return spring Relay valve piston Diaphragm Vacuum valve Aic valve 10. "1 12. 13 4, — To wake lock vive Hydraulie piston Air bleeding plug Hydraulic cylinder Check valve ball Yoke Piston stop washer Push rodOPERATION 1 When not being operated {when not depressing brake pedal) When both power piston chambers A and B are vacuum, and the power piston (2) is pushed to the left side by the return spring (3), the power eylinder is balanced. [At this time the hydraulic piston (8) hits against the piston stopper washer (13) and pushes the yoke (12) to the right and since the check valve ball (11) is open, brake oil from the master cylinder passes through the hole in the middle of the hydraulic piston to the wheel cylinder, Accordingly, even ‘though the hydromaster is nat operating, it operates {san ordinary oil brake. ee Denali > To brake lock vive 41-272. When being operated (when depressing brake pedal) When the brake pedal is depressed, hydraulic pressure is transmitted from the master cylinder to the hydraulic cylinder (10) and the relay valve. Hydraulic pressure acting on the relay valve operates the relay valve piston (4) 00 the right side and at the same time the diaphragm (5) is pushed to adhere tightly te the vacuum valve (6). As hydraulic pressure from the master cylinder further increases, the air valve (7) separates from its seat surface and air from the air cleanor flows into the chamber A on the power cylinder braking side. (At this time chamber B is a vacuum.) This results in a pressure difference between the two sides of the power pistons and it is pushed to the right. This is transmitted directly to the hydraulic, piston (8) by the push rod (14), and the hydraulic, piston also operates, When the piston begins to move, the yoke that was in contact with the piston, stopper washer 13) separates, and shuts the check valve ball (11) and shuts off brake oil on the master cvlinder side and wheol cylinder side, and prevents 4 back flow of high pressure oil that has arisen on the wheel cylinder side. To brake tock valve pump a 1 10 8 in 41-28 Pwe0-3When brake is released. (When foot is removed from brake pedal and braking stops.) When the brake pedal is released, hydraulic pressure in the relay piston left section drops. Then the air valve (7) adheres tightly to its seat and cuts off air flow from outside, Next, the diaphragm (5) separates from the vacuum chamber and opens ‘the pastage of both chambers A and B in the power cylinder, and air from chamber A flows into cham- ber B, Furthermore, because of the suction of the engine vacuum pump, inside the hydromaster once ‘again becomes vacuum. The power piston (2) returns, being pushed to the left by a return spring (3), and at the same time the hydraulic piston (8) also returns to its original position before operation. Also, atmospheric pressure, applying on the relay valve (vacuum valve (6), air valve (7)) and the diaphragm (5) during operation, can be felt normal: ly through the brake pedal as a direct hydraulic pressure reaction. Therefore, the operator, being aware of the degree of brake engagement, can brake freely. From brake lock vaive 41-29BRAKE SWIVEL JOINT {ianemision se FUNCTION © The lower travel unit is stopped in 2 fixed position, bbut the upper structure can rotate 360”, The brake cll from the upper structure must be transmitted to the wheel brake (through the brake lock valve. If this is done simply by connecting with piping, the piping will twist when the upper structure swings To avoid this, a swivel joint for the brake (including the transmission High-Low speed selection lever linkage) is provided in the center of the rotating part (the hole in the center of the center swivel joint 41-30 A I> Tobrake took valve 1. Shaft 2. Ball joint 3. Body Pwe0-3BRAKE LOCK VALVE FUNCTION The brake lock vaive is installed in the circuit between the Hydromaster and the wheel cylinder When the machine is stopped, or during machine ‘operations, the wheel brakes must be Kept locked. In such cases, place the parking brake switch at LOCK, and depress the