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SEN02632-02

40 Troubleshooting

PC300, 350-8

E-22 Monitoring function fails to display “bucket CURL” normally

Circuit diagram related to Bucket CURL PPC oil pressure switch

Trouble

• Bucket CURL is not displayed normally by machine monitoring function (Special functions).

Related infor-

mation

• Monitoring code:01901 (Output Switch 2)

Possible causes

and standard

value in normal

state

Cause

Standard value in normal state/Remarks on troubleshooting

Defective bucket CURL pres-
sure sensor (internal discon-
nection or short circuit)

Prepare with starting switch OFF, then start engine and carry
out troubleshooting.

P01

Bucket lever

Voltage

Between (3) – (1)

Neutral

4.5 – 5.5 V

Between (2) – (1)

CURL

0.5 – 4.5V

Disconnection in wiring har-
ness
(Disconnection in wiring or
defective contact in connec-
tor)

Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.

Wiring harness between CP01 (female) (73)
– P01 (female) (2)

Resis-

tance

Max. 1

Wiring harness between P01 (female) (1) –
chassis ground

Resis-

tance

Max. 1

Ground fault in wiring har-
ness
(Short circuit with GND cir-
cuit)

Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.

Wiring harness between CP01 (female) (73)
– P01 (female) (2) and chassis ground

Resis-

tance

Min. 1 M

Hot short (Short circuit with
24V circuit) in wiring harness

Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Wiring harness between CP01 (female) (73)
– P01 (female) (2) and chassis ground

Voltage

Max. 1 V

5 Defective pump controller

Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

CP01 Voltage

Between (9) – (18)

4.5 – 5.5V

Between (73) – (18)

0.5 – 4.5V

Содержание ecot3 PC300-8

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

Страница 2: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 120: ......

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

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

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

Страница 124: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 825: ...kg cm2 ON 2 84 3 43 MPa 29 35 kg cm2 2 Malfunction of main relief valve Main relief valve may have malfunction Check it directly Failure phe nomenon In a compound operation work equipment with larger...

Страница 826: ...bleshooting 1 Malfunction or defective seal of LS selector valve LS selector valve may have malfunction or defective seal Check it directly Failure phe nomenon In a compound operation of swing travel...

Страница 827: ...h engine stopped then run engine at high idle and carry out troubleshooting Measured oil pressure Oil pressure ratio All lever in neutral Travel with no load Lever operated halfway Pump discharge pres...

Страница 828: ...opped then run engine at high idle and carry out troubleshooting Travel speed Travel lever LS EPC output pres sure Lo Neutral Approx 1 4 MPa Approx 14 kg cm2 Hi Lifting operation 0 MPa 0 kg cm2 4 Malf...

Страница 829: ...kg cm2 Either side operated 2 84 3 43 MPa 29 35 kg cm2 5 Malfunction of merge divider valve Merge divider valve may have malfunction Check it directly 6 Malfunction of travel control valve spool Spoo...

Страница 830: ...Monitoring 15 Lo Fine control such as releasing decelerator 690 mA Mi 740 mA Hi 0 mA a Prepare with engine stopped then run engine at high idle and carry out troubleshooting Travel speed Travel lever...

Страница 831: ...have defective seal Check it directly 2 Defective seal of travel motor safety valve Safety valve of travel motor may have defective seal Check it directly 3 Defective seal of travel motor check valve...

Страница 832: ...section of swing motor may have malfunction Check it directly 3 Defective adjustment or mal function of swing motor safety valve a Prepare with engine stopped then run engine at high idle and carry o...

Страница 833: ...tral 0 MPa 0 kg cm2 Swing Min 2 7 MPa Min 28 kg cm2 2 Malfunction of swing control valve spool Spool of swing control valve may have malfunction Check it directly 3 Defective seal of swing motor sucti...

Страница 834: ...2 Malfunction of swing motor holding brake Holding brake section of swing motor may have malfunction Check it directly 3 Defective adjustment or mal function of swing motor safety valve a Prepare with...

Страница 835: ...of swing control valve spool Spool of swing control valve may have malfunction Check it directly 3 Malfunction of swing control valve pressure compensa tion valve Pressure compensation valve of swing...

Страница 836: ...infor mation Set the working mode in P mode before start Possiblecauses and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of swing PPC va...

Страница 837: ...and left side may be checked by replacing them with each other and seeing change of condi tion Trouble Large sound is made when upper structure stops swinging Related infor mation Set the working mode...

Страница 838: ...it directly Trouble 2 Hydraulic drift of swing is large when swing holding brake is released Related infor mation When swing emergency reset switch is turned ON in an emergency swing holding brake is...

Страница 839: ...40 Troubleshooting SEN02633 03 PC300 350 8 33...

Страница 841: ...does not pick up smoothly 10 S 4 Engine stops during operations 11 S 5 Engine does not rotate smoothly 12 S 6 Engine lacks output or lacks power 13 S 7 Exhaust smoke is black incomplete combustion 14...

Страница 842: ...SEN02634 02 40 Troubleshooting 2 PC300 350 8 S 16 Vibration is excessive 23...

