CONTENTS

10 STRUCTURE AND FUNCTION.......................................................................................................... 10-1

20 TESTING AND ADJUSTING............................................................................................................... 20-1

30 REMOVAL AND INSTALLATION..................................................................................................... 30-1

40 MAINTENANCE STANDARD............................................................................................................ 40-1

PC20R-8 PC27R-8 00-1

 10 STRUCTURE AND FUNCTION

Power train 2.................................................................................................CLSS

52
Swing circle.....................................................................................4 Swivel joint.....................................................................................69
Swing machinery 6.....................................................................................Swing motor
70
Final drive....................................................................................... 7 Travel motor...................................................................................74
Track frame..................................................................................... 8 Cylinder..........................................................................................77
Recoil spring 10....................................................................................Accumulator
81
Carrier roller..................................................................................11 PPC Valve......................................................................................82
Track roller....................................................................................11 PPC Valve......................................................................................86
Steel shoe.......................................................................................12 Servocontrol feed unit....................................................................89
Hydraulic system...........................................................................13 Electrical circuit diagram (1/3).........................................91
Hydraulic circuit diagram 17 Electrical circuit
diagram (2/3) 93
Hydraulic pump.............................................................................20 Electrical circuit diagram (3/3).........................................95
Control valve.................................................................................44
PAGE INTENTIONALLY
LEFT BLANK
 1. Bucket cylinder
2. Arm cylinder
3. Boom swing cylinder
4. Control valve
5. R.H. PPC valve
6. Hydraulic tank
7. Hydraulic oil cooler
8. L.H. PPC valve
9. Hydraulic pump
10. Final drive
11. Servocontrol feed unit
12. Swivel joint
13. Blade cylinder
14. Swing motor
15. Boom cylinder

RKP03660

10-15
PAGE INTENTIONALLY
LEFT BLANK
HYDRAULIC PUMP

PC27R-8

1. Gear pump a- PS Port - From hydraulic tank

2. Main pump b -P2 Port - To control
valve (P2 port)
c - P1 Port - To control valve (P port)
d - PLS Port - To control valve (LS port)
10-24
• The main pump is an integrated unit consisting of
the pump, servo piston, TCC valve and LS valve.
The explanation of the structure and function is di-
vided into separate sections:
1. Main pump
2. TCC valve
3. LS valve

10-25
1. Main pump

1. Shaft
2. Oil seal
3. Case
4. Swash plate
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston

10-26
FUNCTION
• The rotation and torque transmitted to the pump
shaft is converted to hydraulic energy and pressur-
ized oil is discharged according to the load.
• It is possible to change the discharge amount by
changing the swash plate angle.

STRUCTURE
• Cylinder block (7) is supported to shaft (1) by a • Piston (6) carries out motion relative to the axial di-
spline, and shaft (1) is supported by the front and rection inside each cylinder chamber of cylinder
rear bearings. block (7).
• The end of piston (6) has a concave ball shape and
• The cylinder block (7) carries out rotation relative to
shoe (5) is caulked to it to form one unit. valve plate (8) while sealing the pressurized oil, and
Piston (6) and shoe (5) form a spherical bearing. this surface ensures that the hydraulic balance is
• Rocker cam (4) has plane A, and shoe (5) is always maintained
correctly
.
The oil inside each cylinder chamber of cylinder
pressed against this surface as it slides in a circle.
block (7) is sucked in and dischar ed throu h valve
Rocker cam (4) forms a static bearing sending high ( g g
plate (8)
pressure oil at cylindrical surface В with to the .
case, and carries out a sliding movement.

PC20R-8 PC27R-8 10-27

1. Pump operation
1 - The cylinder block (7) rotates together with the
shaft (1 ), and the shoe (5) slides on the flat sur-
face A.
At this time, the rocker cam (4) moves along
the cylindrical surface В, so the angle a be-
tween the center line X of the rocker cam (4)
and the inclination of the cylinder block (7) in
the axial direction changes.
This angle a is called the swash plate angle.
2 - When the center line X of the rocker cam (4)
maintains the swash plate angle a in relation
to the axial direction of the cylinder block (7),
the flat surface A acts as a cam for the shoe
(5).
By this, the piston (6) slides on the inside of
the cylinder block (7), creates a difference be-
tween capacities E and F, then suction and
discharge of oil for the amount of this differ-
ence (F - E) will be carried out.
In other words, oil is discharge as the capacity
of the chamber F decreases when the cylinder
block (7) rotates.
In the mean time, the capacity of the chamber
E increases, and the oil is sucked at this pro-
cess.
(The figure shows the state of the pump when
suction of the chamber F and discharge of the
chamber E have completed).
3 - When the center line X of the rocker cam (4)
becomes in line with the axial direction of the
cylinder block (7) (swash plate angle = 0),
the difference between capacities of E and F
inside the cylinder block (7) becomes 0, so
the pump does not carry out any suction or dis-
charge action of oil.
(In actual fact, the swash plate angle never be-
comes 0).
4 - In other words, discharge amount of the pump
is directly proportional to the swash plate an-
gle a.

10-28
2. Control of discharge amount
• As the swash plate angle a becomes larger, dif-
ference between the capacities E and F be-
comes larger, so the discharge amount Q in-
creases.
The swash plate angle a is changed by the ser-
vo piston.
• The servo piston moves in a linear reciprocating
motion (£) under the signal pressure of TCC
and LS valve.
This linear motion is transmitted to the rocker
cam (4), which is supported by the cylindrical
surface of the case (3), and the rocker cam
slides in the semi-circular reciprocating direc-
tion ($).
• The upper and lower pressure receiving area of
the servo piston are different from each other,
and to the pressure chamber of the smaller pis-
ton side (upper), discharge pressure (self pres-
sure) Pp of the main pump is always introduced.
To the pressure chamber of the larger piston
side (lower), output pressure Pen of the LS valve
is introduced.
Movement of the servo piston is controlled by
the relationship between pressures Pp and
Pen and the proportion of the pressure receiving
areas of the smaller and larger pistons.

10-29
SERVO PISTON a - P1 Port - Main pump pressure inlet port
1. Spring b - GH Port - Gear pump pressure inlet port
2. Spacer c - PLS Port - From control valve (LS port)
3. Piston
4. Servo piston
LS VALVE
5. Piston
6. Piston
7. Sleeve
8. Spring
9. Union

10-30
LS VALVE
Function
• The LS valve controls the pump discharge amount
according to the amount of movement of the control
lever (that is the oil flow demanded by the actuator).
• The LS valve detects the oil flow demanded by the
actuator from the differential pressure APLS be-
tween main pump discharge pressure PP and con-
trol valve outlet pressure PLS, and controls main
pump discharge amount Q.
(PP is called the pump pressure, PLS is called the
LS pressure, and APLS is called the LS differential
pressure).
• In other words, the pressure loss ( = LS differential
pressure APLS) generated by the flow of oil from the
pump passing through opening area of the control
valve spool is detected.
By controlling pump discharge amount Q so that
this pressure loss remains constant, a pump dis-
charge amount is supplied in accordance with the
demands of the control valve by controlling pump
discharge amount Q.
• However, when carrying out fine control or in other
cases where the range does not exceed the maxi-
mum flow of the pump (the flow demanded by the
control valve is always supplied), the discharge
amount is the same as when the engine is at high
idling, even if the engine is at low idling.
To overcome this, a function has been added to
automatically lower the LS differential pressure
and reduce the discharge amount when the engine
is running at low idling.
• The engine speed is detected by pressures GH and
GL on both sides of the fixed throttle (metering
throttle) in the gear pump discharge passage.
This acts on LS valve No. 3 and No. 4 pressure re-
ceiving chambers a2 and b2, and changes the LS
setting. When the engine is running at low idling,
the gear pump discharge amount is reduced, so
pressures GH and GL on both sides of the metering
throttle become almost the same (the metering dif-
ferential pressure between GH and GL becomes
lower).
On the other hand, when the engine is run at full
throttle, the gear pump discharge amount is in-
creased and the metering differential pressure be-
comes higher.
• When the metering pressure is high (engine
speed is high) the LS setting is made higher.
• When the metering pressure is low (engine
speed is low) the LS setting is made lower.
• Pump pressure PP, LS pressure PLS, and the pres-
sures on both sides of gear pump metering throttle
(GH and GL) are brought to the LS valve.
The relationship between pump discharge amount
Q and LS differential pressure APLS changes as
shown in the diagram on the right.

10-31
OPERATION
1. When control valve is at HOLD position

• LS pressure PLS is brought from the control valve

(Spring chamber a is connected to the drain circuit
outlet port to spring chamber a of the LS valve. through the control valve spool).
Pump pressure PP is brought to chamber b at the At the same time, pump pressure PP is held at the
tip of piston (6) on the opposite side. unload pressure of approx. 26 bar (27 kg/cm 2).
• The position of piston (6) is determined by the size • For this reason, piston (6) is pushed to the left («-),
of pump pressure PP, the combined force of LS port c and port d are interconnected, and pump
pressure PLS + force of spring (8), and the size pressure PP passes from port c to port d, and is
of the differential pressure (GH - GL) on both sides brought to chamber X at the large diameter end
of the gear pump metering throttle. of servo piston (4).
• Before the engine is started, servo piston (4) is • Pump pressure PP is always supplied to chamber Y
pushed to the left (direction of maximum swash at the small diameter end of servo piston (4), but
plate angle) by spring (1). the force applied to the large diameter end of servo
• After the engine is started, if all the control valves piston
(4) is greater because of the difference in
are at the HOLD position, no pressure oil flows to area at both ends of the piston, so servo piston
the control valve outlet port, so LS pressure PLS (4) moves to the right ( " ► ) in the direction of the
is 0 bar ( 0 kg/cm2 ). minimum swash plate angle.

10-32
2. When opening area of control valve is maximum (lever operated freely)

• When control lever is operated fully (that is, when • At this point, port f of the TCC valve is drained in-
the area of opening of the control valve becomes side the pump case through the inside of the pis-
larger), the difference between pump pressure Pp ton, so the pressure in chamber X at the large dia-
and LS pressure Pls (LS differential pressure meter end of servo piston (4) also becomes the
APls) becomes smaller. drain pressure.
• LS pressure Pls brought to spring chamber a of the • Because of this, servo piston (4) is moved to the left
LS valve becomes close to pump pressure Pp, and ( < - ) in the direction of the maximum swash plate
piston (6) is pushed to the right (->•) by the combined angle by pump pressure Pp acting on chamber Y
force of LS pressure Pls + force of spring (8). at the small diameter end of the piston.
This closes port c and interconnects port d and port e.
• As the result, the pressurized oil acting on chamber
X at the large diameter end of servo piston (4) flows
from port d to port e and is connected to port f of
the TCC valve.

10-33
3. When opening area of control valve is small (small movement of lever)

When engine is at high idling

• When the control lever is operated in small move- the LS valve is taken as 16 bar (16 kg/cm2).
ments, or when it is operated to the HOLD position In the range from the neutral position of the control
(in other words, when the area of opening of the valve to the small area of opening of the control
control valve becomes smaller), the difference be- valve (fine control), in the area where LS differential
tween pump pressure Pp and LS pressure Pls (in pressure APls is more than 16 bar (16 kg/cm 2), the
other words, LS pressure APls) becomes larger. pump swash plate angle moves in the minimum di-
• When this happens, the movement is the same as rection. If the area of opening of the control valve is
for "1. When control valve is at HOLD position": further increased, and LS differential pressure
pump pressure Pp pushes piston (6) to the left APls goes below 16 bar (16 kg/cm 2), the pump
(«-), so servo piston (4) is moved to the right swash plate angle is moved in the maximum direc-
(->•) in the direction of the minimum swash plate tion.
angle.
In other words, the LS set differential pressure of

10-34
When engine is at low idling
• The LS set differential pressure of the LS valve is
taken as 7 bar (7 kg/cm 2). In the area where the
LS differential pressure APLS is more than 7 bar
(7 kg/cm2), the pump swash plate angle moves in
the minimum direction. If the area of opening of
the control valve is further increased and LS differ-
ential pressure APLS goes below 7 bar (7 kg/cm 2),
the pump swash plate angle is moved in the maxi-
mum direction. Even if the area of opening of the
control valve is the same, the LS set differential
pressure is lower than when the engine is running
at full throttle (even when the lever is operated to
the same halfway position), so the discharge flow
is reduced below the level when the engine is run-
ning at full throttle.

10-35
4. When pump flow is amount demanded by control valve

Let us take the area receiving the pressure at the As a result, port c, port d and port e open approxi-
large diameter end of servo piston (4) as Ai, the mately the same amount, so the pump pressure
area receiving the pressure at the small diameter flows from port c to port d.
end as A2 , the pressure acting on the large piston Part flows from port e to the tank case and is
diameter end as Pen and the pressure acting on the drained, so the pressure is reduced by approx. 1/2
small piston diameter end as Pp. and flows to chamber X at the large diameter end
When the flow of oil from the pump reaches the of servo piston (4).
flow demanded by the control valve, pump pres- At this point, the relationship between the area re-
sure Pp acting on port b of the LS valve and the ceiving the pressure at both ends of servo piston
combined force of LS pressure Pls + force of (4) is A 2 : Ai = 1 : 2, so the pressure applied to both
spring (8) acting on spring chamber a are balanced, ends of servo piston (4) becomes Pp : Pen = 2 : 1.
so piston (6) stops at almost the central position. This makes the force acting on both ends of servo
piston (4) 1 : 1 , so servo piston (4) stops in that po-
sition and the pump discharge amount is balanced
with the oil flow demanded by the control valve.

10-36
• The force of the spring is adjusted so that
Pp - Pls = APls=16 bar (16 kg/cm2) at the point
where piston ( 6 ) is balanced.
• In other words, when the area of opening of control
valve is 1 /2 , the pump swash plate angle is also 1 /2 ,
and when the area of opening of control valve is 1/4,
the pump swash plate angle is also 1/4. LS differen-
tial pressure APls is always held at 16 bar (16 kg/
cm2), so the pump discharge amount is in accor-
dance with the area of opening of the control valve.
• For example, after balancing at an area of opening
1/4 of the control valve, if the system is operated to
3/4 of the area of opening of the control valve, LS
differential pressure APLS will drop momentarily.
As a result, the LS valve is actuated and the pump
discharge amount is increased, but when the pump
swash plate angle rises to 3/4 the LS differential
pressure APLS rises to 16 bar (16 kg /cm 2), so it
is balanced in this position.

10-37
ТСС VALVE
Function
• When discharge pressure PP becomes higher, the
area of opening of the control valve becomes lar-
ger, and even if the LS valve tries to increase pump
discharge amount Q, the ТСС valve carries out
control to prevent any increase above fixed dis-
charge amount Q to match discharge pressure PP.
It carries out approximate horsepower control to
prevent the hydraulic horsepower absorbed by
the pump from exceeding the engine horsepower.
• In other words, if the load during operations be-
comes larger and pump discharge pressure PP
rises, pump discharge amount Q is reduced; and
if pump discharge pressure PP goes down, pump
discharge amount Q is increased.
• The relationship between pump discharge pressure
PP and pump discharge amount Q is as shown in
the diagram on the right.

10-38
OPERATION

1. When actuator load is large (pump discharge pressure P p is high)

• When the load on the actuator becomes high and • If pump discharge Pp rises further, piston (3) moves
pump discharge pressure Pp rises, piston (3) is to the left (4-) and servo piston (4) moves to the
pushed to the left («-). right ( - > ) in the direction of the minimum swash
• As a result, port f and chamber Y are intercon- plate angle because of the pressure in chamber X
nected, pump pressure Pp flows from chamber Y at the large diameter end.
to port f, and at the same time, port f and the drain • When servo piston (4) moves to the right ( - ► ) in
circuit are shut off. the direction of the minimum swash plate angle,
• If the LS valve takes action to increase the pump spring (1) is compressed, and piston (3) is moved
discharge amount, spool (6) of the LS valve is to the right (-► ).
moved to the right (->•) and port d and port e are • When piston (3) is moved to the right (->■) and port
interconnected. f and chamber Y are shut off, servo piston (4) stops
• As a result, pump pressure Pp from port f of the moving to the right.
TCC valve flows from port e of the LS valve to port • The position where servo piston (4) stops is higher
d, enters chamber X at the large diameter end of (closer to the minimum swash plate angle) than
servo piston (4), and stops the movement of servo when the pump discharge pressure is low.
piston (4).

10-39
2. When actuator load becomes smaller (pump discharge pressure P p drops)

• When the load on the actuator becomes smaller

and pump discharge pressure Pp drops, piton (3)
is pushed to the right ( - ► ) by the pressure in cham-
ber X.
• As a result, chamber Y and port f are shut off, and
at the same time, port f is connected to the drain
circuit.
• When this happens, if the LS valve is acting to in-
crease the pump discharge pressure, the limit of
the ТСС valve disappears, so the pressurized oil
in chamber X at the large diameter end of servo pis-
ton (4) passes from port d of the LS valve to port e,
and flows from port f of the ТСС valve to the drain
circuit as explained in the section on the LS valve.
• For this reason, servo piston (4) is moved to the left
( « - ) in the direction of the maximum swash plate
angle by the pressure in chamber Y at the small
diameter end.

10-40
3. Action of spring

The spring load of spring (1) in the TCC valve is

changed by the swash plate angle. In addition,
spring (1) consist of 2 types of pitch: rough and fine.
When servo piston (4) moves, the compression of
spring (1) changes by that amount.
If piston (4) moves to the right (-►), first, both the
rough and fine pitch of spring (1) are compressed.
If it moves further to the right ( - > ) the fine pitch
portion comes into close contact, so only the rough
pitch portion functions as a spring from this point.
In other words, the spring load is changed by piston
(4) extending or contracting spring (1).
The pump absorption torque curve, which shows
the relationship between pump discharge pressure
Pp and discharge amount Q, is a bent curve as
shown in the diagram on the right because spring
(1) has different spring pitches.

10-41
• The position where piston (3) stops, in other words,
the pump absorption torque, is determined by the
position where the force of spring (1) + pump pres-
sure Pp acting on piston (3) are in balance.
• In other words, if pump discharge pressure P p in-
creases, pump discharge amount Q is reduced;
and if pump discharge pressure P p goes down,
pump discharge amount Q is increased.

10-42
PAGE INTENTIONALLY
LEFT BLANK
CONTROL VALVE

10-44
a. LS Port - From hydraulic pump (PLS Port)
b. PA1 Port - From L.H. PPC valve (P3 Port)
c. PA6 Port - From L.H. PPC valve (P1 Port)
d. PA7 Port - From R.H. PPC valve (P2 Port)
e. PA8 Port - From R.H. PPC valve
(P3 Port)
f. PA9 Port - From work equipment
PPC valve (P2 Port)
g. P2 Port - From hydraulic pump (P2 Port)
h. S Port - From hydraulic tank
i. B1 Port - To swing motor (A Port)
j. B2 Port - To swivel joint (D Port)
k. B3 Port - To swivel joint (A Port)
I. B4 Port - To boom swing cylinder (Head side)
m. B5 Port - To swivel joint (F Port)
n. B6 Port - To arm cylinder (Head side)
p. B7 Port - To boom cylinder (Bottom side)
q. B8 Port - To bucket cylinder (Bottom side)
r. B9 Port - To attachment (R.H. side)
s. Pi2 Port - To ST1 solenoid valve (P Port)
t. A9 Port - To attachment (L.H. side)
u. A8 Port - To bucket cylinder (Head side)
v. A7 Port - To boom cylinder (Head side)
x. A6 Port - To arm cylinder (Bottom side)
y. A5 Port - To swivel joint (E Port)
w. A4 Port - To boom swing cylinder (Head side)
z. A3 Port - To swivel joint (C Port)
aa. A2 Port - To swivel joint (B Port)
bb. A1 Port - To swing motor (B Port)
cc. P Port - From hydraulic pump (P1 Port)
dd. PB9 Port - From work equipment PPC valve (P1 Port)
ee. PB8 Port -FromR.H. PPC valve (P4 Port)
ff. PB7 Port -FromR.H. PPC valve (P1 Port)
gg. PB6 Port -FromL.H. PPC valve (P2 Port)
hh. PB1 Port -FromL.H. PPC valve (P4Port)
ii. TS Port - To hydraulic tank
II. T Port - To hydraulic tank

10-45
1 - Safety valve 7 - Suction valve
2 - Suction valve (Work equipment R.H. side)
(L.H. Travel reverse) 8 - Suction valve
3 - Suction valve (Lower boom)
(R.H. Travel reverse) 9 - Suction valve
4 - Suction valve (Close arm)
(L.H. Boom swing) 10 - Suction valve
5 - Suction valve (R.H. Travel forward)
(Raise boom) 11 - Suction valve
6 - Suction valve (L.H. Travel forward)
(Close bucket)

10-46
1 - Spool (hammer) 6 - Spool (boom swing)
2 - Spool (bucket) 7 - Spool (R.H. travel)
3 - Spool (boom) 8 - Spool (L.H. travel)
4 - Spool (arm) 9 - Spool (swing)
5 - Spool (blade) 10 - Main relief valve

10-47
 1. Unload valve REDUCING PRESSURE COMPENSATION VALVE
FLOW COMPENSATION VALVE 10 - Attachment
2 - Swing 11 - Bucket
3 -L.H. Travel 12 - Boom
4 - R.H. Travel 13 -Arm
5 - Boom swing and blade 14 - Piston (boom swing and blade)
6 - Arm 15 - Boom swing and blade
7 - Boom 16 - R.H. Travel
8 - Bucket 17 -L.H. Travel
9 - Attachment 18 - Swing
19 - LS bypass plug
20 - Cooler check valve

10-48
1 - Lift check valveTRAVEL VALVE
2 - Cooler check valve 10 - Suction valve (FORWARD)
3 - Safety valve 11 - Suction valve (REVERSE)
4 - Main relief valve 12 - Reducing pressure compensation
valve
5 - LS bypass plug 13 - Flow compensation valve
6 - Unload valve 14 - Spool

SWING VALVE
7 - Spool
8 - Reducing pressure compensation valve
9 - Flow compensation valve

10-49
BOOM SWING VALVE 9 - Reducing
1 - Suction valve (L.H. swing) pressure
2 - Reducing pressure compensation valve compensation valve
3 - Flow compensation valve 10 - Flow compensation valve
4 - Spool BOOM VALVE
BLADE VALVE 11 - Suction valve (raise)
5 - Spool 12 - Check valve

ARM VALVE 13 - Suction valve (lower)

14 - Reducing pressure compensation valve
6 - Spool
15 - Flow compensation valve
7 - Check valve
8 - Suction
valve

10-50
BUCKET VALVE HAMMER VALVE
1 - Suction valve 6 - Suction valve
2 - Check valve 7 - Check valve
3 - Reducing pressure compensation valve 8 - Reducing pressure compensation valve
4 - Flow compensation valve 9 - Flow compensation valve
5 - Spool 10 - Spool
11 - Plug
12 - Cover
13 - Pilot relief valve:

10-51
CLSS

1. OUTLINE
FEATURES
The term "CLSS" stand for the "Closed Center Load Sensing System" which has the following features.
a) Fine-controllability not affected by loads.
b) Controllability enabling digging even in the fine control mode.
c) Complex operability ensured by flow distribution determined according to the opening areas of spools during
complex operation.
d) Energy-saving feature using variable pump control.
STRUCTURE
• The CLSS consists of a variable displacement single piston pump, control valve and actuators.
• The pump body consists of the main pump, TCC valve and LS valve.

10-52
2. BASIC PRINCIPLE
1) Control of pump swash plate angle
• The pump swash plate angle (pump discharge amount) is so controlled that the LS differential pressure APLS,
which is the difference between the pump discharge pressure PP and the LS pressure PLS at the outlet port of the
control valve (actuator load pressure), is maintained at a constant level.
(LS differential pressure APLS = Pump discharge pressure PP - pressure PLS).
• If the LS differential pressure APLS becomes lower than the setting pressure of the LS valve, the pump swash
plate angle becomes larger, and if it becomes higher, the pump swash plate angle becomes smaller.
• For the details of this action, refer to the descriptions of «HYDRAULIC PUMP».

10-53
2) Pressure compensation control
• Valves (pressure compensation valves) are installed at the inlet port side of the spools of the control valves to
balance the loads.
When the actuators are complex-operated, the pressure differences AP at the upstream (inlet) and downstream
(outlet) are made equal by these valves.
In this way, the flow from the pump are distributed in proportion to the opening areas S1 and S2 of each valve.

10-54
3. Functions and operation of each valve
NAMES OF HYDRAULIC CIRCUITS AND VALVES
1. Unload valve LS + 16 bar
(16 kg/cm2)
2. Safety valve: 206 bar
(210 kg/cm2)
3. Pressure compensation
valve
4. Suction valve
5. Main relief valve:
235 bar (240 kg/cm2)
6. Back pressure check valve
(cracking pressure):
0.45 bar (4.5 kg/cm2)
7. Cooler by-pass valve
(cracking pressure):
0.4 bar (4 kg/cm2)
8. Pilot relief valve:
29 bar (30 kg/cm2)

10-55
1. Unload valve

FUNCTION
1) When the control valve is at HOLD, pump discharge amount Q discharged by the minimum swash plate angle is
released to the tank circuit. When this happens, pump discharge pressure PP is set to 16 bar (16 kg/cm ) by
spring (2) inside the valve.
(LS pressure PLS = 0 bar (0 kg/cm2)

OPERATION PP =Pump circuit

When control valve is at HOLD PLS = LS circuit
• At the left end of spool (1), pump pressure PP is act- T =Tank circuit
ing on area S1, and at the right end of spool (1), A =To valves
pump pressure PP is acting on area S2, and LS В =Topump LS valve
pressure PLS is acting on area S3.
• When the control valve is at HOLD, LS pressure
PLS is not generated, so only pump discharge PP
has any effect, and PP is set by the load of spring
(2).
• As pump discharge pressure PP rises and reaches
the PPXS1 = PPXS2 + spring force of spring (2),
spool (1) is moved to the right.
Pump circuit PP is then connected to tank circuit T
through the drill hole.
• In this way, pump discharge pressure PP is set to
16 bar (16 kg/cm2).

10-56
2) During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by
the minimum swash plate angle of the pump, pump discharge pressure PP is set to LS pressure PLS +16 bar (16
kg/cm2).
When the difference in pressure between pump discharge pressure PP and LS pressure PLS reaches the load of
spring (2) (16 bar (16 kg/cm2)) the unload valve opens, so LS differential pressure APLS becomes 16 bar (16 kg/
cm2).

OPERATION
During fine control of control valve
• When fine control is carried out on the control
• In other words, pump discharge pressure PP is set
valve, LS pressure PLS is generated and acts on
to a pressure equal to the force of spring (2) (16 bar
area S3 at the right and of spool (1).
(16 kg/cm2)) + LS pressure PLS, and LS differential
When this happens, the area of the opening of the
pressure APLS becomes 16 bar (16 kg/cm2).
control valve spool is small, so there is a big differ-
ence between LS pressure PLS and pump dis-
charge pressure PP.
• When the difference in pressure between pump
discharge pressure PP and LS pressure PLS
reaches the load of spring (2), spool (1) moves to
the right, and pump circuit PP and tank circuit T
are connected.

10-57
3) When the control valve is being operated and the demand flow for the actuator becomes greater than the pump
discharge from the minimum swash plate angle, the flow of the oil out, to tank circuit T is shut off, and all of pump
discharge amount Q flows to the actuator circuit.

OPERATION
Control valve operated
• When the control valve is operated to a larger
• As a result, pump circuit PP and tank circuit T are
stroke, LS pressure PLS is generated and acts on
shut off, and all the pump discharge amount Q
area S3 at the right end of spool (1).
flows to the actuator circuit.
When this happens, the area of the opening of the
control valve spool is large, so the difference be-
tween LS pressure PLS and pump discharge pres-
sure PP is small.
• For this reason, the difference in pressure between
pump discharge pressure PP and LS pressure PLS
does not reach the load of spring (2) (19.69.8 bar
(2010 kg/cm2)), so spool (1) is pushed to the left
by spring (2).

10-58
2. Introduction of LS pressure
FUNCTION
• The LS pressure is the actuator load pressure at the outlet port end of the control valve.
• It actually reduces pump pressure PP at reducing valve (3) of the pressure compensation valve to the same pres-
sure as actuation circuit pressure A, and sends it to the LS circuit PLS.
• With the boom swing and blade valves, pump pressure PP is reduced to the same pressure as actuator circuit
pressure A by one reducing valve (3) used for both systems, and the pressure is sent to the LS circuit PLS.

OPERATION
1) Boom, arm, bucket, travel valve
• When spool (1) is operated, pump pressure PP • Actuator circuit pressure PA ( = A) acts on the left
flows from control valve (2) and notch a in spool
end of reducing valve (3); the reduced pump pres-
(1) through bridge passage b to actuator circuit A.
sure PP acts on the other end.
• At the same time, reducing valve (3) also moves to • As a result, reducing valve (3) is balanced at a po-
the right, so pump pressure PP has its pressure re- sition where actuator circuit pressure PA and the
duced by the pressure loss at notch C. It is intro- pressure of spring chamber PLSI are the same.
duced to LS circuit PLS, and then goes to spring Pump pressure PP reduced at notch C becomes ac-
chamber PLSI. tuator circuit pressure A and is taken to LS circuit
• When this happens, LS circuit PLS is connected to PLS.
tank circuit T from LS by-pass plug (4) (see the sec-
tion on the LS by-pass plug).

10-59
2) Boom swing, blade valve
• When boom swing spool (1) is operated, pump
pressure PP is reduced by reducing valve (3) (in • As a result, pump pressure PP is reduced at notch
the same way as in item 1), and is sent to the LS d, becomes the actuator circuit pressure, and is
circuit PLS. sent to LS circuit PLS.
• When the blade spool (5) is operated, pump pres- • The boom swing and blade valves are different
sure PP flows from flow control valve (2), passage from the boom, arm, bucket, and travel valves:
e, and notch a in blade spool (5) through bridge they share one pressure compensation valve
passage b to actuator circuit A. and bring in the LS pressure.

• At the same time, the actuator circuit pressure

passes through notch f in hammer spool (6), then
goes through passage d, and acts on the left end
of piston (7). Piston (7) and reducing valve (3) then
move to the right.

10-60
3. LS by-pass plug
FUNCTION
• It releases the residual pressure of LS pressure PLS.
• It makes the speed of the rise in pressure of LS pressure PLS more gentle. In addition, with this discharge
throttled flow, it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the sta-
bility by lowering the effective LS differential pressure.

OPERATION
• The pressurized oil for LS circuit PLS passes from
clearance filter a (formed by the clearance between
LS by-pass plug (1) and the valve body) through or-
ifice b and flows to the tank circuit T.
PP =Pump circuit
PLS = LS circuit
T =Tank circuit
A =To valves
В =To pump LS valve

10-61
4. Pressure compensation valve
FUNCTION
• During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to
increase, compensation is received. (When this happens, the other actuator being used for compound operation
(right side) is at a higher load than the actuator on this side (left side)).

OPERATION
• If the load pressure of the other actuator (right side)
• Flow control valve (2) and reducing valve (1) are ba-
becomes higher during compound operations, the
lanced in position where the difference in pressure
oil flow in actuator circuit A on this side (left side)
between PLS and PA acting on both ends of redu-
tries to increase.
cing valve (1) and the pressure loss between PP
• If this happens, the LS pressure PLS of the other ac- and PPA on both sides of flow control valve (2) are
tuator acts on spring chamber PLSI, and reducing the same.
valve (1) and flow control valve (2) are pushed to
• In this way, the pressure difference between up-
the left («-).
stream pressure PPA and downstream pressure
• Flow control valve (2) throttles the area of opening PA of both spools used during compound opera-
between pump circuit PP and spool upstream tions is the same, so the pump flow is divided in
PPA, and pressure loss is generated between PP proportion to the area of opening of notch a of each
and PPA. spool.

10-62
 Ratio of area S1 and S2
Valve Ratio Valve Ratio
Arm 0.98 Boom swing 0.98
Travel 1.00 Blade 0.98
Boom 0.95 Hammer 1.00
Bucket 1.00 Swing 0.95

10-63
6. Throttling LS introduction of pressure compensation valve
FUNCTION
• In the other actuator is relieved during compound operations, LS introduction throttle b of reducing valve (1) di-
vides the flow and sends more oil to the side receiving compensation.
OPERATION

If the other actuator (right side) is relieved during • Pls2 passes through LS introduction throttle b of
compound operations, each circuit pressure (Ppa, reducing valve (1) and becomes Pls. Pls is con-
Pa) of the other actuator becomes the same as nected to the tank circuit from LS by-pass plug
the pump circuit pressure (Pp = relief pressure). (4), so pressure loss is generated at LS introduction
In this case, spring chamber Pls2 of the other ac- throttle b (the condition becomes Pls < Pls2).
tuator (right side) becomes the same as pump cir- • As a result, even if the other actuator is relieved, a
cuit pressure Pp because of the balance of redu- pressure differential is created between Pp and
cing valve (1). Pls, so more oil flows to actuator circuit A on this
side (left side).

10-64
7. L.H., R.H. travel junction circuit
FUNCTION
• To compensate for any difference in the oil flow in the left and right travel circuits when travelling in a straight
line, the junction circuit opens when the left and right travel spools are operated.
In this way, the flow of oil to the left and right travel motors is almost the same when travelling in a straight line, so
there is no travel deviation.
• When steering the machine, the difference in the load pressure returns the reducing valve of the travel on the
inside of the turn and the opening of the notch in the travel junction valve spool becomes smaller, so the machine
can be steered.

OPERATION
When travelling in a straight lint
• When left and right travel spools (1) are operated,
the pump discharge flows from pump circuit PP
and circuits PAL and PAR to actuator circuits A L
and AR.
• When travelling in a straight line, to make actuator
circuits PAL and PAR equal, left and right reducing
valves (2) are pushed to the right by the same
amount, and notch a and the travel junction circuit
are opened.
• In this way, the left and right travel actuator circuits
are interconnected by the travel junction circuits, so
if any difference occurs in the flow of oil to the left
and right travel motors, the compensation is carried
out to prevent any deviation in travel.

10-65
Steering when travelling
• When travelling in a straight line, if left travel spool
(1L) is returned to the neutral position and the
steering is operated, a difference (AR> AL) is gen-
erated in the load pressure of left and right travel
actuator circuits PAL and PAR, and LS pressure
PLS becomes the same pressure as AR (the side
with the high load pressure).
• As a result, flow control valve (3) on the left travel
side is pushed on the left by LS circuit PLS.
Because of this, the opening of the left notch a is
made smaller, so it becomes possible to operate
the steering when travelling.
• Damper b is provided in the circuit to dampen any
excessive characteristics in the opening or closing
of the travel junction circuit if the spool is operated
suddenly.

10-66
8. Servocontrol reducing valve
FUNCTION
• This valve set servocontrol pressure to 29.5 bar (30 kg/cm 2).

OPERATION
• The discharge pressure from the gear pump enter-
ing chamber A acts on the bottom of valve (1).
The gear pump discharge pressure is set to 29.5 bar
(30 kg/cm2).

10-67
a. S Port - To accumulator 1. Y2 Servocontrol
b. A Port - To PPC valve (P port) 2. Y1 Travel increment
c. В Port - To swivel joint (G port)
d. P Port - From control valve (Pi 2 port)
e. T Port - To hydraulic tank

10-89
20 TESTING AND ADJUSTMENTS

Normal or standard technical data.................................................2

Control and regulation of the pressures in the
Special tools..................................................................................24 hydraulic circuits..........................................................................39
Checking the engine speed...........................................................25 Control and regulation of the ls differential pressure
Adjustment of valve clearance.....................................................26 and adjustment of the LS valve (PC20R-8)................................44
Normal or standard tech ..............................................................26 Regulation of the PC valve (PC20R-8).......................................46
Measurement of the compression pressure.................................27 Control and regulation of the ls differential pressure
Control and adjustment of the tension and adjustment of the LS valve (PC27R-8) ...............................47
of the fan belt................................................................................28 Regulation of the PC valve (PC27R-8) ......................................49
Control and adjustment of the injection timing..........................29 Control and regulation of the servo-control
power supply ................................................................................50
Control and adjustment of the accelerator stroke.. 31
Elimination of residual pressures - pressurisation
Adjustment of the stroke of the
of the tank ....................................................................................51
blade command lever................................................................... 32
Bleeding air from the hydraulic circuits......................................52
Adjusting the flexible cables........................................................33
Control of hydraulic drifts - analysis of the causes
Control and adjustment of the stroke of the of a drift ........................................................................................54
travel lever.....................................................................................34 Checking for any leakages inside the working
Adjustment of the stroke of equipment cylinders......................................................................60
the boom swing command pedal..................................................35 Checking for any leakages inside
Adjustment of the ppc valve clearances......................................36 the swing motor ...........................................................................61
Methods for testing for leakages inside the
Adjustment of the rubber pad and safety
microswitch for servo-control engagement.................................37 swivel joint....................................................................................62
Control and adjustment of
the track-shoe tension ................................................................. 38

When carrying out controls, adjustments or analyses for troubleshooting, park the machine on firm, level
ground. Apply all the machine safety devices and use blocks to prevent any machine movement.
When more than one person is engaged in the work, use the prescribed notices that indicate that the machine
is undergoing maintenance. Do not allow any unauthorised persons to remain in the vicinity.
When checking the level of the cooling liquid, wait until this liquid has cooled. If the radiator cap is removed
while the liquid is still hot and under pressure, it may cause severe burns.
Take great care not to get entangled in moving parts (fan, alternator belt or any of the rotating elements).

20-1
 Machine model PC20R-8
Classifi Standard Permissible
- Check item Test condition Unit value value
cation
Theoretical flow cm3 2.75

Motor speed rpm 2600

Gear pump P2 Test pressure kg/cm2 30 + 5

Pumps

Nominal capacity
€/min 6.6
• Hydraulic oil temperature: 45-55 0C

Piston pump P1 See next page

 Machine model PC20R-8
Classif
i- • Delivery piston pump P1
cation • Pump speed: 2600 rpm
• Hydraulic oil temperature: 45-550C
 Machine model PC27R-8

Classifi- Check item Test condition Unit Standard Permissible

cation
value value
Theoretical flow cm3 3.44

Motor speed rpm 2600

Gear pump P2 Test pressure kg/cm2 30 + 5

Nominal capacity €/min 8.3

Pumps

• Hydraulic oil temperature: 45-55 0 C

Piston pump P1 See next page

20-22
 Machine model PC27R-8
Classif
i- • Delivery piston pump P1
cation • Pump speed: 2600 rpm
• Hydraulic oil temperature: 45-550C
Measurement check points Symbol Code Name Q.ty Remarks

Valve clearance A 1 Commercially Feeler gauge 1 —

available

Compression pressure B 1 ATR800090 Compression gauge 1 0-70 kg/cm2

2 ATR800130 Adapter 1 —

Engine speed C 1 ATR800070 Multi-scale tachometer 1 20 - 4000 rpm

2 ATR800060 Stroboscopic tachometer 1 6 - 30000 rpm

1 ATR800170 Compression gauge 1 Scale 60 bar

2 ATR800140 Compression gauge 1 Scale 400 bar

Hydraulic pressure E 3 ATR800010 Compression gauge 1 Scale 600 bar

4 ATR800200 Servocontrol kit 1 —

(Differential pressure)

5 3F3055600 Elbow 1 P2 Pressure

Track shoe tension G 1 823001135 Grease nipple 1 Included in the

machine tool kit

20-24
TESTING AND ADJUSTMENTS CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION

CONTROL AND ADJUSTMENT OF THE TRACK-SHOE TENSION

1. Test
★ Test conditions:
• Solid, flat ground.
• Working equipment: resting on the ground.

1 - Only for machines with rubber track-shoes

Move the machine backwards and forwards until
the track-shoe joint (mark M) is uppermost and
halfway between the sprocket wheel and the
track-shoe stretcher wheel.
2 - Rotate the revolving frame 900 towards the side of
the track-shoe to be checked.
3 - Close the bucket, bring the arm perpendicular to
the ground and rest the bucket on the ground.
4 - Force the boom downwards until the track-shoe to
be checked is completely raised.
5 - Measure the distance «A» in the following posi-
tions:
PC20R-8: Between the 2 nd sprocket track roller
and the track shoe.
PC27R-8: Between the 3 rd sprocket track roller
and the track shoe.

★ Standard measurements

Model RUBBER TRACK-SHOE STEEL TRACK-SHOE

PC20R-8 A=10-15 mm A=10-30mm

PC27R-8 A=10-15 mm A=10-30mm

2. Adjustment
If the track-shoe tensions do not fall within permissible
limits, adjust them as follows:

• On completion of the adjustment and before en-

gaging the greasing pump G1, thoroughly clean
the grease nipple and surrounding area.
1 - If the tension is too low.
Inject grease through the grease nipple (1) using
the grease pump G1.
★ If difficulties are found when injecting the
grease, move the machine slowly backwards
and forwards over a short distance.

2 - If the tension is too high.

Slowly loosen the union (2) in order to let grease
out of the valve.

The grease in the stretcher cylinder is under

* pressure and could seriously injure the op-
erator. For this reason the valve should not
be loosened for more than one turn.
★ If the grease does not come out easily,
move the machine slowly backwards
and forwards over a short distance.

20-38
Command Ports
Swing (R.H. - L.H.) A1 - B1
Travel motor L.H. A2 - B2
(Forwards - Backwards)
Travel motor R.H.
(Forwards - Backwards)

<
CO
00
CO
Boom swing (R.H. - L.H.) A4 - B4
Blade (Raise - Lower) A5 - B5
Arm (Close - Open) A6 - B6
Boom (Lower - Raise) A7 - B7
Bucket (Dump - Curl)

<
CO
00
CO
Hammer (Suction - Delivery)

<
o>
00
o>

20-39
PC27R-8
1. Control of operating pressure (unloading valve)
1 - Remove the plug (1) of pump P1 and mount a
pressure adapter.

2 - Connect a pressure gauge E1 (60 bar).

3 - Start the engine and bring it up to high idling with

all levers in neutral position.
4 - Check the pressure.
★ Normal pressure:
35±5 kg/cm2 (34.3±4.9 bar)
Л The unloading valve cannot be re-adjusted. If
the pressure differs from the normal value the
valve must be substituted.

2. Control the operating pressures of the working

equipment and machine travel
1 - Remove the plug (1) of pump P1 and mount a
pressure adapter.
2 - Connect a pressure gauge E2 (400 bar) or E3
(600 bar).

3 - Start the engine and bring it up to high idling.

4 - Check the pressure for each movement with the

command lever at the end of its stroke and with
the pressure stabilised.

Л To check the pressure of the working equip-

ment, push the piston to the end of its stroke.
Л To check the pressure of machine travel, in-
sert a block "A" between the chassis and
the sprocket wheel.
★ Normal pressures:
Working equipment and travel:
210 + 10 kg/cm2 (206 + 10 bar)

3. Check the operating pressure of the turret

swing
1 - Set the main relief valve of the control valve to a
value higher by 20 bar than the maximum pres-
sure to be checked.
2 - Remove the caps (1) of the swing motor and
mount the pressure adapters.
3 - Connect a pressure gauge E2 (400 bar) or E3 (600
bar).
Insert the turret swing locking-pin.
4 - Start the engine and bring it up to high idling.
5 - Check the pressure for a swing to the right and a
swing to the left, bringing the lever of the left-hand
PPC valve to the end of its stroke and with the
pressure stabilized.
★ Normal pressure:
215+5 kg/cm2 (211+5 bar)
6 - Restore the setting of the main relief valve.

20-41
PC27R-8
Valve adjustment
★ The unloading valve cannot be re-adjusted, only sub-
stituted.

1. Adjustment of the main relief valve

If the pressures measured for the working equipment
and machine travel do not fall within normal values,
adjust the main relief valve (1) as follows:
2 - Loosen the lock nut (2) and rotate the adjusting
screw (3).
• To INCREASE pressure, turn in a CLOCK-
WISE direction.
• To DECREASE pressure, turn in a COUN-
TER-CLOCKWISE direction.
• Each turn of the adjusting screw (3) varies the
pressure by about 125 bar (128 kg/cm 2).
3 - Lock the nut (2).
SZEEO Nut: 59±10 Nm
• After adjustment, check the adjustment of the
main relief valve with the same procedures as
used for the measurements.

2. Adjustment of the safety valve of the swing mo-

tor
Л Do not calibrate the valves when the circuits are
under pressure.
★ To perform these adjustments, follow the proce-
dures described in the calibration control section.
If the pressures measured for the swings to the right
and to the left do not come within the normal values,
adjust the safety valve (1) of the swing motor as fol-
lows:

1 - Loosen the lock nut (2) and turn the adjusting

screw (3).
• To INCREASE pressure, turn in a CLOCK-
WISE direction.
• To DECREASE pressure, turn in a COUN-
TER-CLOCKWISE direction.
• Each turn of the adjusting screw (3) varies the
pressure by about 100 bar (102 kg/cm 2).

2 - Lock the nut (2).

Nut: 8.8±1 Nm

20-43
CONTROL AND REGULATION OF THE LS DIFFERENTIAL
PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC27R-8)
Test
1. Test method with differential pressure gauge E3
1 - Remove the plugs (1) and (2), mount the elbow E5
and mount two pressure adapters.
2 - Connect the differential pressure gauge E4.
★ Connect the high-pressure side to the adapter
(2) and the low-pressure side to the adapter
(1).
3 - Start the engine and use the working equipment
to raise one track-shoe.
4 - Bring the engine up to high idling and check the
LS differential pressure according to the test con-
ditions in Table 1.

Table 1

|LSr^t(agpmssuj ^

Max 34 3 The LS differential pressure

Neutral «Jfcx тс? is equal to the pressure gi-
( 35)
ven by the unloading valve
Half the
stroke (Swing
without load)

2. Test method with pressure gauges E2 or E3

★ The
m
ax
i
1 - Remove the plugs (1) and (2) and mount two
pressure adapters.
2 - Connect pressure gauge E2 or E3 to the pres-
sure adapter (2).
3 - Start the engine and use the working equipment
to raise one track-shoe.
4 - Bring the engine up to high idling and measure
th
e
d
el
iv
er
5 - Disconnect the pressure gauge E2 or E3 from the
p
u
m
6 - Measure the LS pressure in the same conditions
indicated at point 4. Make a note of the value read.
7 - Subtract the LS pressure from the delivery pres-
s
u
re
o

20-47
 CONTROL AND REGULATION OF THE LS DIFFERENTIAL
PRESSURE AND ADJUSTMENT OF THE LS VALVE (PC27R-8)

LS valve adjustment
If the APLS value is not the one indicated, adjust the LS
valve (1) as follows:
1 - Disconnect the tube (2).
2 - Loosen the lock nut (3) and turn the adjusting screw
(4).
• To INCREASE pressure, turn in a CLOCKWISE
direction.
• To DECREASE pressure, turn in a COUNTER-
CLOCKWISE direction.
★ Each turn of the adjusting screw (4) varies the
pressure by about 13 bar (13 kg/cm 2).
3 - Lock the nut (3).
Nut: 31 ±3.5 Nm
★ After the adjustment, check the setting of the LS
valve (1) following the procedure used for the test.

20-48
 REGULATION OF THE PC VALVE (PC27R-8)

REGULATION OF THE PC VALVE (PC27R-8)

★ If the engine speed decreases when an increase in

pressure or delivery is requested, or when the speed
of the working equipment is low, even though the en-
gine speed, the delivery pressure and the LS differen-
tial pressure are all normal, the PC valve (1) should be
regulated as follows:
1 - Loosen the check-nut (2).
2 - Turn the adjustment screw (3).
• If the working equipment speed is low, turn the
screw (3) in a CLOCKWISE direction to INCREASE
the torque absorption of the pump.
• If the engine rpm suffer an abnormal drop, turn
the screw (3) in a COUNTER-CLOCKWISE direc-
tion to DECREASE the torque absorption.
3 - After adjustment, tighten the check-nut (2).

20-49
 CONTROL AND REGULATION OF THE
SERVO-CONTROL POWER SUPPLY

CONTROL AND REGULATION OF THE SERVO-CONTROL

POWER SUPPLY
★ Test conditions:
• Engine: at working temperature.
• Hydraulic oil temperature: 45-55 0C.

Before removing the cap to measure the pressure,

* release the residual pressures from the circuits
(See «ELIMINATION OF RESIDUAL PRESSURES
OF THE CIRCUIT AND THE TANK») and put the
safety device engagement levers into their locked
position.
Д After connecting the pressure gauge, pressurise the
tank. For details see «PRESSURISATION OF THE
TANK».

1. Checking the pressure of the servo-controls

1 - Remove the R.H. hood (1).

2 - Remove the cap (2) of pump P2 and a pressure

adapter.

3 - Connect the pressure gauge E1 (60 bar).

4 - Start the engine and bring it up to high idling with

all leers in neutral position.
5 - Check the pressure.
о о 2
★ Normal pressure: 29+5 bar (30+5 kg/cm2)

2. Regulating the servo-control valve

If the pressure value does not fall within the toler-
ances, regulate the valve (3) as follows:

1 - Loosen the lock nut (4) and turn the adjusting

screw (5).
• To INCREASE pressure, rotate in a CLOCK-
WISE direction.
• To DECREASE pressure, rotate in a COUN-
TER-CLOCKWISE direction.
★ Each turn of the screw (5) varies the pressure
by 56 kg/cm2 (55 bar).

2 - Lock the nut (4).

Nut: 22±2.5 Nm

20-50
 40 STANDARD MAINTENANCE

Swing circle......................................................................................2 Hydraulic pump.............................................................................12

Swing machinery.............................................................................3 Control valve.................................................................................14
Final drive........................................................................................4 Swivel joint....................................................................................20
Sprocket............................................................................................5 Swing motor...................................................................................21
Track frame and recoil spring.........................................................6 Travel motor..................................................................................24
Idler...................................................................................................7 PPC Valve (for boom, arm, bucket, swing).................................26
Carrier roller.....................................................................................8 PPC Valve (for hammer)...............................................................27
Track roller.......................................................................................9 Cylinder..........................................................................................28
Track shoe..................................................................................... 10 Work equipment............................................................................30
40-13
CONTROL VALVE

40-14
40-15
No. Check item Criteria Remedy
Standard size Repair limit
1 Spool return spring Free length Installed Installed Free Installed When
(arm, swing, arm, bucket) x0.D. length load length load
29x17.5 28.5 22.6 N
—
18.1 N damage or
(2.3 kg) (1.84 kg) deformation
is found,
2 Spool return spring 46.2x20 25.4 98 N —
78.4 N replace the
(boom, blade) (10 kg) (8 kg) spring
3 Spool return spring 42x20 25.4 74.5 N
—
59.6 N
(travel) (7.6 kg) (6.1 kg)

40-16
No. Check item Criteria Remedy
Standard size Repair limit
1 Pressure compensation Free length Installed Installed Free Installed
valve spring x 0.D. length load length load
16.8x8.4 15 7.64 N —
6.11 N
(0.78 kg) (0.62 kg)
2 Pressure compensation 20x8.4 12 6.86 N —
5.49 N When
valve spring (0.7 kg) (0.56 kg)
3 Unload valve spring 28.94x11.8 13 22.5 N —
18 N damage or
(2.3 kg) (1.84 kg) deformation
4 38.2x9.2 20 — is found,
Pressure compensation 30.4 N 24.3 N
replace the
valve spring (3.1 kg) (2.5 kg)
spring
5 Cooler check valve spring 29.1x18.7 18 82.4 N
—
65.9 N
(8.4 kg) (6.7 kg)
6 Back pressure check 27.2x13.2 21 78.8 N —
63 N
valve spring (8.04 kg) (6.43 kg)
7 Spool return spring (hammer) 29x17.5 28.5 22.6 N —
18.1 N
(2.3 kg) (1.84 kg)

40-17
No. Check item Criteria Remedy
Standard size Repair limit When
1 Check valve spring Free length Installed Installed Free Installed damage or
(arm) x0.D. length load length load deformation
is found,
21.9x5 15.8 1.96 N
—
1.57 N replace the
(0.2 kg) (0.16 kg) spring

40-18
No. Check item Criteria Remedy
Standard size Repair limit
1 Check valve spring Free length Installed Installed Free Installed When
x 0.D. length load length load damage or
deformation
21.9x5 15.8 1.96 N
—
1.57 N is found,
(0.2 kg) (0.16 kg) replace the
2 Pilot relief valve spring 32.4x10.4 27 83.3 N
—
66.6 N spring
(8.5 kg) (6.8 kg)

40-19
No. Check item Criteria Remedy

Standard size Repair limit When

damage or
1 Check valve spring Free Installed Installed Free Installed deformation
length length load length load

30.1 15.7 2.3 N 25.5 1.6 N

2 Clearance between Standard clearance Clearance limit

piston and cylinder 0.03-0.15 0.4 Replace

3 Clearance between 0 .01 -0.02 0.4

shoe and piston

40-22