brake. The wheel brake is ‘then locked However, as only ball check valve (4) is used to prevent any return flow of oil, and the system uses high pressure, the hydraulic pressure will escape slowly, For this reason, always apply the parking bbrake and block the wheels, particularly when parking on slope. Pweo-3 Nipple Plug Spring Check valve ball Nipple 1 zoBros2 Piston Body Plug Lock nut Brake lock releasing bolt 41-31OPERATION Wheel brake locked © To lock the wheel brake, set the parking brake switch to the LOCK position. When this is done, the solenoid vaive is switched, the pressure oil entering chamber B of the lock valve is drained, and piston (6) becomes free. i a Ieflsar ess Ce ne exaegerte | 41.32 pweo-aIn this condition, if the brake pedal is depressed, oil from the Hydromaster enters chamber A of the lock valve and pushes piston (6) to the right. At the same time, it pushes open check valve (4) and actuates the whee! brake. Pwe0-3 2539 and up 41-33 3‘© When oil finishes entering the wheel brake, check valve (4) is pushed against plug (2) by spring (3), ‘As a result, the circuit between the lock valve and. wheol brake is closed, and the wheel brake is locked. Serial No. 2539 and up 4133-1 Pweo-3Wheel brake released To release the wheel brake lock, move the parking brake switch to the FREE position. When this happens, the solenoid valve is switched and pres: surized oil from the charging pump enters chamber B of the lock valve. It pushes piston (6) to the left ‘and pushes open check valve (4). When check valve (4) is opened, the oil entering the wheel brake returns to the Hydromaster and the wheel brake is released Pweo-3 41-33-2 3PARKING BRAKE SELECTOR SOLENOID VALVE Serial No. 2001 — 2538 FUNCTION © The solenoid valve is interconnected with the parking brake switch inside the operator's com: partment, It switehes the flow of pressurized oil from the charging pump to the parking brake cylinder and brake lock valve. © This solenoid valve ‘is also used in the suspension lock eireuit. 41-34 3 Solenoid valve assembly Push pin Spring Spring retainer Spoo! Valve body Spring retrainer Spring Plug Pwe0-3Serial No. 2539 and up Oi Solenoid valve assembly Push pin Spring retainer Spool Valve body Spring Plug wegeens Pw60-3 41341WHEEL BRAKE Caliper assembly Front and rear wheels: Dise brake (4-piston type} Pad Dust seal Insert Ball Piston Cylinder 1 a 3 4 5. 6. 7. PW60-3 41-35PARKING BRAKE & Section =C 1 2 A ba \ 3.4 5 6 Section AA Section 8 208F 086 1, Camshaft 5. Adjustment screw 2. Return spring 6. Spring 3. Brake drum 7. Spring 4, Brake shoe 8, Parking brake cylinder FUNCTION AND OPERATION ‘©The parking brake is an internat expanding mecha nical brake which acts on the drive shaft. Camshaft (1) acts on brake shoe (4). This brake mechanism is called a duo servo type. © The parking brake body is installed at the trans mission output shaft (drive shaft) coupling and the cam lever is connected to the parking brake cylinder (8), Actuating the parking brake valve by means of the eam lever causes the force of spring (7) to automatically apply the brake. (The figure on the right shows the parking brake operation.) 41-36 ‘PWE0-3PARKING BRAKE CYLINDER Cylinder Stroke: 30mm Rod (piston) Spring Cylinder head Holder 1a. From parking brake solenoid valve b. To breather Pw60-3 41-37SUSPENSION SYSTEM Serial No. 2539 and up Detail? Suspension lock eylinder Suspension lock valve Travel motor Center swivel joint Suspension lock solenoid valve Hydraulic tank Charging pump, 41:38 wensSCHEMATIC OF SUSPENSION SYSTEM me Totravel PPC valve Engine Charging pump Suspension lock switch Suspension lock solenoid valve Center swivel joint Travel motor Suspension lock valve 3. Suspension lock cylinder Al Ao Pwe0-3HYDRAULIC CIRCUIT DIAGRAM 41-41 Pwe03SUSPENSION LOCK VALVE u ley oop a 1. Returnspring a, To RLM. suspension leck cylinder «© Check valve cracking pressure: Max. 0.3 kg/em? 2. Cover b. To L.H. suspension lack cylinder «© ~—‘Spool switching pressure: Max. 20 ka/om? 3. Plug From travel motor drain 4, Spoot 1d. From suspension