Страница 843: ...pending on their level Check items Items to be simply checked by the serviceman to narrow down causes They corresponds to C in the chart on the right Causes Items to be narrowed from the questions and...

Страница 844: ...st smoke is black Let us assume that Clogged air cleaner is taken to be the cause of black exhaust gas 3 symptoms have causal relationship with this problem Color of exhaust gas gradually became black...

Страница 845: ...634 02 PC300 350 8 5 If we look from these 3 symptoms to find the causes we find that there is a relationship with 5 causes Let us explain here the method of using this causal relationship to pinpoint...

Страница 846: ...preheated or when temperature is low preheating monitor does not indicate normally if monitor is installed w During operation charge level monitor indicates abnormal charge if monitor is installed w...

Страница 847: ...Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes...

Страница 848: ...in w Q w w E Replacement of filters has not been carried out according to Operation and Mainte nance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank c...

Страница 849: ...installed w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed there is...

Страница 850: ...more frequently w Dust indicator is red if indicator is installed w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel pipi...

Страница 851: ...ped w Q Q Q Non specified fuel is being used Q Q Q Replacement of filters has not been carried out according to Operation and Mainte nance Manual w Fuel level monitor indicates low level if monitor is...

Страница 852: ...iod E Condition of hunting Occurs at a certain speed range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out ac...

Страница 853: ...quently Q Q Dust indicator is red if indicator is installed w w Air breather hole of fuel tank cap is clogged w w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of ope...

Страница 854: ...Q Q Dust indicator is red if indicator is installed w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode...

Страница 855: ...Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in inta...

Страница 856: ...r history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Engine oil must be added more frequently w Metal particles are found when oil filter is drained Q...

Страница 857: ...Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When...

Страница 858: ...air history Degree of use of machine Operated for long period E E Increase of oil level Suddenly occurred Q Q Gradually occurred Q Q Hard water is being used as coolant Q Q Oil level has risen oil is...

Страница 859: ...ing used Q Q Replacement of filters has not been carried out according to Operation and Maintenance Man ual w Oil pressure moni tor if installed Indicates pressure drop at low idle w Indicates pressur...

Страница 860: ...requently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check...

Страница 861: ...ms When fan belt is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light pass...

Страница 862: ...machine Operated for long period E Condition of abnor mal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles ar...

Страница 863: ...uestions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q...

Страница 865: ...8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly General information on disassembly and asse...

Страница 866: ...cedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q The common tools necessary for the removal work are indicated 1 2 and their part Nos part na...

Страница 867: ...ble from Komatsu in Japan i e must be made locally Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the oil and coola...

Страница 868: ...iner q Quick setting adhesive q Setting time Within 5 sec to 3 min q Used mainly to stick metals rubbers plas tics and woods Aron alpha 201 790 129 9130 2 g Polyethyl ene con tainer q Quick setting ad...

Страница 869: ...YGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various q Feature Lithium grease with extreme pres sure lubrication performance q General purpose type Molybdenum dis ulfide grease LM G G2 M SYG2 400M SY...

Страница 870: ...27250 20 ml Glass con tainer q Used as primer for sash Almite Using limit 4 months after date of manufacture Adhesive SUNSTAR PEN GUINE SEAL580 SUPER S or W 417 926 3910 320 ml Polyethyl ene con tain...

Страница 871: ...nlet con nector 2 795 799 6700 Puller t 1 Removal of fuel injector assembly 3 790 331 1110 Wrench q 1 Tightening of cylinder head bolt Engine and hydraulic pump assembly C 96 460 1210 Oil stopper q 1...

Страница 872: ...apter 2 Control valve assem bly M 1 796 946 1310 Guide t 1 Replacement of pressure compensation valve seal For 723 46 40100 723 46 40601 796 946 1810 Guide t 1 For 723 46 43100 723 46 43400 796 946 21...

Страница 873: ...rip 1 01010 50816 q Bolt 1 6 790 201 1500 Push tool kit t 1 Press fitting of dust seal 790 101 5021 q Grip 1 01010 50816 q Bolt 1 790 201 1660 q Plate for boom and bucket 1 790 201 1670 q Plate for ar...

Страница 874: ...assembly and assembly 10 PC300 350 8 SEN02635 02 Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches D2 push tool E1 push...

Страница 875: ...SEN02635 02 PC300 350 8 11 50 Disassembly and assembly Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches E5push tool M4 Push tool...

Страница 876: ...50 Disassembly and assembly 12 PC300 350 8 SEN02635 02 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches M5 Push tool M6 Push tool...

Страница 877: ...SEN02635 02 PC300 350 8 13 50 Disassembly and assembly...

Страница 879: ...cooling system Removal and installation of fuel supply pump assembly 2 Removal and installation of engine front seal 5 Removal and installation of engine rear seal 8 Removal and installation of cylin...

Страница 880: ...tor M34 8 6 Loosen air conditioner compressor belt 9 and remove it 2 7 Remove air conditioner compressor 10 and bracket together and move them to a place where they will not be obstacle to the work 8...

