Transcript
SEBM014302
Pc300,300Lc-6 Pc350,350Lc-6 MACHINE
MODEL
SERIAL NUMBER
PC300-6
33001 and up
PC3OOLC-6 PC350-6
33001 and up 12001 and up
PC35OLC-6
12001 and up
.
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
.
PC300, 350-6 mount the SAAGD108-2 engine. For details of the engine, see the 108-2 Series Engine Shop Manual.
0 1997 KOMAlbU All Rights Reserved 12-97(01)01301
00-l 0
CONTENTS No. of page
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01-l
IO
STRUCTURE
10-I
20
TESTING AND ADJUSTING
30
DISASSEMBLY
40
MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . ..n........s.......
40-l
SO
OTHERS . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90-I
00-2 0
AND FUNCTION
... . ... . ... .. ... . ... .. .. .. . ... ... .. ...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m.......
AND ASSEMBLY
STANDARD
. . . . . . . . . . . . . ..a.................
20-I
30-I
PC300, 350-6
LIST OF REVISED PAGES
The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.
t
Mark
Indication
0
Page to be newly added
0
Page to be replaced
Replace
Page to be deleted
Discard
1 1
Action required
Add
I
I
Pages h Gng no marks are those previously revised or made additions.
LIST OF REVISED PAGE Mark
Page
Time of revision Vlark Page
Time oi Mark revision
Page
Time of Mark revision
Page
Time of vlark Page revision
0
oo- 1
@
Ol- 3
IO-18
IO-49
IO-78
0
oo- 2
@
Ol- 4
IO-19
IO-50
IO-80
0
oo- 2-l
@
Ol- 5
IO-20
IO-51
IO-81
0
oo- 2-2
@
Ol- 6
IO-21
IO-52
IO-82
0
00- 2-3
@
Ol- 7
IO-22
IO-53
IO-84
l
00- 2-4
@
Ol- 8
IO-24
IO-55
IO-85
0
oo-
2-5
@
Ol- 9
IO-25
IO-56
IO-86
oo- 3
01-10
IO-26
IO-57
IO-88
oo- 4
01-11
IO-27
IO-58
IO-89
oo- 5
01-12
IO-28
IO-59
IO-90
00- 6
01-13
IO-29
lo-60
IO-92
oo- 7
IO-30
IO-61
IO-93
00- 8
IO-31
IO-62
10-94
Time of revision
oo- 9
lo- 1
IO-32
IO-63
IO-96
00-10
IO- 2
IO-33
IO-64
IO-97
00-11
IO- 3
IO-34
IO-65
IO-98
00-12
IO- 4
IO-35
IO-66
10-100
00-13
IO- 5
IO-36
IO-67
10-101
00-14
IO- 6
IO-38
IO-68
IO-102
00-15
IO- 7
IO-39
IO-69
IO-104
00-16
IO- 8
IO-40
IO-70
IO-105
00-17
IO- 9
IO-41
IO-71
IO-106
00-18
IO-IO
IO-42
IO-72
lo-108
00-19
IO-12
IO-43
IO-73
IO-109
IO-13
IO-44
IO-74
10-110
IO-14
IO-45
IO-75
IO-112
Ol- 1
IO-15
IO-46
IO-76
IO-113
Ol- 2
IO-17
IO-48
IO-77
IO-114
PC300, 350-6
oo-2- 1 0
LIST OF REVISED PAGES
Mark
Page
Time o Mark revisior
Page
Time o Mark revision
Page
Time o Mark revision
Page
Time o Mark revisior
Page
Time of revision
IO-116
IO-159
IO-204
20-102
@
20-203
@
IO-117
IO-160
lo-205
20-103
@
20-204
@
lo-118
lo-162
IO-206
20-104
@
20-205
@
IO-120
lo-163
IO-207
20-105
@
20-206
@
10-121
IO-164
lo-208
20-106
@
20-207
@
10-122
lo-165
IO-209
20-107
@
20-208
@
IO-123
IO-166
IO-210
20-108
@
20-209
@
lo-124
IO-168
IO-212
20-109
@
20-210
@
lo-125
IO-169
IO-213
20-110
@
20-211
@
lo-126
IO-170
IO-214
20-111
@
20-212
@
IO-128
10-171
IO-215
20-112
0
20-214
@
IO-129
IO-172
IO-216
20-113
@
20-215
@
@
20-216
0
@
20-217
@
IO-130
IO-173
IO-217
20-114
IO-131
10-174
IO-218
20-115
IO-132
IO-175
IO-219
20-116
@
20-218
@
IO-133
IO-176
IO-220
20-117
0
20-219
0
IO-134
IO-178
10-221
20-118
@
20-220
0
10-135
IO-179
IO-222
20-119
(iJ
20-221
0
IO-136
lo-180
IO-223
20-120
@
20-222
@
IO-137
lo-181
20-121
@
20-223
@
IO-138
lo-182
20-122
@
20-224
@
10-139
lo-183
20- 1
20-123
@
20-225
@
IO-140
IO-185
20- 2
20-124
@
20-226
@
@
10-141
IO-186
20- 4
20-125
20-227
@
IO-142
IO-187
20- 5
20-126
@
20-228
0
IO-143
IO-188
20- 6
20-127
0
20-229
@
10-144
IO-189
20- 7
20-128
@I
20-230
@
IO-145
IO-190
20- 8
20-129
@
20-231
@)
lo-146
IO-191
20- 9
20-130
0
20-232
@
10-147
IO-192
20-10
20-131
@
20-233
@
lo-148
IO-193
20-11
20-132
@
20-234
@
IO-149
IO-194
20-12
20-133
@)
20-235
@
IO-151
lo-196
20-13
20-134
@
20-236
0
IO-152
10-197
20-14
20-135
@
20-237
@
IO-153
IO-198
20-15
20-136
0
20-238
@
IO-154
IO-199
20-16
20-137
0
20-239
@
IO-155
IO-200
20-17
20-138
@)
20-240
@
lo-156
IO-201
20-18
20-241
@
10-157
IO-202
20-19
20-201
@
20-242
@
IO-158
lo-203
20-20
20-202
@
20-243
@
00-2-2 0
PC300,
350-6
Mark
Page
Time of revision
Mark
Page
Time of revision
Mark
Page
Time of revision
Mark
Page
Time of revision
Mark
Page
Time of revision @
20-244
@
20-401
@
20-468
@
20-511
@
20-601
20-245
@
20-402
@
20-469
@
20-512
@
20-602
@
20-246
@
20-403
@
20-470
@
20-513
@
20-604
@
20-247
@
20-404
@
20-471
@
20-514
@
20-605
@
20-248
@
20-405
@
20-472
@
20-606
@
20-406
@
20-473
@
20-551
@
20-607
@
20-301
0
20-407
@
20-474
0
20-552
@
20-608
@
20-302
@I
20-408
@
20-475
0
20-553
@
20-609
@
20-303
0
20-409
@
20-476
@)
20-554
@
20-610
@
20-410
@
20-477
@
20-555
@
20-611
@
20-351
@
20-411
0
20-478
0
20-556
@
20-612
@
20-352
@
20-412
@
20-479
0
20-557
@
20-613
@
20-354
@
20-413
@
20-480
0
20-558
@
20-614
@
20-355
@
20-414
@
20-481
0
20-559
@
20-615
0
20-356
0
20-415
@
20-482
0
20-560
@
20-616
@
20-357
@
20-416
@
20-483
@
20-561
@
20-617
0
20-358
@
20-417
@
20-484
@
20-562
@
20-618
@
20-359
@
20-418
@
20-485
0
20-564
@
20-619
0
20-360
0
20-419
@
20-486
@
20-565
@
20-620
@
20-361
0
20-420
@
20-487
@
20-566
@
20-621
@
20-362
@
20-421
@
20-488
@
20-567
@
20-622
@
20-363
@
20-422
@
20-489
@
20-568
@
20-623
@
20-364
@
20-423
@
20-490
@
20-569
@
20-624
@
20-365
@
20-491
@
20-570
@
20-625
@
20-366
0
20-451
@
20-492
@
20-571
@
20-626
0
20-367
@
20-452
0
20-493
@
20-572
@
20-627
0
20-368
@
20-454
@
20-494
@
20-573
@
20-628
@
20-370
@
20-455
@
20-495
@
20-574
@
20-629
@)
20-371
@
20-456
@
20-496
@
20-575
@
20-630
@
20-372
0
20-457
@
20-576
@
20-631
@
20-373
0
20-458
0
20-501
0
20-577
@
20-632
0
20-374
@
20-459
@
20-502
@
20-578
@
20-633
@
20-375
@
20-460
@
20-503
@
20-579
@
20-634
@
20-376
@)
20-461
@
20-504
@
20-580
@
20-635
@
20-377
0
20-462
0
20-505
0
20-581
@
20-636
0
20-378
@
20-463
@
20-506
0
20-582
@
20-638
@
20-379
0
20-464
@
20-507
@
20-583
@
20-639
0
20-380
0
20-465
@
20-508
@
20-584
0
20-640
@
20-585
@
20-381
PC300, 350-6
@
20-466
0
20-509
@
20-467
@
20-510
@)
20-641
@
20-642
0
00-2-3 0
.
LIST OF REVISED PAGES
Mark
Page
Time oi Mark revisior
Page
Time of Wark revision
Page
Time 01 Mark revisior
Page
Time of dark revision
20-643
0
30-36
0
30-76
0
30-116
@
20-644
0
30-37
0
30-77
0
30-117
@
20-645
0
30-38
0
30-78
0
30-118
@
0
30-39
0
30-79
0
30-119
@
0
30-40
Page
30-156
@
0
30-157
@
0
30-158
@
0
0
30-80
0
30-120
@
0
30- 1
0
30-41
0
30-81
0
30-121
@
40- 1
0
30- 2
0
30-42
0
30-82
0
30-122
@
40- 2
0
30- 3
0
30-43
0
30-83
0
30-123
@
40- 4
0
30- 4
0
30-44
0
30-84
0
30-124
@
40- 5
0
30- 5
0
30-45
0
30-85
0
30-125
@
40- 6
0
30- 6
0
30-46
0
30-86
0
30-126
@
40- 8
0
30- 7
0
30-47
0
30-87
0
30-127
@
40- 9
0
30- 8
0
30-48
0
30-88
0
30-128
@
40-10
0
30- 9
0
30-49
0
30-89
0
30-129
@
40-12
0
30-10
0
30-50
0
30-90
0
30-130
@
40-13
0
30-11
0
30-51
0
30-91
0
30-131
@
40-14
0
30-12
0
30-52
0
30-92
0
30-132
@
40-15
0
30-13
0
30-53
0
30-93
0
30-133
@
40-16
0
30-14
0
30-54
0
30-94
0
30-134
@
40-17
0
30-15
0
30-55
0
30-95
0
30-135
@
40-18
0
30-16
0
30-56
0
30-96
0
30-136
@
40-19
0
30-17
0
30-57
0
30-97
0
30-137
@
40-20
0
30-18
0
30-58
0
30-98
0
30-138
@
40-22
0
30-19
0
30-59
0
30-99
0
30-139
@
40-23
0
30-20
0
30-60
0
30-100
0
30-140
@
40-24
0
30-21
0
30-61
0
30-101
0
30-141
@
40-25
0
30-22
0
30-62
0
30-102
0
30-142
@
40-26
0
30-23
0
30-63
0
30-103
0
30-143
@
40-27
0
30-24
0
30-64
0
30-104
0
30-144
@
40-28
0
30-25
0
30-65
0
30-105
0
30-145
@
40-29
0
30-26
0
30-66
0
30-106
0
30-146
@
40-30
0
30-27
0
30-67
0
30-107
0
30-147
@
40-31
0
30-28
0
30-68
0
30-108
0
30-148
@
40-32
0
30-29
0
30-69
0
30-109
0
30-149
@
40-33
0
30-30
0
30-70
0
30-110
0
30-150
@
40-34
0
30-31
0
30-71
0
30-111
0
30-151
@
40-35
0
30-32
0
30-72
0
30-112
0
30-152
@
40-36
0
30-33
0
30-73
0
30-113
0
30-153
@
40-37
0
30-34
0
30-74
0
30-114
0
30-154
@
40-38
0
30-35
0
30-75
0
30-115
0
30-155
@
40-40
00-2-4 0
Time of revision
PC300,
350-6
LIST OF REVISED PAGES
Mark
Time revisit
Page
t
Mark
Page
Time o revision
Mark
Page
Time c revisio
Mark
Page
Time o revision
Mark
Page
Time of revision
40-41 40-42 40-43 40-44 40-45 40-46 40-47 40-48 40-49
go- 1 go-
PC300,
3
go-
5
go-
7
go-
9
350-6
00-Z-5
SAFETY NOTICE
SAFETY
SAFETY
r-~-
SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper
service
and
repair
is extremely
service and repair techniques are both effective designed
manual.
for safe
by Komatsu
and safe. Some of these techniques
by Komatsu
To prevent
important
recommended
for the specific
injury to workers,
The cautions
take the necessary
situation
operation.
require the use of tools specially
is used to mark safety precautions
these symbols
should
arises or may possibly
always
be followed
arise, first consider
Read the Operation carefully
6. Decide
are extremely
BEFORE operating
2. When
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
and Maintenance
1. Before carrying
a place
in the repair
the tools Always
workshop
parts. Always
and parts in their correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
Smoke
only in the areas provided
for smok-
ing. Never smoke while working.
are fixed to the machine. carrying
out any operation,
wear safety shoes and helmet. loose work clothes,
always
. Always
or clothes with buttons
wear
safety glasses when
wear
safety
trained,
adding
hitting
oil or making
welder
out welding gloves,
out the work,
apron,
al-
hand
shield, cap and other clothes suited for welding work.
or more workers,
with two
always agree on the operbefore
starting.
Always
in-
form your fellow workers before starting any step of the operation.
Before starting
work,
REPAIR signs on the controls
in the operator’s
compartment. in good condition
the correct way to use them.
the
from moving. blade,
ripper,
bucket or any other work equipment
starting
work,
to the
If this
lower
equipment
is not
from falling.
to lock all the control
and learn
possible,
insert
In addition,
the
be sure
levers and hang warn-
ing signs on them. 9. When disassembling
out any operation
ating procedure
and
safety pin or use blocks to prevent the work
carrying
carrying
to prevent
carry
welding
Keep all tools
or tracks
ground.
work. When
hang UNDER
Before
repairs,
always have a
ways
wear
grind-
etc.
repairs are needed, experienced
when
any
on hard, level ground,
block the wheels machine
glasses
ing parts with a grinder, 3. If welding
Before
park the machine
parts with a hammer. . Always
PREPARATIONS FOR WORK
Do not wear
missing.
When
care-
safety, and
keep tools and removed in operation
in this
actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes
The
in this manual
purpose.
the symbol A
accompanying
fully. If any dangerous
machine
and described
the
machine
with
before starting 10. Remove
or assembling, blocks,
jacks
support or stands
work.
all mud and oil from
the steps or
other places used to get on and off the machine. Always
use the handrails,
ladders
steps when
getting
Never
on or off the machine.
jump
impossible
or
on or off the machine.
to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY
SAFETY NOTICE
19. Be sure to assemble
PRECAUTIONS DURING WORK
original 11 When removing or
hydraulic
loosen them spurting Before
the oil filler cap, drain plug pressure
slowly to prevent
plugs,
the oil from
or removing
of the oil, water
remove
the pressure
compo-
or air circuits, completely
first
from
the
circuit. 12. The
and
oil in the circuits
the engine
is stopped,
are hot
so be careful
for the oil and water
carrying
out any work
to cool
before
on the oil or water
circuits.
the battery.
Always
the negative
(-) terminal
remove
the lead from
20. When sure
installing that
high pressure
they
use a hoist
ful when circuits.
installing Also,
or parts which
vibrate
aligning
fingers
caught
ample
capacity.
Install
the lifting
which
has
to prevent
or crane
and
the component
operate from
hit-
part. Do not work with
any
removing
covers which
ternal
pressure
or under
always
leave two
bolts in position
sides. Slowly
release the pres-
are under in-
pressure
from
a
sure, then slowly loosen the bolts to remove. 16. When
removing
to break wiring 17. When
components,
or damage
be careful not
the wiring.
may cause electrical removing
piping,
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor
Fuel or oil
can cause you to slip, or can
even start fires. 18. As a general
rule, do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
or rotate at
careful to check
correctly.
Be careful
not to get your
in a hole.
measuring
hydraulic
that the measuring
of gasoline
when
24. Take care when
pressure,
tool is correctly
electrical
removing
tracks of track-type When
removing
rates suddenly,
15. When
on opposite
violently
check assem-
at the correct
part still raised by the hoist or crane.
spring,
When
bled before taking any measurements. equipment
Use a hoist
ting any other
23. When
equipment
parts, always torques.
two holes, never insert your
Check that the wire rope, chains and hooks lifting
parts
parts such as guards,
be particularly
or hand.
use
tightening
protective
fingers
are free from damage.
connecting
or installing
use the specified
22. When
care-
tubes for high pressure
check that
21 When assembling
high speed,
Damaged
so be extremely
installed.
or crane.
Always
is be-
hoses, make
are not twisted.
that they are installed
first.
14. When raising heavy components,
places.
be sure
by contact
ing operated.
installing
13. Before starting work, remove the leads from
slowly
parts with new parts.
hoses and wires,
that they will not be damaged
are correctly
not to get burned. Wait
installing
tubes are dangerous,
water
when
Replace any damaged . When
with other parts when the machine
out. disconnecting
nents
measuring
all parts again in their
places.
or installing
the
machines.
the track,
the track sepa-
so never let anyone stand at
either end of the track.
GENERAL
FOREWORD
FOREWORD GENERAL This
shop
serviceman
manual
has been
an accurate
prepared
as an aid to improve
understanding
repairs and make judgements.
the quality
of the product and by showing
Make sure you understand
of repairs
by giving
the
him the correct way to perform
the contents
of this manual
and use it to full
effect at every opportunity.
This shop manual
mainly
service workshop.
For ease of understanding,
chapters
are further
contains
divided
the necessary
technical
the manual
information is divided
for operations
performed
into the following
in a
chapters; these
into the each main group of components.
STRUCTURE AND FUNCTION This section explains an understanding
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material
for troubleshooting.
TESTING AND ADJUSTING This
section
adjustments
explains
checks
to be made
to be made at completion
Troubleshooting
charts correlating
before
and
after
performing
repairs,
as well
as
of the checks and repairs.
“Problems”
to “Causes” are also included
in this section.
DISASSEMBLY AND ASSEMBLY This section assembling
explains
the order to be followed
each component,
MAINTENANCE
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
specifications
time
and
with
the
contained
without latest
any
advance
in this notice.
shop
manual
Use the
are subject
specifications
to change given
in the
at any book
date.
00-5
HOW TO READ THE SHOP MANUAL
FOREWORD
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series
pages.
Electrical volume: Attachments volume:
I
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available.
DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
a manual
((iJ@@....)
is revised,
is recorded
an edition
on the
bottom
mark of the
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):
Symbol
AL
Item Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening toraue during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
10 - 3
l-T
Item number Y~~~~~~6,ge
*
(IO. Structure number
for
each item. Example
el kg
2 (Engine volume):
12 - 5
TT
l-
Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.
3. Additional cated
pages:
by a hyphen
page number. Example:
Additional
pages are indi-
(-1 and number
after the
File as in the example.
1o-4
12-203
IO-5
12-204
00-6
&
Q
Remarks
Places where
oil or water
HOISTING INSTRUCTIONS
FOREWORD
HOISTING INSTRUCTIONS HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol &
.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I) Check
for
removal
of all bolts fastening
the part to the relative 2) Check for existence ing interference
the
part caus-
part to be re-
moved.
71%
79%
41%
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
A
WIRE ROPES 1) Use adequate weight
88%
SAM)0479
of another
with
100%
parts.
ropes
depending
of parts to be hoisted,
on the
referring
to
the table below: 4)
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing)
*
l-
Allowable
load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
18 20
Rope diameter
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg) vertically, at various hanging angles. When two ropes sling a load vertically,
up
to 19.6 kN 12000 kg) of total weight
can be
2.8
suspended.
9.8 kN
35.3
3.6
(1000
43.1
4.4
hanging
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
This weight
kg) when angle.
two
becomes
ropes
make
On the other
ropes are subjected
a 120”
hand,
to an excessive
two force
as large as 39.2 kN 14000 kg) if they sling a 19.6 kN (2000 kg) load at a lifting angle of 150”.
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle of the hook.
portion
I
I
I
I
I
30
60
90
17.0
Lifting
mole
(deoreel
I
150 SAD00480
00-7
COATING MATERIALS
FOREWORD
COATING
MATERIALS
Sr The recommended coating materials such as adhesives, gasket sealants and greases disassembly and assembly are listed below. Ir For coating materials not listed below, use the equivalent of products shown in this list.
Category
force of spring (8) + (area 0d x pressure PR), so .valve (2) moves to the right to the end of the stroke. As a result, the amount of opening from port PI + P2 increases and the resistance in the passage is reduced, so the loss of engine horsepower is reduced. .
VALVE
(when moving LOWER or arm
IN)) Note: When load pressure P2 is lower than output pressure PR of the self-reducing pressure valve. . Valve (2) receives force in the direction to close the passage from port PI + P2 from spring (3) and pressure PR (when the engine is stopped, the pressure is 0 MPa 10 kg/cm21). However, when hydraulic oil flows in from port PI, the pressure is balanced so that pressure PI k force of spring (8) + (area Od x pressure PR), and the opening from port Pl + P2 is adjusted so that pressure PI is kept at a certain value above pressure PR. . When pressure PR goes above the set pressure, poppet (5) opens, and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (9) + opening of poppet (5) + tank port T. As a result, a pressure difference is created on both sides of hole a inside spool (9), so spool (9) moves in the direction to close the opening from port PI + PR. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point, and is supplied as pressure PR. (See Fig. 2)
3.
PRESSURE
SWPO5089
Control
valve
If pressure PR goes above the set pressure, poppet (5) opens and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (8) + opening of poppet (5) + tank port T. As a result, a pressure difference is created on both sides of hole a is inside spool (91, so spool (9) moves in the direction to close the opening from port PI + PR. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point, and is supplied as pressure PR. (See Fig. 3) (F i 9. 3)
PC300, 350-6
SWPO5090
10-51
STRUCTURE
4.
AND
FUNCTION
SELF-REDUCING
PRESSURE
VALVE
When there is abnormal high pressure When pressure PR of the self-reducing pressure valve becomes abnormally high, ball (12) pushes against the force of spring (II), separates from the seat, and allows hydraulic oil to flow from output port PR + T, so pressure PR goes down. This action protects the equipment at the destination for the hydraulic pressure supply (PPC valve, electromagnetic valve, etc.) from abnormally high pressure. (See Fig. 4)
12
II (Fig.41
1o-52
SWPO5091
PC300, 350-6
STRUCTURE
SUCTION
AND
FUNCTION
SUCTION
SAFETY
VALVE
SAFETY VALVE
FOR SERVICE VALVE 1. Suction valve 2. Main valve 3. Piston 4. Piston spring 5. Poppet 6. Poppet spring 7. Suction valve spring 8. Sleeve 9. Adjustment screw 10. Locknut SBPOO198
Part No. 709-70-74800
20.6 MPa (210 kg/cm?
709-70-75100 709-70-75300 709-70-74600
PC300, 350-6
Set pressure
Use at 19Oelmin
For breaker
(Okada)
20.1 MPa 1205 kg/cm*} at 5e/min
For breaker
(Mitsubishi
16.7 MPa (170 kg/cm*) at 190rYmin
For breaker
(Matsuda)
For crusher
(Okada)
1 24.5 MPa 1250 kg/cm*) at 5e/min
Krupp)
1o-53
STRUCTURE AND FUNCTION
CLSS
CLSS Outline
of CLSS To actuators
-:_
-I
__---_---
I
I
Control valve
----__
I
1
I
I
I
I I
I I
I
I
I
I
I
I
I I
I I
I
I
I I
I I I
I
I I I I
I
l- -_ -
I
--L-J
TVC valve
I
_ _ __
I
:c LS valve
- - - -
I
r-x--I I
r_i
I I
LSvalve
I
I-----
I
l
L___Jti_____
--
I J
sBPoo199
Outline . CLSS stands for Closed center Load Sensing System, and has the following features. Features Fine control not influenced by load Control enabling digging even with fine control. . Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. . Energy saving using variable pump control
. .
PC300, 350-6
Structure The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. . The main pump consists of the pump itself, the TVC valve and LS valve. l
1o-55
STRUCTURE
AND
CLSS
FUNCTION
Basic principle I) Control of pump swash plate angle . The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (LS pressure APLS = Pump discharge pressure PP - LS pressure PLS)
Actuator
@
Control valve
_______~ _----_- I
Puma
Passaoe
fferential
Pressure
SWPO5161
.
If LS differential pressure APLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.
t
Max.
a 1 :: 0 Q
E
0. c
LS valve
set Min.
LS differential
pressure
APLS SAP00384
1 O-56
PC300, 350-6
STRUCTURE
2) .
AND
CLSS
FUNCTION
Pressure compensation A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When two actuators are operated together, this valve acts to make pressure difference AP between the upstream (inlet port) and downstream (outlet pot-t) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings Sl and S2 of each valve.
Load
Pump
PC300, 350-6
1o-57
STRUCTURE AND FUNCTION
CLSS
Operation for each function of CLSS Hydraulic circuit diagram for system iPPS1
_____‘Ek-~:-fF,~~ ICC
-7
------
I
B_,
A-,
FI ;
rrr;
1
7 To travel
junction
val
travel
3
motor
junction valve
9
Boom cylinder
12
r
Main
solenoid
A% 5% -IP”mP
valve
Swins
motor
Swing
motor
13
To trave ‘1 junction
valve
To wins stroke switch valve
To travel junction va I ve
J9-t --__--L________ ._
I I I ,
,
c::::
_
,
,
jA6
r<
: B6 I I I I
3
Arm cylinder
.____i_P_L1 .-_------PTRI
L..LL_.__&__L_l I PPS2
lo-58
SWPO5092
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
IA. Main relief valve (bucket group) Set pressure: 34.8 2 0.5 MPa {355 2 5 kg/cm21 IB. Main relief valve (arm group) Set pressure: 34.8 r 0.5 MPa (355 f 5 kg/cm*) 2A. Unload valve (bucket group) Clutch pressure: 2.9 2 0.2 MPa (30 f 2 kg/cm21 2B. Unload valve (arm group) Clutch pressure: 2.9 + 0.2 MPa (30 + 2 kg/cm*1 3. Pressure compensation valve 4A. Safety-suction valve Set pressure: 17.2 t 0.5 MPa 1175 + 5 kg/cm*} 4B. Safety-suction valve Set pressure: 35.8 + 0.5 MPa {365 +. 5 kg/cm’) 5. Safety-suction valve (for large flow) Set pressure: 35.8 2 0.5 MPa (365 f 5 kg/cm21 6. Safety-suction valve (2-stage) Set pressure: l-stage: 28.4 + 0.5 MPa (290 f 5 kg/cm21 2-stage: 14.7 k 0.5 MPa II50 f 5 kg/cm21 7. Bucket spool 8. LS shuttle valve 9. R.H. travel spool IO. Suction valve 11. Boom Lo spool 12. Check valve (for boom regeneration circuit) 13. Swing spool 14. L.H. travel spool 15. Arm Lo spool 16. Check valve (for arm regeneration circuit) 17. Boom Hi spool 18. Arm Hi spool 19. LS select valve 20. Merge/flow divider valve
PC300, 350-6
1o-59
STRUCTURE
AND
CLSS
FUNCTION
SYSTEM DIAGRAM * This shows actuator in the merge mode.
(6A) at stroke end relief
SWPO4730
IA. IB. 2A. 2B. 3A. 38. 4.
Main pump Main pump Main relief valve Main relief valve Unload valve Unload valve Merge/flow divider valve
1 O-60
5A. 5B. 6A. 6B. 7A. 7B. 8A. 8B.
Control valve Control valve Actuator Actuator Pump passage Pump passage LS circuit LS circuit
9A. Tank passage 9B. Tank passage 1OA. Valve 1OB. Valve 1 IA. Spring 11 B. Spring 12. LS bypass valve
PC300, 350-6
STRUCTURE
When
AND
unload
FUNCTiON
valve
CLSS
is actuated 8A,8B
llA,ilB
A-
lOA,lOB
C
9A,9B SBPOO205
Function . When all the control valves are at neutral, the oil discharged when the pump is at the minimum swash plate angle is drained. When this happens, the pump pressure becomes a pressure that matches the set load of springs (1 IA, IIB) inside the valve (PI pressure). The LS pressure is drained from LS bypass valve (121, so LS pressure g tank pressure $ 0 MPa (0 kg/cm?. . When operated (for operations in the discharge range for the minimum swash plate angle), the discharge pressure of the oil discharged with the pump at the minimum swash plate angle is LS pressure + PI pressure. In other words, the LS control differential pressure (APLS) of the oil discharged at the minimum swash plate angle is the PI pressure. Operation . The pressure in pump passages (7A, 7B) is received by the end face of valves (IOA, IOB). The control valve is at neutral, so the pressure in LS circuits (8A, 8B) is 0 MPa (0 kg/ cm?. . The pressurized oil in pump passages (7A, 7B) is stopped by valves (IOA, IOB). There is no way for the pressurized oil discharged by the pump to escape, so the pressure rises. When this pressure becomes larger than the
PC300, 350-6
force of springs (1 IA, 1 IB), valves (IOA, IOB) move to the left, ports B and C are connected and the pump pressure flows to tank passages (9A. 9B). In addition, the pressurized oil in LS circuits (8A, 8B) passes from orifice A through port C, and is drained to tank passages (9A, 9B). Therefore, when the valve is actuated, LS pressure 6 tank pressure. When the unload operation is carried out, the differential pressure (pump discharge pressure - LS circuit pressure) is greater than the pump LS control pressure, so a signal is sent to move the pump swash plate to the minimum angle.
I
llA,llB
A
8A,8B /
C
l?A,lOB
9A,9B
757B
SBPOO206
10-61
CLSS
STRUCTURE AND FUNCTION
2. Operation of relief valve (1) Cut-off control actuated Function . When cut-off control is being carried out on
Qt
Pump flow
the pump by the NC valve, the pump swash plate angle is at the minimum. The relief valve acts to relieve the oil flow when the pump is at the minimum swash plate angle in order to maintain the overall balance.
l
valve flow
Operation Balance
When the cylinder reaches the end of its stroke, main relief valves (2A, 2B) open and pump discharge amount Q is relieved to tank passages (9A, 9B). When pump delivery pressure PP comes close to the relief pressure, the governor, pump controller sends a signal to the solenoid of the TVC valve and carries out the cut-off function to make pump discharge amount Q the minimum. The spool is at the end of its stroke, so there is no flow of oil upstream or downstream from the spool. As a result, pump delivery pressure PP and LS pressure PLS are almost the same pressure, and LS differential pressure APLS becomes 0. LS differential pressure APLS is lower than the LS set pressure of the LS valve, so the LS valve acts to try to move the pump swash plate angle to the maximum. However, because of the structure, the action of the TVC valve is given priority over the action of the LS valve, so the pump is held at the minimum swash plate angle by the cut-off function of the TVC valve.
canceled (power max. mode, fine control mode, travel) Function, operation . In the power max. mode, fine control mode,
point
SAW0207
J
(2) Cut-off
l
or travel mode, the torque cut-off signal is not given, so the torque moves on the pump output curve. When this happens, the pump discharge amount is relieved from the relief valve, so the overall balance is maintained.
1 O-62
Qt
Pump flow When cut-off is canceled
Relief valve flow
PC300, 350-6
CLSS
STRUCTURE AND FUNCTION
3. *
Introduction
of LS pressure
The IN.
shows
diagram
the condition
for arm
Upstream pressure of pressure compensation valve (for spool meter-in downstream)
1. 2. 3. 4. 5. 6 7.
Main pump Main spool Pressure compensation Valve Ball valve LS circuit LS shuttle valve
Function . The upstream valve
pressure I= spool meter-in downstream pressure) of pressure compensation valve (3) is introduced and goes to shuttle valve (7) as the LS pressure. When this happens, it is connected to port B of the actuator through valve (41, and LS pressure % actuator load pressure. Introduction hole a inside the spool has a small diameter, so it also acts as a throttle.
Operation . When spool (2) is operated,
the pump pressure passes through introduction hole a, enters port C, and is taken to the LS circuit. When the pump pressure rises and reaches the load pressure of port B, ball valve (5) opens.
PC300, 350-6
1O-63
CLSS
STRUCTURE AND FUNCTION
4.
LS bypass valve
SLFoo211
1. 2. 3. 4. 5. 6.
Main pump Main spool Pressure compensation LS shuttle valve LS bypass valve LS circuit
1O-64
Function l
valve
.
The residual pressure in LS circuit (6) is released from orifices a and b. This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between throttle c of main spool (2) and LS shuttle valve (4) according to the bypass flow from LS bypass valve (5). As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased.
PC300, 350-6
STRUCTURE
5.
Pressure
AND
CLSS
FUNCTION
compensation
valve .6
SLfoO212
1. 2. 3.
Main pump Valve Shuttle valve
Function 1) During independent operation and at maximum load pressure (during compound operations, when load pressure is higher than other work equipment) . The pressure compensation valve acts as a load check valve. Operation . If the pump pressure (LS pressure) is lower than the load pressure at port C, shuttle valve (3) inside pressure compensation valve piston (4) moves to interconnect spring chamber E and port C. From this condition, the force of spring (5) acts to move piston (4) and valve (2) in the direction of closing.
Piston Spring LS shuttle valve
this machine, this is employed for the bucket valve (at the cylinder bottom) and service va Ive. With the integrated compensation valve, as a basic rule, port C and spring chamber E are not interconnected, so even if a high peak pressure is generated at port C, valve (7) does not hit the valve chamber. (However, the system is designed so that port C and spring chamber E are interconnected just before the bucket valve is seated.)
Reference:
.
Integrated pressure compensation va Ive When high peak pressure is generated in the actuator circuit or when peak pressure is generated repeatedly over a continuous period (such as when using a breaker), valve (2) may hit valve chamber seat s and generate a high stress. To prevent this, an integrated pressure compensation valve combining valve (2) and piston (4) is used. On
4. 5. 6.
PC300, 350-6
SAP00387
1 O-65
STRUCTURE
CLSS
AND FUNCTION
From LS shuttle valve for other work equipment
-t
Spool meter-in
upstream
pressurGe
)c/
Upstream pressure of pressure compensation (for spool meter-in downstream)
3L
valve
’ SLWO213
2)
l
When receiving compensation (during compound operations, when load pressure is lower than other work equipment) The pressure compensation valve is closed by the LS pressure of port D, and the spool meter-in downstream pressure of port B becomes the same as the maximum pressure of the other work equipment. The spool meter-in upstream pressure of port A is the pump pressure, so spool meter-in differential pressure (upstream pressure (pressure of port A) - downstream pressure (pressure of port B)) becomes the same for all spools that are being operated. In this way, the pump flow is divided in proportion to the area of the meter-in opening.
1O-66
Operation Spring chamber E is interconnected with port D. Piston (4) and valve (2) are actuated by the LS circuit pressure from the other work equipment at port F in the direction of closing (to the right). In other words, the valve upstream pressure of port B I= spool meterin downstream pressure) is controlled by the LS pressure. l
PC300, 350-6
STRUCTURE
AND
CLSS
FUNCTION
Shuttle valve From LS circuit Throttle,
1
I I
To actuator
1
Al
t Spool meter-in downstream txessure
SLPoo218
< Area ratio of pressure compensation valve > The condition of the flow division changes according to the ratio of the areas of portion Al and portion A2 of the pressure compensation valve. Area ratio = A2/Al . When area ratio = 1: Spool meter-in downstream pressure = Max. load pressure, and oil flow is divided in proportion to area of opening of spool. . When ratio is more than 1: Spool meter-in downstream pressure > Max. load pressure, and a smaller oil flow is divided than the proportion between the areas of opening of the spool. . When ratio is less than 1: Spool meter-in downstream pressure < Max. load pressure, and a larger oil flow is divided than the proportion between the areas of opening of the spool.
PC300, 350-6
c Pressure compensation valve for service valve > The service valve uses a variable type pressure compensation valve, so it can adjust the division of the oil flow suitably to match the attachment installed. l
1O-67
CLSS
STRUCTURE AND FUNCTION
6.
Shuttle
valve inside
pressure
compensation
valve
SLP00214
1.
2. 3. 4.
Main pump Valve Shuttle valve inside pressure va Ive Piston
1O-68
compensation
Function When holding pressure at port A > LS pressure in spring chamber 6. l
Shuttle valve (3) is pushed to the right by the pressure of port A, and the circuit between ports A and C is shut off. In this condition, the holding pressure at port A is taken to spring chamber B, and pushes piston (4) to the left to prevent piston (4) and valve (2) from separating.
PC300, 350-6
STRUCTURE
AND
FUNCTION
CLSS
SLPuO215
< For travel> . No holding pressure is generated at port A in the travel circuit, so a pressure compensation valve without a shuttle valve is used.
SBPOO216
Reference: When there is no shuttle valve . If there is no shuttle valve, piston (4) and valve (2) will separate. In this condition, if another actuator is operated, the piston acts as an accumulator, so there is a time lag.
LS pressure ,
/
,
I-
Time lag
I-P-
Holding pressure
L
I
w
Time SAW0217
PC300, 350-6
lo-69
STRUCTURE
7.
AND
Variable type pressure (for service valve)
From valve
1. 2. 3. 4. 5. 6. 7. 8.
Valve Spring Sleeve Poppet Spring Screw Locknut Plastic cap
1O-70
CLSS
FUNCTION
service ~~001
compensation
a binder port
valve
b Load other
~reeeure from work equipment
SWPO5093
Function . It is possible to adjust the division of the oil flow to the service valve when the service valve (for attachment) is operated together with the main control valve (boom RAISE, etc.). (Variable in proportion to surface area) . The pump pressure leaving the service valve spool acts on the left end of valve (I), and at the same time passes through throttle a and enters chamber g. The maximum LS pressure passes through throttle d and enters chamber e. At the same time, the cylinder port pressure passes through passage c and throttle f, and goes to chamber h. In addition, the force of spring (2) acts on valve (I), and the force of spring (5) acts on poppet (4). The force of spring (5) can be adjusted with screw (6)
PC300, 350-6
STRUCTURE
AND
FUNCTION
Operation Simultaneous operation with work equipment under heavy load (boom RAISE, etc.) 1. The pump pressure and LS pressure are determined by the pressure of the other work equipment, but the cylinder port pressure becomes the actuating pressure of the attachment. When the difference between the pump pressure and the cylinder pressure is less than the force of spring (51, then balance of the force acting on valve (I) is as follows. PxAl=PxA2+LS(A2-Al)+F Al: Cross-sectional area of diameter Dl A2: Cross-sectional area of diameter D2 ( F: Force of spring 2.
If the difference between pump pressure P and the cylinder pressure becomes greater than the force of spring (51, poppet (4) is pushed to the right and the passage opens, so the pump passage is connected to the cylinder port through throttle a, chamber g, and passages b and c, and the oil flows to the cylinder port. When this happens, a differential pressure is formed between the upstream and downstream sides of throttle a, and the pressure in chamber g goes down, so the force pushing valve (I) to the left is reduced. In other words, the area ratio becomes smaller, so valve (I) moves to the right and increases the flow from the pump to the cylinder.
PC300, 350-6
CLSS
Dl
From valve
service ~~001
D2Dl
I
port SWPO5094
@p From valve
service spool
\
CvI inder port SWPO5095
10-71
CLSS
STRUCTURE AND FUNCTION
8.
Boom regeneration
Raise
circuit
Lower
SWPO5096
1. 2. 3A. 3B. 4A. 4B. 5. 6. 7. 8.
Main pump Main spool Pressure compensation valve Pressure compensation valve Suction valve (with safety) Suction valve Check valve LS shuttle valve Drain circuit circuit Regeneration
Function I) Cylinder head pressure < cylinder bottom pressure (free fall, etc.) . A return flow circuit is provided from the cylinder bottom to the cylinder head so that when the boom is lowered, the return flow can be used to increase the flow of oil from the pump to the cylinder bottom.