lock solencid valve 5. Valve body 6. Check valve 7. Spring 8. Block 41-42FUNCTION © This is installed in the suspension circuit. When the suspension lock switch is set to LOCK or FREE, the pilot pressure from the solenoid valve opens and closes the inlet circuit of the suspension lock evlinder. OPERATION Suspension lock ON ‘© When the suspension lock switch is moved to the LOCK position, the solenoid valve is switehed and the oil in chamber P is drained os [As result, spool (4 is pushed to the left by sp00! sipensen return spring (1), suspension lock eylinder ports A Senter 4nd B are closed, and the suspension is kept locked. soem Suspension Pweo-3Suspension lock RELEASED. When the suspension lock switch is set to the FREE position, the solenoid valve is switched. Pressurized oil from the charging pump enters chamber P and pushes spool (4) to the right ‘Suspension lock cylinder ports A and B are joined by the notch in the outside circumference of the spool. At the same time, they are also connected to tank drain port T, so the suspension lock is re leased. oa —— st cl We i [mem eg teas mye ro =H C1 sei Pweo-3SUSPENSION LOCK CYLINDER 41-44 Piston rod Dust seal Rod packing Cylinder Pw60-3STEERING AND BRAKE SYSTEM ee 42 TESTING AND ADJUSTING Pw60-3 42-1TESTING AND ADJUSTING TOE-IN TESTING TOE-IN 1. Take any point ¥ on the circumference of the tire (height H from ground) and measure A with a stect tape. 2. Using a jack, raise the tire off the ground, rotate it in the direction of the arrow, then lower it to the ground again. Measure B with a steel tape at point ¥* (height H from ground) 2 \ fear = HY Sa rom | * sesra0sa | * Standard toe-in (A — B): 0 mm ‘If the result of the inspection shows that the toe-in is. ot within the standard range, adjust it as follows, ADJUSTING TOE-IN Loosen the lock bolts and nuts of yoke (2) at both ends of tie rod (1), and turn the tie rod to adjust so that the toe-in is within the standard range, =) Yoke locknut: 17.5 + 26 kgm + After adjusting the toe-in, use the procedure for test ing the toe-in to check the toe-in again. The camberis 0”. zonea206 422 Pwe0-3ADJUSTING MAXIMUM STEERING ANGLE FOR FRONT AXLE 1. Adjust the toe-in, ‘For details, see ADJUSTING TOE-IN. 2. Set the front tires facing directly the center of the loft and right turning radial gauge. 3. Turn the steering wheel fully to the right or left, read the turning angle of the wheel with the turning radial gauge, and adjust with the stopper bolt to the speci- fied valve. ‘* Max. steering angle: Outside: 29°8" Inside 30° + Tighten locknut (2) of stopper bolt (1) securely. Locknut: 10 = 2 kgm PW60-3 423ADJUSTING PARKING BRAKE % If the braking effect of the parking brake is poor, adjust as follows 1. Block the front wheels securely 2. Raise the rear wheels with the blade or work equip- ment, and put a stand under the axle to prevent the rear wheels from touching the ground 3. Place the forward-reverse selector lever at the for- ward of reverse position, and the travel speed selec- tor lever at the neutral position. 4, Turn the drive shaft, and align the position of adjust: ment hole | and the adjustment screw. % The adjustment screw is exactly at the bottom 5. Insert a screwdriver into the adjustment hole and turn the adjustment screw upwards until it cannot be turned any more. 6. Turn the adjustment screw back approx. 10 clicks. + The clearance at this point is approx. 0.28 mm 424 Direction to expand beake shoe Pweo-3ADJUSTING PARKING BRAKE ROD 1. Adjust the clearance of the parking brake to the standard value. For details, see ADJUSTING PARKING BRAKE 2. With the brake released, adjust the length of rod (1) with the turnbuckle so that the distance from the end face of the bracket to the center of the pin is 221 Applied 208 foleased: 21 mm Pw60-3 425BLEEDING AIR FROM BRAKE CIRCUIT + After repairing the brakes or after changing the brake {luid, bleed the air as follows, 1, Fill the brake oll tank with brake fluid to the specified level % While bleeding the air, add more fluid whenever necessary to prevent the tank from becoming empty. 