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Komatsu PC500LC-10R Shop Manual Download Page 14

FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL

• Some of the attachments and options described in this shop manual may not be available in some areas. If

they are required, consult your Komatsu distributor.

• The materials and specifications are subject to change without notice.
• Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual

for the machine which has the same engine model.

• Actual machine may differ from the images which are contained in this manual. A typical model is shown in

the illustrations of this shop manual.

Composition of the shop manual

This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.

00 INDEX AND FOREWORD

This section describes the index, foreword, safety, and basic information.

01 SPECIFICATIONS

This section describes the specifications of the machine.

10 STRUCTURE AND FUNCTION

This section describes the structure and operation of each component with respect to each system. "STRUC-
TURE  AND  FUNCTION"  is  helpful  in  not  only  understanding  the  structure  of  each  component  but  performing
troubleshooting.

20 STANDARD VALUE TABLE

This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.

30 TESTING AND ADJUSTING

This section describes the measuring tools and measuring methods for testing and adjusting as well as the ad-
justing method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in "STANDARD VALUE TABLE".

40 TROUBLESHOOTING

This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

50 DISASSEMBLY AND ASSEMBLY

This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation,  disassembly,  and  assembly  of  the  components  and  parts.  In  addition,  tightening  torques,  quantity,  and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.

60 MAINTENANCE STANDARD

This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.

80 THE OTHER INFORMATION

This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.

90 Circuit diagrams

This section describes hydraulic circuit diagrams and electrical circuit diagrams.

Symbols

Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.

HOW TO READ THE SHOP MANUAL

00 INDEX AND FOREWORD

00-12

PC500LC-10R

Summary of Contents for PC500LC-10R

Page 1: ...HYDRAULIC EXCAVATOR SEN06722 00 PC500LC 10R SERIAL NUMBERS 100001 and up...

Page 2: ......

Page 3: ...00 INDEX AND FOREWORD PC500LC 10R 00 1...

Page 4: ...METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 54 HOW TO READ ELECTRICAL WIRE CODE 00 55 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 59 STANDARD TIGHTENING TORQUE TA...

Page 5: ...T PARTS OF TRAVEL SYSTEM 10 254 UNDERCARRIAGE AND FRAME 10 275 LAYOUT DRAWING OF UNDERCARRIAGE 10 275 WORK EQUIPMENT 10 276 STRUCTURE OF WORK EQUIPMENT 10 276 FUNCTION OF WORK EQUIPMENT 10 277 WORK EQ...

Page 6: ...LVES 30 93 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30 94 TEST OIL LEAKAGE 30 96 BLEED AIR FROM HYDRAULIC CIRCUIT 30 99 CAB AND ITS ATTACHMENTS 30 104 TEST CAB TIPPING STOPPER 30 104 M...

Page 7: ...EN UPPER STRUCTURE IS SWING TO LEFT 90 15 HYDRAULIC CIRCUIT DIAGRAM WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG TO LEFT 90 17 HYDRAULIC CIRCUIT DIAGRAM 1 2 90 19 HYDRAULIC CIRCUIT DIAGRAM 2 2 90...

Page 8: ...Control Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retard...

Page 9: ...so that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from ea...

Page 10: ...er KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of t...

Page 11: ...pump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pum...

Page 12: ...ea of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low...

Page 13: ...d out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission 00 INDEX AND FOREWORD ABBR...

Page 14: ...eck the standard values for testing and adjusting and judge troubles in troubleshooting 30 TESTING AND ADJUSTING This section describes the measuring tools and measuring methods for testing and adjust...

Page 15: ...icates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated with adhesive grease etc in assembling work Oil and coolant Th...

Page 16: ...n good physical condition and good preparation Always be alert and careful General precautions k If the machine is handled incorrectly it is dangerous Read and understand what is described in the oper...

Page 17: ...levers and hang UNDER REPAIR warning tag on them When performing the disassembling or assembling work support the machine securely with blocks jacks or stands before starting the work Remove all mud a...

Page 18: ...aught in ro tating parts or moving parts When raising a heavy component heavier than 25 kg use a hoist or crane Before starting work check that the slings wire ropes webbing slings chains and hooks ar...

Page 19: ...orkers must communicate with each other fre quently The appointed signaler must make specified signals clearly at a place where he is well seen from the operator s seat and where he can see the workin...

Page 20: ...k is maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions fo...

Page 21: ...o work and passage After operating the hoist do not swing the control switch Remember the position of the main switch so that you can turn off the power immediately in an emer gency If the hoist stops...

Page 22: ...o use 2 wrenches use one wrench to fix and use the other one to loosen the nut Precautions for air conditioner piping When installing the air conditioner piping be careful so that dirt dusts and water...

Page 23: ...An O ring is fitted to every joint of the air conditioner piping For tightening torques see THE OTHER INFORMATION Pre cautions for disconnection and connection of air conditioner piping 00 INDEX AND...

Page 24: ...attached to or around the engine exhaust manifold muffler or battery or on the undercovers To prevent fires from being caught remove any flammable materials such as dry leaves chips pieces of paper c...

Page 25: ...ee the Operation and Maintenance Manual for the setting procedure Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting equipment with anti e...

Page 26: ...en they are inhaled Do not breathe the fumes After a fire there may be harmful compounds left If they touch your skin they may have a bad influence on your body Be sure to wear rubber gloves when hand...

Page 27: ...vers seas or lakes Observe the laws and regulations when disposing of harm ful objects such as oil fuel coolant solvent filters and batteries Avoid exposure to burning rubber or plastics which produce...

Page 28: ...e remaining pressure from the hydraulic circuit always before performing the work In the field there is a risk of dust entering the component during disassembling or maintenance work and perform ance...

Page 29: ...RK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir cuit Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic...

Page 30: ...can remove the ultra fine approxi mately 3 m particles that the filter built in the hydraulic equip ment cannot remove So it is very effective device PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 IN...

Page 31: ...when storing shims Prepare the slings with sufficient strength for hoisting the components When using forcing screws to remove any component tighten the forcing screws uniformly and alternately Befor...

Page 32: ...of the split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 10...

Page 33: ...643 51232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379...

Page 34: ...ive to the threaded portion When applying liquid gasket clean and degrease the surface and apply it uniformly after making sure that the surface is free from dust or damage Clean all of the parts If t...

Page 35: ...nt is drained be sure that the drain valve is securely tightened then refill the coolant reser voir with the coolant Komatsu recommends to the specified level Start the engine to circulate the coolant...

Page 36: ...tallation portion Re place the part if there is any damage Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any loo...

Page 37: ...re frequently re moved and installed again so they are likely to suffer de formation or damage For this reason it is necessary to be extremely careful when handling and maintenance of the wiring harne...

Page 38: ...city Entry of water dirt or dust when disconnecting a con nector If any water mud or dust is stuck to the outside surface of a connector it can enter inside the connector when the connector is disconn...

Page 39: ...pollute the environ ment Do not discard the oil inconsiderately Ask the customer for disposal or bring it back to dispose it appropriately How to clean parts when dirt is stuck If any dirt or dust st...

Page 40: ...n servicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment Sealin...

Page 41: ...ndness of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following act...

Page 42: ...onnection 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2...

Page 43: ...isconnection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition...

Page 44: ...raight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface...

Page 45: ...ning adapter part and push body 2 straight un til sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH PULL TYPE...

Page 46: ...th each other when the connec tor is connected When removing a connector from a clip pull the con nector in parallel with the clip as removing stoppers NOTICE If the connector is pried up and down or...

Page 47: ...protrusion of the boot and misalignment of the wiring harness If the connector is with the boot correct any extrusion of the boot In addition if the wiring harness is misaligned or the clamp is out of...

Page 48: ...from becoming too hot as this will cause deformation or damage to the connector 3 Perform a continuity test on the connector After drying leave the wiring harness disconnected con nect T adapter 1 an...

Page 49: ...fore disconnecting or connecting the connectors Before performing troubleshooting check all the related connectors for loose connection REMARK Check the related connectors for their performance by dis...

Page 50: ...Push in female connector 2 horizontally and insert it straight until it clicks Arrow x 2 In order to check whether locks a and b are completely inserted insert female connector 2 by rocking it vertica...

Page 51: ...and if connector 1 does not come out when it is pulled toward you push up portion A with a small flat head screwdriver while pressing lock L2 and then pull out connector 1 to ward you Method for conne...

Page 52: ...Lock L2 is located behind connector 1 in the figure Method for connecting slide lock type connector FRAMATOME 24 Insert it straight until it clicks METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK T...

Page 53: ...ck to pull Disconnect the connector 2 by pulling lock B on the wiring harness side of connector 2 outward Method for connecting connector with lock to pull Insert the connector securely until it click...

Page 54: ...K If the lock is located on the underside use flat head screwdriver 1 since you cannot insert your fingers While pushing up lock C of the connector with flat head screwdriver 1 pull out connector 3 in...

Page 55: ...connector 5 in the direction of the arrow REMARK Pull up the connector straight Method for connecting connector with lock to push SUMITOMO 3 Insert it straight until it clicks Method for disconnectin...

Page 56: ...ft and pull it out REMARK Housing H1 is left on the wiring harness side Method for connecting connector with housing to rotate 1 Insert the connector to the end while aligning its groove to the other...

Page 57: ...AVS has a circular com pressed conductor It differs from AV and AVS in the outside diameter of conductor and thickness of the coating AEX is similar to AV in thickness and outside diameter of the coat...

Page 58: ...00 Conductor Number of strands 50 84 41 70 85 108 127 169 217 Diameter of strand 0 45 0 45 0 80 0 80 0 80 0 80 0 80 0 80 0 80 Cross sec tional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 1...

Page 59: ...ck GB Green and Black RG Red and Green GL Green and Blue RL Red and Blue Gr Gray RW Red and White GR Green and Red RY Red and Yellow GW Green and White Sb Sky Blue GY Green and Yellow Y Yellow L Blue...

Page 60: ...cuit Charge R WG R Ground B B Start R R Light RW RB RY RG RL O Instrument Y YR YB YG YL YW Y Gr Signal G GW GR GY GB GL G Br Others L LW LR LY LB L Br BrW BrR BrY BrB Lg LgR LgY LgB LgW O Gr P Sb Dg C...

Page 61: ...dard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side Example Standard dimension Tolerance 120 0 022 0 126 The tolerance may be i...

Page 62: ...le value or allowable dimension The dimension of parts changes due to the wear or deformation while they are used When the dimension changes exceeding certain value parts cannot be used any longer Thi...

Page 63: ...The parts whose interferences are out of the allowable interference must be replaced or repaired 00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD PC500LC 10R 00 61...

Page 64: ...1 2 17 14 22 153 to 190 15 5 to 19 5 16 24 235 to 285 23 5 to 29 5 1 22 18 27 320 to 400 33 to 41 20 30 455 to 565 46 5 to 58 22 32 610 to 765 62 5 to 78 24 36 785 to 980 80 to 100 27 41 1150 to 1440...

Page 65: ...12 7 1 3 2 9 to 3 9 0 3 to 0 4 3 43 0 35 5 16 18UNC 24 5 to 34 3 2 5 to 3 5 29 4 3 6 9 to 8 8 0 7 to 0 9 7 8 0 8 3 8 16UNC 44 1 to 58 8 4 5 to 6 52 0 5 3 9 8 to 14 7 1 to 1 5 11 8 1 2 7 16 14UNC 73 5...

Page 66: ...41 0 45 5 16 24UNF 34 3 to 39 2 3 5 to 4 34 3 3 5 7 8 to 9 8 0 8 to 1 8 8 0 9 3 8 24UNF 53 9 to 68 6 5 5 to 7 61 8 6 3 14 7 to 19 6 1 5 to 2 16 7 1 7 7 16 20UNF 83 4 to 108 8 5 to 11 96 1 9 8 24 5 to...

Page 67: ...o 19 0 157 16 0 10 12 33 363 to 480 37 0 to 49 0 422 43 0 14 42 746 to 1010 76 0 to 103 883 90 0 Table of tightening torque for O ring boss plugs REMARK Tighten the plug for O ring boss to the torque...

Page 68: ...e un less otherwise specified The table is applied to the threaded portion coated with engine oil wet threaded portion Nominal No of hose Width across flats mm Tightening torque Nm kgm Taper seal Face...

Page 69: ...25 5 2 6 11 16 16UN 17 5 12 24 27 43 to 47 4 4 to 4 8 45 4 6 13 16 16UN 20 6 15 16 30 32 60 to 68 6 1 to 6 8 64 6 5 1 14UNS 25 4 22 20 36 90 to 95 9 2 to 9 7 92 5 9 4 13 16 12UN 30 2 Tightening torqu...

Page 70: ...102 107 and 114 series engines to the torques shown in the following table unless otherwise specified Material of female screw In cast iron or steel In aluminum Nominal thread size Tightening torque...

Page 71: ...ce to the right to restore the target value This gives 550 mm 21 65 in mm to in B 1 mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 0 0 039 0 079 0 118 0 157 0 197 0 236 0 276 0 315 0 354 10 0 394 0 433 0 472 0 5...

Page 72: ...80 194 01 196 21 90 198 42 200 62 202 83 205 03 207 24 209 44 211 64 213 85 216 05 218 26 to U S Gal 1 0 2642 U S Gal 0 1 2 3 4 5 6 7 8 9 0 0 0 264 0 528 0 793 1 057 1 321 1 585 1 849 2 113 2 378 10...

Page 73: ...28 0 535 2 542 5 549 7 556 9 564 2 571 4 80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2...

Page 74: ...200 3214 3229 3243 3257 230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399 240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542 Temperature Conversion of Fahrenheit to Celsius A simple way to conv...

Page 75: ...65 149 0 37 8 100 212 0 20 0 4 24 8 0 6 31 87 8 18 9 66 150 8 40 6 105 221 0 19 4 3 26 6 0 32 89 6 19 4 67 152 6 43 3 110 230 0 18 9 2 28 4 0 6 33 91 4 20 0 68 154 4 46 1 115 239 0 18 3 1 30 2 1 1 34...

Page 76: ......

Page 77: ...01 SPECIFICATIONS PC500LC 10R 01 1...

Page 78: ...ICATION DRAWING PC500LC 10R 01 9 WORKING RANGE DRAWINGS 01 10 WORKING RANGE PC500LC 10R 01 10 SPECIFICATIONS 01 11 SPECIFICATIONS PC500LC 10R 01 11 WEIGHT TABLE 01 14 WEIGHT TABLE PC500LC 10R 01 14 TA...

Page 79: ...r Control Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Reta...

Page 80: ...r so that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from...

Page 81: ...fler KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of...

Page 82: ...y pump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic p...

Page 83: ...area of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and lo...

Page 84: ...led out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 01 SPE...

Page 85: ...D Shoe width mm 600 E Cab height mm 3360 F Tail swing radius mm 3765 G Overall length of the track mm 5385 H Distance between the tumbler centers mm 4350 J Minimum ground clearance mm 605 Travel speed...

Page 86: ...mm 11985 B Maximum digging depth mm 7695 C Maximum digging height mm 10885 D Maximum vertical wall digging depth mm 6335 E Maximum dumping height mm 7650 F Minimum dumping height mm 2985 G Maximum dig...

Page 87: ...ree 15 Travel speed Lo Mi Hi km h 3 0 4 2 5 5 Gradeability Degree 35 Ground pressure standard shoe kPa kg cm2 86 3 0 88 Dimensions Overall length mm 12260 Overall width mm 3340 Overall width of track...

Page 88: ...Alternator 24 V 60 A Battery 4 12 V 140 Ah x 2 pieces Radiator type Corrugated aluminum 4 lines 3 Indicates when swing is locked 4 The battery capacity Ah is indicated in the 5 hour rate REMARK The e...

Page 89: ...s mm 2308 Arm cylinder 6 Type Double acting piston Inside diameter of cylinder bore mm 185 Diameter of piston rod mm 130 Stroke mm 1985 Max distance between pins mm 4740 Min distance between pins mm 2...

Page 90: ...g head guard and front half guard 520 Operator s seat 20 Counterweight 10741 Swing machinery 518 Control valve 275 Swing motor 105 Travel motor 220 x 2 Center swivel joint 40 Track frame assembly excl...

Page 91: ...pin 110 Boom cylinder bottom pin 25 x 2 Boom cylinder head pin 89 Arm cylinder bottom pin 27 Arm cylinder head pin 28 Boom and arm connecting pin 70 Bucket cylinder bottom pin 17 Bucket pin 54 41 Buc...

Page 92: ...oling system Non Amine Engine Coolant AF NAC Note 4 AF NAC KES 30 50 Fuel tank Diesel fuel ASTM D975 No 1 D S15 ASTM D975 No 1 DS500 30 20 ASTM D975 No 1 D S15 ASTM D975 No 2 DS500 0 50 KES Komatsu En...

Page 93: ...n the areas where freezing is not an issue the use of coolant is essential Komatsu machines are supplied with Non Amine Engine Coolant AF NAC Non Amine Engine Coolant AF NAC has excellent anti corrosi...

Page 94: ......

Page 95: ...10 STRUCTURE AND FUNCTION PC500LC 10R 10 1...

Page 96: ...SYSTEM DIAGRAM 10 26 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 10 27 AUTOMATIC IDLE STOP SYSTEM 10 28 AUTOMATIC IDLE STOP SYSTEM DIAGRAM 10 28 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 10 28 COMPONENT...

Page 97: ...SH UP SYSTEM DIAGRAM 10 197 FUNCTION OF MACHINE PUSH UP SYSTEM 10 198 PPC LOCK SYSTEM 10 199 PPC LOCK SYSTEM DIAGRAM 10 199 FUNCTION OF PPC LOCK SYSTEM 10 199 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK...

Page 98: ...ORK EQUIPMENT 10 276 FUNCTION OF WORK EQUIPMENT 10 277 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10 278 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10 278 BUCKET CLEARANCE ADJUSTMENT SHIM 10 2...

Page 99: ...ntrol Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retarder...

Page 100: ...that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from each...

Page 101: ...KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of the...

Page 102: ...mp PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump...

Page 103: ...of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low fu...

Page 104: ...out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 10 STRUCTU...

Page 105: ...AWING OF BOOT UP SYSTEM 1 Engine controller 2 KOMTRAX terminal 3 Fuse box 4 Pump controller 5 Machine monitor 6 Battery 7 Battery disconnect switch 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF BOOT UP...