Operation . When the cylinder
head pressure < cylinder bottom pressure, part of the pressurized oil from the cylinder bottom passes through the notch in spool (21, goes through port B, and enters drain circuit (7). The rest of the oil goes from port C, enters regeneration circuit (81, opens check valve (51, and passes through ports C and D to flow back to the cylinder head.
1 O-72
PC300, 350-6
STRUCTURE
AND
FUNCTION
RAISE
2)
.
CLSS
LOWE
Cylinder head pressure > Cylinder bottom pressure (digging operations, etc.) Check valve (5) in regeneration circuit (8) acts to shut off the flow from the cylinder head to the cylinder bottom.
PC300, 350-6
1o-73
STRUCTURE
9.
AND
CLSS
FUNCTION
Arm regeneration
circuit
IN
OUT
38
4A SWPO5097
1. 2. 3A. 3B. 4A. 4B. 5. 6. 7. 8.
Main pump Main spool Pressure compensation Pressure compensation Safety valve Safety valve Check valve LS shuttle valve Drain circuit circuit Regeneration
valve valve
Function Cylinder head pressure > cylinder bottom pressure . A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved IN, the flow of oil to the cylinder becomes the pump discharge amount + the return flow. This covers for any negative pressure at the cylinder bottom, and, as a result, increases the cylinder speed. Operation When the cylinder head pressure > cylinder bottom pressure, the pressurized oil from the cylinder head passes through the notch in spool (21, enters port C and opens check valve (8), then passes through ports D and E to flow back to the cylinder bottom. l
1o-74
PC300, 350-6
STRUCTURE
AND
10. Merge/flow
CLSS
FUNCTION
divider 5
valve A
0
C
7
D
8’
PS
'OFFJ
To control
valve
To control
valve
P2
PI SWPO5098
1. 2. 3. 4. 5. 6. 7. 8.
Main spool Spring LS spool Spring LS circuit (bucket) LS circuit (arm) LS circuit (arm) LS circuit (bucket)
Function This acts to merge or divide (send each to its own control valve group) oil flows PI and P2 of pressurized oil discharged from the two pumps. . At the same time, it also carries out merging and dividing of the LS circuit pressure. l
PC300, 350-6
Operation I) When merging pump flow (when pilot pressure PS is OFF) . Pilot pressure PS is OFF, so main spool (I) is pushed fully to the left by spring (21, and ports E and F are interconnected. Therefore, pressurized oil flows PI and P2 discharged from the two pumps are merged at ports E and F, and are sent to the control valve that demands the oil. . In the same way, LS spool (3) is also pushed fully to the left by spring (41, so the ports are connected as follows. Connected ports: A ++ D, B t) C Therefore, the LS pressure supplied from the spools of each control valve to LS circuits (5), (61, (71, and (8) is all sent to the pressure compensation valve and other valves.
l
1o-75
STRUCTURE
AND
CLSS
FUNCTION
To bucket control
To arm control
P2
21 l
.
When dividing pump flow (when pilot pressure PS is ON) When pilot pressure PS is ON, main spool (I) is moved to the right by the PS pressure, and ports E and F are disconnected. Therefore, the pressurized oil discharged from each pump is sent to its own control valve group. Pressure PI: To bucket, R.H. travel, boom group Pressure P2: To swing, L.H. travel, arm group In the same way, LS spool (3) is also moved to the right by the PS pressure, and the ports are connected as follows. Connected ports: B t) D, others are not connected. Therefore, LS circuits (5), (61, (7), and (8) are all connected to their own control valve group.
1O-76
PC300, 350-6
STRUCTURE
AND
FUNCTION
CLSS
11.
LS select valve
*
The diagram shows the situation when the swing and left travel are operated at the same time. (BP pressure ON)
9
1. 2. 3. 4. 5. 6. 7. 8. 9.
Valve Spring Piston Piston Swing spool L.H. travel spool Arm spool LS shuttle valve LS circuit
SLPO0225
Function This valve is used to increase the ease of operating the work equipmentlt prevents high pressure from being generated when the swing is operated. It also prevents the high LS pressure from the swing circuit from flowing into any other LS circuit when the swing is operated together with the work equipment.
l
Operation 1) When pilot pressure BP is OFF . Pilot pressure BP is OFF, so piston (3) is pushed to the left by spring (2). If the swing is then operated, swing LS pressure PI passes through swing spool (5) and enters port A. It pushes valve (I) to the left and connects ports A and B. Therefore, swing LS pressure PI flows to LS shuttle valve (8). 2) When pilot pressure BP is ON . When pilot pressure BP is ON, piston (3) is moved to the right against spring (2) by the BP pressure. It pushes valve (I) to the right and closes the circuit between ports A and B. As a result, swing LS pressure PI stops flowing to LS shuttle valve (81, and even if swing LS pressure PI rises to a high pressure, it does not influence any other LS circuit.
PC300, 350-6
4
3
2
B
1
A
To LS shuttle valve SLFQO226
3
2
Bl
p
BY
(ON)
To LS shuttle valve SLPO0227
1o-77
STRUCTURE
12.2~stage
AND FUNCTION
safety
valve
(installed
CLSS
to boom cylinder
head) 1. 2. 3. 4.
Spring Piston Spring Holder
SAP00228
Function . The set pressure of the safety valve can be set to two stages and the low pressure setting can be made smaller. Because of this, when digging with boom, even if high pressure is brought to bear on the boom cylinder, it is possible to let the boom escape without operating the control lever. This makes it possible to carry out operations with high efficiency and with little vibration of the chassis. Operation . The set pressure of the safety valve is determined by the load pressure of spring (I). 1) When pilot pressure P is OFF: high pressure setting . Pilot pressure P is OFF, so piston (2) is pushed to the left by spring (3). (Installed load of spring (1) c installed load of spring (3)). When this happens, the installed load of spring (I) becomes the maximum, and the set pressure is set to high pressure. In addition, passage B is connected to the drain circuit through passage C and chamber D. 21 When pilot pressure P is ON: low pressure setting . When pilot pressure P is ON, the pilot pressure goes to portion A through passage B, and piston (2) acts on the diameter of portion A receiving the pressure (d2 - dl). Piston (2) is moved to the right against spring (3) by this pilot pressure. It moves the full stroke until it contacts holder (4). As a result, spring (I) extends, the installed load becomes the minimum, and the set pressure is set to low pressure. In addition, an amount of oil equivalent to the piston stroke passes through passage C and chamber D, and is drained.
1 O-78
SAP00229
lA23B4
SAW0230
PC300, 350-6
STRUCTURE
AND
OPERATION When all work
CLSS
FUNCTION
OF CLSS SYSTEM AS A WHOLE equipment
is at neutral
Sr The valves and circuits that are not connected with the explanation operation of the CLSS hydraulic system have been omitted.
of the
r
SWPO4733
1 O-80
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
Max.
Mi'n
I
-
SWPO4734
PC300, 350-6
lo-81
STRUCTURE AND FUNCTION
1. 2A. 2B. 3A. 3B. 4A. 4B. 5A. 5B. 6. 7. 8. 9. IO. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Hydraulic tank Main pump (front) Main pump (rear) TVC valve (front) TVC valve (rear) LS valve (front) LS valve (rear) Merge/flow divider valve (main) Merge/flow divider valve (for LS) Bucket spool R.H. travel spool Boom Lo spool Swing spool L.H. travel spool Arm Lo spool Boom Hi spool Arm Hi spool Pressure compensation valve (with shuttle valve) Pressure compensation valve (with shuttle valve, integrated type) (bucket CURL) Pressure compensation valve (without shuttle valve) (travel) Safety-suction valve Safety-suction valve (bucket CURL) 2-stage safety-suction valve (boom LOWER)
ass
20. Plug 21. LS shuttle valve (bucket) 22. LS shuttle valve (R.H. travel) 23. LS shuttle valve (boom) 24. LS shuttle valve (L.H. travel) 25. LS shuttle valve (arm) 26. Check valve (for boom regeneration circuit) 27. Check valve (for arm regeneration circuit) 28A.Main relief valve (bucket group) 28B. Main relief valve (arm group) 29A.Unload valve (bucket group) 29B. Unload valve (arm group) 30. LS select valve 31. LS check valve 32. LS bypass valve 33. Suction valve 34. Service spool 35. Variable type pressure compensation valve 36. LS shuttle valve (service)
Note: Groups of control valves by main pump circuit Bucket group: Bucket, R.H. travel, boom Lo, boom Hi, Arm Hi Arm group: Swing, L.H. travel, arm Lo Operation (When all work equipment is at neutral) When the levers are at neutral, the pump is at the minimum swash plate angle, and the oil flow is drained from unload valves (29A, 29B). The LS pressure is connected to hydraulic tank (I) by LS bypass valve (32). The LS differential pressure APLS (unload pressure -tank pressure) at this point is APLS > pump LS control pressure, so the pump swash plate angle is the minimum. l
l
1 O-82
PC300, 350-6
STRUCTURE
When
AND
pump flow
CLSS
FUNCTION
merged,
bucket
CURL operated
independently
I I
i
SWPO4735
Connection of ports when pump flow is merged Connected ports: A - D, B - C
1 O-84
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWP04736
PC300, 350-6
1 O-85
STRUCTURE
AND FUNCTION
CLSS
Operation (When pump flow merged, bucket CURL operated independently) . When the bucket CURL is operated, unload valves (29A, 29B) are closed. . The swash plate of the main pump is controlled (LS control) to match the area of the meter-in opening of bucket spool (61, so the pump swash plate is balanced at a position which matches the oil flow demanded by the spool meter-in. (APLS = pump LS control pressure)
1O-86
PC300, 350-6
STRUCTURE
AND
FUNCTION
When pump flow merged, boom RAISE operated (Boom Lo valve + boom Hi valve)
CLSS
independently
SWPO4737
Connection of ports when pump flow is merged Connected ports: A - D, B - C
1O-88
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
Max
Mi’n
I
I
SWP04738
PC300, 350-6
1O-89
STRUCTURE
AND
FUNCTION
CLSS
Operation (When pump flow merged, boom RAISE operated independently) . When the boom RAISE is operated, unload valves (29A, 29B) are closed. The swash plate of the main pump is controlled (LS control) to match the total area of the meter-in opening of boom Lo spool (8) and boom Hi spool (12). (APLS = pump LS control pressure) . When the spool meter-in opening comes near the maximum, both pumps are at the maximum swash plate angle. (When the pump discharge is the maximum, the maximum area of opening of the spool is also large, so the LS differential pressure is smaller than the LS control pressure and the swash plate angle is always at the maximum.) (APLS c pump LS control pressure) l
1O-90
PC300, 350-6
STRUCTURE
AND FUNCTION
When pump flow merged, arm IN operated (Arm Lo valve + arm Hi valve)
CLSS
independently
SWPO4739
Connection of ports when pump flow is merged Connected ports: A - D, B - C
1 O-92
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWPO4740
PC300, 350-6
1o-93
STRUCTURE
AND
FUNCTION
CLSS
Operation (When pump flow merged, arm IN operated independently) . When the arm IN is operated, unload valves (29A, 29B) are closed. . The swash plate of the main pump is controlled (LS control) to match the total area of the meter-in opening of arm Lo spool (I I) and arm Hi spool (13). (APE = pump LS control pressure) . When the spool meter-in opening comes near the maximum, both pumps are at the maximum swash plate angle. (When the pump discharge is the maximum, the maximum area of opening of the spool is also large, so the LS differential pressure is smaller than the LS control pressure and the swash plate angle is always at the maximum.) (APLS c pump LS control pressure)
1o-94
PC300, 350-6
STRUCTURE
AND
FUNCTION
When pump flow merged, arm OUT operated (Return circuit arm Lo + arm Hi)
CLSS
independently
To
Hi
valve
SWPO5133
Connection of ports when pump flow is merged Connected ports: A - D, B - C
1O-96
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWP04742
PC300, 350-6
1o-97
STRUCTURE
AND
FUNCTION
CLSS
Operation (When pump flow merged, arm OUT operated independently) When the arm OUT is operated, unload valves (29A, 29B) are closed. . The swash plate of the main pump is controlled (LS control) to match the area of the meter-in opening of arm Lo spool (II), so the pump swash plate is balanced at a position which matches the oil flow demanded by the spool meter-in. (APLS = pump LS control pressure) . When this happens, the oil from the cylinder bottom is divided, sent to the Lo and Hi spools, and then returned, so it is possible to keep the pressure loss in the circuit small. l
1O-98
PC300, 350-6
STRUCTURE
When
AND
FUNCTION
pump flow divided,
travel
CLSS
operated
independently
SWPO4743
Connection of ports when Connected ports: B - D Disconnected ports: A, C
10-100
pump flow is divided
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWPO4744
PC300, 350-6
10-101
STRUCTURE
AND
FUNCTION
CLSS
Operation (When pump divided, travel operated independently) . Pilot pressure PA of merge/flow divider valve (5A) ON I) . When the STRAIGHT TRAVEL is operated, a flow of oil is supplied from the main pump to match the stroke of the left and right travel spools (IO) and (7). Flow of oil from main pump (2A): To L.H. spool (IO) (arm group) Flow of oil from main pump (28): To R.H. spool (7) (bucket group) . The straight travel is compensated by the travel junction valve. 2) .
From the condition in I) above, if the lever on the side being steered is returned (the oil flow becomes small) or the lever on the other side is operated in the opposite direction (the direction of travel is reversed), the oil flow from the pump is being divided, so the left and right travel circuits are controlled independently and the machine is steered.
10-102
PC300, 350-6
STRUCTURE
When
AND
pump flow
FUNCTION
merged,
arm IN + boom
CLSS
RAISE operated
simultaneously
c
SWPO4745
Connection of ports when pump flow is merged Connected ports: A - D, B - C
10-104
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWP04746
PC300,
350-6
10-105
STRUCTURE
AND
FUNCTION
Operation (When pump flow merged, boom RAISE operated simultaneously)
CLSS
arm IN +
1) . When the arm and boom are operated .
simultaneously, the swash plate angle for both pumps becomes the maximum. When this happens, the load pressure at the boom RAISE side is higher than at the arm side, so the LS pressure passes through ports E and F of boom Lo spool (8), enters boom LS shuttle valve (23) and is sent to the LS circuit. This LS pressure is transmitted to port G of pressure compensation valve (141, and acts to increase the set pressure of the pressure compensation valve. Because of this, the pressure between port H of arm Lo spool (II) and port I of pressure compensation valve (14) rises, and the spool meter-in LS differential pressure (pump pressure LS pressure = APL9 becomes the same as that at the boom end.
2) . Because of the above operation, the oil flow
.
is divided in proportion to the total area of opening of boom Lo spool (8) and boom Hi spool (121, and the total area of opening of arm Lo spool (II) and arm Hi spool (13). Meter-in LS differential pressure APLS during boom RAISE + arm IN is APLS c pump LS control pressure, so the main pump swash plate angle is set to maximum.
lo-106
PC300, 350-6
STRUCTURE
When
AND
pump flow
FUNCTION
merged,
swing
CLSS
+ boom
RAISE operated
simultaneously
SWPO4747
Connection of ports when pump flow is merged Connected ports: A - D, B - C
lo-108
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWPO4748
PC300, 350-6
10-109
STRUCTURE AND FUNCTION
CLSS
Operation (When pump flow merged, swing + boom RAISE operated simultaneouslv) When the boom RAISE is being operated in the heavy-duty digging mode the swing is operated simultaneously, the pilot pressure of LS divider valve (30) is turned ON. When this happens, the LS divider valve is shut off, and the high pressure generated when the swing is operated does not flow to the LS circuit, so the LS circuit pressure becomes the boom pressure. The swash plate of the main pump is controlled (LS control) by the difference in pressure between the boom and LS pressure. In addition, the pump pressure is determined by the boom pressure, so even if the swing drive pressure is high, the pump can deliver an ample flow of oil regardless of the pump output curve.
LS select valve ON
10-l10
LS select valve OFF
P SWPO5099
PC300, 350-6
STRUCTURE
AND
FUNCTION
When pump flow divided operated simultaneously
(pump
CLSS
pressure:
19.6 MPa (200 kg/cm21 or above),
travel
+ boom
RAISE
SUP04149
Connection of ports when Connected ports: B - D Disconnected ports: A, C
10-112
pump flow is divided
PC300, 350-6
CLSS
STRUCTURE AND FUNCTION
PLS2 @-I
II-
PLSl@---j’[
iTF--I
w-l
SWPO5134
PC300, 350-6
10-113
STRUCTURE AND FUNCTION
CLSS
Operation (When pump flow divided (pump pressure: 19.6 MPa I200 kg/cm*} or above), travel + boom RAISE operated simultaneously) l When the travel and boom RAISE are operated simultaneously (such as when raising the boom before traveling up a steep slope), if the pump pressure rises to 19.6 MPa (200 kg/cm*), the merge/flow divider valve pilot is turned ON and the pump flow is divided. . In addition, the boom Hi spool does not move because of the travel PPC pressure. The flow of oil to the boom at this point is restricted, so the travel pressure is maintained and it is possible to carry out compound operations easily.
10-114
PC300, 350-6
STRUCTURE
AND
FUNCTION
When pump flow divided simultaneously
(pump pressure:
CLSS
19.6 MPa (200 kg/cm*}
or above),
travel + arm IN operated
Travel PPC Dressure
SWPO5135
Connection of ports when Connected ports: B - D Disconnected ports: A, C
10-116
pump flow is divided
PC300, 350-6
STRUCTURE AND FUNCTION
CLSS
SWPO4752
PC300, 350-6
10-117
STRUCTURE
AND
FUNCTION
CLSS
Operation (When pump flow divided (pump pressure: 19.6 MPa I200 kg/cm21 or above), travel + arm IN operated simultaneously) When the travel and arm IN are operated l simultaneously (such as when using the digging action of the arm to help the machine travel up a steep slope), if the pump pressure rises to 19.6 MPa (200 kg/cm*), the merge/flow divider valve pilot is turned ON and the pump flow is divided. . In addition, the stroke of the arm Lo spool is restricted by the travel PPC pressure. The flow of oil to the arm at this point is restricted, so the travel pressure is maintained and it is possible to carry out compound operations easily.
lo-118
PC300, 350-6
STRUCTURE AND FUNCTION
SWING
SWING MOTOR
MOTOR
KMFl60ABE-3 T2
SWPO4753
B : From swing brake solenoid S : From lift check valve MA: From control valve MB: From control valve Tl :To tank T2 : To port S
valve
Specifications Model: Theoretical
KMFlGOABE-3 160.7 cc/rev Safety valve set pressure: 28.7+Od5 MPa delivery:
1293’5, kg/cm21 Rated speed: Brake releasing
10-120
1,680 rpm pressure: 1.8 + 0.4 MPa U8.4 f 4 kg/cm2}
PC300, 350-6
STRUCTURE
AND
FUNCTION
SWING
MOTOR
A-A SWPO4754
1. 2. 3. 4. 5. 6. 7. 8.
Spring Output shaft Oil seal Case Plate Disc Brake piston Housing
PC300, 350-6
9. 10. 11. 12. 13. 14. 15. 16.
Piston assembly Cylinder block Spring Center shaft Valve plate Suction valve spring Suction-safety valve Reverse prevention valve
10-121
STRUCTURE
AND
FUNCTION
SWING
MOTOR
SUCTION-SAFETY VALVE Function . When the swing is stopped, the outlet port circuit of the motor is closed by the control valve, but the motor continues to be turned by the inertia of the swing. As a result, the pressure at the outlet port of the motor becomes abnormally high and there is danger that the motor will be damaged. The safety valve is installed to prevent this problem. It acts to release the abnormally high pressure oil from the outlet port of the motor to port S, and also functions as a swing brake. The suction valve supplies an amount of oil equivalent to the amount of oil released by the safety valve. It sends this oil from port S to the inlet port of the motor to prevent any cavitation. l
l
Operation 1. When starting swing . If the swing control lever is operated to swing to the right, the pressurized oil from the pump passes through the control valve and it supplied to port MA. . When this happens, the pressure at port MA rises and the starting force is generated in the motor, so the motor starts to turn. The oil from the outlet port of the motor flows from port MB through the control valve and returns to the tank. 2. When stopping swing . When the swing control lever is returned to the neutral position, no more pressurized oil is supplied from the pump to port MA. At the same time, the oil from the outlet port of the motor returns from the control valve to the tank, and the circuit is closed. . The pressure at port MB rises, and rotating resistance to the motor is generated, so the brake starts to take effect. If the pressure at port MB rises to the set pressure of safety valve (I), safety valve (I) opens and releases the pressurized oil at port MB to port S. . No pressurized oil is supplied at port MA, but the swing continues, so negative force is generated. When this negative pressure drops to the set pressure of suction valve (2), suction valve (2) opens and oil is supplied from port S to prevent cavitation.
10-122
SAP00246
PC300, 350-6
STRUCTURE
SWING
AND FUNCTION
Operation of swing brake 1) Swing brake solenoid valve de-energized If the swing brake solenoid valve is de-energized, the flow of pressurized oil from the main pump is shut off, and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (I), pushes disc (6) and plate (5) together, and the brake is applied.
Main
MOTOR
PumP
swP05100
2)
Swing brake solenoid valve energized When the swing brake solenoid valve is energized, the valve is switched, and pressurized oil from the main pump enters port B and flows to brake chamber a. The pressurized oil entering chamber a overcomes brake spring (1) and pushes brake piston (7) up. As a result, disc (6) and plate (5) are separated and the brake is released.
SWPO5101
PC300, 350-6
lo-123
STRUCTURE AND FUNCTION
REVERSE
PREVENTION
SWING
MOTOR
VALVE
Operation 1. 2. 3. 4. 5. 6. 7.
,/ 8, .: 5: I,
Valve body Spool (MA side) Spring (MA side) Plug Spool (MB side) Spring (MB side) Plug
,, , i // ::
5: 5, :, 5, 5, I,
I, :,
WA
Swind
control
valve
NV SAP03475
Explanation
of effect
:wlth ----------
Pressure
MA
Pressure
MB
Motor
Reversal
reversal
:without
pr ‘eventton
reverea
valve
Prevention
valve
Pressure
speed
I
L
Start
1
Brake
_I_
Reversa
I Time
-
SAP03476
lo-124
PC300, 350-6
STRUCTURE
AND
FUNCTION
SWING
MOTOR
Outline This valve reduces the swing back generated in the swing body by the inertia of the swing body, the backlash and rigidity of the machinery system, and the compression of the hydraulic oil when the swing is stopped. This is effective in preventing spillage of the load and reducing the cycle time when stopping the swing (the positioning ability is good and it is possible to move swiftly to the next job).
/ Notch
SAP03477
Operation II When brake pressure is being generated at port MB . Pressure MB passes through the notch and goes to chamber d, spool (5) pushes spring (6) according to the difference in area Dl > D2, moves to the left, and MB is connected to e. When this happens, pressure MA is below the set pressure of spring (3), so spool (2) does not move. For this reason, the pressure oil is closed by spool (21, and the braking force is ensured.
2) After motor stops The motor is reversed by the closing pressure generated at port MB. (1st reversal) When this happens, reversal pressure is generated at port MA. Pressure MA goes to chamber a, so spool (2) pushes spring (3) and moves to the right, and MA is connected to B. At the same time, b is connected to f through the drill hole in spool (5), so the reversal pressure at port MA is bypassed to port T to prevent the 2nd reversal. l
SAP02642
PC300, 350-6
lo-125
STRUCTURE
AND
FUNCTION
CENTER
SWIVEL
JOINT
CENTER SWIVEL JOINT
El
E2
A-4
A-A
T2
82
D2
A2
c2 SBPOO249
1. 2. 3. 4. 5.
Cover Body Slipper O-ring Shaft
lo-126
seal
Al A2 Bl B2 Cl C2
: From control : To R.H. travel : From control : To L.H. travel : From control : To R.H. travel
valve port 62 motor port PB valve port B5 motor port PA valve port A2 motor port PA
Dl D2 El E2
: From control valve port A5 : To L.H. travel motor port PB : From travel speed EPC valve : To L.H. and R.H. travel motors port P Tl : To tank T2 : From L.H. and R.H. travel motors port T
PC300, 350-6
STRUCTURE AND FUNCTION
TRAVEL MOTOR
TRAVEL MOTOR HMVl60ADT-2
6
z
P : From travel speed solenoid T :To tank PA: From control valve PB : From control valve
valve
Specifications Model: Theoretical delivery: Brake releasing Travel speed pressure:
pressure:
SWPO4757
HMVI 60ADT-2 Min 110.1 cc/rpm Max 160.8 cc/rpm 1.2 f 0.4 MPa {I2 + 4 kg/cm21
switching 0.8 $1” MPa (8 :f kg/cm*)
lo-128
PC300, 350-6
TRAVEL MOTOR
STRUCTURE AND FUNCTION
‘a
21
22 SWPO4758
B-0
1. 2.
3. 4. 5. 6. 7. 8.
Output shaft Motor case Rocker cam Piston Cylinder Valve plate End cover Slow return valve
PC300, 350-6
9. 10. 11. 12. 13. 14. 15. 16.
Brake spring Brake piston Plate Disc Regulator piston Spring Check valve spring Check valve
17. 18. 19. 20. 21. 22.
valve Counterbalance Spool return spring Safety valve Ball Regulator valve Spring
lo-129
TRAVEL MOTOR
STRUCTURE AND FUNCTION
Operation of motor 1) At low speed (motor swash plate angle at maximum)
I
The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P. For this reason, regulator valve (21) is pushed fully to the right by spring (22). Because of this, it pushes slow return valve (81, and the main pressure oil from the control valve going to end cover (7) is shut off by regulator valve (21). Fulcrum a of rocker cam (3) is eccentric to point of application b of the combined force of the propulsion force of the piston of cylinder (51, so the combined force of the piston propulsion force acts as a moment to angle rocker cam (3) in the direction of the maximum swash plate angle.
10-130
.
l
At the same time, the pressurized oil at regulator piston (13) passes through orifice c in regulator valve (21) and is drained to the motor case. As a result, rocker cam (3) moves in the maximum swash plate angle direction, the motor capacity becomes maximum, and the system is set to low speed.
PC300, 350-6
STRUCTURE AND FUNCTION
2)
At high speed (motor swash plate angle at minimum)
.
When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (21) to the left. Because of this, the main pressure oil from the control valve passes through passage d in regulator valve (21), enters regulator piston (131, and pushes regulator piston (13) to the right. As a result, rocker cam (3) moves in the minimum swash plate angle direction, the motor capacity becomes minimum, and the system is set to high travel speed.
.
.
PC300, 350-6
TRAVEL MOTOR
10-131
STRUCTURE
AND
FUNCTION
TRAVEL
MOTOR
Operation of parking brake 1) When starting to travel l When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (17), opens the circuit to the parking brake, and flows into chamber a of brake piston (10). It overcomes the force of spring (91, and pushes piston (IO) to the right. When this happens, the force pushing plate (II) and disc (12) together is lost, so plate (11) and disc (12) separate and the brake is released.
SWPO5104
21 When stopping travel . When the travel lever is placed in neutral, counterbalance valve spool (17) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber a of brake piston (10) is drained to the case from the orifice in the brake piston, and brake piston (IO) is pushed fully to the left by spring (9). As a result, plate (11) and disc (12) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (8) when the brake piston returns, and this ensures that the brake is applied after the machine stops.
lo-132
SWPO5105
PC300, 350-6
STRUCTURE
AND
FUNCTION
TRAVEL
MOTOR
Operation of brake valve . The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as shown in the diagram on the right. (Fig. 1) . The function and operation of each component is as given below.
1) Counterbalance valve, check valve Function . When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount). Operation when pressurized oil is supplied . When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open check valve (18a) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by check valve (18b) and spool (191, so the pressure at the supply side rises. (Fig. 2). . The pressurized oil at the supply side flows from orifice El in spool (19) and orifice E2 in the piston to chamber Sl. When the pressure in chamber Sl goes above the spool switching pressure, spool (19) is pushed to the right. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig. 3).
(Fig. I)
Control valve -1
(Fig. 2) SAP00263
Control valve
(Fig. 3)
PC300, 350-6
SAW0262
STRUCTURE
TRAVEL
AND FUNCTION
Operation of brake when traveling downhill . If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber Sl through orifices El and E2 will also drop. When the pressure in chamber Sl drops below the spool switching pressure, spool (19) is returned to the left by spring (20), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. (Fig. 4)
(Fig. 4)
Safety valve (Pdirection operation, 2-stage set safety valve) Function When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment.
MOTOR
SBPO0265
2)
l
(Fig. 5) SBPO0266
Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) . When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. (Fig.
.
5) If the pressure goes above the set pressure, the force produced by the difference in area between Dl and D2 [7c4(D12 - D22) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the opposite side. (Fig. 6).
10-134
D2 Dl
MB
I
P&et (Fig. 6) SBP00267
PC300, 350-6
STRUCTURE
2) .
AND
FUNCTION
TRAVEL
MOTOR
When pressure in chamber MA has become high (when rotating counterclockwise) When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. (Fig. (Fig. 7)
7)
SBPC0268
.
If the pressure goes above the set pressure, the force produced by the difference in area between Dl and D3 [~/4(D3~ - D12) x pressure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the opposite side. (Fig. 8)
Poppet (Fig. 8) SBPOO269
Operation of mechanism for varying set pressure II When starting travel (high-pressure setting) . When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (191, and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a large drawbar pull is made available.
Piston
Spr ino
\
MA
I
Travel valve
control
IF i g. 9)
PC300, 350-6
SWPO5106
10435
STRUCTURE
2) .
AND
FUNCTION
TRAVEL
When stopping travel (low-pressure setting) When the travel lever is placed at neutral, the pressure in chamber PA drops and counterbalance valve spool (19) returns to the neutral position. While the counterbalance valve spool is returning to the neutral position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed.
[Set pressure When starting, when traveling >
Piston
Sprina
of safety valve]
:
High-pressure setting
37.8 MPa (385 kg/cm*)
When stopping: Low-pressure setting
1 27.5
MPa (280 kg/cm?
(Fia. 101
10-136
MOTOR
SWPOSI07
PC300, 350-6
STRUCTURE AND FUNCTION
VALVE CONTROL
VALVE CONTROL
SWPO4765
1. 2. 3. 4. 5. 6. 7. 8.
Travel PPC valve L.H. travel lever R.H. travel lever Right PPC valve Right work equipment lever Active solenoid valve (Swing) Accumulator Solenoid block
PC300, 350-6
9. 10. 11. 12. 13.
Control valve Hydraulic pump LS-EPC valve PPC shuttle valve Left work equipment lever 14. PPC safety lock valve 15. Left PPC valve 16. Safety lock lever
Lever positions : NEUTRAL : Boom RAISE : Boom LOWER : Bucket DUMP : Bucket CURL : NEUTRAL : Arm IN : Arm OUT : Swing right
@ @ @ @I @ @ 0 @ @
@J : Swing left @ : NEUTRAL @I : Travel REVERSE @ : Travel FORWARD @ : LOCK @ : FREE
10-137
STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
l
SWING
l
SWING PPC VALVE
PPC VALVE
SBP04416
P : From main T: To tank
lo-138
pump
PI P2 P3 P4
: L.H.* : L.H.* : L.H.* : L.H.*
Arm OUT/R.H.* Boom LOWER Arm IN/R.H.* Boom RAISE Right swing/R.H: Bucket CURL Left swing/R.H.* Bucket DUMP
PC300, 350-6
STRUCTURE AND FUNCTION
WORK EQUIPMENT
l
SWING PPC VALVE
uu 1'
c-c
A-A
11
r----y
D-D
B-B
E-E SBpoO274
1. Spool Metering spring 3. Centering spring 4. Piston 5. Disc 6. Nut (for connecting
7. 8. 9. 10. 11.
2.
PC300, 350-6
Joint Plate Retainer Body Filter
lever)
10-139
STRUCTURE AND FUNCTION
WORK EQUIPMENT
SWING PPC VALVE
l
OPERATION I) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). (Fig. I)
2)
During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed; spool (I) is also pushed by metering spring (21, and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port PI to port
/ :
:
(Fig.
1) SBPO3493
A. When the pressure at port PI becomes higher, spool (I) is pushed back and fine control 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 PI. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with the pressure at port PI. The relationship in the position of spool (I) and body (IO) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced. (Fig.21
10-140
3;
I)
I/ I/
Control valve iFia.
2)
p@,
,,,,
SBPO3494
PC300, 350-6
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
l
SWING
PPC VALVE
During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port PI. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port PI is released. If the pressure at port PI drops too far, spool (I) is pushed down by metering spring (21, and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port Pl recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3)
SBPO3495
4)
At full stroke When disc (5) pushes down piston (41, and retainer (9) pushes down spool (I), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (fig. 4)
(Fig.4) SBPO3496
PC300, 350-6
10-141
STRUCTURE AND FUNCTION
TRAVEL PPC VALVE
TRAVEL PPC VALVE
II nI nII 4
C-4
SWP04766
P T PI P2 P3 P4
: From main :To tank : L.H. travel : L.H. travel : R.H. travel : R.H. travel
lo-142
pump REVERSE FORWARD REVERSE FORWARD
PC300, 350-6
STRUCTURE AND FUNCTION
TRAVEL PPC VALUE
A-A
f 0
D-D
c-c
1. 2. 3. 4.
PC300,
Plate Body Piston Collar
350-6
SAP01250
5. 6. 7. 8.
Metering spring Centering spring Valve Bolt
10-143
STRUCTURE
AND
FUNCTION
TRAVEL
PPC VALVE
OPERATION 1) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). (Fig. I)
2)
Fine control (neutral -+ fine control) When piston (4) starts to be pushed by disc (51, retainer (9) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the main pump is sent from port A through fine control hole f to port PI. When the pressure at port PI rises, spool (I) is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port PI escapes. As a result, spool (I) moves up and down until the force of metering spool (2) is balanced with the pressure of port PI. The relationship of the position of spool (1) and body (IO) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port PI) and the force of the return spring of the control valve spool are balanced. (Fig.2)
10-144
(Fig.
II
(Fig.
‘2)
SBPO3497
SBPO3498
PC300, 350-6
STRUCTURE
3)
4)
AND
FUNCTION
TRAVEL
Fine control (control lever returned) When disc (5) starts to be returned, spool (I) is pushed up by the force of centering spring (3) and the pressure at port PI. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port PI is released. If the pressure at port PI drops too much, spool (1) is pushed up by metering spring (21, so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port PI supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)
(Fia
3)
PPC VALVE
SBP03499
At full stroke Disc (5) pushes down piston (4), and retainer (9) pushes down spool (I). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. (Fig. 4) f/1
Self-Reducing
PP
(Fig.
PC300, 350-6
4)
10-145
STRUCTURE AND FUNCTION
SERVICE PPC VALVE
SERVICE PPC VALVE
q---f-rp -__------------------_
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Pin Cam Ball Piston Cover Sleeve Centering spring Metering spring Spool Body
A: B: P: T :
To service valve P-l To service valve P-2 From main pump To tank
B SWP04767
10-146
PC300, 350-6
STRUCTURE
AND
FUNCTION
SERVICE
PPC VALVE
OPERATION At neutral . The pressurized oil from the main pump enters from port P and is blocked by spool (9). . Ports A and B of the control valve and ports a and b of the PPC valve are connected to drain port T through fine control hole X of spool (9).
SBPO3500
When operated . When cam (2) is moved, metering spring (8) is pushed by ball (3), piston (41, and sleeve (61, and spool (9) is pushed down by this. . As a result, fine control hole X is shut off from the drain circuit. At almost the same time, fine control portion Y is connected with port a, and the pressurized oil from port P flows from port a to port A of the control valve.
ISelf-Reducing
1
SBPO3501
PC300, 350-6
10-147
STRUCTURE AND FUNCTION
.
l
l
When the pressure at port a becomes higher, spool (9) is pushed back by the force acting on the end of the spool. When fine control portion Y closes, fine control hole X is connected to the drain circuit at almost the same time. As a result, spool (9) moves up and down to balance the force at port a and the force at metering spring (8). Therefore, metering spring (8) is compressed in proportion to the amount the control lever is moved. The spring force becomes larger, so the pressure at port a also increases in proportion to the amount the control lever is operated. In this way, the control valve spool moves to a position where the pressure of port A (the same as the pressure at port a) is balanced with the force of the return spring of the control valve spool.
lo-148
SERVICE PPC VALVE
SBPO3502
PC300, 350-6
STRUCTURE
PPC SAFETY LOCK VALVE PPC ACCUMULATOR
AND FUNCTION
PPC SAFETY LOCK VALVE 1. 2. 3. 4. 5.
PPC ACCUMULATOR
1. 2. 3. 4. 5. 6.
Lever Body Seat Ball End cap
Gas plug Shell Poppet Holder Bladder Oil port
Specifications Gas volume: 500 cc
SBPOO290
PC300, 350-6
10-149
STRUCTURE AND FUNCTION
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
PPC SHUTTLE VALVE, TRAVEL JUNCTION
VALVE
SDP01315
1. 2.
PPC shuttle valve Travel junction valve
PC300, 350-6
Outline . The PPC shuttle
valve valve form a combined
and travel structure.
junction
10-151
STRUCTURE
PPC SHUTTLE
AND
FUNCTION
PPC SHUTTLE
TRAVEL
JUNCTION
VALVE
VALVE
P 6.1 P12
VALVE,
P2 1
P22 Al P42
A8
P62
A3
P32
A2
P52
A7
P82
P72
PB2
PA2
PC2
P92
A4
P71
/ PA1
Pi1
PC1
\ PBl
P‘81
PR \
V-AA
AA PF
SWPO476tl
Function . The PPC shuttle valve sends the PPC valve output pressure to the control valve and travel junction valve. It is provided with a mount port for the pressure switch for detecting the pilot pressure.
10-152
PC300, 350-6
STRUCTURE
Al A2
: Mount : Mount
A3 A4 A5
: Mount : Mount : Mount
A6 A7
: Mount : Mount
A8
: Mount
AND
PPC SHUTTLE
FUNCTION
VALVE,
TRAVEL
JUNCTION
VALVE
port for swing pressure switch port for bucket CURL pressure
switch pot-t for arm IN pressure switch port for arm OUT pressure switch port for boom RAISE pressure
switch port for travel pressure switch port for boom LOWER pressure
switch
PI1 PI2 P21 P22 P31 P32 P41 P42 P51 P52 P61 P62 P71 P72 P81 P82 P91 P92 PA1 PA2 PBI PB2 PC1 PC2 PF PR PLS
port for bucket DUMP switch : To control valve (swing) : From swing PPC valve : To control valve (swing) : From swing PPC valve : To control valve (bucket) : From bucket PPC valve : To control valve (bucket) : From bucket PPC valve : To control valve (boom) : From boom PPC valve : To control valve (arm) : From arm PPC valve : To control valve (arm) : From arm PPC valve : To control valve (boom) : From boom PPC valve : To control valve (R.H. travel) : From R.H. travel PPC valve : To control valve (R.H. travel) : From R.H. travel PPC valve : To control valve (L.H. travel) : From L.H. travel PPC valve : To control valve (L.H. travel) : From L.H. travel PPC valve : To travel junction valve : To travel junction valve : From LS select valve
PC300, 350-6
pressure
10-153
STRUCTURE AND FUNCTION
PPC SHUlTLE
F-F
A-A
G-G
B-0
VALVE, TRAVEL JUNCTION
VALVE
N-N
J-J (PPLACES)
L
K-K (2PLACES)
L-L
D-D
-4 M-M
E-E AA-AA SDP00293
1. 2. 3.
Body Plug Ball
10-154
PC300,
350-6
PPC SHUlTLE
STRUCTURE AND FUNCTION
VALVE, TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE PF
T2
T4
Tl
T3
SDP04412
A-A
1. 2. 3. 4. 5. 6.
Body Plug Spring Spool Spring Plug
PC300, 350-6
Tl T2 T3 T4 PF PR
: From : From : From : From : From : From
L.H. R.H. L.H. R.H. PPC PPC
travel control travel control travel control travel control shuttle valve shuttle valve
valve valve valve valve
10-155
PPC SHUTTLE VALVE, TRAVEL JUNCTION
STRUCTURE AND FUNCTION
STRAIGHT-TRAVEL
VALVE
SYSTEM PPC shuttle
valve
assembly
L.H.travel motor
R.H.travel
motor
Right PPC valve Bucket Boom
Bucket
CURL
Bucket
DUMP
Boom Arm
LOWER IN
LS select
Arm
aver
ppc
vaIveL---4-----i--)-t4--
Boom
R.H.