2. Set the parking brake switch to the FREE position, % If the brakes are in the LOCK position, the air master circuit is connected, so it is impossible to bleed the air. 3. Connect a vinyl hose to air bieeder (1), and put the other end into a container of brake fluid. 4. Depress the brake pedal repeatedly, then keep the pedal depressed and loosen bleeder (1) approx. 1/2 turns. Check that brake fluid flows out, then tighten the screw % Tighten the bleeder before releasing the brake pedal 5. When bleeding the air, start from the point farthest from the air master, and bleed the air from all four wheels lfront and rear) pozor0as 4246 Pweo-3STEERING AND BRAKE SYSTEM S 43 DISASSEMBLY AND ASSEMBLY ag ‘STEERING PUMP Removal Installation ‘STEERING CYLINDER Removal Installation FRONT AXLE Removal Installation REAR AXLE Removal Installation FRONT FINAL DRIVE AND HUB Removal Installation FINAL DRIVE Removal Installation DIFFERENTIAL Removal Installation Disassembly Assembly Pweo-3 43. 43. 43. 43. 43. 43. 43. 4 43. 43-6 43. 6 43. 8 43-10 43-12 43.12 43-14 43-16 WHEEL. Removal Installation FRONT CALIPER, Removal Installation REAR CALIPER Removal Installation CALIPER Disassembly Assembly PARKING BRAKE Removal Installation SUSPENSION LOCK VALVE Removal Installation ‘SUSPENSION LOCK CYLINDER Removal Installation Disassembly ‘Assembly 43.20 43-20 43-20 43-20 43-22 43-22 43-22 43-22 43-24 43-24 43-24 43-24 43-26 43.26 43-26 43-26REMOVAL OF STEERING PUMP ASSEMBLY % After disconnecting the tubes, fit blind plugs to prevent dirt and dust from entering, 1. Remove drain plug of hydraulic tank and drain hydraulic ol wate Hydraulic tank: Approx. 88 « 2. Remove alternator assembly For details, see 13 REMOVAL OF ALTERNATOR ASSEMBLY. 3. Disconnect pump outlet tube (1). (See P1) 4, Disconnect pump inlet tube (2). (See P2) 5. Remove steering pump assembly (3). (See P2) INSTALLATION OF STEERING PUMP ASSEMBLY 1. Fit O-ring and install steering pump assembly (3) (See P2) 2. Fit O-ring and connect inlet tube (2). (See P2) 3. Fit O-ring and connect outlet tube (1). (See P1) 4. Install alternator assembly. For details, see 13 INSTALLATION OF ALTER NATOR ASSEMBLY 5. Tighten drain plug of hydraulic tank and add hy raulic oil through oil filler to the specified level a Hydraulic tank: Approx. 88 & * Run the engine to circulate the oil through the system, Then check the oil level again REMOVAL OF STEERING CYLINDER ASSEMBLY 1. Disconnect steering cylinder hoses (1). (See P3) % After disconnecting the hoses, fit biind plugs to prevent dirt and dust from entering 2. Remove left and right pins (2), then remove cylin- der assembly (3), (See P3, P4) INSTALLATION OF STEERING CYLINDER ASSEMBLY 1, Set cylinder assembly (3) in mounting position, and install eft and right pins (2). (See P3, PA) Pin: Antifriction compound (LM-P) Mounting bolt: 5.6 = 2 kgm 2. Connect steering cylinder hoses (1). (See P3) Pweo-3Pwe0-3 43-3REMOVAL OF FRONT AXLE ASSEMBLY ‘+ Raise the chassis with the work equipment, and put a stand under the frame to keep the wheels just off the ground. Ai Put the suspension lock switch to the FREE position, 1. Remove left and right front whee! assemblies, For details, see 43 REMOVAL OF WHEEL ASSEMBLY 2. Disconnect left and right brake hoses (1), (See Pt) * Brake oil will flow out, so use blind plugs to stop it 3. Disconnect drive shaft assembly (2). (See P1) 4. Remove mounting pin (3) of steering cylinder as- sembly. (See P2) 5. Using transmission jack 1), remove front axle assembly (4), (See P3) tg) Frontaxle assembly: 305 kg INSTALLATION OF FRONT AXLE ASSEMBLY 1. Using transmission jack 1, install front axle as- sembly (4), (See P3) > Mounting bolt: Thread tightener {LT-2) "=) Mounting bolt: 28.25 * 3.25 kgm 2. Install mounting pin (3) of steering cylinder as. sembly, (See P2) > Mounting bolt: Thread tightener (LT-2) =] Mounting bolt: 6.5 + 2 kgm 3. Connect drive shaft assembly (2), (See P1) > Mounting bolt: Thread tightener (LT-2) ==) Mounting bolt: 9.0 + 3.5 kgm 4. Connect left and right brake hoses (1). (See P1) 5. Install left and right front wheel assemblies. For details, see 43 INSTALLATION OF WHEEL ASSEMBLY. 6. Bleed air from brake circuit For details, see 42 TESTING AND ADJUSTING, Bleeding air from brake circuit 43-4 3 REMOVAL OF REAR AXLE ASSEMBLY % Raise the chassis with the work equipment, and ut a wooden block under the frame to keep the wheels just off the ground, 1. Remove left and right rear wheel assemblies. For details, see 43 REMOVAL OF WHEEL ASSEMBLY. 2. Disconnect drive shaft assembly (1). (See P4) 3. Disconnect left and right brake tubes (2), (See Ps) + Brake oil will flow out, so use blind plugs to stop it 4. Using transmission jack 1), remove rear axle as- sembly (3), (See P6) [ te) Rear axle assembly: 260 kg INSTALLATION OF REAR AXLE ASSEMBLY 1, Using transmission jack 1 , install rear axle as- sembly (3), (See P6) 7. Mounting bolt: Thread tightener (LT-2) ==] Mounting bolt: 28.26 = 3.25 kam 2. Connect left and right brake tubes (2). (See PS) 3. Connect drive shaft assembly (1), See P4) > Mounting bolt; Thread tightener (LT-2) <5) Mounting bolt: 9.0 + 3.6 kgm. 4._ installleft and right rear wheel assemblies. For details, see 43 INSTALLATION OF WHEEL ASSEMBLY. 5. Bleed air from brake circuit For details, see 42 TESTING AND ADJUSTING, Bleeding air from brake circuit. Pwe0-3Pweo-3REMOVAL OF FRONT FINAL DRIVE, HUB ASSEMBLY Remove wheel assembly. For details, see REMOVAL OF ASSEMBLY, WHEEL 2. Remove drain plug and drain oil from differentiat case. wien Differential case: 72 3. Remove drain plug and drain oil from final drive. Final drive: 1 &(each) 4. Disconnect brake tube (1). (See P1) ‘+ The brake oil will flow out, so stop the hole with a plug. 5. Remove caliper assembly (2). (See P1) 6. Remove tie rod pin (7), and disconnect tie rod (3). (See P2) 7. Remove brake hose bracket (4), and move to- wards frame. (See P2) & Using forcing screws 1 bottom king pins (6). (See P3) % Check the number and thickness of the shims, and keep in a safe place. remove top and 9. Raise front final drive and hub assembly (6), pull out shaft, then lift off. (See Pa) tg) Final drive, hub assembly: 70 kg INSTALLATION OF FRONT FINAL DRIVE, HUB ASSEMBLY Special tool Part No. Part Name. ary A | 790-425-1470 Shaft i + Before installing the final drive and hub assembly, adjust the shims for the king pins as follows. Coat bushing and seal of axle housing with engine cil, and install toot A. (See PS). ii) Install final drive and hub assembly to axle housing, then install king pins, and tighten bolts temporarily * Tighten the top and bottom king pin mounting bolts uniformly, and check that the tool A moves smoothly. il) Measure clearances ¥ and Z between top and bettom king pin flanges and knuckle with feeler gauge. (See F1) + Total shim thickness (R) RY +Z+0.08mm + Bottom shim thickness (R1) RI: Z— 0.26 mm + Top shim thickness (Ru) fv: R- RT iv) After setting shim thickness, remove top and bottom king pins. then remove tool A. 1. Raise final drive and hub assembly (6), align spline of universal joint and install. (See P5) Pwe0-3PW60-3, 43-7 32. Check thickness of shim (7) selected when ad- justing king pin shim, then install king pin (5) (See P1) ~~ Washer, seal: Grease (LM-G) 3. Install brake hose bracket (4), ‘See P2) 4. Connect tie rad (3), (See P2) 1 Bushing inside surface: Grease iLM-G) SS Nut formounting pin: 4.75 * 2.45 kgm 5. Install caliper assembly (2). (See P3) Mounting bolt: Thread tightener (LT-2) G3] Mounting bot: 76 + 8.0 kgm 6. Connect brake tube (1). (See P3) 7. Tighten drain plug and add gear oil through oil filler to the specified level. 8, Install wheel assembly. For details, see INSTALLATION OF WHEEL ASSEMBLY. 9. Bleed air from brake circuit For details, see TESTING AND ADJUSTING, “Bleeding air from brake circuit” 10. Adjust toe-in, For details, see TESTING AND ADJUSTING "Ad- justing toe-in” 43-7-1 3 Pweo-3Pweo-3 43-7 -2 3REMOVAL OF FINAL DRIVE ASSEMBLY 1. Remove wheel assembly. For details, see 43 REMOVAL OF WHEEL ASSEMBLY. 