Page 106: ...8 System operating lamp 9 Fusible link LAYOUT DRAWING OF BOOT UP SYSTEM 10 STRUCTURE AND FUNCTION 10 12 PC500LC 10R...

Page 107: ...AX terminal may maintain its communication under this condition ON and OFF of system operating lamp Voltage of 24 V is constantly applied to one side of system operating lamp LED Light Emitting Diode...

Page 108: ...m operating lamp is lit If battery disconnect switch 1 is turned off while system operating lamp is lit it may erase the data in the controller and damage the controller seriously Do not turn the batt...

Page 109: ...il filter 4 Rear engine mount 5 Engine controller 6 Stopper pin 7 Friction plate 8 Torsion spring 9 Drive plate 10 Alternator 11 Auto tensioner 12 Vibration damper 13 Front engine mount 14 Starting mo...

Page 110: ...Turbocharger 16 Muffler SPECIFICATIONS OF ENGINE SYSTEM Type of damper Wet type Oil for damper TO30 Quantity of damper oil 1 6 LAYOUT DRAWING OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION 10 16 PC500LC 1...

Page 111: ...ry switch 8 Engine controller 9 Lock lever 10 PPC lock switch 11 Starting motor cut off relay for PPC lock 12 Starting motor cut off relay for personal code 13 Fuel control dial 14 Safety relay 15 Sta...

Page 112: ...to starting motor 15 and the engine starts If lock lever 9 is in FREE position starting motor cut off relay 11 operates to cut off the starting current to starting motor 15 and the engine does not st...

Page 113: ...ch 6 to engine controller 8 is cut off and the command current to fuel supply pump 16 is also cut off Fuel supply pump 16 stops supplying fuel the engine speed decreases and the engine stops Mechanism...

Page 114: ...Main pump 10 Control valve 10a Self pressure reducing valve 10b Merge divider valve 10c Travel junction valve 11 PPC lock solenoid valve FUNCTION OF AUTO DECELERATION SYSTEM When all the control lever...

Page 115: ...es the engine speed to approximately 1000 rpm when all the control levers remain NEUTRAL more than four seconds with the engine running at approximately 1000 rpm or more It holds the control speed app...

Page 116: ...use box 6 Resistor for PC EPC valve 7 Pump controller 8 Engine controller 9 Machine monitor 10 Air conditioner unit 11 Pump drive secondary switch 12 Fuel control dial 13 Fuel supply pump 14 Various s...

Page 117: ...ns Operates when all of the follow ing conditions are satisfied Actuated Coolant temperature Less than 30 C Engine speed Max 1250 rpm Approx rpmEngine speed Canceling conditions Canceled when any of t...

Page 118: ...e box 6 Resistor for PC EPC valve 7 Pump controller 8 Engine controller 9 Machine monitor 10 Air conditioner unit 11 Pump drive secondary switch 12 Fuel control dial 13 Fuel supply pump 14 Various sen...

Page 119: ...oil temperature Min 102 C Working mode P E ATT P or ATT mode Engine speed Kept as it is Lowers the pump absorption torque to reduce engine load according to the torque control signal Coolant temperat...

Page 120: ...use box 6 Resistor for PC EPC valve 7 Pump controller 8 Engine controller 9 Machine monitor 10 Air conditioner unit 11 Pump drive secondary switch 12 Fuel control dial 13 Fuel supply pump 14 Various s...

Page 121: ...oil pressure Less than 50 kPa 0 51 kg cm2 Protection of turbocharger see following figure A Starting of engine B Turbocharger protection time approximately 0 to 20 sec onds C Modulation time approxima...

Page 122: ...e stop function is enabled If the engine is stopped by the automatic idle stop function when the engine is running with high speed a message is displayed on the machine monitor to turn on the auto dec...

Page 123: ...not operate and the related items are not displayed on service menu and user menu 1 minute Set the minimum time to 1 minutes on Auto Idle Stop Time Fixing menu and Auto Idle Stop Time Set menu 3 minu...

Page 124: ...splayed at an abrupt engine stop varies with the number of occurrence and the mes sage displayed on the machine monitor varies according to the failure code Action level Failure code Failure displayed...

Page 125: ...as outlet E Oil inlet F Oil outlet 1 Blower housing 2 V band 3 Center housing diffuser portion 4 Center housing water cooled center housing 5 Heat shield 6 Turbine housing 7 Blower impeller 8 Insert 9...

Page 126: ...mm Weight 16 kg BLOWBY PRESSURE SENSOR STRUCTURE OF BLOWBY PRESSURE SENSOR 1 Connector 2 Sensor 3 O ring FUNCTION OF BLOWBY PRESSURE SENSOR This sensor is installed to the blowby outlet side It detec...

Page 127: ...denser 4 Aftercooler outlet hose 5 Oil cooler outlet hose 6 Oil cooler inlet hose 7 Aftercooler 8 Aftercooler inlet hose 9 Oil cooler 10 Radiator cap 11 Radiator inlet hose 12 Fan guard 13 Shroud 14 R...

Page 128: ...valve cracking pressure 0 09 MPa 0 9 kg cm2 Cracking pressure of vacuum valve 0 005 MPa 0 05 kg cm2 Oil cooler Core type CFA5 Fin pitch 3 5 2 mm Heat dissipation area 46 32 m2 Aftercooler Core type A...

Page 129: ...sensor signal b CAN signal coolant temperature sensor signal en gine speed sensor signal c Cooling fan speed sensor signal d Solenoid signal e CAN signal air conditioner fresh air temperature sensor...

Page 130: ...led by engine speed hydraulic oil temperature and coolant temperature Fan speed is controlled also by outside air temperature and information of air conditioner control air condi tioner compressor sig...

Page 131: ...2 Coolant temperature sensor 3 Engine speed sensor 4 Hydraulic oil temperature sensor 5 Air conditioner compressor 6 Air conditioner fresh air temperature sensor 7 Air conditioner controller 8 Machin...

Page 132: ...Image of engine output when fan speed varies ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 10 STRUCTURE AND FUNCTION 10 38 PC500LC 10R...

Page 133: ...y 4 Shaft Engine mounting portion SPECIFICATIONS OF FAN CLUTCH Type Fluid coupling FUNCTION OF FAN CLUTCH Fan speed which is transmitted from the engine to the shaft is decreased by built in fluid cou...

Page 134: ...CONTROL SYSTEM LAYOUT DRAWING OF CONTROL SYSTEM 1 Rearview camera 1 1 Indicates machine with rearview camera LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION 10 40 PC500LC 10R...

Page 135: ...2 CAN terminating resistor 3 Engine controller 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM PC500LC 10R 10 41...

Page 136: ...4 Machine monitor 5 Communication antenna 6 GPS antenna 7 Pump controller 8 Resistor for PC EPC valve 9 KOMTRAX terminal LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION 10 42 PC500LC 10R...

Page 137: ...ew camera FUNCTION OF MACHINE MONITOR SYSTEM The monitor system keeps the operator informed of all the machine conditions by monitoring them by using the sensors and switches installed in various part...

Page 138: ...Display of camera image machine with camera The switches on the machine monitor also have the functions to control the machine MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION 10 44 PC500LC 10R...

Page 139: ...office can supply various services to the customers by referring to the fol lowing information KOMTRAX system can transmits the following information Positional information Working information Alarm a...

Page 140: ...aining the information with the sensors and switches installed in various parts of the machine processes the information instantly to display on the machine monitor and informs the operator of the mac...

Page 141: ...Maintenance Manual for the following items Display screen display Switches Guidance icons and function switches INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR 070 18P CM01 Pin No Signal name Input output...

Page 142: ...er connect these pins Malfunctions or failures may occur 070 20P CM03 Pin No Signal name Input output signal 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1...

Page 143: ...emperature gauge Range Temperature Monitor back ground Indicates corresponding tem perature range When exceeds 105 C If monitor background color is white warm up the engine W1 105 C Red W2 102 C Red W...

Page 144: ...ions Average Fuel Consumption Display on user menu TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR Symbol Item to be dis played Range and method for display Remarks Range Caution lamp display back...

Page 145: ...on lamp lights up when an ab normality is detected while engine is stopped Normal Not lit Air cleaner clogged 1 When it is abnor mal Above specified pressure Lit yellow L01 3 Caution lamp lights up wh...

Page 146: ...Caution lamp lights up and alarm buzzer sounds when engine over run is detected State of air conditioner When the air conditioner is ab normal Lit yellow L01 3 Caution lamp lights up when an ab normal...

Page 147: ...can be changed on Maintenance Mode Setting of SERVICE MODE 3 These items are lit for 2 seconds and then go out 4 For machine with KomVision TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR Symbol Ite...

Page 148: ...lit No message Indicates the state of receiving messages Message No return mes sage already read message Lit There is a message which has been read but not been replied Not lit No message Indicates t...

Page 149: ...ome items may require special switch operation Items available in the operator mode are as follows Category 1 Item Display order 2 V W X Y Z A KOMATSU logo display 1 1 1 1 1 Password input display 2 S...

Page 150: ...ng switch is turned to ON position to the time when display changes to the standard screen and display which is displayed after starting switch is turned to OFF position B Display when the machine mon...

Page 151: ...Electrical Sys Abnormality Record Maintenance Record Maintenance Mode Setting Phone Number Entry Default Key on mode Unit With Without Attachment Camera Auto Idle Stop Time Fixing KomVision With With...

Page 152: ...connect these pins otherwise it may cause malfunctions and failures KOMTRAX TERMINAL STRUCTURE OF KOMTRAX TERMINAL General view Model TC630 TC635 TC330 TC730 1 GPS antenna connection port 2 Machine wi...

Page 153: ...in which the system is used you must give notice to Komatsu Ltd TC630 TC635 TC330 and TC730 can be used in different countries When operating TC330 in Japan it is required to install a TC330 terminal...

Page 154: ...switch ACC Input 4 Alternator R Input 5 1 6 Power supply Input 7 Power supply Input 8 1 9 1 10 1 11 Starting switch C Input 12 1 1 Never connect these pins otherwise it may cause malfunction or failur...

Page 155: ...1 Continuous power supply 24 V Input 2 Continuous power supply return Input 3 Window washer Output 4 Continuous power supply 24 V Input 5 Continuous power supply return Input 6 Potentiometer power su...

Page 156: ...gnal Input 23 1 24 Starting switch ACC signal Input 25 1 26 CAN R _L Input and out put 27 1 28 Hydraulic oil temperature sensor Input 29 1 30 Rear pump oil pressure sensor Input 31 L H swing PPC oil p...

Page 157: ...C signal Input 62 External starting signal Input 63 NC 64 CAN C _L Input and out put 65 1 66 1 67 1 68 1 69 Bucket CURL PPC oil pressure sensor Input 70 1 71 1 72 Right travel FORWARD PPC oil pressure...

Page 158: ...97 Attachment flow adjustment EPC valve Output 98 Fuel feed pump drive relay Output 99 Fan clutch solenoid valve Output 100 System in use signal Output 101 Swing parking brake solenoid valve Output 1...

Page 159: ...sure Compensation EPC Abbreviation for Electromagnetic Proportional Control STRUCTURE OF RESISTOR FOR PC EPC VALVE General view 1 Resistor 2 Connector SPECIFICATIONS OF RESISTOR FOR PC EPC VALVE Resis...

Page 160: ...the high frequency signals at the CAN communication line termi nal so that noises are not mixed in the CAN communication signals sent and received between each terminals REMARK If the CAN terminating...

Page 161: ...hield Return 12 NC 13 Engine oil pressure sensor Output 14 NC 15 Coolant temperature sensor Output 16 Sensor 5 V power supply Power supply 17 NC 18 NC 19 EGR valve position sensor Output 20 NC 21 NC 2...

Page 162: ...ector 1 Ground Shield Return 54 Injector 2 Input 55 Injector 3 Input 56 Injector 4 Input 57 Injector 6 Input 58 Injector 4 Ground Shield Return 59 Injector 6 Ground Shield Return 60 Injector 5 Ground...

Page 163: ...ld Return 30 NC Input 31 NC Input 32 NC Ground Shield Return 33 GND Ground Shield Return 34 NC Ground Shield Return 35 NC Input 36 NC Input 37 NC Ground Shield Return 38 NC Output 39 Key switch ACC In...

Page 164: ...eturn 3 Power supply 24 Vcontinuous Power supply 4 NC Power supply 1 Never connect these pins otherwise it may cause malfunctions or failures FUEL CONTROL DIAL STRUCTURE OF FUEL CONTROL DIAL The fuel...

Page 165: ...tiome ter 1 varies according to this rotation and throttle signals are sent to the controller REMARK The hatched area in the following graph is the abnormality de tection area When the throttle voltag...

Page 166: ...1 Body 2 Connector FUNCTION OF FUEL FEED PUMP The fuel feed pump is controlled and driven by monitor operation in the following cases Bleed air from fuel passage engine side Control by monitor operat...

Page 167: ...LAYOUT DRAWING OF HYDRAULIC SYSTEM 1 Control valve 2 Fuel supply pump 3 Engine controller 4 Main pump 5 Hydraulic tank 6 Solenoid valve 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM PC...

Page 168: ...ge divider EPC valve for LS spool 11 Variable back pressure solenoid valve 12 Rear pump oil pressure sensor 13 Front pump oil pressure sensor 14 LS EPC valve 15 Rear pump PC EPC valve 16 Front pump PC...

Page 169: ...sensor 21 Bucket DUMP sensor 22 Boom RAISE sensor 23 Swing LEFT sensor 24 Arm OUT sensor 1 Machine monitor 2 Fuel control dial 3 Pump controller 4 Resistor for PC EPC valve 10 STRUCTURE AND FUNCTION...

Page 170: ...sure sensor 7 Left travel FORWARD pressure sensor 8 Left travel REVERSE pressure sensor 9 Right travel REVERSE pressure sensor 10 Service pressure switch 11 Pump secondary drive switch LAYOUT DRAWING...

Page 171: ...ont and rear and controls the flow rate by changing the swash plate angle 2 Servo piston Piston actuates in accordance with the inlet pressure to change the pump swash plate angle 3 Valve for control...

Page 172: ...Servo piston 9 Pump 10 Engine Unload valve It returns the minimum discharged volume from the pump to the tank at neutral although the flow amount is little there is no place for this oil to go Operati...

Page 173: ...spring chamber is drained to the tank through LS bypass valve 3 and it become to 0 MPa Note The pressure is for PC200 10 When lever is operated before relief When lever is operated spool opens and cy...

Page 174: ...essure PP and control valve outlet LS pressure actuator load pressure is constant LS differential pressure PLS Pump discharged pressure PP LS pressure PLS Constant The pump swash plate shifts toward t...

Page 175: ...OPERATION OF PUMP SWASH PLATE ANGLE OIL FLOW CONTROL When lever is in NEUTRAL 1 PPC valve 2 Hydraulic cylinder 10 STRUCTURE AND FUNCTION CLSS PC500LC 10R 10 81...

Page 176: ...e 6 Unload valve 7 LS bypass valve 8 Main pump 9 Seavo piston 10 LS valve 11 PC valve 12 PC EPC valve 13 LS EPC valve 14 Controller 15 Self pressure reducing valve 16 2 stage relief solenoid valve CLS...

Page 177: ...When balanced 10 STRUCTURE AND FUNCTION CLSS PC500LC 10R 10 83...

Page 178: ...When lever is returned to fine control state CLSS 10 STRUCTURE AND FUNCTION 10 84 PC500LC 10R...

Page 179: ...When lever is pulled at a stroke 10 STRUCTURE AND FUNCTION CLSS PC500LC 10R 10 85...

Page 180: ...When lever is in stroke end CLSS 10 STRUCTURE AND FUNCTION 10 86 PC500LC 10R...

Page 181: ...Mi is selected or when L mode is setting When the lever is in NEUTRAL LS pressure is 0 mA Accordingly the LS valve is fixed at left position and the swash plate angle of pump becomes minimum pump pre...

Page 182: ...ings 1 and 2 and decreases the pump discharged volume PC EPC command current increases PC EPC output pressure and the PC EPC output pressure pushes PC valve to the right against spring This function e...

Page 183: ...ecomes maximum and flow rate becomes maximum 2 Range A in P Q diagram Service piston 2 and follow up link 3 are mechanically connected As the swash plate angle decreases follow up link 3 pushes back P...

Page 184: ...compressed PC valve spool 4 moves to the right and pump pressure is transmitted to the large diameter side of piston 2 4 Range B in P Q diagram As the pump pressure increases further and compressed s...

Page 185: ...6 electronic control by PC EPC valve 8 is prepared in order to match to the engine horsepower setting If PC valve 4 fails the engine stops due to the excessive pump absorption horsepower Controller 7...

Page 186: ...detects the high pressure close to the max set pressure it is cut off by PC EPC valve Travel control As travel speed selector switch is switched to Hi Mi or Lo command current from controller changes...

Page 187: ...after main spool 4 become the same As a result the flow rate control in proportion to the travel of levers 3 in the combined operation becomes available without influenced by the load A Heavy load B...

Page 188: ...to the resistance in the circuit from orifice c of main spool 2 to LS shuttle valve 4 The effective LS differential pressure decreases and the dynamic stability of the actuator is improved 3 5 6 4 2...

Page 189: ...ft by the reaction force of spring 2 2 When the swing operation is performed swing LS pres sure P1 passes through swing spool 5 and enters port A 3 Swing LS pressure P1 pushes valve 1 to the left and...

Page 190: ...l pressure sensor signal g One touch power maximizing switch signal h Oil pressure switch signal i 1st throttle signal j Fuel supply pump control signal k Various sensor signals 1 Battery disconnect s...

Page 191: ...rking modes of P E L ATT P ATT E and B by using the working mode selector switch on the machine monitor The operator can select the opti mum engine torque T and pump absorption torque ac cording to th...

Page 192: ...mp absorption up per limit torque PT Graph 1 If the load increases further the engine speed decreases further as well Graph 2 The controller decreases pump absorption upper limit tor que PT to reduce...

Page 193: ...pt constant The controller controls pump absorption upper limit torque PT so that the engine torque is kept constant along the equal engine horsepower curve 10 STRUCTURE AND FUNCTION ENGINE AND PUMP C...

Page 194: ...ve switch 1 is a switch that enables the temporary work to be done with absorption torque equivalent to E mode for the time when an abnormality occurs in the controller etc the main pump does not oper...

Page 195: ...a Emergency when abnormal b Normal when normal 10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM PC500LC 10R 10 101...

Page 196: ...drive signal i 2 stage relief solenoid valve drive signal j Variable back pressure solenoid valve drive signal k 1st throttle signal l Fuel supply pump control signal m Various sensor signals 1 Batte...

Page 197: ...ial pressure DLS according to the operation method of the actuator The start up time of the pump discharged volume is optimized and the combined operation and fine control performance are improved A 0...

Page 198: ...MPa 380 kg cm2 Variable back pressure function Variable back pressure function is a function that changes the set pressure of the back pressure valve according to the operating state of the machine Op...

Page 199: ...ith the stroke sensor 8 Strainer 9 Filter element 10 Suction strainer SPECIFICATIONS OF HYDRAULIC TANK Hydraulic tank refill capacity 377 Hydraulic tank refill capacity 279 Bypass valve set pressure 0...

Page 200: ...TANK BREATHER Sectional view 1 Nut 2 Cover 3 Filter element 4 Case 5 Valve assembly 6 Body FUNCTION OF HYDRAULIC TANK BREATHER Prevention of negative pressure in hydraulic tank Since the hydraulic tan...

Page 201: ...is sensor is installed to the return filter case Bypass valve stroke sensor of hydraulic tank is a sensor that detects the pressure loss of return filter Bypass valve is opened when the pressure loss...

Page 202: ...MAIN PUMP STRUCTURE OF MAIN PUMP General view COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION 10 108 PC500LC 10R...

Page 203: ...pressure pickup port PLSF Front pump load pressure input port PLSFC Front pump load pressure pickup port PLSR Rear pump load pressure input port PLSRC Rear pump load pressure pickup port PMF Front pum...

Page 204: ...al surface a Spline 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 PC valve 13 Servo piston 14 Slider COMPONENT...

Page 205: ...each bearing 15 at the front and rear The tip of piston 6 is shaped as a concave sphere and is crimped with the shoe 5 Piston 6 and shoe 5 form a spherical bearing Rocker cam 4 has flat surface A and...

Page 206: ...le sealing the pressurized oil Oil pressure is balanced properly on this surface Pressurized oil is sucked in and discharged from each cylinder chamber in the cylinder block 7 through the valve plate...

Page 207: ...ker cam 4 and the axis of cylinder block 7 2 Piston 6 slides inside the cylinder block 7 and a differ ence is made between volume E and volume F in cylin der block 7 3 Oil in amount of F minus E per e...

Page 208: ...pressure PEN of LS valve is supplied to the pres sure chamber on large diameter piston side 6 The area of servo piston 13 for receiving the pressure are not identical on the right side and left side M...

Page 209: ...een pump discharged pressure PP and control valve outlet port pres sure PLS This valve receives main pump pressure PP pressure PLS called LS pressure from the control valve output and pressure PSIG ca...

Page 210: ...SIG also called LS setting selector pres sure entering the port G of EPC valve for LS valve set force of the spring changes 2 Servo piston 12 is pushed to the left before the engine starts See the fig...

Page 211: ...in port and the oil pressure between circuits D and K is set to drain pressure PT The operation of PC valve is explained later 4 The pressure at the large diameter side of servo piston 12 becomes drai...

Page 212: ...he pump discharged pressure PP is transmitted from the port C to the port D and then through port K to the large diameter side of the piston 3 Although the pump discharge pressure PP is sent to the sm...

Page 213: ...that from port C to port D are approximately equal 3 The relationship between the pressure receiving areas at both ends of servo piston 12 is A0 A1 3 5 Under the balanced state the ratio of the pressu...

Page 214: ...e PP also increases during work the pump discharged volume is reduced When the pump discharged pressure decreases the pump discharged volume is increased The relation between the average of front and...

Page 215: ...4 and 6 is balanced with the pump pressure PP1 self pressure and PP2 other pump pressure which pushes spool 3 The pressure output from PC valve pressure of port C varies depending on the position 4 T...

Page 216: ...pressing piston 2 changes 5 The spring loads of the springs 4 and 6 varies also with the command current X of PC EPC valve sole noid 6 The port C of PC valve is connected to the port E of LS valve 7...

Page 217: ...st of PC EPC valve solenoid and forces of springs 4 and 6 When the pump controller is normal the actuator load is large and the pump pressures PP1 and PP2 are high AEP19359 1 When the load is high and...

Page 218: ...rvo piston 9 is an gled since springs 4 and 6 are 2 stage springs 9 The relationship between average of pump pressures PP1 PP2 2 and average of pump discharged volume Q is as shown in the figure below...

Page 219: ...is stabilized the force pressing piston 2 is stabilized 2 When main pump pressures PP1 and PP2 are low the combined force of the force of PC EPC valve solenoid 1 and pump pressure is lower than the s...

Page 220: ...t more compared with when the main pump load is low and is balanced at the position shown in the previous figure 3 Since the pressure from port B flows in port C servo piston 9 moves to the right smal...

Page 221: ...ontroller is normal A MAIN PUMP LS EPC VALVE LS Abbreviation for Load Sensing EPC Abbreviation for Electromagnetic Proportional Control STRUCTURE OF MAIN PUMP LS EPC VALVE LS EPC valve generates EPC o...

Page 222: ...nal view C To LS valve P From self pressure reducing valve T To hydraulic tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7 Plunger COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION...

Page 223: ...ntroller is zero coil de energized 1 When the signal current from the pump controller does not flow through coil 2 coil 2 is de energized 2 Spool 5 is pushed to the left by spring 4 3 Port P is closed...

Page 224: ...al of the pressure in port C and the re action force of spring 4 7 The circuit pressure between the EPC valve and LS valve is controlled in proportion to the amperage of signal cur rent When signal cu...

Page 225: ...lve generates EPC output pressure and outputs it to PC valve General view and sectional view C To PC valve P From self pressure reducing valve T To hydraulic tank 1 Connector 2 Coil 3 Body 4 Spring 5...

Page 226: ...p controller is zero coil de energized 1 When the signal current from the pump controller does not flow through coil 2 coil 2 is de energized 2 Spool 5 is pushed to the left by spring 4 3 Port P is cl...

Page 227: ...r 7 is bal anced with the total of the pressure in port C and the re action force of spring 4 7 The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage...

Page 228: ...e and arm quick return valve Since these valves are formed in one unit with connecting bolts and the passages are connected inside the control valve is compact and serviced very easily The structure o...

Page 229: ...To boom cylinder bottom A4 To swing motor A5 To right travel motor A6 To arm cylinder head A 1 To boom cylinder bottom A 2 To attachment B1 To bucket cylinder head B2 To left travel motor 10 STRUCTURE...

Page 230: ...valve PLS2 To rear pump LS valve PLSC LS pressure pickup port PP1 From front pump PP2 From rear pump PPC Pilot source pressure pickup port PP1S Front pump oil pressure sensor mounting port PP2S Rear p...

Page 231: ...ensation valve bucket CURL 7 Pressure compensation valve boom Hi RAISE 8 Pressure compensation valve service 9 Pressure compensation valve arm Hi IN 10 Pressure compensation valve bucket DUMP 11 Press...

Page 232: ...ket 22 Spool left travel 23 Spool boom 24 Spool swing 25 Spool right TRAVEL 26 Spool arm 27 Spool boom Hi Sectional views C C D D AE AE 1 Suction valve arm OUT 2 Suction valve right travel REVERSE 3 S...

Page 233: ...stage safety valve boom LOWER 12 Suction valve right travel FORWARD 13 Suction safety valve arm IN 14 LS shuttle valve arm 15 LS shuttle valve right TRAVEL 16 LS select valve 17 LS shuttle valve boom...

Page 234: ...0 Check valve for regeneration circuit 11 Suction valve dump 12 Pressure compensation valve DUMP Right travel valve 13 LS shuttle valve 14 Pressure compensation valve FORWARD 15 Spool 16 Suction valve...

Page 235: ...ydraulic drift prevention valve 8 LS shuttle valve 9 Pressure compensation valve LOWER 10 Spool 11 Suction safety valve LOWER 12 Check valve for regeneration circuit 13 Suction valve RAISE 14 Pressure...

Page 236: ...ve 24 Pressure compensation valve DUMP 25 Spool 26 Suction safety valve DUMP 27 Suction safety valve digging 28 Pressure compensation valve digging Sectional views N N AA AA AB AB AD AD BB BB Boom Hi...

Page 237: ...valve boom Hi RAISE Service valve 9 LS shuttle valve 10 Pressure compensation valve 11 Spool 12 2 stage suction safety valve 13 Suction safety valve 14 Pressure compensation valve 15 Unload valve 16...

Page 238: ...HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF VALVES 1 Arm valve 2 Right travel valve COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION 10 144 PC500LC 10R...

Page 239: ...2 5 2 5 kg cm2 190 min 38 Main relief valve arm right travel and swing Set pressure 35 9 0 25 MPa 366 2 5 kg cm2 160 min When digging force is increased 38 5 0 25 MPa 392 5 2 5 kg cm2 190 min 39 Unloa...

Page 240: ...e compen sation valve piston 4 connects spring chamber E and port c Piston 4 and valve 2 are moved in the closing direction by the force of spring 5 When high peak pressure occurs in the actuator circ...

Page 241: ...r in downstream pressure at port B becomes equal to the maximum pressure in the other actuator Since the spool meter in upstream pressure at port A is the pump pressure the spool meter in differential...

Page 242: ...d 1 Spring chamber E is interconnected with port D 2 Piston 4 and valve 2 move in the closing direction right side with the LS circuit pressure from other work equipment of port F 3 The valve upstream...

Page 243: ...s equal to the maximum load pressure and oil flows corresponding with the opening area ratio When the surface area ratio is larger than 1 the spool meter in downstream pressure is higher than the maxi...

Page 244: ...PENSATION VALVE OF CONTROL VALVE When traveling 1 Main pump 5 Pressure compensation valve Pressure compensation valve 5 without shuttle valve is employed since no holding pressure is applied to port A...

Page 245: ...valve 1 Shuttle valve 3 is pressed to the right by port A pressure and disconnects port A and port C 2 The holding pressure in port A is sent to spring chamber B and presses piston 4 to the left so th...

Page 246: ...ro duced as LS pressure into LS shuttle valve 7 This pressure is connected to port B of the actuator through valve 4 and LS pressure Actuator load pressure Introduction hole a in main spool 2 is small...

Page 247: ...introduction port a and it is introduced to LS circuit 2 When the pump pressure reaches the load pressure on port B the check valve 5 opens and the pressur ized oil flows LS BYPASS PLUG OF CONTROL VA...

Page 248: ...BYPASS PLUG OF CONTROL VALVE 1 Main pump 2 Main spool 3 Pressure compensation valve 4 LS shuttle valve 5 LS bypass plug 6 LS circuit COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION 10 1...

Page 249: ...ng down the rais ing speed of the LS pressure When oil bypasses through LS bypass plug 5 pressure loss occurs due to the resistance in the circuit from orifice c of main spool 2 to LS shuttle valve 4...

Page 250: ...e arm is moved OUT arm Hi valve operates simul taneously with arm Lo valve and decreases the flow from the cylinder head side OPERATION OF HI VALVE OF CONTROL VALVE Hi valve looks as if it has only 1...

Page 251: ...ge to the bottom of arm cylinder 2 3 When the arm OUT operation is performed arm OUT PPC pressure D enters chamber b and pushes boom Hi spool 3 to the right then flows to the drain passage At the same...

Page 252: ...er head to in crease the oil flow to the cylinder head When the cylinder head pressure is higher than the bottom pressure when dig ging etc Check valve 6 installed to regeneration circuit C closes to...

Page 253: ...bottom pressure some of pressurized oil A from the cylin der bottom flows to drain circuit B from the notch of boom spool 2 The remaining oil flows to regeneration circuit C opens check valve 6 and fl...

Page 254: ...3 Pressure compensation valve 4 Suction safety valve 5 Suction valve 6 Check valve 7 LS shuttle valve Cylinder speed is increased by the regeneration circuit from cylinder head to cylinder bottom duri...

Page 255: ...lower than bottom pressure Check valve 6 installed to regeneration circuit C closes to cut the oil flow from the cylinder head to the cylin der bottom 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDR...

Page 256: ...rt of pressurized oil A from the cylinder head flows to drain circuit B through the notch of arm spool 2 The remaining oil flows to the regeneration circuit C opens check valve 6 and flows to the cyli...

Page 257: ...e 7 LS circuit bucket side 8 LS circuit arm side 9 Merge divider EPC valve for selecting main spool 10 Merge divider EPC valve for selecting LS spool 1 Main spool 2 Spring 3 LS spool 4 Spring 5 LS cir...

Page 258: ...sure is 0 MPa 0 kg cm2 2 Main spool 1 is pushed to the right by the spring 2 and the port E and port F are interconnected 3 Pressurized oil P1 and P2 discharged from the two pumps merge at ports E and...

Page 259: ...essure To bucket left travel boom P2 pressure To swing right travel arm 3 EPC valve drive signal IS2 for the LS spool 3 is given It moves to the left and the port A and port C are connected by the out...

Page 260: ...uip ment OPERATION OF LS SELECT VALVE OF CONTROL VALVE When pilot pressure BP is cut off 1 Since pilot pressure BP is cut off piston 3 is pressed to the left by the reaction force of spring 2 2 When t...

Page 261: ...t flow to LS shuttle valve 8 4 Even swing LS pressure P1 increases it does not affect other LS circuits SELF PRESSURE REDUCING VALVE OF CONTROL VALVE FUNCTION OF SELF PRESSURE REDUCING VALVE OF CONTRO...

Page 262: ...e circuit between port PR and port TS is closed 2 Since valve 14 is pressed to the left by spring 13 the circuit between port P2 and port TS is closed 3 Since valve 7 is pressed to the left by spring...

Page 263: ...d kept constant at set pres sure according to the area of the opening at this time and it is supplied as pressure PR When load pressure P2 is high 1 Load pressure A2 is increased by the operation of d...

Page 264: ...nnected and oil is supplied evenly to R H and L H travel motors to keep the straight travel performance When the travel lever is operated for steering the travel junction valve receives pilot pressure...

Page 265: ...by the reaction force of spring 1 and port PTL and port PTR are connected 2 When there is difference between the inflow rates to R H and L H travel motors oil is supplied from the port on the high pre...

Page 266: ...upplied travel junction spool 2 com presses spring 1 and moves to the right and port PTL and port PTR are disconnected 2 Independent oil flows are supplied to R H and L H travel motors TRAVEL PPC SHUT...

Page 267: ...ough the internal circuit of the control valve OPERATION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE When travel lever is in NEUTRAL AEP21627 1 The oil in stroke limit signal chamber a flows through...

Page 268: ...l cham ber a and travel PPC valve 3 By performing right travel REVERSE or FORWARD operation the pilot pressure from travel PPC valve is sent through orifice 6 of piston 4 to the left end surface of pi...

Page 269: ...OL VALVE AEP21629 When the boom is not operated with the R H work equipment control lever this function is used to prevent the pressurized oil in the boom cylinder bottom from leaking through spool 1...

Page 270: ...e right side of the ring area S whose outside diameter is diameter d1 of the poppet 5 and inside diameter is seat diameter d2 2 The force acting leftward on area S pushes and compresses spring 4 and m...

Page 271: ...ward on the left side of area S of the ring formed by the difference between outside diameter d1 of poppet 5 and seat diameter d2 3 The combined force of the force acting rightward on area S and the r...

Page 272: ...3 Chamber b in the poppet is connected to drain port T and the pressure in chamber b decreases 4 When the pressure in chamber b decreases below the pressure in port B poppet 5 opens 5 When poppet 5 o...

Page 273: ...en the arm is not operated with the L H work equipment control lever this function is used to prevent the pressurized oil in the arm cylinder head from leaking through spool 1 and causing arm hydrauli...

Page 274: ...o the right side of the ring area S whose outside diameter is diameter d1 of the poppet 5 and inside diameter is seat diameter d2 2 The force acting leftward on area S compresses spring 4 and moves po...

Page 275: ...on the left side of area S of the ring formed by the difference between outside diameter d1 of poppet 5 and seat diameter d2 3 The combined force of the force acting rightward on area S and the react...

Page 276: ...ort T through orifice a chamber b and orifice c 3 Chamber b in the poppet is connected to drain port T and the pressure in chamber b decreases 4 When the pressure in chamber b decreases below the pres...

Page 277: ...TION VALVE OF CONTROL VALVE OPERATION OF SUCTION SAFETY VALVE FOR HYDRAULIC DRIFT PREVEN TION VALVE OF CONTROL VALVE When the abnormally high pressure occurs AEP21610 10 STRUCTURE AND FUNCTION COMPONE...

Page 278: ...OL VALVE When the arm is moved OUT much oil returns from the cylinder bottom This function is used to decrease the pressure loss in this process OPERATION OF ARM QUICK RETURN VALVE OF CONTROL VALVE Wh...

Page 279: ...the arm cylinder bottom side is drained from port B directly to the tank When arm is in NEUTRAL AEP21612 1 When the Arm is returned from DUMP to NEUTRAL operation the pilot pressure from the PPC valve...

Page 280: ...n swing or travel operation 1 Pressurized oil PR output from self pressure reducing valve 1 flows to variable back pressure solenoid valve 3 2 Since drive signal IS3 to variable back pressure solenoid...

Page 281: ...ring 5 acts on valve 6 and pushes valve 6 to the right 4 Pressure PA in drain circuit A of the control valve acts on the right end surface area of diameter d1 of valve 6 and pushes valve 6 to the left...

Page 282: ...load at installed height of the spring 1 The first level When the 1st stage is set again as for the 2nd stage as well the set pressure of the same amount as in crease and decrease of the 1st stage cha...

Page 283: ...load of spring 1 and the set pressure becomes high 2 STAGE SUCTION SAFETY VALVE OF CONTROL VALVE STRUCTURE OF 2 STAGE SUCTION SAFETY VALVE OF CONTROL VALVE Sectional view Port B of boom valve and por...

Page 284: ...ssed to the left by the reaction force of spring 3 Load at instal led height of spring 1 load Load at installed height of spring 3 2 Load at installed height of spring 1 is maximum so that the set pre...

Page 285: ...rt 1 Bucket cylinder 2 Arm cylinder 3 Boom cylinder 4 Attachment selector valve 5 Accumulator 6 Hydraulic oil additional filter with clogging switch 7 Fuel supply pump 8 Engine controller 10 STRUCTURE...

Page 286: ...8 Main pump 9 Rear pump PC EPC valve 10 Front pump PC EPC valve LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION 10 192 PC500LC 10R...

Page 287: ...d valve 15 Attachment selector solenoid valve 16 Machine push up solenoid valve 17 PPC lock solenoid valve 18 Rear pump oil pressure sensor Around cab and floor 1 Machine monitor 2 R H work equipment...

Page 288: ...ent EPC valve 11 1st line attachment PPC valve 12 Right travel FORWARD pressure sensor 13 Travel PPC valve 14 Left travel FORWARD pressure sensor 15 Left travel REVERSE pressure sensor 16 Right travel...

Page 289: ...ox 6 Resistor for PC EPC valve 7 Pump controller 8 Engine controller 9 Machine monitor 10 Pump drive secondary switch 11 Fuel control dial 12 Fuel supply pump 13 Various sensors 14 One touch power max...

Page 290: ...P or ATT E the hydraulic force increases approximately 7 and the digging force increases Each function is set automatically as follows Function Setting Engine and pump combined control Matching at rat...

Page 291: ...signal h 1st throttle signal i Fuel supply pump control signal j Various sensor signals 1 Battery disconnect switch 2 Battery 3 Battery relay 4 Fusible link 5 Fuse box 6 Resistor for PC EPC valve 7 P...

Page 292: ...id valve 23 Suction safety valve 24 Boom valve 25 Boom cylinder FUNCTION OF MACHINE PUSH UP SYSTEM The push force of the boom is increased by operating ma chine push up switch 1 This function is used...

Page 293: ...switch 7 Lock lever 8 PPC lock switch 9 Pump controller 10 Work equipment automatic lock relay 11 PPC lock solenoid valve 12 Control valve 12a Merge divider valve 12b Self pressure reducing valve 13...

Page 294: ...PPC lock switch 9 Pump controller 10 Work equipment automatic lock relay 11 PPC lock solenoid valve 12 Control valve 12a Merge divider valve 12b Self pressure reducing valve 13 Main pump 14 Lock leve...

Page 295: ...tomatic lock control may not operate Control when lock lever automatic lock cancel switch is ON If PPC solenoid valve does not operate and the operator can not work because of abnormality in the contr...

Page 296: ...Attachment flow adjustment EPC valve drive signal g Oil pressure switch signal h 1st throttle signal i Fuel supply pump control signal j Various sensor signals 1 Battery disconnect switch 2 Battery 3...

Page 297: ...valve 23 Attachment circuit selector valve 24 Attachment 25 Accumulator FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT When the attachment control pedal is depressed fully the oil flow to the at...

Page 298: ...TEM WORK EQUIPMENT AND SWING PPC VALVE PPC Abbreviation for Proportional Pressure Control STRUCTURE OF WORK EQUIPMENT AND SWING PPC VALVE General view COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUC...

Page 299: ...o control valve swing RIGHT port T To hydraulic tank R H work equipment control lever P From self pressure reducing valve P1 To control valve boom LOWER port P2 To control valve boom RAISE port P3 To...

Page 300: ...Sectional view 1 Spool 2 Piston 3 Disc 4 Nut for connecting lever COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION 10 206 PC500LC 10R...

Page 301: ...1 increases The fine control hole f is disconnected from the pump pressure chamber PP and it is connected to the drain chamber D almost simultaneously Then the pressure in the port P1 is decreased 5 T...

Page 302: ...in the valve on the side that is not operated The oil passes through the port P2 and it flows to the port B to replen ish the port with pressurized oil When the lever is stroked to the end 1 The disc...

Page 303: ...iew P From self pressure reducing valve P1 To control valve service valve 1 port P2 To control valve service valve 1 port T To hydraulic tank 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMEN...

Page 304: ...on of work equipment and swing PPC valve EPC VALVE OF 1ST LINE ATTACHMENT PPC VALVE PPC Abbreviation for Proportional Pressure Control EPC Abbreviation for Electromagnetic Proportional Control STRUCTU...

Page 305: ...From self pressure reducing valve C To PPC valve R H attachment T To hydraulic tank 1 Body 2 Spool 3 Spring 4 Coil 5 Plunger 6 Push pin 7 Connector 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQ...

Page 306: ...rtion to that sig nal current and outputs it to the control valve OPERATION OF EPC VALVE OF 1ST LINE ATTACHMENT PPC VALVE When signal current is zero coil is de energized AEP21636 1 When the signal cu...

Page 307: ...spool 2 to the right and the pressurized oil from port P flows into port C 3 When the pressure at port C increases combined force on surface a of spool 2 and the reaction force of spring 3 becomes lar...

Page 308: ...nger 5 also becomes the maxi mum 2 The spool 2 is pushed to the right by push pin 6 3 The maximum rate of the pressurized oil flows from port P to port C and the circuit pressure between EPC valve and...

Page 309: ...SOLENOID VALVE STRUCTURE OF SOLENOID VALVE General view and sectional view 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM PC500LC 10R 10 215...

Page 310: ...15 Block Check valve 16 Plunger 17 Spring 18 Plug OPERATION OF SOLENOID VALVE AND CHECK VALVE When the solenoid valve is de energized circuit is blocked 1 The coil 1 is de energized when the signal c...

Page 311: ...s held Check valve When engine is running 1 When the engine is running the pilot pressure in port P pushes plunger 1 to the right and port P and port ACC are interconnected ATTACHMENT CIRCUIT SELECTOR...

Page 312: ...her attachment crusher etc is installed this function is used to discon nect the main circuit from the accumulator OPERATE ATTACHMENT CIRCUIT SELECTOR VALVE When attachment other than breaker is insta...

Page 313: ...ATT is connected to port T 3 The pressurized oil returning from the breaker returns di rectly to the hydraulic tank through port T without passing through the control valve PILOT CIRCUIT ACCUMULATOR S...

Page 314: ...its own weight HYDRAULIC OIL ADDITIONAL FILTER WITH CLOGGING SWITCH STRUCTURE OF HYDRAULIC OIL ADDITIONAL FILTER WITH CLOGGING SWITCH 1 Filter case 2 Filter element 3 Bypass valve 4 Filter head 5 Clog...

Page 315: ...ream side exceeds the operation pressure of clogging switch of hydraulic oil additional filter the hydraulic oil addition al filter caution lamp lights up on the machine monitor 10 STRUCTURE AND FUNCT...

Page 316: ...YOUT DRAWING OF SWING SYSTEM Chassis part 1 Swing circle 2 Center swivel joint 3 Swing machinery 4 Swing motor 5 Control valve 6 Main pump LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION 10 2...

Page 317: ...7 Right swing oil pressure sensor 8 Left swing oil pressure sensor 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM PC500LC 10R 10 223...

Page 318: ...9 Swing parking brake solenoid valve 10 2 stage swing relief solenoid valve Around cab and floor LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION 10 224 PC500LC 10R...

Page 319: ...rk equipment PPC valve 3 Swing lock switch 4 L H work equipment PPC valve 5 Attachment PPC valve 6 Swing parking brake cancel switch 7 Pump controller 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING...

Page 320: ...Travel junction valve 14 Swing motor 14a 2 stage relief valve 15 Swing parking brake solenoid valve 16 2 stage swing relief solenoid valve FUNCTION OF SWING CONTROL SYSTEM Swing lock and swing parking...

Page 321: ...brake cancel function k While the swing parking brake is canceled only the hydraulic brake is applied by the relief valve If swing is stopped on a slope the hydraulic drift may occur Take care Cancel...

Page 322: ...MPa 380 kg cm2 2 stage swing relief function During swing acceleration the set pressure of 2 stage swing relief valve is changed to reduce the relief flow and improve the fuel consumption Operating co...

Page 323: ...ressure is set B Flow rate when high pressure is set C Flow rate necessary to swing Z Loss reduction fuel efficiency improvement range during relief 10 STRUCTURE AND FUNCTION SWING CONTROL SYSTEM DIAG...

Page 324: ...MB From control valve swing LEFT port B From swing parking brake solenoid valve S From control valve variable back pressure valve T To hydraulic tank PU 2 stage swing relief solenoid valve 1 Reverse p...

Page 325: ...ive shaft 3 Oil seal 4 Case 5 Disc 6 Plate 7 Brake piston 8 Housing 9 Piston 10 Cylinder block 11 Valve plate 12 Center shaft 13 Center spring 14 Check valve 10 STRUCTURE AND FUNCTION COMPONENT PARTS...

Page 326: ...up per structure SWING PARKING BRAKE OF SWING MOTOR OPERATION OF SWING PARKING BRAKE OF SWING MOTOR When solenoid valve is de energized swing parking brake is operated When the swing parking brake so...

Page 327: ...a through port B 2 The pressurized oil in chamber a compresses brake spring 1 and the brake piston 7 is moved upward 3 The disc 5 and plate 6 are separated Accordingly the swing parking brake is canc...

Page 328: ...winging the motor outlet circuit is closed by control valve 6 but the motor is turned by the inertial force If the motor outlet circuit pressure increases abnormally it may damage the motor Abnormally...

Page 329: ...g torque is generated and the motor starts rotating 3 The pressure is supplied to port PU of the motor and the set pressure of the motor increases 4 During swing acceleration the pilot pressure from t...

Page 330: ...e 1 and port S 4 Rotational resistance occurs in the motor and the brake starts working 5 The pressure in port MA exceeding that in port MA pushes the shuttle valve 4 6 The pressure in chamber C becom...

Page 331: ...TION OF 2 STAGE SWING RELIEF VALVE OF SWING MOTOR The set pressure can be changed to 2 stages The set pressure depends on the load at installed height of spring 4 During swing acceleration the relief...

Page 332: ...y loss A When pilot pressure is stopped low pressure set B When pilot pressure is applied high pressure set P 27 9 MPa 286 kg cm2 Q1 260 min Q2 100 min OPERATION OF 2 STAGE SWING RELIEF VALVE OF SWING...

Page 333: ...e receiving area d2 d1 2 The spring 4 is compressed and its installed load increases and the pump discharged volume is reduced by the controller and the passage between valve 2 and valve seat 1 is cho...

Page 334: ...SWING MOTOR REVERSE PREVENTION VALVE STRUCTURE OF SWING MOTOR REVERSE PREVENTION VALVE General view and sectional view COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION 10 240 PC500LC 10R...

Page 335: ...ation is stopped the upper structure may swing back This is due to inertia of the weight of the upper structure the backlash and rigidity of the swing machinery system or compression of the hydraulic...

Page 336: ...en motor reverse pressure occurs in port MA 1 The motor rotates in reverse by the closed pressure gener ated in port MB First reverse rotation 2 The reverse pressure is generated in port MA side Pres...

Page 337: ...SWING MACHINERY STRUCTURE OF SWING MACHINERY General view and sectional view 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM PC500LC 10R 10 243...

Page 338: ...ity of teeth 30 11 No 1 planetary carrier 12 No 2 planetary carrier 13 Drain plug SPECIFICATIONS OF SWING MACHINERY Reduction ratio 19 80 19 x 16 64 16 26 053 Swing reduction ratio 26 053 x 84 13 168...

Page 339: ...of outer race soft zone b Position of inner race soft zone mark S 1 Greasing port of swing circle pinion 2 Inner race quantity of teeth 84 3 Ball 4 Outer race 5 Seal 10 STRUCTURE AND FUNCTION COMPONEN...

Page 340: ...soft zone mark S 1 Greasing port of swing circle pinion 2 Inner race quantity of teeth 84 3 Ball 4 Outer race 5 Seal SPECIFICATIONS OF SWING CIRCLE Reduction ratio 84 13 6 462 Grease G2 LI Quantity o...

Page 341: ...FUNCTION OF SWING CIRCLE The swing circle connects the upper structure and carrier unit 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM PC500LC 10R 10 247...

Page 342: ...TEM LAYOUT DRAWING OF TRAVEL SYSTEM 1 Control valve 2 Fuel supply pump 3 Engine controller 4 Main pump 5 LS EPC valve 6 Travel alarm LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION 10 248 PC...

Page 343: ...p controller 11 Right travel REVERSE pressure sensor 12 Right travel FORWARD pressure sensor 13 Travel PPC valve 14 Left travel FORWARD pressure sensor 15 Left travel REVERSE pressure sensor 10 STRUCT...

Page 344: ...17 Travel speed increase solenoid valve 18 Travel junction solenoid valve 19 Rear pump oil pressure sensor 20 Front pump oil pressure sensor LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION 1...

Page 345: ...21 Center swivel joint 22 Travel motor 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM PC500LC 10R 10 251...

Page 346: ...rol dial 5 Fuel supply pump 6 Various sensors 7 Front pump oil pressure sensor 8 Rear pump oil pressure sensor 9 Oil pressure sensor 10 Travel alarm 11 Front pump 11a Servo 11b LS valve 11c PC valve 1...

Page 347: ...peed selector switch is kept at Hi position While traveling at low speed set by the automatic gear shift with load when the load decreases on a flat or downhill slope and the travel pressure is 22 5 M...

Page 348: ...eft travel FORWARD port R H travel motor PA From control valve right travel FORWARD port PB From control valve right travel REVERSE port P From travel speed increase solenoid valve T To hydraulic tank...

Page 349: ...Cylinder block 5 Valve plate 6 End cover 7 Slow return valve 8 Quick return valve 9 Regulator piston 10 Plate 11 Disc 12 Check valve spring 13 Check valve 14 Counterbalance valve spool 10 STRUCTURE AN...

Page 350: ...3 5 cm3 rev Rated pressure 37 3 MPa 380 kg cm2 Rated speed at Min delivery 2650 rpm Rated speed at Max delivery 1550 rpm Brake canceling pressure 0 98 MPa 10 kg cm2 Travel speed selector pressure 0 7...

Page 351: ...t pressure oil flows from the self pressure reducing valve to port P 2 Regulator valve 17 is pressed down by spring 18 3 The pressurized oil from control valve pushes the check valve 21 flows to the e...

Page 352: ...the port P 2 It pushes up the regulator valve 17 3 The pressurized oil in chamber b is drained into the case The pressurized oil from control valve pushes the check valve 21 flows to the end cover 6 a...

Page 353: ...tes counterbalance valve spool 14 and it opens the parking brake circuit 2 The pressurized oil flows into the chamber e of brake piston 20 The spring 19 is compressed and the piston 20 is pushed to th...

Page 354: ...asses through the throttle of slow return valve 7 until the counterbalance valve spool 14 returns to the neutral position 3 When the counterbalance valve spool 14 returns to the neutral position the o...

Page 355: ...valve 14 Counterbalance valve When the machine travels downhill it tends to travel faster than the motor engine rotation because of its own weight If the machine travels downhill with the engine at lo...

Page 356: ...side increases since the motor outlet side is closed by the check valve 13B and spool 14 4 The pressurized oil on the supply side flows to chamber S1 through orifice E1 of spool 14 and orifice E2 5 W...

Page 357: ...inlet side are balanced with the pressure of motor outlet port MB 6 The motor outlet circuit is throttled and the machine travels at speed corresponding to the pump discharged volume SAFETY VALVE OF...

Page 358: ...force of Circular area difference between D1 and D2 x Pressure compresses spring 2 4 The pressurized oil moves poppet 1 to the left and flows into chamber MA in the circuit on the opposite side Both...

Page 359: ...ling high pres sure set pressure 1 When the travel lever is operated the pressurized oil from the pump moves spool 14 to the right 2 It opens the pilot circuit to the safety valve and flows into chamb...

Page 360: ...set to NEUTRAL position 2 The pressurized oil in chamber J continues to flow to chamber PA through passage H and chamber G until spool 14 returns to the neutral position 3 Piston 3 moves to the left...

Page 361: ...FINAL DRIVE STRUCTURE OF FINAL DRIVE General view and sectional view 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM PC500LC 10R 10 267...

Page 362: ...avel motor 14 No 2 planetary gear number of teeth 33 SPECIFICATIONS OF FINAL DRIVE Reduction ratio 10 104 10 x 17 87 17 1 68 741 Quantity of lubricating oil for each set 9 3 FUNCTION OF FINAL DRIVE Th...

Page 363: ...P1 To control valve left travel REVERSE port P2 To control valve left travel FORWARD port P3 To control valve right travel REVERSE port P4 To control valve right travel FORWARD port T To hydraulic tan...

Page 364: ...Sectional view A A B B D D C C 1 2 3 4 5 6 B B A 4 P 1 4 8 8 2 1 Plate 2 Case 3 Piston 4 Seal 5 Spool 6 Damper COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION 10 270 PC500LC 10R...

Page 365: ...ole f and port P1 4 The spool 1 is pushed back when the pressure in the port P1 increases The fine control hole f is disconnected from the pump pressure chamber PP and it is connected to the drain cha...

Page 366: ...5 The pump pressure is supplied until the pressure in the port P1 is restored to that equivalent at the lever position 6 When the spool of control valve returns the pressurized oil in the drain chambe...

Page 367: ...everse travel motor port PA C2 From control valve port A5 D1 To R H forward travel motor port PB D2 From control valve port B5 E1 To R H and L H travel motors port Pi E2 From travel speed increase sol...

Page 368: ...e to travel motor installed to the lower structure while rotating Center swivel joint would not be twisted unlike hoses or tubes which would be twisted if they are installed for the upper structure ro...

Page 369: ...Track roller 6 Track shoe 7 Roller guard 8 Front guard 9 Idler cushion SPECIFICATIONS OF UNDERCARRIAGE Number of track rollers one side 8 pieces Standard shoe Shoe width 600 mm Link pitch 228 6 mm Nu...

Page 370: ...UIPMENT STRUCTURE OF WORK EQUIPMENT General view 1 Bucket 2 Bucket link 3 Bucket cylinder 4 Arm 5 Arm cylinder 6 Boom 7 Boom cylinder STRUCTURE OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION 10 276 PC500...

Page 371: ...hole work equipment up and down The arm is operated by the arm cylinder and pulls in or pushes out the bucket The bucket is operated by the bucket cylinder The bucket link increases the moving range o...

Page 372: ...t clearance adjustment shim Steel shim The purpose of the steel shim is to reduce the clearance in the right and left direction Depending on the amount of clearance adjustment you may not have to inse...

Page 373: ...lit type steel shims are used for the joint of the arm and bucket You can adjust the clearance in the joint by changing the num ber of the shims You can reduce the large clearance by reduc ing the shi...

Page 374: ...CAB General view 1 Front window 2 Windshield wiper 3 Headlamp 4 Ceiling window 5 KOMTRAX GPS antenna 6 Radio antenna 7 Door 8 Mirror FUNCTION OF ROPS CAB ROPS cab protects the operator wearing seat be...

Page 375: ...olving frame The type of each damper depends on the location as shown in the identification table below Location of damper Bent claw Identification seal color Front left Made Red Front right Made Red...

Page 376: ...nal view 1 Bolt 2 Lock plate bolt for fixing 3 Lock plate for fixing FUNCTION OF CAB TIPPING STOPPER Cab tipping stopper is installed at 1 place in the rear part to secure the cab when the machine tip...

Page 377: ...20 STANDARD VALUE TABLE PC500LC 10R 20 1...

Page 378: ...INE 20 9 STANDARD VALUE TABLE FOR ENGINE PC500LC 10R 20 9 STANDARD VALUE TABLE FOR MACHINE 20 13 STANDARD VALUE TABLE FOR MACHINE PC500LC 10R 20 13 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMA...

Page 379: ...ontrol Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retarde...

Page 380: ...o that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from eac...

Page 381: ...r KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of th...

Page 382: ...ump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump...

Page 383: ...a of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low f...

Page 384: ...out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 20 STANDA...

Page 385: ...perature 45 to 55 C Fuel control dial MAX High idle position Working mode P Power Mode Auto deceleration switch OFF Swing lock switch ON rpm 1770 50 Engine speed at low idle Engine coolant temperature...

Page 386: ...re kPa mmHg Min 140 Min 1050 113 850 Absolute pres sure Min 241 3 Min 1810 214 3 1610 Exhaust tem perature Whole speed range outside air temperature 20 C C Max 700 Exhaust gas color Engine cool ant te...

Page 387: ...relieved One touch power maximizing function is actuated kPa mmH2O Max 1 96 Max 200 Max 3 92 Max 400 Fuel system Machine model PC500LC 10R Engine SAA6D125E 5 Item Measurement condition Unit Standard v...

Page 388: ...idle position Min 0 08 Min 0 8 0 05 0 5 Engine oil tem perature Whole speed range inside oil pan C 90 to 110 120 1 KES diesel engine oil Cooling fan Machine model PC500LC 10R Engine SAA6D125E 5 Item...

Page 389: ...ngine speed when oil pres sure of 2 pumps are relieved One touch power maximizing is ac tuated Engine coolant temperature 60 to 100 C Hydraulic oil temperature 45 to 55 C Fuel control dial MAX High id...

Page 390: ...valve Travel of control lever Machine model PC500LC 10R Engine SAA6D125E 5 Item Measurement condition Unit Standard value for new machine Repair limit Boom control lever Engine Stopped Center of lever...

Page 391: ...1 3 0 3 21 6 or less 2 2 or less Swing control lever 12 7 2 9 1 3 0 3 21 6 or less 2 2 or less Travel control lever 24 5 5 9 2 5 0 6 39 2 or less 4 0 or less Travel control pedal 74 5 18 6 7 6 1 9 107...

Page 392: ...to 365 Arm relief pres sure PFC PRC 34 8 1 47 1 18 353 15 12 37 3 1 47 1 18 380 15 12 33 2 to 36 8 338 to 375 35 6 to 39 2 363 to 400 Bucket relief pressure PFC PRC 34 8 1 47 1 18 353 15 12 37 3 1 47...

Page 393: ...ion Fuel control dial MIN Low idle po sition MPa kg cm2 2 09 21 3 2 09 21 3 Fuel control dial MAX High idle position 0 98 10 0 98 10 LS differential pressure PFC PLSF PRC PLSR Hydraulic oil tempera tu...

Page 394: ...ner gized 2 84 to 3 43 29 to 35 2 84 to 3 43 29 to 35 PPC valve outlet pressure Hydraulic oil tempera ture 45 to 55 C Fuel control dial MAX High idle position Working mode P Pow er Mode Each control l...

Page 395: ...complete 5 swings after 1 swing Measuring posture See Machine posture and procedure for measur ing performance Fig 2 sec 33 0 3 3 5 0 38 or less Swing drift on a slope Hydraulic oil temperature 45 to...

Page 396: ...mper ature 45 to 55 C Fuel control dial MAX High idle po sition Working mode P Power Mode Time required for traveling 20 m after running up 10m on a flat ground Measuring posture See Machine pos ture...

Page 397: ...Machine model PC500LC 10R Engine SAA6D125E 5 Item Measurement condition Unit Standard value for new machine Repair limit Whole work equipment Hydraulic drift measured at tooth tip Hydraulic oil temper...

Page 398: ...posture See Machine pos ture and procedure for measuring per formance Fig 9 Boom RAISE sec 4 2 0 4 5 0 or less Arm speed Hydraulic oil temper ature 45 to 55 C Fuel control dial MAX High idle po sition...

Page 399: ...0 3 3 5 or less Operation time lag Machine model PC500LC 10R Engine SAA6D125E 5 Item Measurement condition Unit Standard value for new machine Repair limit Boom time lag Hydraulic oil temperature 45 t...

Page 400: ...po sition Working mode P Power Mode Set the bucket at the maximum arm OUT position Time required for bucket to start moving toward buck et CURL side again after stopping once around the vertical posit...

Page 401: ...SE swing start at 90 Hydraulic oil temperature 45 to 55 C Fuel control dial MAX High idle position Working mode P Power Mode Bucket soil sand heap 1 1 slope or rated load 2 5 m3 3960 kg Arm in vertica...

Page 402: ...e margin of error increases When measuring with the pump mounted on the machine if it is impossible to set the engine speed to the specified speed by using the fuel control dial take the pump discharg...

Page 403: ...MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM ANCE Fig 1 Fig 2 Fig 3 Fig 4 20 STANDARD VALUE TABLE MACHINE POSTURE AND PROCEDURE FOR MEASURING PER FORMANCE PC500LC 10R 20 27...

Page 404: ...Fig 5 Fig 6 Fig 7 Fig 8 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER FORMANCE 20 STANDARD VALUE TABLE 20 28 PC500LC 10R...

Page 405: ...Fig 9 Fig 10 Fig 11 Fig 12 20 STANDARD VALUE TABLE MACHINE POSTURE AND PROCEDURE FOR MEASURING PER FORMANCE PC500LC 10R 20 29...

Page 406: ...Fig 13 Fig 14 Fig 15 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER FORMANCE 20 STANDARD VALUE TABLE 20 30 PC500LC 10R...

Page 407: ...30 TESTING AND ADJUSTING PC500LC 10R 30 1...

Page 408: ...STING TOOL 30 37 TEST FUEL PRESSURE 30 39 METHOD FOR TESTING FUEL PRESSURE 30 39 TEST FUEL RETURN RATE AND LEAKAGE 30 41 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 30 41 BLEED AIR FROM FUEL SYSTE...

Page 409: ...ULIC DRIFT IN WORK EQUIPMENT 30 94 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 30 94 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER...

Page 410: ...IAGNOSTIC TESTS MENU 30 152 ADJUSTMENT MENU 30 154 METHOD FOR PERFORMING NO INJECTION CRANKING 30 167 KOMTRAX SETTINGS MENU 30 168 METHOD FOR DISPLAYING SERVICE MESSAGE 30 171 METHOD FOR STARTING UP K...

Page 411: ...ontrol Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retarde...

Page 412: ...that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from each...

Page 413: ...r KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of th...

Page 414: ...ump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump...

Page 415: ...a of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low f...

Page 416: ...out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 30 TESTING...

Page 417: ...Meter 1 2 6215 11 8180 Sensor 1 Tools for testing exhaust gas color Symbol Part No Part name Q ty Remarks A 799 201 9002 Handy smoke checker 1 Bosch index 0 to 9 B Commercially available Smoke meter 1...

Page 418: ...99 101 5002 Hydraulic tester 1 1 799 101 5160 Nipple 1 Size R1 8 B 799 401 2320 Gauge 1 Pressure range 1 MPa Testing tools for fuel return rate and leakage Symbol Part No Part name Q ty Remarks A 6151...

Page 419: ...nd travel circuits Symbol Part No Part name Q ty Remarks A 799 101 5002 Hydraulic tester 1 1 799 101 5110 Gauge 1 Pressure range 60 MPa 2 799 101 5130 Gauge 1 Pressure range 6 MPa B 790 261 1205 Digit...

Page 420: ...1023 O ring 4 E 799 401 2701 Differential pressure gauge 1 Pressure range 50 MPa F 796T 440 1101 Sensor adapter 1 Pressure range 50 MPa Tools for testing outlet pressure of solenoid valve Symbol Part...

Page 421: ...Commercially available Measuring cylinder 1 B 07379 01044 Flange 2 Size 10 C 07376 70522 Plug 1 Size 4 D Commercially available Plate 1 Size 250x260x32 E Commercially available Pin 1 Size 200x80 30 TE...

Page 422: ...AND ADJUSTING Note Komatsu does not take any responsibility for special tools manufactured according to these sketches Sensor adapter Nipple SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND A...

Page 423: ...Socket Plug 30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING PC500LC 10R 30 17...

Page 424: ...sting condition range 4 Set the working mode to P Power Mode 5 Turn off the auto deceleration 6 Turn the swing lock switch to ON position 7 Turn the fuel control dial to MAX High idle position 8 Check...

Page 425: ...ndition range 4 Set the working mode to P Power Mode 5 Turn off the auto deceleration 6 Turn the fuel control dial to MAX High idle position 7 Operate the work equipment control lever to relieve the o...

Page 426: ...he engine speed de creases to the speed at auto deceleration Check the engine speed at this time For details see STRUC TURE AND FUNCTION ENGINE SYSTEM For standard values see STANDARD VALUE TABLE STAN...

Page 427: ...HINE MONITOR 1 Start the engine 2 Select and display Pre defined Monitoring 01 11 by referring to SET AND OPERATE MACHINE MONI TOR 3 Set the engine coolant temperature and the hydraulic oil temperatur...

Page 428: ...he gauge A1 4 Start the engine 5 Keep the engine speed at medium or higher by adjusting the fuel control dial 6 Insert the connecting portion of the hose half way into the gauge to drain the oil REMAR...

Page 429: ...LUE TABLE FOR ENGINE REMARK Charge Pressure on the monitoring is displayed in absolute value The absolute pressure includes the atmospheric pressure Check the atmospheric pressure because it changes w...

Page 430: ...engine k The parts and oil are still very hot immediately after the engine is stopped It may cause burn injury Wait for the temperature to go down and then start the work Check this item under the fol...

Page 431: ...de air temperature intake air temperature of the engine correct the value by using the following formula if an abnormal value is recorded Corrected value C Measured value 2 x 20 Ambient temperature Pr...

Page 432: ...r to the handy smoke checker A 2 Insert the exhaust gas intake pipe of handy smoke checker A into the tailpipe REMARK Insert the probe so that its tip is at the center of the piping and it is in paral...

Page 433: ...ck switch to ON position 8 Turn the fuel control dial to MAX High idle position and operate the work equipment control lever Collect the ex haust gas to the filter paper by operating the smoke meter B...

Page 434: ...and oil are still very hot immediately after the engine is stopped It may cause burn injury Wait for the temperature to go down and then start the work Check and adjust this item under the following...

Page 435: ...t at its compression top dead center In that case ro tate the crankshaft one more turn Only 1 stamped line is made on the circumference 6 While No 1 cylinder is at the compression top dead center chec...

Page 436: ...on top dead center adjust valve clearance of No 1 cylinder 1 Loosen lock nut 7 with adjustment screw 6 fixed 2 Insert feeler gauge B in the clearance between rocker arm 8 and crosshead 9 and adjust th...

Page 437: ...e exhaust manifold or muffler or get caught in a rotating part Check this item under the following conditions Engine oil temperature 40 to 60 C Refer to this section when testing the compression press...

Page 438: ...ter adjusting valve clearance install intake connector 6 with clamp 3 Mounting clamp 10 5 0 5 Nm 107 5 kgm 10 Install the hose D to the disconnected part of the tube on the common rail side to drain t...

Page 439: ...0 to 7 5 kgm 4 Insert the harness 14 into the rocker arm housing and fix it with the mounting bolt 15 5 Insert the wiring harness 14 into holder 16 6 Alternately tighten 2 nuts at the end of wiring ha...

Page 440: ...the engine 2 Select and display Pre defined Monitoring 01 11 by referring to SET AND OPERATE MACHINE MONI TOR 3 Set the engine coolant temperature and the hydraulic oil temperature so that it is with...

Page 441: ...onnected outlet side hose 2 and connect the gauge A1 to it 5 Start the engine 6 Select and display Pre defined Monitoring 01 11 by re ferring to SET AND OPERATE MACHINE MONITOR 7 Set the engine coolan...

Page 442: ...dard values see STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE Remove the testing tools and restore the machine after the test is finished TEST BLOWBY PRESSURE 30 TESTING AND ADJUSTING 30 36 PC5...

Page 443: ...sure to perform troubleshooting refer to this section METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 1 Start the engine 2 Select Pre defined Monitoring 01 11 or the following monitoring ite...

Page 444: ...so that it is within the testing condition range 7 Set the auto decelerator to be disabled 8 Test the oil pressure with fuel control dial at MIN Low idle position and MAX High idle position For stand...

Page 445: ...us k Wait for the remaining pressure in the fuel circuit to have been released for at least 30 seconds after stopping the engine Then perform removing or installing the testing tools Do not start the...

Page 446: ...n the testing condition range 7 Test the fuel pressure when the fuel control dial is turned to MAX High idle position For standard values see STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE Remov...

Page 447: ...a stable posture set the lock lever to LOCK position and stop the engine k Wait for 30 seconds at least after stopping the engine until the remaining pressure in the fuel circuit is released Then per...

Page 448: ...e arm IN circuit with the swing lock switch ON in working mode 8 After the engine speed is stabilized measure the leakage amount for 1 minute with measuring cylinder E REMARK You can obtain the leakag...

Page 449: ...t by 3 to judge When the failure code Common Rail Pressure Low Er ror is displayed the engine speed may not increase In this case record the engine speed during testing as well For standard values see...

Page 450: ...imiter valve For bleeding air from fuel system to perform troubleshooting refer to this section METHOD FOR BLEEDING AIR FROM FUEL SYSTEM Bleed air according to this procedure in the following cases Wh...

Page 451: ...ted item 5 Operate the electric fuel primer pump with a function switch on Operate elec fuel primer pump screen F5 Selection is canceled The screen returns to Machine Setting screen F6 Enters the sele...

Page 452: ...ed When the fuel circuit is out of fuel in the cases as fuel has run out or the fuel piping or supply pump is re placed operate the electric fuel primer pump again af ter the fuel feed pump stops auto...

Page 453: ...s stabilized REMARK Turn the fuel control dial to MAX High idle the engine automatic warm up function is canceled For the condition of canceling the engine automatic warm up function see ENGINE AUTOMA...

Page 454: ...form the checks from step 1 again Testing method of fuel circuit for leakage at engine rated speed 1 Start the engine 2 Run the engine with fuel control dial at MIN Low idle and stop it after the engi...

Page 455: ...when a cyl inder is cutout with the cylinder cutout mode operation that cylinder has a failure The possible failures are as follows Compression gas leakage from cylinder head gasket area Defective in...

Page 456: ...nders electrically The purpose and effect of this operation are as follows No injection cranking is performed to lubricate the engine parts and to protect them from seizure It is performed before the...

Page 457: ...following cases There is a horizontal abrasion a crossed with a vertical abrasion b The fan belt is partly frayed c Replacement is not required if there are only horizon tal scratches NOTICE The follo...

Page 458: ...ury Wait for the temperature to go down and then start the work For testing of alternator belt to perform troubleshooting or others refer to this section METHOD FOR TESTING ALTERNATOR BELT 1 Remove th...

Page 459: ...perating environment When oil or grease is attached to the side of the alternator belt If the belt is visibly worn the auto tensioner may be worn as well and the pulley may have a rough surface In tha...

Page 460: ...and e of auto tensioner 3 NOTICE Replace the auto tensioner 3 if there is any crack or damage on it 3 Auto tensioner 3 45 to 55 Nm 4 6 to 5 6 kgm 3 Check that the arm stopping portion c of the auto te...

Page 461: ...e auto ten sioner 3 does not contact to the spring case stopping portion d or e when the alternator belt 2 is installed NOTICE Replace the alternator belt 2 if the arm stopping portion c of the auto t...

Page 462: ...e fuel control dial is in MIN Low idle position PARTIAL Engine speed 1200 rpm position and MAX High idle position See STANDARD VALUE TABLE STANDARD VALUE TA BLE FOR MACHINE for standard values REMARK...

Page 463: ...ine 2 Set the work equipment to the maximum reach posture and set the bucket tip to the height of the underside of the revolving frame The front side of the upper structure lowers and the rear side ri...

Page 464: ...asure the maximum clearance a between the square bar A and the track shoe Standard max clearance a 16 to 34 mm METHOD FOR ADJUSTING TRACK TENSION Adjust the track shoe tension according to the followi...

Page 465: ...ernal pressure of the grease 2 Check that the tension is correct Run the engine with the fuel control dial at MIN low idle position and move the machine slowly forward by length of track on ground the...

Page 466: ...sconnecting a pipe between a hydraulic cylinder and the control valve release the remaining pressure from the circuit according to the following procedure Method for releasing remaining pressure in hy...

Page 467: ...hown in the figure Release the remaining pres sure from the boom cylinder circuit according to the procedure described above 9 When oil starts to flow out from the hose A tighten the bleeder 3 for arm...

Page 468: ...run it with the fuel control dial at MIN Low idle position for approximately 10 seconds to increase the pressure in PPC accumulator 6 Repeat steps 2 to 5 several times and all remaining pressure is re...

Page 469: ...own and then start the work k Lower the work equipment to the ground and stop the engine Operate the control lever several times to release the remaining pressure in the piping Loosen the oil filler c...

Page 470: ...Pre defined Monitoring 04 11 or Monitoring Se lection Menu and display the following monitoring items by referring to SET AND OPERATE MACHINE MONI TOR Monitoring code 01100 Front Pump Pressure Monito...

Page 471: ...lve operates is displayed See STANDARD VALUE TABLE STANDARD VALUE TA BLE FOR MACHINE for standard values Remove the testing tools and restore the machine after the test is finished METHOD FOR TESTING...

Page 472: ...an also be used in stead of the gauge A1 6 Start the engine 7 Select and display Pre defined Monitoring 01 11 by re ferring to SET AND OPERATE MACHINE MONITOR 8 Adjust the hydraulic oil temperature so...

Page 473: ...ion 7 Measure the Front Pump Pressure and Rear Pump Pressure by operating the swing control lever to re lieve the oil pressure in the right or left swing circuit The pressure of the swing motor safety...

Page 474: ...turned on the main relief valve is set for high pressure relief 11 Turn the fuel control dial to MAX High idle position 12 Measure the Pump Pressure by operating the swing con trol lever to the right...

Page 475: ...sure to perform correct lever operation by using clear hand signals and checking Otherwise wrong lever operation can be a cause of an accident k Before operating the travel lever and the pedal check t...

Page 476: ...range 10 Set the working mode to P Power Mode 11 Turn the fuel control dial to MAX High idle position 12 Measure the Pump Pressure by operating the travel lever and the pedal and then relieve the tra...

Page 477: ...ally When the low pressure relief pressure is turned on the 2 stage relief solenoid valve is OFF and thus the pilot pressure is not applied to the selector port 1 Disconnect the pilot hose 5 The figur...

Page 478: ...tment per turn of the holder 10 Approx 25 3 MPa 258 kg cm2 4 Tighten the lock nut 11 with the holder 10 fixed 3 Lock nut 11 93 to 123 Nm 9 5 to 12 5 kgm 5 Connect the pilot hose 9 After the adjustment...

Page 479: ...the swing 2 stage relief valve 14 according to the fol lowing procedure when the swing relief pressure is not normal 1 Disconnect pilot hose 15 2 Loosen the lock nut 17 with the holder 16 fixed 3 Tur...

Page 480: ...tem under the following conditions Hydraulic oil temperature 45 to 55 C Perform testing and adjusting of control circuit pressure for troubleshooting by referring to this section METHOD FOR TESTING OI...

Page 481: ...adjust the relief valve for the control circuit oil pressure REMARK Control circuit oil pressure can be tested with the nipple C at tached to the pressure pickup port PEPB PEPB EPC source pressure pi...

Page 482: ...following conditions Hydraulic oil temperature 45 to 55 C Before testing this item check that the oil pressure in the work equipment swing and travel circuits and control circuit oil pressure is norma...

Page 483: ...e the work equipment control lever and relieve the pressure in the arm IN circuit and measure the pump discharged pressure and PC valve outlet pressure servo piston inlet pressure at the same time See...

Page 484: ...ESSURE IN PUMP PC CONTROL CIRCUIT When the phenomena shown below occur and PC valves 7 and 8 seem to be defective adjust them accord ing to the following procedure As the working load increases the en...

Page 485: ...adjustment screw 10 is as described below Counterclockwise Within 1 turn Clockwise Within 1 turn 4 Tighten the lock nut 9 3 Lock nut 9 27 to 34 Nm 2 8 to 3 5 kgm After the adjustment see METHOD FOR TE...

Page 486: ...ressure in the piping and then loosen the oil filler cap of the hy draulic tank slowly to release the internal pressure k Provide an enough work space to run the track idle off the ground Test this it...

Page 487: ...e Sensor Monitoring code 04401 Hydraulic Oil Temperature 8 Adjust the hydraulic oil temperature so that it is within the specified range 9 Raise the L H track shoe off the ground by operating the work...

Page 488: ...rt from where the oil pressure pickup plugs PFC PRC PLSFC and PLSRC are re moved 5 Connect the differential pressure gauge E or gauge A1 of hydraulic tester A to the nipple C When using differential p...

Page 489: ...the testing tools and restore the machine after the test is finished METHOD FOR TESTING LS VALVE OUTLET PRESSURE SERVO PISTON INLET PRESSURE NOTICE To measure the LS valve outlet pressure servo pisto...

Page 490: ...in the specified range 9 Raise the L H track shoe off the ground by operating the work equipment control lever When measuring the front circuit L H track When measuring the rear circuit R H track 10 S...

Page 491: ...values Remove the testing tools and restore the machine after the test is finished METHOD FOR ADJUSTING LS VALVE If the LS differential pressure is not normal adjust the LS valves 8 and 9 according t...

Page 492: ...section METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 1 Release the remaining pressure by referring to RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 2 Remove the upper cover of the control v...

Page 493: ...sole noid valve Overheat 1st setting is ON OFF de ener gized When overheat 2nd setting is applied All signals of work equipment swing and travel are OFF Swing lock switch ON ON ener gized When travel...

Page 494: ...tion solenoid valve operation table Operating condition of solenoid valve Operating state of sole noid valve When travel steering signal is conducted ON ener gized When travel steering signal is not c...

Page 495: ...perating condition of solenoid valve Operating state of sole noid valve PPC lock lever LOCK position Lock OFF de ener gized UNLOCK position Canceled ON ener gized 30 TESTING AND ADJUSTING TEST OUTLET...

Page 496: ...ETTING AND OPERATION OF MACHINE MONITOR Monitoring code 07400 Boom Raise PPC Pressure Monitoring code 07500 Boom Lower PPC Pressure Monitoring code 07200 Arm IN PPC Pressure Monitoring code 07600 Arm...

Page 497: ...ht travel REVERSE 12 P12 Arm OUT 8 P08 Arm IN 4 P04 5 Install the joint C install the nipple A2 of the hydraulic test er A and then connect them to gauge A1 REMARK Gauge in the digital hydraulic teste...

Page 498: ...lever and pedal of the circuit to be checked are operated to stroke end See STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE for standard values Remove the testing tools and restore the machine...

Page 499: ...VES 1 Remove the boot 1 2 Loosen the locknut 2 and tighten it until disc 3 touches the heads of pistons 4 4 pieces REMARK Do not move the piston when tightening 3 Fix the position of disc 3 and tighte...

Page 500: ...k equipment to perform troubleshooting refer to this section METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 1 Set the work equipment in the same posture as w...

Page 501: ...n case there is a difference of hydraulic drift between LOCK and FREE positions the PPC valve is defective internal defect REMARK Operate the control lever when the starting switch is turned to ON pos...

Page 502: ...G PRESSURE FROM HYDRAULIC SYSTEM REMARK Operate the lever only with the boom RAISE direction to release the remaining pressure 3 Disconnect the hose 1 on the cylinder head side and block the hose side...

Page 503: ...re from the piping on the bucket cylinder head side by referring to RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM REMARK Operate the lever only with the bucket CURL direction to release the remaini...

Page 504: ...ne 3 Disconnect the drain hose 5 of the travel motor and block the hose side by using a plug C 4 Start the engine 5 Select and display Pre defined Monitoring 01 11 by re ferring to SET AND OPERATE MAC...

Page 505: ...immediately after the engine is stopped It may cause burn injury Wait for the temperature to go down and then start the work For releasing the air from hydraulic systems to perform troubleshooting re...

Page 506: ...iping x x Replacement and repair of the control valve Removal of the control valve piping x x x Replacement and repair of the cylinder Removal of the cylinder piping x x x Replacement and repair of th...

Page 507: ...trol dial at MAX High idle position for 3 seconds or more with the starting switch in ON position and automatic warm up function will be canceled Method for bleeding air from cylinder REMARK Perform t...

Page 508: ...tighten the hose 4 4 Swing slowly right and left twice or more Method for bleeding air from travel motor 1 Remove the travel motor cover 2 Start the engine and run it with the fuel control dial at MIN...

Page 509: ...rk equipment to the ground and stop the engine 2 Check the oil level by sight gauge 6 at the rear of the hy draulic tank When the oil level is between the lines H and L it is correct When the oil leve...

Page 510: ...he tightening torque of mounting bolt 2 of lock plate 1 3 Bolt 2 98 to 123 Nm 10 to 12 5 kgm Note that the tightening torque for mounting bolt 4 of cab tip ping stopper 3 is different from that of a c...

Page 511: ...or Mirror C Machine R H side mirror Mirror D Mirror on counterweight PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR A k To prevent the machine from moving during the work make sure that the followi...

Page 512: ...T MIRROR A k To prevent the machine from moving during the work make sure that the following conditions are met before starting the work k The machine is placed on a firm level ground k The work equip...

Page 513: ...ure to tighten bolts to the specified torque Adjust the mirror so that the side of the machine is reflect ed in it as shown in the figure PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR B k The fol...

Page 514: ...djustment method see PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR B PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR B k The following conditions must b...

Page 515: ...s KOMATSU logo is at the right side of the machine body NOTICE Tighten the right and left bolts of each bracket al ternately so that their right and left clearances R and L become equal If the mirror...

Page 516: ...engine is stopped Adjust it so that people on the ground within 1 m around the machine can be seen from the operator s seat W 1 m The regular position of the mirror is as follows Adjust the mirror 1...

Page 517: ...ting the mirror Put proper stepladder or step on the level and firm ground and adjust the camera in secure posture If you try to work standing on the counterweight there is a danger of serious injury...

Page 518: ...ELECTRICAL SYSTEM SET AND OPERATE MACHINE MONITOR SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING 30 112 PC500LC 10R...

Page 519: ...itch 8 Numeral 8 input switch Air conditioner switch 9 Numeral 9 input switch Air conditioner switch 0 Numeral 0 input switch Air conditioner switch Each switch has the function indicated by the icon...

Page 520: ...EN DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN CHECKING FUNCTION BY LCD LIQUID CRYSTAL DISPLAY CHECKING FUNCTION OF SERVICE METER METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENA...

Page 521: ...HOD FOR CONFIRMING KOMTRAX SETTINGS GPS AND COMMUNICATION STATUS METHOD FOR CONFIRMING KOMTRAX SETTINGS MODEM STATUS METHOD FOR DISPLAYING SERVICE MESSAGE OPERATOR MODE The following are items which n...

Page 522: ...n the customer side When turning the starting switch to ON position input ID press F6 or F1 and the screen changes to check before starting screen without switch operation Confirm that it is not neces...

Page 523: ...set for an user limitation setting of the machine monitor Password input screen appears when resetting the maintenance items once the password is set For the operation method of Operator ID Change see...

Page 524: ...ownward F4 Moves the selection upward F5 Selection is canceled The screen to the previous screen F6 Enters the selected item 4 Select a setting on Usage Limitation ON OFF screen with the function swit...

Page 525: ...ch F5 The inputted number is deleted The screen returns to the standard screen F6 Enters inputted password REMARK If the password is different from the previous one the mon itor displays a message pro...

Page 526: ...er the selected item with F6 Items with 2 digit codes are the menus displayed on Service Menu screen The items on the right are the menus on the next hierarchy The following are the items selectable o...

Page 527: ...TOP BY AIS 09 Adjustment Pump Absorption Torque F METHOD FOR ADJUSTING Pump Absorption Torque F Pump Absorption Torque R METHOD FOR ADJUSTING Pump Absorption Torque R Travel Low Speed METHOD FOR ADJUS...

Page 528: ...art is hatched F5 The screen returns to the Service Menu screen REMARK The items not displayed in Pre defined Monitoring can be selected and checked in Self define Monitor ing items When the working m...

Page 529: ...define Monitoring items screen display Unit Applicable component SI Metric Imperial 1 01002 Engine Speed r min rpm rpm ENG 2 01100 Front Pump Pressure MPa kg cm2 psi PUMP 3 01101 Rear Pump Pressure MP...

Page 530: ...pm rpm ENG 2 07400 Boom Raise PPC Pressure MPa kg cm2 psi PUMP 3 07500 Boom Lower PPC Pressure MPa kg cm2 psi PUMP 4 07200 Arm IN PPC Pressure MPa kg cm2 psi PUMP 5 07600 Arm OUT PPC Pressure MPa kg c...

Page 531: ...MATION The machine monitor monitors the condition of the machine in real time using signals from various switches sensors actuators which are installed on various parts of the machine and the informat...

Page 532: ...down Approximately 2 seconds Execution with the numeral input switches Input 99999 and press F6 If monitoring items are selected up to the limit number monitoring is executed automatically REMARK Whe...

Page 533: ...eleted by us ing function switches F1 Saves the monitoring item F2 Clears the monitoring item When a monitoring item is saved a confirmation screen appears asking whether the saved item should be disp...

Page 534: ...V V ENG 36501 Charge Pressure Sensor Voltage V V V ENG 36401 Rail Pressure Sensor Voltage V V V ENG 18101 EGR Valve Position Sensor Volt V V V ENG Only PC500LC 10 M0 17500 Engine Power Mode Selection...

Page 535: ...ront Solenoid Current mA mA mA PUMP 01302 PC EPC Rear Solenoid Current mA mA mA PUMP 01500 LS EPC Solenoid Current mA mA mA PUMP 10018 Fan Clutch Solenoid PWM Command PUMP 08000 Merge divider Main Sol...

Page 536: ...N OFF PUMP Travel Speed ON OFF ON OFF ON OFF PUMP 02301 Solenoid Valve 2 Swing Pressure Cut Off ON OFF ON OFF ON OFF PUMP Service Return ON OFF ON OFF ON OFF PUMP Variable Back Pressure ON OFF ON OFF...

Page 537: ...0 Battery Charge Voltage V V V MON 04200 Fuel Level Sensor Voltage V V V MON 05600 Water in Fuel Sensor Voltage V V V MON 05601 WIF Caution Detecting Base Volt V V V MON 05602 WIF Caution Detect Count...

Page 538: ...F ON OFF MON SW 10 ON OFF ON OFF ON OFF MON SW 11 ON OFF ON OFF ON OFF MON SW 12 ON OFF ON OFF ON OFF MON 04506 Monitor 5th Row SW SW 13 ON OFF ON OFF ON OFF MON SW 14 ON OFF ON OFF ON OFF MON SW 15 O...

Page 539: ...ormality To check the mechanical system abnormality record perform the following procedures For the failure code list see Failure code list for troubleshooting 1 Select Abnormality Record on Service M...

Page 540: ...g or correction of it is not confirmed For all of the failure codes that the machine monitor can record see Troubleshooting Failure code list If the characters in the failure are many the character st...

Page 541: ...s of failure is scrolled to left again REMARK If no abnormality is recorded No Abnormality Record is displayed The screen shows 20 cases of the electrical systems abnormality which currently stored in...

Page 542: ...a selected abnormality record select the abnormality record with F3 or F4 and then press F6 to execute the deletion of abnormality record To clear all abnormality records together press F2 and then a...

Page 543: ...eletion of a selected abnormality record is completed This is the screen displayed when the deletion of all abnormality records is completed METHOD FOR CONFIRMING MAINTENANCE RECORD The machine monito...

Page 544: ...which can be selected on the maintenance re cord screen Cod e Item 49 Air Cleaner Cleaning or Change 68 Additional Hyd Oil Filter Change 30 Hyd Oil Pilot Filter Change 76 Additional Fuel Filter Change...

Page 545: ...set ting with the function switches or numeral input switches F1 The screen proceeds to the next screen F2 The screen returns to the previous screen F3 Moves the selection downward F4 Moves the select...

Page 546: ...erval 99 All Default Value 3 Select Maintenance Mode Change Perform setting with the function switches on the appeared screen To use Functions of all maintenance items are enabled in operator mode Not...

Page 547: ...of the maintenance items When the individual maintenance item screen is displayed select On or Off Setting F3 Moves the selection downward F4 Moves the selection upward F5 Selection is canceled The s...

Page 548: ...otice time set on the machine monitor Recommended by the manufacturer and not changeable Set value Maintenance notice time that is arbitrarily set Maintenance reminder function works according to this...

Page 549: ...was successful if Maintenance Mode Setting screen is displayed METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING The telephone number can be displayed together with Current Abnormality in the operator...

Page 550: ...n the operator mode when F6 is pressed without inputting any digit since there is no information of telephone number for it DEFAULT MENU METHOD FOR SETTING DEFAULT KEY ON MODE Default setting menu is...

Page 551: ...tch is turned to ON position REMARK Default value at shipment is in Mode at Previous Key off If With Attachment is not selected Attachment P Mode and Attachment E Mode are unavailable If you change th...

Page 552: ...2 On the Default screen select With Without Attachment with function switches or numeral input switches REMARK See METHOD FOR OPERATING SERVICE MODE in SERVICE MODE for selecting method 3 Select a se...

Page 553: ...stalled or removed 1 Select Default on Service Menu screen REMARK See METHOD FOR OPERATING SERVICE MODE in SERVICE MODE for selecting method 2 Select Camera with the function switches or numeral in pu...

Page 554: ...en F6 Enters the selected item in each line Not Use Camera is not used Use Images from connected camera are displayed as a normal image mirror images if it is used for rearview monitor Reverse images...

Page 555: ...e camera is connected the graphic mark of camera is not displayed at F3 in the operator mode According ly the image of the camera cannot be used When the camera is installed check that the right and l...

Page 556: ...Setting in the operator mode is disabled METHOD FOR SETTING WITH DEFAULT SETTING MENU WITH WITHOUT Eco mode Easy Setting Default setting menu is used to check or change default values of the machine m...

Page 557: ...values of the machine monitor and the machine For setting With Without of WIF sensor refer to this section 1 Select Default on Service Menu screen REMARK See METHOD FOR OPERATING SERVICE MODE in SERVI...

Page 558: ...used to identify a cylinder that does not output power normally combus tion in it is abnormal 1 Select Diagnostic Tests on Service Menu screen REMARK For selecting method see METHOD FOR OPERATING SER...

Page 559: ...machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cyl inder the background a of the cylinder number becomes red 5 Each time F4 is pressed during the cylind...

Page 560: ...n with the function switch F5 Returns to the Diagnostic Tests screen F6 Executes resetting REMARK Rest the number of abrupt stop after the turbocharger is replaced ADJUSTMENT MENU METHOD FOR ADJUSTING...

Page 561: ...een returns to Adjustment screen REMARK The 3 digit number in the left column does not change This is the code for this function Relation between the set value and torque adjustment value Code Set val...

Page 562: ...alue and torque ad justment value F3 Decreases the set value F4 Increases the set value F6 The setting is confirmed and entered The screen re turns to Adjustment screen REMARK The 3 digit number in th...

Page 563: ...lue decreases F4 Set value increases F6 The setting is checked and entered The screen re turns to Adjustment screen REMARK The 3 digit number in the left column does not change This is the code for th...

Page 564: ...value increases F6 Setting is confirmed or entered The screen returns to Adjustment screen REMARK The 3 digit number in the left column does not change This is the code for this function Relationship...

Page 565: ...speed Code Set value Mode speed 055 000 Normal control 001 100 1815rpm 002 70 1271rpm When either 001 or 002 is selected as set value selected fan speed mode cannot be changed until Fan Speed Mode Se...

Page 566: ...flow of Pump Calibration Matching Speed Check is shown in the figure In adjustment menu of Service Menu Before starting calibration set the machine under the following condition Perform warm up opera...

Page 567: ...is required to check abnormality or cur rent condition of the machine Selecting method is the same as on Service Menu screen The alphabet letter at the right top of the screen indicates the following...

Page 568: ...control dial MAX Swing lock switch ON Air conditioner OFF k The work equipment must be operated when checking Secure sufficient area around the ma chine k When operating the work equipment ensure the...

Page 569: ...arts the matching speed check F5 Returns to arm IN relief screen 9 Wait under the following conditions Hydraulic oil temperature 45 to 55 C Working mode P Power Mode Fuel control dial MAX Swing lock s...

Page 570: ...ition Check that the fuel control dial is in MAX posi tion E 1 When the oil pressure in arm IN circuit is re lieved arm IN PPC pressure is below specified value or arm IN PPC pressure sensor is within...

Page 571: ...check the matching speed for arm IN relief and bucket CURL relief and to set the matching speed of the engine correctly when the pump or pump controller is replaced 1 Select Adjustment on Service Men...

Page 572: ...EFAULT SETTING Use the adjustment menu to check the various settings of the machine or to adjust the value The Pump Calibration function is used to check the matching speed for arm IN relief and bucke...

Page 573: ...ted after long storage of the machine it may be worn or damaged because of insufficient lubrication with oil To prevent this the machine has a function to crank the engine without injecting fuel to lu...

Page 574: ...ervice Menu F6 Executes 3 If no injection cranking no fuel injection on every cylinder is enabled No injection cranking is possible Please turn the key off after no injection ends is displayed on the...

Page 575: ...Communication Inspection State of radio sta tion establishment GMT time Greenwich Mean Time add 9 hours to it for Ja pan time F5 Returns the screen to KOMTRAX Settings screen METHOD FOR CONFIRMING KO...

Page 576: ...ansmitted F5 Returns the screen to KOMTRAX Settings screen METHOD FOR CONFIRMING KOMTRAX SETTINGS MODEM STATUS The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Se...

Page 577: ...nts are displayed If there is no message No message is displayed F5 Returns the screen to Service Menu screen REMARK This message is different from that sent to the op erator with the machine monitor...

Page 578: ...ent to the operator in the operator mode Since this message is special for the technician the message monitor is not displayed as it is dis played in the operator mode SET AND OPERATE MACHINE MONITOR...

Page 579: ...KOMTRAX support center via KOMTRAX administrator in the subsidiary For details see Global KOMTRAX Web Reference Manual For Key Person Operating the KOMTRAX client PC requires the KOMTRAX key person au...

Page 580: ...m step 2 If Already Open is displayed KOMTRAX Communication Inspection is not needed 2 KOMTRAX Communication Inspection Observe the following when performing KOMTRAX Com munication Inspection 1 On Ser...

Page 581: ...smits data correctly Inspection State When all items of Modem GPS and Transmission are OK OK is displayed on Inspection State It takes 90 seconds to 15 minutes for all items to be OK While waiting for...

Page 582: ...b GPS antenna cable is not connected to the machine monitor or they are loose Check for the connection If the connection is loose secure it Modem does not become OK The mobile phone is out of communic...

Page 583: ...30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL PC500LC 10R 30 177...

Page 584: ...If you try to work standing on the counterweight there is a danger of serious injury or death due to falling off from the machine Adjust the angle of the rearview camera so that people within approxim...

Page 585: ...When re moving the cover 1 record the places and quantities of the shims When installing the cover insert the shims according to the record Take care of shim 6 since it comes off together with cover 1...

Page 586: ...Tightening torque 11 8 to 14 7 Nm 1 2 to 1 5 kgm 8 68 to 10 8 lbft REMARK A part of the machine is shown on the monitor screen ADJUST REARVIEW CAMERA ANGLE 30 TESTING AND ADJUSTING 30 180 PC500LC 10R...

Page 587: ...gine must be performed only when the starting switch and battery disconnect switch are in OFF position Even when you perform troubleshooting do not start the engine while a T adapter is inserted into...

Page 588: ...witch to OFF position If the battery disconnect switch is turned to OFF position the battery power supply circuit is shut off while the system operating lamp is lit a controller data loss error may oc...

Page 589: ...ective Indicated value changes Continuity normal In the case of a silicon diode a value in the range between 460 to 600 mV is indicated METHOD FOR TESTING DIODE USING ANALOG TESTER 1 Selects the scree...

Page 590: ...mm Operating condition Quarry Mining Construction Type of soil Coal Gold Limestone Construction civil engineering Road Tunnel Rock Gravel Sand Clay Check of oil and coolant levels Radiator coolant En...

Page 591: ...me h Last h B HANS Times First time h Last h Times First time h Last h CA234 Times First time h Last h Times First time h Last h DKR2NX Times First time h Last h Times First time h Last h F BBZL Times...

Page 592: ...rpm 1720 to 1820 Engine speed at low idle 1 Engine coolant temperature 60 to 100 C Hydraulic oil temperature 45 to 55 C Fuel control dial MIN Low idle position Working mode P Power Mode All control le...

Page 593: ...rpm 1620 to 1820 1620 to 1820 Engine speed when auto decel eration is actuated 1 Engine coolant temperature 60 to 100 C Hydraulic oil temperature 45 to 55 C Fuel control dial MAX High idle position Wo...

Page 594: ...5W40 EO10W30 DH EO15W40 DH MPa kg cm2 0 08 or more 0 8 or more 0 05 or more 0 5 or more Blowby pressure Engine coolant temperature 60 to 100 C Hydraulic oil temperature 45 to 55 C Fuel control dial MA...

Page 595: ...ture Fully extended boom See the STANDARD VALUE TABLE MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM ANCE Work equipment 2 sec 3 8 to 4 6 5 0 or less Arm IN Hydraulic oil temperature 45 to 55 C F...

Page 596: ...STANDARD VALUE TABLE MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM ANCE Work equipment 3 sec 3 3 to 4 1 4 4 or less Bucket CURL Hydraulic oil temperature 45 to 55 C Fuel control dial MAX High i...

Page 597: ...55 C Fuel control dial MAX High idle position Working mode P Power Mode Measurement range Time required to complete 5 swings after 1 swing Measurement posture See Standard value table Lift truck post...

Page 598: ...e Time required to com plete 5 idle turns get ting the track off the ground after 1 idle turn Measurement posture See Standard value table Lift truck pos ture and measurement posture for measuring per...

Page 599: ...1 slope or rated load 2 5 m3 3960 kg All control levers and control pedals in NEUTRAL position Measurement posture Hori zontal boom top face fully re tracted arm and fully extended bucket cylinder on...

Page 600: ...Auto deceleration switch OFF All control levers and control pedals in NEUTRAL position MPa kg cm2 3 2 to 5 2 32 to 52 3 2 to 5 2 32 to 52 Work equip ment arm relief pres sure 1 Hydraulic oil temperat...

Page 601: ...a kg cm2 27 94 to 31 37 285 to 320 27 4 to 31 9 280 to 325 Travel relief pressure 1 Hydraulic oil tem perature 45 to 55 C Fuel control dial MAX High idle position Working mode P Power Mode Travel spee...

Page 602: ...ion Working mode P Power Mode Swing lock switch ON Work equipment Relieve the oil pressure in arm IN circuit Front pump discharged pressure MPa kg cm2 36 12 to 38 77 368 to 395 35 6 to 39 2 363 to 400...

Page 603: ...g cm2 Approx 2 09 Approx 21 3 Reference value Approx 2 09 Approx 21 3 Reference value Fuel control dial MAX High idle position Approx 0 98 Approx 10 Reference value Approx 0 98 Approx 10 Reference val...

Page 604: ......

Page 605: ...60 MAINTENANCE STANDARD PC500LC 10R 60 1...

Page 606: ...ULIC SYSTEM 60 31 MAINTENANCE STANDARD OF MAIN PUMP 60 31 MAINTENANCE STANDARD OF SWING MOTOR 60 33 MAINTENANCE STANDARD OF TRAVEL MOTOR 60 36 MAINTENANCE STANDARD OF CONTROL VALVE 60 39 MAINTENANCE S...

Page 607: ...ontrol Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retarde...

Page 608: ...o that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from eac...

Page 609: ...r KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of th...

Page 610: ...ump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump...

Page 611: ...a of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low f...

Page 612: ...out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 60 MAINTE...

Page 613: ...INE MOUNT No Item Judgment criteria Remedy 1 Tightening torque of the bolt 824 to 1030 Nm 84 to 105 kgm Re tighten 2 Tightening torque of the bolt 245 to 309 Nm 25 to 31 5 kgm 60 MAINTENANCE STANDARD...

Page 614: ...htening torque of the clamp 10 8 to 11 8 Nm 1 1 to 1 2 kgm Re tighten 2 Tightening torque of the nut 10 8 to 26 5 Nm 1 1 to 2 7 kgm 3 Tightening torque of the clamp 10 8 to 11 8 Nm 1 1 to 1 2 kgm MAIN...

Page 615: ...ne with tube Unit mm No Item Judgment criteria Remedy 1 Axial clearance of the bear ing when installed on machine Standard clearance Allowable clearance Replace 0 5 to 1 6 3 2 60 MAINTENANCE STANDARD...

Page 616: ...ent criteria Remedy 1 Axial clearance of the bear ing when installed on machine Standard clearance Allowable clearance Replace 0 5 to 1 6 3 2 MAINTENANCE STANDARD OF SWING CIRCLE 60 MAINTENANCE STANDA...

Page 617: ...MAINTENANCE STANDARD OF SWING MACHINERY 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MACHINERY PC500LC 10R 60 13...

Page 618: ...motor shaft and No 1 sun gear 0 18 to 0 28 6 Backlash between No 1 plane tary carrier and No 2 sun gear 0 40 to 0 72 1 40 7 Clearance between plate and No 2 sun gear 2 6 0 71 8 Clearance between plat...

Page 619: ...MAINTENANCE STANDARD OF FINAL DRIVE 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF FINAL DRIVE PC500LC 10R 60 15...

Page 620: ...n gear 0 15 to 0 51 1 00 4 Backlash between No 1 planetary gear and ring gear 0 17 to 0 62 1 20 5 Backlash between No 1 planetary gear and No 1 sun gear shaft 0 13 to 0 46 0 90 6 Backlash between No 1...

Page 621: ...imensions Repair limit Repairing by build up welding or replacing 355 343 2 Thickness of tooth bottom 21 8 15 8 3 Width of tooth 90 84 4 Wear of tooth profile Repair limit 6 Use Full scale drawing of...

Page 622: ...ALE DRAWING REMARK Make the dimensions of the figure to the full scale and duplicate the figure onto an OHP sheet and fit it to sprocket to judge MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL SC...

Page 623: ...60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL SCALE DRAWING PC500LC 10R 60 19...

Page 624: ...sions Tolerance Repair limit Repairing by build up weld ing or replacing Vertical width of idler guard Track frame 159 3 1 163 Idler support 156 0 5 155 2 Lateral width of idler guide portion Track f...

Page 625: ...coil spring Standard dimensions Replace Free height x out side diameter Installed height Load at installed height 845 3 x 262 690 239 0 kN 24375 kg 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAC...

Page 626: ...MAINTENANCE STANDARD OF IDLER MAINTENANCE STANDARD OF IDLER 60 MAINTENANCE STANDARD 60 22 PC500LC 10R...

Page 627: ...ween bushing and support total of both clearances at outside and inside 0 46 to 0 86 8 Clearance between the shaft and bushing Standard dimen sions Tolerance Standard clearance Allowable clearance Rep...

Page 628: ...uild up welding or re place 250 2 Outside diameter of tread 210 198 3 Thickness of tread 59 2 53 2 4 Overall width 291 2 5 Width of tread 58 2 6 Width of flange 37 4 7 Clearance between bushing and co...

Page 629: ...learance Replace bushing Shaft Hole 84 0 250 0 350 0 174 0 029 0 279 to 0 524 9 Interference between roller and bushing Standard dimension Tolerance Standard in terference Allowable interfer ence Shaf...

Page 630: ...ween shaft and bushing Standard dimension Tolerance Standard clearance Allowable clearance Shaft Hole 57 0 250 0 280 0 100 0 036 0 214 to 0 380 7 Interference between roller and bushing Standard dimen...

Page 631: ...Unit mm No Item Judgment criteria Remedy 1 Link pitch Standard dimensions Repair limit Turn 180 deg or replace 228 9 231 9 2 Outside diameter of bushing Standard dimensions Repair limit 76 71 3 Thickn...

Page 632: ...sion of regular bushing 5 25 14 Overall length of pin 258 15 Overall length of bushing 167 9 16 Thickness of spacer 17 Press fitting force Bushing 127 to 333 kN 13 to 34 t 18 Regular pin 198 to 510 kN...

Page 633: ...egular pin and bushing Standard dimen sions Tolerance Standard clear ance Shaft Hole 48 8 0 184 0 034 0 864 0 364 0 180 to 0 830 24 Interference between master pin and link Standard dimen sions Tolera...

Page 634: ...grouser Standard dimensions Repair limit Repair by build up welding or re place 37 22 2 Overall height of shoe 52 37 3 Thickness of plate 15 4 Length of grouser base 33 5 27 6 Length of grouser end 2...

Page 635: ...HYDRAULIC SYSTEM MAINTENANCE STANDARD OF MAIN PUMP 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF MAIN PUMP PC500LC 10R 60 31...

Page 636: ...MAINTENANCE STANDARD OF MAIN PUMP 60 MAINTENANCE STANDARD 60 32 PC500LC 10R...

Page 637: ...MAINTENANCE STANDARD OF SWING MOTOR 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MOTOR PC500LC 10R 60 33...

Page 638: ...MAINTENANCE STANDARD OF SWING MOTOR 60 MAINTENANCE STANDARD 60 34 PC500LC 10R...

Page 639: ...formed Free height x outside di ameter Installed height Load at in stalled height Free height Load at in stalled height 66 5 x 25 6 45 0 6 96 N 0 71 kg 5 59 N 0 57 kg 2 Shuttle valve spring 24 5 x 11...

Page 640: ...1 Tightening torque of bolt 490 to 608 Nm 50 to 62 kgm Re tighten 2 Tightening torque of LS relief valve 372 to 421 Nm 38 to 43 kgm 3 Tightening torque of the bleeder 27 4 to 35 3 Nm 2 8 to 3 6 kgm M...

Page 641: ...60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL MOTOR PC500LC 10R 60 37...

Page 642: ...f the plug 147 1 to 186 3 Nm 15 to 19 kgm 11 Tightening torque of the plug 373 to 466 Nm 38 to 47 5 kgm 12 Quick return spring Standard dimensions Repair limit Replace the spring if dam aged or de for...

Page 643: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE PC500LC 10R 60 39...

Page 644: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60 40 PC500LC 10R...

Page 645: ...Load at in stalled height 54 5 x 34 8 53 5 120 6 N 12 3 kg 96 4 N 9 8 kg 2 Spool return spring 54 6 x 34 8 53 5 139 3 N 14 2 kg 111 3 N 11 4 kg 3 Spool return spring 54 2 x 34 8 53 5 94 1 N 9 6 kg 75...

Page 646: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60 42 PC500LC 10R...

Page 647: ...m aged or de formed Free length x outside di ameter Installed height Load at in stalled height Free length Load at in stalled height 46 8 x 7 5 40 6 5 5 N 0 56 kg 4 4 N 0 45 kg 2 Check valve spring 11...

Page 648: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60 44 PC500LC 10R...

Page 649: ...ed height Free length Load at in stalled height 117 84 x 31 8 52 31 4 N 3 2 kg 25 1 N 2 56 kg 2 Check valve spring of hy draulic drift prevention valve 71 1 x 19 3 31 35 3 N 3 6 kg 28 2 N 2 88 kg 3 Ch...

Page 650: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60 46 PC500LC 10R...

Page 651: ...3 5 x 18 4 61 5 200 N 20 4 kg 200 N 20 4 kg 3 Spring of merge divider valve main 64 5 x 32 3 63 0 177 5 N 18 1 kg 142 N 14 5 kg 4 Check valve spring of hy draulic drift prevention valve 71 1 x 19 3 31...

Page 652: ...MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60 48 PC500LC 10R...

Page 653: ...am aged or de formed Free length x outside diameter Installed height Load at in stalled height Free length Load at in stalled height 71 1 x 19 3 31 35 3 N 3 6 kg 29 0 N 3 0 kg 2 Arm quick return valve...

Page 654: ...MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60 MAINTENANCE STANDARD 60 50 PC500LC 10R...

Page 655: ...60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE PC500LC 10R 60 51...

Page 656: ...stalled height Load at in stalled height Free height Load at in stalled height 42 5 x 15 5 34 0 17 7 N 1 80 kg 14 1 N 1 44 kg 2 Centering spring for P1 P2 port 44 5 x 15 5 34 0 29 4 N 3 0 kg 23 5 N 2...

Page 657: ...Item Judgment criteria Remedy 1 Tightening torque of bolt 27 to 34 Nm 2 8 to 3 5 kgm Re tighten 2 Tightening torque of bolt 0 441 to 0 588 Nm 0 045 to 0 06 kgm 60 MAINTENANCE STANDARD MAINTENANCE STA...

Page 658: ...MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60 MAINTENANCE STANDARD 60 54 PC500LC 10R...

Page 659: ...ht Load at in stalled height Free height Load at in stalled height 48 57 x 15 5 32 5 108 N 11 kg 86 3 N 8 8 kg 2 Metering spring 26 53 x 8 15 24 9 16 7 N 1 7 kg 13 3 N 1 36 kg 3 Tightening torque of b...

Page 660: ...INTENANCE STANDARD OF 1ST LINE ATTACHMENT PPC VALVE WITH EPC VALVE Machines with attachment MAINTENANCE STANDARD OF 1ST LINE ATTACHMENT PPC VALVE WITH EPC VALVE 60 MAINTENANCE STANDARD 60 56 PC500LC 1...

Page 661: ...alled height Load at in stalled height Free height Load at in stalled height 33 9 x 15 3 28 4 125 N 12 7 kg 100 N 10 2 kg 2 Metering spring 22 7 x 8 10 22 0 16 7 N 1 70 kg 13 3 N 1 36 kg 3 Tightening...

Page 662: ...ring spring Standard dimensions Repair limit Replace EPC valve assembly if damaged or deformed Free height x outside diameter Installed height Load at in stalled height Free height Load at in stalled...

Page 663: ...ghtening torque of the bolt 9 8 to 12 7 Nm 1 0 to 1 3 kgm Re tighten 3 Tightening torque of the fil ter 8 8 to 11 8 Nm 0 9 to 1 2 kgm 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF 1ST LINE ATTACHMEN...

Page 664: ...MAINTENANCE STANDARD OF SOLENOID VALVE REMARK The figure is for the machines ready for installation of attachment MAINTENANCE STANDARD OF SOLENOID VALVE 60 MAINTENANCE STANDARD 60 60 PC500LC 10R...

Page 665: ...limit Replace spring if damaged or deformed Free height x outside di ameter Installed height Load at in stalled height Free height Load at in stalled height 132 x 29 114 5 834 N 85 0 kg 667 N 68 0 kg...

Page 666: ...shaft Standard dimen sions Standard clear ance Allowable clear ance Replace 80 0 050 to 0 110 0 111 2 Tightening torque of the bolt 31 4 2 9 Nm 3 2 0 3 kgm Re tighten 3 Tightening torque of the plug 3...

Page 667: ...WORK EQUIPMENT MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE PC500LC 10R 60 63...

Page 668: ...MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD 60 64 PC500LC 10R...

Page 669: ...ld ing 5 Clearance between mount ing pin and bushing of arm and link 100 0 036 0 090 0 329 0 259 0 295 to 0 419 1 0 Replace the pin and bushing 6 Inside diameter of bushing insertion portion on arm si...

Page 670: ...0 hours L13 1 Adjust by combining shims whose thickness is 0 8 mm 1 and 1 5 mm 5 L13 2 R13 1 R13 2 14 The joint of boom and arm cylinder 126 1 2 129 3 1 5 0 2 1 to 6 0 Clearance is Max 1 0 mm 2 100 ho...

Page 671: ...e is Max 1 0 mm 2 50 hours L20 Adjust by combining shims whose thickness is 0 8 mm 1 and 1 5 mm 3 R20 21 The joint of arm and bucket 411 0 2 0 7 412 2 6 0 1 0 7 to 4 3 Adjust the clearance to be 0 5 t...

Page 672: ...s Tolerance Shaft Hole 1 110 0 036 0 090 0 1 0 2 Arm side 129 3 1 5 0 Cylinder head side 126 1 2 3 Boom side 395 0 5 0 Arm side 391 0 3 0 8 4 130 0 043 0 106 0 1 0 5 647 7 1 MAINTENANCE STANDARD OF WO...

Page 673: ...2 760 0 5 13 574 8 14 1804 15 100 0 036 0 090 0 1 0 16 Bucket side 412 1 0 Link side 411 0 5 17A 110 0 036 0 090 0 2 0 17B 110 0 036 0 090 0 144 0 074 18 Arm as a bare unit 395 0 0 5 With the bushing...

Page 674: ...DIMENSIONS OF BUCKET MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD 60 70 PC500LC 10R...

Page 675: ...574 8 5 1786 6 241 7 52 35 8A 150 0 1 0 8B 140 0 063 0 8C 100 0 1 0 9 412 1 0 10A 72 10B 77 11 149 12 613 5 0 5 2 5 13 26 14A 165 14B 165 15A 255 15B 240 16 150 17 158 18 147 5 19 108 20 450 2 0 21 69...

Page 676: ...shaft and bushing 120 0 036 0 071 0 457 0 370 0 406 to 0 528 1 0 Replace the pin and bushing 3 Clearance between the cylin der bottom support shaft and bushing 110 0 036 0 090 0 210 0 075 0 111 to 0 3...

Page 677: ...haft and bushing 110 0 036 0 090 0 457 0 370 0 406 to 0 547 1 0 Replace the pin and bushing 3 Clearance between the cylin der bottom support shaft and bushing 110 0 036 0 090 0 457 0 370 0 406 to 0 54...

Page 678: ...and bush ing 100 0 036 0 090 0 457 0 370 0 406 to 0 547 1 0 Replace the pin and bushing 3 Clearance between cylinder bottom support shaft and bushing 100 0 036 0 090 0 457 0 370 0 406 to 0 547 1 0 4...

Page 679: ...90 CIRCUIT DIAGRAMS PC500LC 10R 90 1...

Page 680: ...UIT DIAGRAM 5 7 90 35 ELECTRICAL CIRCUIT DIAGRAM 6 7 90 37 ELECTRICAL CIRCUIT DIAGRAM 7 7 90 39 CONNECTOR AND WIRING HARNESS CHART 1 15 90 41 CONNECTOR AND WIRING HARNESS CHART 2 15 90 43 CONNECTOR AN...

Page 681: ...Control Travel and brake This is a function that automatically operates the retarder with a constant braking force when let ting go of the accelerator pedal on the downhill HD HM ARSC Automatic Retar...

Page 682: ...so that it re duces combustion temperature and reduces emission of NOx EMMS Equipment Manage ment Monitoring System Machine monitor This is a function with which operator can check information from e...

Page 683: ...ler KDPF Komatsu Diesel Particu late Filter Engine This is a component that is used to purify the ex haust gas KDOC catalyst and KCSF filter to capture soot are built in it It is installed instead of...

Page 684: ...pump PPC Proportional Pressure Control Hydraulic system This is a system that operates actuators in pro portion to the oil pressure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pu...

Page 685: ...rea of the exhaust passage is variable VHPC Variable Horse Power Control Engine control This is a function that finely controls the maxi mum output of the machine so that high work effi ciency and low...

Page 686: ...ed out S T Steering STRG SIG Signal SOL Solenoid STD Standard OPT Option OP PRESS Pressure SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission ABBREVIATION LIST 90 CIRC...

Page 687: ...ain piping route Pilot and drain route Flexible piping such as hose Crossing of disconnected route Connected route Flow of fluid Throttle Variable Electric Spring Pickup port Pickup port and pressure...

Page 688: ...Hydraulic pump Reference in the figure shows outlet Variable displacement hydraulic pump Hydraulic motor Reference and in the figure show the direction of oil flow into hydraulic motor and as directio...

Page 689: ...pilot valve Lock valve Drain valve Pressure regulating valve safety valve relief valve Pressure regulating valve safety valve relief valve when the oil pressure is discharged to the low pressure side...

Page 690: ...Symbol Content Unit SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 CIRCUIT DIAGRAMS 90 12 PC500LC 10R...

Page 691: ...2 HYDRAULIC CIRCUIT DIAGRAM WHEN BOOM IS RAISED PC500LC 10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas PC500LC 10R 90 13...

Page 692: ......

Page 693: ...2 HYDRAULIC CIRCUIT DIAGRAM WHEN UPPER STRUCTURE IS SWING TO LEFT PC500LC 10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas PC500LC 10R 90 1...

Page 694: ......

Page 695: ...C CIRCUIT DIAGRAM WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG TO LEFT PC500LC 10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas PC500LC...

Page 696: ......

Page 697: ...HYDRAULIC CIRCUIT DIAGRAM 1 2 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 19...

Page 698: ......

Page 699: ...HYDRAULIC CIRCUIT DIAGRAM 2 2 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 21...

Page 700: ......

Page 701: ...d Combined wire Terminal Grounding by chassis ground Grounding by terminal Contact switch Push button switch N O type N O Normally Open Push button switch N C type N C Normally Closed Push button swit...

Page 702: ...tor Variable resistor Diode Light emitting diode LED Photo diode Low voltage diode Zener diode Transistor PNP type Transistor NPN type Electromagnetic coil Battery Fuse SYMBOLS USED IN ELECTRICAL CIRC...

Page 703: ...s the disconnected state Plug type connector left male right female REMARK Figure shows the connected state Solenoid Motor Lamp Pressure switch N O type N O Normally Open Pressure switch N C type N C...

Page 704: ...Symbol Content Buzzer Antenna SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90 26 PC500LC 10R...

Page 705: ...ELECTRICAL CIRCUIT DIAGRAM 1 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 27...

Page 706: ......

Page 707: ...ELECTRICAL CIRCUIT DIAGRAM 2 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 29...

Page 708: ......

Page 709: ...ELECTRICAL CIRCUIT DIAGRAM 3 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 31...

Page 710: ......

Page 711: ...ELECTRICAL CIRCUIT DIAGRAM 4 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 33...

Page 712: ......

Page 713: ...ELECTRICAL CIRCUIT DIAGRAM 5 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 35...

Page 714: ......

Page 715: ...ELECTRICAL CIRCUIT DIAGRAM 6 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 37...

Page 716: ......

Page 717: ...ELECTRICAL CIRCUIT DIAGRAM 7 7 PC500LC 10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas PC500LC 10R 90 39...

Page 718: ......

Page 719: ...1764 KA 2RL 1402 FP 1 25GR 1407 FS 2RY 1408 HL 3RB 3818 AC02 3 0 5RL 1016 JB 3RL 1414 JB 5RL 1415 JA 5RL 1411 3R 1220 FN R06 1 0 5GL 1757 H16 8 0 5GL 1518 CP01 79 0 5GL 1300 HX 0 85R 1327 J01 4 0 85R...

Page 720: ......

Page 721: ...2B 1451 M09 2 0 85B 1644 HP R48 5 0 85LgY 1781 CP01 41 0 5GY 1282 J06 1 0 85LgY 1582 D03 3 0 85LgY 1344 MY H16 7 0 85LgR 1517 S25 17 0 85LgR 1541 R48 3 0 85LgR 1780 CP01 78 0 5GR 1299 FH H16 4 0 85GY...

Page 722: ......

Page 723: ...GW 1235 R07 2 0 5BR 1236 J05 12 1 25RL 1237 J06 5 0 5G 1238 J01 16 0 5LW 1239 J02 19 0 5RW 1240 J02 13 0 5RY 1241 J01 7 0 5LR 1242 P21 1 0 85Y 1243 J01 20 0 5L 1244 PR MI GF CR GP GX EW GK GV PI PC MN...

Page 724: ......

Page 725: ...0 85P 1279 CJ 1 25BR 1733 1 3 DV 0 85B 1725 CP01 34 0 85LgY 1278 AV 0 85WB 1726 1 3 DU 0 85B 1727 CP01 15 0 85Lg 1268 AU 0 85WB 1728 TRAVEL LEFT FORWARD PRESSURE SENSOR CN P09 AMP TRAVEL LEFT REAR PRE...

Page 726: ......

Page 727: ...0 FM 0 5LR 1301 GRO 116 115 114 117 118 121 120 119 82 90 98 106 89 97 105 113 GRO GRO R48 1 0 85G 1310 V03 1 0 85BrR 1305 V07 1 0 85BrG 1306 GRO ET 0 85GY 2028 V24 1 0 85RL 1V24 GRO GRO GRO V04 1 0 8...

Page 728: ......

Page 729: ...1313 DE 0 85B 1652 E01 20R 1378 1 2 R04 3R 1428 PQ 3R 1429 7 BLACK TAPE 2 1 FQ 1 25GR 1626 PT 1 25RL 1627 7 7 HUSIBLE LINK CN F05 M F12 20R 1431 HEATER RELAY DRIVE CN R17 R17 20R 1431 SLOW BLOW FUSE C...

Page 730: ......

Page 731: ...1A85 GH 0 85B 2A85 CP02 111 0 85Y 3A85 GH 0 85B 4A85 CP01 17 0 85G 4001 CB 0 5B 4002 GRO C A B FK 0 85WB 3901 PI 0 85B BP67 CP01 74 0 85LB CP67 FROM 3 15 TO 8 15 FROM 6 15 AJ AH 0 85WB 1020 P04 3 0 8...

Page 732: ......

Page 733: ...1820 2 1 CP02 113 0 85RW 1316 DX 0 85B 1821 2 1 ATT RETURN CHANGE SOLENOID VALVE ATT CN V07 DT CP02 86 0 85BrG 1306 DX 0 85B 1819 2 1 CP02 89 0 85RL 1V24 GH 0 85B 2V24 2 1 CP02 112 0 85LR 1V23 GH 0 85...

Page 734: ......

Page 735: ...ZB 0 5W ZBNW CE02 46 0 85W 46CE02 K02 A 1 25W AK02 NX YB 0 5L YBNX CE02 47 0 85B 47CE02 K02 B 1 25L BK02 41 31 21 11 1 50 40 30 20 10 0 4 GRO GRO GRO GRO GRO GRO GRO GRO H15 15 0 85L 15H15 GRO GRO GRO...

Page 736: ......

Page 737: ...V11 S25 5 0 85B 2V11 2 1 ET 0 85GY 1V19 GF 0 85B 2V19 2 1 R10 5 2RL 1002 BB 2B 1003 GRO REAR WORKING LAMP OPT CN A15 DT 7 REAR BEACON CN L05A DT GRO BB BB V19 V12 V11 2 1 R42 4 0 85Y 1624 BB 0 85B 162...

Page 738: ......

Page 739: ...PE 15 15 15 15 WHITE TAPE GRO 2 1 NI 0 85L 1K12 NJ 0 85G 2K12 22 7 WASHER MOTOR CN M06 YAZAKI 2 1 J03 5 0 85GY 1559 J03 9 0 85WL 1561 FROM 8 15 PW BRAID 0V15A PH BRAID 0V15B FAN CLUCH CN V15 DT CA P24...

Page 740: ......

Page 741: ...3 0 5GL 1429 A 0 5LR 1431 B 0 5LW 1432 7 10 A B TO 12 15 FROM 2 15 3 1 2 3 1 0 3B M01A 1 2 0 3BW 0 3L M01A 2 CN M01B 0 3L M01B 2 0 3BW M01B 1 0 3B M01B 3 M01A 3 AUX AUX CONNECTOR CN M01A TO 12 15 M01C...

Page 742: ......

Page 743: ...0 18 17 67 68 78 79 36 38 37 04 03 02 01 HOUSING SUMITOMO HOUSING SUMITOMO HOUSING SUMITOMO HOUSING PACKARD HOUSING AMP HOUSING FRAMATOME HOUSING PACKARD HOUSING PACKARD HOUSING AMP HOUSING FRAMATOME...

Page 744: ......

Page 745: ...H15 16 0 5B 3P20 1 4 3 6 GRO GRO H15 10 0 5WR 1503 H15 11 0 5YL 1504 H15 12 0 5RW 1505 H15 13 0 5B 1506 D H15 8 0 5GR 1501 S02 4 0 85GR 1785 S02 3 0 5GR 1784 1 11 22 10 S05 5 0 85GL 1475 S05 6 0 5Y 1...

Page 746: ......

Page 747: ...X SERVICE PRESSURE SWITCH B B CN P13 X FLOOR HARNESS 2 1 B B A L B B A B 2 A CN P15 X SERVICE PRESSURE SWITCH 1 P13 1 P14 1 P15 1 L P13 2 B P14 2 B P15 2 B A B L L L FROM 4 15 OPT SERVICE PRESSURE SWI...

Page 748: ......

Page 749: ...return valve of control valve Operation 10 184 Arm regeneration circuit of control valve 10 160 Arm regeneration circuit of control valve Function 10 160 Arm regeneration circuit of control valve Ope...

Page 750: ...ss chart 2 15 90 43 Connector and wiring harness chart 3 15 90 45 Connector and wiring harness chart 4 15 90 47 Connector and wiring harness chart 5 15 90 49 Connector and wiring harness chart 6 15 90...

Page 751: ...30 26 Exhaust gas color Test by smoke meter 30 27 Exhaust gas temperature Test 30 24 F Fan belt Test 30 51 Fan clutch 10 39 Fan clutch Function 10 39 Fan clutch Specification 10 39 Fan clutch Structu...

Page 752: ...MTRAX terminal Start 30 173 KOMTRAX terminal Structure 10 58 L Left front mirror Adjust 30 105 Left front mirror A Adjust to the regular position 30 106 LS bypass plug 10 93 LS bypass plug Function 10...

Page 753: ...10 25 Overheat prevention system System diagram 10 24 P P Q diagram and PC valve Relation 10 89 Parking brake of travel motor Operation 10 259 PC valve Function 10 88 PC valve outlet pressure servo pi...

Page 754: ...alve 10 183 Suction safety valve for hydraulic drift prevention valve of control valve Operation 10 183 Surface area ratio of pressure compensation valve of control valve Function 10 149 Swing circle...

Page 755: ...agram 10 26 Type 1 push pull type coupler Disconnect Connect 00 40 Type 2 push pull type coupler Disconnect Connect 00 41 Type 3 push pull type coupler Disconnect Connect 00 42 U Undercarriage Layout...

Page 756: ...avel circuits Test Adjust oil pressure 30 63 Work equipment swing and travel circuits oil pres sure Test 30 64 Work equipment Travel Adjust relief pressure 30 71 Work range drawing PC500LC 10R 01 10 W...

Page 757: ......

Page 758: ...PC500LC 10R HYDRAULIC EXCAVATOR Form No SEN06722 00 2018 KOMATSU All Rights Reserved Printed in Japan 11 2018...

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