OUT RAISE
L.H.travel
travel
FORWARD L.H. travel REVERSE
I I I
R.H. i-_-i
:______.
14
(h-4
---A-r__+
_.-_-‘-..+____ , r-----J
!
i
j_____c_ I
Travel
,.
travel
REVERSE
L.H.travel FORWARD
I-.____________-
swP05108
Function . A travel junction
.
valve is installed between the travel valve and travel motor to compensate for any difference in the oil flow to the left and right travel circuits when traveling in a straight line. Because of this, the flow of oil to the left and right travel motors when traveling in a straight line is almost the same, so there is no travel deviation.
The travel junction valve interconnects the travel circuits when the straight-travel is operated independently or when the straight travel + another actuator are operated simultaneously. When steering, if the difference in the movement of the travel levers is more than approx. 10 mm, the travel junction valve is switched, and the left and right travel circuits are shut Off.
lo-156
PC300, 350-6
STRUCTURE
AND
FUNCTION
Operation A: PPC output pressure (R.H. travel REVERSE or L.H. travel FORWARD) B: PPC output pressure (R.H. travel FORWARD or L.H. travel REVERSE)
PPC SHUTTLE
VALVE,
TRAVEL
From control valve (L.H. REVERSE)
JUNCTION
VALVE
From control valve (L.H. FORWARD)
When traveling in a straight line in forward or reverse . When traveling forward (or in reverse), there is no difference in the pilot pressure from the PPC shuttle valve (the output pressure of each PPC valve), so the spool is balanced in the middle. In this condition, the R.H. FORWARD and L.H. FORWARD, and R.H. REVERSE and L.H. REVERSE are interconnected through the spool. T----Y From control valve (R.H. REVERSE)
From control valve (R.H. FORWARD) SBPOO296
When steering in forward or reverse When the steering is operated in forward (or reverse), if the difference in the pilot pressure from the PPC shuttle valve becomes greater than the switching pressure (spring force), the spool moves to the right or left and the left and right forward and left and right reverse passages are separated. Because of this, a difference in pressure is created in the left and right circuits, and the steering can be operated.
.
From control valve (L.H. REVERSE)
From control valve (L.H. FORWARD)
From PPC shuttle
., ^
t From control valve (R.H. REVERSE)
“f’ From control valve (R.H. FORWARD) SBPO0297
PC300, 350-6
10-157
STRUCTURE
AND FUNCTION
LS-EPC VALVE
LS-EPC VALVE
A-A
1. 2. 3. 4.
Body Plug Spring Push pin
lo-158
SWPO4770
5. 6. 7.
Coil Pluger Connector
C : To LS valve T : To tank P : From main pump
PC300, 350-6
STRUCTURE
AND
FUNCTION
Function The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. . When it receives signal current i from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
LS-EPC VALVE
MPa
kg/en+)
l
2.9 (30)
-
2.5 (25)
-
2.0
_
1.5 (15)
-
e ; P h ej P 2
(20)
l.O_ (10)
0
200
400
Current
600
800
1000
i
WA) SAP00303
Operation 1. When signal current is 0 (coil de-energized) . There is no signal current flowing from the controller to coil (51, coil (5) is de-energized. . For this reason, spool (2) is pushed to the right by spring (3). As a result, port P closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time, the pressurized oil from the LS valve passes from port C through port T and is drained to the tank.
'
PC300, 350-6
SWPO5109
10-159
STRUCTURE
2. .
. .
.
.
3. . .
.
AND
FUNCTION
When signal current is very small (coil energized, fine control) When a very small signal current flows to coil (51, coil (5) is energized, a propulsion force is generated, and this pushes plunger (6) to the left. Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port P to port C. When the pressure at port C rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (61, spool (2) is pushed to the right. The circuit between port P and port C is shut off, and at the same time, port C and port T are connected. As a result, spool (2) moves up and down so that the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port C. Therefore, the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current.
LS-EPC VALVE
/
LS
valve
+j+
SWPOSI 10
When signal current is maximum (coil energized, operated fully) When the signal current flows to coil (51, coil (5) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (6) is also at its maximum. For this reason, spool (I) is pushed fully to the left by push pin (4). As a result, the flow of pressurized oil from port P flows at its maximum to port C, and the circuit pressure between the EPC valve and LS valve becomes the maximum. At the same time, port T closes and stops the oil from flowing to the tank.
SWPO5111
lo-160
PC300, 350-6
SOLENOID VALVE
STRUCTURE AND FUNCTION
SOLENOID
VALVE
FOR ACTIVE MODE, PUMP MERGE-DIVIDER, SWING BRAKE SOLENOID VALVE
BOOM Hi 2-STAGE SAFETY VALVE, TRAVEL SPEED,
Pl n
/ ACC
SWPO4774
P6C
1. 2. 3. 4. 5.
Active mode solenoid valve Boom Hi 2-stage safety valve solenoid Pump merge-divider solenoid valve Travel speed solenoid valve Swing brake solenoid valve
10-162
valve
: T Al : A2 : A3 : A4 : A5 : PI : ACC: PPC :
To tank To main valve (active mode) To L.H. and R.H. travel motor To main valve (pump merge-divider To main valve (boom control valve) To swing motor From main pump To accumulator To PPC valve
valve)
PC300, 350-6
STRUCTURE
AND
SOLENOID
FUNCTION
1. 2. 3. 4. 5. 6. 7.
VALVE
Connector Movable core Coil Cage Spool Block Spring
‘6
7
SWPO4775
Deactiva
Operation When solenoid is deactivated . When the signal current does not flow from the PPC lock switch or swing lock switch, solenoid (3) is deactivated. For this reason, spool (5) is pushed fully to the right by spring (6). As a result, the circuit between ports P and A closes and the pressurized oil from the main pump does not flow to the actuator. At the same time, the pressurized oil from the actuator flows from port A to port T, and is then drained to the tank. When solenoid is excited . When the signal current flows from the PPC lock switch or swing lock switch to solenoid (3), solenoid (3) is excited. For this reason, spool (5) is pushed to the left in the direction of the arrow. As a result, the pressurized oil from the main pump flows from port P through the inside of spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this stops the oil from flowing to the tank.
c
SWPOSI 12
Exe i
t
SWPO5I13
PC300, 350-6
lo-163
STRUCTURE
AND
BOOM
FUNCTION
BOOM HOLDING
HOLDING
VALVE
VALVE
A-A
;
SWPO4778
1. 2. 3. 4. 5.
Safety-suction Pilot spring Pilot spool Poppet spring Poppet
lo-164
valve
T V Cy Pi
: : : :
To tank From control valve To boom cylinder bottom From PPC valve (pilot pressure)
PC300, 350-6
STRUCTURE
AND
FUNCTION
BOOM
HOLDING
VALVE
Operation 1) At boom RAISE When the boom is raised, the main pressure from the control valve pushes poppet (5) up. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom cylinder.
’
I
Control
lever (Boom)
SWPOSI 14
2)
Boom lever at HOLD When the boom is raised and the control lever is returned to HOLD, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5). At the same time, the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spool (3). As a result, the boom is held in position.
Cont;Epobmjever
a
SWPOCl I5
PC300, 350-6
lo-165
STRUCTURE
3)
AND
FUNCTION
BOOM
HOLDING
VALVE
At boom LOWER When the boom is lowered, the pilot pressure flows to port Pi from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port Cy rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered by orifice a. If the pressure in chamber b drops below the pressure at port V, poppet (5) opens, the pressurized oil flows from port Cy to port V, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, safety valve (I) is actuated and drain oil from port Cy to port T.
SWPO5Il6
10-166
PC300, 350-6
STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
6
SBP00311
1. 2. 3. 4. 5. 6.
Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket
10-168
PC300, 350-6
STRUCTURE AND FUNCTION
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER
PIPING
SBP02755
1. 2. 3. 4. 5. 6. 7. 8.
Hot water pickup piping Air conditioner compressor Refrigerant piping Condenser Receiver tank Hot water return piping Air conditioner unit Duct
PC300, 350-6
A: Fresh air B: Recirculated C:
Hot air/cold
air air
10-169
STRUCTURE AND FUNCTION
ACTUAL ELECTRIC WIRING
ACTUAL ELECTRIC WIRING DIAGRAM
DIAGRAM
(l/2)
10-170
PC300, 350-6
STRUCTURE
PC300, 350-6
AND
FUNCTION
ACTUAL
ELECTRIC WIRING
DIAGRAM
STRUCTURE AND FUNCTION
ACTUAL ELECTRIC WIRING DIAGRAM
38 43
44
48 45
47
62
63 49 64
72
lo-172
71
i0
w
'69
swPo4784
PC300, 350-6
STRUCTURE
AND
1. Working lamp 2. Front pump pressure sensor 3. Rear pump pressure sensor 4. Radiator water level sensor 5. Engine speed sensor 6. Front pump TVC solenoid 7. Rear pump TVC solenoid 8. Window washer tank 9. Hydraulic oil level sensor 10. LS-EPC valve 11. Horn (high tone) 12. Horn (low tone) 13. Battery relay 14. Battery 15. Right head lamp 16. Fuel level sensor 17. Active (swing) solenoid valve 18. Swing brake solenoid valve 19. Travel speed solenoid valve solenoid valve 20. Pump merge/divider 21. Boom Hi 2-stage safety solenoid valve 22. Active (boom) solenoid valve 23. Swing pressure switch 24. Bucket DUMP pressure switch 25. Bucket CURL pressure switch 26. Arm IN pressure switch 27. Boom LOWER pressure switch 28. Arm OUT pressure switch 29. Travel pressure switch 30. Boom RAISE pressure switch sensor 31. Engine water temperature 32. Electrical intake air heater 33. Engine oil pressure sensor 34. Starting motor 35. Air conditioner compressor 36. Engine oil level sensor
PC300, 350-6
ACTUAL
FUNCTION
37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72.
ELECTRIC WIRING
DIAGRAM
Alternator Additional right head lamp Right front lock Room lamp Auto pull-up motor Window limit switch (rear) Left front lock Window limit switch (front) Additional left head lamp Left knob switch Wiper motor Horn switch Fuse box Alarm buzzer Starting switch Fuel control dial Cigarette lighter Swing lock switch Wiper, washer switch Lamp switch Buzzer cancel switch Car heater fan switch Machine push-up switch Front window auto pull-up switch Speaker Kerosene mode connector Air conditioner control panel Governor, pump controller Radio TVC prolix resistor Wiper motor controller Lamp relay Lamp relay Monitor panel Swing prolix switch Pump prolix switch
10-173
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM * For details of this page, see Section 90. (l/31
1
PC300, 350-6
ELECTRIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
*
For details of this page, see Section
P/3)
90. :” -a
“”
UY:
ir
[
’I ~I
(I i
!
i
i ’!
350-6
10-175
\uO
(TO $1
PANEL
LUBRICATION~OPTI
FOR A/C ~ ~~ -.~~ ‘cmi
AIR CONDITIONI r -
iR
UNIT
CONTROLLER
I
TO BATTERY’ RELAY
I’
’
STRUCTURE
AND
FUNCTION
ENGINE
CONTROL
ENGINE CONTROL
SWPO4786
1. 2. 3. 4. 5. 6. 7. 8.
Battery relay Battery Starting switch Fuel control dial Governor motor Starting motor Governor, pump controller Fuel injection pump
lo-178
Function . The engine can be started and stopped simply by using the starting switch (3). . A dial-type engine control is used to control the engine speed. The governor, pump controller (7) receives the control signal from the fuel control dial (4), sends a drive signal to the governor motor (51, and controls the angle of the governor lever in the fuel injection pump.
PC300, 350-6
STRUCTURE
AND
FUNCTION
1. Operation of system Starting engine . When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the governor and pump controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
ENGINE
CONTROL
(Power source)
SBPO0321
Engine speed control . The fuel control dial sends a signal to the governor and pump controller according to the position of the dial. The governor and pump controller calculates the angle of the governor motor according to this signal, and sends a signal to drive the governor motor so that it is at that angle. When this happens, the operating angle of the governor motor is detected by the potentiometer, and feedback is sent to the governor and pump controller, so that it can observe the operation of the governor motor.
Starting
SBPOO322
Stopping engine . When governor and pump controller detects that the starting switch is turned to the STOP position, it drives the governor motor so that the governor lever is set to the NO INJECTION position. . When this happens, to maintain the electric power in the system until the engine stops completely, the governor and pump controller itself drives the battery relay. SEPOO323
PC300, 350-6
10-179
STRUCTURE
ENGINE
AND FUNCTION
CONTROL
2. Components of system Fuel control dial HIGH
1. 2. 3. 4. 5. 6.
Front machi
R
31 U
6
A-A
2 3 l=D
w B
Composition
Knob Dial Spring Ball Potentiometer Connector
1 2 3 of circuit
SBPOO324
Function The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the governor and pump controller. The shaded area in the graph on the right is the abnormality detection area and the engine speed is set at low idling. l
10480
PC300, 350-6
STRUCTURE
Governor
AND
ENGINE
FUNCTION
CONTROL
motor 1. 2. 3. 4. 5. 6. 7. 8.
Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector
Ar-a-l
A-A
@+--+
I L-l I L
I
T
Composition
of circuit
\
8 SBPOO326
Function The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the governor and pump controller. A stepping motor is used for the motor which provides the power. In addition, a potentiometer for giving feedback is installed to allow observation of the operation of the motor. The rotation of the motor is transmitted to the potentiometer through a gear.
PC300, 350-6
Operation Motor stationary . Both A phase and B phase of the motor are continuous, and a holding torque is generated in the motor. Motor rotating . A pulse current is applied to the A phase and B phase from the governor and pump controller to give synchronous rotation with the pulse.
lo-181
STRUCTURE AND FUNCTION
ENGINE CONTROL
Governor, pump controller
CN-Cl7
\ I
CN-co3
\
I
x
I
II ++++++++
CN-Cl6
++++++++++
I
~
/ x
1
++++ +++++ ++++ ++++ x L
CN-co 1
lo-182
CN-co2
I
I SWPO4787
PC300, 350-6
STRUCTURE
AND
Input and output
ENGINE
FUNCTION
signals CN-CO3
CN-CO1 Pin No.
of signal
Pin uo.
relay drive output
Output
d.::
1
Battery
2
Pump merge/divider solenoid/NC
I I 3
Swing
holding
I
Jl 8
9
output
4
selector
solenoid
Active mode solenoid (swing)
11
NC
12
GND
13
Power source
potentiometer
Pressure
Solenoid
of signal
power
source
(+24V)
sensor
9
Knob switch
Output
1.
Hydraulic oil temperature sensor (monitor panel)
Input
Hydraulic
13
Pump R pressure
14
Feedback potentiometer
GND
17
Potentiometer
Governor
motor phase A 1-J Output
18
Starting switch (terminal C)
4
Governor
motor phase B ItI
Output
,g
5
Governor
motor phase B (-)
Output
Automatic controller
I+)
1 (t)
IOutDut
I 9 I TVC solenoid
2 (+)
I Outputl
1TVC
11 12 13 14
I 8 I Radiator
I Input
Input
1 9 1Hydraulic
Input
I 10 I Engine
input
I 11 I Bucket CURL pressure switch
Input
water
level sensor
oil level sensor
speed sensor
GND
Input
1
1 Input 1 1 Input
I
I
Input
I
Input
I
1 12
I Bucket
DUMP pressure switch
I
1 :;
iTNrrl
pressure
1 :;I:;
switch
I
1
Input 15 I 16
Input
17
Engine oil pressure sensor L
I Engine
I but I
oil level sensor
Air cleaner
clogging
Input
sensor
Input
I lnwt I Input Input
greasing abnormality
I
filter sensor
I Input I
Pin No.
Name
Input
I
NC
Input/ output
of signal
Input
1
PPC pressure
2
Boom RAISE pressure switch switch
I I
Input
Input
I Input I
I
Input,
4
S-NET(+)
5
Model
selection
1
Input
6
Model
selection
3
Input
7 I Model
selection
5
8
Swing
prolix switch
9
Overload
output
I
NC
I TVC
solenoid
1 (-)
output
19
TVC solenoid
2 (-)
output
20
NC
18
I
GND
I 3 I Arm IN pressure
Solenoid power source (t24V)
I Input I I Input I I lnout I
CN-Cl7
output
solenoid
8
I Hydraulic
switch
output
input
3
LS-EPC solenoid
valve oressure switch
IGND
) 7 I Engine oil pressure sensor H
Input sensor
Input
I 6 I Service
NC
I Pressure
Input Input
pressure
Input
Output
GND
I 5 I Swing
I
input
motor phase A (+)
7
speed sensor
GND
(alternator
Governor
NC
Engine
3
type)
2
6
2
oil temperature
(thermistor
Battery charge terminal R)
20
speed sensor
(AC0
12
16
Engine
Input/ output
of signal
I4
power
switch
sensor
15
1
output
1Output
Input/ output
Input
Name
I power
Starting
Input
Pin No.
1 Input 1
(+24V)
8
Output
CN-CO2 Name
input
Potentiometer source (+5V)
, ,
,
1Throttle
,
Input (+24V)
of signal
Input/ output
Engine water temperature sensor
source
IO
Pin No.
Name
5 /NC 6
Active mode solenoid (boom)
1Travel
I
I
I
INC
1
output
brake
solenoid
14
CN-16
Input/ output
Name
CONTROL
j
I Input I Input Input
sensor
I IO / Boom LOWER pressure switch1 Input 11 121
1PGND
Arm OUT pressure switch
I Input I
/ 15 I Kerosene 16
PC300, 350-6
Input
1Swing
mode
selection
lock switch
I
Input
I
Input
lo-183
STRUCTURE
AND
ELECTRONIC
FUNCTION
CONTROL
SYSTEM
ELECTRONIC CONTROL SYSTEM CONTROL
FUNCTION 1 Pump & Engine
Mutual
control function
2 Pump and valve control function
3 Power
I
Electronic
control
maximizing
function
3
system
5 Engine automatic warming-up, prevention system
overheat
6 ~
Swing
control function
Active
mode system
8
l-1
*
For details of the self-diagnostic
PC300, 350-6
function,
Self-diagnostic
function
I
see TROUBLESHOOTING.
lo-185
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
?
r
/
Solenoid Active(Swina)
valve
___i
3-
i-~~____________________________________________----------____________________
r
III !-)). Act
Boom
Swine
Hi
i ve
(Bppm),
._/i\_____________________--------_ :
[--,---c”
Work levers
eouiome
2-stat
brake i
Travel
lever
6
If I’ II II /I II ,~______________________------______________----_______-----------------
0
/
1 R
q ip 11
JS
!---------____-----_________---------_________----------______----------J~
Starting switch
box
lo-186
SWPO5120
PC300, 350-6
STRUCTURE AND FUNCTION
ELECTRONIC CONTROL SYSTEM
-=I _L_________,
_4________.
I I I / j
?A
____________________----------------_-__________----------_________--________~
:
I
____________________----------------____________----------____________-________~
ii
r
rr
Buzzer
cancel
switch
knob switch Network
9 Engine throttle controller
A-L 7
Lz______________
L4_____________
1 Resistor
I
I
I(
19
SWPO5121
PC300, 350-6
lo-187
STRUCTURE
AND
FUNCTION
Pump & Engine Mutual
ELECTRONIC
control
CONTROL
SYSTEM
system
w Work
knob
eauiDment
levers
switch
Travel
Shuttle Fuel control
lever
valve
:,
dial
H i
Engine
throttle
controller
(Network
signal)
Monitor
Function There are five modes available for selection with the working mode switch on the monitor panel. These modes are the heavy-duty operation mode (H/O), general operation mode (G/O), finishing operation mode (F/O), lifting operation mode L/O), and the breaker mode (B/O). It is possible to select the most suitable engine torque and pump absorption torque to match the nature of the work.
.
.
Engine torque
.
curve
Engine
Panel SWP05122
.
horsepower H/O, power
The governor and pump controller detects the actual engine speed and the speed set by the engine governor through the fuel control dial in accordance with the pump absorption torque set for each mode, and carries out control so that the pump absorbs all of the torque at each output point of the engine.
curve
.
Pump output
curve
max.
% H/O, power max.
& 3 x I b _c .-: : w
Engine speed N
10488
SAP00330
Engine speed N
SAP00331
Pump discharge
amount
Q
SAP00332
PC300, 350-6
STRUCTURE
1) Control Heavy-duty
AND
Engine speed N
SAP00333
Matching point in heavy-duty mode: Rated output point
operation
172.8 kW (232 HP)/1,950
Heavy-duty
breaker,
finishing
operation
SAP00334
rpm
Pump discharge
amount
%AP00335
mode
.--, I-
___.
LYm.ll ‘.
J
‘\
e
‘.
-\
B
.-F
*.
-.
‘-._
--._
F?
\,
Lu
Engine speed N
.
SYSTEM
When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens, the pump discharge amount is reduced, and the engine speed is controlled so that it becomes near the rated output point. If the reverse happens and the pressure goes down, the system is controlled so that the pump discharge amount is increased until the engine speed becomes near the rated output point. By repeating this control, the engine can always be used at near the rated output point.
l
PC300, 350-6
General,
CONTROL
method in each mode operation mode
Engine speed N
.
ELECTRONIC
FUNCTION
Matching
Partial output
PC300, 350-6
.
point
Mode
F/O
Engine speed N
SAP00336
point
G/O
B/O
90%
85%
136 kW (182 HP)/1,700
F/O 80%
SAP00337
-I
Pump discharge amount Q
SAP00338
When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens, mutual control of the engine and pump is used to control the system so that the pump absorption torque follows the equal horsepower curve of the engine, and the engine speed is lowered while keeping the torque constant. In this way, the engine is used in a range which provides good fuel efficiency
rpm
lo-189
STRUCTURE
Lifting
AND
operation
+ ? P s .-E ? w
ELECTRONIC
FUNCTION
SYSTEM
mode
--__ --._
--__ -0
, :I
1
Engine speed N
.
Matching
Engine speed N
SAP00339
point in lifting operation mode: 60% partial output point
l
PC300, 350-6
YO
Power
102.9 kW (138 HP)/1,500
rpm
SAP00340
Pump discharge
amount
Q
SAP00341
When the lifting operation mode is selected, the engine speed is automatically lowered to the partial position. In this condition, control is carried out in the same way as for the general operation, finishing, and breaker operation modes to match the load on the pump. In this way, the fuel consumption is reduced and the fine control ability is improved.
max. mode, travel
Engine speed N
.
CONTROL
Matching
Engine speed N
SAP00342
point in power
max. mode: Rated output
. point
PC300, 350-6 Power
10-190
max.
172.8 kW (232 HPV1.950
rpm
SAP00343
Pump discharge
amount
Q
SAP00344
When the pump load increases, the engine speed drops. When this happens, the pump discharge is reduced to prevent the engine speed from going down and to ensure that the engine is used at near the rated output point. The cut-off at relief is canceled and the oil flow at relief is increased.
PC300, 350-6
ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
2)
Control ON
function
when
TVC prolix switch
is
SBPO0348
.
Even if any abnormality should occur in the controller or sensor, the TVC prolix switch can be turned ON to provide an absorption torque more or less equivalent to the general operation mode, thereby allowing the machine to maintain its functions.
PC300, 350-6
Pump discharge
amount
0
SAP00349
In this’ case, it is designed to allow a constant current to flow from the battery to the TVC valve, so oil pressure sensing is carried out only by the TVC valve.
10-191
STRUCTURE AND FUNCTION
2.
Pump and valve control
ELECTRONIC CONTROL SYSTEM
function
r---
1
I
’
LS select
m 1
Merge/flow divider valve
,
‘-‘mi
Electric BoVernor
1
Fuel
control
G Servo
\ dia
valve
Hi LS-EPC valve
t
Monitor
panel
SWPO5123
Function . Optimum
matching under various working conditions with the fine control mode function which reduces the hydraulic loss and improves the ease of fine control.
lo-192
PC300, 350-6
STRUCTURE
1) *
.
2) .
AND
ELECTRONiC
FUNCTION
LS control function The switching point (LS set differential pressure) for the pump discharge amount inside the LS valve is changed by changing the output pressure from the LS-EPC valve to the LS valve according to the operating condition of the actuator. Because of this, the timing for starting the discharge amount from the pump can be optimized, to give excellent ease of compound operation and fine control.
CONTROL
LS set differential
Cut-off function If the load becomes large during the operation and the pump discharge pressure rises to a point close to the relief pressure, the pump pressure sensor detects this, and the controller sends a signal to the TVC valve to reduce the discharge amount in order to reduce the relief loss.
pressure
SYSTEM
SAP00351
MPa
Pump discharge
amount
Q SAP00352
31 Cut-off cancel function . The cut-off cancel function stops the actuation of the cut-off function in order to ensure the flow of oil from the pump near the relief pressure, thereby preventing any drop in speed. . The relief pressure when the cut-off function is actuated is 33.8 MPa {345 kg/cm*), but when the cut-off is canceled, the relief pressure rises to approx. 34.8 MPa (355 kg/cm*). Because of this, the hydraulic pressure is increased by one stage. .
Switches
Cut-off canceled
is
Cut-off
is
Z Pump discharge
amount
0
SWPO5124
and cut-off functions Working
Cut-off function %
MPa
mode switch
Swing
Heavy digging
Digging
ON
Actuated
Actuated
Canceled
lock switch OFF Actuated
Knob switch ON Canceled
OFF Actuated
When the swing lock switch is set to ON, hydraulic oil is quickly warmed, also when the swing lock switch is set to ON, the function is canceled. Under these conditions, when work equipment is relieved, hydraulic oil temperature goes up more quickly, and warming time is shortened.
PC300, 350-6
10-193
ELECTRONIC CONTROL SYSTEM
STRUCTURE AND FUNCTION
4) .
Fine control mode function When the finishing mode is selected as the working mode, the pump LS valve is controlled, and the pump discharge amount is reduced to improve the ease of fine control and the precision when finishing.
.
Relationship between working (for independent operation)
*
In each working mode, the full flow of the pump at the set engine speed is taken as 100%.
10-194
mode and pump discharge
amount
PC300, 350-6
AND FUNCTION
STRUCTURE
3.
Power
max. function,
swift
ELECTRONIC CONTROL SYSTEM
slow-down
function
Engine Electric governor
Fuel
_ fuel
control
dial]
T 1 rzz
R I
I
Work equipment lever knob switch
rl
\
/ Monitor
Panel
SWPO5125
Function This function provides an increase in the digging power for a certain time or switches the working mode to the fine operation to reduce the speed. It is operated using the L.H. knob switch to momentarily match the operating conditions. Ir The power max. function and swift slowdown function are operated with the same switch. Only one of these functions can be selected at any time; they cannot both be operated together. l
10-196
PC300, 350-6
STRUCTURE
AND
ELECTRONIC
FUNCTION
CONTROL
SYSTEM
1) Power max. function . During digging operations,
.
when that extra bit of digging power is needed (for example, when digging up boulders), the L.H. knob switch can be pressed to raise the hydraulic pressure by approx. 10% and increase the digging force. If the L.H. knob switch is pressed ON when the working mode is at H/O or G/O, each function is automatically set as follows.
Working mode
Engine, pump control
Cut-off
I function
I
Actuating time
2) Swift slow-down function . During normal operations,
.
if it is desired to carry out lifting operations or finishing operations for a moment, the working mode can be switched to L/O by operating the L.H. knob switch. If the L.H. knob switch is pressed ON when the working mode is at H/O or G/O, each function is automatically set as follows.
Working
Lifting operation
PC300, 350-6
Actuating
mode
1 While
time
switch is kept pressed
10-197
STRUCTURE
4.
AND
FUNCTION
Auto deceleration
ELECTRONIC
CONTROL
SYSTEM
system
Right
work
equipment
level
Engine
Fuel
control
dial
1
Engine
Monitor
~
throttle
controller
Panel
SWPO5126
Function . If all the control levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. . If any lever is operated, the engine speed returns immediately to the set speed.
lo-198
PC300, 350-6
STRUCTURE
AND
FUNCTION
ELECTRONIC
Operation Control levers at neutral . If the engine is running at above the deceleration actuation speed (approx. 1400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. . If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1400 rpm), and is kept at that speed until a lever is operated.
Speed
CONTROL
SYSTEM
When control lever is operated If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial. l
(rpm)
Less than 1
Less than 2
4
I
ITime (set)
Levers at neutral
Lever operated SAP00356
PC300, 350-6
10-199
STRUCTURE
5.
Automatic
AND
FUNCTION
warming-up
ELECTRONIC
and engine
(Water
Monitor
temDerature
overheat
prevention
CONTROL
SYSTEM
function
sisnall
Panel
SWPO5127
Function . If the water temperature is low, this automatically raises the engine speed to warm up the engine after it is started. (Automatic warming-up function). In addition, if the water temperature rises too high during operations, it reduces the load of the pump to prevent overheating. (Engine overheat prevention function)
1O-200
PC300, 350-6
STRUCTURE
AND
ELECTRONIC
FUNCTION
CONTROL
SYSTEM
function II Engine automatic warming-up . After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm up the engine. Conditions
for actuation
Coolant temperature: Engine speed:
Less than 30°C Less than 1,250 rpm
I! I
Conditions
for cancellation
k
temperature:
Coolant
Actuation
(both are necessary)
Engine speed: 1,250 rpm or below
(any one)
Cancellation
30°C or above
Engine speed: As desired
Automatic Manual
Fuel control dial: Held at more than 70% of full throttle for more than 3 seconds
2) Engine overheat prevention function . This function protects the engine by lower-
.
ing the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too far. This system is actuated when the water temperature is 105°C and above.
I
Actuation Water temperature: Water temperature
condition 105°C and above gauge: Red range)
Actuation,
I
d
remedy
I
Working mode: In any mode Engine speed: Low idling Monitor warning lamp: Lights up Alarm buzzer: Sounds
Cancel condition Water temperature: Fuel control dial:
l
PC300, 350-6
Below 105°C Return temporarily to low idling position
When the above conditions are met, the system returns to the condition before the overheat prevention function was actuated (manual reset)
10-201
STRUCTURE AND FUNCTION
6.
ELECTRONIC CONTROL SYSTEM
Swing control system
Work
Swine
equipment
lever
motor
HYdrauI switch
Monitor
ic
Panel
OFF I
(Swine
Main
Pump
lock
switch
’ prolix
sional)
switch OFF
(Drive Enoine throttle controller
bins
Battery
sional) lever
sional)
relay
Battery
SWPO5128
Function l
The system is provided with a swing and swing holding brake function.
1O-202
lock
PC300, 350-6
STRUCTURE
AND
FUNCTION
1) Swing lock, swing holding brake function . The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so it prevents any hydraulic drift after the swing is stopped.
ELECTRONIC
.
Swing lock switch holding brake Lock switch
OFF
*
*
Operation of swing lock prolix switch If any abnormality should occur in the controller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled. When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift.
Swing brake
OFF
Swing holding brake
When swing lever is placed at neutral, swing brake is applied after approx. 5 set; when swing lever is operated, brake is canceled and swing can be operated freely
Swing lock
Swing lock is actuated and swing is held in position. Even when swing lever is operated, swing lock is not canceled and swing does not move.
(when controller is abnormal)
Swing lock applied
1
lock, swing
Operation
I
L prolix
swing
Functior
+
x .
and
SYSTEM
Lock lamp
ON
ON
CONTROL
Swing lock canceled
1
(when controller
Swing lock applied
1
is normal)
Swing holdi;;z;;ie
/
2) Hydraulic .
oil quick warm-up function when swing lock switch is ON When the swing lock switch is turned ON, the pump cut-off is canceled. If the work equipment is relieved in this condition, the hydraulic oil temperature will rise more quickly and the warming-up time can be reduced. SBPOO362
PC300, 350-6
1 O-203
STRUCTURE AND FUNCTION
7.
ELECTRONIC CONTROL SYSTEM
Travel control system
Travel
motor
I
Travel
0 PPC
I---_-____A
%
I
L_ :
Travel speed tioid valve - LS-EPC valve
1 <
Fuel
control
Monitor
(Pressure
(Thrott
seaser sianall Ie sianall
I
Engine throttle cant rol ler
(Drive
sianal)
(Drive
signal).
Panel
&ware sensor signal) (Switch signal) ,,
Function l
When traveling, the pump control is carried out, and the travel speed can be selected manually or automatically to give a travel performance that suits the nature of the work or the jobsite.
1 O-204
PC300, 350-6
STRUCTURE
AND
ELECTRONIC
FUNCTION
CONTROL
SYSTEM
11 Pump control function when traveling . If the travel is operated in any working mode
*
other than the heavy-duty operation mode, this increases the pump absorption torque while keeping the working mode and engine speed as they are. For details, see PUMP & ENGINE MUTUAL CONTROL.
2) Travel speed selection function i) Manual selection using travel speed switch If the travel speed switch is set to Lo, Mi, or Hi, the governor and pump controller controls the pump flow and motor volume at each speed range as shown on the right to switch the travel speed. ii) Automatic selection according to engine speed If the engine speed is reduced to below 1,350 rpm by the fuel control dial: . If the machine is traveling in Lo, it will not shift even if Mi or Hi are selected. . If the machine is traveling in Mi, it will not shift even if Hi is selected. . If the machine is traveling in Hi, it will automatically shift to Lo. iii) Automatic selection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi, and the load increases, such as when traveling up a steep hill, if the travel pressure continues at 32.4 MPa (330 kg/cm? for more than 1.0 set, the pump volume is automatically switched and the travel speed changes to Lo. (The travel speed switch stays at Hi.) The machine continues to travel in Lo, and when the load is reduced, such as when the machine travels again on flat ground or goes downhill, and the travel pressure stays at 21.6 MPa (220 kg/cm*) or less for more than 1.0 set, the pump volume is automatically switched and the travel speed returns to Hi.
PC300, 350-6
Travel speed switch
CLow:peed)
Pump flow (%) Motor
volume
Travel speed (km/h)
Hi (High speed)
‘“;;;9e
80
60
100
Max.
Min.
Min.
3.2
4.5
5.5
Travel speed Hi
I
Isec
lsec
Lo _---------__
I
21.6 (220)
32.4 Travel (330) pressure (MPalkg/cmV SAP00364
1O-205
STRUCTURE AND FUNCTION
8.
ELECTRONIC CONTROL SYSTEM
ACTIVE MODE FUNCTION
Work equipment IBoom)
lever
________---------___________,
~------------
Active
II II I I I I
mode
/I /
Active solenoid (Boom)
mode valve
/
Fuel
Engine
throttle
controller SWPO5130
FUNCTION . When the active mode switch on the moni-
l
tor panel is ON (lighted up), the work equipment speed is increased. The bucket lift is also increased during swing + boom RAISE operations, so it is effective in loading dump trucks. The active mode is actuated only when the fuel control dial is at the Max. position. If the fuel control dial is not at the Max. position, the load sensing function is actuated but the pump discharge increase function is not actuated.
1O-206
PC300, 350-6
STRUCTURE
II
AND
ELECTRONIC
FUNCTION
Increase in engine speed The pump discharge amount is increased by the increase in the engine speed. This means that the cycle time can be reduced, giving increased production.
CONTROL
SYSTEM
Active (heavy-duty dissins. travel, power UP)
Heavy-duty operation
Engine
speed
(rpm) SWPO5131
I I
PC300
pc35o
2)
2-stage boom lowering speed When the active mode switch is ON, the stroke of the boom LOWER spool is switched (9.0 mm + 11.5 mm) to increase the lowering speed. Change in spool stroke: A: 9.0 mm (active mode OFF) B: 11.5 mm (active mode ON)
I
I I
Heavy-duty digging operations
Active
172.8kW/1,950rpm ~231.7HP/1,950rom~
172.8kW/2,050rpm {231.7HP/2.050rom~
172.8kW/1,950rpm {231.7HP/1,950rpmI
172.8kW/2,050rpm {231.7HP/2,050rpml
I
-R
SWPO47 ‘99
31
2-stage stroke for swing spool When the active mode switch is ON and the boom is operated to RAISE, the stroke of the swing spool is switched (9.5 mm + 7.0 mm). This increases the bucket lift during swing + boom RAISE operations, so it is effective in loading dump trucks. Change in spool stroke: C: 9.5 mm (active mode OFF) D: 7.0 mm (active mode ON) SWPO4800
PC300, 350-6
10207
STRUCTURE
9. I)
ELECTRONIC
AND FUNCTION
CONTROL
SYSTEM
Components of system Engine speed sensor
1
2
4
3
-‘-
&z-i I
Composition
u-
of circuit SBP00365
1. 2. 3. 4. 5.
Function . The engine speed sensor is installed to the ring gear portion of the engine flywheel. It counts electrically the number of gear teeth that pass in front of the sensor, and sends the results to the governor and pump controller. This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet.
Wire Magnet Terminal Housing Connector
l
21
PPC hydraulic
switch 1. 2. 3.
Plug Switch Connector
Specifications Composition of points: Normal open points Actuation (ON) pressure: 0.5 + 0.1 MPa (5.0 & 1.0 kg/cm*) Reset (OFF) pressure: 0.3 + 0.05 MPa (3.0 f 0.5 kg/cm*) Function
Composition circuit
1O-208
of SBPOO366
dition of each actuator is detected from the PPC pressure, and this is sent to the governor and pump controller.
PC300, 350-6
STRUCTURE
3)
AND
ELECTRONIC
FUNCTION
Pump pressure
CONTROL
SYSTEM
sensor
1
1. 2.
2
Sensor Connector
1
L~/____J
Composition
of circuit
SBP00367
Insulation
layer
Function . This sensor is installed to the inlet port circuit of the control valve. It converts the pump discharge pressure to a voltage and sends this to the governor and pump controller. Operation When the pressurized oil entering from the pressure introduction portion pressurizes the diaphragm of the pressure detection portion, the diaphragm deflects and changes shape. A gauge layer is installed to the face opposite the diaphragm, and the resistance of the gauge layer converts the deflection of the diaphragm into an output voltage and sends it to the amp (voltage amplifier). The voltage is further amplified by the amplifier and is sent to the governor and pump controller. Relationship between P pressure (MPa (kg/ cm*)) and output voltage (VI. V=O.O08xP+ 1.0
(strainless
0
9.8 19.6 29.4 39.2 (100) (200) (300) (400) Pressure P (MPa (kg/cmz))
steel)
49.0 (500) SAP00369
PC300, 350-6
1 O-209
STRUCTURE
4)
AND
ELECTRONIC
FUNCTION
CONTROL
SYSTEM
TVC prolix resistor
swPo4aol
1. 2.
Resistor Connector
Function This resistor acts to allow a suitable current to flow to the TVC solenoid when the NC prolix switch is ON. No current flows when the TVC prolix switch is OFF. l
Specification Resistance: 8.5 51
l
5)
Fuel control dial, governor motor, and pump controller * See ENGINE CONTROL
6)
Monitor panel Ir See MONITORING
7)
TVC valve + See HYDRAULIC
1o-21 0
SYSTEM
governor
8)
LS-EPC valve * See LS-EPC VALVE
91
Solenoid valve . Active solenoid valve (boom) . Boom Hi 2-stage safety valve solenoid valve . Merge/flow divider valve solenoid valve Travel speed solenoid valve . Swing brake solenoid valve Ir See SOLENOID VALVE
l
PUMP
PC300, 350-6
STRUCTURE AND FUNCTION
MACHINE
MACHINE MONITOR SYSTEM
MONITOR
SYSTEM
Monitor
panel
G-?
Network circuit
1110 H/O
G;O
oo-
F/O
L/O
660
Caution, Coolant Fuel level signal
temp.,
I
r \*8@>
Sensor
Sensor
Power
sour*e
Buzzer
Engine throttle Pump controller
signal
signal
f
.-7zil ;-I-I Q
\
Buzzer
Battery
SAP03675
10-212
PC300, 350-6
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
1.
IMONITOR
PANEL
cN-P02_
CN-PO
1
SAP03677
OUTLINE . The monitor
.
.
panel consists of the time display, monitor display, and mode selector switches. It has a built-in CPU (Central Processing Unit), and processes, displays, and outputs the data from the sensors and controllers. The monitor display and monitor display panels use a liquid crystal display (LCD) and LED lamp. The mode switches are flat sheet switches.