2. Disconnect brake tube (1), and remove caliper assembly (2). (See P1) + Brake oil will flow out, so use blind plugs to stop it 3. Remove drain plug and drain oil from gear case. ‘ ey Gear case: 1 (each) 4. Remove carrier assembly (3). (See P2) 5. Remove snap ring (4), then remove pinion (5) (See P3) 6. Remove plate (6), then remove ring gear (7) (See P4) 7. Remove ring (8), retainer (9), and shim (10). (See P4, 5) 4 Check the number and thickness of the shims, and keep ina safe pla 8. Using transmission jack 1), remove gear (11) and hub assembly (12). (See P6) (ie) Hub assembly: 30 kg 9. Remove disc plate (13). (See P7) 10. Remove oil seal (1.4) and bearing (16). (See P8) 11, Remove outer race (16). (See P9) Pweo-3PWe0-3 43-9INSTALLATION OF FINAL DRIVE ASSEMBLY 1. Using push too}, install outer race (16). (See P1) 2. Using push tool, install bearing (15) and oil seat (14). (See P2, F1) 7 Outer circumference of oil seal Gasket sealant (LG-1) +7 Up surface of oil seal: Grease (G2-LI) Insertion amount for oil seal: 8 mm 3. install dise pte (13), (See P3) 2 Mounting bolt: Thread tightener(LT-2) 31 Mounting bolt: 28.5 + 3 kom 4. Using transmission jack 1), set hub assembly (12) in mounting position, then install gear (11) (See P4) + Be careful not to damage the lip surface of the oil seal 43-10 3 5. Assemble shim (10), then install retainer (9) anc ring (8). (See P5, P6) + Adjust preload of whee! bearing as follows (See F2) 1) Without using shim, insert fuse, then tighten retainer with 3 bolts (coat thread portion and seat surface portion with tngine of CLASS CD SAE 30) to a tightening torque of 1.8 kgm + Rotate the hub 5 or 6 times, and tighten uniformly unt the tightening torque is constant. 2) Measure fuse with micrometer, add 0.17 #905 mm to measured value “A to determine shim thickness, then assemble 3) Standard shim thickness: 2 mm /\. Mounting bolt Thread tightener (LT-2) GE] Mounting bolt: 6.5 + 2 kgm After tightening the botts, rotate the hub 5 oF 6 times, thon check that there is no abnormality in the rotating torque Rotating force referencve value 2.0 ~ 4.5 kg {wheel stud portion) 6. Installing gear (7) and plate (6). (See PS) 7. Mounting bolt: Thread tightener (LT-2) S32} Mounting bolt: 2.5 + 1.0 kam 7. Install pinion (6) and snap ring (4). (See P7) 8. Fit O-ring and install carrier assembly (3). (See Pa) O-, Onting: Grease (G2-L Pweo-3th Pasion he ae] — if = a A acers003 LE9. Tighten drain plug and add gear oi! through oil filler to the specified level, 10. Install caliper assembly (2), and connect brake tube (1), (See P1) ~~. Mounting bolt: Thread tightener (LT-2) =) Mounting bolt: 76 + 8.0 kgm 11. Install wheel assembly. For details, see 43 INSTALLATION OF WHEEL ASSEMBLY. 12. Bleed air from brake circuit. For details, see 42 TESTING AND ADJUSTING, Bleeding air from brake circuit REMOVAL OF DIFFERENTIAL ASSEMBLY 1. Remove front final drive and hub essembly. For details, see 43 REMOVAL OF FRONT FINAL DRIVE AND HUB ASSEMBLY, + For the rear differential assembly, drain the «il from the case, then remove left and right carrier assemblies (1), and pull out left and right sun gear shafts (2) to a point where the differential spline is disconnected, (See Pt P2) 2. Disconnect drive shaft (3). (See P3) 3. Remove tie rod (4). (See Pa) 4. Using transmission jack 1, remove differentia! assembly (5). (See P4) INSTALLATION OF DIFFERENTIAL ASSEMBLY 1. Fit O-ring, and using transmission jack 1, install differential assembly (6). (See PA) 2. Install tie rod (4), (See Pa) GE) Nutof mounting pin: 4.75 + 2.45 kgm 3. Connect drive shaft (3). (See P3) “~~~ Mounting bolt: Thread tightener (LT-2) =] Mounting bolt: 9 + 3.5 kgm 4, Install front final drive and hub assembly. For details, see 43 INSTALLATION OF FRONT FINAL DRIVE AND HUB ASSEMBLY. * For the rear differential, align left and right sun gear shafts (2) with spline of differential. Install, then fit O-rings and install carrier as- sembly (1), (See P2, P1) * Tighten the drain plug and add gear oil ‘through the oil filler to the specified level. a’ Differentiat case: 6 %(G090) na? Planetary portion: 18 (GO80) each Pweo-3