Страница 881: ...m 1 0 05 kgm 2 a Adjust the belt tension For details see Test ing and adjusting Testing and adjusting air conditioner compressor belt 3 k Don t correct high pressure tube by bend ing it for re use k A...

Страница 882: ...e Out q Supply pump outlet high pressure pipe supply pump side and common rail side Out 4 a Clean the inside of the hose connector and insert the connector securely 5 a Install the fuel supply pump as...

Страница 883: ...tion A before rotating it The spring of the tensioner assembly 2 is strong If the wrench is loosely inserted the wrench may accidentally come off while being rotated and it is extremely dangerous k Af...

Страница 884: ...t do not remove it from the front seal a Pilot tool 1 is in the spare front seal 1 Clean the seal inserting part of the crankshaft 2 Set front seal 10 to tool A2 with its lip up 3 Apply neutral deterg...

Страница 885: ...across flats T 12 7 mm of the tensioner assembly 4 and rotate it to the winding up direction a k Make sure that the wrench is secured at the portion A before rotating it The spring of the tensioner a...

Страница 886: ...damper assembly 1 1 3 Install the sling to flywheel 2 and lift off the fly wheel 4 Flywheel 40 kg 4 Disconnect connector CRANK 3 5 Temporarily sling engine assembly and remove engine rear side mount b...

Страница 887: ...the outside of aligning tool 1 touches the housing a Do not remove the pilot tool from the rear seal 2 Check the ends and seal inserting parts of the crankshaft for burrs and rust and clean them thor...

Страница 888: ...et sealant 1 3 mm in diameter to the housing mount ing flange face and around each mounting bolt hole 2 Tighten the mounting bolts in the order of the numbers shown in the figure 3 Mounting bolt 77 12...

Страница 889: ...mporarily tighten the mounting bolt with fingers remove guide bolt 101 installed in step 1 3 Using plate 103 fit the flywheel in fly wheel housing 4 Using torque wrench 102 tighten the mounting bolts...

Страница 890: ...phery a When measuring bring the crankshaft to the front or rear side so that an error will not be caused by the end play 2 Rotate the flywheel by 1 turn and measure the difference between the lowest...

Страница 891: ...or M34 8 7 Loosen air conditioner compressor belt 9 and remove it 2 8 Remove air conditioner compressor 10 and bracket together and move them to a place where they will not be obstacle to the work 9 D...

Страница 892: ...CLY3 and CYL4 25 and CYL5 and CYL6 26 16 Remove bracket 27 17 Remove high pressure pipes 28 33 6 18 Remove bracket 34 19 Disconnect drain tube 35 20 Remove common rail 36 5 a Never remove fuel pressur...

Страница 893: ...her 32 Remove heat insulation covers 55 56 and 57 33 Disconnect lubrication hoses 58 and lubrica tion tube 59 12 34 Sling the turbocharger and exhaust manifold assembly temporarily 35 Remove 12 mounti...

Страница 894: ...move crossheads 69 14 a Record the position of each crosshead and the positions of holes a and b for the valve 41 Remove the fuel injector assembly according to the following procedure 15 1 Clean the...

Страница 895: ...lder 75 6 Using tool B2 remove fuel injector assem bly 76 a Do not pry up the injector top 42 Remove 12 push rods 77 17 43 Remove 7 mounting bolts 78 and rocker housing assembly 79 18 44 Remove 26 mou...

Страница 896: ...a new fuel pressure sensor 2 Threaded part of fuel pressure sensor Gear oil 90 3 Fuel pressure sensor 70 5 Nm 7 1 0 5 kgm 5 Connect the engine wiring harness At this time take care not to connect the...

Страница 897: ...ghten the mounting bolts of common rail 36 temporarily with the fingers 2 Tighten drain tube 35 temporarily 3 Install supply pump outlet high pressure pipe 18 3 Sleeve nut 37 3 4 Nm 3 8 0 4 kgm 4 Inst...

Страница 898: ...47 14 7 44 1 Nm 1 5 4 5 kgm 6 Fix the bracket 92 by tightening the bolt 93 94 7 Tighten clamp 46 with fitting nuts q The installation angle and position of the clamp 46 Rotate 90 in a clockwise direc...

Страница 899: ...installing the crosshead and rocker arm assembly observe the following precautions a Install the crosshead so that parts a and b on its back side will be at the positions checked when removed When ins...

Страница 900: ...or too a Check the inlet connector for the following items If it is defective replace it a If there are burrs or deformation at the inlet or outlet of the connector do not use the inlet connector b If...

Страница 901: ...gm 7 Tighten bolts 74 of holder 75 alter nately a The top of the holder must be in par allel with the top of the cylinder head q Allowable angle 2 4 3 Bolt 9 8 2 0 Nm 1 0 0 2 kgm 8 Tighten inlet conne...

Страница 902: ...3 kgm 17 a Check that the push rod end is in the tappet 2 Push rod Engine oil EO15W 40 18 a Tighten the rocker housing mounting bolts in the order of the numbers shown in the figure 3 Mounting bolt 24...

Страница 903: ...ach bolt Engine oil EO15W 40 5 Tighten the bolts in the order of the num bers shown in the figure 1st time 150 9 8 Nm 15 3 1 0 kgm 2nd time Return all bolts 360 3rd time 115 4 9 Nm 11 7 0 5 kgm 4th ti...

Страница 904: ...e lowers and then drain the coolant 1 Open the engine hood and sling the radiator temporarily 2 Pull out pin 1 3 Remove bolt 2 4 Set hole 3 to the position of bolt 2 to fix the engine hood 5 Remove th...

Страница 905: ...e reverse order to removal 1 a Apply ThreeBond 4324 or equivalent to the adapters of hoses 4 7 8 and 9 q Refilling with coolant Add coolant through the coolant filler to the specified level Run the en...

Страница 906: ...248 l 2 Remove the bottom cover of the hydraulic oil cooler 3 Open the cover at the front of the hydraulic oil cooler 4 Open the engine hood and sling the hydraulic oil cooler temporarily 5 Remove the...

Страница 907: ...ft off hydraulic oil cooler assembly 12 4 Hydraulic oil cooler assembly 50 kg Installation q Carry out installation in the reverse order to removal q Refilling with oil Add oil through the oil filler...

Страница 908: ...e battery 1 Open the front cover of the aftercooler 2 Disconnect connector M06 1 3 Disconnect hose 2 and remove reservoir tank 3 4 Disconnect hoses 4 and 5 1 5 Remove 4 mounting bolts 6 and aftercoole...

Страница 909: ...ing tool C remove the drain plug to drain oil from the hydraulic tank and piping 6 Hydraulic tank 248 l 2 Drain the engine coolant 6 Coolant 36 l 3 Open the engine hood 4 Remove clamps 1 and 2 U bolt...

Страница 910: ...21 14 Remove clamps 22 and 23 15 Disconnect ground wire 24 16 Remove clamp 25 4 17 Loosen clamp 26 and remove tube 27 and hose together 5 18 Disconnect heater hoses 28 and 29 19 Disconnect B terminal...

Страница 911: ...een the engine and hydraulic pump 24 Remove covers 37 40 25 Disconnect hoses 41 and 42 from the engine oil filter 26 Disconnect connectors V19 43 and V11 44 27 Disconnect hoses 45 52 28 Disconnect tub...

Страница 912: ...0 05 kgm 2 6 a Apply ThreeBond 4324 or equivalent to the adapter of the hose 3 a Adjust the belt tension For details see Test ing and adjusting Testing and adjusting air conditioner compressor belt 4...

Страница 913: ...50 Disassembly and assembly SEN02636 03 PC300 350 8 35...

Страница 915: ...60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly Power train Removal and installation of final drive assembly 2 Disassembly and assembly of final drive assembly 3 Removal and installati...

Страница 916: ...and then lift off final drive assembly 6 1 a Be careful so that the nipple sealing sur face on the hose mounting block may not be damaged a When lifting off the final drive assembly do not use a tappe...

Страница 917: ...se 2 Remove cover 1 using eyebolt 2 3 Spacer Remove spacer 2 4 No 1 carrier assembly 1 Remove No 1 carrier assembly 3 Symbol Part number Part name Necessity Q ty N R Sketch D 1 796 627 1610 Wrench ass...

Страница 918: ...No 1 sun gear shaft Remove No 1 sun gear shaft 11 6 No 2 sun gear shaft Remove No 2 sun gear shaft 12 7 Thrust washer Remove thrust washer 13 8 Ring gear Remove ring gear 14 using eyebolt 3 9 No 2 ca...

Страница 919: ...ckplate 23 2 Use tool D1 to remove nut 24 11 Hub assembly 1 Using eyebolts 4 remove hub assembly 25 from travel motor 2 Disassemble the hub assembly as follows 1 Remove floating seal 26 2 Remove beari...

Страница 920: ...g seal a After installing the floating seal check that the angle of the floating seal is within 1 mm a After installing the floating seal coat the sliding surface thinly with engine oil EO30 3 Using t...

Страница 921: ...en installing the lockplate avoid notch j of the travel motor and fit it to the spline totally under the condition of k 2 Thread of mounting bolt Adhesive LT 2 3 Mounting bolt 59 74 Nm 6 7 5 kgm a Do...

Страница 922: ...If there is a groove avoid placing the claws on that groove a After inserting the pin caulk the pin portion of the carrier a After assembling the carrier assembly check that gear 20 rotates smoothly 2...

Страница 923: ...m thrust washers 7 and 10 and then set the gear assembly on carrier 6 2 Align the position of pin holes on the shaft and carrier then tap with a plas tic hammer to install shaft 5 a Install the shaft...

Страница 924: ...is case check again 10 Cover 1 Using eyebolts 2 install cover 1 2 Cover mounting surface Gasket sealant LG 6 2 Tighten the mounting bolts according to the following procedure 3 Mounting bolt 1st step...

Страница 925: ...g brake port B 2 Disconnect arm cylinder hoses 6 3 Remove the mounting bolts 4 Tighten a forcing screw in position a shown in the following figure to separate the swing motor and swing machinery assem...

Страница 926: ...emove the 6 mounting bolts to remove swing motor assembly 1 3 No 1 sun gear Remove No 1 sun gear shaft 2 4 No 1 carrier assembly 1 Remove No 1 carrier assembly 3 2 Disassemble No 1 carrier assembly as...

Страница 927: ...car rier assembly 13 2 Disassemble No 2 carrier assembly as follows 1 Insert pin 14 and drive shaft 15 out of carrier 16 a After removing the shaft remove pin 14 2 Remove thrust washer 17 gear 18 bea...

Страница 928: ...liding surfaces with engine oil and then assemble the parts 1 Bearing Using push tool E3 4 press fit bearing 27 to case 32 a Use a new bearing a Press fitting force Reference value 0 26 4 kN 0 2 690 k...

Страница 929: ...from slanting a Hit the flange of case assembly 25 frequently and lightly to correct the lean of case assembly 25 In partic ular adjust the flange so that oil seal mating face B of the shaft will be...

Страница 930: ...the thin walled portion on the carrier Portion b Take care however that the thin walled portion can be on the opposite side of the carrier depending on actual individual items Pay attention so that a...

Страница 931: ...and then install it 3 Final drive assembly mounting bolt 245 309 Nm 25 31 5 kgm 8 No 1 carrier assembly 1 Assemble No 1 carrier assembly as fol lows 1 Press fit shaft 5 into the carrier in the direct...

Страница 932: ...ssembly 1 Set swing machinery assembly 33 to block 1 2 Install swing motor assembly 1 3 Install ring gear 10 and swing motor assembly 1 to the following positions 2 Swing motor mounting face Gasket se...

Страница 933: ...l 2 Sling swing circle assembly 1 at 3 points and remove the mounting bolt to remove the assembly 1 4 Swing circle assembly 500 kg Installation q Installation is done in the reverse order of removal 1...

Страница 935: ...Disassembly and assembly Undercarriage and frame Disassembly and assembly of carrier roller 2 Disassembly and assembly of track roller assembly 3 Disassembly and assembly of idler assembly 4 Disassemb...

Страница 936: ...l stick to the contact surface of the float ing seal a After inserting the floating seal with tool F1 check that its slant is less than 1 mm and its pro jection a is 5 7 mm q Carrier roller a Check th...

Страница 937: ...a After inserting the floating seal with tool G1 check that its slant is less than 1 mm and its pro jection a is 5 7 mm q Mounting roller cover mounting bolt 3 Track roller cover mounting bolt 44 12 5...

Страница 938: ...4 from shaft 5 and support assembly 7 a Oil of 230 10 cc is in the idler Drain it at this time or spread cloths to absorb it 4 Remove floating seal 6 on the opposite side from idler 4 shaft 5 and supp...

Страница 939: ...haft 5 and support 7 assembly a Before installing the floating seal completely degrease both contact surfaces of the O ring and the floating seal hatched area in the il lustration Furthermore take car...

Страница 940: ...l and be careful not to let any dirt or dust get stuck to it a Remove all grease and oil from the contact surfaces of the O ring and the floating seal 6 Install O ring then install support 2 using dow...

Страница 941: ...ockplate 3 then nut 4 a Compress the spring until the nut be comes loose a Release the hydraulic pressure slowly and release the tension of the spring a Free length of spring 811 5 mm 3 Remove yoke 6...

Страница 942: ...liding part Grease G2 LI 3 Apply hydraulic pressure slowly to compress the spring and then tighten nut 4 so that the installed length of the spring is dimension a and secure it with lockplate 3 a Inst...

Страница 943: ...ack shoe assembly h 2 Swing work equipment 90 push up chassis with work equipment and place blocks 1 between track frame and track shoe 3 Remove the mounting bolt and then lift off sprocket 1 1 4 Spro...

Страница 944: ...the work equipment to the ground and loosen lubricator 1 in order to loosen track shoe tension 1 k Inner pressure of the adjustment cylinder is extremely high Never loosen the lubri cator more than on...

Страница 945: ...the gChecking and adjusting track shoe tension h section in the Testing and ad justing chapter of this manual 2 2 Mounting bolt Seizure prevention agent Maruzen Morimax No 2 or equivalent 3 Mounting b...

Страница 946: ...ly h 2 Remove the counterweight assembly For details see gRemoval and installation of coun terweight assembly h 3 Disconnect 4 boom cylinder hoses 1 a Plug the hose to stop oil flow out 4 Sling boom c...

Страница 947: ...off revolving frame assembly 20 1 a Using the lever block adjust fore and aft as well as right and left balance of the revolving frame assembly with only 2 mounting bolts being left in the front and r...

Страница 948: ...lamp 4 If equipped 3 Sling counterweight assembly 2 2 rear camera specification 1 Disconnect connector A40 3 of camera 1 RC1 2 Disconnect connector CN L09 5 and wiring harness clamps 6 from rear worki...

Страница 949: ...lving frame and counterweight become 10 5 mm 3 The difference in level in left to right direction between the exterior of door D and counter weight C a 10 4 mm The difference in level in left to right...

Страница 950: ...according to the following procedure 1 Attach the noise insulation sheets 1 2 3 and 4 to the front surface of the counter weight a The surface of the counterweight for noise insulation sheets to be a...

Страница 951: ...SEN02638 03 PC300 350 8 17 50 Disassembly and assembly...

Страница 953: ...sembly and assembly of center swivel joint assembly 4 Removal and installation of hydraulic tank assembly 5 Removal and installation of control valve assembly 7 Disassembly and assembly of control val...

Страница 954: ...ort q 4 Center swivel joint D port RH travel motor PB port q 5 Center swivel joint A port LH travel motor PB port q 6 Center swivel joint C port RH travel motor PA port q 7 Center swivel joint E port...

Страница 955: ...ected to the front of the machine in the direction of the arrow Part 19 in the following figure is the sprocket q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to...

Страница 956: ...Install dust seal 6 to cover 7 2 Lip of dust seal Grease G2 LI Apply 2 3 cc 4 Set swivel shaft 5 to block then using push tool tap swivel rotor 4 with a plastic hammer to install 2 Contact surface of...

Страница 957: ...nnect the negative terminal from battery 1 Remove covers 1 and 2 2 Drain oil from the hydraulic tank 6 Hydraulic tank 248 l 3 Open the engine hood 4 Remove control valve top cover 3 5 Disconnect hoses...

Страница 958: ...ion is done in the reverse order of removal q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate in the hydraulic system by...

Страница 959: ...ure inside the tank Then move the work equipment lock lever to the LOCK position k Disconnect the negative terminal from battery a Attach an identification tag to each piping to avoid a mistake in the...

Страница 960: ...5 port hose swivel joint D port B6 port tube arm bottom side 7 Disconnect the 6 PPC hoses at right q 13 Bucket dump Hose band Black 14 LH forward Hose band Red 15 Boom Hose band Brown 16 Right swing 1...

Страница 961: ...p pressure sensor 12 Remove the 3 mounting bolts and then lift and remove control valve assembly 36 4 Control valve assembly 250 kg Installation q Installation is done in the reverse order of removal...

Страница 962: ...merge divider valve 2 Mating face of the merge divider valve Seal End 242 or equivalent q Tighten the mounting bolts for the merge divider valve in the same sequence as that for the control valve cov...

Страница 963: ...a Attach an identification tag to each piping to avoid a mistake in the position of installation later 1 Remove the hydraulic tank strainer and stop the flow of oil using tool C a When not using tool...

Страница 964: ...t hose Color band Red q 15 EPC source pressure port hose Color band Yellow q 16 Rear pressure input port hose Color band Yellow q 17 Front pressure input port hose q 18 Rear pump delivery port hose q...

Страница 965: ...c tank 2 48 l q Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder For details see Testing and adjusting Bleeding air from vari ous parts Removal and installation...

Страница 966: ...Plug 2 6 11 Nm 0 6 1 1 kgm a When installing plug 3 to body 1 check the insertion depth so that the tip of plug does not enter the inside 20 hole of the body 3 Plug 3 4 9 Nm 0 4 0 9 kgm a Install spri...

Страница 967: ...ng positions 2 Female screw A of body LOCTITE No 262 3 Joint 12 39 49 Nm 4 5 kgm a Apply grease G2 LI to the sliding parts of joint 12 and contact surfaces of disc 13 and pis ton 8 2 Quantity of greas...

Страница 968: ...case 5 Remove mounting bolt 10 to remove plate 22 a Check the thickness and the mounting position of washer 18 a Remove pin 23 from body 1 6 Remove seal 9 and collar 8 7 Remove piston 7 to remove reta...

Страница 969: ...semble shaft 14 in the following procedure 1 Using tool M4 insert bushing 10 in case a Insert the bushing 10 from the 10 chamfered side a Insert bushing so that dimension a will be as follows q Dimens...

Страница 970: ...e between both sides at the stroke end of the lever exceeds 0 7 change the washer thickness to reduce the difference to below 0 7 If the washer thickness is reduced by 0 3 mm the stroke end angle is i...

Страница 971: ...arm and bucket cylinder Screw size M12 Pitch 1 75 a If the caulking of screw 3 is too strong and it cannot be removed tighten the screw fully then fit a tap to the thread and remove the screw Symbol P...

Страница 972: ...q Boom and arm cylinder only 6 Remove head assembly 7 7 Remove cap 8 pull 12 balls 9 and then remove plunger 10 q Arm cylinder only 2 Disassembly of piston assembly 1 Remove ring 11 2 Remove wear ring...

Страница 973: ...all dust seal 17 and then secure it with snap ring 16 5 Install backup ring and O ring 15 2 Disassembly of piston assembly 1 Press fit oil seal 13 using tool N3 a Set the piston ring on tool N3 and tu...

Страница 974: ...2 until the position of the screw thread hole matches a Remove all burrs and flashes using a file 2 Tighten screw 3 2 Screw thread Loctite No 262 3 Screw 58 9 73 6 Nm 6 7 5 kgm 3 Caulk 4 places of th...

Страница 975: ...3 6 Nm 6 7 5 kgm 5 Caulk thread at 4 places using a punch 7 Assemble piston rod assembly 2 a Set the ring end gap C horizontally sideways and then insert it aligning the axial center of cylinder tube...

Страница 977: ...NUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Work equipment...

Страница 978: ...to prevent the cylinder from hanging toward the bottom a In the latter case remove the bottom side grease nipple a Remove the boom cylinder on the other side in the same manner a When the work equipm...

Страница 979: ...t 0 5 1 5 mm clearance a is maintained between the plate and nut after the tightening 2 2 Inside surface of bushing when assembling pin Antifriction agent LM P 2 Feed grease after assembling pin Greas...

Страница 980: ...to 1 mm or less by use of shims Thickness of standard shim 2 0 2 5 3 0 and 3 5 mm q Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder For details see Test ing a...

Страница 981: ...50 Disassembly and assembly SEN02640 00 PC300 350 8 5...

Страница 983: ...p PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Cab and its attachments Removal and installation of operator s cab assembly 2 Removal and installation...

Страница 984: ...to Removal and installation of monitor assembly and remove monitor assembly 4 5 Remove covers 5 and 6 6 Remove cover duct assembly 7 7 Insert key 8 turn it right and open the out side air filter cove...

Страница 985: ...27 from the opera tor s cab If equipped 21 Disconnect cab wiring intermediate connectors H09 28 H08 29 and H16 30 a Cut tie wrap T 22 Disconnect radio antenna 31 a 23 is removed plate 23 Remove ducts...

Страница 986: ...ate 43 1 33 Remove bolt 44 2 34 Dismount 6 mounting bolts 45 and 4 mount ing nuts 46 a Check the bolt length beforehand 35 Lift off and remove operator s cab assembly 47 4 Operator s cab assembly 470...

Страница 987: ...lacing front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to the opera tor s cab a For the procedu...

Страница 988: ...may not be stuck perfectly a Clean the all black part on the back side of the window glass a After cleaning the sticking surfaces leave them for at lease 5 minutes to dry 3 Apply primer 10 a The usin...

Страница 989: ...s applied more than 2 times its performance will be lowered a Parts to be coated with primer Apply the prim er all over dimension a q Dimension to apply primer a 25 mm a In addition to the above parts...

Страница 990: ...tween the black part and transparent part of the glass a After applying the primer leave it for at least 5 minutes within 8 hours to dry a Never apply the wrong primer If the paint primer etc is appli...

Страница 991: ...ck dam rubber 6 for left side window glass 2 to the position as shown in the figure 3 Stick dam rubber 6 for door lower win dow glass 3 to the position as shown in the figure a Stick dam rubber 6b add...

Страница 992: ...glass 9 and operator s cab 8 with a knife etc and then remove the window glass a Do not remove the tapes left on the window glass and the operator s cab before installing the window glass a When posit...

Страница 993: ...elease tape of dam rubber on the glass adhesive side 5 Apply adhesive 15 to the outside of dam rubber 6 of the operator s cab a Apply adhesive 15 with dimensions s and t for dam rubber 6 of oper ator...

Страница 994: ...perform this work efficiently by pulling window glass 9 from inside of the operator s cab with suc tion cup X2 a After installing front window glass 4 fill the clearances between it and cen ter trim s...

Страница 995: ...w glass 1 After installing right window glass 1 to the operator s cab insert stopper rubbers X3 to 2 places v at the bottom of the glass to fix the glass 2 By using styrene foam blocks 9 and rub ber b...

Страница 996: ...adhesive before it is dried up a When cleaning the glass do not give an impact on it 10 Protect the stuck window glass 1 Keep the stopper rubbers styrene foam blocks and rubber bands installed for 10...

Страница 997: ...t corner block are used to hang the pull up assist cable in the following step 6 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a little Put out rollers 5 and 6 under t...

Страница 998: ...hough the rail opening portion and lower it gradually 8 Lower front window assembly 10 completely a Do not let the front window assembly touch the monitor 9 Twist front window assembly 10 to the right...

Страница 999: ...e the front window assembly and fix it with the rear locks on both sides a Check that the locks in the rear of the operator s cab are securely fastened 4 Install right corner block 2 a Fully tighten t...

Страница 1000: ...ht and left locks 16 and 17 do not work normally 1 Loosen lock fitting bolt 18 move lock 16 forward and then tighten the bolt again a The same applies to the right side 2 After moving the lock recheck...

Страница 1001: ...witch works a Limit switch 19 is used to prevent the windshield wiper from moving when turning the wiper switch on by mistake when the front window assembly is in Open position If the wiper operates w...

Страница 1002: ...e turn of rubber stopper 18 to the left is equivalent to squashing the rubber for approxi mately 1 5 mm a When the front window assembly is in Open position the front window assembly must be push ing...

Страница 1003: ...1 After finishing the adjustment of steps 6 9 check that latching efforts of both right and left locks 16 and 17 are even a Check the latching efforts on both Close side in the front of the opera tor...

Страница 1004: ...Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accordingly put on protective goggles while you are collect ing the refrigera...

Страница 1005: ...19 a Check the connecting point a Plug the hose to stop oil flow out a Disconnect the work equipment PPC at joint box side See item 33 17 Disconnect hose 20 a Check the connecting point a Plug the hos...

Страница 1006: ...ve cover 38 32 Disconnect clamp 39 33 Disconnect PPC hose 40 of the work equip ment From the top the color of the band is White Brown None Blue Black Green Red Yellow a Prepare an oil sump 34 Pull out...

Страница 1007: ...ring a When connecting the refrigerant piping coat the O ring with compressor oil for new refrig erant R134a Denso ND OIL8 Zexel ZXL100PG PAG 46 or equivalent 3 Mounting bolt 8 12 Nm 0 8 1 2 kgm 2 a...

Страница 1009: ...C350 8 60001 and up PC350LC 8 60001 and up 50 Disassembly and assembly1 Electrical system Removal and installation of air conditioner unit assembly 2 Removal and installation of KOMTRAX communication...

Страница 1010: ...al traders for collecting and fill ing operation of refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If refrigerant gas R134a gets in your eyes you may lose your sight Accor...

Страница 1011: ...pin 18 and remove duct 19 15 Remove ducts 20 and 21 a Cut tie wrap 16 Remove ducts 22 and 23 a Cut tie wrap 17 Remove duct 24 upper and lower 18 Remove duct 25 upper and lower 19 Disconnect plate 26...

Страница 1012: ...at there is O ring at the piping connector of the air condi tioner hose a Check that there is no defect or deterioration on the O ring a When connecting the refrigerant piping coat the O ring with com...

Страница 1013: ...assembly Removal k Disconnect the negative terminal from battery 1 Remove covers 1 4 2 Twist antenna wire 5 and disconnect it 3 Disconnect connectors K01 6 and CK02 7 4 Remove the 4 mounting bolts an...

Страница 1014: ...ws 1 1 Insert flat head screwdriver inside slit SL and push it upward 2 Release lock L and remove the cover 3 Disconnect wiring connector M04 of the cigarette lighter from the back of cover 5 5 Remove...

Страница 1015: ...onitor assembly 6 with 4 mounting bolts and then install cover 5 2 With cover 5 installed tighten the mounting bolts of monitor assembly q Carry out the rest of installation in the reverse order to re...

Страница 1016: ...iring connectors C01 6 and C02 7 as follows q Tilt lock L12 inside while pressing lock L1 a Bar B comes out and the lock is re leased 5 Remove the 4 mounting bolts and pump con troller assembly 8 Inst...

Страница 1017: ...from the upper position to the left position lock position in the figure a B C Claws a If the sliders and lever are not set as shown in the following figure the con nector is not disconnected or locke...

Страница 1018: ...d installation of engine controller Removal k Disconnect the negative terminal from the battery 1 Open the engine hood 2 Disconnect connectors EC01 1 ENG 2 and CE03 3 3 Remove engine controller 4 Inst...

Страница 1019: ...50 Disassembly and assembly SEN02642 02 PC300 350 8 11...

Страница 1021: ...OP MANUAL PC300 8 PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 90 Diagrams and drawings 1 Hydraulic d...

Страница 1022: ...SEN02004 01 90 Diagrams and drawings 2 PC300 350 8...

Страница 1023: ...3 Hydraulic circuit diagram PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02004 01 Hydraulic circuit diagram 1 PC300 300LC 8 PC350 350LC 8...

Страница 1024: ...90 Diagrams and drawings SEN02004 01 PC300 350 8 5...

Страница 1026: ...PC300LC 8 PC350 8 PC350LC 8 Machine model Serial number PC300 8 60001 and up PC300LC 8 60001 and up PC350 8 60001 and up PC350LC 8 60001 and up 90 Diagrams and drawings 1 Electrical diagrams and draw...

Страница 1027: ...SEN02005 03 90 Diagrams and drawings 2 PC300 350 8...

Страница 1028: ...3 Electrical circuit diagram 1 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 1 5...

Страница 1029: ...5 Electrical circuit diagram 2 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 2 5...

Страница 1030: ...7 Electrical circuit diagram 3 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 3 5...

Страница 1031: ...9 Electrical circuit diagram 4 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 4 5...

Страница 1032: ...11 Electrical circuit diagram 5 5 PC300 300LC 8 PC350 350LC 8 PC300 350 8 SEN02005 04 Electrical circuit diagram 5 5...

Страница 1033: ...V 9 N10 4 A C unit T 8 P01 AMP 3 Bucket DIG pressure sensor L 2 P02 X 2 Boom down pressure switch L 2 P03 X 2 Swing right pressure switch L 2 P04 AMP 3 Arm DIG pressure sensor L 2 P05 X 2 Bucket dump...

Страница 1034: ...90 Diagrams and drawings SEN02005 03 PC300 350 8 15...

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Komatsu ecot3 PC300-8, Руководство по ремонту

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