PC300, 350-6
Input and output signals CN-PO1
CN-PO2
10-213
STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
MONITOR DISPLAY
SAP02731
1. Clock
2. Service meter 3. Fuel level gauge 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Fuel level caution lamp Engine oil level caution lamp Hydraulic oil level caution lamp Preheating pilot lamp Swing holding brake pilot lamp Oil maintenance pilot lamp Battery charge caution lamp Air cleaner clogging caution lamp Engine oil pressure caution lamp Coolant level caution lamp Coolant temperature caution lamp Coolant temperature gauge
10-214
PC300, 350-6
STRUCTURE AND FUNCTION
Content
MACHINE MONITOR SYSTEM
of display
Symbol
Display
item
43
Coolant
level
Display
range
When
Below
low
level
Below below
1500 rpm: 0.05 MPa
engine
Flashes
is stopped
when
abnormal
SAP00519
Engine SAP00520
oil
pressure
{0.5 kg/cm*) Above 1500 rpm: above 0.15 MPa
Lights
up when
normal
(goes
out when starts)
engine
Flashes
when
When
engine
is running
Flashes and buzzer sounds when abnormal
Flashes
and buzzer
when
sounds
abnormal
{I .5 kg/cm*}
SAP00521
Air cleaner clogging
Charge
level
When
When
SAP00522
Engine
oil level
clogged
charging defective
is
abnormal
Lights up when (goes out when starts)
normal engine
OFF
Flashes
when
Below
low
level
Flashes
when
abnormal
OFF
Below
low
level
Flashes
when
abnormal
OFF
abnormal
SAP00523
Hydraulic
oil level
SAP00524
SAT00098
Parking (Swing lock)
Oil maintenance
When swing locked
See next
page
is
“OIL
Lights up when swing lock switch is ON, flashes when swing lock prolix switch is ON
MAINTENANCE
FUNCTION.“.
SAP02732
Preheating
During
Lights up for 30 seconds when starting HEAT, then flashes for IO seconds to preheating is completed
preheating
SAP00526
Coolant SAP00527
B
SAP00528
PC300, 350-6
temperature
Fuel level
Flashes
when
above
buzzer
sounds
when
Flashes
when
below
102”C, above
low
flashes
switch indicate
is at that
and
105°C
level SWPO4803
10-215
STRUCTURE
AND
OIL MAINTENANCE 1.
MACHINE
FUNCTION
MONITOR
SYSTEM
FUNCTION
Function, operation The oil maintenance function uses LED lamps on the monitor panel to inform the operator at a fixed interval after the engine oil is changed that the oil change interval has been reached. At the same time, it also functions to display the service contact telephone number on the liquid crystal display. 1) Confirmation of elapsed time Normally, no display is given until the elapsed time reaches the point B on the right diagram after reset. However, if the buzzer cancel switch is pressed and the key is turned to the ON position (with the buzzer cancel switch hold for 2.5 seconds), the elapsed time is displayed on the service meter display. 2) Oil change display When the elapsed time has reached or passed the point B on the right diagram, the service meter display gives the elapsed time and the LED flashes when the key is turned ON.
A:Reset B:lOh before C:Set time
set
time
swP04701
2. Setting change interval 1) The change interval can be set by using the interval setting mode. The time that can be set are [I25 hl, I250 hl, [500 hl, [no setting], and [demo model. The default setting is [no setting]. 2) To enter the change interval setting mode, keep the time switch and active mode switch (swing priority switch) pressed simultaneously for 2.5 seconds. 3) If the buzzer cancel switch is pressed in the change interval setting mode, the time display will change from [...I -+ [I251 + 12501 -+ 15001 + [ dl ([...I indicates [no setting] and I dl indicates [demo model). 4) To save the change interval time, set the monitor panel display to the desired time (mode), then keep the time switch and active mode switch (swing priority switch) pressed simultaneously for 2.5 seconds.
10-216
PC300, 350-6
STRUCTURE
3.
AND
Display timing, content I) Oil change display After all the lamps light up, the elapsed time is displayed for IO seconds. For the next 10 seconds, the telephone number is displayed. However, if no telephone number has been input, the elapsed time is displayed for 20 seconds after all the lamps light 2)
up* Elapsed time confirmation After all the lamps light up, the elapsed time is displayed for 10 seconds.
4.
Elapsed time reset I) During the oil change interval display and the elapsed time display, for 10 seconds after all lamps light up (during the elapsed time display), if the buzzer cancel switch is pressed and held for 3 seconds, the elapsed time is reset. When the elapsed time is reset, the elapsed time shows [Oh] for 1 second. 2) When the set time is changed, the elapsed time is reset to Oh.
5.
Demo mode 1) The set time in the demo mode is 250h and the elapsed time is set to 240h. When the key is turned ON, the oil change display is given. However, the elapsed time does not increase. It is also possible to carry out the reset operation during this display. In the demo mode, after the key is turned ON three times, the interval setting is automatically set to [no setting] from the 4th time. In addition, the elapsed time is reset to Oh and the elapsed time count starts.
PC300, 350-6
MACHINE
FUNCTION
All
IamPs
I I
Tel No. i input I
, I
No Tel No. input
I L,
; ;
lioht
UD
Elapsed display
Elapsed
II II
time
Tel No. displayed
II
timeldisplav J
k
; ;
Elapsed display
SYSTEM
IO set
I
Elapsed time confirmation’
MONITOR
time
1I III
Time
/ I I
I II I
I
I I I
, SWPO4702
lo-217
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
MODE SELECTION SWITCHES
1. 2. 3. 4. 5.
I 5
CZXZI
A
Working mode switch Auto-deceleration switch Active mode switch Travel speed switch Knob button switch
SWPO5132
Switch actuation table l
The bold letters indicate
the default
position
of the switch when the starting
AUTO
MODE
DECEL
KNOB BU-I-TON TRAVEL
SPEED
ACTIVE MODE
is turned
ON.
Action
Item WORKING
switch
r’
H/O *
G/O tj ON tj
F/O tj
L/O H
OFF (Note
B/O ‘I
I)
POWER UP tj SPEED DOWN Hi t) ON tj
Mi t)
Lo
OFF (Note 2)
Note 1:
If the working mode is operated F/O + G/O or L/O + B/O, the auto-deceleration switch is automatically turned ON if it is OFF. (If it is already ON, it stays ON.) Conversely, if it is operated G/O + F/O or B/O + L/O, the auto-deceleration switch is automatically turned OFF if it is ON. Note 2: Even if it is ON, when the working mode switch is pressed, it is automatically turned OFF.
lo-218
PC300, 350-6
MACHINE MONITOR SYSTEM
STRUCTURE AND FUNCTION
2. .
Sensors The signals from the sensors are input directly to the monitor panel. The contact type sensors are always connected at one end to the chassis GND. Name
of sensor
Coolant Engine
Type of sensor
level oil level
Hydraulic level
oil
Engine oil pressure
ntFi$
ab~~~~a,
Contact
type
ON (closed)
OFF (open)
Contact
type
ON (closed)
OFF (open)
Contact
tVpe
(clz!ed)
OFF (open)
Contact type
OFF (open)
(clzzded)
Coolant temperature
Resistance
type
-
-
Fuel level
Resistance
type
-
-
Air cleaner clogging
Contact
OFF (closed)
ON (open)
type
Coolant level sensor 1. 2. 3. 4.
Composition
of
Sub-tank Float Sensor Connector
circuit
SOP04068
PC300, 350-6
10-219
STRUCTURE
AND
MACHINE
FUNCTION
MONITOR
SYSTEM
Engine oil level sensor Hydraulic oil level sensor
0“00
1. 2. 3. 4.
Connector Bracket Float Switch
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
1. 2. 3.
Connector Plug Thermistor
0
4
Composition circuit
of ;BPoo376
Engine oil pressure
1
2
sensor (both Lo and Hi)
4
3
5
6
Composition
of circuit
SBPOO378
Coolant
temperature
sensor
1
@=@a
Composition
of circuit
SBPOO379
1O-220
PC300, 350-6
STRUCTURE
Fuel
level
AND
MACHINE
FUNCTION
sensor
1. 2. 3. 4.
; : Q FULL
F
k
MONITOR
SYSTEM
Float Connector Cover Variable resistor
E
Y
Composition
of circuit
SBP00380
Air cleaner
clogging
sensor
Composition
of citcuit
SBPO0381
PC300, 350-6
10-221
FRONT WINDOW AUTO PULL-UP SYSTEM
STRUCTURE AND FUNCTION
FRONT WINDOW
AUTO PULL-UP SYSTEM
4
SBPOO382
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Front window assembly Bracket assembly (tension roller) Right block (roller support) Right geared cable Right return cable Controller Control switch Right lock assembly Right tightening motor Limit switch (front) Right bracket assembly (slide link) Harness Right rail
1o-222
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Rear cover Bracket (for motor mount) Cable assembly Motor assembly (for lifting) Motor output shaft Geared cable assembly Spoiler cover Limit switch (rear lock) Rear lock Left block (dovetail) Left block (return cable guide) Left block (return cable holder) Left cover (return cable holder)
PC300, 350-6
STRUCTURE
AND FUNCTION
FRONT WINDOW
AUTO
PULL-UP
SYSTEM
Function . An electric motor is used for the front glass (top) of the operator’s cab. This makes it possible to open, close, or tighten simply by operating the switch. Operation 1. Opening front window 1) Press the UP control switch. 2) When left and right front locks (8) are actuated in the OPEN direction, front window (I) is moved to the LOWER position by slide link (II). When the release operation is completed, the movement of front lock (8) stops. 3) After the movement of front lock (8) has been completed, operate lift motor (17) to the OPEN direction. Geared cable (191, which is meshed with motor output shaft (18), will move and pull up front window 4)
2.
(I). Front window (I) is set at the OPEN position, and lift motor (17) stops operating at the point where rear lock (12) is engaged.
Closing front window 1) Press the DOWN control switch, and push the release lever of rear lock (22) at the same time. 2) Lift motor (17) moves in the CLOSE direction and moves front window (I) down. 3) When front window (I) has moved down fully, lift motor (17) stops. of lift motor (17) 4) When the movement has been completed, front locks (8) are moved in the tightening direction by left and right tightening motors (9). When the tightening is completed, the motor stops.
PC300, 350-6
1 O-223
20 STANDARD
VALUE
STANDARD
TABLE FOR ENGINE
VALUE
STANDARD TESTING
TESTING AND ADJUSTING RELATED
TABLE FOR CHASSIS
VALUE
PARTS.. ............................................................
RELATED
TABLE FOR ELECTRICAL
PARTS ..........................................................
PARTS .......................................................................
20-
4
20-
5
20-
13
AND ADJUSTING
Tools for testing,
adjusting,
and troubleshooting..
.....................................................................
20-102
Measuring
engine
speed ...............................................................................................................
20-103
Measuring
exhaust
color ...............................................................................................................
20-104
Adjusting
valve clearance
Measuring
compression
Measuring
blow-by
Testing
20-105 20-106
pressure .........................................................................................................
and adjusting
Measuring
.............................................................................................................. pressure.. ...............................................................................................
engine
fuel injection
oil pressure
Testing
and adjusting
alternator
Testing
and adjusting
water
Testing
and adjusting
belt tension
Adjusting
engine
Measuring
timing
belt tension
pump
belt tension
20-I 12
pressure
hydraulic
Testing
and adjusting
LS valve output
(servo piston input pressure)
in work equipment, pressure
swing,
travel circuit .............
(servo piston input pressure)
..................
solenoid
when
pressure
and LS differential
self-pressure
valve output
PPC valve output work equipment,
Testing
travel deviation
Testing
locations
pressure .................................................
is reduced)
........................................................................
pressure ....................................................................................... pressure
swing
and testing
PPC shuttle valve.. ....................................
PPC valve.. ............................................................................
.................................................................................................................
causing
hydraulic
drift of work equipment
...................................................
oil leakage .................................................................................................................... remaining
pressure
Testing
clearance
Testing
wear of sprocket
Testing
and adjusting
in hydraulic
of swing circle bearing
circuit.. .................................................................... ...................................................................................
...............................................................................................................
track shoe tension ....................................................................................
air .....................................................................................................................................
TROUBLESHOOTING
20-I 13 20-I 16
20-I 18
circuit oil pressure
(oil pressure
PC300, 350-6
20-I 10
lever stroke ...................................................................
TVC valve output
Bleeding
20-I 10
motor
and adjusting
Releasing
20-109
governor
and adjusting
Measuring
20-109
20-I 11
Testing
Adjusting
........................................
20-108
.........................................................................................
Testing
Measuring
compressor..
20-107
(boost pressure)
and adjusting
Testing
.........................................................................
speed .................................................................................................................
air supply
control
.............................................................................
for air conditioner
Testing
Testing
.................................................................................
.....................................................................................................
20-106
..............................................................................................................................
20-121 20-122 20-125 20-127 20-128 20-129 20-131 20-133 20-134 20-135 20-136 20-137 20-201
20-l 0
Note the following troubleshooting.
when making judgements
using the standard value tables for testing, adjusting, or
The standard value for a new machine given in the table is the value used when shipping the machine from the factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as a reference value when carrying out repairs. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure. These standard values are not the standards used in dealing with claims. a
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving.
a
When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
a
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns.
a
Be careful not to get caught in the fan, fan belt or other rotating parts.
20-2 0
PC300, 350-6
TESTING
AND ADJUSTING
STANDARD
STANDARD
VALUE
TABLE FOR ENGINE
model
PC300, 350-6
Engine item
SAAGDI 08E-2
f
Measurement
condition5
Unit
Standard value for new machine
High idling speed
2,050 f 70
Low idling
900
rpm
Rated speed Rated speed
Exhaust
Air supply pressure (boost pressure)
kPa mmH9
At sudden
Bosch index
acceleration
At high idling Valve clearance (normal temperaure)
pressure
+‘O” l-8
Service
limit value
2,050 + 50
120 - 147 (900 - 1,100)
120 - 147 1900 - l,lOO}
5.5
7.5
Max.
1.5
2.5
0.34
-
0.66
-
MPa kg/cm>
Min. 2.7 (28)
2.3 (231
(rpm)
(250 - 300)
mm valve
Oil temperature: 40 - 60°C
(Engine (Water Blowby pressure (SAE oil)
-
Max.
Intake valve Exhaust
+‘0° 50
900
2,050
gas color
Compression (SAE oil)
PARTS
VALUE TABLE FOR ENGINE RELATED PARTS
Applicable
Engine
RELATED
speed)
temperature: Operating range)
kPa nmHz0
Max.
1.47 I1501
(250
- 300)
2.94
(3001
235.2
(2.4)
At rated output (Water
temperature: Operating range)
At high idling 392
(SAESO) At high idling
Oil pressure
- 637
kPa (g/cm2
(SAE 1 OW)
- 6.5)
Min.
At low idling
(4.0
-
98 (1.0)
78.4
IO.81
(SAE30) At low idling
Min. 78.4 (0.8}
49 IO.51
80 - 110
120
17 f 0.75
17 f 0.75
(SAEIOW) Whole speed range (inside oil pan)
Oil temperature
“C 0
Fuel injection
Belt tension
timing
Before top dead center
Deflection when pressed with finger force of approx. 58.8N (6 kg}
Crankshaft pulleyalternator
Fan pulley water pump
degree:
I
Crankshaftpulley air conditioner compressor
20-4 0
mm
15-
3
6-
10
3
6-
10
18
15-
18
PC300,
350-6
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS *
The Standard value for new machine measured in the heavy-duty mode. Applicable
and Service
model
Measurement
At 2-pump relief
limit value in the table below are all values when
PC300, 350-6 conditions
. Engine water temperature: Within ooeratina ranae . Hydraulic oil tempergture: 45 - 55°C . Engine at full throttle . In H/O mode . Arm IN relief . Engine at full throttle . In H/O mode . Arm IN relief + power max. OF
Engine speed when auto-deceleration is actuated
Unit
. Auto-deceleration
Standard value For new machine
;ervice limit value
When swing lock switch is OFF: 2,100 f 100
When swing lock switch is OFF: 2,100 I!I 100
When swing lock switch is ON: 1,950 f 100
When swing lock switch is ON: 1,950 f 100
wm 100
1,950 f 100
1,400 f 100
1,400 f 100
1,950 f
switch ON
. Fuel control dial at MAX. . Control levers at neutral.
Boom Lo control valve
b
Boom Hi control valve
mm
/
a
b
9.5 + 0.5
9.5 + 0.5
l---l -
Bucket control valve
P
l
BLPoolOl
I Boom control lever
. Center of lever knob . Read max. value to end of trave . Engine stopped . Exclude play at neutral.
mm
85+ 10
Max. 95 Min. 75
85 f 10
Max. 95 Min. 75
85+ 10
Max. 95 Min. 75
85+
Max. 95 Min. 75
10
115 + 12
Max. 127 Min. 103
Work equipment, swing
Max. 10
Max. 15
Travel
Max. 20
Max. 30
T 1 Travel control lever
PC300, 350-6
I
20-5 0
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Applicable Cats gcr
Item Boom control lever Arm control lever Bucket control lever
PC300, 350-6
model
Measurement
conditions
Unit
f~~n~$ft!!!$$r~e
Service
limit value
. Engine at full throttle . Oil temperature: 45 - 55°C . Fit push-pull scale to center of
15.68 3.92 Il.6 f+_0.41
Max. 24.5 12.5)
control lever knob or tip of pedal to measure . Measure max. value to end of travel
15.68 + 3.92 II.6 f 0.4)
Max. 24.5 f2.51
12.74 2.94 II.3 +f 0.3)
Max. 21.56 12.21
12.74 2.94 11.3 ff 0.3)
Max. 21.56 12.2)
Lever
24.5 +_5.88 I2.5 k 0.6)
Max. 31.92 I4.0)
Pedal
74.48 18.62 (7.6 f+_1.9)
Max. 107.8 1111
3.92 f 0.98 140 +_101
3.92 + 0.98 (40 +_IO)
Swing control lever
Travel control lever
Unload pressure
. Engine at full throttle . Oil temperature: 45 - 55°C . All levers at neutral . Pump outlet port pressure 33.81
RAISE Boom
Swing Left travel
0
EYg){
;“y;
(;r,y;;)}
31.36 + 1.47 I320 f 15)
Max. 33.32 I3401 Min. 29.4 {300)
2 -1
At low-pressure setting
18.13 f 0.98 1185 f IO)
Max. 19.6 {200) Min. 16.66 (170)
33.81
i 0.98 (34.79
i 0.98)
I345 * 10 (355 f 10))
. Oil temperature: 45 - 55°C . Engine at full throttle . In heavy-duty mode . Pump outlet port pressure . Relieve only circuit being measured j, The values in ( ) are the value: when using the power max.
Self-reducing valve
20-6
;;;;
At high-pressure setting
Right travel
LS differential pressure
k 0.981
c
Arm Bucket
f 0.98 (34.79
(345 * 10 (355 t 1011
. Oil temperature: 45 - 55’C All levers Engine at full at neutral throttle . In heavv-dutv mode ’ ’ b * LS-differential Travel Hi unde sssure= no load, travel :I’ mp outlet lever at halfport -I --assure prl nrClII_ l way position - LS pr,,,,,,
33.81
t 0.98 (34.79
+ 0.98)
1345 * 10 (355 * 1011
MPa {kg/ cm*}
zz
$Z){
rzfn
(~Z)}
MtxJ5.77(MaxB){
Max265 (t&xX0)}
Min.3234 Min.3332
Min. 330 Mm.340
30.87+;;:; { 315;;; }
Max. 32.34 I3301 Min. 28.42 1290)
34.79;;;;
{ 355:;; }
$;;
34.79;:;;
{ 355:;; }
f$‘n”: ;.$;;
;;$!
;;$ ii;;;
3.23 ? 0.2 I33 f 21
Max. 3.43 (351 Min. 2.84 129)
3.92 f 0.98 I40 f IO)
3.92 f 0.98 (40 + IO)
2.45 f 0.1 I25 f 11
PC300, 350-6
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Applicable Catr?-qorY
Measurement
Item
PC300, 350-6
model Unit
conditions
Work equipment posture Max. reach
Overrun when stopping swing
BKPOO102
PC300
Deg.
. Engine at full throttle . Hydraulic oil temperature: 45 - 55-C . In H/O mode . Stop after swinging one turn and measure distance that swing circle moves Work equipment posture
Max.
120
limit value
PC300
PC350
Vlax. 140
Max. 150
3.6 f 0.4
Max.
4.5
5.1 * 0.5
Max.
6.1
30 * 1.5
Max.
35
BKP00326 .
Engine
at full throttle
. Hydraulicoil temperature:45 - 55°C ,80Q . In H/O mode . Time taken to swing 90”and 180” from starting
position
Work equipment posture Max. reach
Time
Vlax. 110
iervice
Max. reach 90’
Time taken to start swing
Standard value for new machine
Set
taken to swing Engine at full throttle BKpoo102 Hydraulic oil temperature: 45 - 55’C In H/O mode Swing one turn, then measure time taken to swing next 5 turns
Hydraulic
Leakage motor -
PC300, 350-6
drift of swing
from
swing
. Engine stopped . Hydraulic oil temperature: 45 - 55°C . Set machine on 15” slope, and set upper structure at 90’ to the side. - Make match marks on swing circle outer race and track frame. . Measure distance that match marks move apart after 5 minutes. . Engine
mm
0
0
at full throttle
. Hydraulic oil temperature: 45 - 55’C ’ Swing lock switch ON . Relieve swing circuit.
Umin
Max.
5.5
Max.11
20-7 0
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
Applicable
-G
Measurement
Item
-V’
PC300, 350-6
model Jnit
conditions
Standard value lr new machine
xvice
limit value
T ravel apeed -
Lo
rravel speed (1) 3.5 f 5.5
Mi
Engine at full throttle Hydraulic oil temperature: 45 - 55’C In H/O mode Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.
-t
43 f 6
Hi Set Lo
23.3 -+ 4.4
18.9 - 31.0
Mi
16.7 4 2.2
14.4 - 21.0
Hi
13.1 I? 1.0
12.1 - 15.1
Max. 200
Max. 300
Travel speed (2) Engine at full throttle Hydraulic oil temperature: 45 - 55-c In H/O mode Run up for at least 10 m, and measuretime taken to travel next 20 m on flat ground.
-
BKFW106
Travel deviation
Engine at full throttle Hydraulic oil temperature: 45 - 55°C In H/O mode Travel speed : Hi Run up for at least 10 m, and measure deviation when travelins next 20 m on flat ground. * Use a hard horizontal surfact
1
*
mm
20m
Measure dimension
x.
-
20-8 a
PC300, 350-6
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable
T
model
PC300, 350-6
L
te’W
Item
Hydraulic
Measurement
conditions
drift of trave !I
Unit
Standard 1For new
value machine
kervice
limit
mm
0
0
!/mm
Max. 15
Max. 30
value
. Engine stopped
. Hydraulic oil temperature: 45 - 55’C . Stop machine on 12” slope with sprocket facing straight up the slope. . Measure the distance the machine moves in 5 minutes.
i ,
ILeakage of travel motor
Lock’pin BKP00109
. Engine at full throttle . Hydraulic oil temperature: 45 - 55’C . Lock shoes and relieve travel circuit. Posture for measurement
PC300
Total work equipmen t (hydraulic drift at tip of bucket teeth)
PC350
flax. 675 Max. 825
BKPOOllO
Boom cylinder (amount of retraction of cylinder)
Arm cylinder (amount of extension of cylinder)
Bucket cylinder (amount of retraction of cylinder)
PC300, 350-6
Vlax. 25 Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Bucket: Rated load 21.2 kN (2160 kg) Horizontal, flat ground Levers at neutral Engine stopped Hydraulic oil temperature: 45 - 55-C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes.
Max. 30
flax. 38
Max. 45
mm
lax. 135 Max. 165
lax. 203 Max. 248
vlax. 20
Aax. 30
Max. 25
Max. 38
20-9 0
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable
:e-
Item
ry
T
model
Measurement
PC300, 350-6 conditions
Unit
Standard value for new machine
service limit value
Boom 3.9 ?F0.4
Max. 4.7
3.0 f 0.3
Max. 3.5
Bucket teeth in contact with grounc 3 $rll$“e’dfU Ily
BKWOlll
. Enaine at full throttle . Hydraulic oil temperature: 45 - 55-c . In H/O mode
Arm Cylinder fully retracted 5: Fully extended
PC300
PC350
Max. 4.6
Max. 4.9
Vlax. 3.6
Max. 4.1
BKPOOllZ
Engine at full throttle . Hydraulic oil temperature: 45 - 55°C . In H/O mode .
3ucket 3.2 + 0.3
Max. 3.8
2.3 k 0.3
Max. 2.9
Max. 3.0
Max. 3.6
Max. 3.0
Max. 3.6
Cylinder fully -etracted $ Fully extended
3oom
BKP00113
Engine at full throttle Hydraulic oil temperature: 45 - 55°C In H/O mode
BKP00114
Set
. Lower boom and measure timl taken from point where bucket contacts ground to point wherl chassis rises from ground . Engine at low idling . Hydraulicoil temperature:45 - 55°C
9rm BKP00115
. Stop arm suddenly and measure time taken for arm to stop . Engine at low idling . Hydraulicoil temperature:45 - 55°C
20-10 0
PC300, 350-6
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
T
Applicable model Cat go’
Item
Measurement
conditions
(9.
Bucket
//////////////////////,
Unil
PC300, 350-6
Standard value for new
machine
service
limit
value
,
I_ BKP00116
Set
Max. 3.0
Max. 5.0
Max.
4.5
Max.
20
Max.
10
Max.
50
. Stop bucket suddenly and measure time taken for bucket to stop at bottom and then start again . Engine at low idling . Hydraulic oil temperature: 45 - 55’C Cylinders
. Hydraulic oil temperature: 45 - 55°C . Engine at full throttle . Relieve circuit to be measured
ccl min
Center swivel joint . Hydraulic oil temperature: 45 - 55’C * Use a hard horizontal surface. Ir Measure dimension x.
20m
Travel deviation when work equipment + travel are operated
mm
Max. 400
Max. 440
BKP00107
. Oil temperature:
Piston pump
PC300, 350-6
See next page
45 - 55°C
e./min
See next page
20-l 1 0
TESTING
Cat 901
AND ADJUSTING
PC300.350:
STANDARD
Discharge
amount
VALUE
of main piston pump
TABLE FOR CHASSIS
RELATED
PARTS
(in H/O mode)
(Urnin)
300
J
(2001
i 1001 Pump
. Pump speed: At 2050
Check point
As desired
discharge
pressure
= 2
34. 3 (3501
(MPa(ka/cm*l)
PltP2 TWP01401
rpm, TVC current 180 mA
Test pump discharge pressure (MPa {kg/cm%
PI
+ As far as possible, bring pump pressure when measuring. The error is large near the point * When measuring with the pump the specified speed with the fuel the point of measurement, and specified speed.
20-12 0
29. 4 (3001
19. 6
9. 6
Discharge pressure of other pump (MPa {kg/cm*})
Average pressure (MPa Ikg/cm21)
PI + P2
P2
discharge
2 pressures
PI
and
Standard value for discharge Q U?/min)
Judgement standard lower limit Q (Urnin)
See graph
See graph
amount
P2 as close as possible
to the average
where the graph curves, so avoid measuring at this point. mounted on the machine, if it is impossible to set the engine speed to control dial, take the pump discharge amount and the engine speed at use them as a base for calculating the pump discharge amount at the
PC300,
350-6
TESTING AND ADJUSTING
STANDARD Name of component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
VALUE TABLE FOR ELECTRICAL PARTS Zonnecto r In No. n
Judgment
Measurement conditions
table
1) Turn starting switch OFF. 2) Disconnect connector.
If the condition is within the range shown in the table below, it is normal Fuel control
dial
E06 (male)
Between
(I) - (2)
0.25 - 7 kQ
Between
(2) - (3)
0.25 - 7 kR
1 Between
(1) - (3)
1
4-6kR
I
If the condition is within the range shown in the table below, it is normal Potentiometer
E04 [male)
1 Between I Between
(I) - (2)
I
0.25 - 7 kR
I
(2) - (3)
I
0.25 - 7 kR
I
4-6kR
1 Between (I) - (3)
I
If the condition is as shown in the table below, it is normal Motor
Between (I) - chassis
No continuity
I
Between (3) - chassis
No continuitv
I
If the condition
is within the range shown it is normal
BetweenLmale) (1) - (2)
500 - 1,000 a
BetweenLmale) (2)- chassis Engine speed sensor
1) Turn starting switch OFF. 2) Disconnect connector.
E05 [male)
in the table below,
E07
(1) - (2)
I) Turn starting switch OFF. 2) Disconnect connector.
Min. 1 MQ
Measure with AC range Between
1) Turn starting switch OFF. 2) Disconnect connector.
0.5 - 3.0 V
1) Start engine. 2) Insert T - adapter.
1) Screw in rotation sensor until it contacts ring gear, then turn back 1 f l/6 turns. 2) &rnt;tvyrk normally when adjusted ravel SO1 DamRAISE SO2 rm OUTS03 3omLOWER SO 4
PPC oil pressure switch
rm IN SO5 ucketCURL SO 6 ’
If the condition is as shown in the table below, it is normal When boom, arm, and bucket levers are operated Between (male) (1) - (2)
-
All levers at neutral
Min. 1 M&2
Levers operated
Max. 1 R
Between (male) (l),(2) - chassis
1) Start engine (or with engine stopped and accumulator charged) 2) Disconnect connectors SO1 - S08.
Min. 1 MR
I Jcket DUMP SO; MingSO8
PC300, 350-6
20-l 3
TESTING AND ADJUSTING
Name of component
Zonnecto No.
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
In d
Judgment
If the condition is as shown below, it is normal CO7 (male (rear) CO8 (male (front;
Pump pressure sensor
Between
All levers At arm
lock switch
x05 (male)
I
at neutral
0.5 - 1.5 V
IN relief
3.1 - 4.5 v in the table
I
I
*etween(,1_,2I When switch Between 13)- (4) I
When switch
I
is OFF
Min.
is ON
I
Max.
valve
co4 (male) Cl3 (male)
Between (1) - (2) Between(l), (2) -chassis
JO4 [male)
Between (I) - (2) Between(l), (2) - chassis
_S select solenoid valve
JO6 :male)
IO3 male)
20 - 60 Q
Between(l), (2) - chassis
Min.
Between(l), (2) - chassis
Min.
Between (1) - (2)
shown
20 - 60 L2
I) Turn starting switch OFF. 2) Disconnect connector V04.
1) Turn starting switch OFF. 2) Disconnect connector V06.
1) Turn starting switch OFF. !I Disconnect connector V02.
1) Turn starting switch OFF. !I Disconnect connector V03.
1 MR shown
20 - 60 R Min.
1) Turn TVC prolix switch OFF. 2) Turn starting switch OFF. 3) Disconnect connectors co4, c13.
1 MR
If the condition is within the range in the table below, it is normal
Between(l), (2) - chassis
20-14 0
shown
20 - 60 S2
Min.
J
1 MR
Between (1) - (2)
Between(l), (2) - chassis
Machine push-up solenoid valve vo5 ~governor,pump controller (male) foes not carry out control)
shown
Between (1) - (2)
Between (1) - (2)
I) Turn starting switch OFF. 2) Disconnect connector X05.
1 MR
Min.
If the condition is within the range in the table below, it is normal ‘ump merge/divider solenoid valve
shown
20 - 60 Q
If the condition is within the range in the table below, it is normal JO2 male)
shown
1 MR
Min.
If the condition is within the range in the table below, it is normal Travel speed solenoid valve
1 R
IO-22R
If the condition is within the range in the table below, it is normal Swing holding brake solenoid valve
1 MR
I
If the condition is within the range in the table below, it is normal TVC solenoid
1) Start engine. 2) Turn fuel control dial to MAX position. 3) Insert T - adapter.
18-28V
If the condition is as shown below, it is normal Swing
in the table
(2) - (1)
Between (3) - (1)
Measurement conditions
table
I) Turn starting switch OFF. 2) Disconnect connector V05.
1 MR
PC300, 350-6
TESTING AND ADJUSTING
STANDARD
VALUE TABLE FOR ELECTRICAL PARTS
sy! ter -
Name of component
Connect0 r II r No.
Judgment
Measurement conditions
table
If the condition is within the range shown in the table below, it is normal LS-EPC solenoid
Cl0
Between(I) - (21
(male)
1) Turn starting switch OFF. 2) Disconnect connector ClO.
7-14Q
Between(l),(2) - chassis
Min. 1 MQ
If the condition is within the range shown in the table below, it is normal Power source voltage
Between CO1 (71,113) - (61,112)
co1 co2
I
Between CO2 (1 I),(211 - (6).(12)
I) Turn starting switch ON. 2) Insert T - adapter.
20 - 30 v 20 - 30 v
If the condition is as shown in the table below, it is normal
Fuel control diaI
Between (7) - (17) (power source)
4.75 - 5.25 V
Between (4) - (17) (low idling)
4.0 - 4.75 v
Between (4) - (17) (high idling)
0.25 - 1.0 V
I) Turn starting switch ON. 2) Insert T - adapter.
co3
If the condition is as shown in the table below, it is normal
Governor potentiometer
co3
L
-
Between (14) - (17) (low idling)
2.9 - 3.3 v
Between (14) - (17) (high idling)
0.5 - 0.9 v
Between (7) - (17) (power source)
4.75 - 5.25 V I
I) Turn starting switch ON. 2) Insert T - adapter.
i I
II
If the condition is as shown in the table below, it is normal Coolant temperature sensor
PO7 (male)
I) Turn starting switch OFF. 2) Disconnect connector P07. 3) Insert T - adapter. into connector at sensor end.
Normaltemperature (25°C) Approx. 37 - 50 kf2 100X
Approx. 3.5 - 4.0 kQ
If the condition is within the range shown in the table below, it is normal Governor motel
co2
Between (2) - (3)
1.8 - 4.6 V
Between (4) - (5)
1.8 - 4.6 V
I
II Turn starting switch ON. 2) Insert T - adapter.
I
1) Turn starting switch ON. 2) Insert T - adapter.
If the condition is within the range shown in the table below, it is normal Battery relay
co1
Between (I) - (6)
20 - 30 v
Ir This is only for 2.5 set after the starting switch is operated ON + OFF; at other times it must be 0 V.
PC300, 350-6
20-15 0
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
Name of :omponent
Zonnec No.
Judgment
Measurement conditions
table
’ the condition is as shown in the table lelow, it is normal
Swing holding brake solenoid
co1
1) Start engine. 2) Turn swing lock switch OFF. 3) Turn swing lock prolix switch OFF. 4) Insert T - adapter. * The lever can be operated slightly (without moving the equipment).
When either swing or work equipment control lever is operated (solenoid ON, swing holding brake canceled) Approx. 5 set after swing lever and work equipment control levers are placed at neutral (solenoid OFF, swing holding brake applied)
Between (3) (6),(12)
1) Start engine. 2) Insert T - adapter. 3) Turn fuel control dial to MAX position. 4) Operate the lever slightly not enough to move the machine. To check that the solenoid is OFF, measure with the fuel control dial at ~~lZI~1200 rpm or
the condition is as shown in the table elow, it is normal
Travel speed solenoid
co1
With travel speed switch at Hi or Mi (solenoid ON, travel motor swash plate angle MIN) When travel speed switch is at Lo (solenoid OFF, travel motor swash plate angle MAX)
20 - 30 V Between (9) (6),(12) o-3v
-r f the condition is as shown in the table below, it is normal
Active (boom) solenoid
co1
When active mode switch is OFF (solenoid ON, boom lower spool stroke 9 mm) When active mode switch is ON (solenoid OFF, boom lower spool stroke 11.5 mm)
1) Turn starting switch ON. 2) Insert T - adapter.
20 - 30 v Between (8) (6),(12) o-3v
1 _
’ the condition is as shown in the table elow, it is normal.
Pump merge/ divider valve solenoid
co1
When travel is operated independently (solenoid ON, divided) When levers and pedals are at neutral (solenoid OFF, merged)
20-16 0
20 - 30 v Between (2) (6),(12) o-3v
I) Turn starting switch ON. 2) Insert T - adapter. * The lever can be operated slightly (without moving the equipment).
PC300, 350-6
TESTING AND ADJUSTING
I s-
n
Name of component
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Eonnecto r In No. n
,n d
Judgment
Measurement conditions
table
1) Turn starting
If the condition is as shown in the table below, it is normal . H/O mode
TVC solenoid valvt (default value
switch ON. 2) Turn fuel control dial to MAX position 3) Turn prolix switch OFF. 4) All levers at neutral
Betweenfront (8) - (18) 360 + 100 mA Betweenrear (9) - (19)
LS-EPC solenoid valve (default value
If the condition is as shown in the table below, it is normal . H/O mode
II Turn starting switch ON. 2) Turn fuel control dial to MAX position 3) All levers at neutral.
co2 Between (7) - (17)
900 f 80 mA
If the condition is as shown in the table below, it is normal I
L.H. knob switc
co3
I
I
When switch is ON
Between
20 - 28 V
When switch is OFF (‘I - GND
O-IV
If the condition is as shown in the table below, it is normal S-NET
Cl7 Between (4),(12) - GND
4-8V
If the condition is as shown in the table below, it is normal Kerosene mod{
Cl7
Standard mode
. Between (15)-GND
Kerosene mode
20 - 28 V
Monitorin! 3 . code 16
I
Active
Approx. 2303 (during operation) Approx. 2050 (idling)
H/O
Approx. 2200 (during opration) Approx. 2050 (idling)
G/O
Approx. 2050 (during operation) Approx. 1900 (idling)
F/O
Approx. 1900
UO
Approx. 1700
Power max. (H/O) (G/O)
Approx. 2250
Swiftslow-down(H/O)(G/O)
Approx. 1700
If the condition is as shown in the table below, it is normal
Model selectiol
PC300, 350-6
Cl7 - co2
1) Turn starting switch ON. 2) Insert1 T - adapter. 1) Turn starting switch ON. 2) Insert1 T - adapter.
o_2v
If the condition is as shown in the table below, it is normal High idling (rpm)
No. 2 throttle signal
I) Turn starting switch ON. 2) Insert1 T - adapter.
No continuity
Between selection 1
Cl7(5) - CO2(11)
Between selection 2
Cl7(13) - CO2(11) Continuity
Between selection 3
Cl7(6) - CO2lll)
Continuity
Between selection 4
Cl7(14) - CO2(1I)
No continuity
Between selection 5
C17(7) - CO2(11)
No continuity
I) Start engine. 2) Set monitoring code to 10 or 16 (command value). 3) Operate working mode switch and L.H. knob switch.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T - adapter to wiring harness end.
20-17 0
TESTING
G ten
STANDARD
AND ADJUSTING
Name of component
Ionnectol No. PI1
Air cleaner clogging sensor
VALUE
TABLE
FOR ELECTRICAL
Measurement conditions
Judgment table
I)
If the condition is as shown in the table below, it is normal
Start engine.
2) Disconnect Pll. P12.
Ke’ (female) I
I
I
I
1) Turn starting switch OFF. 3) Disconnect connector.
If the condition is within the range shown in the table below, it is normal 500 - 1000 n
Between (I) - (2)
Min. 1 MR
Between(l),(2) - chassis Engine speed sense
PARTS
E07
I) Start engine. 2) Insert T - adapter.
Measure with AC range 0.5 - 3.0 V
Between (I) - (2) I)
Screw in rotation sensor until it contacts ring gear, then turn back 1 ? l/6 turns 2) ltsm;;tvyork normally when adjusted If the condition is as shown in the table below, it is normal
1) Turn starting switch OFF.
2) Disconnect Coolant level sensor
PO8 (male)
Above LOW level in sub-tank
Max. 1 R I
I
Below LOW level in sub-tank
I
I
Min. 1 MQ
I) Turn starting switch OFF. 2) Disconnect connector P05. 3) Drain oil, then
If the condition is as shown in the table below, it is normal
v’ Engine oil level sensor
PO5 (male)
Raise float
Max. 1 Q
remove sensor.
BLPCOOOZ
ly:
Lowerfloat
1 Min. 1 MQI
If the condition is as shown in the table below, it is normal Coolant temperature sensor
20-18 0
PO7 (male)
1 Normal temperature (25’C) 1 Approx. 1OO’C
connector P08. 3) Insert T-adapter into connector at sensor end.
37 - 50 kfi
Approx. 3.5 - 4.0 kR
1
I) Turn starting switch OFF. 2) Disconnect connector P07. 3) Insert T - adapter. into connector at sensor end.
PC300, 350-6
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
‘SSY
telm -
Name of component
lonnecto #r Ir r No.
Judgment
Measurement conditions
table
I) Install oil pressure measurement gauge. 2) Remove wirina ” harness terminal. 3) Start engine. 4) Put tester in contact High pressure end
If the condition is as shown in the table below, it is normal Low pressure end
Engine oil pressure sensor
-
between sensor
terminal screw and chassis.
I) Turn starting switch OFF. 2) Disconnect connector P06. 3) Drain fuel, then remove sensor. 4) Inset-t T - adapter into sensor. * Connect the T - adapter to the connector and sensor flange.
If the condition is as shown in the table below, it is normal . Fuel level sensor
.,
ti
PO6 (male)
Approx. 12 Q or below
Raise float to stopper
BLmoo4
Lower float
. k-
* 1 to stopper
Approx. 85- IIOR
ELF90005
I) Turn starting switch OFF. 2) Disconnect connector PO9. 3) Drain oil, then remove sensor. 4) Insert T - adapter into sensor.
If the condition is as shown in the table below, it is normal
1-l Hydraulic oil level sensor
PO9
(male)
Raise float
/ Max. 1 RI
Lowerfloat
lfvlin. 1 fvl*i
BLRWOOZ
IVY=’
I
BLW0003
I
I
If the condition is as shown in the table below, it is normal
Air cleaner clogging sensor
Air cleaner normal
Continuity
Air cleaner clogged
No continuity
I) Start engine. 2) Disconnect Pll, P12. 3) Put tester in contact with connector at sensor end to measure.
‘I 1 ‘12
BLFmo96
-
PC300, 350-6
20-19 0
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
Name
of component
Alternator
onnector
Inspection method
No.
Judgment
Measurement conditions
table
When engine is running (l/2 throttle or above] below, the sensor is defective. j27.5 - 29.5 V + If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
between llternator erminal I and hassis
Position of gauge display Starting
switch
ON
Displav level resistance (Monitor panel input resistance) Starting
switch
kR
I) Insert a dummy resistance with the starting switch OFF, or measure the resistance of the sensor. 2) Check the display with the starting switch ON.
kR
I) Insert a dummy resistance with the starting switch OFF, or measure the resistance of the sensor. 2) Check the display with the starting switch ON.
OFF
Min. - Max. All OFF(10)
!igdh,’
9 Measure resistance between coolant temperature gauge CO3 (female) (I 1 - co3 (female) (’16)
t
8 7
Display position
6 5
I
- 0.646
0.575
- 0.342
3.156
- 3.708
3.422
- 3.900
3.600
- 4.349
I) Start engine.
4 L
3 2
--
Left side
1
*_ Levels 8 and 9 flash.
Gauges Display level resistance [Monitor panel input resistance)
Position of gauge display Starting
switch
ON
Starting
switch
Min. - Max. Right side
- 13.82 11.71 - 21.25
Measure resistance between fuel level gauge CO3 (f;rn;;E;s(2) -
18.90 - 28.45
t
Display position
Left side *
20-20 0
- 31.85
29.18
- 39.91
37.00
- 44.60
41.77
- 55.14
2
50.42
- 77.07
1
72.98
- 691.5
5 4
r
I
25.82
3
M
638.00
OFF
-
Level 1 flashes.
PC300, 350-6
TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING
TOOLS FOR TESTING, Check or measurement
ADJUSTING,
AND TROUBLESHOOTING
AND TROUBLESHOOTING
item
Engine speed
Coolant and oil temperatures
-
6
1799-101-1502
2
1 Digital temperature
799-101-5220
Nipple
07002-I 1023
0 ring
gauge ( -50 - 1,200”C
10 xl.25 Both 14 x Both 18 x Both 22 x
l790-261-1311 l790-261-1321
3
C
Oil pressure
Adapter
l790-261-1331 4
799-401-2701
Differential pressure gauge
790-261-1360
Adapter
Both male and female 14 x 1.5 (female PT l/8)
790-261-1370
Nut
For 14 x 1.5 blind
5 07003-31419 (07040-11409 6 ) 799-401-2320
-
1 Compression
pressure
3
Blowby
E
pressure
For blind
Gasket
( For 14 x 1.5 blind
1 Plug 1 Hydraulic
795-502-1590
2
-
gauge
Compression
795-472-l 370
1 1.0 MPa {IO kg/cm21
gauge
0 - 6.9 MPa IO -70 kg/cm?
Adapter
I799-201-1504
I Blow-by
I
I
Kit Part No.: 795-502-1205 checker
) 0 - 4.9 kPa IO - 500 mmHzO1 I
Air supply pressure (boost pressure)
F
799-201-2202
Pressure gauge
Valve clearance
G
$$$)~~~cially
Feeler gauge
799-201-9000
Handy Smoke Checker
1
-101.3 - 200 kPa l-760 - 1500 mmHn)
Discoloration 0 - 70% (with standard color) (Discoloration % x l/10 = Bosch index)
H
Exhaust color
2 $;a~~bgcially Smoke meter
0 - 294N (30 kg}
79A-264-0020 Operating
Push-pull scale
J
effort
79A-264-0091
0 - 490N {50 kg}
Stroke, hydraulic
drift
K
~~~~~~cially
Scale
Work equipment
speed
L
$$$l!&$cial’y
Stop watch
M
79A-264-0211
Tester
) 1
799-601-7100
T-adapter
Measuring voltage resistance values
and
Troubleshooting of wiring harnesses and sensors Measuring
20-102 a
wear of sprockei
v
box
799-601-7070
2 P
male and female 1.5 (female PT l/8) male and female 1.5 (female PT l/8) male and female 1.5 (female PT l/8)
799-601-7360 /796-627-1130
For SWP14 Adapter ) Wear gauge
For relay 5P
I
PC300, 350-6
TESTING AND ADJUSTING
MEASURING
MEASURING ENGINE SPEED
ENGINE SPEED
AWhen removing or installing the measuring equipment, be careful not to touch any high temperature parts. Measure the engine speed under the following * conditions. . Coolant temperature: Within operating range . Hydraulic oil temperature : 45 - 55°C 1.
Remove
the fan guard.
2.
Remove
cover (1).
3.
Install the gear box A2.
4
i
4. Install the sensor of multi-tachometer speed pull out port, then tachometer Al.
connect
Al to the it to multi-
5. Start the engine, and measure the engine speed when it is set to the conditions for measuring. 1) Measuring low idling and high idling speeds Measure the engine speed with the fuel control dial set to low idling and high idling. Ir Measure in the heavy-duty mode with the auto-deceleration OFF. 2) Measure the speed at near the rated speed. i) Set the working mode the H/O mode. slow-down ii) Set the power max./swift switch to the power max. position. iii) Run the engine at full throttle, set the knob switch to the ON position, operate the arm lever, and measure the speed when the arm IN circuit is relieved. * Even if the L.H. knob switch is kept pressed, the power max. function is automatically turned off after approx. 8 seconds, so measure during the first 8 seconds. * Measuring speed when travel is operated: Knob switch ON 3) Measuring speed at 2-pump relief: i) Set the working mode the H/O mode. ii) Run the engine at full throttle, operate the arm lever, and measure the engine speed when the arm IN circuit is relieved.
PC300, 350-6
20- 103 0
MEASURING
TESTING AND ADJUSTING
MEASURING
EXHAUST
EXHAUST COLOR
COLOR
.
When measuring in the field when there is no air or power supply, use handy smoker checker HI; when recording official data, use smoke meter H2. Raise the coolant temperature to the operating * range before measuring. AWhen removing or installing the measuring equipment, be careful not to touch any high temperature part.
1.
Measuring with handy smoke checker HI
1) Fit filter paper in tool Hl. 2) Insert the exhaust gas intake port into the
3)
2.
exhaust pipe, accelerate the engine suddenly, and at the same time operate the handle of tool HI to catch the exhaust gas on the filter paper. Remove the filter paper and compare it with the scale provided to judge the condition.
Measuring with smoke meter H2
1) Insert the probe of tool H2 into the outlet
2)
3)
4)
5) 6)
7)
port of exhaust pipe(l), then tighten the clip to secure it to the exhaust pipe. Connect the probe hose, accelerator switch plug, and air hose to tool H2. * The pressure of the air supply should be less than 1.47 MPa (15 kg/cm2). Connect the power cord to the AC power source socket. * When connecting the port, check first that the power switch of tool H2 is OFF. Loosen the cap nut of the suction pump, then fit the filter paper. * Fit the filter paper securely so that the exhaust gas does not leak. Turn the power switch of tool H2 ON. Accelerate the engine suddenly, and at the same time, depress the accelerator pedal of tool H2 and catch the exhaust gas color on the filter paper. Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (IO sheets or more) inside the filter paper holder, and read the indicated value.
BLP00297
I
f&Y,* t BKPOO215
20-104 0
PC300, 350-6
TESTING
AND ADJUSTING
ADJUSTING
VALVE
CLEARANCE
ADJUSTING VALVE CLEARANCE 1. Remove
the cylinder
head cover.
2.
Rotate the crankshaft in the normal direction to align TOP 1.6 line (1) on the crankshaft pulley with pointer (2). When rotating, check the movement of the intake valve of No. 6 cylinder.
3.
When No. 1 cylinder is at compression top dead center, adjust the valves marked l in the valve arrangement chart. Next, rotate the crankshaft one turn (360”) in the normal direction and adjust the valve clearance of the remaining valves marked o.
4.
To adjust the valve clearance, loosen locknut (61, then insert feeler gauge G between rocker lever (3) and valve stem (41, and turn adjustment screw (5) until the clearance is a sliding fit. Then tighten locknut (6) to hold the adjustment screw in position. m Locknut : 44.1 f 4.9 Nm 14.5 f 0.5 kgm)
*
The firing order is as follows: 1 - 5 - 3 - 6 - 2 4. After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 120” each time and adjust the valve clearance of the intake and exhaust valves of each cylinder according to the firing order. For details of the valve clearance, see the STANDARD VALUE TABLE for engine related parts. After tightening the locknut, check the valve clearance again.
*
*
*
VALVE ARRANGEMENT DIAGRAM
I
TYPO1432
BLPOO299
BLPOO300
PC300, 350-6
TESTING
AND ADJUSTING
MEASURING PRESSURE a
1. 2. 3. 4. 5. 6.
MEASURING MEASURING
COMPRESSION PRESSURE BLOW-BY PRESSURE
COMPRESSION
When measuring the compression pressure, be careful not to touch the exhaust manifold or muffler, or to get your clothes caught in the fan, fan belt or other rotating parts. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. Warm up the engine to make the oil temperature 40 - 60°C. Remove nozzle holder assembly (I) from the cylinder to be measured. Install adapter D2 in the mount of the nozzle holder, then connect pressure gauge Dl. Connect tachometer Al and gear box A2. For details, see MEASURING ENGINE SPEED. Disconnect the fuel control rod, place the governor lever of the injection pump in the NO INJECTION position, then crank the engine with the starting motor and measure the compression pressure. Measure the compression pressure at the point where the pressure gauge indicator remains steady. When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. After measuring the compression pressure, install nozzle holder assembly (I).
MEASURING PRESSURE
BLOW-BY BLPOO303
+
1. 2. 3.
Measure the blow-by pressure under the following conditions. . Coolant temperature: Within operating range . Hydraulic oil temperature: 50 - 80°C Install the nozzle of blow-by checker E to blowby hose (1). Connect the nozzle and gauge with the hose. Run the engine at near the rated output and read the gauge measurement. Ir Near rated output . Relieve the arm IN circuit in the H/O mode and power max. mode. Sr Measure the blow-by at the point where the gauge indicator remains steady.
zo-106 0
BLP00304
PC300, 350-6
TESTING AND ADJUSTING
TESTING AND ADJUSTING
FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING Testing Ir If the fuel injection 1.
pump has been removed, check as follows. Check that line a on the injection pump is aligned with line b on the mounting case.
BLPOO305
Adjusting * If the lines are not aligned, adjust as follows. 1. Loosen nut (1) at the oblong portion and pump mounting nut (21, then move fuel injection (3) to align the lines.
pump
2.
Tighten nuts (I) and (2). w Nut : 66.15 f 7.35 Nm (6.75 + 0.75 kgm}
Ir
If the gear flange and gear train for the fuel injection pump drive has been disassembled, adjust the fuel injection timing. For details, see the 108-2 Series Shop Manual.
PC300, 350-6
20- 107 0
TESTING AND ADJUSTING
MEASURING PRESSURE *
MEASURING
ENGINE OIL PRESSURE
ENGINE OIL
Measure the engine oil pressure under the following conditions. Coolant temperature: Within operating range
l
1.
Remove engine oil low-pressure sensor (PTIB) (I) and high-pressure sensor (PTV8) (21, then install nipple C2 and oil pressure gauge C6 (1.0 MPa {IO kg/cm*)).
2.
Start the engine, and measure the oil pressure with the engine at low idling and at high idling.
*
For low-pressure sensor (I), measure the engine oil pressure caution end with the engine at low idling, and for high-pressure sensor (21, measure the engine oil pressure caution end and the controller trouble data display end with the engine at high idling.
20- 108 0
PC300, 350-6
TESTING AND ADJUSTING
TESTING AND ADJUSTING ALTERNATOR BELT TENSION TESTING AND ADJUSTING WATER PUMP BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION *
If the deflection of the belt when it is pressed at a point a midway between the alternator pulley and the fan pulley is not within the standard value, or after carrying out maintenance or replacing the belt, adjust the belt tension as follows. . Deflection of V-belt : 3 mm 1. Remove the upper fan guard of the alternator. 2. Loosen mounting bolts (2) and mount bolt (3) of alternator (I). 3. Loosen locknut (41, turn belt tension adjustment bolt (51, and move alternator (I) to adjust the tension of the belt. When the tension is adjusted, tighten locknut (4). 4. Tighten mounting bolt (2) first, then tighten mount bolt (3). w Mount bolt: 110.25 f 12.25 Nm (11.25 _+1.25 kgm1 5. After adjusting the belt tension, check again to confirm that the belt tension is within the standard value.
pulley
Crankshaft pulley BLPoo310
BLPOO311
TESTING AND ADJUSTING WATER PUMP BELT TENSION *
1. 2.
3.
4.
If the deflection of the belt when it is pressed at a point a midway between the water pump pulley and the fan pulley is not within the standard value, or after carrying out maintenance or replacing the belt, adjust the belt tension as follows. . Deflection of V-belt : 3 mm Loosen mounting bolts (2) and locknut (3) of tension pulley (1). Turn belt tension adjustment bolt (4) and move tension pulley (I) to adjust the tension of the belt. When the tension is adjusted, tighten mounting bolts (2). m Mounting bolt : 66.15 f 7.35 Nm (6.75 f 0.75 kgm} Loosen adjustment bolt (4) 112 turns, then tighten locknut (3). Ir To prevent the adjustment bolt from falling out, loosen the tension applied to the bolt. QEI Locknut: 30.87 f 3.43 Nm I3.15 + 0.35 kgm} After adjusting the belt tension, check again to confirm that the belt tension is within the standard value.
PC300, 350-6
a
u
Crankshaft pulley BLPoO312
20- 109 0
TESTINGAND ADJUSTING
TESTINGAND ADJUSTING BELTTENSION FORAIR CONDITIONERCOMPRESSOR ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 1. *
2. 3. 4.
5.
a Crankshaft
Remove the upper fan guard of the air conditioner compressor. If the deflection of the belt when it is pressed at a point a midway between the drive pulley and the compressor pulley is not within the standard value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows. . Deflection of V-belt : 15 - 18 mm Loosen mount bolt (I) and (2). Move the position of compressor (3) to adjust the tension of the belt. When the position of the compressor is fixed, tighten mount bolts (I) and (2) to secure in position. After adjusting the belt tension, repeat the above procedure to check that the belt tension is within the standard value.
pulley Air conditioner compressor pulley
BKP00314
BWP03004
ADJUSTING SENSOR 1. 2. 3. *
*
ENGINE SPEED
Screw in until the tip of sensor (I 1 contacts
gear
(2). When gear (2) contacts sensor (I), turn back 1 f l/6 turns. Tighten locknut (3). m Locknut : 58.8 f 9.8 Nm {S f 1 kgm} Be particularly careful when handling the sensor wiring to ensure that no excessive force is brought to bear on the wiring. Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to the sensor tip.
BLPO0316
BLPO0317
20-110 a
PC300, 350-6
TESTING AND ADJUSTING
MEASURING
AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) A
When
1.
Remove air supply pressure measurement (1) (PT1/8), then install the nipple C2.
2.
Connect the oil pressure measurement hose to the coupler and pressure gauge F (-101.3 - 200 kPa I-760 - 1,500 mmHg).
removing or installing the measuring equipment or when carrying out the measurements, be careful not to touch any high temperature parts or rotating parts.
Note:
plug
Run the engine at a mid-range speed or above, and use the self-seal portion of the gauge to bleed the oil from inside the hose. . Insert the gauge about half way, and repeatedly open the self-seal portion to bleed the oil. Ir The gauge does not work if there is any oil inside the hose, so always be sure to bleed all the oil.
3.
Run the engine at near the rated speed and measure the pressure indicated by the gauge. * Near rated output . Run the engine at near the rated output. For details, see the measurement of the engine speed when the arm IN circuit is relieved in the H/O mode and power max. mode.
*
The air supply pressure (boost pressure) should be measured with the engine running at rated output. However, when measuring in the field, a similar value can be obtained with the above conditions.
PC300, 350-6
20-l 11 0
TESTING AND ADJUSTING
TESTING AND ADJUSTING
GOVERNOR MOTOR LEVER STROKE
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE Testing * Use the governor motor adjustment mode. 1. Preparatory work 1) Keep the monitor panel time switch + travel speed (R.H.) switch + working mode (R.H.) switch pressed for 2.5 seconds. 2) Set the fuel control dial to MAX, and the auto-deceleration switch to OFF. * Any working mode can be used. 2. In this condition, check the governor lever and spring rod. 3. After checking, repeat the procedure in Step 1 to complete the governor motor adjustment mode.
II
--
BLPW320
Adjusting 1. Turn the starting switch OFF, then remove the nut and disconnect joint (I 1 from governor lever (2). 2. Repeat the procedure in Step 1 above to set to the governor motor adjustment mode. 3. Set governor lever (2) to a position where it contacts full speed stopper (3) of the fuel injection pump, then turn joints (I) and (4) to adjust the length of spring assembly (5) and adjust to the position of the hole of governor lever (2). 4. From the above position, shorten joints (I) and (4) a total of 2 turns (approx. 2.5 mm), and secure in position with the locknut. Caution When the spring assembly is removed and the starting switch is at the OFF position, if the governor motor lever is moved suddenly, the governor motor will generate electricity, and this may cause a failure in the governor controller. When moving the governor motor lever, disconnect connector E05 first.
20-112 0
PC300, 350-6
TESTING
AND ADJUSTING
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT, SWING, TRAVEL CIRCUIT
PRESSURE
IN WORK
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT Measuring Sr Oil temperature when measuring: 45 - 55’C &Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position. 1. Remove the upper cover of the main pump. 2. Remove pressure pick-up plug (I) or (2) (thread dia.=lOmm, Pitch=1.25mm) from the circuit to be measured, then install the nipple C2 and oil pressure gauge Cl (58.8 MPa 1600 kg/cm*}). 3. Measuring unload pressure I) Run the engine at full throttle and measure in the H/O mode. 2) Measure the hydraulic pressure when all levers are at neutral. 4. Measuring main relief pressure 1) Run the engine at full throttle and measure in the H/O mode. 2) Measure the hydraulic pressure when each actuator is relieved. * If the power max. switch is turned ON, the pressure will rise, so measure with both the switch OFF and ON. (When the switch is turned ON, it is automatically turned OFF after approx. 8 seconds, so measure during the first 8 seconds.) * Note that the set pressure of the safety valve for the swing motor and head end of the boom is lower than the LS relief pressure, so the value measured will be the relief pressure of the safety valve. * To check the operation of the safety valve at the boom LOWER end, measure the hydraulic pressure when the machine push-up switch is OFF (low pressure) and ON (high pressure). Ir When measuring the hydraulic pressure in the boom LOWER circuit, block the hose (fit blind plug) at the boom cylinder head end. Ir If the swing lock switch is turned ON, the pressure will rise, so always keep the lock switch OFF when measuring. * To relieve the travel circuit, put block under the track shoe grouser, or put block between the sprocket and frame to lock the track.
PC300, 350-6
Table
Plug
1
1 Combination of pumps and actuators controlled when flow from front and rear pumps is divided Pump
Controlled actuator
Front pump
Boom cylinder (Lo, Hi) Arm cylinder (Hi) Bucket cylinder R.H. travel Service
2
Rear pum
motor
Arm cylinder Swing motor L.H. travel
(Lo)
motor
20-113 0
TESTING
AND ADJUSTING
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT, SWING, TRAVEL CIRCUIT
PRESSURE
IN WORK
Adjusting * The unload valve cannot be adjusted. 1. Main relief valve (1): For front pump (2): For rear pump Loosen locknut (3), then turn adjustment screw (4) to adjust. * Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of adjustment screw: Approx. 12.6 MPa (128 kg/cm*) m Locknut : 29.4 - 39.2 Nm I3 - 4 kgm} l
l
l
l
2.
Boom cylinder head safety valve * Adjust the safety valve at the high-pressure end first, then adjust the low-pressure end. . (I): Boom cylinder head (LOWER) end 1) Disconnect pilot hose (2). 2) Adjusting high-pressure setting Loosen locknut (31, then turn holder (4) to adjust. m Locknut : 93 - 123 Nm 19.5 - 12.5 kgm} setting 3) Adjusting low-pressure Loosen locknut (51, then turn holder (6) to adjust. w Locknut : 78 - 93 Nm IS - 9.5 kgm} * Turn the holder to adjust as follows. . To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of holder: Approx. 21.8 MPa (222 kg/cm*}
8LFoO122
l
[Reference]
The oil pressure acting on port Cp is as follows. Machine push-up switch ON (high pressure): 0 MPa IO kg/cm*) Machine push-up switch OFF (low pressure): 2.74 MPa (28 kg/cm*}
3
456
CP
20-114 0
PC300, 350-6
TESTING AND ADJUSTING
3.
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
Swing motor safety valve . (I): For starting left swing (stopping right swing) . (2): For starting right swing (stopping left swing)
1) Remove 2)
the mounting bolts, then remove cover (3) and spring (4). Loosen locknut (51, then turn adjustment screw (6) to adjust. Carry out the adjustment with the valve * assembly installed to the motor. * Turn the adjustment screw to adjust as follows. . To INCREASE pressure, turn CLOCKWISE. . To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of adjustment screw: Approx. 3.9 MPa 139.5
w
3)
kg/cm*)
Locknut : 118 - 147 Nm I12 - 15 kgm} After completing the adjustment, install spring (4) and cover (31, then tighten the mounting bolts to the specified torque. w Cover mounting bolt : 98 - 123 Nm {IO.0 - 12.5 kgm}
PC300, 350-6
20-l 15 0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) Measuring * Oil temperature
when measuring: 45 - 55°C ALower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position.
1.
Remove pressure measurement plugs (I), (21, (31, and (4) (Thread dia.=10 mm, Pitch=1.25 mm), then install nipple C2 and oil pressure gauge
:.~
*
Install a 39.2 MPa (400 kg/cm*Igauge to the servo valve end, and a 58.8 MPa 1600 kg/ cm21 gauge to the pump outlet port end.
2.
Turn the swing
lock switch
3.
Set the working mode to H/O mode and set the knob switch function to POWER MAX.
4.
Run the engine at full throttle, turn the L.H. knob switch ON, and measure the oil pressure when the arm IN circuit is relieved. For the front pump, measure the oil pressure at plugs (I) and (3) at the same time; for the rear pump, measure the oil pressure at plugs (2) and (4) at the same time. The power max. function is automatically turned OFF 8 seconds after it is switched ON, so measure during the first 8 seconds. Check that the servo piston input pressure is 2/5 of the pump discharge pressure.
j
Iltii
BWP02976
ON.
[Reference] If there is any abnormality in the LS valve or servo piston, the servo piston input pressure will be almost the same or 0 of the pump discharge pressure.
20-116 0
PC300, 350-6
TESTING AND ADJUSTING
TESTING AND ADJUSTING NC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)
Adjusting Ir If the load becomes
larger, the engine speed will drop. Or if the engine speed remains normal, the work equipment speed will drop. In such cases, if the pump discharge pressure and LS differential pressure are normal, adjust the TVC valve as follows.
1.
Loosen locknut (I), and turn screw (2) to adjust. Ir The direction to turn differs according to the position of the eccentric position punch mark on the screw, so check the mark before turning. * Turn the screw as follows. . If work equipment is slow, turn in INCREASE direction . If engine speed drops, turn in DECREASE direction. Punch mark Range @
Range
@
Increase
Punch mark showing eccentric position
Decrease
Within 90’ in Within 90’ in counterclockwise clockwise direction direction Within 90” in
Within 90” in
clockwise direction
counterclockwise direction BLPO0132
2.
Af?ei completing (I). m
the adjustment,
tighten
locknut
Locknut : 24.5 - 34.3 Nm t2.5 - 3.5 kgm)
Note: The screw is an eccentric cam, so if it is turned from the 0 position in the graph, the stroke of the servo piston (change in oil flow) will move as shown in the graph. If it is turned one full turn, it will return to the original position, but the screw will become looser, so there will be play in the screw. Therefore, turn the screw a maximum of 90’ to the left or right from the position set when the machine was shipped.
PC300, 350-6
“!y$ flow
(f!/min)
so
180'
270'
360
Angle of turning of eccentricpin BKPO0131
20-l 17 0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE * 1.
Oil temperature
when
measuring:
45 - 55°C
Measuring LS valve output pressure (servo piston input pressure)
1) Rrimoie
pressure measurement plugs (I 1, (21, (31, and (4) (Thread dia.= 10 mm, Pitch=1.25 mm), and install nipple C2 and oil pressure gauge Cl. Plugs and measured pressure
~ discharge pressure Install a 39.2 MPa (400 kg/cm21 gauge to the servo valve end, and a 58.8 MPa 1600 kg/cm*} gauge to the pump outlet port end. Set the working mode to H/O mode, and turn the travel speed switch to Hi. Use the work equipment to raise the track assembly on one side. Ir When measuring the front pump, push up the right track; when measuring the rear pump, push up the left track. Run the engine at full throttle, set to the conditions shown in Table 1, and measure the pump discharge pressure and servo inlet pressure. Ir For the front pump, measure the oil pressure at plugs (I) and (3) at the same time; for the rear pump, measure the oil pressure at plugs (2) and (4) at the same time.
2) 3)
4)
Table
Travel
H/O mode
BWP02976
1
wz;%g H/O mode
IlV
lever Neutral
Servo inlet Pump pressure port pressure (MPa{kglcm2H (MPaIkg/cm*I) 3.92 * 1.0 {40 * IO)
valf,(travel Approx. “r$‘;O~d~r 12.74 11301
20-118 0
3.92 + 1.0 I40 + IO] Approx. 4.9 {501
Remarks About same pressure About 2/5 of pressure
PC300, 350-6
TESTING AND ADJUSTING
2.
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Measuring LS differential pressure 1)
Measuring with a differential pressure gauge i) Remove pressure measurement plugs (I), (2), (3), and (4) (Thread dia.=lOmm, Pitch=l_25mm), and install nipple C2 and differential pressure gauge C4. * Plugs and measured pressure
Ir
Connect the pump discharge pressure to the high-pressure side of the differential gauge and the LS pressure to the low-pressure side. ii) Set the working mode to H/O mode, and turn the travel speed switch to Hi. iii) Use the work equipment to raise the track assembly on one side. * When measuring the front pump, push up the right track; when measuring the rear pump, push up the left track. iv) Run the engine at full throttle, set to the conditions shown in Table 2 and measure the LS differential pressure. Table 2
H/O mode
H/O mode
Note:
2)
Neutral Half (travel circuit under no load)
3.92 f 1.0 I40 f IO}
(Note)
2.45 f 0.1 I25 + 1)
When all control levers are at neutral, the LS differential pressure is the same as the unload pressure.
Measuring with oil pressure gauge differential pressure is * The maximum 2.94 f 1.0 MPa (30 f 10 kg/cm*), so measure with the same gauge. plugs i) Remove pressure measurement (I), (2), (3), and (4) (thread dia.=lOmm, pitch=l.25mm), and install the nipple C2. Carry out the same operation as in Step ii) I)-ii), iii) above.
PC300, 350-6
BWPO2977
Ici
BWPO2978 .
20-119 0
TESTING AND ADJUSTING
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Install oil pressure gauge Cl (58.8 MPa (600 kg/cm*)) to the measurement plug for the pump discharge pressure. Ir Use a gauge with a scale in units of 1.0 MPa {IO kg/cm*). (If no 58.8 MPa 1600 kg/cm*} pressure gauge is available, a 39.2 MPa (400 kg/ cm*) pressure gauge can be used.) iv) Set to the conditions in Table 2 and measure the pump discharge pressure. * Stand directly in front of the indicator and be sure to read it correctly. VI Remove oil pressure gauge Cl and nipple C2, then install it to the LS pressure measurement plug. vi) Set to the conditions in Table 2 and measure the LS pressure. * Stand directly in front of the indicator and be sure to read it correctly. (Pump discharge pressure) - (LS pressure) = LS Differential pressure iii)
BWPO2978
Oil pressure
gauge
BLPOO138
3.
Adjusting LS valve When the differential pressure is measured under the conditions above, and the results show that the differential pressure is not within the standard value, adjust as follows. 1) Loosen locknut (I) and turn screw (2) to adjust the differential pressure. * Turn the screw to adjust the differential pressure as follows. . To INCREASE pressure, turn CLOCKWISE . To DECREASE pressure, turn COUNTER-CLOCKWISE * Amount of adjustment for one turn of adjustment screw: Approx. 1.29 MPa (13.2 kg/cm*) Note: Always measure the differential pressure while adjusting. 2) After adjusting, tighten locknut. m Locknut: 58.8 - 78.5 Nm (6 - 8 kgm)
20-120 0
PC300, 350-6
TESTING AND ADJUSTING
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED)
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED) Measuring * Oil temperature
when measuring: 45 - 55°C ALower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then put the safety lock lever in the LOCK position.
1.
2.
Remove oil pressure measurement plug (2) (PTl/ 8) from LS-EPC solenoid valve block (I). Install nipple C2, then connect oil pressure gauge
Cl (5.8 MPa {60kg/cm21). 3.
Start the engine and measure full throttle.
PC300, 350-6
with the engine at
20-l 21 0
TESTING SOLENOID VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING
TESTING SOLENOID VALVE OUTPUT PRESSURE *
Oil temperature
1.
Measuring valve
when
measuring:
45 - 55°C
output pressure of LS-EPC solenoid
1) Disconnect
output hose (1) of the LS-EPC solenoid valve. Install adapter C3 and nipple C2 in the oil pressure gauge kit, and install oil pressure gauge Cl (5.8 MPa 160 kg/cm*)) Measure the output pressure under the conditions in Table 1.
2)
3)
Table
l
1 output pressure MPaIkn/cm*I)
Reference] Current (A)
Min. 1500
2.94 f 0.2 (30 + 21
900 + 30
H/O mode or control lever with travel at
*
ingine speed (rpm)
Min. 1900
The engine speed and LS-EPC current measured using the monitoring code monitor panel. . Engine speed : 1101 or [401 . LS-EPC current : 1151
20-122 0
can be on the
PC300, 350-6
TESTING AND ADJUSTING
TESTING SOLENOID VALVE OUTPUT PRESSURE
2.
Measuring output pressure of ON/OFF solenoid valve I) Disconnect outlet hoses (I), (2). (31, (41, (5) and (6) of the solenoid valve to be measured. 2) install adapter C3 and nipple C2, and install oil pressure gauge Cl (5.8 MPa (60 kg/cm21). 3) Measure the output pressure under the conditions in Table 2.
1//f
PC300, 350-6
-’
-----A
BWPO2987
20-123 0
TESTING AND ADJUSTING
TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2 Hou
5
6
With monitoring code (231, check at the same time that the solenoid is switched ON/OFF electrically. (The machine push-up solenoid is not displayed.) The measurement conditions in the table are typical conditions for measuring the output pressure. The solenoid valve may be actuated (ON/OFF) under conditions other than the measurement conditions given above. Operate the lever slightly not enough to move the machine.
20- 124 0
PC300, 350-6
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUlTLE VALVE
TESTING AND ADJUSTING
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHlJlTLE VALVE Sr Oil 1.
temperature
Measuring
when
measuring:
45 - 55°C
PPC valve output pressure
1) Disconnect hose (I) of the circuit to be measured.
2) Install adapter C3 and nipple C2. 3)
Install
oil pressure
gauge
Cl
(5.8 MPa
I60
kg/cm*I). 4)
2.
Run the engine at full throttle, operate the control lever of the circuit to be measured, and measure the oil pressure.
Checking PPC shuttle valve It If the output pressure at the control
valve end is low, check for leakage of oil from the PPC shuttle valve as follows. 1) Disconnect hose (1) between the PPC valve and the shuttle valve of the circuit to be measured. Disconnect the hose from the shuttle valve together with the nipple. 2) Install adapter C5 and nipple C2 to the tip of the hose, then install oil pressure gauge Cl (5.8 MPa (60 kg/cm*)). * Install a blind plug to the shuttle valve. 3) Run the engine at full throttle, operate the control lever, and measure the output pressure. * If the output pressure becomes normal, there is leakage from the PPC shuttle valve; if there is no change, the PPC valve is defective.
PC300, 350-6
20- 125 0
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE
TESTING AND ADJUSTING
Checking defective operation of PPC shuttle valve I) Remove the applicable oil pressure switch, then install nipple C2 and oil pressure gauge Cl (5.8 MPa (60 kg/cm2)). * Disconnect the outlet hose of the LS select shuttle valve before installing the oil pressure gauge. 2) Run the engine at full throttle, operate the applicable lever, and measure the output pressure. * If output pressure is generated for all the applicable operations, the shuttle valve is normal. * If no output pressure is generated all the applicable operations, the shuttle valve is defective. Swing left, right shuttle valve LS select shuttle valve (boom RAISE, arm OUT, all travel) Boom RAISE, arm OUT shuttle valve L.H. travel FORWARD, R.H. travel REVERSE shuttle valve All travel shuttle valves (L.H., R.H. FORWARD, REVERSE) L.H. travel REVERSE, R.H. travel FORWARD shuttle valve
Pressure arrangement
Bucket 606)
switch diagram
CURL
\
Arm IN (SO5)
/
I
’
Boom LOWER (SO4)
@ QPL -.-
‘Arm OUT (SO3)
/ I (SOI)
Trave
‘Boom 602)
RA ISE
TWP01402
R. H. work PPC “a
PPC
eauioment
Ive
shuttle.
travel iunctron“*lye
(Bucket
DUMP)
TWP01403
ZO-126 0
PC300, 350-6
TESTING AND ADJUSTING
ADJUSTING
WORK EQUIPMENT,
SWING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE Ir
A
If there is excessive play in the work equipment or swing lever, adjust as follows. Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then set the safety lock lever to the LOCK position.
1.
Remove the PPC valve assembly. For details, see DISASSEMBLY AND ASSEMBLY, Removal of work equipment PPC valve assembly.
2.
Remove
3.
Loosen locknut (21, then screw in disc (3) until it contacts the 4 heads of piston (4). -)r When doing this, do not move the piston.
4.
Secure disc (3) in position, then tighten locknut (2) to the specified torque. m Locknut : 98 - 127 Nm {IO - 13 kgml
boot (I).
l-.--III BLPOO154
5. Install boot (I). Ir
With the above adjustment, the clearance tween disc (3) and piston (4) becomes 0.
PC300, 350-6
be-
20- 127 0
TESTING TRAVEL DEVIATION
TESTING AND ADJUSTING
TESTING TRAVEL DEVIATION Sr 1.
2.
Travel posture
When traveling on level ground. Set the machine in the travel posture. * For the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom angle at 45”.
?I
Travel for 10 m, then measure the deviation when traveling for the next 20 m. + Set to H/O mode and measure with the engine at full throttle. * Install the hydraulic pressure gauge and measure the pump discharge pressure at the same time.
BKW0156
20m
Make a mark
p I-
Make a mark at the 10m midway point
10m midway 20m point
Run up for IOm
Make a mark
point
0
Lay out a string \
/\ Measure distance
the amount of a at this point
Mark hark
BLW0157
20-128 0
PC300, 350-6
TESTING AND ADJUSTING
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT Ir
If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve.
1.
Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, and stop the engine. ii) Operate the boom control lever to RAISE or the bucket control lever to CURL. . If the lowering speed increases, the packing is defective. . If there is no change, the boom lock valve (boom) or the control valve (bucket) is defective. 2) Checking arm cylinder i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the control lever to arm IN. . If the lowering speed increases, the packing is defective. . If there is no change, the control valve is defective. + If the pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again before operating. [Reference] If the cause of the hvdraulic drift is in the packing, and the above operation is carried out, the downward movement becomes faster for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster.
PC300, 350-6
SKW015S
I
BKFO0159
20-129 0
TESTING AND ADJUSTING
2.
3.
TESTING
LOCATIONS
CAUSING
Checking boom lock valve ASet the work equipment at the maximum reach, and the top of the boom horizontal, then stop the engine. Lock the work equipment control levers and release the pressure inside the hydraulic tank. 1) Disconnect pilot hose (I) of the boom lock valve and drain hose (21, and install a blind plug in the hose. * Pilot hose side blind plug: 07376-50315 * Blind plug for drain hose: 07376-50522 * Leave the boom lock valve end open. 2) Start the engine, charge the accumulator, then stop the engine. the boom control lever to the 3) Operate LOWER position. * If any oil leaks from the port that is left open, the boom lock valve is defective. * When disconnect hoses, take care to spout of oil and movement of work equipment, and loosen them gradually.
HYDRAULIC
DRIFT OF WORK EQUIPMENT
EKP00572
Checking PPC valve If the hydraulic drift differs when the safety lock lever is in the LOCK or FREE position, (engine running), the PPC valve is defective.
20-130 0.
PC300, 350-6
TESTING AND ADJUSTING
MEASURING + 1.
MEASURING OIL LEAKAGE
OIL LEAKAGE
Oil temperature when measuring: 45 - 55°C Work equipment cylinder If the hydraulic drift of the work equipment is outside the standard value, measure the leakage inside the cylinder as follows, and judge if the cause of the hydraulic drift is in the cylinder or in the control valve. . If the leakage is within the standard value, the problem is in the control valve. . If the leakage is greater than the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder to be measured, then stop the engine. 2) Disconnect piping (I) at the head end, then block the piping at the chassis end with a blind plug. ABe careful not to disconnect the piping at the bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at full throttle. + Boom cylinder : RAISE Arm cylinder : IN Bucket cylinder : CURL 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.
Posture for measuring
boom cylinder
BLWO161
Posture for measuring
arm, bucket cylinder
BLPOO162
Arm cylinder
BLPO0164
PC300, 350-6
20431 0
TESTING AND ADJUSTING
MEASURING
OIL LEAKAGE
Bucket cylinder
BLPOO165
BLPOO166
2.
Swing motor 1) Disconnect drain hose (I) from the swing motor, then install a blind plug at the tank end. 2) Turn the swing lock switch ON. 3) Start the engine and operate the swing relief with the engine at full throttle. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. Jr After measuring, swing 180’ and measure again.
20-132 0
PC300, 350-6
TESTING AND ADJUSTING
3.
RELEASING REMAINING
PRESSURE IN HYDRAULIC CIRCUIT
Travel motor 1) 2)
3)
4)
Disconnect drain hose (I) from the travel motor, then fit a blind plug at the hose end. Fit block @ under the track shoe grouser, or fit block @ between the sprocket and frame to lock the track. Start the engine and operate the travel relief with the engine at full throttle. A When measuring the oil leakage from the travel motor, mistaken operation of the control lever may lead to a serious accident, so always use signals and check when carrying out this operation. Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. Ir When measuring, move the motor slightly (to change the position between the valve plate and cylinder, and piston and cylinder), and measure several times.
BLWO170
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT *
1.
If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. The travel circuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap. Loosen the oil filler cap slowly to release the pressure inside the tank.
2.
Operate the control levers. * When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed.
3.
Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. Ir Repeat the above operation 2 - 3 times to release all the remaining pressure.
PC300, 350-6
20- 133 0
TESTING
AND ADJUSTING
TESTING
CLEARANCE
OF SWING
CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING Method of testing clearance of swing circle bearing when mounted on machine 1. Fix a magnet-type dial gauge to the outer circle (or inner circle) of the swing circle, and put the tip of the probe in contact with the inner circle (or outer circle). Set the dial gauge at the front or rear.
BLP00172
2.
Extend the work equipment to the maximum reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. When this is done, the upper structure will tilt forward, so the front will go down and the rear will rise.
3.
Set the dial gauge to the zero point.
BKPOO173
4.
5.
6.
Set the arm more or less at right angles to ground surface, then lower the boom until front of the machine comes off the ground. When this is done, the upper structure will back, so the front will rise and the rear will down.
the the tilt go
Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing. When carrying out the measurement, do not a put your hand or feet under the undercarriage.
BKP00174
Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Steps 3 to 5.
zo- 134 a
PC300, 350-6
TESTING WEAR OF SPROCKET
TESTING AND ADJUSTING
TESTING WEAR OF SPROCKET Wear
limit line
TWP01404
1.
Remove the track shoe assembly. * For details, see TESTING AND ADJUSTING, REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Align wear gauge P with the sprocket. * Align the benchmark line, then align the sprocket wave pattern and wear gauge wave pattern.
3.
Judge the wear of the sprocket. + If the sprocket wave pattern is above the wear limit line, it is possible to use the sprocket as it is. * If the sprocket wave pattern has reached the wear limit line, replace the sprocket with a new part.
PC300, 350-6
zo- 135 0
TESTING
TESTING
AND ADJUSTING
AND ADJUSTING
TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. Raise the track frame and boom. 2.
on one side using the arm
Measure the clearance a (tension) between the bottom of the track frame and the top of the track shoe. . Measurement position STD : 4th track roller from the sprocket. Midway between the 4th and 5th LC : track roller from the sprocket. . Standard clearance a (tension) : 331 + 20 mm
Adjusting * If the track shoe tension is not within the standard value, adjust as follows. 1. If the track tension is too high: Loosen plug (1) gradually, and release the grease. AThere is danger that the plug may fly out under the high internal pressure of the grease, so never loosen plug (I) more than 1 turn. * If the grease does not come out easily, move the machine backwards or forwards slowly. 2.
BWPO3019
If the track tension is too low: Pump in grease through grease fitting. * If the grease cannot be pumped in easily, move the machine backwards and forwards slowly.
zo- 136 0
PC300, 350-6
TESTING AND ADJUSTING
BLEEDING AIR
BLEEDING AIR Order for operations
and procedure
for bleeding
air Air bleeding procedure
Air bleeding item 1
2
Bleedingair Nature
Change hydraulic - Clean strainer l
* Replace
4
oil O
+
0
return filter element
* Replace, repair pump * Remove suction piping
O
0
+
j+
O
5
-j+
Ofnote,T’
-!
0
> I
I
I
0
-!
0
I
I
I
0
-L
0
I
I
I
0
-0
I l
Replace,
repair control valve
Replace cylinder - Remove cylinder
O
I
I
0
Start operations
‘(noter;)
I
I
6
Bleeding air from Bleeding air from travel motor swing motor
Bleedingair from cylinder
Start engine
from pump
of work
3
>
0
>
0
>
0
l
piping
Reoplace swing motor * Remove swing motor piping l
- Replace l
Remove
travel motor, swivel travel motor, swivel piping
0
I
-0 I
Note: Bleed the air from the swing and travel motors only when the oil inside the
1.
Bleeding air from pump
1) Loosen air bleed plug (11, and check that oil oozes out from the plug.
2) When oil oozes out, tighten plug(l). m
* 3) 4) 5) 6)
*
*
Air bleed plug: 7.8 - 8.8 Nm IO.8 - 1.0 kgm} If no oil oozes out from the air bleed plug: Leave plug (I) loosened and remove drain hose (2) and elbow (3). Pour in oil through the elbow mount hole until oil oozes out from plug (1). Fit elbow (3) and install drain hose (2). Tighten air bleed plug (I). w Air bleed plug: 7.8 - 9.8 Nm IO.8 - 1.0 kgm} Precautions when starting the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes. if the coolant temperature is low and automatic warming-up is carried out, cancel it by using the fuel control dial after starting the engine.
PC300, 350-6
0
I motor
)
0.L
0
case
has been drained.
TESTING
2.
AND ADJUSTING
Bleeding air from hydraulic cylinders 1) Start the engine-and run ai idling for approx. 5 minutes. 2) Run the engine at low idling, then raise and lower the boom 4 - 5 times in succession. Ir Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 21. After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. * When the cylinder has been replaced, bleed the air before connecting the piston rod. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder.
3.
Bleeding air from swing motor I) Inside motor case Run the engine at low idling for 5 minutes. * This operation will bleed the air inside the motor case automatically. 2) Inside brake case + Normally, the air inside the brake case is bled automatically, but if it feels that the brake is dragging when operating the swing, bleed the air as follows. Loosen the sleeve nut of brake hose (I), start the engine, and operate the swing prolix switch ON-OFF repeatedly. When oil oozes out, tighten the sleeve nut.
4.
Bleeding air from travel motor 1) Run-the engine at low idling, loosen air bleed plug (I), and check that oil oozes out from the plug. 2) When oil oozes out, tighten air bleed plug (II again. w Air bleed plug: 7.84 - 9.8 Nm IO.8 - 1.0 kgm1
BLEEDING
AIR
1 Boom cylinder
BLPO0179
BLPOOl81
20-138 0
PC300, 350-6
POINTS TO REMEMBER WHEN TROUBLESHOOTING
TROUBLESHOOTING
POINTS TO REMEMBER g
WHEN TROUBLESHOOTING
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A When
carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
A
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
A
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
removing the plug or cap from a location which is under pressure from oil, water, or air, always release A When the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers.
20-202 0
4) 5)
4.
5.
6.
Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure . Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting . Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure . Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
PC300, 350-6
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
-----
21
.
Type,
.
Details
serial number of jobsite,
of machine
etc.
Ask questions lem.
to gain an outline
.
of failure
Condition
Work being carried
of the prob-
out at the time of the
failure * .
Operating
environment
Past history,
details
of maintenance,
etc.
. / step 2
TEP01348
lDetermining
probable
location
of cause
. / >tep 3 Preparation 11
of troubleshooting
tools
Look at the table of troubleshooting the shop manual
and prepare
tools in
the necessary
tools.
2)
-
T-adapter
-
Hydraulic
pressure
gauge
kit, etc.
Look in the parts book and prepare essary
replacement
the nec-
parts.
11
.
Before
starting
repair simple
2)
*
Check before
-
Other check items
that
Drive manual
starting
See the Troubleshooting manual,
Shoe
troubleshooting,
select
matches
and
and
items Section
of the shop
a troubleshooting the symptoms,
operate
the condition
locate
failures.
the
and judge
flowchart
and carry
machine
out
to confirm
if there
is really
a
r
L
Was there
anything
strange
chine before the failure -
Did the failure
about
the ma-
occurred?
occur suddenly?
Had any repairs been carried out before the TEWOOl9
PC300, 350-6
20-203 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1.
POINTS TO REMEMBER ELECTRIC EQUIPMENT
WHEN
HANDLING
1)
Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are 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 to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
ImProPer
insertion
TEP01352
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
Improper
comDression
TEP01353
20-204 0
PC300, 350-6
TROUBLESHOOTING
@
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
\’ @
@
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the ,compressed air completely before cleaning with compressed air.
PC300, 350-6
TEW00194
TEW00195
TEW00196
20-205 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2)
Removing, installing, and drying connectors and wiring harnesses
0
Disconnecting connectors Hold the Connectors when disconnecting.
Press when
When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand.
Iiohtlv removing
TEPOl35
When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. * If the connector is twisted up and down or to the left or right, the housing may break.
TBW00484
I 0
TEP01355
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. Ir If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
TEW00198
20-206 0
PC300, 350-6
TROUBLESHOOTING
0
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors
0
Check the connector visuallv. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). de2) Check that there is no deformation, fective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. * If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. * If there is any damage or breakage, replace the connector.
Cliks into position
II
TEP01356
Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. If the connector cannot be corrected eas* ily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
PC300, 350-6
TEWOOZOO
TBW00487
20-207 0
TROUBLESHOOTING
l
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. @ Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEW00196
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. Ir Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
TEW00202
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassem ble.
T-adapter
TEP01357
20-208 0
PC300, 350-6
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TROUBLESHOOTING
3)
Handling control box The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
TEW00204
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
TEW00205
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
2.
Points to remember
when
troubleshooting
electric
circuits
1) 2)
Always turn the power OFF before disconnecting or connect connectors. Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. Ir If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. * If there is any change, there is probably defective contact in that circuit.
PC300, 350-6
20-209 0
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TROUBLESHOOTING
3.
POINTS TO REMEMBER HYDRAULIC EQUIPMENT
WHEN
HANDLING
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
11 Be careful of the operating
environment. Avoid adding hydraulic oil, replacing filters, repairing the machine in rain or high winds, places where there is a lot of dust.
or or
21 Disassembly
and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.
3)
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal.
TEW00208
41
Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
TEW00209
20-210 0
PC300, 350-6
TROUBLESHOOTING
POINTS
TO REMEMBER
5)
Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
61
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
WHEN
CARRYING
OUT MAINTENANCE
Flushino oil
TEP01358
7)
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
I
PC300, 350-6
TEW00211
20-211 0
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING $Jtyment
Item
Action
Check fuel level, type of fuel
-
Add fuel
2.
Check for impurities
-
Clean,
3.
Check hydraulic
oil level
-
Add oil
strainer
-
Clean,
-
Add oil
-
Add oil
level
-
Add water
Check dust indicator
-
Clean or replace
-
Replace
-
Tighten
or replace
-
Tighten
or replace
-
Tighten
or replace
-
Repair
1.
4. 5.
Check hydraulic Check swing
6.
Check engine
7.
Check coolant
8.
in fuel
machinery
oil level
oil level (oil pan oil level), type of oil
9.
Check hydraulic
1.
Check for looseness,
for clogging
filter corrosion
of battery
terminal,
wiring
Check for looseness,
corrosion
of alternator
3.
Check for looseness,
corrosion
of starting
1.
Check for abnormal
2.
Check for oil leakage
-
Repair
3.
Carry out air bleeding
-
Bleed air
1.
Check battery
voltage
2.
Check battery
electrolyte
(engine
wiring
20 - 3ov
stopped)
level
burnt, exposed
4.
Check for missing
5.
Check for water
leaking
to water
on connectors
wiring
clamps, on wiring
corroded
wiring
hanging
wiring
(be particularly
careful
attention
Check for blown,
7.
Check alternator
voltage
(engine
Add or replace
-
Replace
-
Repair
-
Disconnect connector
8.
Check operating
sound
of battery
-
fuses running
at l/2 throttle
Replace
-
or terminals)
6.
20-212 a
motor terminal,
noise, smell
Check for discolored,
leaking
wiring
drain
2.
3.
terminal,
drain
or above)
(when switch is turned ON/OFF)
4fter running for several minutes: 27.5 - 29.5V -
and dry
Replace Replace
Replace
PC300,
350-6
TROUBLESHOOTING
CONNECTOR Ir
CONNECTOR TYPES AND MOUNTING
TYPES AND MOUNTING
The Address column in the table above shows the address (2-dimensional drawing).
20-214 0
LOCATIONS
LOCATIONS in the connector
arrangement
drawing
PC300, 350-6
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
LOCATIONS
Add. Mounting SW1
-
20
Air conditioner
control
solenoid
ress panel
P-2 A-5
vo2
x
2
LS select
vo3
x
2
Pump merge/divider solenoid valve
7:;
vo4
x
2
Swing holding brake solenoid valve
7::
vo5
x
2
Machine push-up solenoid valve
z:i
V06
X
2
Travel speed selector solenoid
B-8 l-8
vo7
x
2
Active
WOI
KESl
4
Right front lock (option, with power window)
L-9
W02
KESI
4
Left front lock (option, with power window)
P-8
Intermediate
N-9 .
wo3 )2Lorl1
PC300, 350-6
location
(swing)
valve
U-R
valve
solenoid
J-6
connector
K-2
W04
M
6
Wiper
W05
KESI
2
Power window motor (with power windowi
-
W06
070
Intermediate connector (with power window)
h:i
W07
KESI
Front limit switch (with power window)
-
W08
070
18
Wiper
N-l
wo9
070
14
Wiper motor controller (with power window)
O-l
WI0
M
4
Intermediate connector (with power window)
N-l
WI2
-
3
Power
X01
MIC
X05
M
X07
MIC
14 2
21
motor
motor
window
Intermediate
4
Swing
17
K-6
controller
switch
c-2 o-5
connector
lock switch
Intermediate
M-4
connector
P-3
I
I
I
I
I
I
I
I
20-215 0
TROUBLESHOOTING
CONNECTOR ARRANGEMENT * For details of this page, see Section 90.
CONNECTOR ARRANGEMENT
DIAGRAM
DIAGRAM
PO8
SO4
'
SO7
\
SO8
Cb3
M28 Ml2 BWPO3002
20-216 0
t
PC300, 350-6
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
DIAGRAM
+
so4
.”
SO6 so3
___
PC300, 350-6
Fl 1 _. .
\
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
DIAGRAM
M22
X
iO6
x0 I M38 PO3
M20
/
x05 \
PO4 PO2
\
w M46
20-218 0
\ \ \
-w10
--
ROS
R04
co5
BWPO3030
PC300, 350-6
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION *
TABLE FOR CONNECTOR
The terms male and female refer to the pins, while refer to the mating portion of the housing.
No. of pins
T
PIN NUMBERS
the terms
male housing
and female
Female
housing)
housing
X type connector Male (female
housing)
(male
-
I
2
‘2
1
3
2
1
PC300,
350-6
3
1
2 TEW00223
TEW00224
TEW00225
TEWOO226
3
20-2 19 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector Male (female housing)
Female (male housing)
6
TEWOO235
BLmOO33
8
4
8
Ei
TEW00237
12
b TEW00238
1
4
5
8
9
12 BLF0JO35
1 4
8
11
3
10 i4
11
8
4
1
, z= 14
-I 7
14’16
TEW00239
TEW00240
1 5
16
20-220 0
9
4
5
8
9
2
PC300, 350-6
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector Male (female
housing)
Female
(male
housing)
2
1
i
BLPOoO38
3
2 I.
3 x
1
‘1 TEW00243
TEW00244
3
1
4 DS
2’
‘4
4
2
TEW00245
TEW00246
4
1
6
\ 3’
6’
‘6 TEW00247
3
TEWO0248
8
-5 Bl_P00040
PC300, 350-6
20-221 0
CONNECTION
TROUBLESHOOTING
No. of pins
r
TABLE FOR CONNECTOR PIN NUMBERS
S type connector Female (male housing)
Male (female housing)
8
/ 4
\
1
6
6
io
8
TEW00249
10
1
TEW00251
Id
6
6
5
BLPOOO42
1
12
5
12
8
16
8
I
16
7
4=E0
7
20-222 0
TEW00254
BLPooO43
16
ELF00044
TEW00256
PC300, 350-6
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
-l-
MIC connector Male (female
housing)
Female
(male
housing)
5
BLPQOO45
BLPOoO46
9
BLPOCQ47
BLPOOO46
13
8
13
t
BLPOOO49
BLPoOO50
9
17
17
L-___._/
BLPOOO51
1
11
12
21
BLPOO052
21
I
PC300, 350-6
J
TEW00259
TEW00260
20-223 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
AMP040
type connector l-
Male (female
housing)
Female
n
8
(male
housing)
4
8
I
I
I
BLW0054
BLPOO053
12
6
7
i
12 I
I
,
BLPOCk355
8
BLFOOO56
16
16
8
16
9
1
BLPoOO57
10
20
20
1
BLWOO5B
20-224 0
ii
i TEW00234
PC300, 350-6
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. of pins
AMP070 Male (female
type connector
housing) 1
Female
(male
housing)
7
8
6
4
BLP03059
14
'6 9
BK=UCGC
1
12
BLW0062
PC300, 350-6
20-225 0
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
No. of pins
T
2
L type type connector Male (female
Female
housing)
(male
housing)
1
El q
q
2
EliI
TEW00257
20-226 0
PC300, 350-6
TROUBLESHOOTING
No. of pins
CONNECTION
Automobile Male (female
housing)
TABLE FOR CONNECTOR
PIN NUMBERS
connector Female
(male
housing)
B
2
BLPmO63
BLPOfmi4
3
3
2
BVLO1140
BVLOl142
BVL01141
4
BVLO1143
8
BLPiXO72
PC300, 350-6
20-227 0
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T
Relay connector Male (female
housing)
Female
(male
housing)
5
1
3
6
5
3
6
BLFWO73
BLPC0074
6
6
M
I
I J
BLFQOO75
20-228 0
5
BLFO0076
PC300, 350-6
TROUBLESHOOTING
EXPLANATION
EXPLANATION
OF CONTROL MECHANISM
OF CONTROL MECHANISM
FOR ELECTRICAL SYSTEM
FOR ELECTRICAL
SYSTEM 1. Explanation of machine control functions The control mechanism for the electrical system consists of the monitor panel and governor and pump controller. The monitor panel and the governor and pump controller input the signals that are necessary, and together with the signals selected by the monitor panel, the governor and pump controller outputs or inputs the necessary signals and control the pump absorption torque and engine output.
TVC output source
Each
power F. R
solenoid
control IIMN
Work equipment Pressure switch
oil
Boom Ra i se/Lower Arm Bucket
Travel
irt;t;y
oil
Engine sensor
oil pressure signal
Ensine sensor
oil PressureIHii sIanal
level
r-X;1
Engine throttle controller
level
ra -___i
ra
Fuel
F DUMP Pressure
sensor
R Pump Pressure
sensor
c Battery
sensor
relay
drive
0
c
L___Coolant sensor
Pressure
(Lo)
Air cleaner clogging sensor signal Coolant signal
CurI/DumP
sensor
I
Air cleaner closaina sensor
oil
In/Out
Governor signal
temperature signal
level
sensor
sisnal
potention.
Governor motor Power source
r---1 /3'
drive
-___i
Hydraulic oil sensor signal
level ,Fuel
dial
signal
m
TWPOl405
PC300, 350-6
20-229 0
DISPLAY
TROUBLESHOOTING
DISPLAY METHOD
METHOD
AND SPECIAL
FUNCTIONS
AND SPECIAL FUNCTIONS
OF MONITOR
PANEL
OF MONITOR
PANEL 1.
Display on machine monitor When the starting switch is turned on, all the monitor and gauge lamps light up for approx. 3 seconds, and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self diagnosis, and after it has finished, it returns to the normal display.
2.
Recording of service codes and user code display function 1) All the abnormality data for the governor and pump controller is sent to the monitor panel. When the monitor panel receives this data, it records the abnormality data, and at the same time, depending on the nature of the abnormality, it displays the user code on the time display panel to advise the operator of the action to take. However, in cases of abnormalities which are not urgent and do not require the user code to be displayed, only the content of the abnormality is recorded, and no display is given.
2) Types of user code and system E02 E03 E05 *
3)
(TVC system) (Swing holding brake system) (Governor motor system) For details of the service codes included in the user code, see the action taken by the controller when an abnormality occurs, the symptoms on the machine or the judgement table.
Displaying user code If it becomes necessary to display the user code, the time displayed panel is automatically switched to advise the operator to take the necessary action. Actual display (Example: Disconnection in the cancel solenoid system for the swing holding brake) l
OFF
OFF
5-----+~~~V OFF
OFF
User code
OFF
OFF
OFF BKF90077
20-230 0
PC300, 350-6
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
4)
*
Display of trouble data The monitor panel records both service codes which are included in the user code, and service codes which are not included. This data can be displayed on the time display as follows. For details of the service codes that are not included in the user code, see ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGEMENT TABLE
Time
.Servi
di splay
ce meter Time
SW
Workinc I mode switch
Travel switch
speed
Monitor
i) Method
of displaying
Panel
Monitor
front
trouble
To set to the trouble data display mode, Keep the TIME switch + L.H. travel speed switch pressed for 2.5 seconds. Note: It is possible to call it up at the following times. 1) In the normal mode 2) In the user code display mode 3) In the machine data monitoring mode 4) In the time adjustment mode
rear
TWP01406
data Display
Operation 1.
Panel
1.
On the time display and service meter display, the service code and number of hours (service meter hours) that have elapsed since the occurrence of the abnormality are displayed. . Example of display : When E212 has occurred 12 hours before (service meter) 2) Display of elapsed time 1) Display of service code OFF
OFF
WW-VV-V OFF
2.
3.
To go to the next service code display, press the time switch + R.H. woking mode switch. To go back to the previous service code display, press the time switch + L.H. woking mode switch.
3)
OFF
Service
code
If any abnormality displayed.
OFF
Elapsed ON time data BKP00079
exists at this time, the E mark is
If there is an abnormality, self diagnosis, the output
PC300, 350-6
OFF
or the controller is carrying out is shut off, and E is displayed. BKPOOOEO
20-231 0
TROUBLESHOOTING
DISPLAY
METHOD
AND SPECIAL
Operation 4.
OF MONITOR
PANEL
Display
To finish with the trouble data display mode, keep the TIME switch + L.H. travel speed switch pressed for 2.5 seconds. To erase the memory, keep the time switch pressed, turn the starting switch from OFF to ON, and keep the time switch pressed for 5 seconds.
5.
FUNCTIONS
4) If there is no abnormality
code in memory
OFF
OFF
W-V-V -
OFF
is displayed
OFF
-
is displayed
OFF BKP00081
3.
Machine data monitoring function The input signals from the sensors and the output the time display and service meter display.
Time
.vice
di SPlaY
signals to drive the solenoid
are displayed
on
meter Time swi
Working switch
mode
Knob b utton funct i on switch
. Monitor
1)
Method
of displaying
Panel
front
monitoring
Monitor
To set to the machine data moni- 1 1. toring mode, do as follows. Keep the time switch + knob button function switch pressed for 2.5 seconds. Note: This is possible at the following times. 1) During the normal mode 2) During the user code display mode 3) During the time adjustment mode 4) During the trouble data display mode
20-232 0
rear
TWP01407
code
Operation 1.
Panel
Display On the time display and service meter display, the monitoring code and data are displayed. . Example of display 1) When engine speed is monitored (monitoring code IO) 0,FF
OFF
vv-wv
v-w OFF
OFF
Monitoring code
OFF
OFF (example
Monitoring code data
OFF
OFF
of 1950 rpm) BKP00083
PC300, 350-6
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
Display
Operation 2.
3.
4.
2)
To go to the next monitoring code display, press the time switch + R.H. working mode switch. To go back to the previous monitoring code display, press the time switch + L.H. working mode switch. To finish with the machine data monitoring code mode, keep the time switch + knob button function switch pressed for 2.5 seconds.
When displaying bit pattern . For monitoring codes 08, 20 - 24, 36, 37, 47 49, 4A. display the bit pattern. . Example of monitoring code 20 OFF
OFF
OFF
.
2)
Table of machine data monitoring codes Ir For details of the B in the Unit column,
Displays monitoring code
OFF
Displays bit pattern
OFF
OFF OFF BKW0084
The code No. is displayed in the monitoring code portion, and the display lights up to display bit patterns (I) - (6).
see the bit pattern
Item
No.
-Displays
chart in the next section.
Unit
Name of component
Monitor model code
-
Monitor panel
Governor, pump controller model code
-
Governor, pump controller
03
Governor, pump controller model code
-
Governor. oump controller
08
S-NET component condition display
B
Governor, pump controller
10
Engine speed
IOrpm
Governor, pump controller
11
Pump discharge pressure (F) input
MPa{kg/cm2} Governor, pump controller
12
Pump discharge pressure (R) input
MPa{kg/cm2} Governor, pump controller
13
TVC current (F) output
IOmA
Governor, pump controller
14
TVC current (R) output
IOmA
Governor. Dump controller
15
LS-EPC current output
10mA
Governor, pump controller
16
No. 2 throttle command
10mA
Governor, pump controller
20
Governor, pump controller PPC oil pressure
21
Governor,
pump
controller
22
Governor,
pump
controller
23
Governor,
24
Input condition
25
Input condition 2 of sensor for governor,
30
Fuel control
31
Potentiometer
01 02
PC300, 350-6
pump
B
Governor,
PPC oil pressure switch input signal (2)
B
Governor, pump controller
PPC oil pressure
B
Governor,
pump
controller
B
Governor,
pump
controller
B
Governor,
pump
controller
B
Governor,
pump
controller
IOmV
Governor,
pump
controller
IOmV
Governor,
pump
controller
controller
solenoid
switch
switch
input
input
signal
signal
(I)
(3)
actuation
1 of sensor for governor, pump controller monitor warning
dial input voltage
value
pump controller monitor warning
pump
controller
20-233 0
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
TROUBLESHOOTING
Ir
For details of the B in the Unit column,
No.
see the bit pattern
Item
chart in the next section. Unit
Name of component
1OOmV
Governor,
pump controller
motor A phase current
IOmV
Governor,
pump controller
motor B phase current
IOmV
Governor,
pump controller
100mV
Governor,
pump controller
32
VBB voltage
(batten/ voltage)
33
Governor
34
Governor
35
Battery relay output voltage
36 1Governor
governor
input condition
B
1Governor.
pump controller
37
Governor
governor
output condition
B
Governor,
pump controller
40
Engine speed
IOrpm
Governor,
pump controller
41
Coolant temperature
IOmV
Governor,
pump controller
42
Fuel sensor input voltage
IOmV
Governor,
pump controller
43
Battery charge input voltage
IOOmV
Governor,
pump controller
47
Monitor
panel output condition
48
Monitor
panel input condition
49
Monitor
4A 4C
sensor voltage
1
B
Monitor
panel
1
B
Monitor
panel
panel input condition
2
B
Monitor
panel
Monitor
panel input condition
3
B
Monitor
panel
Monitor
panel input condition
4
B
Monitor
panel
20-234 0
I
PC300, 350-6
TROUBLESHOOTING
3)
DISPLAY
Bit pattern chart As shown in the diagram below, the signal is being transmitted. CODE.)
METHOD
AND SPECIAL
FUNCTIONS
OF MONITOR
the time display has bit numbers which light up to show that (For details, see METHOD OF DISPLAYING MONITORING
OFF
OFF
PANEL
OFF
OFF
Code portion
OFF
OFF
OFF BKP00085
Content
Code
08
Connection
of S-NET
Details
Bit
components
(1)
ISovernor,pump
(2)
ISovernor,
(condition
when
controller
connected
pump controller
lighted
connected
up)
(ID=2) (ID=31
(3) (4) (5) (6) (1)
20
Input condition
of governor,
pump controller
input condition 21
of governor,
pump controller
PPC switches
and
other switches
Input condition 22
of governor,
pump controller
model
fravel
(3)
E3oom LOWER switch ON E3oom RAISE switch ON
(4)
PPC switches
selection
and other switches
!Swing switch ON
(2)
switch ON
(5)
I Qrn IN switch
(6)
I Irm
ON
(1)
E3ucket CURL switch ON
OUT switch
ON
(2)
E3ucket DUMP
(3)
Swing
(4)
Service switch ON
(5) (6)
IModel selection 5 ,Swing prolix switch ON
(I)
IModel selection
1 GND connected
(2)
IModel selection
2 GND connected
(3)
IModel selection
3 GND connected
(4)
IModel selection
4 GND connected
(5)
I Failure mode “Engine does not start” . Procedure: Check if the service code is being displayed on the monitor panel.
1) 2)
If a service code is being displayed on the monitor panel ......go to troubleshooting [E3:001 for the governor, pump controller (governor control system). If no service code is displayed on the monitor panel, and the engine does not start:
l
Check that starting motor rotates
PC300, 350-6
Starting motor rotates .... ...... ........ Go to troubleshooting mechanical system
S-2 of
Starting motor does not rotate.... Go to troubleshooting electrical system
E-8 of
20-239 0
TROUBLESHOOTING
2.
METHOD OF USING JUDGEMENT
TABLE
When using judgement table for governor, pump controller (governor control system) and hydraulic related parts . If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (&IO). (A 0 mark is put at the places where the failure mode and service code match.) . If a problem has appeared but no service code is displayed on the monitor panel, go to the point where the failure mode matches the input signal, and check the display for the input signal (the display at the place with a 0 mark). . If it is displayed normally, go to the troubleshooting code on the right of the judgement table (H-OO). . If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottom of the judgement table (F-00). Failure mode “Upper structure does not swing”. Procedure: Check if the service code is being displayed on the monitor panel.
[JIJdgementl 1) 2)
If a service code is being displayed on the monitor panel...... go to troubleshooting [E2:001 for the governor, pump controller (pump control system). If no service code is displayed on the monitor panel, and the upper structure does not swing: .
.
20-240 0
Check governor, pump controller input signal (Check in monitoring mode)i
There is a signal.... Go to troubleshooting mechanical system
H-25 of
There is no signal . Go to troubleshooting F-00 of governor, pump controller input signal system (F mode for applicable system)
PC300, 350-6
TROUBLESHOOTING
METHOD 1.
Category
METHOD
OF USING TROUBLESHOOTING of troubleshooting
Troubleshooting CodeNo.
TROUBLESHOOTING
code number Component of communication
Service code
Troubleshooting
E-00
Troubleshooting of electrical system for governor, pump controller (governor control system) Troubleshooting
CHARTS
CHARTS
N-00
s-00
2.
OF USING
abnormality
system
E218 group E3-00
of engine related parts
c-00
1Troubleshooting of electrical system for governor, pump controller (pump control system) I_E2-00 ~~~
F-00
1Troubleshooting
of governor,
pump controller
H-00
Troubleshooting
of hydraulic,
mechanical
M-00
Troubleshooting
of machine
monitor
group -
(input signal system)
I
group
-
system El-00
group
Method of using troubleshooting table for each troubleshooting mode code number and problem 1) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode (problem with the machine). (See Example (I)) 2) Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a), so go to the appropriate section to carry out troubleshooting. (See Example (2)) If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. chart 3) Method of following troubleshooting YES . Check or measure the item inside v, and according to the answer follow either the YES line or the NO line to go to the next I. (Note: The number written at the top right corner of the I is an index number; it does not indicate the order to follow.) . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) . Below the / there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. . Below the I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item I). 4) General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with * (See Example (4)) . The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the I. tools 5) Troubleshooting When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
PC300, 350-6
20-241 0
TROUBLESHOOTING
6)
METHOD OF USING TROUBLESHOOTING
CHARTS
Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem). (I) M-9 When starting switch is turned ON (engine stopped), check item for previous troubleshooting flashes (4) * * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Check that the coolant is at the specified level before carrying out troubleshooting
(2) a) 0 -
(coolant
level) flashes
SAP00519
Divided (engine
into sections
a) and b)
oil level) flashes
SAP00523
(3)
Cause
4 YES
out when short connected to PO8
p$zKz-[ 24 lighted up?
* Disconnect P08. _ . Turn starting switch ON.
(female ) (8) and chassis as shown
1 PO8
I.,\ ___I
. Turn starting switch OFF.. 9 Disconnect P08.
l-l
* Turn starting switch OFF. NO * Disconnect C16, P08. * Connect H disconnect short connector to PO8 (female).
I NO
IL
. Turn starting NO switch ON. - Set to monitoring :ode 24.
Remedy
Defective coolant level sensor system (see M-26:
-
Defective governor, pump controller
Replace
Defective monitor panel
Replace
Defective contact, or disconnection in wiring harness between Cl6 (female) (8) - PO8 (female) (1)
Repair or replace
Defective contact, or disconnection in wiring harness between PO8 (female) (2) -chassis ground
Repair or replace
Table
1
20-242 0
PC300, 350-6
TROUBLESHOOTING
DETAILS
OF TROUBLESHOOTING
DETAILS OF TROUBLESHOOTING
AND TROUBLESHOOTING
PROCEDURE
AND TROUBLESHOOTING
PROCEDURE If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the judgement table for that type of failure (governor, pump controller (governor control system) and governor, pump controller (pump control system). For details of the troubleshooting and troubleshooting procedure, refer to this flow chart. When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine, and check the following items before starting. (I) Condition of controller connection (check with monitoring codes 02 - 03) (2) Blown fuses (3) Battery voltage (monitoring mode 32) (4) Electricity generation (charge input) voltage (monitoring code 43) The procedure for carrying following pages.
YI
out check
items
No. 3 and 4 in the flow
E
chart
below
is given
E0.2 (TVC system)
E03 (Swing holding brake system) Go to Item 2
E05 (Governor motor system)
1
E200 group: Troubleshooting for governor, pump controller (pump control system ) (C mode)
Yf r
E3a group: Troubleshooting for governor, pump controller (governor control system ) (E mode)
Carry out troubleshooting in applicable mode (Note: For E218, carry out troubleshooting of the communication abnormality system (N mode).) Carry out troubleshooting for engine (S mode) Carrywt troubleshooting for engine electrical system (E mode). (Use flow chart for items where there is no display)lEll - E15)
YE
Is service code I
4 * Operate and check service code.
Are governor,
YI
3
* Check using monitoring
NC
I
Are monitor codes 02,03, 08 normal?
* Check connection condition of S-NET in monitoring codes O&03,08.
*
For details, see governor, JUDGEMENT TABLE.
PC300, 350-6
on the
pump controller
code.
* Governor controller:
IO
30,31,
33,34
- Pump
* After adjusting 1Hydraulic (mechanical) oil pressure, judge from system engine weed. * Is all work equipment slow and does engine speed drop under heavy load?
Carry out troubleshooting for hydraulic (mechanical) system (H mode)
Carry out troubleshooting for input signal system (F mode).
controller:
lo-24 .
Valve controller: 50-69
IO
Carry out troubleshooting for communication abnormality system (N comde).
(governor
control system)
(pump control system)
in the
20243 0
DETAILS OF TROUBLESHOOTING
TROUBLESHOOTING
AND TROUBLESHOOTING
PROCEDURE
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken that the output signal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the operation is defective, use the following procedure when checking directly. If any abnormality occurs in the S-NET system, the system is automatically switched to the following default mode, so be careful when carrying out troubleshooting. Default Mode when pump controller
communications
be carried
out for the monitor
Working mode Throttle signal Auto-deceleration Coolant temperature Active mode Power max. mode Travel speed Automatic warming
signal
up
G/O mode FULL ON (deceleration mode OFF OFF ON (power max. possible) Lo -
and governor,
Governor
control
H/O mode FULL ON (deceleration
mode)
Pump control
Set mode 1 2 3 4 5 6 7 8
cannot
ON (automatic warming-up
mode)
I-
l.
Procedure for checking monitor panel output signal j, 1.
2.
For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. Connection condition of components 1) Set to the monitoring mode and display monitoring code 08. 2) The time display (bits) will light up to display the components that are connected. * Governor, pump controller (pump control system) (I) and governor, pump controller (governor control system) (2) will light up. Checking working mode signal {check No. 2 throttle signal (monitoring code 16) at the same time) 1) Set to the monitoring mode and display monitoring code 10. 2) Switch the working mode as shown in Table 1 and check that the engine speed changes. Table
1
Working
High idling speed (rpm) [The figures in ( ) are the rated speed1
mode
H/O
I
G/O
2220cduring operation> 2050
(1950)
Approx. Approx.
2050
(1850)
operation>
I
I
I I
F/O
Approx.
1900 (1700)
L/O
Approx.
1700 (1500)
Active
20-244 a
Approx. Approx.
Approx. Approx.
2300
operation>
(2050)
PC300, 350-6
TROUBLESHOOTING
3.
4.
2.
DETAILS
OF TROUBLESHOOTING
AND TROUBLESHOOTING
PROCEDURE
Checking travel speed selection signal mode and display monitoring code 23. I) Set to the monitoring 2) Change the speed selector switch to Hi or Mi and run the engine at 1500 rpm or above. Check that bit (6) lights up when traveling at Hi or Mi (front or rear pump oil pressure: 21.56 - 32.34 MPa I220 - 330 kg/cm*} Checking swing priority mode signal If the travel oil pressure switch signal is not input to the controller, the flow from the front * and rear pumps will remain divided. mode and display monitoring code 23. 1) Set to the monitoring 2) Check that bit (4) lights up when the travel is operated (even when operated slightly). Ir Check the operating condition of the pump merge/divider solenoid valve
Checking input signal of governor, pump controller Ir Check the input signals for each controller as follows. . Pump control system 1. Checking input signal 1) Check hydraulic switch i) Set to the monitoring mode, and display monitoring ii) Operate each work equipment lever, and check how * For details of the bit pattern chart, see MONITOR FUNCTIONS. 2) Check speed sensor (check engine speed) i) Set to the monitoring mode, and display monitoring ii) Use the fuel control dial to change the speed, and done. 3) Check pump discharge pressure sensor i) Set to the monitoring mode, and display monitoring * Code 11 is for the front pump and code 12 is for ii) Refer to Table 2 and measure the hydraulic pressure Table 2 Pump
%
PC300, 350-6
merge/flow
logic and pumps
actuated
codes 20 and 21. the bit pattern lights up. PANEL DISPLAY AND SPECIAL
code 10. measure the speed
when
this is
codes 11 and 12. the rear pump. at the front or rear pump. by control
levers
Conditions for compound operation with travel. (I) When measuring the oil pressure for any circuit other than travel, operate the travel lever slightly or connect a short connector (X-2P) to the travel oil pressure switch connector (CN-SOI). (2) The circuits merge when the pressure of the front pump or rear pump is more than 19.6 MPa (200 kg/cm2}.
20-245 0
DETAILS OF TROUBLESHOOTING
TROUBLESHOOTING
4)
5)
2.
AND TROUBLESHOOTING
PROCEDURE
Check kerosene mode input signal i) Set to the monitoring mode, and display monitoring code 22. ii) Connect the CN-M36 connector and check that bit (5) lights up. Check knob switch input signal . i) Set to the monitoring mode, and display monitoring code 22. ii) Turn the knob switch ON and check that bit (6) lights up.
Check output signals 1) Check LS-EPC solenoid output current i) Set to the monitoring mode, and display monitoring code 15. ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode, and measure the current. * All levers at neutral: 900 + 80 mA Engine at high idling, any lever operated (other than travel): 0 A 2) No. 2 throttle signal i) Set to the monitoring mode, and display monitoring code 16. ii) Use the procedure in Item 2 for checking the monitor panel output signal, and measure the engine speed. 3) Checking ON ++ OFF solenoid condition i) Set to the monitoring mode, and display monitoring code 23. ii) Refer to Table 3 and check that the applicable bit lights up. Table 3 Types of solenoid Name
of solenoid
Active
holding
Pump
merge/divider
* 4)
brake
speed selector
Active Operate
Actuation
(boom)
Swing
Travel
and conditions
(swing)
Active Swing
condition
Travel
operated
Active mode switch raise lever operated
lever operated
independently
speed selector
not enough
Bit that lights up
mode switch OFF
or work equipment Travel
the lever slightly
for actuation
switch
Hi or Mi
ON + swing + boom simultaneously
(2) (3) (4) (6) (5)
to move the machine.
Check TVC solenoid output current i) Set to the monitoring mode, and display monitoring codes 13 and 14. Code 13 is for the front pump and code 14 is for the rear pump. ii) With the starting switch kept at the ON position (G/O mode), measure the current when the fuel control dial is turned to the MAX position. . Current with starting switch ON (G/O mode) and fuel control dial at MAX : 520 f 80 (mA)
l
l
Governor control system
20-246 0
PC300, 350-6
l
Governor control system 1. Check input signal 1) Check fuel control dial input voltage i) Set to the monitoring mode, and display monitoring code 30. ii) Measure the voltage when the fuel control dial is turned from low idling to high idling. * Voltage: 0.25 - 4.75 V 2) Check governor potentiometer voltage i) Set to the monitoring mode, and display monitoring code 31. ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to high idling. * Voltage: 0.5 - 3.3 V 2.
Check output signal 1) Check governor motor drive current i) Set to the monitoring mode, and display monitoring codes 33 and 34. * Code 33 is the A phase (engine speed acceleration direction) and code 34 is the B phase (engine speed deceleration direction) ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration direction and deceleration direction. + Current: 700 + 70 (mA) 2)
Measure battery relay drive output voltage i) Set to the monitoring mode, and display monitoring code 35. ii) Measure the battery relay drive output voltage when the starting switch is turned from ON to OFF. or iii) Set to the monitoring mode, and display monitoring code 37. iv) Check that bit (I) lights up when the starting switch is turned from ON to OFF.
PC300, 350-6
20-247 0
SERVICE CODE TABLE
TROUBLESHOOTING
SERVICE CODE TABLE Service code
Abnormal
Service code
system
El01 1Abnormality
in error
El02
Abnormality
in time data
El03
Short circuit in buzzer output, with
24V wiring
history
harness
clogging
data
I
I
contact
for buzzer
drive
El04
Air cleaner
detected
El06
Abnormality in engine oil pressure sensor (Hi) detected
El08
Water
temperature
over
1Short circuit in wiper motor drive normal rotation system
I
I
E 113
1Short circuit in wiper motor drive reverserotation system I
I
El14
1Short
(
(
I
I
I
I
washer drive system
E207
Short circuit in active mode (boom) solenoid
E208
Disconnection
E217
Error in model
E218
Network
Error
in auto-greasing
E315
Short
circuit
E316
Step-out
E317
Disconnection
E318
Short
in battery
in governor
circuit
User code
controller relay output
(option) system
motor
in governor
in governor
motor
system
E05 E05
motor system
I
I
I
I
system
in active mode (boom) solenoid system
selection
response
input
overtime
error
E222
1Short circuit
E223
Disconnection
E224
Abnormality
E225
1Abnormality
E226
1Ab normality in pressure sensor system power source
in LS-EPC solenoid
system
in LS-EPC solenoid
system
in F pump pressure sensor system in R pump
pressure
sensor
system
Abnormality
E231
Short circuit in active mode (swing) solenoid
system
E232
Short
system
E233
Disconnection
E235
Disconnection in active mode (swing) solenoid system
E236
Short circuit in R pump TVC solenoid
E237
Disconnection
E306
Abnormality
E308
Abnormality
circuit
I
I
in engine speed sensor
E227
20-248 0
E313
I I
system
105°C
E 112
circuit in window
Abnormal
in F pump in F pump
TVC solenoid TVC solenoid
in R pump TVC solenoid in feedback
potentiometer
in fuel control
dial input
system
system system
E02 E02
E02 E02
system value
E05
PC300, 350-6
1
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)
N-l
PC300,
[E2181 Communication
350-6
abnormality
.. . . . . .. .. . .. . .. .. . .. . . . .. .. . .. . . . .. .. . . . . .. .. .. . .. . .. . . . . . . .. . . . . . .. . .. . . . .. . .. .. . .. . . . 20-302
20-301 a
TROUBLESHOOTING
N-l
N-l
[E218] Communication
abnormality
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that the service code displays E. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the reCause Remedy lated connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Has been reset
4 YE: Is resistance YES between PO1 (4) - (I 1) and chassis or 3 ~ PO1 (4) (11) and PO1 (12) normal? When Cl7 is ; disconnected,do bits * Disconnect Nr connector C17, (1) and (2) light up in POl, and install monitoringcode OS? T-adapter to POI. * Min. 1 MR * Disconnect connector ~17. NO * Turn starting switch ON. YES 5
* Disconnect C17. *Turn starting switch ON. * See Table 1.
* See Table 2. * Turn starting switch ON.
Is voltage bwtween Cl7 (4) h t (12) and chassis normal? * Turn starting switch ON. * Min. 7.5 V * Disconnect Cl7 and measure voltage at harness end.
Table
1
__
..
.
Monitoring 01 I
Monitor
6 YE!
I
Is resistance between POl(4). NO (11) and Cl7 (4), (12) normal? * Disconnect POI, c17. Max. IQ
code
Disconnection is betweer POl(4) (11) and PO1 (12) or chassis
Repair
Defective governor, pump controller
Replace
Defective governor, pump controller
Replace
Defective monitor panel
Replace
Disconnection in wiring harness between POl(4). (11) and Cl7 (4). (12)
N(
I
I
0
When each controller is connected to the network, U-fl is displayed. If the correct alphanumerics are not displayed (another model is displayed), each controller shows model selection abnormal.
.
Note: Checks can be carried out with code 08 only when there is a disconnection. The display does not change when there is a short circuit. Therefore, checks when there is a short circuit should be carried out basically using Table 1.
300
02
Governor,
pump controller
model code
300
03
Governor,
pump controller
model
300
code
Replace
l
-. 1Uisplay
panel model code
Defective monitor panel
Table 2
08
.
Network
connection
condition
Light up when connected (I) Governor, punp controller (2) Governor, punp controller
20-302 0
PC300, 350-6
TROUBLESHOOTING
N-l
Related
electric
N-l
circuit diagram
Governor, pump controller C16(MIC17)
Monitor panel PO1 (04020)
-
HI4 @
(M6)
AT C17(04016) BKFQ0092
PC300, 350-6
20-303 0
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) Points to remember pump controller
when
Electrical
when
table for governor,
and engine
out troubleshooting
of governor,
system . .. . . . .. .. . .. . .. . . . .. . . . . . . . . . . .. . .. . . . . . . .. .. . . . .. . .. .. . .. . . . .. . .. .. . . . .. . . . .. . .. .. .. . . . . . . .. . .. . . . . . . . . . . . .. . . . . 20-352
Action taken by controller Judgement
carrying
related
Abnormality
occurs and problems
pump controller
(governor
on machine .. .. . .. .. . . . .. . . . . . . . . . . . 20-354
control
system)
parts . . . . . .. . .. .. . .. . . . .. . . . . . . . . . . . .. . . . .. . . . .. .. . .. . . . . . . .. .. .. . .. . . . .. . . . .. . .. . . . .. . . .. . . . . . . . .. . . . .. . . . .. .. . . . .. . . 20-358
circuit diagram
E- 1
abnormality
for E mode system .. . . . .. . . . . . .. . . . . . . .. . .. .. . .. .. . . . .. . . . .. . . . .. . .. . . . . . . .. . . . .. . . . .. . . . . . . . . . . .. . . . .. 20-360 in governor,
pump controller
power
E- 2
IE3081 Abnormality
in fuel control
E- 3
[E3171 Abnormality
(disconnection)
dial input value is displayed
E- 4
[E3181 Abnormality
(short circuit) in motor drive system
E- 5
IE3061 Abnormality
in feedback
in motor
potentiometer
drive system
system
....................
20-364
.......................
20-365
...........................
20-366
is displayed
is displayed
(short circuit)
[E3161 Abnormality
(step-out)
E- 8
Engine does not start .........................................................................................................
20-370
E- 9
Engine speed
20-372
is displayed..
system
is displayed
......... 20-367
[E3151 Abnormality
E- 7
in motor
relay output
.20-363
.................................
is displayed
E- 6
is irregular
in battery
LED is OFF) .... 20-362
source (controller
...................................................
...................................................................................................
a)
Idling speed is irregular . _.............................................................................................
b)
There
is hunting
...........................................................................................................
Lack of output
E-l 1
Engine does not stop .........................................................................................................
E-12
Defective
PC300, 350-6
(engine
high idling speed is too low). ...................................................
E-10
operation
of battery
relay system
(engine
does not stop). ..........................
.20-368
20-372 20-374 .20-376 20-378 20-380
20-35 1 0
TROUBLESHOOTlNG
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT OF GOVERNOR, PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM 1.
Points to remember when there is abnormality which is not displayed by user code The engine is controlled by the governor and pump controller. The problems that may occur with this system include the following. 1. Idling speed is too high (too low) 2. High idling speed is too low 3. Auto-deceleration speed is too high (too low) 4. Engine speed for automatic warming-up operation is too high (too low) 5. There is hunting 6. Engine does not stop If any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor panel, use the troubleshooting table to determine the appropriate troubleshooting flow chart from E-l to E-12.However, if there is any abnormality in the machine and no abnormality display is given, it is necessary to determine whether the problem is in the mechanical system or in the electrical system. If the linkage between the governor motor and the injection pump is not properly adjusted, problems 1 to 6 listed above may occur. Therefore, if there is no abnormality display, but one of problems 1 to 6 above has occurred, carry out troubleshooting as follows. YES 2 ~ YES h If linkage between governor motor 1 and injection pump - is disconnected, If linkage between governor motor and does operation of injection pump is governor motor disconnected and _ become normal? NO pump lever is *With starting switch at ON, operate fuel operated by hand or is fixed with wire, control dial and working mode switch. does condition NO retUren t0 nOrrd?
Defective adjustment of governor motor likage See TESTING AND ADJUSTING.
Go to troubleshooting electrical system
E-9-E-12
of
Go to troubleshooting engine system
S-l -S-l6
of
* If engine
does not stop, push governor lever to STOP position and check if engine stops.
Disconnect the linkage as explained above, or check the adjustment flow chart for the mechanical system or electrical system. For details of the procedure for adjusting the linkage, see TESTING
and go to the troubleshooting AND ADJUSTING.
2.
Points to remember if abnormality returns to normal by itself In the following two cases, there is a high probability that the same problem will occur again, so it is desirable to follow up this problem carefully. I) If any abnormality returns to normal by itself, or 2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure, and the service code is no longer displayed, or if the monitor display returns to normal. 3) After completing troubleshooting, always erase the service code from memory.
3.
User code memory retention function When displaying the abnormality code in memory and carrying out troubleshooting, note down the content of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to the failure code that is displayed. (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function. Erasing the data in this way saves any wasted work.)
20-352 a
PC300, 350-6
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code
E308
Abnormal
E318
20-354 0
of abnormality
Abnormality in fuel control dial input value
1. Short circuit in wiring harness between CO3 (7) - (14). (7) - (171, (14) - (17) 2. Short circuit in wiring harness between E04 (1) - (2), (1) (3), (2) - (3) 3. Short circuit in wiring harness between E06 (I) - (21, (I) (3), (2) - (3) 4. Short circuit in wiring harness between CO3 (7) - (4), (4) (17) 5. Disconnection in wiring harness between CO3 (7) - X07 (6) - E06 (1) 6. Disconnection in wiring harness between CO3 (4) - X07 (5) - E06 (2) 7. Disconnection in wiring harness between CO3 (17) - X07 (4) - E06 (3) 8. Defective fuel control dial 9. Defective contact of C03, X07, E06 connectors
Abnormality (disconnection) drive system
1. 2. 3. 4. 5. 6.
E05 E317
Nature
system
Abnormality (short circuit) drive system
in motor
in motor
Disconnection inside governor motor Disconnection in wiring harness between Disconnection in wiring harness between Disconnection in wiring harness between Disconnection in wiring harness between Defective contact of E05 connector
CO2 CO2 CO2 CO2
(2) (4) (3) (5)
-
E05 E05 E05 E05
(I) (3) (2) (4)
1. Short circuit inside governor motor 2. Wiring harness between CO2 (2) - E05 (I) and between CO2 (4) - E05 (3) short circuiting with wiring harness between CO2 (3) - E05 (2) 3. Wiring harness between CO2 (4) - E05 (3) and between CO2 (2) - E05 (1) short circuiting with wiring harness between CO2 (5) - E05 (4) 4. Wiring harness in Items 2 and 3 short circuiting with ground
PC300, 350-6
ACTION TROUBLESHOOTING
Condition when normal (voltage, current, resistance) co3 (female) (7) - (4) (4) - (17) (7) - (17)
E06 (male) (1) - (2) (2) - (3) (1) - (3)
Between each pin and chassis
Resistance value 0.25 - 7kQ 0.25 - 7kQ 2 - 3kR 4 - 6kR _
TAKEN
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Maintains engine speed at position of fuel control dial immediately before abnormality occurred
1. Does not become partial speed when set at MAX position 2. Does not reach high idling when set at partial speed 3. There are cases of hunting 4. Lacks output (max. speed of engine is too low)
Takes no particular action
1. When there is a disconnection in both the A phase and B phase at the same time, the problem is the same as for a short circuit in the governor motor system 2. When there is a disconnection in only one of A phase or B phase I) Engine does not stop 2) Stops moving at position immediately before failure, so engine speed cannot be controlled 3) There are cases of hunting
Sets motor drive current to 0
1. If during operation 1) Set to low idling 2) Engine does not stop 3) There are cases of hunting 2. When stopped I) Engine starts, but stays at low idling 2) Engine does not stop after starting 3) There are cases of hunting
Min. 1 MD
-
E05 (male)
co2 (female)
(1) - (2) (3) - (4) (1) - (3) (1) - (4) Between
(2) - (3) (4) - (5) (2) - (4) (2) - (5) Between
Resistance value 0.25 - 7kR 0.25 - 7k.Q Min. 1 MI Min. 1 MD
pins (11, (2). pins (21, (31, (31, (4) and (4), and (5) Min. 1 MR and chassis chassis
Motor drive current: Hold: 0.7 A Start: 0.84 A
E05 (male) (1) - (2) (3) - (4) (I) - (3) (1) - (4) Between
co2 (female) (2) - (3) (4) - (5) (2) - (4) (2) - (5) Between
Resistance value 0.25 - 7kR 0.25 - 7kQ Min. 1 MD Min. 1 MR
pins (I), (2), pins (21, (31, (3), (4) and (41, and (5) Min. 1 MR and chassis chassis Motor drive current:
PC300, 350-6
Hold: 0.7 A Start: 0.84 A
20-355 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
Service code
-
E306
-
E315
Abnormal
system
Nature
Abnormality in feedback potentiometer system
Abnormality
(short
cir-
cuit) in battery relay output system
of abnormality
1. Short circuit in wiring harness between CO3 (7) - (14), (7) - (17), (14) - (17) 2. Short circuit in wiring harness between E04 (1) - (2), (1) (3). (2) - (3) 3. Short circuit in wiring harness between E06 (I) - (2), (1) (3). (2) - (3) 4. Short circuit in wiring harness between CO3 (7) - (4), (4) (17) 5. Disconnection in wiring harness between CO3 (7) - E04 (I) 6. Disconnection in wiring harness between CO3 (14) - E04 (2) 7. Disconnection in wiring harness between CO3 (17) - E04 (3) 8. Defective governor motor potentiometer 9. Defective contact of C03, E04 connectors
If excess current flows between CO3 (1) and battery relay -k This occurs only when turning starting switch to OFF and
stopping engine
1. Defective adjustment of rod or scuffing of loose spring -
E316
Abnormality (step-out) in motor
2. Abnormality in governor motor
3. Abnormality in governor, pump controller
20-356 0
PC300, 350-6
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal (voltage,
current,
co3 (female)
E04 (male)
(7) - (14) (7) - (17) (14) - (17)
(I) - (2) (2) - (3) (1) - (3)
Between each pin and chassis
-
resistance)
Resistance value 0.25 - 7kQ 0.25 - 7kQ 2 - 3kR 4 - 6kR
Action by controller when abnormality is detected
Calculates position of motor and carries out control from value of voltage immediately before abnormality occurred
Min. 1 MR
Between CO3 (1) and chassis: 20 - 30 V *_ Holds with the motor in the stop position for 2 - 2.5 set, returns to the low idling position, then turns the battery relay OFF.
~~~~t~~ry
1. Linkage adjustment correct
1. Displays when returning from high idling to low idling
2. Must move lightly when connector is removed 3. Normal
PC300, 350-6
relay drive cur_
* $t&rt$4gain
trepeats
2. In some cases it may not display when returning from partial speed to low idling
Problem
that appears
on machine
when there is abnormality 1. Precision of engine speed control may be reduced. For example: 1) Engine does not rise to high idling speed (a little too low) 2) Engine does not go down to low idling speed (a little too high) 3) Defective engine speed for autodeceleration or automatic warming-up 4) Engine may not stop * The governor motor moves in the direction to stop the engine, but the motor may not move completely to the position to stop the engine. 5) There are cases of hunting
Engine does not stop
Engine speed cannot be controlled (particularly at high idling), so there is hunting
20-357 0
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS Governor,
pump controller,
EI f!ngine related parts (E3: system m f Self-diagnostic display 2i
ii
73
2
&
z
E .o E s x
; 2 z E $ 8 .r > C z E
User code
Failure mode
Service code 1
Engine does not start easily
2
Engine does not start
3
Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor
4
Engine stops during operation When idling speed is irregular
5
Engine rotation is irregular When there is hunting
6
Lack of output (engine high idling speed is too low)
7
Auto-deceleration
8
Engine does not stop
9
Warming-up
10
Exhaust gas is black
1 12
1 Oil
% m g .? .S > C -5 E
:
i
$ -
9 -
-
E05
-
306 -
_
-
i -
G -
-
-
-
;
-
; -
5 -
; -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
E-5 -
does not work
operation
1 11 1 Oil consumption
-
-
8 5 s t 3 x : = e E 8
is defective
is excessive, or exhaust gas is blue
becomes dirty prematurely
13
Fuel consumption
is excessive, or exhaust gas is blue
14
Oil is mixed in coolant
15
Engine oil pressure caution lamp lights up
16
Oil level rises
17
Coolant temperature
18
Abnormal
19
There is excessive vibration
20
Engine speed does not change even when working mode is switched
rises too high (overheating)
noise is generated
Troubleshooting
code when service code is displayed
Troubleshooting
code when there is abnormality
in monitoring
I-1 -
or machine monitor check
-
0 : This shows applicable item for service code % : This shows item that needs only checking with monitoring
20-358 0
PC300, 350-6
‘_ Does starting
motor
turn?
Is red range displayed?
-
F :
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM
FOR E MODE SYSTEM
FUEi-!!L
STARTING
SWITCt
E06 (M3) FNCINE THROTTLE CONT ROLLER CO1 (MICl.?) _.-. lsATTERY m JQy,R SUPPLY (+24V) LI.Y
I
GND POWER SUPPLYh24Vl
CO3
(04020)
I I
L
p -62
7* ;;
,
12*2w .__
1
I IJ’,
,n ";.3 Y.J”
A
A
,
I
I
I
/
I
"V
-II’
I-, I
5 6 _I
a 9 10
MACHINE SELECT CONNECTOR Cl6
(MIC17)
TWP01409
20-360 0
PC300, 350-6
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Electric governor actuator ,--1 Potentiometer 1
otor,
r-----’
DlB(KES1) 1 2
085~’ Oi5BRI
I
:,
2
1
I
a 9 lo__-----..
-------
J
H15(L2)
Fuse box 2w
Battery
’ 858 IIII II.’ l
II 85BII l
I I=$ BKP00095
PC300, 350-6
20-36 1 0
TROUBLESHOOTING
E-l
*
* * * *
E-l
Abnormality LED is OFF)
in governor,
pump controller
power source (controller
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Check that fuse 1 is not blown. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8.)
YES
1
1
Is voltage between CO1 (7) (13) and CO2 (11) (21) normal? _ * Turn starting switch ON. ~20-30V
-
2
Is voltage between fuse 1 NO and chassis normal? * Turn starting switch ON. *20-30V
E-l Related
electric
Governor,
I
YES
NO
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between fuse 1 and CO1 (female) (7) (13)
Repair or replace
Defective contact, or disconnection in wiring harness between fuse l-HI5 (2kM14 (2) Ilkbattery relay M
Repair or replace
circuit diagram
pump controller
COl(MIC13) H14fM6)
04
1
Fuse
H15(L2)
2 O-
C02(MIC21) Battery
/l-II BKl-20096
20-362 0
PC300, 350-6
E-2
TROUBLESHOOTING
[E308] Abnormality
E-2
*
* *
in fuel control dial input value is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
2 rescstance between each pin YES of CO3 (female) (4) , - (7) (17), or between each pin and chassis as shown in Table l? *Turn starting switch OFF. * Disconnect C03. Is
Is resistance between E06 (male) W(2). W (3) as show in Tablel? * Turn starting switch OFF. * Disconnect E06.
Jr
I
Defective governor, pump controller
Replace
Defective wiring harness in system with defective resistance
Replace
Defective fuel control dial
Replace
NO
If E306 also occurs at the same time, check the wiring harness below. . Wiring harness between CO3 (female) (7) - E04 (female) (I) short circuiting contact with other wiring harness
Table
1
Remedy
Cause
with
ground,
or
1
co3 (female)
E04 (male)
(7) - (4) (4) - (17) (7) - (17)
(1) - (2) (2) - (3) (I) - (3)
Between each pin and chassis
E-2 Related
electric
-
Resistance value 0.25 - 7kQ 0.25 - 7kQ 2-3k!S 4-6kL2 Min. 1 MQ
circuit diagram
Governor, pump controller CO3104020) Throttle command
Throttle power source (+I Feedback Throttle power source (-1 BKW0097
PC300, 350-6
20-363 0
E-3
TROUBLESHOOTING
E-3 [E317] Abnormality displayed *
*.
* A Ir *
(disconnection)
in motor drive system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. During operation, if there is 1) a simultaneous disconnection in A phase and B phase: 1) the engine will run at low idling 2) the engine will not stop 2) a disconnection in either A phase or B phase, the engine speed will remain the same as before the abnormality occurred If the problem occurs when the engine is stopped, 1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Remedy
Cause
2 YES
- Turn starting switch OFF. - Disconnect E05.
Table
I
I NO
Defective governor, pump controller
Replace
Defective wiring harness in system with defective resistance
Replace
Defective governor motor
Replace
1
E05 (male)
co2 (female)
(1) - (2) (3) - (4)
(2) - (3) (4) - (5)
E-3 Related
electric
I Resistance
I
value 2.5 - 7.5kQ 2.5 - 7.5kR
circuit diagram
Governor, pump controller , C02(MIC21) ,
E05(X4)
I I
Governor motor
BKW0098
20-364 0
PC300, 350-6
E-4
TROUBLESHOOTING
E-4 [E3181 Abnormality displayed
a * +
(short circuit) in motor drive system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. If the abnormality occurs during operation, because of the force of the spring, 1) the engine will run at low idling 2) the engine will not stop If the problem occurs when the engine is stopped, I) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started. . Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
2 YES -IS resistance
Remedy
Defective governor, pump controller
Replace
Defective wiring harness in system with defective resistance
Replace
Defective governor motor
Replace
between each pin of
~
YES coz wemaw,or 1 - between each pin Is resitiance between each
* Turn starting switch OFF. * Disconnect E05.
Table
~
pin of
E05 (male), or between each pin and chassis as shown in Table 17
_
-
and chassis as shwon in Table l?
J
* Turn starting switch OFF. * Disconnect C02.
NO
NO
1
E05 (male)
co2 (female)
(2) - (3) (1) - (2) (3) - (4) (4) - (5) (2) - (4) (l)-(3) (2) - (5) . (l)-(4) Between chassis Between chassis and pins and pins (l)(2)(3)(4) G!)(3)(4)(5)
E-4 Related
electric
1 Resistance
1
value 2.5 - 7.5k!L! 2.5 - 7.5kQ Min. 1 MQ Min. 1 MR Min.
1 MQ
circuit diagram
Governor, pump controller C02(MIC21) Governor motor A(+)
@
N-1
@
B(+) @ &-I I
$0
BKP00098
PC300, 350-6
20-365 0
TROUBLESHOOTING
E-5
E-5 [E306] Abnormality
in feedback
potentiometer
system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are oroperly inserted. Always connect any disconnected connectors before going on the next step. ’
1Table l?
I
?risconnect
Defective governor, pump controller
Replace
Defective wiring harness in system with defective resistance
Replace
Defective governor motor
Replace
1
C03.
* Turn starting switch OFF. - Disconnect E04.
If E308 also occurs at the same time, check the wiring harness below. . Wiring harness between CO3 (female) (7) - X07 (6) - E06 (female) ground, or contact with other wiring harness
+
Table
(1) short
circuiting
with
1
co3 (female)
E04 (male)
(7) - (4) (14) - (17) (7) - (17)
(1) - (2) (2) - (3) (1) - (3)
Between each pin and chassis
E-5 Related
electric
I Resistance
Min. 1 MQ
-
circuit diagram X07(MIC17)
Governor, pump controller CO3(04020) Throttle command
I
value 0.25 - 7kQ 0.25 - 7kQ 2-3kQ 4-6kQ
@ -3
E06(M3)
$)
3
3
-3
Fuel control dial
$J E04(X3)
Throttle power source (+I Feedback Throttle power source (-)
7 . @
c
3 3
I
Governor potentiometer
3 BKFO0097
20-366 0
PC300, 350-6
TROUBLESHOOTING
E-6
E-6 [E315] Abnormality displayed
a * * Ir
(short circuit) in battery relay output
system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or.when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. This only occurs when the engine is stopped and the starting switch is turned OFF.
Remedy
Cause
YES
I
E-6 Related
electric
Replace
Defective battery relay
Replace
I) Contact between other wiring harness and wiring harness between CO1 (female) (II-HO2 KU-battery relay BR. 2) When light is connected
- Between CO1 NO (female) (1) and battery relay BR: Max 1 R - Beetween wiring harness and chassis: Min. 1 MR. - Turn starting switch OFF. - Disconnect CO1 and battery relay BR.
* Turn starting switch OFF. - Disconnect COl.
Defective governor, pump controller
circuit diagram Fuse
Hi4 (MI
Ml 1 IL21
8 Start switch
ins a
Engine throttle
controller
CO1 (MIC13) relay
drive
1 B
CO3 (04020)
PC300, 350-6
D13 (KEsi
2)
m
TWP01410
20-367 0
E-7
TROUBLESHOOTING
E-7 [E316] Abnormality
(step-out)
in motor is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed. the problem has been removed. If any other service code [E3061- [E318] has occurred at the same time, start troubleshooting from the code except codeIE3161. Check that the fuse is normal. “Adjusting travel of governor motor Read the precautions given in TESTING AND ADJUSTING, lever” before carrying out the troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
Go to applicable failure mode
1
.,
J
YI3
*Turn starting switch ON.
Id
operate fuel control dial 0 ++ MAX and turn starting switch OFF. Is operation normal? P *Turn starting switch ON. ND *Turn auto deceleration OFF.
I
,,Ll;:,“$;:%t;; / -Turn starting switch ON. *Turn autodeceleration OFF. * Set to governor motor adjustment mode. . See TESTING AND ADJUSTING.
20-368 0
YES
I
N0
4YE! Is there any scuffing when spring rod is moved to injection pump end? * Disconnect E05 * Disconnect linkage at governor motor end.
Remedy
-
Defective governor, pump controller
Replace
1) Defective linkage 2) Defective injection
Adjust or replace
pump
NC
Defective governor motor
Replace
Defective governor linkage
Adjust (For details, see TESTING AND ADJUSTING)
PC300, 350-6
TROUBLESHOOTING
E-8
E-8 Engine does not start When starting motor does not rotate. Check that fuse No. 14 is not blown before starting troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.
inserted.
4 YES Is voltage between YES starting motor terminal B and chassis normal? 3 * Turn starting Is there sound of switch ON. starting motor - . Approx.24” pinion engaging?
Yl
NO
5
YES
Is voltage between _ starting switch NO terminal C and chassis normal?
When starting switch is turned OFF, is sound heard from batten/ relay?
SYES
Is resistance ofwiring harness YES between starting switch BR and battery relay BR 7 normal?
. Turn starting switch ON-OFF
-
~
specific gravity of
Is voltage of starting switch b , terminal B normal?
* Min. 24V * Specific gravity: Min. 1.26
E-8 Related
+ Connect f-J end of tester to battery terminal H. *20-29v
electric
Is there continuity YE? between starting switch terminal B 6 andBR? _ -
* Turn starting switch ON. * Remove terminal B.
a
_
Is there continuity YES between chassis ground and battery 8 relay terminal E? NO
- Betweenstarting switchBRand banery NO relayBR:Max. 1 R * Betweenwiringharnessand chassis:Min. 1 MR *Disconnectbothstartingswitchand batteryrelayends. NO
NO
circuit diagram
Fusible
Start motor
NO
. Turn starting switch to START. * Approx. 24V
2
link
ins
R
B
TWP0141 I
20-370 0
PC300, 350-6
E-8
TROUBLESHOOTING
Cause
Remedy
f Defective starting motor
Replace
Defective contact of wiring harness between battery (+)-battery relay B-batten/ relay M-starting motor terminal B (including battery relay)
Replace
Defective contact, or disconnection in wiring harness between starting switch terminal C-X07 (lONO (1) -M2 (I)-starting motor terminal S Defective starting switch (between terminals B and C)
Defective battery relay Defective contact of wiring harness between battery relay terminal E and revolving frame grond connection terminal
PC300, 350-6
Defective contact, or disconnection in wiring harness between starting switch terminal BR-DlSbattery relay terminal BR
Replace
Defective starting switch (between B and BR)
Replace
Defective contact, or disconnection in wiring harness between battery terminal (+)-Mll-HO5 (6)-X07 (l&starting switch terminal B (including fusible link)
Replace
Lack of battery capacity
Charge or replace
20-371 0
E-9
TROUBLESHOOTING
E-9 Engine speed is irregular j, *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.
inserted.
a) Idling speed is irreaular YES
YES
4
2
‘When hnkage between governor Yf33 motor and pump is adjusted, does condition become normal?
Is E218 displayed? .---I l
NO
* See TESTING AND ADJUSTING.
Turn starting switch ON.
Starting motor signal 7
YES
1 1 Is controller
*Turn starting switch ON.
* Turn starting switch ON. Set to monitoring code 03 or 02.
7
YEiS Fuel control dial
5
Is voltage 1 between CO3 (41
1
. At MIN: 2.9 - 3.3V I_ NO
l
* At MIN : 4.0 - 4.75v
: NO
NO
Table
1 Controller
model
I Ir
code
BKFO0210
The diagram code 03.
20-372 0
shows
I
monitoring
PC300, 350-6
E-9
TROUBLESHOOTING
I
Remedy
Cause
Defective linkage
adjustment
Defective
injection
of
pump
Adjust
See S mode
Replace
starting switch ACC-X07 (17)-CO3 (fernal) (8), or defective starting switch
E-9 Related
electric
throttle
Sta ON Fue
S
tins ianal dial
-
See E-2
-
See C-14
-
X0
switch
controller
co3 (0 I
See E-5
circuit diagram Starting
Engine
Repair or replace
switch
17)
E06
B 1
2
Fuel dial
3
Power SUDDIY for fuel dial (+I Feedback signal Power SUPPIY for fuel dial (-1
PC300, 350-6
Governor Potent iometer TWP01412
20-373 0
E-9
TROUBLESHOOTING
b) There is hunting
2
co&i,yn
become
11 NO
. Turn starting switch ON. motor signal 7 YES IF Is voltage between YES ~03 (8) and 6 chassis normal and stable? Starting
disconnectedand Potentiometer *
model code as shown in Table
l
* Turn starting switch ON. * Set to monitoring code 03 or 02.
Table
Fuel control dial 5 ~ Is voltage between CO3 (4) _ , and (17) normal and stable?
Is voltage between CO3 (14) _ and (17) normal and stable? . At MIN : 2.9 - 3.3v *At MAX : 0.5 - 0.9v
* During operation :20-30V
L NO
NO
. At MIN : 4.0 - 4.75V *At MAX : 0.25 - 1 .OV
model
code
BKP00210
The diagram code 03.
20-374 0
YES
1 Controller
*
Turn starting switch ON. Turn fuel control dial from MIN to MAX and stop also at midway L,
shows
I
monitoring
PC300, 350-6
TROUBLESHOOTING
E-S
F
Cause
-
See N mode
=I
Defective linkage
adjustment
Defective
injection
of
pump
Adjust
See S mode
Replace Defective contact of wiring harness between starting switch ACC X07 (17) - CO3 (female) (81, or defective starting switch
E-S Related
electric
throttle
See E-5
-
See E-2
-
. SeeC-14
-
circuit diagram Start
Engine
Repair or replace
insxch
X07(MI~I{)
714 (F6,l
Fuse
I
controller
CO3 (040201 ON signal Fuel dial
supply for fuel dial !+) Feedback signal Power supply for fuel dial (-)
Fuel dial
Power
Governor Potent iometer TWPOl412
PC300, 350-6
20-375 0
TROUBLESHOOTING
E-10
E-10 Lack of output * Jr
(engine high idling speed is too low)
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.
inserted.
YES
H
Y
2
‘ES Is E218 displayed?
I
* Turn starting switch ON.
dYES
9
Potentiometer Is voltage
6
and (17) normal Fuel control dial ! * Start engine. * Set fuel control dial to MAX. * H/O mode.
1Is voltage
r(:,:z;LG’““’
YES between CO3 (4)
4
*At MAX : 0.5 - 0.9v
* At MIN : 4.0 - 4.75v * At MAX : 0.25 - l.OV
* Turn starting switch ON. Set to monitoring code 03 or 02.
NO
l
* See TESTING AND ADJUSTING.
Table
1 Controller
model
I Ir
No
code
BKP00210
The diagram code 03.
20-376 0
shows
I
monitoring
PC300, 350-6
TROUBLESHOOTING
E-10
Cause
Remedy
-
See N mode
Defective injection pump
Starting motor signal
7
Is voltage between CO3 (8) and chassis normal and stable? * During operation: 20 3ov
YES
See S mode
Defective governor motor Defective contact of wiring harness between starting switch ACC X07 (17) - CO3 (female) [8), or defective starting switch
NO
Repair or replace -
See E-5
-
See E-2
-
defective adjustment of Jovernor motor linkage
Adjust
1
-
see S mode
-
See C-l 4
E-10 Related
Engine
electric
circuit
throttle
diagram
Start
ina
X07(MIC17)
switch
H14 (M6)
Fuse
controller
CO3 (04020)
x07 (MI Cl_71
Start ina switch ON signal Fuel dial
Q-
E06 (hi31 -3
.a
a
3
3
Fuel dial
3 I
I
fuel dial Feedback fuel
dial
I+) signal
I
I
I
tu4 l-n.
K7-l (IJ 3
IV.31
\AJl
Governor potent iometer
(-1 TWP01412
PC300,
350-6
20-377 0
TROUBLESHOOTING
E-II a * * *
E-II
Engine does not stop
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor lever” before carrying out the troubleshooting. YES
YES
YI
r
Potentiometer
Trun starting switch ON+ OFF.
n
Relav drive sional ~_~
fi
* See TESTING AND ADJUSTING.
model code as shown in Table *Turn starting switch ON. . Set to monitoring code 03 or 02.
Table
Starting motor
chassis normal? . Max. 1V
GYES
IES FH !_ i
When starting YES switch is OFF, does * When engine is voltage bwtween stopped _ CO1 (1) and (6) (12) 4 change as shown in * 2.9-3.3v Table2 ? 1 . 20-30V hIO
NO
NO
1 Controller
model
code
BKP00210 *
The diagram code 03.
shows
monitoring
Table 2 When ON (Approx. 24V) Voltage from starting switch (CO3 (8)) iL
To baaenl relay (8R)
OFF See Note ______ __ Condition of actuation of controller circuit co1 (1)
H
1
Voltage output from controller when starting switch is OFF
When ON (Approx. 24V) OFF[
1 Drive time
_
Min. 4,0;anen/
re’ay fBR)
Max. 7sec. (when it is impossible to set to NO IINJECTION because of failure in motor)
Note 1:When the starting switch is ON, the controller end is OFF, but a voltage always flowing from starting switch BR, so if the voltage is measured voltage of 20 - 3ov.
20-378 0
BKP00206
of approx. 20 - 30V is at CO1 (I), there is a
PC300, 350-6
E-11
TROUBLESHOOTING
F
Remedy
Cause
Defective motor
-
governor
I
-
See E-5
Defective governor, pump controller
-
Replace
Contact with 24V harness of wiring harness between switch ACC -X07 CO3 (female) (8). defective starting
Replace
wiring starting (17) or switch
Replace
-
. See C-14
E-II
Related
Engine
electric
throttle
circuit diagram
controller
CO3 (04020)
x07 (MIC17)
Starting switch ON signal Power SUPPIY for
I
Battery drive
mm_ Start switch
ine
relay Battery relay
co1 (MIC13)
D13 (KESl
2)
7iT TWP01413
PC300,
350-6
20-379 0
E-12
TROUBLESHOOTING
E-12 Defective operation stop) Ir A * j,
of battery
relay system (engine does not
This only occurs when the engine is stopped and the starting switch is turned OFF. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
II Is E315 displayed?
l
Turn starting switch ON.
Remedy
-
See E-6
H.
YES
Relay drive signal 2 I monitoring code
u
3 YES
* Turn starting switch OFF. *20-30V NO harnessand chassis normal?
* Between
I
Defective governor, pump controller
Replace
Defective battery relay
Replace
I)Disconnection in wiring harness between CO1 (female) (1) -battery relay BR !)When light is connected
Replace
CO1 (female) (1) and battery relay RR: Max. 1 0 * Between wiring harness and chassis: Max. 7 MD *Turn starting switch OFF. * Disconnect CO1 and battery relay RR.
Table
1 Voltage from starting switch (CO3 (81) ~~prox~
To banery relay (gR)
24v) OFF
Voltage output from controller when starting switch is OFF
See Note 1 .___----. 1 When Condition of actuation of controller circuit co1 (1)
I
ON (Approx. 24V)
OFF i
) Drive time
_
Min, 4.0Eanery
re’av ‘BR)
Max. 7sec. (when it is impossible to set to NO IINJECTION because of failure in motor)
Note l:When the starting switch is ON, the controller end is OFF, but a voltage always flowing from starting switch BR, so if the voltage is measured voltage of 20 - 30V.
20-380 0
BKP00206
J
of approx. 20 - 30V is at CO1 (I), there is a
PC300, 350-6
TROUBLESHOOTING
E-12
Related
electric
E-12
circuit diagram
x07
(MIC17)
H 14 (M6)
M_l1 (L2)
Fuse
I
I-
Fusible
Battery Engine
throttle
link
relay
controller
CO3 (04020)
TWP01414
PC300, 350-6
20-38 1 0
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
Method
of using troubleshooting
s- 1
Starting
S- 2
Engine (I)
performance
charts .............................................................................................
is poor (starting
20-402
always takes time) .................................................
.20-406
does not start ...............................................................................................................
20-407
Engine does not turn ..........................................................................................................
20-407
(2) Engine turns but no exhaust (3) Exhaust
smoke comes
smoke comes
out, but engine
out (fuel is not being injected)
..............
20-408
does not start (fuel is being injected) ........... 20-409
S- 3
Engine does not pick up smoothly
S- 4
Engine
stops during
S- 5
Engine
does not rotate smoothly
S- 6
Engine
lacks output (no power) ...............................................................................................
20-413
S- 7
Exhaust
gas is black .................................................................................................................
20-414
S- 8
Oil consumption
S- 9
Oil becomes
S-IO
Fuel consumption
S-l 1
Oil is in cooling
operations
is excessive
contaminated
S-12
Oil pressure
S-13
Oil level rises (water,
S-14
Water temperature
S-15
Abnormal
S-16
Vibration
PC300, 350-6
..............................................................................................
caution
(hunting)
(or exhaust
..........................................................................
gas is blue). .......................................................
quickly .........................................................................................
is excessive water,
.........................................................................................
or water
................................................................................................ spurts back, or water
level goes down.. ........................
lamp lights up (drop in oil pressure)
..................................................
fuel in oil) .............................................................................................
becomes
too high (overheating)
...........................................................
noise is made .......................................................................................................... is excessive
...............................................................................................................
20-410 20-41 1 .20-412
.20-415 20-416 20-417 20-418 20-419 20-420 .20-421 20-422 20-423
20-401 0
TROUBLESHOOTING
METHOD
METHOD
OF USING
OF USING TROUBLESHOOTING
TROUBLESHOOTING
CHARTS
CHARTS
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @I in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user’s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under @ in the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].
20-402 a
PC300, 350-6
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
The basic method of using the troubleshooting chart is as follows. items listed for [Questions] and [Check items1 that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with Q. Check each of the [Questions] and [Check items1 in turn, and marked the 0 or Q in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ’ %I. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. How+ ever, do not use this when making calculations to narrow down the causes. ,%2. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
PC300, 350-6
20-403 0
TROUBLESHOOTING
.
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
combustion) s-7 Exhaust gas is black (incomplete General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel injection . Excessive injection of fuel
20-404 a
PC300, 350-6
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
CHARTS
J
Three symptoms t
4
’
Step 2 Add up the total of Oand Omarks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (I 1 Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 0 (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: 0 (5) Worn piston ring, cylinder: 0 Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
PC300, 350-6
20-405 0
TROUBLESHOOTING
S-l
Starting
S-l
performance
is poor (starting always takes time)
*
Check that the monitor panel does not display any abnormality in the governor control system. General causes why exhaust smoke comes out but engine takes time to start Defective electrical system . Insufficient supply of fuel . Insufficient intake of air . Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1) * Battery c harging rate Am&mrnny lob% 90% 80% 75% 70% XaWW,* 1.26 1.24 1.23 1.22 20°C 1.28 1.27 1.25 1.24 1.23 0°C 1.29 -10°C 1 1.30 1 1.28 1 1.26 1 1.25 1 1.24 l
. .
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table. Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period) 0 : Items to confirm the cause
,..
Confirm recent repair history Degree of use of machine 1Operated f8 1Gradually became \ Ease of starting c-__._ . ..L__
L Replacement of filtershasnotbeencarriedoutaccording to OperationManual
I
I engine,
temperature
of some cylinders is low ~~~
’ - --.-----.--+ I I I I I I I I I 17 I I I I
ion pump sleeve
ed I I I I I I I I I I I I I I.1 sx It is not permitted to replace only the regulator.
20-406 0
IRemedylilg1i1i1g1
PC300, 350-6
TROUBLESHOOTING
s-2
S-2 Engine does not start (I) Engine does not turn General .
.
causes why engine
I does
not
Causes
I
turn
seized Ir If internal parts of the engine are seized, carry out troubleshooting for “Engine stops during operations”. Defective electrical system Internal
parts
of engine
e causes (judging from Questions and check items) e to length of use (used for a long period)
turned to START, pinion moves out, but k
0
Makesrattlingnoiseand does notturn
When starting switch isturned to START, pinion does not move out
1 1 1 1 1 1 1
1
C %
al 6
When starting switch is turned to ON, there is no clicking sound
0
Battery terminal is loose
0
When battery is checked, battery electrolyte is found to be low
0
Specific gravity of electrolyte, voltage of battery is low For the following conditions 1) - 5). turn the starting switch
E
OFF, connect the cord, and carry out troubleshooting
4 2 z .o
at ON
I) When terminal B and terminal C of starting switch are connected, engine starts
‘u 0)
2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal C of safety relay are
% zz !G ‘: e +
connected, engine starts 4) When terminal of safety switch and terminal B of starting motor are connected, engine starts 5) There is no 24V between battery relay terminal M and terminal E
I
I
1
When ring gear is inspected directly, tooth surface is found to be chipped
0 6
PC300, 350-6
20-407 0
TROUBLESHOOTING
s-2
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)
*
Check that the monitor panel does not display any abnormality in the governor control system. General causes why engine turns but no exhaust smoke comes out l Supply of fuel impossible l Supply of fuel is extremely small . Improper selection of fuel (particularly in winter) *
Standards
Causes
/
for use of fuel Ambient temprature
Type of fluid
-22 -30
-4 -20
14 -10
32 0
50 10
66 20
86 30
104°F 40°C
Diesel fuel
Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period)
l : Items
to confirm the cause.
Mud is stuck to fuel tank cap When fuel filter is drained, When engine C % al i:
fuel does not come out
is cranked with starting
1) Injection
pump coupling
motor, 0
does not turn
2) No fuel comes out even when fuel filter air bleed plug is loosened
0
3) No fuel spurts out even when injection pipe sleeve nut is loosened 0
00 0
Rust and water are found when fuel tank is drained Inspect injection P ‘+= ; +I ?? ‘: e I-
pump directly
00 0
When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly
0 0
When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged 1 When fuel cap is inspected
0
0
directly,
0
0 a
it is found to be clogged
#
20-408 0
PC300, 350-6
I
TROUBLESHOOTING
(3) Exhaust smoke comes not start (Fuel is being injected) * . . . .
s-2
out but engine
does
General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil
Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use fused for a long period) 0:
1) Little fuel comes out even when injection pump
I lb I I I I I I I I I I
sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately starting engine, temperature
PC300, 350-6
after
of some cylinders is low
20-409 0
TROUBLESHOOTING
s-3
S-3 Engine does not pick up smoothly
(follow-up
is poor)
*
Check that the monitor panel does not display any abnormality in the governor control system. General causes why engine does not pick up smoothly . Insufficient intake of air . Insufficient supply of fuel . Improper condition of fuel injection . Improper fuel used
Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n : Possible causes due to length of use fused for a long period) l : Items to confirm the cause. Confirm recent repair history z .B I 2 CY
Degree of use of machine
Operated for long period
Replacement
of filters has not been carried out according
to Operation
Manual
Non-specified fuel is being used Engine oil must be added more frequently Rust and water are found when fuel tank is drained Air cleaner clogging caution lamp flashes Noise of interference
is heard from around turbocharger
Engine pick-up suddenly became poor Blue under light load Color of exhaust gas Black Clanging sound is heard from around cylinder head 1
1 Mudisstucktofueltankcap There is leakage from fuel piping High idling speed under no load is normal,
:,.
but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately starting engine, temperature
0
000
after
of some cylinders is low
Blow-by gas is excessive
00 0
1 When air cleanerelementis inspecteddirectly,it is foundto be clogged 1 When fuel filter,strainerare inspecteddirectly,they are found to be clogged Whenfeed pumpstraineris inspecteddirectly,it is foundto be clogged ? ‘E z 5 2 .a 2 ;
Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy, or does not return When compression pressure is measured, it is found to be low When turbocharger
is rotated by hand, it is found to be heavy
Whenvalveclearanceis checked directly, it is found to be outside standard value 1 When fuel cap is inspected directly, it is found to be clogged 1 When feed pump is operated, operation is too light or too heavy
Remedy
20-410 0
PC300, 350-6
s-4
TROUBLESHOOTING
S-4 Engine stops during operations Sr
Check that the monitor panel fuel level display shows that there is still fuel remaining. General causes why engine stops during operations . Seized parts inside engie . Insufficient supply of fuel . overheating Ir If there is overheating and the engine stops, carry out troubleshooting for overheating. . Failure in main piston pump * If the engine stops because of a failure in the main piston pump, carry out troubleshooting for the hydraulic system (H MODE).
Causes
Legend 0: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.
0 n
Abnormal Condition
noise was heard
when
engine stopped Engine overheated
and stopped
hey are found to be clogged
PC300, 350-6
20-411 0
s-5
TROUBLESHOOTING
S-5 Engine does not rotate smoothly
(hunting)
*
Check that the monitor panel does not display any abnormality in the governor control system. General causes why engine does not rotate smoothly Air in fuel system . Defective governor mechanism . Defective electric governor mechanism * If hunting does not occur when the rod between the governor motor and the injection by uspump is disconnected, troubleshoot ing the electrical system troubleshooting mode). l
Legend
0 : Possible causes
(judging from Questions and check items)
: Most probablecauses (judgingfrom Questionsand Check items) : Possible causes due to length of use fused for a long period) : Items to confirm the cause.
0 n
Condition of hunting
When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be _ _.
.c 5 e 1 o : ;
improperly adjusted
l
0
l
When control rack is pushed, it is found to be heavy, or does not return When fuel cap is inspected directly, it is found to be clogged
0 4
0
When feed pump strainer is inspected directly, it is found to be clogged
a
II II
When fuel filter, strainer are inspected directly, they are
I
20-412 0
found to be clogged
PC300, 350-6
S-6
TROUBLESHOOTING
S-6 Engine lacks output
(no power)
*
Check that the monitor panel does not display any abnormality in the governor control system. Measure the engine speed and judge if the cause is in the engine or in the chassis. General causes why engine lacks output . Insufficient intake of air . Insufficient supply of fuel . Improper condition of fuel injection . Improper fuel used (if non-specified fuel is used, output drops) . Lack of output due to overheating * If there is overheating and insufficient output, carry out troubleshooting for overheating.
Questions and check items) om Questionsand Check items) of use (used for a long period)
Replacement
of filters has not been carried out according
Air cleaner clogging caution lamp flashes Black Color of exhaust gas
Blue un
Blow-by gas is excessive Engine pickup is poor and combustion
is irregular
High idling speed under no load is normal, but speed suddenly drops when load is applied starting engine, temperature
of some cylinders is low
There is huntino from enaine (rotation is irreaular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping Water temoerature
PC300, 350-6
oauoe is in red ranoe
20-413 0
TROUBLESHOOTING
s-7
S-7 Exhaust smoke is black (incomplete combustion)
Causes llllJllll/
General causes why exhaust smoke is black . insufficient intake of air . improper condition of fuel injection . Excessive injection of fuel
Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A:
Possible causes due to length of use fused for a long period) to confirm the cause
l : Items
1 Confirm
recent repair history
1 Ooerated
1 Dearee of use of machine
Color of exhaust
for Ion
gas
Power was lost
1 When turbocharger
is rotated
by hand, it is found to be heav\
/ When air cleaner is inspected directly, it is found to be clogged r” ._ B 2 4 _o 2 E
When compression
pressure is measured, it is found to be low
Speed does not change when operation of certain cylinders is stopped Whencheckis madeusingdelivery method, injection riming is found to be incorrect Injection
pump test shows that injection
amount
is incorrect
Whenvalve clearanceis checkeddirectly it is found to be outside standardvalue When muffler
is removed,
exhaust
color returns to normal
When control rack is pushed, it is found to be heavy, or does not return
Remedy
20-414 0
PC300, 350-6
S-8
TROUBLESHOOTING
S-8 Oil consumption
is excessive (or exhaust smoke is blue)
+
Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive . Abnormal combustion of oil . External leakage of oil Wear of lubrication system l
Causes
Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items)
: Possible causes due to
n
l : Items to confirm -
length of use (used for a long period) the cause.
Confirm recent repair history Degree of use of machine Oil consumption
E .P $ S c1
1
Operated for long period
suddenly increased
Engine oil must be added more frequently Engine oil becomes contaminated
quickly
Exhaust smoke is blue under light load
1 yk? Amount of blow-by gas I Area around engine is dirty with oil There is oil in engine cooling water When exhaust oioe is removed, inside is found to be dirty with oil
E .= :: m 6
When turbocharger
air supply pipe is removed, inside is
found to be dirty with oil Oil level in PTO chamber rises Clamps for intake system are loose
-
I
r
When compression pressure is measured, it is found to be low When breatherelementis inspected,it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness
test of oil cooler shows there is leakage
Excessive play of turbocharger
shaft
1 When intake manifold is removed, dust is found inside
1
When intake manifold is removed, inside is found to be dirty with oil
PC300, 350-6
20-4 15 a
TROUBLESHOOTING
S-9 Oil becomes contaminated
s-9
quickly
General causes why oil becomes contaminated quickly . Intake of exhaust gas due to internal wear . Clogging of lubrication passage . Improper fuel . Improper oil used . Operation under excessive load
Legend 0 : Possible causes (judging from Questions and check items) 0 : Mo9 probable causes (judgingfrom Questionsand Check items) A:
Possible causes due to length of use (used for a long period) the cause.
l : Items to confirm 1
1 Confirm recent repair history
Amount of blow-by gas
20-416 0
PC300, 350-6
TROUBLESHOOTING
S-IO Fuel consumption
s-10
is excessive
General causes why fuel consumption is excessive . Leakage of fuel . Improper condition of fuel injection . Excessive injection of fuel
Legend 0: Possible causes (judging from Questions and check items) 0 A:
: Most probable causes (judgingfrom Questionsand Check items) Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Condition of fuel
PC300, 350-6
S-l 1
TROUBLESHOOTING
S-II
Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water . Internal leakage in lubrication system . Internal leakage in cooling system
Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items)
: Possible causes due to
n
length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history
‘G 8
p
Pressure-tightness
g-
Remove cylinder head and inspect directly
a
+
20-418 0
test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage
Remove oil pan and inspect directly
w
I0
a
I0 1 14
PC300, 350-6
TROUBLESHOOTING
s-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure) *
Check that the monitor panel engine oil level lamp is not lighted up. Ir When the oil pressure sensor is normal (see M mode). General causes why oil pressure lamp lights up . Leakage, clogging, wear of lubricating system . Defective oil pressure control . Improper oil used (improper viscosity) . Deterioration of oil due to overheating Sr
Standards
for engine
oil selection
Ambient temperature Type of fulid
-4 -20
32 0
-?I
I
50 10
68 20
1 86 30
104°F 40°C
Engine oil
Legend
@: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) 0:
Items to confirm the cause. Confirm
recent repair history
I
g .o 5 2
Degree of use of machine Replacement
of filters
to Operation
Manual
Non-specified
Operated
for long period
has not been carried out according 0
oil is being used
00 Lights up at low idling
Condition
/
when oil Lrghts up at low, high idling lamp lights up
@
1
fin_
1 / V~V~V60~0~
E P) C
pressure
Y
There is clogging,
6
Metal particles
are found when oil is drained
Q
Metal particles
are stuck to oil filter element
0
Sometimes
Oil is cloudy
white
1
a
nn
leakage from hydraulic
1 1
lights up piping (external)
or smells of diesel oil
0
0 G ti
m
When oil filter is inspec j
ve or regulator
standard
PC300, 350-6
valve, spring or
value
20-419 0
TROUBLESHOOTING
s-13
S-13 Oil level rises (water, fuel in oil) *
If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. General causes why oil level rises . Water in oil . Fuel in oil (diluted, and smells of diesel fuel) l Entry of oil from other component
Causes
Legend
: Possible causes (judging from Questions and check items) : Most probable causes (judgingfrom Questionsand Check items) : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.
0 0 n
There is oil in radiator cooling water Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Water pump breather hole is clogged with mud When water pump breather hole is cleaned, water comes out Oil level goes down in damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Fuel must be added more frequently 1 Pressure-tightness
test of oil cooler shows there is leakaae
1 Pressure-tiahtness test of cvlinder head shows there is leakaae When compression pressure is measured, it is found to be low .-P 5 2 4 ‘: e I-
Remove water pump and inspect directly Remove rear seal and inspect directly When main pump is removed, seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly 1 Defective contact of thermostat
seal valve
Remove oil pan and check directly
/
20-420 0
PC300, 350-6
TROUBLESHOOTING
S-14 Water temperature
s-14
becomes too high (overheating)
Ir
Check that the monitor panel coolant level caution lamp is not lighted up. Ir When the monitor panel water temperature gauge is normal, go to troubleshooting of machine monitor system (M mode). General causes why water temperature becomes too high . Lack of cooling air (deformation, damage of fan) . Drop in heat dissipation efficiency . Defective cooling circulation system * Carry out troubleshooting for chassis. Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) a: Possible causes due to length of use (used for a long period)
Condition of overheating
PC300, 350-6
20-42 0
1
TROUBLESHOOTING
S-15 Abnormal
s-15
noise is made
*
Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion Air sucked in from intake system
l
l
l
starting engine, temperature
of some cylinders is low
Leakage of air between turbocharger
and head, loose clamp
Vibrating noise is heard from around muffler
20-422 0
PC300, 350-6
TROUBLESHOOTING
S-16 Vibration
S-16
is excessive
+
If there is abnormal noise together with the vibration, carry out troubleshooting for “Abnormal noise is made”. General causes why vibration is excessive l Defective parts (abnormal wear, breakage) . Improper alignment . Abnormal combustion
Legend 0: Possible causes (judging from Questions and check items)
: Most probable causes (judgingfrom Questionsand Check items)
0 A:
Possible causes due to length of use (used for a long period)
.I5 I
Degree of use of machine
Condition of vibration
2
erated for ion
Kr
eased
Exhaust smoke is black
Remove oil pan and inspect directly p .5 2 I ::
Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside of output shaft (damper) directly
Y
Remove front cover and inspect directly
e I-
Remove head cover and inspect directly Injection pump test shows that injection amount is incorrect
PC300, 350-6
I
I.1
I
I
I
I
I
0 0 0 0 0 a
20-423 0
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)
when troubleshooting
Points to remember
Action taken by controller Judgement
Electrical
c-
1
related
abnormality
when
table for governor,
hydraulic
pump controller
occurs and problems
pump controller
(pump
control
circuit diagram Abnormality
in controller
source system
power
iE2321
c- 3
IE2331 Disconnection
c- 4
IE2361 Short circuit in rear pump TVC solenoid
c- 5
IE2371 Disconnection
and 20-462 20-464
c- 7
(E2081 Disconnection
C- 8
[E2031 Short circuit in swing
c- 9
IE2131 Disconnection
[E2041 Short circuit in pump
merge/divider
C-l 1
IE2141 Disconnection
c-12
IE2061 Short circuit in travel speed solenoid
c-13
[E2161 Disconnection
C-l 4
IE2311
Short circuit in active mode (swing)
c-15
[E2351
Disconnection
C-16
[E2171 Model
c-17
[E2221 Short circuit in LS-EPC solenoid
C-18
[E2231 Disconnection
in pump
solenoid
merge/divider
system
in travel speed solenoid
c-19
[E2241 Abnormality
in front pump
system
c-20
IE2251 Abnormality
in rear pump
c-21
IE2261 Abnormality
in pressure
c-22
[E2271 Abnormality
in engine
in machine
pressure
is displayed.. is displayed
sensor system sensor system
sensor power
solenoid
20-473
.....................
20-475
................
20-476
...................................
.20-477
................................
.20-479
...................
20-481
................
20-482
...................................
.20-483
................................
.20-484
....................
is displayed system
is displayed
system
20-485
..... 20-486 .20-487
..........................................
.20-489
........................................
.20-490
is displayed.. is displayed
source system
speed sensor system
push-up
.........................
.................................................................
system
pressure
is displayed
solenoid
system
in LS-EPC solenoid
20-471
is displayed..
system
(swing)
input error is displayed
............................
is displayed..
solenoid
circuit in active mode
selection
is displayed
is displayed
system
20-469
is displayed..
system
system
solenoid
.........................
is displayed
is displayed
system
20-467
is displayed..
system
system
brake solenoid
C-IO
system
20-466
............................
is displayed
is displayed..
system
solenoid
brake solenoid
in swing
system
solenoid
in action mode (boom)
is displayed
system
in rear pump TVC solenoid
[E2071 Short circuit in action mode (boom)
LED is OFF) ........................
(controller
in front pump TVC solenoid
C- 6
PC300, 350-6
system)
20-454
for C mode ..................................................................................................
Short circuit in front pump TVC solenoid
Abnormality
.......................
on machine..
parts ......................................................................................................................
c- 2
C-23
.20-452
system .............................................
......................
20-491
.........................
20-492
is displayed..
is displayed
..................
....................................
(no service code displayed)
20-493 .20-494
........... 20-495
20-451 0
POINTS TROUBLESHOOTING
POINTS TO REMEMBER CONTROLLER SYSTEM 1.
TO REMEMBER
WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM
WHEN TROUBLESHOOTING
PUMP
Points to remember if abnormality returns to normal by itself In the following two cases, there is a high probability that the same problem will occur again, so it is desirable to follow up this problem carefully. 1) If any abnormality returns to normal by itself, or 2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure, and the service code is no longer displayed, or if the monitor display returns to normal. 3) After completing troubleshooting, always erase the user code from memory.
2. User code memory retention function When displaying the abnormality code in memory and carrying out troubleshooting, note down the content of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to the failure code that is displayed. (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function. Erasing the data in this way saves any wasted work.)
20-452 0
PC300, 350-6
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code
Service code
~232
E233
Abnormal
system
Short circuit in front &HT~~~TVC solenoid
Disconnection in front pump TVC solenoid system
E02
E236
E237
E203
Short circuit in rear pump TVC solenoid system
Disconnection in rear pump TVC solenoid system
Short circuit in swing holding brake solenoid system
E03
E213
20-454 0
in Disconnection swing holding brake solenoid system
Nature
of abnormality
1. Short circuit with ground, short circuit inside front pump TVC solenoid 2. Short circuit with power source, short circuit with ground in wiring harness between controller CO2 (8) and TVC solenoid Cl3 (I) ((+I side) 3. Short circuit with power source in wiring harness between controller CO2 (18) and TVC solenoid Cl3 (2) ((-1 side) 4. Defective governor, pump controller 1. Disconnection, defective contact inside front pump TVC solenoid 2. Disconnection, defective contact in wiring harness between controller CO2 (8) and TVC solenoid Cl3 (1) ((+) side) 3. Disconnection, defective contact, short circuit with ground in wiring harness between controller CO2 (18) and TVC solenoid Cl3 (2) (1-I side) 4. Defective governor, pump controller
1. Short circuit with ground, short circuit inside rear pump TVC solenoid 2. Short circuit with power source, short circuit with ground in wiring harness between controller CO2 (9) and TVC solenoid CO4 (1) ((+) side) 3. Short circuit with power source in wiring harness between controller CO2 (19) and TVC solenoid CO4 (2) ((-1 side) 4. Defective governor, pump controller 1. Disconnection, defective contact inside rear pump TVC solenoid 2. Disconnection, defective contactin wiring harness between controller CO2 (9) and TVC solenoid CO4 (1) ((+I side) 3. Disconnection, defective contact, short circuit with ground in wiring harness between controller CO2 (19) and TVC solenoid CO4 (2) ((-1 side) 4. Defective governor, pump controller
1. Short circuit with ground, short circuit inside swing holding brake solenoid 2. Short circuit with ground in wiring harness between controller CO1 (3) and solenoid V04 (2) ((+) side) 3. Defective governor, pump controller
1. Disconnection, defective contact inside swing holding brake solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller CO1 (3) and solenoid V04 (2) ((+) side) 3. Disconnection, defective contact in wiring harness between solenoid V04 (I) and chassis ground ((-1 side) 4. Defective governor, pump controller
PC300, 350-6
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal voltage, current, resistance)
.
Resistance IO-22R
of solenoid:
Resistance of solenoid: IO-22R Current: 1000 mA (H/O mode, auto-deceleration ON, levers at neutral, fuel control dial at MAX.)
Action
by controller when mality is detected
abnor-
1. Makes output to TVC solenoid 0. 2. Displays user code E02 on monitor panel. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.) 1. The current stops flowing to the TVC solenoid, so no particular action is taken. 2. If there is a short circuit with the ground at the (-1 end, the current (min. IA) continues to flow to the TVC solenoid. 3. It displays user code E02 on the monitor panel. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Problem that appears on machine when 1.
2.
1. 2.
there
is abnormality
No current flows to the front pump TVC solenoid. Therefore, when the load is large, there is a big drop in the engine speed which may result in the engine stalling. The swing acceleration is poor
In the case of 1, it is the same as E232. In the case of 2, the current (min. 1A) continues to flow to the front pump TVC solenoid, so the output of the front pump TVC valve increases and the overall speed becomes slower.
1. Makes output to TVC solenoid 0. 2. lI~n~;ys user code E02 on monitor Resistance IO-22a
of solenoid:
Resistance of solenoid: 10-22 R Current: 1000 mA (H/O mode, auto-deceleration ON, levers at neutral, fuel control dial at MAX.)
Resistance 20 - 60 R
Resistance 20 - 60 Q
PC300, 350-6
of solenoid:
of solenoid:
*
If the’abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
1. The current stops flowing to the TVC solenoid, so no particular action is taken. 2. If there is a short circuit with the ground at the (-1 end, the current (min. IA) continues to flow to the TVC solenoid. 3. It displays user code E02 on the monitor panel. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Same as E232 pump)
(but
for
the
rear
Same
(but
for
the
rear
pump)
as E233
1. Makes output to TVC solenoid 0. 2. Displays user code E03 on monitor panel. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
When the swing is operated, the motor brake is not released, so the upper structure does not swing.
1. The current stops flowing to the solenoid, so no particular action is taken. 2. Displays user code E03 on monitor panel. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Same
as display
for ~203
20-455 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
-
-
-
-
-
Service code
Abnormal
system
of abnormality
1. Short circuit with ground, short circuit inside pump merge/divider solenoid 2. Short circuit with ground in wiring harness between controller CO1 (2) and solenoid V03 (2) ((+I side) 3. Defective governor, pump controller
E204
Short circuit in pump merge/divider solenoid system
E206
Short circuit in travel speed solenoid systern
E207
Short circuit in active mode (boom) solenoid system
1. Short circuit with ground, short circuit inside active mode (boom) solenoid 2. Short circuit with ground in wiring harness between controller CO1 (8) and solenoid V02 (2) ((+I side) 3. Defective governor, pump controller
Disconnection in active mode (boom) solenoid system
1. Disconnection, defective contact inside active mode (boom) solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller CO1 (9) and solenoid V02 (2) ((+I side) 3. Disconnection, defective contact in wiring harness between solenoid V02 (1) and chassis ground ((-) side) 4. Defective governor, pump controller
Disconnection in pump merge/divider solenoid system
1. Disconnection, defective contact inside pump merge/divider solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller CO1 (2) and solenoid V03 (2) ((+I side) 3. Disconnection, defective contact in wiring harness between solenoid V03 (2) and chassis ground ((-) side) 4. Defective governor, pump controller 1. Disconnection, defective contact inside travel speed solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller CO1 (9) and solenoid V06 (2) ((+I side) 3. Disconnection, defective contact in wiring harness between solenoid V06 (1) and chassis ground ((-) side) 4. Defective governor, pump controller
E208
E214
-
E216
Disconnection in travel speed solenoid system
-
E217
Model selection input error
20-456 0
Nature
1. Short circuit with ground, short circuit inside travel speed solenoid 2. Short circuit with ground in wiring harness between controller CO1 (9) and solenoid V06 (2) ((+I side) 3. Defective governor, pump controller
1. Disconnection, defective contact, short circuit with ground in model selection wiring harness C17(5) (6) (7) (13) (14) 2. Defective governor, pump controller
PC300, 350-6
ACTION
TAKEN
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
Action
by controller when mality is detected
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
abnor-
Problem that appears on machine when there is abnormality
Resistance of solenoid: 20 - 60 Q
1. Makes output to solenoid 0. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
The pump merge/divider valve continues to merge the oil flow. 1. In the L/O and F/O modes, the work equipment and swing speeds become faster. 2. The steering is difficult to turn.
Resistance of solenoid: 20 - 60 Sz
1. Makes output to solenoid 0. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Even if the travel speed is switched, the travel speed does not change (remains at Lo)
Resistance of solenoid: 20 - 60 R
1. Makes output to solenoid 0. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
When mode is STD (active mode OFF), the boom lower speeds become faster.
1. The current stops flowing to the solenoid, so no particular action is taken. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Same content as display for E207
Resistance of solenoid: 20 - 60 R
1. The current stops flowing to the solenoid, so no particular action is taken. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Same content
as display for E204
.
Resistance of solenoid: 20 - 60 R
1. The current stops flowing to the solenoid, so no particular action is taken. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Same content
as display for E206
.
Between Cl7 (61, (13) and chassis: Max. 1 Q Between Cl7 (5),(7),(14) and chassis: Min. 1 MR
.
.
.
.
.
Resistance of solenoid: 20 - 60 R
PC300, 350-6
Detects abnormality in input 1) Retains data when starting switch is ON 2) Functions as PC100 when non-set conditions are input
1. Engine stalls, or 2. Work equipment, swing, travel speeds are all slow, and there is no power
20-457 0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User
Service
code
code
Abnormal
system
Nature of abnormality 1. Disconnection, short circuit, short circuit with ground wiring harness 2. Abnormality in governor, pump controller 3. Abnormality in monitor
-
-
-
-
-
-
-
20-458 0
E218
E222
E223
E224
E225
E226
E227
Network overtime
in network
response error
Short circuit in LSEPC solenoid system
Disconnection in LSEPC solenoid system
1. Short circuit with ground, short circuit inside LS-EPC solenoid 2. Short circuit with power source, short circuit with ground in wiring harness between controller CO2 (7) and solenoid Cl0 (1) ((+I side) 3. Short circuit with power source in wiring harness between controller CO2 (17) and solenoid Cl0 (2) ((-) side) 4. Defective governor, pump controller 1. Disconnection, defective contact inside LS-EPC solenoid 2. Disconnection, defective contact in wiring harness between controller CO2 (7) and solenoid Cl0 (1) ((+) side) 3. Disconnection, defective contact, short circuit with ground in wiring harness between controller CO2 (17) and solenoid Cl0 (2) ((-1 side) 4. Defective governor, pump controller
Abnormality in front pump pressure sensor system
1. Disconnection, defective contact, short circuit, short circuit with ground inside front pump pressure sensor 2. Disconnection, defective contact, short circuit in wiring harness between controller CO3 (6) and pressure sensor CO8 (2) ((+I side) and between CO3 (16) and CO8 (1) ((-1 side) 3. Disconnection, defective contact, short circuit with power source, short circuit with ground in wiring harness between controller CO3 (3) and pressure sensor CO8 (3) (SIG side) 4. Defective governor, pump controller
Abnormality in rear pump pressure sensor system
1. Disconnection, defective contact, short circuit, short circuit with ground inside rear pump pressure sensor 2. Disconnection, defective contact, short circuit in wiring harness between controller CO3 (6) and pressure sensor CO7 (2) ((+I side) and between CO3 (16) and CO7 (1) ((-1 side) 3. Disconnection, defective contact, short circuit with power source, short circuit with ground in wiring harness between controller CO3 (13) and pressure sensor CO7 (3) (SIG side) 4. Defective governor, pump controller
Abnormality in pressure sensor power source system
Abnormality in speed sensor system
1. Short circuit, short circuit with ground inside front pump pressure sensor or rear pump pressure sensor 2. Short circuit, short circuit with ground in wiring harness between controller CO3 (6) and front pressure sensor CO8 (2) or rear pressure sensor CO7 (2) ((+) side) 3. Defective governor, pump controller
1. Disconnection, defective contact, short circuit inside engine speed sensor 2. Disconnection, defective contact, short circuit with ground in wiring harness between controller Cl6 (1) and speed sensor E07 (2) ((-1 side) and between Cl6 (2) and E07 (I) (SIG side) 3. Defective governor, pump controller
PC300, 350-6
ACTION
TAKEN
TROUBLESHOOTING
Condition when normal voltage, current, resistance)
Action
by controller when mality is detected
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
abnor-
Problem that appears on machine when there is abnormality
1. When communications are impossible with the monitor, control is carried out with the following settings. 1 Working mode: G/O 2 Priority mode: OFF 3 Travel speed: Lo 4 Auto-deceleration: ON 15 Power max. : ON (others are as usual)
1. @ Even when travel is operated, the power max. function does not work @ The swift speed-down function does not wor @II The auto-deceleration cannot be canceled @I The travel speed does not increase 5 The priority mode has no effect 86 The automatic mode has no effect
1. Makes output to LS-EPC solenoid 0. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
1. The Lo travel speed is too fast. 2. In L/O and F/O modes, the work equipment speed is too fast. 3. When the engine is running at low idling, the swing speed is too fast.
1. The current stops flowing to the LSEPC solenoid, so no particular action is taken. 2. If there is a short circuit with the ground at the (-1 end, the current (min. IA) continues to flow to the LS-EPC solenoid. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
1. In the case of 1, it is the same as E222 2. In the case of 2, electric current (min. 1A) continues to flow to the LS-EPC solenoid, so the work equipment, travel, and swing speeds are slow
Between CO3 (3) and (16): 0.5 - 4.5 v Between CO3 (6) and (16): 18-28V Between CO3 (female) (3) and (161, (3) and chassis Resistance: Min. 1 MR (Disconnect connectors CO3 and CO8.)
1. Takes front pump pressure as 0 MPa IO kg/cm21 when actuating. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
1. The travel speed does not automatically shift (it does not change from Hi to Lo). * If the button is operated manually, the panel display is switched.
Between CO3 (13) and (16): 0.5 - 4.5 V Between CO3 (6) and (16): 18-28V Between CO3 (female) (13) and (16), (13) and chassis Resistance: Min. 1 MR (Disconnect connectors CO3 and CO7.)
1. Takes rear pump pressure as 0 MPa IO kg/cm*) when actuating. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
1. The travel speed does not automatically shift (it does not change from Hi to Lo). t If the button is operated manually, the panel display is switched.
1. Takes front pump and rear pump pressure as 0 MPa 10 kg/cm*} when actuating. 2. When abnormality is detected, it switches the output OFF, and when all levers are returned to neutral, it outputs again. Ir This automatic resetting is repeated up to 3 times.
1. The travel speed does not automatically shift (it does not change from Hi to Lo). Sr If the button is operated manually, the panel display is switched.
1. It functions in the equivalent 0 mode (the speed rises)
It operates about the same as G/O mode (prolix) (the power is slightly lower)
Resistance 7-14R
of solenoid:
Current: Approx. 705 mA (Levers at neutral, low idling)
Voltage between CO3 (6) and (16): 18 - 28 V
Resistance: 500 - 1000 R Voltage (AC range) : 0.5 - 3.0 V (engine started)
PC300, 350-6
of the G/
20-45
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
User code
-
-
20-460 0
Service code
E231
E235
Abnormal
system
Nature
of abnormality
Short circuit in active mode (swing) solenoid system
1. Short circuit with ground, short circuit inside active mode (swing) solenoid 2. Short circuit with ground in wiring harness between controller CO1 (10) and solenoid V07 (2) ((+I side) 3. Defective governor, pump controller
Disconnection in active mode (swing) solenoid system
1. Disconnection, defective contact inside active mode (swing) solenoid 2. Disconnection, defective contact, short circuit with power source in wiring harness between controller CO1 (IO) and solenoid V07 (2) ((+I side) 3. Disconnection, defective contact in wiring harness between solenoid V07 (1) and chassis ground ((-1 side) 4. Defective governor, pump controller
PC300, 350-6
ACTION
TAKEN
TROUBLESHOOTING
Condition when normal (voltage, current, resistance)
.
.
ip?;gn;
of solenoid:
Resistance of solenoid: 20 - 60 R
PC300, 350-6
Action
by controller when mality is detected
BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
abnor-
1. Makes output to solenoid 0. * If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.) 1. The current stops flowing to the solenoid, so no particular action is taken. Ir If the abnormality is restored by the vibration of the machine, it resets the power source to restore to the proper condition. (However, the service code display does not go out.)
Problem that appears on machine when there is abnormality In active mode and heavy-duty mode, the rise in the bucket edge is the same in swing + boom RAISE. There is no priority.
Same as E231
20-461 0
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
TROUBLESHOOTING
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS Governor,
oumo controller (E2:XX svsteml
f ; $ -? z
si 5
Auto-deceleration
s.
does not work
Fine control ability is poor or response is poor Boom is slow or lacks power Arm is slow or lacks power Bucket is slow or lacks power Boom does not move Arm does not move Bucket does not move Excessive hydraulic drift Excessive time lag (engine at low idling) Other equipment
moves when single circuit is relieved
In L/O, F/O modes, work equipment speed is faster than specified speed Machine push-up function does not work -c
5 :
E 6 E 0 z 2
Deviation is excessive during normal travel
Travel deviation
Deviation is excessive when starting
Travel speed is slow
B
Steering does not turn or lacks power
5
Travel speed does not switch or is faster than specified speed
I
Does not move (one side only) Both left and right
Does not swing
One direction onlv
Swing acceleration
E
is poor
Both left and right
or swing speed is slow
One direction only
Excessive overrun
Both left and riaht
1 Swing speed is faster than specified swing speed Troubleshooting
code when service code is displayed
Troubleshootinq
code when there is abnormality
r:This l :This f :This 3 :This
20-462 0
shows shows shows shows
in monitoring check
applicable item for service code (simultaneous abnormality applicable item for service code item that needs only checking with monitoring item to check with monitoring or machine monitor
at ront or rear)
PC300, 350-6
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
TROUBLESHOOTING
*
If service code E218 (abnormality
‘24225 226227 I
0
20
in network
21
221
system)
is displayed,
23 -_
-- _
go to troubleshooting
_ _
In7llnlllIl7llnll~ll~
for N mode.
_
c: III
/III/ I
I
1 - 1- 1 - ~F-l~F-2~F-3~F-4~F-5~F-6~F-7~F-E~F-S~F-lO~F-11~ -1 - I- 1-
PC300, 350-6
20-463 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
FOR C MODE
FOR C MODE TVC
MONITOR
PANEL
III I I I I
55 TWP01415
20-464 0
PC300,
350-6
TROUBLESHOOTING
MACHINE
PUSH
UP SWITCH
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
SWING
LOCK SWITCH
PUMP
REDUNDANCY
CIRCUIT
SWITCH
EOS(SWP141
E07 (X21 -
ENGINE SENSOR
SPEED
3!zBzm
TWP01416
PC300, 350-6
20-465 0
C-l
TROUBLESHOOTING
C-l
Abnormality OFF)
in controller
power source system (controller
LED is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. Check that fuse 1 is not blown. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
Remedy
Cause
Defective governor, pump controller
YES 1 I
Replace
Defective contact, or disconnection in wiring harness between fuse 1 and CO1 (female) (7) (13)
C-l Related
electric
Defective contact, or disconnection in wiring harness between fuse 1 H15(2)-M14(2)(1)banery relay M
NO
* Turn starting switch ON. *20-30V
Repair or replace
Repair or replace
circuit diagram
Governor, pump controller COl(MIC13) H14(M6)
Fuse
H15(L2)
1 @
I PGND PGND
0 @
4,
Battery relay
Fusible link
m C02(MIC21)
BKPOO186
20-466 0
PC300, 350-6
TROUBLESHOOTING
c-2
C-2 [E232] Short circuit in front pump WC displayed
solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Always turn the n/C prolix switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
3 YES Is resistance YES between CO2 2 - (female) (8) and (18), (8) and chassis as shown in Table l? NO (male) (I) and (2), - * Turn starting switch OFF. (1) and chassis as Disconnect C02. shown in Table
Defective governor, pump controller
-
Replace
GotoA
l
connector
with NO
-
Disconnect
C13.
1
* Turn
starting switch OFF. - Interchange CO4 with C13. + Turn starting switch ON.
Defective front pump TVC solenoid (internal short circuit or short circuit with ground)
NO
Short circuit with ground or short circuit with power source in wiring harness between CO2 (female) (8) H12 (5) - CO5 (female) cl), or short circuit with power source in wiring harness between CO2 (female) (18) H12 (7) -CO5 (female) (2)
“W
I Is resistance 4 I Is resistance
Defective NC prolix switch (internal short circuit with ground or short circuit with power source)
1
* Turn starting switch OFF. * Disconnect C05. * Turn TVC prolix switch OFF.
. Turn starting switch OFF. * Disconnect C05.
Table
Replace
Replace
Short circuit with ground or short circuit with power source in wiring harness between CO5 (female) (3) - H 12 (3) Cl3 (female) (1). or short circuit with power source in wiring harness between CO5 (female) (4) -H12 (4) -Cl3 (female) (2)
hIO
Repair or replace
Repair or replace
1 Troubleshooting
Troubleshooting
No. 2
No. 3
Between
Cl3 (male) (1) - (2)
Between
Between
Cl3 (male)
Between CO2 (female) (8) - chassis
(I) - chassis
CO2 (female)
(8) - (18)
Troubleshooting
No. 4
Between
CO5 (female)
(3) - (4)
Between
CO5 (female) (3) - chassis
Resistance
value
IO-22R Min. 1 MR
Table 2 Troubleshooting
No. 5
Between
CO5 (male) (1) - (31, (2) - (4)
Between
CO5 (male)
PC300, 350-6
(l)(2)(3)(4)
- chassis
Resistance
value
Max. 1 f2 Min. 1 MR
20-467 0
c-2
TROUBLESHOOTING
C-2 Related
electric
circuit diagram
TVC prolix switch
BKPO0187
20-468 a
PC300, 350-6
TROUBLESHOOTING
c-3
C-3 [E2331 Disconnection displayed *
* *
* * *
in front pump WC
solenoid svstem is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid. If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flow to the solenoid. Always turn the TVC prolix switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
3 YES
Defective governor, pump controller
Is resistance YES between CO2 , r (female) (8) and Is resistance L between Cl3 (male) (1) and (2), (2) and * Turn starting chassis as shown in switch OFF. Table I? * Disconnect C02. * Turn starting NO switch OFF. * Disconnect 03.
YES -
1
Interchange connector with rear pump TVC soleoid. Is LE2331displayed? * Interchange CO4 with C13. + Turn starting switch ON.
Go to
NO
Defective front pump WC solenoid (internal disconnection or defective contact)
I
--
Yr
From A
-i
*
Table
Defective TVC prolix switch (internal disconnection, defective contact, or short circuit wth ground)
*Turn starting switch OFF. * Disconnect C05. * Turn TVC prolix switch OFF.
* