Komatsu ecot3 PC300-8 Shop Manual Download Page 91

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10 Structure, function and maintenance standard

SEN01992-00

PC300, 350-8

Track roller

Unit: mm

No.

Check Item

Criteria

Remedy

Outside diameter of outer flange

Standard size

Rapair limit

Build-up welding

for rebuilding or

replace

216

—

Outside diameter of inner flange
(Double flange)

210

—

Outside diameter of tread

180

168

Thickness of tread

Overal width

250

—

Width of tread

Single flange

—

Double flange

47.7

Width of flange

Single flange

—

Double flange

Width of inner frange
(Double frame)

—

Clearance between bushing and
collar
(Sum of clearance at both sides)

0.44 – 0.97

—

Replace bushing

Clearance between shaft and
bushing

Standard

size

Tolerance

Standard

clearance

Clearance

limit

Shaft

Hole

–0.250
–0.350

+0.186
–0.064

0.186 –

0.536

—

Interference between roller and
bushing

Standard

size

Tolerance

Standard

interference

Interference

limit

Shaft

Hole

+0.108
+0.008

–0.006
–0.036

0.014 –

0.144

—

Summary of Contents for ecot3 PC300-8

Page 1: ...HYDRAULIC EXCAVATOR SEN01983 15 PC300 8 PC300LC 8 PC350 8 PC350LC 8 SERIAL NUMBERS PC300 60001 PC300LC 60001 PC350 60001 PC350LC 60001 and up...

Page 2: ......

Page 3: ...1SHOP MANUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 00 Index and foreword 1 Index Comp...

Page 4: ...al information SEN01986 02 01 Specification SEN01987 01 Specification and technical data SEN01988 01 10 Structure function and maintenance standard SEN01989 08 Engine and cooling system SEN01990 00 Po...

Page 5: ...nd assembly SEN02635 02 Engine and cooling system SEN02636 03 Power train SEN02637 02 Undercarriage and frame SEN02638 03 Hydraulic system SEN02639 02 Work equipment SEN02640 00 Cab and its attachment...

Page 6: ...echnical data SEN01988 01 Specification dimension drawings 2 Dimensions 2 Working ranges 3 Specifications 4 Weight table 10 Table of fuel coolant and lubricants 12 10 Structure function and maintenanc...

Page 7: ...t pressure 9 Testing exhaust gas color 10 Adjusting valve clearance 12 Testing compression pressure 14 Testing blow by pressure 18 Testing engine oil pressure 19 Testing fuel pressure 20 Handling duri...

Page 8: ...r Lock Caution 2 3 Failure code 989N00 Engine Controller Lock Caution 3 4 Failure code AA10NX Air cleaner Clogging 6 Failure code AB00KE Charge Voltage Low 8 Failure code B BAZG Eng Oil Press Low 10 F...

Page 9: ...0 Failure code CA2185 Throt Sens Sup Volt High Error 42 Failure code CA2186 Throt Sens Sup Volt Low Error 43 Failure code CA2249 Rail Press Very Low Error 44 Failure code CA2265 Fuel Feed Pump Open Er...

Page 10: ...isplay by machine monitor are different from applicable machine 22 E 10 Fuel level monitor was lighted in red while engine running 23 E 11 Engine coolant temperature gauge does not indicate normally 2...

Page 11: ...ge sound is made when upper structure stops swinging 31 H 28 Swing hydraulic drift is too big 32 Troubleshooting of engine S mode SEN02634 02 Method of using troubleshooting chart 3 S 1 Starting perfo...

Page 12: ...hydraulic tank assembly 5 Removal and installation of control valve assembly 7 Disassembly and assembly of control valve assembly 10 Removal and installation of hydraulic pump assembly 11 Removal and...

Page 13: ...00 Index and foreword SEN01985 15 PC300 350 8 11...

Page 15: ...1 Foreword and general information Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of...

Page 16: ...ear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding par...

Page 17: ...slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the...

Page 18: ...e hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in...

Page 19: ...le the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the groun...

Page 20: ...in your eyes or contacts your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Re...

Page 21: ...e standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them T...

Page 22: ...ted with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are neces...

Page 23: ...y is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a T...

Page 24: ...s in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the...

Page 25: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely...

Page 26: ...er does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector...

Page 27: ...pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip p...

Page 28: ...is will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For conn...

Page 29: ...e 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are se...

Page 30: ...the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use...

Page 31: ...onnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the pow...

Page 32: ...sassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings...

Page 33: ...w oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and...

Page 34: ...2V140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor...

Page 35: ...the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor wi...

Page 36: ...up 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn...

Page 37: ...dicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material...

Page 38: ...23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor N...

Page 39: ...ue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White...

Page 40: ...use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit...

Page 41: ...he cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for th...

Page 42: ...If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler...

Page 43: ...er 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig...

Page 44: ...hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to disc...

Page 45: ...Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and...

Page 46: ...r bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34...

Page 47: ...idth across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10...

Page 48: ...series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter...

Page 49: ...e are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 2 1 02 0 20 10 12 2...

Page 50: ...so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided...

Page 51: ...79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 1...

Page 52: ...73 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8...

Page 53: ...1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1...

Page 54: ...12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0...

Page 55: ...00 Index and foreword SEN01986 02 PC300 350 8 41...

Page 57: ...PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 01 Specification 1 Specification and technical data Specification dimensio...

Page 58: ...0 11 140 11 140 B Overall height mm 3 250 3 250 3 250 3 250 C Overall width mm 3 190 3 190 3 190 3 190 D Shoe width mm 600 600 600 600 E Cab height mm 3 110 3 110 3 110 3 110 F Tail swing radius mm 3...

Page 59: ...0 11 100 11 100 11 100 B Max digging depth mm 7 380 7 380 7 380 7 380 C Max digging height mm 10 100 10 100 10 100 10 100 D Max vertical wall digging depth mm 6 400 6 400 6 400 6 400 E Max dumping hei...

Page 60: ...ng speed rpm 9 5 9 5 Swing operation max slope angle deg 21 21 Travel speed km h Lo 3 2 Mi 4 5 Hi 5 5 Lo 3 2 Mi 4 5 Hi 5 5 Gradeability deg 35 35 Ground pressure kPa kg cm2 62 9 0 64 59 0 0 60 Dimensi...

Page 61: ...e Flywheel horsepower kW rpm HP rpm 183 9 1 980 250 1 980 Max torque Nm rpm kgm rpm 1 108 1 450 113 1 450 High idle under no load rpm 2 050 Low idle under no load rpm 1 000 Min fuel consumption ratio...

Page 62: ...and parking brake Swing motor KMF230ABE 5 piston type 1 with safety valve shaft brake and reverse prevention valve Hydraulic cylinder Boom 1 Arm 1 2 Bucket Type Double acting piston Double acting pist...

Page 63: ...rpm 9 5 9 5 Swing operation max slope angle deg 18 18 Travel speed km h Lo 3 2 Mi 4 5 Hi 5 5 Lo 3 2 Mi 4 5 Hi 5 5 Gradeability deg 35 35 Ground pressure kPa kg cm2 65 9 0 67 62 9 0 64 Dimensions Over...

Page 64: ...Flywheel horsepower kW rpm HP rpm 183 9 1 950 250 1 950 Max torque Nm rpm kgm rpm 1 108 1 450 113 1 450 High idle under no load rpm 2 050 Low idle under no load rpm 1 000 Min fuel consumption ratio g...

Page 65: ...h safety valve shaft brake and reverse prevention valve Hydraulic cylinder Boom 1 Arm 1 2 Bucket Type Double acting piston Double acting piston Double acting piston Cylinder inner diameter mm 140 160...

Page 66: ...88 Travel motor 164 x 2 164 x 2 Center swivel joint 29 9 29 9 Track frame assembly 7 311 7 979 q Track frame 3 879 4 441 q Swing circle 487 487 q Idler 169 x 2 169 x 2 q Idler cushion 287 5 x 2 287 5...

Page 67: ...ly 7 538 8 183 q Track frame 4 074 4 602 q Swing circle 487 487 q Idler 169 x 2 169 x 2 q Idler cushion 287 5 x 2 287 5 x 2 q Carrier roller 28 x 4 28 x 4 q Track roller double frame 57 5 x 6 57 5 x 8...

Page 68: ...SEN01988 01 01 Specification 12 PC300 350 8 Table of fuel coolant and lubricants 1 a For details of the notes Notes 1 Note 2 in the table see Operation and Maintenance Manual...

Page 69: ...00 350 8 13 Unit l Reservoir PC300 300LC 8 PC350 350LC 8 Specified l Refill l Engine oil pan 40 35 Swing machinery case 16 5 16 5 Final drive case each 9 9 Damper case 1 3 1 3 Hydraulic system 365 188...

Page 71: ...C 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Engine and co...

Page 72: ...nance standard 2 PC300 350 8 Engine related parts 1 1 Drive plate 2 Torsion spring 3 Stopper pin 4 Friction plate 5 Damper assembly 6 Muffler 7 Rear engine mount 8 Front engine mount Outline A wet typ...

Page 73: ...00 PC300 350 8 3 Radiator oil cooler and aftercooler 1 1 Reservoir tank 2 Radiator 3 Radiator cap 4 Oil cooler 5 Guard 6 Aftercooler 7 Radiator inlet hose 8 Radiator outlet hose 9 Shroud Specification...

Page 75: ...LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Power train...

Page 76: ...8 Power train 1 1 Idler 2 Center swivel joint 3 Control valve 4 Final drive 5 Travel motor HMV160ADT 2 6 Engine SAA6D114E 7 Hydraulic pump HPV125 125 8 Travel speed solenoid valve 9 Swing brake soleno...

Page 77: ...th 90 2 Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone S position Specifications Reduction ratio 90 13 6 923 Amount of grease 33 l G2 LI Unit mm No Check Item...

Page 78: ...SEN01991 00 10 Structure function and maintenance standard 4 PC300 350 8 Swing machinery 1...

Page 79: ...ace 0 18 0 28 16 Backlash between No 1 sun gear and No 1 planetary gear 0 15 0 51 1 00 17 Backlash between No 1 planetary gear and ring gear 0 17 0 60 1 10 18 Backlash between No 1 planetary carrier a...

Page 80: ...anetary gear No of teeth 42 4 No 1 sun gear No of teeth 11 5 No 2 sun gear No of teeth 19 6 No 1 planetary carrier 7 No 2 planetary carrier 8 Cover 9 Ring gear No of teeth 97 10 Hub 11 Sprocket 12 Flo...

Page 81: ...ear and ring gear 0 18 0 62 1 2 17 Backlash between No 2 planetary carrier and motor 0 06 0 25 18 Backlash between No 2 sun gear and No 2 planetary gear 0 15 0 51 1 00 19 Backlash between No 2 planeta...

Page 82: ...t mm No Check Item Criteria Remedy 1 Wear of tooth tip Standard size Repair limit Build up welding for rebuilding or replace 336 5 324 5 2 Thickness of tooth root 20 14 3 Width of tooth 87 84 4 Wear o...

Page 83: ...ction and maintenance standard SEN01991 00 PC300 350 8 9 Full size drawing of sprocket tooth shape a The above drawing is reduced to 62 Enlarge it to 160 to return it to the full scale and make a copy...

Page 85: ...8 PC350LC 8 Machine model Serial No PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Undercarriage and frame Tr...

Page 86: ...ing indicates PC300 8 1 Idler 2 Track frame 3 Carrier roller 4 Final drive 5 Track roller 6 Track shoe 7 Center guard 8 Front guard q The dimensions and the number of track roll ers depend on the mode...

Page 87: ...Item Criteria Remedy 9 Vertical width of idler guide Standard size Tolerance Rapair limit Build up welding for rebuilding or replace Track frame 123 2 1 127 Idler sup port 120 0 5 118 10 Horizontal w...

Page 88: ...SEN01992 00 10 Structure function and maintenance standard 4 PC300 350 8 Idler 1...

Page 89: ...ickness of tread 5 Total width 190 6 Width of tread 44 50 7 Clearance between shaft and bush ing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 80 0 225 0 325 0...

Page 90: ...of tread 50 3 4 Thickness of tread 32 25 5 Width of flange 19 6 Clearance between shaft and bush ing Standard size Tolerance Standard clearance Clearance limit Shaft Hole 54 0 250 0 280 0 074 0 040 0...

Page 91: ...al width 250 6 Width of tread Single flange 49 Double flange 47 7 7 Width of flange Single flange 27 Double flange 8 Width of inner frange Double frame 98 9 Clearance between bushing and collar Sum of...

Page 92: ...Check Item Criteria Remedy 1 Link pitch Standard size Repair limit Reverse or replace 216 3 219 3 2 Outside diameter of bushing Standard size Repair limit 66 9 61 9 3 Thickness of bushing metal 10 8 5...

Page 93: ...ten Triple grouser shoe 393 39 40 4 120 10 b Master link Tightening torque Nm kgm Retightening angle deg Lower limit torque Nm kgm 21 Interference between bushing and link Standard size Tolerance Stan...

Page 94: ...PC350 8 PC350LC 8 600 mm width shoe Unit mm No Check Item Criteria Remedy 1 Height Standard size Repair limit Build up welding for rebuilding or replace 36 24 30 18 2 Thickness 11 3 Length of base 32...

Page 95: ...10 Structure function and maintenance standard SEN01992 00 PC300 350 8 11...

Page 97: ...8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 1...

Page 98: ...lic tank 11 Multi pattern selector valve 12 L H PPC valve 13 Work equipment lock lever electric type 14 Center swivel joint 15 R H PPC valve 16 Travel PPC valve 17 Attachment circuit selector valve 18...

Page 99: ...10 Structure function and maintenance standard SEN01993 00 PC300 350 8 3...

Page 100: ...ap 2 Bypass valve 3 Strainer 4 Filter element 5 Sight gauge 6 Hydraulic tank Specifications Tank capacity 275 l Amount of oil inside tank 188 l Safety valve Relief cracking pressure 16 7 6 9 kPa 0 17...

Page 101: ...10 Structure function and maintenance standard SEN01993 00 PC300 350 8 5...

Page 102: ...SEN01993 00 10 Structure function and maintenance standard 6 PC300 350 8 Hydraulic pump 1 Type HPV125 125...

Page 103: ...port PD1R Air breeder PD2F Drain plug PD2R Drain plug PENF Front control pressure detection port PENR Rear control pressure detection port PEPC EPC basic pressure port PEPB EPC basic pressure detecti...

Page 104: ...ructure function and maintenance standard 8 PC300 350 8 1 Front shaft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12 Servo pi...

Page 105: ...e 5 constitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil...

Page 106: ...is way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston 6 sucks and discharges the oil by the amount F E...

Page 107: ...cal surface rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side Main pump...

Page 108: ...sure PP pressure PLS called the LS pressure coming from the con trol valve output and pressure PSIG called the LS selector pressure from the proportional solenoid valve enter this valve q The relation...

Page 109: ...sure of the EPC valve for the LS valve entering port G also changes the position of spool 6 Setting force of the spring is changed q Before the engine is started servo piston 12 is pushed to the right...

Page 110: ...e PC valve is connected to the drain port so the pressure across circuits D and K becomes drain pressure PT The operation of the PC valve is explained later q The pressure at the large diameter end of...

Page 111: ...ssure PP pushes spool 6 to the right q When spool 6 moves main pump pressure PP flows from port C to port D and from port K it enters the large diameter end of the piston q Main pump pressure PP also...

Page 112: ...pening from port D to port E and the dis tance from port C to port D is almost the same q At this point the relationship between the pres sure receiving areas across servo piston 12 is A0 A1 3 5 so th...

Page 113: ...engine hose power q If the pump discharge pressure increases due to increased load during operation this valve decreases the pump delivery q And if the pump delivery pressure goes low it increases the...

Page 114: ...he com bined spool pushing force is balanced by the setting force of springs 4 and 6 as well as the pump pressures PP1 self pressure and PP2 another pump s pressure q The pressure port C pressure outp...

Page 115: ...10 Structure function and maintenance standard SEN01993 00 PC300 350 8 19...

Page 116: ...ve is connected to port E of the LS valve q Self pressure PP1 enters port B and the small diameter end of servo piston 9 and other pump pressure PP2 enters port A q When pump pressures PP1 and PP2 are...

Page 117: ...end of the piston also rises Thus the leftward move of servo piston 9 is stopped q Servo piston 9 stop position Pump deliv ery is decided by the position where the push ing force generated from the p...

Page 118: ...2 Operation q When port E and port G of the LS valve are connected this pressure from port J enters the large diameter end of servo piston 9 stopping servo piston 9 q If main pump pressure PP2 increas...

Page 119: ...mp delivery Q becomes as shown below q If command voltage X sent to PC EPC valve solenoid 1 increases further the relationship between average pump pressure PP1 PP2 2 and pump delivery Q is proportion...

Page 120: ......

Page 121: ...ight and is balanced at the position in the diagram above q In this case the pressure from port B flows to port C so servo piston 9 moves to the right smaller pump delivery and stops at a position to...

Page 122: ...3 00 10 Structure function and maintenance standard 26 PC300 350 8 3 LS PC EPC Valve C To LS PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7 P...

Page 123: ...e in proportion to the size of the signal and outputs it to the LS PC valve Operation 1 When signal current is 0 coil is deener gized q When there is no signal current flowing from the controller to c...

Page 124: ......

Page 125: ...volume valve stabilizes the EPC valve s output pressure Operation q Output pressure from EPC valve is conducted to port C and as the result propulsion force of piston 3 is increased by the load of spr...

Page 127: ...er PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 2 Control valve 2 CLSS 14 Functions an...

Page 128: ...oid valve P1 From bucket PPC and EPC valves P2 From bucket PPC and EPC valves P3 From L H Travel PPC valve P4 From L H Travel PPC valve P5 From boom PPC and EPC valves P6 From boom PPC and EPC valves...

Page 129: ...10 Structure function and maintenance standard SEN01994 01 PC300 350 8 3 General view...

Page 130: ...SEN01994 01 10 Structure function and maintenance standard 4 PC300 350 8 Sectional view 1 5...

Page 131: ...lower 14 Pressure compensation valve Right swing 15 Pressure compensation valve R H travel for ward 16 Pressure compensation valve Arm in 17 Main relief valve 18 Unload valve 19 Unload valve 20 Main...

Page 132: ...SEN01994 01 10 Structure function and maintenance standard 6 PC300 350 8 2 5...

Page 133: ...r 12 Suction valve R H travel forward 13 Safety suction valve Arm in 14 LS shuttle valve Arm 15 LS shuttle valve R H travel 16 LS select valve 17 LS shuttle valve Boom 18 LS shuttle valve L H travel 1...

Page 134: ...SEN01994 01 10 Structure function and maintenance standard 8 PC300 350 8 3 5...

Page 135: ...alve 13 Pressure compensation valve Forward 14 Spool 15 Suction valve Forward 16 Suction valve Reverse 17 Pressure compensation valve Reverse Swing valve 18 LS select valve 19 Pressure compensation va...

Page 136: ...SEN01994 01 10 Structure function and maintenance standard 10 PC300 350 8 4 5...

Page 137: ...tion valve Reverse Bucket valve 23 LS shuttle valve 24 Pressure compensation valve Curl 25 Spool 26 Safety suction valve Curl 27 Safety suction valve Dump 28 Pressure compensation valve Dump Unit mm N...

Page 138: ...SEN01994 01 10 Structure function and maintenance standard 12 PC300 350 8 5 5...

Page 139: ...Hi spool 5 Safety suction valve Arm Hi in 6 Boom Hi spool 7 Pressure compensation valve Boom Hi raise Service valve 1 8 LS shuttle valve 9 Pressure compensation valve 10 Spool 11 2 stage safety sucti...

Page 140: ...uenced by load q Controllability enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energ...

Page 141: ...constant q LS differential pressure EPLS Pump dis charge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure EPLS is lower than the...

Page 142: ...de of the control valve to bal ance the load q When actuators are operated together the pressure difference EP between the upstream inlet port and downstream outlet port of the spool of each valve bec...

Page 143: ...lustration shows actuator 7 in the merge mode with stroke end at the time of relief 1 Front pump 2 Rear pump 3 Main relief valve 4 Unload valve 5 Merge divider valve 6 Control valve 7 Actuator 8 Pump...

Page 144: ...SEN01994 01 10 Structure function and maintenance standard 18 PC300 350 8 Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves...

Page 145: ...k pressure valve 33 Boom drift prevention valve 34 Boom Hi check valve 35 Main relief valve bucket side Set pressure 36 1 0 25 MPa 367 5 2 5 kg cm2 112 l min When digging force increased 38 2 0 25 MPa...

Page 146: ...side the valve this pres sure will be P1 q Since LS pressure is drained from the LS bypass valve LS pressure C tank pressure C 0 MPa 0 kg cm2 Operation q Pressure of pump circuit 3 is received by the...

Page 147: ...cylinder reaches the stroke end the main relief valve opens q The pump delivery Q is relieved to the tank See the system diagram q The pump discharge pressure PP and LS pressure PLS become approximat...

Page 148: ...pool meter in of pres sure compensation valve 3 and leads to LS shuttle valve 7 as the LS pressure q Connected to actuator port B via valve 4 and makes LS pressure C actuator load pres sure q Inlet po...

Page 149: ...the residual pressure in LS pressure circuit 6 from orifices a and b q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres sure q Bypass flow from LS bypass plug 5...

Page 150: ...alve 2 to the closing direction Integrated pressure compensation valve q High stress may occur when valve 2 collides with valve chamber seat portion C if a high peak pressure is generated in the actua...

Page 151: ...l meter in upstream pressure of port A is the pump pressure the spool meter in differential pressure upstream pressure port A pressure downstream pressure port B pressure becomes equivalent to all the...

Page 152: ...ream pressure will be equal to the maximum load pressure and the pressure will be divided according to the opening area ratio q If area ratio 1 or over the spool meter in downstream pressure will be g...

Page 153: ...sure in the springing chamber B 1 Hydraulic pump 2 Valve 3 Pressure compensation valve inner shuttle valve 4 Piston Function q Shuttle valve 3 is pushed to the right by port A pressure and cuts off in...

Page 154: ...re function and maintenance standard 28 PC300 350 8 2 In the case of travel Outline q Since no holding pressure is generated at port A of the travel circuit a pressure compensa tion valve without shut...

Page 155: ...Provides the regeneration circuit from the cyl inder bottom to the cylinder head when the boom is lowered and increases flow to the cyl inder bottom Operation q If the cylinder head pressure is lower...

Page 156: ...tenance standard 30 PC300 350 8 2 If the cylinder head pressure is higher than the bottom pressure digging work etc Function q Check valve 6 provided to regeneration cir cuit C closes to shut off the...

Page 157: ...ration circuit pro vided from the cylinder head to the bottom increases the cylinder speed as the cylinder flow involves the pump delivery plus regener ated flow Operation q If the cylinder head press...

Page 158: ...and maintenance standard 32 PC300 350 8 2 If the cylinder head pressure is lower than the bottom pressure Function q Check valve 6 provided to regeneration cir cuit C closes to shut off the flow from...

Page 159: ...group q Merges and divides LS circuit pressure Operation q Since pilot pressure PS is OFF output pres sure from PPC valve is 0 kg cm2 q Main spool 1 is pressed to the right by spring 2 and ports E and...

Page 160: ...ft and ports E and F are divided q Pressurized oil discharged from the two pumps are sent to respective control valves P1 pressure To bucket L H travel and boom P2 pressure To swing R H travel and arm...

Page 161: ...el spool 7 Arm spool 8 LS shuttle valve 9 LS circuit Operation 1 If pilot pressure BP is OFF q Since pilot pressure BP is OFF piston 3 is pressed to the left by spring 2 q When swing operated swing LS...

Page 162: ...supplies it as control pressure for the solenoid valves EPC valves etc Operation 1 While engine is stopped q Poppet 11 is pressed by spring 12 against the seat and port PR is not connected to TS q Val...

Page 163: ...moves to close the pass between ports P2 and PR q Pressure P2 is reduced by the opening at this time and adjusted to a constant pressure the set pressure and supplied as pressure PR 3 When load pressu...

Page 164: ...re is gener ated q If pressure PR of self pressure reducing valve becomes abnormally high ball 16 con tracts spring 15 and becomes separated from the seat q Allows the pressurized oil to TS from port...

Page 165: ...upplied evenly to both travel motors to improve machine s straight travel performance q When the machine is steered outside pilot pressure PST closes the travel junction valve to improve steering perf...

Page 166: ...travel junction spool 2 is pressed by the force of spring 1 against the right side and the pass between ports PTL and PTR is open q If the oil flow rates to the L H and R H travel motors become differ...

Page 167: ...dumping bucket dig ging or operating dump q When controlling the stroke of the boom arm and or bucket pilot pressure of travel PPC valve passes through the circuit inside the con trol valves to actua...

Page 168: ...e orifice 5 and shut off stroke regulation signal chamber a and the drain circuit of the travel PPC valve q At this time the right travel reverse or forward lever is set PPC pressure is applied throug...

Page 169: ...while the boom lever is not operated Operation q When the boom is raised pressurized oil from the control valve works on the ring shaped area S d1 area d2 area caused by the difference between outside...

Page 170: ...rifice a of poppet 5 is closed by pilot piston 2 q The holding pressure of boom cylinder bottom works on the ring shaped area S caused by the difference between outside diameter d1 of poppet 5 and sea...

Page 171: ...pool 2 q Pressurized oil in chamber b inside the pop pet is drained via orifice c q Pressurized oil of the boom bottom flows to ori fice a o chamber b o orifice c o drain T and the pressurized oil in...

Page 172: ...ile the arm lever is not operated Operation q When the arm OUT is operated pressurized oil from the control valve works on the ring shaped area S d1 area d2 area caused by the difference between the o...

Page 173: ...om orifice a of poppet 5 is closed by pilot piston 2 q The holding pressure of arm cylinder head works on ring shaped area S caused by the difference between outside diameter d1 of poppet 5 and seat d...

Page 174: ...he PPC valve q Pressurized oil in chamber b inside the pop pet is drained via orifice c q Pressurized oil of the arm head flows to orifice a o chamber b o orifice c o drain T and the pressurized oil i...

Page 175: ...er bottom circuit the pressurized oil in port B pushes check valve 6 open then safety valve 3 operates q If arm drift prevention valve optional is installed to the arm cylinder head circuit the boom c...

Page 176: ...side flows to orifice a o chamber b o orifice c o drain T and the pressure in chamber b lowers q If the pressure of chamber b drops lower than that of port A pressure receiving force of the pressure...

Page 177: ...sure from the PPC valve to 0 kg cm2 q The pressurized oil that has flowed and been drained through orifice a in valve 2 is closed by pilot piston 1 q The holding pressure on the arm bottom side works...

Page 178: ...e control valve is con nected with port T through orifice b of valve 1 2 While engine is running q Output pressure PR of the self pressure reducing valve is applied via the control valve to spring cha...

Page 179: ...of relief valve is determined by spring 1 installed load 1st stage q Respective setting is not required for both the 1st and 2nd stages Setting the 1st stage com pletes the setting of the 2nd stage 1...

Page 180: ...s to relieve a load without lever opera tion if high load is applied to the cylinder q Improves work efficiency and reduces machine body vibration Operation q The safety set pressure is determined by...

Page 181: ...d to section A via passage B q Piston 2 works on the pressure receiving bore portion d2 d1 of section A q This pilot pressure contracts spring 3 and piston 2 moves to the right until making con tact w...

Page 182: ...n to the service valve when the service valve attachment and the work equipment valve boom raising etc are operated together Equivalent surface area ratio variable q Pressurized oil from the service v...

Page 183: ...owing equation P x A1 P x A2 LS A2 1 F A1 Area of D1 A2 Area of D2 F Force of spring P Pump discharge oil pressure q If the difference between the pump discharge pressure P and cylinder port pressure...

Page 184: ...selector solenoid valve T To hydraulic oil tank TS To hydraulic oil tank V To control valve 1 Spool 2 Spring Unit mm No Check item Criteria Remedy 3 Spool return spring Standard size Repair limit If d...

Page 185: ...ker is installed q Spool 1 is pressed to the left by the force of spring 2 q Ports ATT and V are interconnected and ports ATT and T are shut off Attachment is thus interconnected to the control valve...

Page 186: ...SEN01994 01 10 Structure function and maintenance standard 60 PC300 350 8 Hydraulic drift prevention valve 1 For the boom and arm...

Page 187: ...5 Check valve 6 Spring Unit mm No Check item Criteria Remedy 7 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Insta...

Page 188: ...q Chambers a and b are shut off q No pressurized oil flows between the control valve and the work equipment cylinder q Accordingly the work equipment is held in position q If the work equipment cylin...

Page 189: ...bers a and b are interconnected q Pressurized oil flows from the control valve to the work equipment cylinder If the piping is bursted q If piping A bursts between the control valve and the work equip...

Page 190: ...position 1st stage stroke q At this point chambers a and b are not interconnected q Pilot pressure further rises and reaches Pilot pressure Force of spring 2 area of d q Spool 1 moves further to the r...

Page 191: ...10 Structure function and maintenance standard SEN01994 01 PC300 350 8 65...

Page 193: ...PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 3 Valve control 2 PPC valve 4 Solenoid va...

Page 194: ...SEN01995 01 10 Structure function and maintenance standard 2 PC300 350 8 Valve control 1...

Page 195: ...er 6 R H PPC valve 7 R H work equipment control lever 8 Solenoid block 9 Accumulator 10 Control valve 11 Hydraulic pump 12 Junction box 13 L H work equipment control lever 14 L H PPC valve Lever posit...

Page 196: ...300 350 8 PPC valve 1 Work equipment and swing PPC valve P From self pressure reducing valve P1 L H PPC Arm out R H PPC Boom lower P2 L H PPC Arm in R H PPC Boom raise P3 L H PPC Swing left R H PPC Bu...

Page 197: ...eck item Criteria Remedy 12 Centering spring for ports P3 and P4 Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free le...

Page 198: ...comes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 q A...

Page 199: ...lied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole f in...

Page 200: ...tructure function and maintenance standard 8 PC300 350 8 Travel PPC valve P From self pressure reducing valve P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward P5 Travel signal P6 Steering s...

Page 201: ...10 Structure function and maintenance standard SEN01995 01 PC300 350 8 9...

Page 202: ...SEN01995 01 10 Structure function and maintenance standard 10 PC300 350 8...

Page 203: ...spool spring Unit mm No Check item Criteria Remedy 11 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load...

Page 204: ...at port P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure...

Page 205: ...ull stroke q Lever 5 pushes down piston 4 and retainer 9 pushes down spool 1 q Fine control hole f is shut off from drain chamber D and is interconnected to pump pressure chamber PP q Therefore the pi...

Page 206: ...1 10 Structure function and maintenance standard 14 PC300 350 8 Operation 1 When in neutral q No output is made from respective output ports from port P1 to P4 travel signal port P5 and steering signa...

Page 207: ...n shows the circuit for travelling straight forward q When operating L H motor forward port P2 output and R H motor forward port P4 out put pressure of both L H spring chamber k and R H spring chamber...

Page 208: ...ference of the pilot pressure between both sides is higher than a certain level the pilot pressure is output as the steer ing signal q The pressure in left spring chamber k of steering signal spool j...

Page 209: ...llustration shows the circuit for travelling left reverse and right forward q When operating L H motor reverse port P1 output and R H motor forward port P4 out put pressure of the R H spring chamber l...

Page 210: ...SEN01995 01 10 Structure function and maintenance standard 18 PC300 350 8 Service PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment swing PPC valve...

Page 211: ...ver 4 Plate 5 Retainer 6 Block 7 Body 8 EPC valve Unit mm No Check item Criteria Remedy 9 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diamet...

Page 212: ...ducing valve T To hydraulic tank 1 Body 2 Plug 3 Spool 4 Push pin 5 Coil 6 Plunger 7 Connector Unit mm No Check item Criteria Remedy 8 Return spring Standard size Repair limit If damaged or deformed r...

Page 213: ...essure in proportion to the size of the signal and outputs it to the control valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controll...

Page 214: ...are con nected q Spool 2 moves up and down so that the pro pulsion force of plunger 6 may be balance with pressure of port C spring load of spring 3 q The circuit pressure between the EPC valve and t...

Page 215: ...10 Structure function and maintenance standard SEN01995 01 PC300 350 8 23...

Page 216: ...SEN01995 01 10 Structure function and maintenance standard 24 PC300 350 8 Service PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment swing PPC valve...

Page 217: ...ver 4 Plate 5 Retainer 6 Block 7 Body 8 EPC valve Unit mm No Check item Criteria Remedy 9 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diamet...

Page 218: ...solenoid valve 3 Merge divider solenoid valve 4 Travel speed solenoid valve 5 Swing brake solenoid valve 6 Machine push up solenoid valve 7 2 stage relief solenoid valve T To tank A1 To PPC valve A2 T...

Page 219: ...o port A is closed and the pressurized oil from the main pump does not flow into the actuator At this time the oil from the actuator is drained through ports A and T into the tank When solenoid is ene...

Page 220: ...SEN01995 01 10 Structure function and maintenance standard 28 PC300 350 8 PPC accumulator 1 1 Gas plug 2 Shell 3 Poppet 4 Holder 5 Bladder 6 Oil port Specifications Gas capacity 300 cc for PPC...

Page 221: ...50 8 29 Return oil filter 1 For breaker 1 Drain plug 2 Filter 3 Case 4 Head cover 5 Relief valve Specifications Rated pressure 6 9 MPa 70 kg cm2 Flow 200 l min Relief valve cracking pressure 0 34 0 05...

Page 222: ...ontrol valve port B2 B2 To L H travel motor FORWARD port PA C1 From control valve port A5 C2 To R H travel motor REVERSE port PA D1 From control valve port B5 D2 To R H travel motor FORWARD port PB E...

Page 223: ...el speed solenoid valve PA From control valve PB From control valve T To tank Specifications Type HMV160ADT 2 Theoretical displacement Min 103 5 cm3 rev Max 160 8 cm3 rev Rated pressure 37 3 MPa 380 k...

Page 224: ...SEN01995 01 10 Structure function and maintenance standard 32 PC300 350 8...

Page 225: ...Ball 18 Regulator valve 19 Spring Unit mm No Check item Criteria Remedy 20 Spool return spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installa...

Page 226: ...ver 7 by pressing slow return valve 8 is shut off by regulator valve 21 q Fulcrum a of rocker cam 3 is eccentric to the working point b of the combined force of the propulsion force of cylinder 5 q Th...

Page 227: ...self pressure reducing valve flows to port P q Regulator valve 21 is pushed to the left q The pressurized oil from the control valve passes through passage d in regulator valve 21 and enters regulato...

Page 228: ...ated pressurized oil from the pump activates counterbalance valve spool 17 opening the parking brake circuit q The pressurized oil is conducted to chamber a of brake piston 10 and compresses spring 9...

Page 229: ...circuit q The pressurized oil in chamber a of brake piston 10 passes through orifice f of brake piston 10 and is drained to the motor case q Brake piston 10 is pushed to the right by spring 9 q Plate...

Page 230: ...its own weight q If the machine travels with the engine at low speed the motor may rotate without load causing the machine to run away resulting in a very dangerous situation q These valves are used t...

Page 231: ...ing downhill the motor will be caused to rotate without load to decrease the inlet side oil pressure q Pressure in chamber S1 is released via ori fices E1 and E2 q As the pressure in chamber S1 goes b...

Page 232: ...abnormal pres sure to the inlet port side of the motor in order to prevent damages to the equipment Bidirectional action 1 When pressure in chamber MB has become high when rotating clockwise q As lon...

Page 233: ...re Difference in areas of circles D1 and D3 x Pressure compresses spring 2 q Poppet 1 is moved leftward and the pressur ized oil flows into chamber MB of the oppo site circuit Operation of mechanism f...

Page 234: ...the process of returning to the neutral position the pressurized oil in chamber J flows to chamber PA via pas sage H and chamber G q Piston 3 moves to the left side decreasing the set load q The safe...

Page 235: ...ing brake solenoid MA From control valve MB From control valve S From control valve T To tank 1 Reverse prevention valve 2 Safety valve Specifications Type KMF230ABE 5 Theoretical displacement 229 4 c...

Page 236: ...SEN01995 01 10 Structure function and maintenance standard 44 PC300 350 8...

Page 237: ...nter spring 14 Check valve 15 Check valve spring 16 Shuttle valve 17 Shuttle valve spring Unit mm No Check item Criteria Remedy 18 Check valve spring Standard size Repair limit If damaged or deformed...

Page 238: ...T q Brake piston 7 is pushed down by brake spring 1 q Disc 5 and plate 6 are pushed together and the brake is applied 2 When solenoid valve is energized Operation q As the swing brake solenoid valve...

Page 239: ...que is generated in the motor and the motor starts to rotate q The pressurized oil from the outlet port of the motor passes from port MB through the con trol valve 6 and returns to the tank 2 When swi...

Page 240: ...SEN01995 01 10 Structure function and maintenance standard 48 PC300 350 8 Reverse prevention valve...

Page 241: ...andard SEN01995 01 PC300 350 8 49 MA From control valve MB From control valve T1 To tank T2 To tank 1 Valve body 2 Spool MA side 3 Spring MA side 4 Plug MA side 5 Spool MB side 6 Spring MB side 7 Plug...

Page 242: ...in areas of circles D1 D2 of spool 5 and moves spool 5 to the left side q Port MB o chamber e will be intercon nected q Since pressure MA is lower than the set pres sure of spring 3 spool 2 does not m...

Page 243: ...10 Structure function and maintenance standard SEN01995 01 PC300 350 8 51...

Page 244: ...SEN01995 01 10 Structure function and maintenance standard 52 PC300 350 8 Hydraulic cylinder 1 Boom cylinder Arm cylinder...

Page 245: ...2 Arm 110 0 036 0 090 0 261 0 047 0 083 0 351 0 412 Bucket 100 0 030 0 076 0 257 0 047 0 083 0 347 0 447 2 Clearance between piston rod support shaft and bushing Boom 100 0 030 0 060 0 190 0 070 0 100...

Page 247: ...PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1...

Page 248: ...SEN01996 01 10 Structure function and maintenance standard 2 PC300 350 8 Work equipment 1...

Page 249: ...m and arm and bushing 110 0 036 0 090 0 179 0 081 0 117 0 269 1 0 3 Clearance between pin connecting arm and link and bushing 90 0 036 0 090 0 165 0 072 0 108 0 255 1 0 4 Clearance between pin connect...

Page 250: ...SEN01996 01 10 Structure function and maintenance standard 4 PC300 350 8 Dimensions of components 1 1 Dimension of arm...

Page 251: ...320 0 5 0 320 0 5 0 Arm side 316 0 3 0 8 316 0 3 0 8 4 110 0 036 0 090 0 1 0 1 110 0 036 0 090 0 1 0 1 5 470 6 1 470 6 1 6 236 5 0 5 236 5 0 5 7 1022 4 1 1022 4 1 8 3178 3 3178 3 9 2975 6 1 2975 6 1 1...

Page 252: ...SEN01996 01 10 Structure function and maintenance standard 6 PC300 350 8 2 Dimension of bucket...

Page 253: ...512 2 0 5 2 37 9 0 5 37 9 0 5 3 94 19 94 14 4 513 6 513 6 5 1658 1666 6 193 208 7 50 42 8 90 0 2 0 0 90 0 2 0 0 9 120 0 054 0 054 120 0 054 0 054 10 125 0 1 0 1 125 0 1 0 1 11 346 1 0 346 1 0 12 68 68...

Page 255: ...NUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance stand...

Page 256: ...andard 2 PC300 350 8 Air conditioner piping 1 1 Hot water pickup piping 2 Receiver tank 3 Hot water return piping 4 Condenser 5 Air conditioner compressor 6 Refrigerant piping 7 Air conditioner unit 8...

Page 257: ...10 Structure function and maintenance standard SEN01997 00 PC300 350 8 3...

Page 259: ...PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 10 Structure function and maintenance standard 1 Electrical system Engine...

Page 260: ...ce standard 2 PC300 350 8 Engine control 1 1 Battery relay 2 Battery 3 Starting switch 4 Fuel control dial 5 Starting motor 6 Engine throttle controller 7 Pump controller Outline q The engine can be s...

Page 261: ...uel control dial sends a signal voltage cor responding to the rotation angle to the engine controller q The pump controller receives the fuel dial posi tion information from the engine controller thro...

Page 262: ...or Function q A potentiometer is installed under the knob As the knob is turned the potentiometer shaft is turned q As the potentiometer shaft is turned the resis tance of the variable resistor in pot...

Page 263: ...r supply for IMA D 3 Atmosphere sensor B 4 NC 5 NC 6 CAN E 7 NC 8 CAN E 9 NC 10 NC Never connect to NC or malfunctions or failures will occur 11 Fuel feed pump return C 12 NC 13 NC B 14 WATER IN FUEL...

Page 264: ...B 6 NC B 7 NC B 8 NC B 9 Fuel control dial B 10 NC B 11 NC B 12 NC B Never connect to NC or malfunctions or failures will occur CN CE01 Pin No Signal name Input output 13 NC B 14 NC B 15 NC B 16 NC B...

Page 265: ...10 Structure function and maintenance standard SEN01998 05 PC300 350 8 7 Coolant temperature sensor 1 Connector 2 Sensor 3 O ring Oil pressure switch 1 Connector 2 Sensor 3 O ring...

Page 266: ...SEN01998 05 10 Structure function and maintenance standard 8 PC300 350 8 Rotation sensor 1 Connector 2 Sensor 3 O ring Boost pressure and temperature sensor 1 Connector 2 Sensor 3 O ring...

Page 267: ...tructure function and maintenance standard SEN01998 05 PC300 350 8 9 WIF water in fuel detection sensor 1 Connector 2 Tube 3 Sensor 4 O ring Engine oil level sensor 1 Connector 2 Bracket 3 Float 4 Swi...

Page 268: ...SEN01998 05 10 Structure function and maintenance standard 10 PC300 350 8...

Page 269: ...Engine and pump composite control function 2 Pump and valve control function 3 Power maximizing function Machine push up function 4 Auto deceleration function 5 Auto warm up and overheat prevention fu...

Page 270: ...SEN01998 05 10 Structure function and maintenance standard 12 PC300 350 8 Machine control system diagram...

Page 271: ...10 Structure function and maintenance standard SEN01998 05 PC300 350 8 13...

Page 272: ...SEN01998 05 10 Structure function and maintenance standard 14 PC300 350 8 1 Engine and pump composite control function...

Page 273: ...all the torque at each output point of the engine according to the pump absorption torque set in each mode 1 Control method in each mode P and E modes q Matching point in P mode Rated speed q If the p...

Page 274: ...torque through the pump and engine compound control function to decrease engine speed N while main taining engine torque T constant along the constant horsepower curve This ensures reduced fuel consu...

Page 275: ...work ing mode and engine speed N do not change but the pump absorption torque is increased 3 Function to control when emergency pump drive switch is turned on q Even if any abnormality occurs in the c...

Page 276: ...ure function and maintenance standard 18 PC300 350 8 2 Pump and valve control function Function q The machine is matched to various types of work properly with the 2 stage relief function to increase...

Page 277: ...function q The relief pressure in the normal work is 34 8 MPa 355 kg cm2 If the 2 stage relief function is turned on however the relief pressure rises to about 37 2 MPa 380 kg cm2 By this operation t...

Page 278: ...ng and machine push up function Function q The power maximizing function allows the operator to increase power for a certain time by operating the left knob switch q The machine push up function allow...

Page 279: ...ally reset after 8 5 seconds when the switch is pressed 2 Machine push up function q The machine push up function allows the operator to increase the boom pushing force that is required for ditching o...

Page 280: ...o the speed set with the fuel control dial Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec during operation at a engine speed above a deceler...

Page 281: ...unction q The engine automatic warm up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts q The overheat prevention function reduces th...

Page 282: ...re Below 95 C Under above condition controller is set to condition before opera tion of function Automatic reset Operating condition Operation Remedy Resetting condition Hydraulic oil or cool ant temp...

Page 283: ...10 Structure function and maintenance standard SEN01998 05 PC300 350 8 25 6 Swing control function Function The swing lock and swing holding brake function are provided as a swing control function...

Page 284: ...topped on a slope the upper structure may swing by its gravity 2 Quick hydraulic oil warm up function when swing lock switch is turned on q If swing lock switch 1 is turned on the pump cut off functio...

Page 285: ...350 8 27 7 Travel control function Function q The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or al...

Page 286: ...s than 1 200 rpm the travel speed changes to Lo when the machine is travelling in Mi or Hi and the travel speed will not change to Mi or Hi 3 Automatic change by pump discharge pressure When traveling...

Page 287: ...function is available only with the attach ment specification q The function acts as follows according to the flow command and working mode from the monitor 1 It throttles the attachment PPC pressure...

Page 288: ...nector Specifications Type of contacts Normally open contacts Operating ON pressure 0 5 0 1 MPa 5 0 1 0 kg cm2 Resetting OFF pressure 0 3 0 05 MPa 3 0 0 5 kg cm2 Function q The junction block has 6 PP...

Page 289: ...ation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part the diaphragm is deformed q The deformation in the diaphragm causes the resistance of the...

Page 290: ...unction and maintenance standard 32 PC300 350 8 3 Pump pressure sensor high pressure 1 Sensor 2 Connector Operation q The relationship between the pressure applied to sensors P and output voltage E is...

Page 291: ...10 Structure function and maintenance standard SEN01998 05 PC300 350 8 33 4 Pump controller...

Page 292: ...ix switch Input 39 Machin select 5 Input 40 Machin select 1 Input 41 Knob switch Input 42 NC 43 PWR_CTR_KEY Input 44 GND_SIG_P Input 45 COMM_CAN_H_0 Input output 46 GND_SIG_A Input 47 GND_SIG_A 48 NC...

Page 293: ...EPC output 98 NC 99 NC 100 NC 101 Swing brake solenoid output 102 NC 103 NC 104 NC 105 NC 106 NC 107 NC 108 Battery relay output 109 2 stage relief solenoid output 110 Travel valve solenoid output 11...

Page 294: ...parts of the machine processes and immedi ately displays the obtained information on the panel The information that appears on the panel is roughly divided as follows 1 Alarms that are issued when th...

Page 295: ...monitor has the functions to dis play various items and the functions to select modes and electric parts q The machine monitor has a CPU Central Pro cessing Unit in it to process display and out put...

Page 296: ...03 Pin No Signal name Input output 1 RS232C CD for communica tion terminal Input 2 RS232C RXD for communica tion terminal Input 3 RS232C SG for communica tion terminal 4 Signal GND for communication t...

Page 297: ...Pin No Signal name Input output 1 Electric power supply for cam era Output 2 Camera NTSC signal input 1 Input 3 Camera NTSC signal input 2 Input 4 Camera NTSC signal input 3 Input 5 Electric power sup...

Page 298: ...SEN01998 05 10 Structure function and maintenance standard 40 PC300 350 8 Monitor control display portion 1...

Page 299: ...leaner clogging monitor 23 Water separator monitor Precautions on the machine monitor display q The liquid crystal display panel may have black spots which do not light up or bright spots which stay o...

Page 300: ...ting Preheater operates at low temperature and symbol keeps lighting up for up to about 30 seconds and then goes off after engine starts Manual preheating Time after setting Display of symbol 0 30 sec...

Page 301: ...not be obtained due to disconnection of CAN Gauge Range Temperature or vol ume Indicator Buzzer sound Engine coolant tem perature C A1 105 Red Q A2 102 Red A3 100 Off A4 80 Off A5 60 Off A6 30 White H...

Page 302: ...l Display item Check before starting item While engine is stopped While engine is running Engine oil pressure q Lights up and buzzer sounds when abnormal Battery charge q Lights up when abnormal Radia...

Page 303: ...n Working mode P E L B ATT Displays set mode Travel speed Displays set speed Auto deceleration ON OFF Displays operating condition ECO indicator ECO indicator Green Work load is light medium Orange Wo...

Page 304: ...unds Depending on the alarm buzzer type it does not stop even if you press the buzzer cancel switch Auto deceleration switch The auto deceleration switch toggles the auto deceleration function on and...

Page 305: ...m Selects item on upper side Selects bottom item after top item Holds monitoring F1 Select item Selects page on lower side Selects top page after bottom page F2 Select item Selects page on upper side...

Page 306: ...Hi o Lo The travel speed setting is confirmable on the travel speed monitor The relationship between the speed setting and the monitor display is shown in the table below Window washer switch While th...

Page 307: ...on with the air conditioner is disconnected or spurting out damper A M damper or refrigerant has a problem the following screen appears Camera screen display function 1 q For an optional camera equipp...

Page 308: ...normal screen q If an abnormality corresponding to an alarm item with the camera screen displayed the alarm monitor appears on the upper left of the screen If it appears return to the normal screen wi...

Page 309: ...350 8 51 Service meter time selector function 1 q Pressing F4 on the normal screen when the service meter is displayed in the top center of the screen switches the display to the time and doing so whe...

Page 310: ...ts the remaining time to return to the nor mal screen No operation at least 30 sec Returns to the nor mal screen q The table below shows the maintenance items and replacement intervals The time remain...

Page 311: ...rom carelessly being reset q The default password is 000000 q Enabling the password lock on an attachment equipped machine locks the breaker attach ment setting screen at the same time a For informati...

Page 312: ...o adjust a flow rate in B mode and ATT mode q For a machine with no attachment this menu does not appear F3 Selects highlights an item one down F4 Selects highlights an item one up F5 Cancels changes...

Page 313: ...eaker mode F3 Selects highlights an item one down F4 Selects highlights an item one up F5 Returns to the breaker setting menu screen F6 Switches to the flow rate level setting screen for the selected...

Page 314: ...highlighted item as a flow rate in attachment mode q Selecting No attachment disables selec tion of attachment mode on the working mode selection screen 2 Attachment flow rate setting screen q On thi...

Page 315: ...F6 and the entered value will be sent q Messages will be deleted when their validity expire or a new message is received q When no message has not been received No message appears at the blue part of...

Page 316: ...ed item Clock adjustment q Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen q On this screen you can change the setting of the time displayed o...

Page 317: ...to be displayed on the monitor Available lan guages are as follows English Japanese Chinese French Spanish Portuguese Italian German Russian Turkish Indonesian and Thai F3 Selects highlights an item...

Page 318: ...is made at least 5 min and the engine is running at idle q No error or caution excluding low hydraulic oil temperature is occurring This screen switches to the normal screen if one of the following c...

Page 319: ...c q When these switches are released the LCD goes out a Continuous operation of the machine monitor may display blue bright spots on this screen it is quite normal Display LCD check function 1 q Conti...

Page 320: ...e 2 are displayed on the portion for the hydraulic oil temperature gauge q If multiple user codes or failure codes are issued they are displayed alternately every 2 sec The drawing below shows the cas...

Page 321: ...sensor of contact type is always connected to the chassis ground Hydraulic oil level sensor 1 Connector 2 Bracket 3 Float 4 Switch Sensor name Type of sensor When normal When abnormal Hydraulic oil l...

Page 322: ...ction and maintenance standard 64 PC300 350 8 Hydraulic oil temperature sensor coolant temperature sensor 1 1 Thermistor 2 Body 3 Tube 4 Tube 5 Wire 6 Connector Fuel level sensor 1 1 Float 2 Connector...

Page 323: ...10 Structure function and maintenance standard SEN01998 05 PC300 350 8 65 Air cleaner clogging sensor 1...

Page 324: ...information of the machine via wireless communication It allows operators of the KOMTRAX to obtain the machine information from the office and to pro vide various services with the customers q The inf...

Page 325: ...used in the countries or territories where it is not authorized by the law a When starting to use the KOMTRAX system or changing the country where it is used you are required to notify the country whe...

Page 327: ...0 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 20 Standard value table 1 Standard service value table Standard value...

Page 328: ...1 0 Max 2 0 Valve clearance Normal temperature Intake valve mm 0 305 0 152 0 559 Exhaust valve mm 0 559 0 381 0 813 Compression pres sure Oil temperature 40 60 C Engine speed Min 170 rpm MPa kg cm2 Mi...

Page 329: ...alve Engine stopped For measuring point see Control valve mm 9 5 0 5 9 5 0 5 Arm control valve Bucket control valve Swing control valve Travel control valve Travel of control levers Boom control lever...

Page 330: ...ved Values marked Hydraulic oil pressure with power max switch in ON reference only 34 81 1 47 0 98 355 15 10 33 34 37 23 340 375 Bucket relief 37 26 1 47 0 98 380 15 10 35 80 39 23 365 400 Swing reli...

Page 331: ...nd 180 from starting point For measuring posture see Swing 1 90 sec 3 3 0 4 Max 4 2 180 sec 4 7 0 5 Max 5 7 Time taken to swing Hydraulic oil temperature Within operating range Engine running at high...

Page 332: ...ng mode P mode Flat ground Time required for traveling 20 m after 10 m trial run For measuring posture see Travel 2 Lo sec 23 3 4 4 18 9 31 0 Mi 16 7 2 2 14 4 21 0 Hi 13 1 0 7 12 1 15 1 Travel devia t...

Page 333: ...00 Max 38 PC350 Max 45 Arm cylinder Extraction dis tance of cylin der PC300 Max 135 PC350 Max 165 PC300 Max 203 PC350 Max 248 Bucket cylinder Retraction dis tance of cylin der PC300 Max 20 PC350 Max 2...

Page 334: ...ature Within operating range Engine at low idle Working mode P mode Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move agai...

Page 335: ...suring with the pump mounted on the machine if it is impossible to set the engine speed to the specified speed with the fuel control dial take the pump discharge amount and the engine speed at the poi...

Page 336: ...easuring performance and measurement procedure Control valve Spool stroke Swing 1 Swing brake angle time taken to start swing time taken to swing Swing 2 Hydraulic drift of swing Travel 1 Travel speed...

Page 337: ...N02624 03 PC300 350 8 11 Travel 4 Hydraulic drift of travel Work equipment 1 Hydraulic drift of work equipment Work equipment 2 Boom speed Work equipment 3 Arm speed Work equipment 4 Bucket speed Work...

Page 338: ...SEN02624 03 20 Standard value table 12 PC300 350 8 Work equipment 6 Arm time lag Work equipment 7 Bucket time lag...

Page 339: ...20 Standard value table SEN02624 03 PC300 350 8 13...

Page 341: ...air boost pressure 9 Testing exhaust gas color 10 Adjusting valve clearance 12 Testing compression pressure 14 Testing blow by pressure 18 Testing engine oil pressure 19 Testing fuel pressure 20 Handl...

Page 342: ...esting and adjusting pump LS control circuit oil pressure 43 Testing solenoid valve output pressure 48 Testing PPC valve output pressure 52 Adjusting play of work equipment and swing PPC valves 53 Ins...

Page 343: ...90 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 2 799 401 2320 Gauge 1 Pressure gauge 1 MPa 10 kg cm2 3 6732 81 3170 Adapter 1 Size 10 x 1 0 mm 6215 81 9710 O ring 1 Testing fu...

Page 344: ...Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 Oil leakage in work equipment cylinder Q Commercially available Measuring cylinder 1 Troubleshooting for engine controller sen sors actuato...

Page 345: ...601 7130 q Adapter for M 1 For M6P 799 601 7140 q Adapter for S 1 For S8P 799 601 7160 q Adapter for S 1 For S12P 799 601 7170 q Adapter for S 1 For S16P 799 601 7210 q Adapter for AMP040 1 For A16P 7...

Page 346: ...sor Commercially available Socket 1 21 mm deep socket MITOLOY 4ML 21 or equivalent Applicable engine serial No 26850001 26857026 795T 981 1010 Socket 1 19 mm deep socket MITOLOY 4ML 19 or equivalent A...

Page 347: ...SEN02625 06 PC300 350 8 7 30 Testing and adjusting Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches Socket...

Page 348: ...et the fuel control dial in the high idle MAX position and set the working mode in the power mode P 3 Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and...

Page 349: ...e self seal of the hose by insert approximately half of the gauge and hose connection Repeat opera tion until the oil is drained out a If Pm kit A is available you may use the air bleeding coupling 79...

Page 350: ...per and compare it with the attached scale for judgement 6 Remove the measurement tool after the measurement and make sure that the machine is back to normal condition 2 Measuring with smoke meter B2...

Page 351: ...ccel erator pedal of smoke meter B2 to collect the exhaust gas into the filter paper 8 Put the polluted filtering paper on non polluted filtering paper more than 10 sheets in the filtering paper holde...

Page 352: ...C1 and rotate the crank shaft forward to set No 1 cylinder to the compression top dead center a Aligning TDC stamp line a of gear cover 7 and supply pump gear stamp line b set No 1 cylinder to the co...

Page 353: ...uge C2 to move slightly 3 Fix adjustment screw 11 and tighten locknut 10 3 Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance again 4 Turn the crankshaft forward by...

Page 354: ...Open the engine hood 2 Remove air intake connector 1 3 Disconnect harness 2 and remove bracket 3 and air heater 4 4 Disconnect wiring harness connectors 5 6 and 7 5 Move fuel filter and corrosion resi...

Page 355: ...e cylinder to be tested to the compres sion top dead center a For the adjustment refer to the section Ad justing valve clearance 12 Remove rocker arm assemblies 18 13 Remove retainer 19 and remove fue...

Page 356: ...n be started during the inspection poten tially inducing risks to the inspecting per sonnel 22 Rotate the engine with cranking the starting motor and measure the compression pressure a Read the pressu...

Page 357: ...eve nut 37 3 4 Nm 3 8 0 4 kgm a After installing the rocker arm assembly adjust the valve clearance For details see Adjusting valve clearance 3 Rocker arm assembly mounting bolt 64 7 4 9 Nm 6 6 0 5 kg...

Page 358: ...nt and hydraulic oil rise to the operating range 4 Measure the blow by pressure at high idle and under the following conditions q Working mode P mode q Swing lock switch ON high pressure relief q Work...

Page 359: ...ple R1 8 1 of hydraulic tester F1 to the plug installation posi tion 4 Connect hose of hydraulic tester F1 to nipple 1 and gauge F2 5 Run the engine at the rated output and low idle and test the oil p...

Page 360: ...nd fuel vacuum gauge G4 3 Run the engine at high idle and measure the pressure in the fuel negative pressure circuit a If the pressure in the fuel negative pres sure circuit is in the following range...

Page 361: ...filter inlet side 1 Remove fuel pressure pickup plug 3 situ ated at the fuel main filter inlet side 2 Install adapterG2 and nipple 1 of hydraulic tester G1 and connect them to gauge G3 3 Measure pres...

Page 362: ...fuel low pressure cir cuit at the fuel filter outlet side is in the following range it is normal q Standard pressure values of the fuel low pressure circuit fuel filter outlet side Min 0 48 MPa Min 4...

Page 363: ...2 Connect M10 computer check fitting G4to gauge G3 3 Turn the starting switch ON operate fuel lift pump 5 and measure the fuel lift pump outlet pressure Reference Fuel lift pump 5 is installed to cool...

Page 364: ...in the standard range while fuel is in the fuel lift pump remove check valve 8 of engine controller cooling plate 7 and check to see if the valve is seized 4 After finishing measurement remove the me...

Page 365: ...ng or cylinder liner Failure on the valve mechanism valve oper ating system Failure in the electrical system 3 Since the common rail fuel injection system controls the injector of each cylinder electr...

Page 366: ...the supply pump is in the following range it is normal k If the engine cannot be started you may measure the fuel return rate while rotating the engine with the starting motor Do not rotate for more t...

Page 367: ...H3 3 Connect blocking tool H2 to the return tube joint connection of the cylinder block side to prevent leakage of the fuel 4 Run the engine at low idle and test the return rate from the injector a I...

Page 368: ...an fuel is not available do not remove the fuel pre filter but fill it with the fuel by op erating priming pump a Do not add fuel to fuel main filter 1 from out side 3 Fill up the fuel tank with fuel...

Page 369: ...If any fuel leakage is detected repair it and check again from step 1 4 Run the engine at low idle 5 Inspect the fuel piping and devices for fuel leakage a Check mainly around the high pressure cir cu...

Page 370: ...ith your finger q Belt depressing force 58 8 N 6 kg or equivalent Adjustment a If the belt deflection amount is not proper adjust it in the following manner 1 Loosen mounting bolt 2 and fixing bolt 3...

Page 371: ...th across flats T 12 7 mm of the tensioner assembly 3 and rotate it to the direction of the arrow to decrease the fan belt 4 tension k Make sure that the wrench is secured at the portion A of the tens...

Page 372: ...B width across flats T 12 7 mm of the tensioner assembly 5 and rotate it to the direction of the arrow to decrease the alternator belt 6 tension k Make sure that the wrench is secured at the portion...

Page 373: ...ch posture and keep the height of the bucket teeth tip level with the lower height of the revolving frame a The upper structure is lowered at the front and raised at the rear at that time 3 Set dial g...

Page 374: ...n free nature 3 Measure maximum clearance a between bar 1 and the track shoe q Standard clearance a 10 30 mm Adjustment a If the track shoe tension is not proper adjust it in the following manner 1 Wh...

Page 375: ...1 For the front pump circuit situat ed in the rear side of the machine q Plug 2 For the rear pump circuit situat ed in the front side of the machine 2 Fit nipple L2 and connect it to oil pressure gau...

Page 376: ...elected the relief pressure is lower than the main re lief pressure a When the boom LOWER is selected turning off the machine push up switch in troduces the low pressure relief pressure and turning it...

Page 377: ...g it counterclockwise decreases the pressure a Quantity of adjustment per turn of holder Approx 20 5 MPa Approx 209 kg cm2 3 Locknut 49 0 58 8 Nm 5 6 kgm 3 Check the pressure again after the adjust me...

Page 378: ...to adjust the relief pressure a Turning the holder clockwise increases the pressure Turning it counterclockwise decreases the pressure a Pressure adjustable from a single turn of the holder Approx 21...

Page 379: ...pressure gauge 1 of hydraulic tester L1 a Use the oil pressure gauge with capacit 6 0 MPa 60 kg cm2 3 Start the engine and keep it running until the hydraulic oil temperature rises to the operating ra...

Page 380: ...e tank 1 Measurement of PC valve output pressure servo piston inlet pressure a PC valve output pressure servo piston inlet pressure is measured along with that of the pump discharge pressure and the r...

Page 381: ...piston input pressure reaches the following val ues both pressures are judged normal a If there is any abnormality with PC valve or servo piston the PC valve output pres sure servo piston input press...

Page 382: ...e rpm is normal but the work equip ment speed is low 1 Loosen locknut 8 and turn holder 9 to adjust the pump absorption torque a Turning the holder clockwise increases the pump absorption torque Turni...

Page 383: ...tank 1 Measurement of LS valve output pressure servo piston inlet pressure a Measure the LS valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously tocompare them...

Page 384: ...quipment swing and travel When all levers are at neutral and when travel lever is at half stroke one side of travel is at idle a Let the raised track shoe idly rotate pay ing enough attention to the s...

Page 385: ...ated in the rear side of the machine q 6 For the rear pump LS pressure situ ated in the rear side of the machine 2 Fit nipple M2 and connect it to oil pressure gauge 1 or differential pressure gauge...

Page 386: ...differential pressure Pump discharge pressure LS pressure a If LS differential pressure is in the follow ing conditions it is judged normal 6 Remove the measurement tools after the measurement and ma...

Page 387: ...ment a When the LS differential pressure is not normal adjust LS valves 8 and 9 in the following pro cedure 1 Loosen locknut 10 and turn adjustment screw 11 to adjust the differential pressure a Adjus...

Page 388: ...rough 7 are in stalled at the center of revolving frame 2 Fit adapter N2 or N3 and then connect hose currently disconnected 3 Fit nipple 1 of hydraulic tester N1 and then connect it to oil pressure ga...

Page 389: ...lowing values it is judged normal 6 Remove the measurement tools after the measurement and make sure that the machine is back to normal condition Table for functioning conditions PPC lock solenoid val...

Page 390: ...n the overheat 2nd setting is ON OFF When the fuel dial is at 1 200 rpm or lower When the travel speed switch is at Lo When the travel speed switch is at Mi or Hi When signal of the travel is OFF When...

Page 391: ...f the travel is ON When signal of the travel is OFF When signals of the work equipment and swing are ON When any mode other than L mode is turned on When F or R pump pressure is 19 6 MPa 200 kg cm2 or...

Page 392: ...es to the operating range 4 Measure the pressure when the engine is running at high idle and the control lever of the circuit to be measured is kept in the NEUTRAL position and at the full stroke a If...

Page 393: ...lowing procedure 1 Remove the work equipment and swing PPC valve assembly 2 Remove boot 1 3 Loosen locknut 2 and screw in disc 3 until it contacts the heads of 4 pistons 4 a Do not move the piston whi...

Page 394: ...sure in the accumulator has dropped run the engine for approx 10 seconds to charge the accumulator again 2 Inspection of arm cylinder 1 Operate the arm cylinder to move the arm to the position 100 mm...

Page 395: ...and release the pressure inside the hydraulic tank k Do not allow anyone to come under the work equipment during the work 2 Disconnect drain hose 1 of the control valve and install an oil stopper plug...

Page 396: ...several times Testing oil leakage amount 1 Measurement of oil leakage amount from boom cylinder 1 Start the engine and keep it running until the hydraulic oil temperature rises to the oper ating rang...

Page 397: ...high idle and relieve the bucket circuit by moving the bucket CURL 4 Continue this condition for 30 seconds then measure the oil leakage amount for 1 minute 5 After the measurement make sure that the...

Page 398: ...e k Wrong operation of the lever can cause an accident Accordingly make signs and checks securely a Start measuring the oil leakage 30 sec onds after relieving is started and mea sure for 1 minute a M...

Page 399: ...m step 2 4 Set the piston rod to the stroke end at low idle and allow it to relieve 5 For bleeding air from the arm cylinder and bucket cylinder follow the same steps explained in Item 2 through 4 abo...

Page 400: ...engine and run it at low idle 2 Swing slowly to bleed air 4 Bleeding air from travel motor 1 Start the engine and run it at low idle 2 Loosen air bleeder 2 and confirm that oil seeps out from the plug...

Page 401: ...ed for silicon diodes a A value between 460 to 600 is indicated for silicon diodes 2 When using analog type circuit tester a When the diode range is set the testing method is the same as that done by...

Page 402: ...Tightening torque of mirror stay bolt 3 15 19 6 Nm 1 5 2 kgm a If the tightening torque is low the bolts may be dragged If the former is too high the body may be broken a Retract the mirror into posi...

Page 403: ...d 2 and stay mounting bolts 3 and 4 and adjust the mirrors so that the operator can see the right and left rear views best which are blind corners from the operator s seat a Adjust the mirror so that...

Page 404: ...30 Testing and adjusting 64 PC300 350 8 SEN02625 06 3 Tighten the stay mounting bolts so that the clearance to the stay mating face will be even...

Page 405: ...SEN02625 06 PC300 350 8 65 30 Testing and adjusting...

Page 407: ...ANUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 30 Testing and adjusting 1 Testing and adj...

Page 408: ...SEN02626 04 30 Testing and adjusting 2 PC300 350 8 Special functions of machine monitor 1 Air conditioner specification...

Page 409: ...Auto decelerator switch 2 Numeral 2 input switch Working mode selector switch 3 Numeral 3 input switch Travel speed shifting switch 4 Numeral 4 input switch Alarm buzzer cancel switch 5 Numeral 5 inp...

Page 410: ...nd screen 9p B Selection of auto deceleration 9p B Selection of working mode 9p B Selection of travel speed 10p B Operation to stop alarm buzzer 10p B Operation of windshield wiper 11p B Operation of...

Page 411: ...ime when starting switch is turned ON to time when screen changes to ordi nary screen and display after starting switch is turned OFF B Display Function when switch of machine monitor is operated C Di...

Page 412: ...is set or Display of check before starting a The following screen may be displayed instead of the above Display of inputting password screen a If this screen is displayed call the person responsible...

Page 413: ...nt other than the breaker is used while the working mode is set to the breaker mode B the machine may move unexpectedly or may not operate normally or the hydraulic components may be dam aged a After...

Page 414: ...indicates the length of the time after the maintenance interval a Set or change the maintenance function in the service mode a After display of this screen is finished the screen changes to Display of...

Page 415: ...working mode Select a working mode according to the following procedure 1 While the ordinary screen is displayed press the working mode selector switch and the working mode selection screen is displa...

Page 416: ...played The buzzer sounds intermittently while this screen is displayed q If the setting is confirmed on this screen the screen changes to the ordinary screen If No is selected Screen returns to screen...

Page 417: ...itor a is not displayed Operation of window washer While the ordinary screen is displayed if the win dow washer switch is pressed the washing liquid is splashed only while the switch is held down a Ev...

Page 418: ...control lever for 10 seconds the screen changes to the ordinary screen and displays the error information a When two or more cameras are connected the image of one of them or the images of two of the...

Page 419: ...nance more operations are necessary Setting and display of user mode Including KOMTRAX messages for user While the ordinary screen is displayed press F6 and the user menu screen is displayed a There a...

Page 420: ...ting con dition the energy saving guidance screen is dis played automatically to urge the operator to the energy saving operation a The energy saving guidance is displayed when the following condition...

Page 421: ...e setting of the working mode If the breaker is being used select the breaker mode B a To return to the ordinary screen press F5 Display of user code and failure code If an abnormality which displays...

Page 422: ...mediately E10 Engine controller power source error Engine controller drive system circuit error engine stopped Have inspection carried out immediately E11 Engine controller system error Output reduced...

Page 423: ...points which do not go off for the reason of its characteristics If the number of the bright points and black points does not exceed 10 those points are not a failure or a defect a To return to the f...

Page 424: ...ut numeral Return to ordi nary screen q F6 Confirm input numeral a Default password 000000 a If the input password is correct the screen changes to the next screen a If the input password is incorrect...

Page 425: ...30 Testing and adjusting SEN02626 04 PC300 350 8 19 5 If the screen to notify completion of setting is displayed and then the ordinary screen is dis played the password is changed successfully...

Page 426: ...hes q F3 Move to lower menu q F4 Move to upper menu q F5 Return to ordinary screen operator mode q F6 Confirm selection a You may enter a 2 digit code with the numeral input switches to select the men...

Page 427: ...tion switches Select an item with F3 or F4 and confirm it with F6 a Selection with numeral input switches Enter a 5 digit code and the item of that code is selected directly Confirm that item with F6...

Page 428: ...nitoring selection menu screen 6 Changing machine setting mode To change the setting of the working mode travel speed or auto deceleration during moni toring operate the corresponding switch under the...

Page 429: ...ider Sol Curr LS mA mA mA PUMP 01700 Service Sol Curr mA mA mA PUMP 03200 Battery Voltage V V V PUMP 03203 Battery Power Supply V V V ENG 04300 Battery Charge Vol V V V MON 36400 Rail Pressure MPa kg...

Page 430: ...t 2 ON OFF PUMP Model Select 3 ON OFF PUMP Model Select 4 ON OFF PUMP Model Select 5 ON OFF PUMP Overload Alarm ON OFF PUMP 02202 Switch Input 3 Key Switch ACC ON OFF PUMP 02204 Switch Input 5 Window...

Page 431: ...of detection of monitoring information ENG The engine controller is in charge of detection of monitoring information PUMP The pump controller is in charge of detection of monitoring information 04505...

Page 432: ...speci fication are different from each other in the display of 03 Air conditioning System which may not be displayed in the heater less specification 3 Information displayed on abnormality record scre...

Page 433: ...The heater specification and heaterless speci fication are different from each other in the display of 03 Air conditioning System which may not be displayed in the heater less specification 3 Informa...

Page 434: ...Reset selected item a To reset items one by one Select the item to be reset with F3 or F4 and press F6 a To reset all items together Press F2 and all the items are reset regardless of selection of th...

Page 435: ...ical Internal Failure ENG Electrical system E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system E11 CA122 Chg Air Press Sensor High Error ENG Electrical system E11 CA123 Chg Air Press Sen...

Page 436: ...tors Drive Circuit Error ENG Electrical system E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system E15 CA428 Water in Fuel Sensor...

Page 437: ...Grid Htr Relay Volt Low Error ENG Electrical system E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system D110KB Battery Relay Drive Short Circuit PUMP Electrical system E01 D19JKZ Personal...

Page 438: ...Electrical system DWA2KA Attachment Sol Open Circuit PUMP Electrical system DWA2KB Attachment Sol Short Circuit PUMP Electrical system DWJ0KA Merge divider Sol Open Circuit PUMP Electrical system DWJ0...

Page 439: ...for indicating to which of the electrical and mechanical system of the ser vice menu s abnormality record a given failure is classified a E of at beginning the action code indicates the following sta...

Page 440: ...ode and confirm it with F6 3 Information displayed on abnormality record screen On the Air conditioning System or Heater System screen the following information is displayed a System Component name b...

Page 441: ...F1 Move to next page screen q F2 Move to previous page screen q F3 Move to lower item q F4 Move to upper item q F5 Return to service menu screen a You may enter a 2 digit code with the numeral input...

Page 442: ...owing items can be selected on the Change of maintenance mode screen 3 Contents of setting of Maintenance mode on off After selecting Maintenance Mode On Off if the screen is displayed set ON or OFF w...

Page 443: ...N Lower q F5 Cancel setting before confirmation and return to Maintenance mode change screen q F6 Confirm setting of upper or lower line a After the setting of the upper and lower lines is confirmed w...

Page 444: ...ng telephone No After the Phone Number Entry screen is dis played register or change the telephone No q F2 Reset all input No q F3 Move to left position if not blank q F4 Move to right position if not...

Page 445: ...q Power Mode P is displayed when key is ON q Economy Mode E is displayed when key is ON q Lifting Mode L is displayed when key is ON q Breaker Mode B is displayed when key is ON q Attachment Mode ATT...

Page 446: ...2 Selecting sub menu After the Default screen is displayed select Unit with the function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Select...

Page 447: ...elect this item similarly to an item on the Service Menu screen 3 Selecting With Without After the With Without Attachment screen is displayed select the setting with the function switches q Without A...

Page 448: ...sword screen is displayed q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to Default screen q F6 Confirm selection and return to Default screen 4 Displaying attachment...

Page 449: ...yed in reverse position as seen directly used as front or side mon itor q F3 Move to left item q F4 Move to right item q F5 Cancel setting before confirmation and return to Default screen q F6 Confirm...

Page 450: ...display setting After the ECO Display screen is displayed select the setting with the function switches q ON Display ECO q OFF Do not display ECO q F3 Move to left item q F4 Move to right item q F5 Ca...

Page 451: ...enu screen 2 Selecting sub menu After the Default screen is displayed select Breaker Detect with the function switches or numeral input switches a Select this item similarly to an item on the Service...

Page 452: ...cting absorption torque After the Pump Absorption Torque screen is displayed select a set value on the right side with the function switches q Set value For actual torque adjustment value see table q...

Page 453: ...put switches a Select this item similarly to an item on the Service Menu screen 3 Selecting travel Low speed After the Low Speed setting screen is dis played select a set value on the right side with...

Page 454: ...ion switches or numeral input switches a Select this item similarly to an item on the Service Menu screen 3 Selecting distribution of oil flow After the screen of Attachment Flow Adjust ment is displa...

Page 455: ...low a One or more cylinders can be Cut Out a In the cylinder Cut Out operation the auto deceleration function can be selected If the auto deceleration is turned ON auto deceleration monitor b is dis p...

Page 456: ...of the machine it may be worn or damaged because of insufficient lubrication with oil To prevent this the function to lubricate the engine before starting it by cranking it without injecting fuel is...

Page 457: ...ing motor 4 Finishing no injection cranking After completing the no injection cranking operation press F6 and finish of no injection cranking is displayed and the screen returns to the Service Menu sc...

Page 458: ...side and mea surement starts a The display unit of the fuel changes according to the unit set with the default unit setting function SI and meter l h inch gal h 3 Display and function during measurem...

Page 459: ...een is dis played select Terminal Status with the func tion switches or numeral input switches a Select this item similarly to an item on the Service menu screen a The following figure shows the displ...

Page 460: ...he function switches or numeral input switches a Select this item similarly to an item on the Service Menu screen a The following figure shows the display when Model TH300 KOMTRAX is installed When TH...

Page 461: ...o of the KOMTRAX communication MODEM 1 Selecting menu Select KOMTRAX Settings on the Service Menu screen 2 Selecting sub menu After the KOMTRAX Settings screen is dis played select Modem S N with the...

Page 462: ...m a message transmitted to the operator in the operator mode a Since this message is special for the ser viceman the message monitor is not dis played when it is received as in the operator mode 3 Dis...

Page 463: ...30 Testing and adjusting SEN02626 04 PC300 350 8 57...

Page 465: ...al number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 30 Testing and adjusting 1 Testing and adjusting Part 3 Handling voltage circuit of engine controller...

Page 466: ...onnec tor between the engine controller and engine be sure to turn the starting switch OFF 2 If a T adapter is inserted in or connected to a connector between the engine controller and engine for trou...

Page 467: ...or 2 Remove cover 2 a The cover is fixed with clips Remove it by pull it up a While removing the cover discon nect connector M04 of the cigarette lighter 3 Remove 1 mounting bolt and duct 3 4 Insert o...

Page 468: ...all the adapters to only the wiring harness side a The connectors of the pump control ler have a special locking mecha nism Disconnect them according to steps a c and connect them according to steps d...

Page 469: ...elow Disconnection a Slide lever b Unlock c Disconnect connector Connection d Connect connector e Lock f Slide lever a Removal and installation of sensor A deep socket is necessary for removal and ins...

Page 470: ...f triangular notch f 8 Common rail pressure sensor FUEL RAIL PRESS a Disconnection and connection of connector The connector of the common rail pres sure sensor has a special locking mecha nism Discon...

Page 471: ...ode does not have conductivity Defective q The indicated value changes The diode has conductivity Normal Note In the case of a silicon diode a value in the range from 460 to 600 is indi cated 2 When u...

Page 472: ...sary T Damper case oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical systems abnormality record Electrical sy...

Page 473: ...30 Testing and adjusting SEN02663 02 PC300 350 8 9 Items related to engine...

Page 474: ...SEN02663 02 30 Testing and adjusting 10 PC300 350 8 Items related to oil pressure...

Page 475: ...Max 260 7 Engine oil pressure ON OFF All levers in neutral rpm 1 300 1 500 No Check item Checking condition Unit Standard value for new machine Service limit value Mea sured value Good Bad Fuel contro...

Page 476: ...pressure ON C C C C 4 Unload valve OFF All levers in neutral D D D D 5 LS valve Right track driven idle Lever moved halfway E E Left track driven idle Lever moved halfway E E 6 Swing motor safety valv...

Page 477: ...MPa 60 kg cm2 6 MPa 60 kg cm2 6 MPa 60 kg cm2 Fuel control dial Work ing mode Left knob switch Operation of work equipment F pump main R pump main F pump F R pump R LS EPC 9 PC EPC F valve PC EPC R v...

Page 479: ...NUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 40 Troubleshooting 1 Failure code table and...

Page 480: ...rror ENG Electrical system E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system E11 CA155 Chg Air Temp High Speed Derate ENG Ele...

Page 481: ...Electrical system E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system D110KB Battery Relay Drive S C PUMP Electrical system E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical syste...

Page 482: ...ectrical system E02 DXA0KA PC EPC Sol Open Circuit PUMP Electrical system E02 DXA0KB PC EPC Sol Short Circuit PUMP Electrical system DXE0KA LS EPC Sol Open Circuit PUMP Electrical system DXE0KB LS EPC...

Page 483: ...witch swing holding release switch 2 30A Pump controller Solenoid power supply Machine push up switch 3 10A PPC oil pressure lock solenoid valve Starting motor cut off relay 4 10A Cigarette lighter Wi...

Page 484: ...SEN02627 04 40 Troubleshooting 6 PC300 350 8 Locations of fusible links Location of fuse box and fuse Nos...

Page 485: ...ned off when the controller outputs the power to the solenoids or relays the power is not supplied to any of the solenoids and relays and all or some of the following failure codes are displayed simul...

Page 486: ...SEN02627 04 40 Troubleshooting 8 PC300 350 8 a Power supply connector CP01 CP02 of pump controller...

Page 487: ...40 Troubleshooting SEN02627 04 PC300 350 8 9...

Page 489: ...PC350LC 8 60001 and up 40 Troubleshooting General Information on troubleshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Checks before troubleshooting 4 Clas...

Page 490: ...lso lose the confidence of the user or operator For this reason when carrying out trouble shooting it is necessary to carry out thorough prior investigation and to carry out trouble shooting in accord...

Page 491: ...SEN02628 04 PC300 350 8 3 40 Troubleshooting Sequence of events in troubleshooting...

Page 492: ...hten or replace 3 Check of starting motor terminals and wiring for looseness and corrosion Retighten or replace Hydrau lic Mechani cal equipment 1 Check for abnormal noise and smell Repair 2 Check for...

Page 493: ...oting for the corresponding Display of code according to the recorded code a If an electrical system failure code is recorded delete all the codes and reproduce them and then see if the trouble is sti...

Page 494: ...oubles in wiring harness q Disconnection Connector is connected imperfectly or wiring harness is broken q Ground fault Wiring harness which is not connected to chassis ground circuit is in contact wit...

Page 495: ...c circuit diagram related to troubleshooting q Connector No Indicates Model Number of pins and Color q Connector No and pin No from each branching merg ing point Shows the ends of branch or source of...

Page 496: ...exhaust smoke is blue S 8 14 Oil becomes contaminated quickly S 9 15 Fuel consumption is excessive S 10 16 Oil is in coolant coolant spurts back or coolant level goes down S 11 17 Oil pressure drops S...

Page 497: ...y some items E 8 54 Contents of display by machine monitor are different from applicable machine E 9 55 Radiator coolant level monitor lights up in red during check before starting B BCZK 56 Engine oi...

Page 498: ...play Bucket DUMP nor mally E 23 76 Monitoring function does not display Swing normally E 24 77 Monitoring function does not display Travel normally E 25 78 Monitoring function does not display Travel...

Page 499: ...8 11 40 Troubleshooting Connection table for connector pin numbers Rev 2009 04 a The terms of male and female refer to the pins while the terms of male housing and female housing refer to the mating p...

Page 500: ...40 Troubleshooting 12 PC300 350 8 SEN02628 04...

Page 501: ...SEN02628 04 PC300 350 8 13 40 Troubleshooting...

Page 502: ...40 Troubleshooting 14 PC300 350 8 SEN02628 04...

Page 503: ...SEN02628 04 PC300 350 8 15 40 Troubleshooting...

Page 504: ...40 Troubleshooting 16 PC300 350 8 SEN02628 04...

Page 505: ...SEN02628 04 PC300 350 8 17 40 Troubleshooting...

Page 506: ...40 Troubleshooting 18 PC300 350 8 SEN02628 04...

Page 507: ...SEN02628 04 PC300 350 8 19 40 Troubleshooting...

Page 508: ...40 Troubleshooting 20 PC300 350 8 SEN02628 04...

Page 509: ...SEN02628 04 PC300 350 8 21 40 Troubleshooting...

Page 510: ...40 Troubleshooting 22 PC300 350 8 SEN02628 04...

Page 511: ...SEN02628 04 PC300 350 8 23 40 Troubleshooting...

Page 512: ...40 Troubleshooting 24 PC300 350 8 SEN02628 04...

Page 513: ...SEN02628 04 PC300 350 8 25 40 Troubleshooting...

Page 514: ...40 Troubleshooting 26 PC300 350 8 SEN02628 04...

Page 515: ...SEN02628 04 PC300 350 8 27 40 Troubleshooting...

Page 516: ...40 Troubleshooting 28 PC300 350 8 SEN02628 04...

Page 517: ...SEN02628 04 PC300 350 8 29 40 Troubleshooting...

Page 518: ...40 Troubleshooting 30 PC300 350 8 SEN02628 04...

Page 519: ...SEN02628 04 PC300 350 8 31 40 Troubleshooting...

Page 520: ...40 Troubleshooting 32 PC300 350 8 SEN02628 04...

Page 521: ...SEN02628 04 PC300 350 8 33 40 Troubleshooting...

Page 522: ...40 Troubleshooting 34 PC300 350 8 SEN02628 04...

Page 523: ...SEN02628 04 PC300 350 8 35 40 Troubleshooting...

Page 524: ...40 Troubleshooting 36 PC300 350 8 SEN02628 04...

Page 525: ...SEN02628 04 PC300 350 8 37 40 Troubleshooting...

Page 526: ...40 Troubleshooting 38 PC300 350 8 SEN02628 04...

Page 527: ...SEN02628 04 PC300 350 8 39 40 Troubleshooting...

Page 528: ...40 Troubleshooting 40 PC300 350 8 SEN02628 04...

Page 529: ...SEN02628 04 PC300 350 8 41 40 Troubleshooting...

Page 530: ...40 Troubleshooting 42 PC300 350 8 SEN02628 04...

Page 531: ...SEN02628 04 PC300 350 8 43 40 Troubleshooting...

Page 532: ...40 Troubleshooting 44 PC300 350 8 SEN02628 04...

Page 533: ...SEN02628 04 PC300 350 8 45 40 Troubleshooting...

Page 534: ...40 Troubleshooting 46 PC300 350 8 SEN02628 04...

Page 535: ...799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 601 2740 Adapter for MIC 21 MIC 21P q q q q q q 799 601 2950 Adapter for MIC 9 MIC 9P q q q q 799...

Page 536: ...q q 799 601 9110 Adapter for DT Gray 12 DT12GR q q 799 601 9120 Adapter for DT Black 12 DT12B q q 799 601 9130 Adapter for DT Green 12 DT12G q q 799 601 9140 Adapter for DT Brown 12 DT12BR q q 799 601...

Page 537: ...mperature 4 1 2 3 4C q q 799 601 4240 Socket for engine CRI T3 PAMB 3 1 2 3A q q 799 601 4250 Socket for engine CRI T3 PIM 3 1 2 3B q q 799 601 4330 Socket for engine CRI T3 G 3 1 2 3 G q q 799 601 43...

Page 539: ...Lock Caution 2 3 Failure code 989N00 Engine Controller Lock Caution 3 4 Failure code AA10NX Air cleaner Clogging 6 Failure code AB00KE Charge Voltage Low 8 Failure code B BAZG Eng Oil Press Low 10 Fa...

Page 540: ...221 Ambient Press Sens High Error 40 Failure code CA222 Ambient Press Sens Low Error 42 Failure code CA227 Sens Supply 2 Volt High Error 44 Failure code CA234 Eng Overspeed 45 Failure code CA238 Ne Sp...

Page 541: ...f machine monitor This trouble may be caused by replacement of machine monitor User code Failure code Trouble Engine controller lock caution 2 Machine monitor system 989M00 Contents of trouble Engine...

Page 542: ...etting If cause of failure disappears system resets itself Problem that appears on machine Related infor mation Method of reproducing failure code Failure code is not reproduced since system is reset...

Page 543: ...40 Troubleshooting SEN02629 03 PC300 350 8 5...

Page 544: ...Cause Standard value in normal state Remarks on troubleshooting 1 Clogging of air cleaner when system is normal a Check the air cleaner for clogging and then clean or replace it if clogged 2 Defective...

Page 545: ...40 Troubleshooting SEN02629 03 PC300 350 8 7 Circuit diagram related to air cleaner clogging switch of machine monitor...

Page 546: ...fective alternator Low power generation a Prepare with starting switch OFF then start engine and carry out troubleshooting Alternator Engine speed Voltage R terminal chassis ground Min medium speed 27...

Page 547: ...40 Troubleshooting SEN02629 03 PC300 350 8 9 Circuit diagram related to starting and charge of machine monitor...

Page 548: ...m is normal a Determine the cause and check the damage to the engine and then modify it 2 Defective engine oil pressure sensor Internal defect a Prepare with starting switch OFF then start engine and...

Page 549: ...40 Troubleshooting SEN02629 03 PC300 350 8 11 Circuit diagram related to engine oil pressure of machine monitor...

Page 550: ...lecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil level when system is normal a Check the engine oil level and add ne...

Page 551: ...40 Troubleshooting SEN02629 03 PC300 350 8 13...

Page 552: ...ay be seized Related infor mation Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor Engine coolant temperature can be checked with monitori...

Page 553: ...40 Troubleshooting SEN02629 03 PC300 350 8 15 Circuit diagram related to engine coolant temperature sensor of machine monitor...

Page 554: ...state Remarks on troubleshooting 1 Lowering of radiator coolant level when system is normal a Check the coolant level and add coolant If this phenomenon frequently occurs investigate the cause 2 Defe...

Page 555: ...40 Troubleshooting SEN02629 03 PC300 350 8 17 Circuit diagram related to radiator coolant level switch of machine monitor...

Page 556: ...ted as it is engine may be seized Related infor mation Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine monitor Hydraulic oil temperature can be ch...

Page 557: ...ve engine controller Engine controller may be defective Since trouble is in system trou bleshooting cannot be carried out Action code Failure code Trouble Engine Ne and Bkup speed sensor error Engine...

Page 558: ...ith wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short in wiring harness Short circuit with 5V...

Page 559: ...40 Troubleshooting SEN02629 03 PC300 350 8 21 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 560: ...harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GND cir c...

Page 561: ...40 Troubleshooting SEN02629 03 PC300 350 8 23 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 562: ...l a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting P20 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accor...

Page 563: ...40 Troubleshooting SEN02629 03 PC300 350 8 25 Circuit diagram related to fuel control dial...

Page 564: ...are with starting switch OFF then turn starting switch ON and carry out troubleshooting P20 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly i...

Page 565: ...40 Troubleshooting SEN02629 03 PC300 350 8 27 Circuit diagram related to fuel control dial...

Page 566: ...ng or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 15 COOLANT TEMP female B Resi...

Page 567: ...40 Troubleshooting SEN02629 03 PC300 350 8 29 Circuit diagram related to engine coolant temperature sensor...

Page 568: ...und fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between J1 female 15 COOL...

Page 569: ...40 Troubleshooting SEN02629 03 PC300 350 8 31 Circuit diagram related to engine coolant temperature sensor...

Page 570: ...ction in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness b...

Page 571: ...40 Troubleshooting SEN02629 03 PC300 350 8 33 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 572: ...chassis ground All range Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch O...

Page 573: ...40 Troubleshooting SEN02629 03 PC300 350 8 35 Circuit diagram related to boost pressure temperature sensor combination sensor...

Page 574: ...unction Code 18500 Boost temperature Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1...

Page 575: ...40 Troubleshooting SEN02629 03 PC300 350 8 37...

Page 576: ...t connector with starting switch OFF then turn start ing switch ON and carry out troubleshooting Disconnect sensor and wiring harness at right in order and carry out operation to reproduce trouble If...

Page 577: ...40 Troubleshooting SEN02629 03 PC300 350 8 39 Circuit diagram related to sensor power supply 2...

Page 578: ...ed with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5V 24V circuit in...

Page 579: ...40 Troubleshooting SEN02629 03 PC300 350 8 41 Circuit diagram related to atmospheric pressure sensor...

Page 580: ...ng harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GND cir...

Page 581: ...40 Troubleshooting SEN02629 03 PC300 350 8 43 Circuit diagram related to atmospheric pressure sensor...

Page 582: ...achine Engine output lowers Related infor mation Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remar...

Page 583: ...n machine Engine speed fluctuates Related infor mation Method of reproducing failure code Run engine at high idle Possiblecauses and standard value in normal state Cause Standard value in normal state...

Page 584: ...rd value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness a Disconnect connector with starting switch OFF then turn start ing switch...

Page 585: ...n 1 chassis ground Min 100 kz 2 Hot short in wiring harness Short circuit with 24V circuit a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harness...

Page 586: ...Wiring harness between CE01 female 2 C17 female 1 Resis tance Max 10 z Wiring harness between CE01 female 32 C17 female 2 Resis tance Max 10 z 3 Ground fault in wiring har ness Short circuit with GND...

Page 587: ...40 Troubleshooting SEN02629 03 PC300 350 8 49 Circuit diagram related to supply pump actuator metering unit...

Page 588: ...Method of reproducing failure code Start the engine Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Residual air in the fuel circuit...

Page 589: ...ning starting switch ON Wiring harness between CE01 female 45 C9 female 3 Resis tance Max 2 z Wiring harness between CE01 female 53 C9 female 4 Resis tance Max 2 z 4 Ground fault in wiring har ness Sh...

Page 590: ...SEN02629 03 40 Troubleshooting 52 PC300 350 8 Circuit diagram related to injector No 1...

Page 591: ...ing starting switch ON Wiring harness between CE01 female 46 C11 female 3 Resis tance Max 2 z Wiring harness between CE01 female 60 C11 female 4 Resis tance Max 2 z 4 Ground fault in wiring har ness S...

Page 592: ...SEN02629 03 40 Troubleshooting 54 PC300 350 8 Circuit diagram related to injector No 5...

Page 593: ...ing starting switch ON Wiring harness between CE01 female 55 C10 female 3 Resis tance Max 2 z Wiring harness between CE01 female 52 C10 female 4 Resis tance Max 2 z 4 Ground fault in wiring har ness S...

Page 594: ...SEN02629 03 40 Troubleshooting 56 PC300 350 8 Circuit diagram related to injector No 3...

Page 595: ...g switch ON Wiring harness between CE01 female 57 C11 female 2 Resis tance Max 2 z Wiring harness between CE01 female 59 C11 female 1 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circui...

Page 596: ...SEN02629 03 40 Troubleshooting 58 PC300 350 8 Circuit diagram related to injector No 6...

Page 597: ...ing starting switch ON Wiring harness between CE01 female 54 C9 female 2 Resis tance Max 2 z Wiring harness between CE01 female 51 C9 female 1 Resis tance Max 2 z 4 Ground fault in wiring har ness Sho...

Page 598: ...SEN02629 03 40 Troubleshooting 60 PC300 350 8 Circuit diagram related to injector No 2...

Page 599: ...ing starting switch ON Wiring harness between CE01 female 56 C10 female 2 Resis tance Max 2 z Wiring harness between CE01 female 58 C10 female 1 Resis tance Max 2 z 4 Ground fault in wiring har ness S...

Page 600: ...SEN02629 03 40 Troubleshooting 62 PC300 350 8 Circuit diagram related to injector No 4...

Page 601: ...40 Troubleshooting SEN02629 03 PC300 350 8 63...

Page 603: ...lure code CA352 Sens Supply 1 Volt Low Error 6 Failure code CA386 Sens Supply 1 Volt High Error 8 Failure code CA428 Water in Fuel Sensor High Error 10 Failure code CA429 Water in Fuel Sensor Low Erro...

Page 604: ...44 Failure code CA2265 Fuel Feed Pump Open Error 46 Failure code CA2266 Fuel Feed Pump Short Error 48 Failure code CA2311 IMV Solenoid Error 50 Failure code CA2555 Grid Htr Relay Volt Low Error 52 Fa...

Page 605: ...None in particular Problem that appears on machine Normal operation engine stopped or start disabled Related infor mation Method of reproducing failure code Turn starting switch ON Possiblecauses and...

Page 606: ...se No 19 If fuse is broken circuit probably has ground fault 3 Defective relay for engine controller power supply a Prepare with starting switch OFF then turn starting switch ON and carry out troubles...

Page 607: ...40 Troubleshooting SEN02630 05 PC300 350 8 5 Circuit diagram related to engine controller power supply...

Page 608: ...connect connector with starting switch OFF then turn start ing switch ON and carry out troubleshooting Disconnect sensor and wiring harness at right in order and carry out operation to reproduce troub...

Page 609: ...40 Troubleshooting SEN02630 05 PC300 350 8 7 Circuit diagram related to sensor power supply 1...

Page 610: ...n Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiring harnes...

Page 611: ...40 Troubleshooting SEN02630 05 PC300 350 8 9...

Page 612: ...ntact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 female 14 C28 female 1 Resis tance Max 10 z Wiring...

Page 613: ...40 Troubleshooting SEN02630 05 PC300 350 8 11 Circuit diagram related to water in fuel sensor...

Page 614: ...rt circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 female 14 C28 female 1 and chassis ground...

Page 615: ...40 Troubleshooting SEN02630 05 PC300 350 8 13 Circuit diagram related to water in fuel sensor...

Page 616: ...assis ground Max 10 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning st...

Page 617: ...40 Troubleshooting SEN02630 05 PC300 350 8 15...

Page 618: ...r engine controller with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 5 Disconnection in wiring har ness Disconnection in wiri...

Page 619: ...se No 19 machine wiring harness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage push in or expansion of pin M...

Page 620: ...ch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective battery voltage a Prepare with starting switch OFF then carry out tr...

Page 621: ...40 Troubleshooting SEN02630 05 PC300 350 8 19 Circuit diagram related to engine controller power supply...

Page 622: ...ut three minutes As air is bled from the fuel circuit the engine speed will be stabilized erasing the error indication 3 Defect in fuel low pressure circuit parts a For check of pressure in fuel low p...

Page 623: ...n rail pres sure While engine is stopped 0 0 39 MPa 0 4 kg cm2 a Prepare with starting switch OFF INSITE connection then start engine and carry out troubleshooting Measured after one minute or more la...

Page 624: ...SEN02630 05 40 Troubleshooting 22 PC300 350 8 Circuit diagram related to common rail pressure sensor and engine controller ground line...

Page 625: ...40 Troubleshooting SEN02630 05 PC300 350 8 23...

Page 626: ...een 3 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judg...

Page 627: ...40 Troubleshooting SEN02630 05 PC300 350 8 25 Circuit diagram related to common rail pressure sensor...

Page 628: ...rness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with GND cir cuit...

Page 629: ...40 Troubleshooting SEN02630 05 PC300 350 8 27 Circuit diagram related to common rail pressure sensor...

Page 630: ...temperature of turbocharger may be abnormally high Check related parts directly 3 Defective engine controller If causes 1 2 are not detected engine controller may be defective Since trouble is in sys...

Page 631: ...40 Troubleshooting SEN02630 05 PC300 350 8 29...

Page 632: ...nlet side Cranking speed Min 150 rpm Pressure in fuel low pressure circuit During cranking Min 0 14 MPa Min 1 4 kg cm2 a For check of pressure in fuel low pressure circuit see Testing and adjusting Ch...

Page 633: ...g and adjusting Checking fuel return rate and leakage Return rate from sup ply pump During cranking if engine cannot be started Max 200 cc 30 sec During low idle if engine can be started Max 300 cc 30...

Page 634: ...wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Breakage or improper clear ance of engine Ne speed sen...

Page 635: ...15 female 1 Resis tance Min 100 kz Wiring harness between CE01 female 27 C15 female 3 and between CE01 female 48 C15 female 2 Resis tance Min 100 kz 9 Defective wiring harness connector Connecting par...

Page 636: ...r breakage of rotation sensor wheel on crankshaft side Rotation sensor wheel on crankshaft side may be installed defec tively or broken Check it according to the following procedure 1 Set No 1 cylinde...

Page 637: ...40 Troubleshooting SEN02630 05 PC300 350 8 35...

Page 638: ...9 If fuse is broken circuit probably has ground fault 5 Defective relay for engine controller power supply a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting...

Page 639: ...40 Troubleshooting SEN02630 05 PC300 350 8 37 Circuit diagram related to engine controller power supply...

Page 640: ...sor Engine Bkup speed sensor may be broken or may have improper clearance Check it directly 4 Breakage of rotation sensor ring Rotation sensor ring may be broken Check it directly 5 Disconnection in w...

Page 641: ...parts between engine Bkup speed sensor engine wir ing harness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage...

Page 642: ...iring harness between CM02 female 10 CP01 female 64 CE02 female 47 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF...

Page 643: ...40 Troubleshooting SEN02630 05 PC300 350 8 41 Circuit diagram related to KOMNET communication...

Page 644: ...l Related infor mation Method of reproducing failure code Turn starting switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Sh...

Page 645: ...andard value in normal state Remarks on troubleshooting 1 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without tur...

Page 646: ...ure error 2 in common rail circuit Action of con troller Limits output and continues operation Problem that appears on machine Engine does not start easily Exhaust gas becomes black Engine output lowe...

Page 647: ...40 Troubleshooting SEN02630 05 PC300 350 8 45...

Page 648: ...in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CE01 female 1 C18 female 1 Res...

Page 649: ...40 Troubleshooting SEN02630 05 PC300 350 8 47 Circuit diagram related to electric lift pump actuator...

Page 650: ...circuit in wiring harness a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harness between CE01 female 1 C18 female 1 and chassis ground Voltage Ma...

Page 651: ...40 Troubleshooting SEN02630 05 PC300 350 8 49 Circuit diagram related to electric lift pump actuator...

Page 652: ...in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGULAT...

Page 653: ...40 Troubleshooting SEN02630 05 PC300 350 8 51 Circuit diagram related to supply pump actuator metering unit...

Page 654: ...Replace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 2 Disconnection in wiring har ness Di...

Page 655: ...40 Troubleshooting SEN02630 05 PC300 350 8 53 Circuit diagram related to preheating starting and charging engine...

Page 656: ...Troubleshooting by replace ment Replace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 2 Sho...

Page 657: ...40 Troubleshooting SEN02630 05 PC300 350 8 55 Circuit diagram related to preheating starting and charging engine...

Page 658: ...d value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective battery relay Internal defect a Prepare with starting switch OFF then carry out troubleshoot ing wit...

Page 659: ...40 Troubleshooting SEN02630 05 PC300 350 8 57 Circuit diagram related to battery relay drive...

Page 660: ...ive personal code relay Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Troubleshooting for relay unit R07...

Page 661: ...40 Troubleshooting SEN02630 05 PC300 350 8 59 Circuit diagram related to engine preheater starting motor charging system...

Page 662: ...particular If cause of failure disappears system resets itself Problem that appears on machine GPS cannot measure position Related infor mation Method of reproducing failure code Turn starting switch...

Page 663: ...k F04 or fuse No 2 If fusible link or fuse is broken circuit probably has ground fault See Cause 3 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepa...

Page 664: ...SEN02630 05 40 Troubleshooting 62 PC300 350 8 Circuit diagram related to pump controller power supply...

Page 665: ...eshooting Disconnect sensors at right in order and carry out operation to reproduce trouble If E of failure code goes off when a sensor is disconnected that sensor is defective Bucket DUMP PPC pressur...

Page 666: ...em Voltage Max 1 V Wiring harness between CP01 female 53 P03 female 2 P03 female 1 J03 ground T08 Swing LEFT PPC pressure sensor system Voltage Max 1 V Wiring harness between CP01 female 73 P04 female...

Page 667: ...40 Troubleshooting SEN02630 05 PC300 350 8 65 Circuit diagram related to pressure sensor power supply of pump controller...

Page 668: ...ector Internal discon nection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON S30 female Resistance Between 1 2 4 7 8 Min 1 Mz Bet...

Page 669: ...40 Troubleshooting SEN02630 05 PC300 350 8 67 Circuit diagram related to model selection connector...

Page 670: ...P01 female 45 Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch O...

Page 671: ...40 Troubleshooting SEN02630 05 PC300 350 8 69 Circuit diagram related to CAN communication of pump controller...

Page 672: ...amera Internal short circuit a Disconnect camera with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect camera and perform failure reproduction operation If fai...

Page 673: ...40 Troubleshooting SEN02630 05 PC300 350 8 71 Circuit diagram related to camera...

Page 674: ...started Action of machine monitor None in particular If cause of failure disappears system resets itself Problem that appears on machine Related infor mation Method of reproducing failure code Turn s...

Page 675: ...40 Troubleshooting SEN02630 05 PC300 350 8 73...

Page 677: ...Abnormality 8 Failure code DHPBMA R Pump Press Sensor Abnormality 10 Failure code DHS3MA Arm Curl PPC Sensor Abnormality 12 Failure code DHS4MA Bucket Curl PPC Press Sensor Abnormality 14 Failure code...

Page 678: ...uit 42 Failure code DXA0KB PC EPC Sol Short Circuit 44 Failure code DXE0KA LS EPC Sol Open Circuit 46 Failure code DXE0KB LS EPC Sol Short Circuit 48 Failure code DXE4KA Service Current EPC Open Circu...

Page 679: ...40 Troubleshooting SEN02631 02 PC300 350 8 3...

Page 680: ...sis tance Max 1 z Wiring harness between CM02 female 10 CP01 female 64 CE02 female 47 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with s...

Page 681: ...40 Troubleshooting SEN02631 02 PC300 350 8 5 Circuit diagram related to CAN communication of machine monitor...

Page 682: ...monitoring function Code 04402 Hydraulic oil temperature sensor voltage Method of reproducing failure code Start engine Possiblecauses and standard value in normal state Cause Standard value in normal...

Page 683: ...40 Troubleshooting SEN02631 02 PC300 350 8 7...

Page 684: ...normal and the signal voltage is not normal perform troubleshooting as follows 1 Turn starting switch to OFF position 2 Replace connector P25 with connector P26 of R pump pressure sensor 3 Turn starti...

Page 685: ...mp controller Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 6 Defective pump controller a Prepare with starting switch OFF then star...

Page 686: ...s normal and the signal voltage is not normal perform troubleshooting as follows 1 Turn starting switch to OFF position 2 Replace connector P26 with connector P25 of R pump pressure sensor 3 Turn star...

Page 687: ...ump controller Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 6 Defective pump controller a Prepare with starting switch OFF then sta...

Page 688: ...with starting switch OFF then start engine and carry out troubleshooting P04 Voltage Between 3 1 4 5 5 5 V Between 2 1 0 5 4 5 V 3 Disconnection in wiring har ness Disconnection in wiring or defectiv...

Page 689: ...40 Troubleshooting SEN02631 02 PC300 350 8 13 Circuit diagram related to arm IN PPC pressure sensor of pump controller...

Page 690: ...l defect a Prepare with starting switch OFF then start engine and carry out troubleshooting P01 Voltage Between 3 1 4 5 5 5 V Between 2 1 0 5 4 5 V 3 Disconnection in wiring har ness Disconnection in...

Page 691: ...40 Troubleshooting SEN02631 02 PC300 350 8 15 Circuit diagram related to bucket curl PPC pressure sensor of pump controller...

Page 692: ...monitor is displayed Action of controller None in particular If cause of failure disappears system resets itself Problem that appears on machine Related infor mation Method of reproducing failure code...

Page 693: ...40 Troubleshooting SEN02631 02 PC300 350 8 17...

Page 694: ...causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel speed sole noid Internal disconnection a Prepare with starting switch OFF t...

Page 695: ...40 Troubleshooting SEN02631 02 PC300 350 8 19 Circuit diagram related to travel speed solenoid of pump controller...

Page 696: ...with monitoring function Code 02300 Solenoid 1 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel speed sole noid Int...

Page 697: ...40 Troubleshooting SEN02631 02 PC300 350 8 21 Circuit diagram related to travel speed solenoid of pump controller...

Page 698: ...ting for failure code DW45KB Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective swing holding brake solenoid Internal dis con...

Page 699: ...ot ing without turning starting switch ON Wiring harness between CP02 female 101 D01 J02 H15 S04 male 3 and chassis ground Resis tance Min 1 Mz Wiring harness between V05 female 2 H15 S04 male 4 and c...

Page 700: ...SEN02631 02 40 Troubleshooting 24 PC300 350 8 Circuit diagram related to swing holding brake solenoid of pump controller...

Page 701: ...40 Troubleshooting SEN02631 02 PC300 350 8 25...

Page 702: ...and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective swing holding brake solenoid Internal short circuit or ground fault a Prepare with starti...

Page 703: ...40 Troubleshooting SEN02631 02 PC300 350 8 27 Circuit diagram related to swing holding brake solenoid of pump controller...

Page 704: ...n normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel junction solenoid Internal disconnection a Prepare with starting switch OFF then carry out troubleshoo...

Page 705: ...40 Troubleshooting SEN02631 02 PC300 350 8 29 Circuit diagram related to travel junction solenoid of pump controller...

Page 706: ...unction Code 02300 Solenoid 1 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel junction solenoid Internal short circ...

Page 707: ...40 Troubleshooting SEN02631 02 PC300 350 8 31 Circuit diagram related to travel junction solenoid of pump controller...

Page 708: ...roducing failure code Turn starting switch ON Set machine in mode other than breaker mode B Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troublesho...

Page 709: ...ng function Code 02301 Solenoid 2 Method of reproducing failure code Turn starting switch ON Set machine in breaker mode B Possiblecauses and standard value in normal state Cause Standard value in nor...

Page 710: ...es and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider solenoid Internal disconnection a Prepare with starting switch OFF then...

Page 711: ...40 Troubleshooting SEN02631 02 PC300 350 8 35 Circuit diagram related to merge divider solenoid of pump controller...

Page 712: ...g function Code 02300 Solenoid 1 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divider solenoid Internal short cir...

Page 713: ...40 Troubleshooting SEN02631 02 PC300 350 8 37 Circuit diagram related to merge divider solenoid of pump controller...

Page 714: ...lue in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief sole noid Internal disconnection a Prepare with starting switch OFF then carry out troubl...

Page 715: ...40 Troubleshooting SEN02631 02 PC300 350 8 39 Circuit diagram related to 2 stage relief solenoid of pump controller...

Page 716: ...Solenoid 1 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relief sole noid Internal short circuit or ground faul...

Page 717: ...40 Troubleshooting SEN02631 02 PC300 350 8 41 Circuit diagram related to 2 stage relief solenoid of pump controller...

Page 718: ...turning starting switch ON V11 male Resistance Between 1 2 7 14 z 2 Defective emergency pump drive switch Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot ing wi...

Page 719: ...40 Troubleshooting SEN02631 02 PC300 350 8 43 Circuit diagram related to LS EPC and PC EPC solenoids of pump controller...

Page 720: ...output equivalent to E mode Failure code DXA0KA is then displayed but it is not defective a Turn emergency pump drive switch OFF during troubleshooting Possiblecauses and standard value in normal sta...

Page 721: ...40 Troubleshooting SEN02631 02 PC300 350 8 45 Circuit diagram related to LS EPC and PC EPC solenoids of pump controller...

Page 722: ...ction a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON V19 male Resistance Between 1 2 7 14 z 2 Disconnection in wiring har ness Disconnection in w...

Page 723: ...40 Troubleshooting SEN02631 02 PC300 350 8 47 Circuit diagram related to LS EPC and PC EPC solenoids of pump controller...

Page 724: ...Code 01500 LS EPC solenoid current Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EPC solenoid Internal short circuit...

Page 725: ...40 Troubleshooting SEN02631 02 PC300 350 8 49 Circuit diagram related to LS EPC and PC EPC solenoids of pump controller...

Page 726: ...Standard value in normal state Remarks on troubleshooting 1 Defective service current EPC solenoid Internal dis connection a Prepare with starting switch OFF then carry out troubleshoot ing without t...

Page 727: ...rent EPC solenoid current value can be checked with monitoring function Code 01700 Service solenoid current Possiblecauses and standard value in normal state Cause Standard value in normal state Remar...

Page 728: ...tarting switch OFF then carry out troubleshooting without turning starting switch ON M05 female Wiper position Resistance Between 6 5 Operating range both ends Max 1 z Other than operating range both...

Page 729: ...40 Troubleshooting SEN02631 02 PC300 350 8 53 Circuit diagram related to wiper motor of pump controller...

Page 730: ...ter nal disconnection a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON M05 female Wiper position Resistance Between 4 5 Storage area Max 1 z Working...

Page 731: ...40 Troubleshooting SEN02631 02 PC300 350 8 55 Circuit diagram related to wiper motor of pump controller...

Page 732: ...ning starting switch ON M06 male Resistance Between 1 2 5 20 z Between 1 2 chassis ground Min 1 Mz 3 Defective assembled type diode D02 Internal short cir cuit a Prepare with starting switch OFF then...

Page 733: ...40 Troubleshooting SEN02631 02 PC300 350 8 57 Circuit diagram related to windshield wiper and window washer...

Page 734: ...n Method of reproducing failure code Turn starting switch ON Turn washer switch ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 D...

Page 735: ...40 Troubleshooting SEN02631 02 PC300 350 8 59 Circuit diagram related to window washer motor of pump controller...

Page 736: ...Turn starting switch ON Set wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter n...

Page 737: ...40 Troubleshooting SEN02631 02 PC300 350 8 61 Circuit diagram related to wiper motor of pump controller...

Page 738: ...starting switch ON Set wiper switch to INT or ON Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal sho...

Page 739: ...40 Troubleshooting SEN02631 02 PC300 350 8 63 Circuit diagram related to wiper motor of pump controller...

Page 741: ...o decelerator does not operate 10 E 3 Automatic warming up system does not operate 12 E 4 Preheater does not operate 14 E 5 All work equipment swing and travel mechanism do not move 16 E 6 Power maxim...

Page 742: ...ction fails to display arm IN normally 42 E 21 Monitoring function fails to display arm OUT normally 44 E 22 Monitoring function fails to display bucket CURL normally 46 E 23 Monitoring function fails...

Page 743: ...40 Troubleshooting SEN02632 02 PC300 350 8 3...

Page 744: ...amp switch swing holding release switch 2 30A Pump controller Solenoid power supply Machine push up switch 3 10A PPC oil pressure lock solenoid valve Starting motor cut off relay 4 10A Cigarette light...

Page 745: ...40 Troubleshooting SEN02632 02 PC300 350 8 5 Locations of fusible links Location of fuse box and fuse Nos...

Page 746: ...short Wiring harness which is not connected to power source 24 V circuit is in contact with power source 24 V circuit Short circuit Independent wiring harnesses are in contact with each other abnormal...

Page 747: ...etween 1 4 OFF Min 1 Mz START Max 1 z 4 Defective safety lock switch internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON S14 fe...

Page 748: ...iring har ness Short circuit with GND cir cuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between battery relay termi nal B R0...

Page 749: ...40 Troubleshooting SEN02632 02 PC300 350 8 9 Circuit diagram related to engine start and battery charging...

Page 750: ...OWER Operation of lever ON Lever in neutral OFF 3 Defective arm IN signal In the case monitoring is not normally indicated proceed to trouble shooting No E 23 Monitoring code Item Normal display 01900...

Page 751: ...ay 01900 Travel Operation of lever ON Lever in neutral OFF 9 Defective attachment signal In the case monitoring is not normally indicated proceed to trouble shooting No E 30 Monitoring code Item Norma...

Page 752: ...ystem is turned OFF Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective engine coolant temperature signal In the case monitori...

Page 753: ...40 Troubleshooting SEN02632 02 PC300 350 8 13...

Page 754: ...Voltage Between 16 chassis ground OFF Max 1 V HEAT 20 30 V Trouble 2 When starting switch is turned to HEAT position preheater does not warm up Related infor mation During low temperature coolant temp...

Page 755: ...40 Troubleshooting SEN02632 02 PC300 350 8 15 Circuit diagram related to engine preheater...

Page 756: ...ween 1 2 20 60 z Between 2 chassis ground Min 1 Mz 4 Defective assembled type diode D01 Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starti...

Page 757: ...40 Troubleshooting SEN02632 02 PC300 350 8 17 Circuit diagram related to PPC lock solenoid...

Page 758: ...ubleshoot ing without turning starting switch ON S11 male Switch Resistance Between 1 2 Released Min 1 Mz Pressed Max 1 z 3 Disconnection in wiring har ness Disconnection in wiring or defective contac...

Page 759: ...40 Troubleshooting SEN02632 02 PC300 350 8 19...

Page 760: ...switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM01 female 1 2 J06 Resis tance Max 1 z Wiring harness between CM01 female 3 4 chassis ground Resis...

Page 761: ...40 Troubleshooting SEN02632 02 PC300 350 8 21 Circuit diagram related to power source in monitor panel...

Page 762: ...ous operation 2 Defective machine monitor Since trouble is in system troubleshooting cannot be carried out If causes stated above are not detected machine monitor may be defective Trouble Contents of...

Page 763: ...is normal a Add fuel 2 Defective fuel level sensor Internal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON P21 male Fuel level Res...

Page 764: ...8 kz 80 C 1 0 1 3 kz 95 C 700 800 z Between B chas sis ground All range Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting s...

Page 765: ...40 Troubleshooting SEN02632 02 PC300 350 8 25 Circuit diagram related to engine coolant temperature sensor...

Page 766: ...Between 2 chas sis ground Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing wit...

Page 767: ...er limit 85 110 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning start...

Page 768: ...ng or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CM02 female 5 J02 S04 male 5 Resis ta...

Page 769: ...40 Troubleshooting SEN02632 02 PC300 350 8 29 Circuit diagram related to swing lock switch...

Page 770: ...elated infor mation a If travel speed selection fails proceed with troubleshooting No H 21 Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshoo...

Page 771: ...40 Troubleshooting SEN02632 02 PC300 350 8 31...

Page 772: ...to front Min 1 Mz When retracted to rear Max 1 z 2 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON M...

Page 773: ...40 Troubleshooting SEN02632 02 PC300 350 8 33 Circuit diagram related to window washer motor of machine monitor...

Page 774: ...ate Related information Condition of window washer switch signal can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possiblecauses and standard value in normal state Caus...

Page 775: ...40 Troubleshooting SEN02632 02 PC300 350 8 35...

Page 776: ...out turning starting switch ON V06 male Resistance Between 1 2 20 60 z Between 2 chassis ground Min 1 Mz 4 Defective assembled type diode D02 Internal short circuit a Prepare with starting switch OFF...

Page 777: ...e in normal state Remarks on troubleshooting 1 Defective machine push up switch Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switc...

Page 778: ...with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 53 P06 female 2 Resis tance Max 1 z Wiring harness between P06 female 1...

Page 779: ...40 Troubleshooting SEN02632 02 PC300 350 8 39 Circuit diagram related to boom RAISE PPC oil pressure switch...

Page 780: ...with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 14 P02 female 2 Resis tance Max 1 z Wiring harness between P02 female 1 c...

Page 781: ...40 Troubleshooting SEN02632 02 PC300 350 8 41 Circuit diagram related to boom LOWER PPC oil pressure switch...

Page 782: ...onnec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 17 P04 female 2 Resis tance Max 1 z Wiring harness be...

Page 783: ...40 Troubleshooting SEN02632 02 PC300 350 8 43...

Page 784: ...starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 15 P08 female 2 Resis tance Max 1 z Wiring harness between P08 female 1 chass...

Page 785: ...40 Troubleshooting SEN02632 02 PC300 350 8 45 Circuit diagram related to arm OUT PPC oil pressure switch...

Page 786: ...ective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 73 P01 female 2 Resis tance Max 1...

Page 787: ...40 Troubleshooting SEN02632 02 PC300 350 8 47...

Page 788: ...with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 34 P05 female 2 Resis tance Max 1 z Wiring harness between P05 female 1...

Page 789: ...40 Troubleshooting SEN02632 02 PC300 350 8 49 Circuit diagram related to bucket DUMP PPC oil pressure switch...

Page 790: ...iring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harnesses between CP01 female 16 P03 male 2 P07 fe...

Page 791: ...40 Troubleshooting SEN02632 02 PC300 350 8 51 Circuit diagram related to right and left swing PPC oil pressure switches...

Page 792: ...en carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 55 J01 P09 female 2 Resis tance Max 1 z Wiring harness between P09 female 1 J05 chassis ground Resis...

Page 793: ...40 Troubleshooting SEN02632 02 PC300 350 8 53 Circuit diagram related to travel PPC oil pressure switch and travel alarm...

Page 794: ...ring har ness Disconnection in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP...

Page 795: ...40 Troubleshooting SEN02632 02 PC300 350 8 55 Circuit diagram related to travel steering PPC oil pressure switch...

Page 796: ...on in wiring or defective contact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between CP01 female 52 P14 female 2...

Page 797: ...40 Troubleshooting SEN02632 02 PC300 350 8 57 Circuit diagram related to service PPC oil pressure switch...

Page 798: ...rks on troubleshooting 1 Defective communication 1 a Turn starting switch ON and check Setting condition or termi nal screen Check item Normal display Communication start check Completion 2 Defective...

Page 799: ...40 Troubleshooting SEN02632 02 PC300 350 8 59...

Page 800: ...ontact in connec tor a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Wiring harness between F01 11 outlet AC01 male 4 Resis tance Max 1 z Wiring h...

Page 801: ...40 Troubleshooting SEN02632 02 PC300 350 8 61 Circuit diagram related to air conditioner...

Page 802: ...ith starting switch OFF then start engine and carry out troubleshooting insert T adapter M14 Travel lever Voltage Between 1 2 Neutral Max 1 V Operated 20 30 V If above voltage is normal and travel ala...

Page 803: ...40 Troubleshooting SEN02632 02 PC300 350 8 63 Circuit diagram related to travel PPC oil pressure switch and travel alarm...

Page 804: ...n M08 2 chassis ground with horn switch turned ON Voltage 20 30 V a Prepare with starting switch OFF then carry out troubleshoot ing without turning starting switch ON Between M08 female 1 chassis gro...

Page 805: ...40 Troubleshooting SEN02632 02 PC300 350 8 65 Circuit diagram related to horn...

Page 807: ...work equipment lack power or travel and swing speeds are slow 8 H 2 Engine speed sharply drops or engine stalls 10 H 3 No work equipment swing or travel move 11 H 4 Abnormal noise is heard from aroun...

Page 808: ...sharply 20 H 18 Machine swerves in travel 21 H 19 Machine travels slowly 22 H 20 Machine cannot be easily steered or lacks power 23 H 21 Travel speed does not shift or it is too slow or fast 24 H 22...

Page 809: ...40 Troubleshooting SEN02633 03 PC300 350 8 3...

Page 810: ...SEN02633 03 40 Troubleshooting 4 PC300 350 8 System chart for hydraulic and mechanical system 1...

Page 811: ...ing SEN02633 03 PC300 350 8 5 a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart Use it as a reference material when troubleshooting the hydraulic and mec...

Page 812: ...ng on machine Relative infor mation Information on the failure occurred as well as the troubleshooting Presumed cause and stan dard value in normalcy Cause Standard value in normalcy and references fo...

Page 813: ...40 Troubleshooting SEN02633 03 PC300 350 8 7...

Page 814: ...normal after adjustment main relief valve may have malfunction or internal defect Check main relief valve directly 3 Malfunction of self pressure reducing valve a Prepare with engine stopped then run...

Page 815: ...e Oil pressure ratio All levers in neutral Travel with no load Lever operated halfway Pump discharge pressure Almost same pres sure 1 LS valve output pres sure Approx 3 5 If oil pressure does not beco...

Page 816: ...at high idle and carry out troubleshooting Measured oil pres sure Measurement condi tion Oil pressure ratio Pump discharge pressure Swing lock ON Arm IN relief 1 PC valve output pres sure Approx 3 5 I...

Page 817: ...pump Piston pump may have malfunction or internal defect Check it by following method Crank the engine with oil pressure measurement plug removed If oil flows out the piston pump is normal 4 Defective...

Page 818: ...elated infor mation Set the working mode in P mode before start Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of LS EP...

Page 819: ...ntrol valve Lo Hi may have malfunction Check it directly 6 Malfunction of boom control valve regeneration valve Regeneration valve of boom control valve Lo may have malfunc tion or defective seal Chec...

Page 820: ...unction Check it directly 6 Malfunction of arm control valve regeneration valve Regeneration valve of arm control valve Lo may have malfunction or defective seal Check it directly 7 Malfunction of arm...

Page 821: ...rectly 4 Malfunction or defective seal of bucket control valve safety suction valve Safety suction valve of bucket control valve may have malfunction or defective seal Check it directly 5 Malfunction...

Page 822: ...tion Set the working mode in P mode before start Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective arm cylinder a Prepare wi...

Page 823: ...al of bucket con trol valve safety suction valve a Seal of safety suction valve of bucket control valve may defec tive Check it directly This safety suction valve may be checked by replacing it with a...

Page 824: ...tly 3 Malfunction of control valve safety suction valve Safety suction valve of control valve may have malfunction Check it directly a The safety suction valve of the arm or boom may be checked by rep...

Page 825: ...kg cm2 ON 2 84 3 43 MPa 29 35 kg cm2 2 Malfunction of main relief valve Main relief valve may have malfunction Check it directly Failure phe nomenon In a compound operation work equipment with larger...

Page 826: ...bleshooting 1 Malfunction or defective seal of LS selector valve LS selector valve may have malfunction or defective seal Check it directly Failure phe nomenon In a compound operation of swing travel...

Page 827: ...h engine stopped then run engine at high idle and carry out troubleshooting Measured oil pressure Oil pressure ratio All lever in neutral Travel with no load Lever operated halfway Pump discharge pres...

Page 828: ...opped then run engine at high idle and carry out troubleshooting Travel speed Travel lever LS EPC output pres sure Lo Neutral Approx 1 4 MPa Approx 14 kg cm2 Hi Lifting operation 0 MPa 0 kg cm2 4 Malf...

Page 829: ...kg cm2 Either side operated 2 84 3 43 MPa 29 35 kg cm2 5 Malfunction of merge divider valve Merge divider valve may have malfunction Check it directly 6 Malfunction of travel control valve spool Spoo...

Page 830: ...Monitoring 15 Lo Fine control such as releasing decelerator 690 mA Mi 740 mA Hi 0 mA a Prepare with engine stopped then run engine at high idle and carry out troubleshooting Travel speed Travel lever...

Page 831: ...have defective seal Check it directly 2 Defective seal of travel motor safety valve Safety valve of travel motor may have defective seal Check it directly 3 Defective seal of travel motor check valve...

Page 832: ...section of swing motor may have malfunction Check it directly 3 Defective adjustment or mal function of swing motor safety valve a Prepare with engine stopped then run engine at high idle and carry o...

Page 833: ...tral 0 MPa 0 kg cm2 Swing Min 2 7 MPa Min 28 kg cm2 2 Malfunction of swing control valve spool Spool of swing control valve may have malfunction Check it directly 3 Defective seal of swing motor sucti...

Page 834: ...2 Malfunction of swing motor holding brake Holding brake section of swing motor may have malfunction Check it directly 3 Defective adjustment or mal function of swing motor safety valve a Prepare with...

Page 835: ...of swing control valve spool Spool of swing control valve may have malfunction Check it directly 3 Malfunction of swing control valve pressure compensa tion valve Pressure compensation valve of swing...

Page 836: ...infor mation Set the working mode in P mode before start Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of swing PPC va...

Page 837: ...and left side may be checked by replacing them with each other and seeing change of condi tion Trouble Large sound is made when upper structure stops swinging Related infor mation Set the working mode...

Page 838: ...it directly Trouble 2 Hydraulic drift of swing is large when swing holding brake is released Related infor mation When swing emergency reset switch is turned ON in an emergency swing holding brake is...

Page 839: ...40 Troubleshooting SEN02633 03 PC300 350 8 33...

Page 841: ...does not pick up smoothly 10 S 4 Engine stops during operations 11 S 5 Engine does not rotate smoothly 12 S 6 Engine lacks output or lacks power 13 S 7 Exhaust smoke is black incomplete combustion 14...

Page 842: ...SEN02634 02 40 Troubleshooting 2 PC300 350 8 S 16 Vibration is excessive 23...

Page 843: ...pending on their level Check items Items to be simply checked by the serviceman to narrow down causes They corresponds to C in the chart on the right Causes Items to be narrowed from the questions and...

Page 844: ...st smoke is black Let us assume that Clogged air cleaner is taken to be the cause of black exhaust gas 3 symptoms have causal relationship with this problem Color of exhaust gas gradually became black...

Page 845: ...634 02 PC300 350 8 5 If we look from these 3 symptoms to find the causes we find that there is a relationship with 5 causes Let us explain here the method of using this causal relationship to pinpoint...

Page 846: ...preheated or when temperature is low preheating monitor does not indicate normally if monitor is installed w During operation charge level monitor indicates abnormal charge if monitor is installed w...

Page 847: ...Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes...

Page 848: ...in w Q w w E Replacement of filters has not been carried out according to Operation and Mainte nance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank c...

Page 849: ...installed w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed there is...

Page 850: ...more frequently w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel pipi...

Page 851: ...ped w Q Q Q Non specified fuel is being used Q Q Q Replacement of filters has not been carried out according to Operation and Mainte nance Manual w Fuel level monitor indicates low level if monitor is...

Page 852: ...iod E Condition of hunting Occurs at a certain speed range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out ac...

Page 853: ...quently Q Q Dust indicator is red if indicator is installed w w Air breather hole of fuel tank cap is clogged w w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of ope...

Page 854: ...Q Q Dust indicator is red if indicator is installed w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode...

Page 855: ...Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in inta...

Page 856: ...r history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Engine oil must be added more frequently w Metal particles are found when oil filter is drained Q...

Page 857: ...Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When...

Page 858: ...air history Degree of use of machine Operated for long period E E Increase of oil level Suddenly occurred Q Q Gradually occurred Q Q Hard water is being used as coolant Q Q Oil level has risen oil is...

Page 859: ...ing used Q Q Replacement of filters has not been carried out according to Operation and Maintenance Man ual w Oil pressure moni tor if installed Indicates pressure drop at low idle w Indicates pressur...

Page 860: ...requently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check...

Page 861: ...ms When fan belt is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light pass...

Page 862: ...machine Operated for long period E Condition of abnor mal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles ar...

Page 863: ...uestions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q...

Page 865: ...8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly General information on disassembly and asse...

Page 866: ...cedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q The common tools necessary for the removal work are indicated 1 2 and their part Nos part na...

Page 867: ...ble from Komatsu in Japan i e must be made locally Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the oil and coola...

Page 868: ...iner q Quick setting adhesive q Setting time Within 5 sec to 3 min q Used mainly to stick metals rubbers plas tics and woods Aron alpha 201 790 129 9130 2 g Polyethyl ene con tainer q Quick setting ad...

Page 869: ...YGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various q Feature Lithium grease with extreme pres sure lubrication performance q General purpose type Molybdenum dis ulfide grease LM G G2 M SYG2 400M SY...

Page 870: ...27250 20 ml Glass con tainer q Used as primer for sash Almite Using limit 4 months after date of manufacture Adhesive SUNSTAR PEN GUINE SEAL580 SUPER S or W 417 926 3910 320 ml Polyethyl ene con tain...

Page 871: ...nlet con nector 2 795 799 6700 Puller t 1 Removal of fuel injector assembly 3 790 331 1110 Wrench q 1 Tightening of cylinder head bolt Engine and hydraulic pump assembly C 96 460 1210 Oil stopper q 1...

Page 872: ...apter 2 Control valve assem bly M 1 796 946 1310 Guide t 1 Replacement of pressure compensation valve seal For 723 46 40100 723 46 40601 796 946 1810 Guide t 1 For 723 46 43100 723 46 43400 796 946 21...

Page 873: ...rip 1 01010 50816 q Bolt 1 6 790 201 1500 Push tool kit t 1 Press fitting of dust seal 790 101 5021 q Grip 1 01010 50816 q Bolt 1 790 201 1660 q Plate for boom and bucket 1 790 201 1670 q Plate for ar...

Page 874: ...assembly and assembly 10 PC300 350 8 SEN02635 02 Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches D2 push tool E1 push...

Page 875: ...SEN02635 02 PC300 350 8 11 50 Disassembly and assembly Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches E5push tool M4 Push tool...

Page 876: ...50 Disassembly and assembly 12 PC300 350 8 SEN02635 02 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches M5 Push tool M6 Push tool...

Page 877: ...SEN02635 02 PC300 350 8 13 50 Disassembly and assembly...

Page 879: ...cooling system Removal and installation of fuel supply pump assembly 2 Removal and installation of engine front seal 5 Removal and installation of engine rear seal 8 Removal and installation of cylin...

Page 880: ...tor M34 8 6 Loosen air conditioner compressor belt 9 and remove it 2 7 Remove air conditioner compressor 10 and bracket together and move them to a place where they will not be obstacle to the work 8...

Page 881: ...m 1 0 05 kgm 2 a Adjust the belt tension For details see Test ing and adjusting Testing and adjusting air conditioner compressor belt 3 k Don t correct high pressure tube by bend ing it for re use k A...

Page 882: ...e Out q Supply pump outlet high pressure pipe supply pump side and common rail side Out 4 a Clean the inside of the hose connector and insert the connector securely 5 a Install the fuel supply pump as...

Page 883: ...tion A before rotating it The spring of the tensioner assembly 2 is strong If the wrench is loosely inserted the wrench may accidentally come off while being rotated and it is extremely dangerous k Af...

Page 884: ...t do not remove it from the front seal a Pilot tool 1 is in the spare front seal 1 Clean the seal inserting part of the crankshaft 2 Set front seal 10 to tool A2 with its lip up 3 Apply neutral deterg...

Page 885: ...across flats T 12 7 mm of the tensioner assembly 4 and rotate it to the winding up direction a k Make sure that the wrench is secured at the portion A before rotating it The spring of the tensioner a...

Page 886: ...damper assembly 1 1 3 Install the sling to flywheel 2 and lift off the fly wheel 4 Flywheel 40 kg 4 Disconnect connector CRANK 3 5 Temporarily sling engine assembly and remove engine rear side mount b...

Page 887: ...the outside of aligning tool 1 touches the housing a Do not remove the pilot tool from the rear seal 2 Check the ends and seal inserting parts of the crankshaft for burrs and rust and clean them thor...

Page 888: ...et sealant 1 3 mm in diameter to the housing mount ing flange face and around each mounting bolt hole 2 Tighten the mounting bolts in the order of the numbers shown in the figure 3 Mounting bolt 77 12...

Page 889: ...mporarily tighten the mounting bolt with fingers remove guide bolt 101 installed in step 1 3 Using plate 103 fit the flywheel in fly wheel housing 4 Using torque wrench 102 tighten the mounting bolts...

Page 890: ...phery a When measuring bring the crankshaft to the front or rear side so that an error will not be caused by the end play 2 Rotate the flywheel by 1 turn and measure the difference between the lowest...

Page 891: ...or M34 8 7 Loosen air conditioner compressor belt 9 and remove it 2 8 Remove air conditioner compressor 10 and bracket together and move them to a place where they will not be obstacle to the work 9 D...

Page 892: ...CLY3 and CYL4 25 and CYL5 and CYL6 26 16 Remove bracket 27 17 Remove high pressure pipes 28 33 6 18 Remove bracket 34 19 Disconnect drain tube 35 20 Remove common rail 36 5 a Never remove fuel pressur...

Page 893: ...her 32 Remove heat insulation covers 55 56 and 57 33 Disconnect lubrication hoses 58 and lubrica tion tube 59 12 34 Sling the turbocharger and exhaust manifold assembly temporarily 35 Remove 12 mounti...

Page 894: ...move crossheads 69 14 a Record the position of each crosshead and the positions of holes a and b for the valve 41 Remove the fuel injector assembly according to the following procedure 15 1 Clean the...

Page 895: ...lder 75 6 Using tool B2 remove fuel injector assem bly 76 a Do not pry up the injector top 42 Remove 12 push rods 77 17 43 Remove 7 mounting bolts 78 and rocker housing assembly 79 18 44 Remove 26 mou...

Page 896: ...a new fuel pressure sensor 2 Threaded part of fuel pressure sensor Gear oil 90 3 Fuel pressure sensor 70 5 Nm 7 1 0 5 kgm 5 Connect the engine wiring harness At this time take care not to connect the...

Page 897: ...ghten the mounting bolts of common rail 36 temporarily with the fingers 2 Tighten drain tube 35 temporarily 3 Install supply pump outlet high pressure pipe 18 3 Sleeve nut 37 3 4 Nm 3 8 0 4 kgm 4 Inst...

Page 898: ...47 14 7 44 1 Nm 1 5 4 5 kgm 6 Fix the bracket 92 by tightening the bolt 93 94 7 Tighten clamp 46 with fitting nuts q The installation angle and position of the clamp 46 Rotate 90 in a clockwise direc...

Page 899: ...installing the crosshead and rocker arm assembly observe the following precautions a Install the crosshead so that parts a and b on its back side will be at the positions checked when removed When ins...

Page 900: ...or too a Check the inlet connector for the following items If it is defective replace it a If there are burrs or deformation at the inlet or outlet of the connector do not use the inlet connector b If...

Page 901: ...gm 7 Tighten bolts 74 of holder 75 alter nately a The top of the holder must be in par allel with the top of the cylinder head q Allowable angle 2 4 3 Bolt 9 8 2 0 Nm 1 0 0 2 kgm 8 Tighten inlet conne...

Page 902: ...3 kgm 17 a Check that the push rod end is in the tappet 2 Push rod Engine oil EO15W 40 18 a Tighten the rocker housing mounting bolts in the order of the numbers shown in the figure 3 Mounting bolt 24...

Page 903: ...ach bolt Engine oil EO15W 40 5 Tighten the bolts in the order of the num bers shown in the figure 1st time 150 9 8 Nm 15 3 1 0 kgm 2nd time Return all bolts 360 3rd time 115 4 9 Nm 11 7 0 5 kgm 4th ti...

Page 904: ...e lowers and then drain the coolant 1 Open the engine hood and sling the radiator temporarily 2 Pull out pin 1 3 Remove bolt 2 4 Set hole 3 to the position of bolt 2 to fix the engine hood 5 Remove th...

Page 905: ...e reverse order to removal 1 a Apply ThreeBond 4324 or equivalent to the adapters of hoses 4 7 8 and 9 q Refilling with coolant Add coolant through the coolant filler to the specified level Run the en...

Page 906: ...248 l 2 Remove the bottom cover of the hydraulic oil cooler 3 Open the cover at the front of the hydraulic oil cooler 4 Open the engine hood and sling the hydraulic oil cooler temporarily 5 Remove the...

Page 907: ...ft off hydraulic oil cooler assembly 12 4 Hydraulic oil cooler assembly 50 kg Installation q Carry out installation in the reverse order to removal q Refilling with oil Add oil through the oil filler...

Page 908: ...e battery 1 Open the front cover of the aftercooler 2 Disconnect connector M06 1 3 Disconnect hose 2 and remove reservoir tank 3 4 Disconnect hoses 4 and 5 1 5 Remove 4 mounting bolts 6 and aftercoole...

Page 909: ...ing tool C remove the drain plug to drain oil from the hydraulic tank and piping 6 Hydraulic tank 248 l 2 Drain the engine coolant 6 Coolant 36 l 3 Open the engine hood 4 Remove clamps 1 and 2 U bolt...

Page 910: ...21 14 Remove clamps 22 and 23 15 Disconnect ground wire 24 16 Remove clamp 25 4 17 Loosen clamp 26 and remove tube 27 and hose together 5 18 Disconnect heater hoses 28 and 29 19 Disconnect B terminal...

Page 911: ...een the engine and hydraulic pump 24 Remove covers 37 40 25 Disconnect hoses 41 and 42 from the engine oil filter 26 Disconnect connectors V19 43 and V11 44 27 Disconnect hoses 45 52 28 Disconnect tub...

Page 912: ...0 05 kgm 2 6 a Apply ThreeBond 4324 or equivalent to the adapter of the hose 3 a Adjust the belt tension For details see Test ing and adjusting Testing and adjusting air conditioner compressor belt 4...

Page 913: ...50 Disassembly and assembly SEN02636 03 PC300 350 8 35...

Page 915: ...60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly Power train Removal and installation of final drive assembly 2 Disassembly and assembly of final drive assembly 3 Removal and installati...

Page 916: ...and then lift off final drive assembly 6 1 a Be careful so that the nipple sealing sur face on the hose mounting block may not be damaged a When lifting off the final drive assembly do not use a tappe...

Page 917: ...se 2 Remove cover 1 using eyebolt 2 3 Spacer Remove spacer 2 4 No 1 carrier assembly 1 Remove No 1 carrier assembly 3 Symbol Part number Part name Necessity Q ty N R Sketch D 1 796 627 1610 Wrench ass...

Page 918: ...No 1 sun gear shaft Remove No 1 sun gear shaft 11 6 No 2 sun gear shaft Remove No 2 sun gear shaft 12 7 Thrust washer Remove thrust washer 13 8 Ring gear Remove ring gear 14 using eyebolt 3 9 No 2 ca...

Page 919: ...ckplate 23 2 Use tool D1 to remove nut 24 11 Hub assembly 1 Using eyebolts 4 remove hub assembly 25 from travel motor 2 Disassemble the hub assembly as follows 1 Remove floating seal 26 2 Remove beari...

Page 920: ...g seal a After installing the floating seal check that the angle of the floating seal is within 1 mm a After installing the floating seal coat the sliding surface thinly with engine oil EO30 3 Using t...

Page 921: ...en installing the lockplate avoid notch j of the travel motor and fit it to the spline totally under the condition of k 2 Thread of mounting bolt Adhesive LT 2 3 Mounting bolt 59 74 Nm 6 7 5 kgm a Do...

Page 922: ...If there is a groove avoid placing the claws on that groove a After inserting the pin caulk the pin portion of the carrier a After assembling the carrier assembly check that gear 20 rotates smoothly 2...

Page 923: ...m thrust washers 7 and 10 and then set the gear assembly on carrier 6 2 Align the position of pin holes on the shaft and carrier then tap with a plas tic hammer to install shaft 5 a Install the shaft...

Page 924: ...is case check again 10 Cover 1 Using eyebolts 2 install cover 1 2 Cover mounting surface Gasket sealant LG 6 2 Tighten the mounting bolts according to the following procedure 3 Mounting bolt 1st step...

Page 925: ...g brake port B 2 Disconnect arm cylinder hoses 6 3 Remove the mounting bolts 4 Tighten a forcing screw in position a shown in the following figure to separate the swing motor and swing machinery assem...

Page 926: ...emove the 6 mounting bolts to remove swing motor assembly 1 3 No 1 sun gear Remove No 1 sun gear shaft 2 4 No 1 carrier assembly 1 Remove No 1 carrier assembly 3 2 Disassemble No 1 carrier assembly as...

Page 927: ...car rier assembly 13 2 Disassemble No 2 carrier assembly as follows 1 Insert pin 14 and drive shaft 15 out of carrier 16 a After removing the shaft remove pin 14 2 Remove thrust washer 17 gear 18 bea...

Page 928: ...liding surfaces with engine oil and then assemble the parts 1 Bearing Using push tool E3 4 press fit bearing 27 to case 32 a Use a new bearing a Press fitting force Reference value 0 26 4 kN 0 2 690 k...

Page 929: ...from slanting a Hit the flange of case assembly 25 frequently and lightly to correct the lean of case assembly 25 In partic ular adjust the flange so that oil seal mating face B of the shaft will be...

Page 930: ...the thin walled portion on the carrier Portion b Take care however that the thin walled portion can be on the opposite side of the carrier depending on actual individual items Pay attention so that a...

Page 931: ...and then install it 3 Final drive assembly mounting bolt 245 309 Nm 25 31 5 kgm 8 No 1 carrier assembly 1 Assemble No 1 carrier assembly as fol lows 1 Press fit shaft 5 into the carrier in the direct...

Page 932: ...ssembly 1 Set swing machinery assembly 33 to block 1 2 Install swing motor assembly 1 3 Install ring gear 10 and swing motor assembly 1 to the following positions 2 Swing motor mounting face Gasket se...

Page 933: ...l 2 Sling swing circle assembly 1 at 3 points and remove the mounting bolt to remove the assembly 1 4 Swing circle assembly 500 kg Installation q Installation is done in the reverse order of removal 1...

Page 935: ...Disassembly and assembly Undercarriage and frame Disassembly and assembly of carrier roller 2 Disassembly and assembly of track roller assembly 3 Disassembly and assembly of idler assembly 4 Disassemb...

Page 936: ...l stick to the contact surface of the float ing seal a After inserting the floating seal with tool F1 check that its slant is less than 1 mm and its pro jection a is 5 7 mm q Carrier roller a Check th...

Page 937: ...a After inserting the floating seal with tool G1 check that its slant is less than 1 mm and its pro jection a is 5 7 mm q Mounting roller cover mounting bolt 3 Track roller cover mounting bolt 44 12 5...

Page 938: ...4 from shaft 5 and support assembly 7 a Oil of 230 10 cc is in the idler Drain it at this time or spread cloths to absorb it 4 Remove floating seal 6 on the opposite side from idler 4 shaft 5 and supp...

Page 939: ...haft 5 and support 7 assembly a Before installing the floating seal completely degrease both contact surfaces of the O ring and the floating seal hatched area in the il lustration Furthermore take car...

Page 940: ...l and be careful not to let any dirt or dust get stuck to it a Remove all grease and oil from the contact surfaces of the O ring and the floating seal 6 Install O ring then install support 2 using dow...

Page 941: ...ockplate 3 then nut 4 a Compress the spring until the nut be comes loose a Release the hydraulic pressure slowly and release the tension of the spring a Free length of spring 811 5 mm 3 Remove yoke 6...

Page 942: ...liding part Grease G2 LI 3 Apply hydraulic pressure slowly to compress the spring and then tighten nut 4 so that the installed length of the spring is dimension a and secure it with lockplate 3 a Inst...

Page 943: ...ack shoe assembly h 2 Swing work equipment 90 push up chassis with work equipment and place blocks 1 between track frame and track shoe 3 Remove the mounting bolt and then lift off sprocket 1 1 4 Spro...

Page 944: ...the work equipment to the ground and loosen lubricator 1 in order to loosen track shoe tension 1 k Inner pressure of the adjustment cylinder is extremely high Never loosen the lubri cator more than on...

Page 945: ...the gChecking and adjusting track shoe tension h section in the Testing and ad justing chapter of this manual 2 2 Mounting bolt Seizure prevention agent Maruzen Morimax No 2 or equivalent 3 Mounting b...

Page 946: ...ly h 2 Remove the counterweight assembly For details see gRemoval and installation of coun terweight assembly h 3 Disconnect 4 boom cylinder hoses 1 a Plug the hose to stop oil flow out 4 Sling boom c...

Page 947: ...off revolving frame assembly 20 1 a Using the lever block adjust fore and aft as well as right and left balance of the revolving frame assembly with only 2 mounting bolts being left in the front and r...

Page 948: ...lamp 4 If equipped 3 Sling counterweight assembly 2 2 rear camera specification 1 Disconnect connector A40 3 of camera 1 RC1 2 Disconnect connector CN L09 5 and wiring harness clamps 6 from rear worki...

Page 949: ...lving frame and counterweight become 10 5 mm 3 The difference in level in left to right direction between the exterior of door D and counter weight C a 10 4 mm The difference in level in left to right...

Page 950: ...according to the following procedure 1 Attach the noise insulation sheets 1 2 3 and 4 to the front surface of the counter weight a The surface of the counterweight for noise insulation sheets to be a...

Page 951: ...SEN02638 03 PC300 350 8 17 50 Disassembly and assembly...

Page 953: ...sembly and assembly of center swivel joint assembly 4 Removal and installation of hydraulic tank assembly 5 Removal and installation of control valve assembly 7 Disassembly and assembly of control val...

Page 954: ...ort q 4 Center swivel joint D port RH travel motor PB port q 5 Center swivel joint A port LH travel motor PB port q 6 Center swivel joint C port RH travel motor PA port q 7 Center swivel joint E port...

Page 955: ...ected to the front of the machine in the direction of the arrow Part 19 in the following figure is the sprocket q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to...

Page 956: ...Install dust seal 6 to cover 7 2 Lip of dust seal Grease G2 LI Apply 2 3 cc 4 Set swivel shaft 5 to block then using push tool tap swivel rotor 4 with a plastic hammer to install 2 Contact surface of...

Page 957: ...nnect the negative terminal from battery 1 Remove covers 1 and 2 2 Drain oil from the hydraulic tank 6 Hydraulic tank 248 l 3 Open the engine hood 4 Remove control valve top cover 3 5 Disconnect hoses...

Page 958: ...ion is done in the reverse order of removal q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate in the hydraulic system by...

Page 959: ...ure inside the tank Then move the work equipment lock lever to the LOCK position k Disconnect the negative terminal from battery a Attach an identification tag to each piping to avoid a mistake in the...

Page 960: ...5 port hose swivel joint D port B6 port tube arm bottom side 7 Disconnect the 6 PPC hoses at right q 13 Bucket dump Hose band Black 14 LH forward Hose band Red 15 Boom Hose band Brown 16 Right swing 1...

Page 961: ...p pressure sensor 12 Remove the 3 mounting bolts and then lift and remove control valve assembly 36 4 Control valve assembly 250 kg Installation q Installation is done in the reverse order of removal...

Page 962: ...merge divider valve 2 Mating face of the merge divider valve Seal End 242 or equivalent q Tighten the mounting bolts for the merge divider valve in the same sequence as that for the control valve cov...

Page 963: ...a Attach an identification tag to each piping to avoid a mistake in the position of installation later 1 Remove the hydraulic tank strainer and stop the flow of oil using tool C a When not using tool...

Page 964: ...t hose Color band Red q 15 EPC source pressure port hose Color band Yellow q 16 Rear pressure input port hose Color band Yellow q 17 Front pressure input port hose q 18 Rear pump delivery port hose q...

Page 965: ...c tank 2 48 l q Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder For details see Testing and adjusting Bleeding air from vari ous parts Removal and installation...

Page 966: ...Plug 2 6 11 Nm 0 6 1 1 kgm a When installing plug 3 to body 1 check the insertion depth so that the tip of plug does not enter the inside 20 hole of the body 3 Plug 3 4 9 Nm 0 4 0 9 kgm a Install spri...

Page 967: ...ng positions 2 Female screw A of body LOCTITE No 262 3 Joint 12 39 49 Nm 4 5 kgm a Apply grease G2 LI to the sliding parts of joint 12 and contact surfaces of disc 13 and pis ton 8 2 Quantity of greas...

Page 968: ...case 5 Remove mounting bolt 10 to remove plate 22 a Check the thickness and the mounting position of washer 18 a Remove pin 23 from body 1 6 Remove seal 9 and collar 8 7 Remove piston 7 to remove reta...

Page 969: ...semble shaft 14 in the following procedure 1 Using tool M4 insert bushing 10 in case a Insert the bushing 10 from the 10 chamfered side a Insert bushing so that dimension a will be as follows q Dimens...

Page 970: ...e between both sides at the stroke end of the lever exceeds 0 7 change the washer thickness to reduce the difference to below 0 7 If the washer thickness is reduced by 0 3 mm the stroke end angle is i...

Page 971: ...arm and bucket cylinder Screw size M12 Pitch 1 75 a If the caulking of screw 3 is too strong and it cannot be removed tighten the screw fully then fit a tap to the thread and remove the screw Symbol P...

Page 972: ...q Boom and arm cylinder only 6 Remove head assembly 7 7 Remove cap 8 pull 12 balls 9 and then remove plunger 10 q Arm cylinder only 2 Disassembly of piston assembly 1 Remove ring 11 2 Remove wear ring...

Page 973: ...all dust seal 17 and then secure it with snap ring 16 5 Install backup ring and O ring 15 2 Disassembly of piston assembly 1 Press fit oil seal 13 using tool N3 a Set the piston ring on tool N3 and tu...

Page 974: ...2 until the position of the screw thread hole matches a Remove all burrs and flashes using a file 2 Tighten screw 3 2 Screw thread Loctite No 262 3 Screw 58 9 73 6 Nm 6 7 5 kgm 3 Caulk 4 places of th...

Page 975: ...3 6 Nm 6 7 5 kgm 5 Caulk thread at 4 places using a punch 7 Assemble piston rod assembly 2 a Set the ring end gap C horizontally sideways and then insert it aligning the axial center of cylinder tube...

Page 977: ...NUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Work equipment...

Page 978: ...to prevent the cylinder from hanging toward the bottom a In the latter case remove the bottom side grease nipple a Remove the boom cylinder on the other side in the same manner a When the work equipm...

Page 979: ...t 0 5 1 5 mm clearance a is maintained between the plate and nut after the tightening 2 2 Inside surface of bushing when assembling pin Antifriction agent LM P 2 Feed grease after assembling pin Greas...

Page 980: ...to 1 mm or less by use of shims Thickness of standard shim 2 0 2 5 3 0 and 3 5 mm q Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder For details see Test ing a...

Page 981: ...50 Disassembly and assembly SEN02640 00 PC300 350 8 5...

Page 983: ...p PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator s cab assembly 2 Removal and installation...

Page 984: ...to Removal and installation of monitor assembly and remove monitor assembly 4 5 Remove covers 5 and 6 6 Remove cover duct assembly 7 7 Insert key 8 turn it right and open the out side air filter cove...

Page 985: ...27 from the opera tor s cab If equipped 21 Disconnect cab wiring intermediate connectors H09 28 H08 29 and H16 30 a Cut tie wrap T 22 Disconnect radio antenna 31 a 23 is removed plate 23 Remove ducts...

Page 986: ...ate 43 1 33 Remove bolt 44 2 34 Dismount 6 mounting bolts 45 and 4 mount ing nuts 46 a Check the bolt length beforehand 35 Lift off and remove operator s cab assembly 47 4 Operator s cab assembly 470...

Page 987: ...lacing front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to the opera tor s cab a For the procedu...

Page 988: ...may not be stuck perfectly a Clean the all black part on the back side of the window glass a After cleaning the sticking surfaces leave them for at lease 5 minutes to dry 3 Apply primer 10 a The usin...

Page 989: ...s applied more than 2 times its performance will be lowered a Parts to be coated with primer Apply the prim er all over dimension a q Dimension to apply primer a 25 mm a In addition to the above parts...

Page 990: ...tween the black part and transparent part of the glass a After applying the primer leave it for at least 5 minutes within 8 hours to dry a Never apply the wrong primer If the paint primer etc is appli...

Page 991: ...ck dam rubber 6 for left side window glass 2 to the position as shown in the figure 3 Stick dam rubber 6 for door lower win dow glass 3 to the position as shown in the figure a Stick dam rubber 6b add...

Page 992: ...glass 9 and operator s cab 8 with a knife etc and then remove the window glass a Do not remove the tapes left on the window glass and the operator s cab before installing the window glass a When posit...

Page 993: ...elease tape of dam rubber on the glass adhesive side 5 Apply adhesive 15 to the outside of dam rubber 6 of the operator s cab a Apply adhesive 15 with dimensions s and t for dam rubber 6 of oper ator...

Page 994: ...perform this work efficiently by pulling window glass 9 from inside of the operator s cab with suc tion cup X2 a After installing front window glass 4 fill the clearances between it and cen ter trim s...

Page 995: ...w glass 1 After installing right window glass 1 to the operator s cab insert stopper rubbers X3 to 2 places v at the bottom of the glass to fix the glass 2 By using styrene foam blocks 9 and rub ber b...

Page 996: ...adhesive before it is dried up a When cleaning the glass do not give an impact on it 10 Protect the stuck window glass 1 Keep the stopper rubbers styrene foam blocks and rubber bands installed for 10...

Page 997: ...t corner block are used to hang the pull up assist cable in the following step 6 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a little Put out rollers 5 and 6 under t...

Page 998: ...hough the rail opening portion and lower it gradually 8 Lower front window assembly 10 completely a Do not let the front window assembly touch the monitor 9 Twist front window assembly 10 to the right...

Page 999: ...e the front window assembly and fix it with the rear locks on both sides a Check that the locks in the rear of the operator s cab are securely fastened 4 Install right corner block 2 a Fully tighten t...

Page 1000: ...ht and left locks 16 and 17 do not work normally 1 Loosen lock fitting bolt 18 move lock 16 forward and then tighten the bolt again a The same applies to the right side 2 After moving the lock recheck...

Page 1001: ...witch works a Limit switch 19 is used to prevent the windshield wiper from moving when turning the wiper switch on by mistake when the front window assembly is in Open position If the wiper operates w...

Page 1002: ...e turn of rubber stopper 18 to the left is equivalent to squashing the rubber for approxi mately 1 5 mm a When the front window assembly is in Open position the front window assembly must be push ing...

Page 1003: ...1 After finishing the adjustment of steps 6 9 check that latching efforts of both right and left locks 16 and 17 are even a Check the latching efforts on both Close side in the front of the opera tor...

Page 1004: ...Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles while you are collect ing the refrigera...

Page 1005: ...19 a Check the connecting point a Plug the hose to stop oil flow out a Disconnect the work equipment PPC at joint box side See item 33 17 Disconnect hose 20 a Check the connecting point a Plug the hos...

Page 1006: ...ve cover 38 32 Disconnect clamp 39 33 Disconnect PPC hose 40 of the work equip ment From the top the color of the band is White Brown None Blue Black Green Red Yellow a Prepare an oil sump 34 Pull out...

Page 1007: ...ring a When connecting the refrigerant piping coat the O ring with compressor oil for new refrig erant R134a Denso ND OIL8 Zexel ZXL100PG PAG 46 or equivalent 3 Mounting bolt 8 12 Nm 0 8 1 2 kgm 2 a...

Page 1009: ...C350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Electrical system Removal and installation of air conditioner unit assembly 2 Removal and installation of KOMTRAX communication...

Page 1010: ...al traders for collecting and fill ing operation of refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accor...

Page 1011: ...pin 18 and remove duct 19 15 Remove ducts 20 and 21 a Cut tie wrap 16 Remove ducts 22 and 23 a Cut tie wrap 17 Remove duct 24 upper and lower 18 Remove duct 25 upper and lower 19 Disconnect plate 26...

Page 1012: ...at there is O ring at the piping connector of the air condi tioner hose a Check that there is no defect or deterioration on the O ring a When connecting the refrigerant piping coat the O ring with com...

Page 1013: ...assembly Removal k Disconnect the negative terminal from battery 1 Remove covers 1 4 2 Twist antenna wire 5 and disconnect it 3 Disconnect connectors K01 6 and CK02 7 4 Remove the 4 mounting bolts an...

Page 1014: ...ws 1 1 Insert flat head screwdriver inside slit SL and push it upward 2 Release lock L and remove the cover 3 Disconnect wiring connector M04 of the cigarette lighter from the back of cover 5 5 Remove...

Page 1015: ...onitor assembly 6 with 4 mounting bolts and then install cover 5 2 With cover 5 installed tighten the mounting bolts of monitor assembly q Carry out the rest of installation in the reverse order to re...

Page 1016: ...iring connectors C01 6 and C02 7 as follows q Tilt lock L12 inside while pressing lock L1 a Bar B comes out and the lock is re leased 5 Remove the 4 mounting bolts and pump con troller assembly 8 Inst...

Page 1017: ...from the upper position to the left position lock position in the figure a B C Claws a If the sliders and lever are not set as shown in the following figure the con nector is not disconnected or locke...

Page 1018: ...d installation of engine controller Removal k Disconnect the negative terminal from the battery 1 Open the engine hood 2 Disconnect connectors EC01 1 ENG 2 and CE03 3 3 Remove engine controller 4 Inst...

Page 1019: ...50 Disassembly and assembly SEN02642 02 PC300 350 8 11...

Page 1021: ...OP MANUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 90 Diagrams and drawings 1 Hydraulic d...

Page 1022: ...SEN02004 01 90 Diagrams and drawings 2 PC300 350 8...

Page 1023: ...3 Hydraulic circuit diagram PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02004 01 Hydraulic circuit diagram 1 PC300 300LC 8 PC350 350LC 8...

Page 1024: ...90 Diagrams and drawings SEN02004 01 PC300 350 8 5...

Page 1026: ...PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 90 Diagrams and drawings 1 Electrical diagrams and draw...

Page 1027: ...SEN02005 03 90 Diagrams and drawings 2 PC300 350 8...

Page 1028: ...3 Electrical circuit diagram 1 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 1 5...

Page 1029: ...5 Electrical circuit diagram 2 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 2 5...

Page 1030: ...7 Electrical circuit diagram 3 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 3 5...

Page 1031: ...9 Electrical circuit diagram 4 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 4 5...

Page 1032: ...11 Electrical circuit diagram 5 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 5 5...

Page 1033: ...V 9 N10 4 A C unit T 8 P01 AMP 3 Bucket DIG pressure sensor L 2 P02 X 2 Boom down pressure switch L 2 P03 X 2 Swing right pressure switch L 2 P04 AMP 3 Arm DIG pressure sensor L 2 P05 X 2 Bucket dump...

Page 1034: ...90 Diagrams and drawings SEN02005 03 PC300 350 8 15...

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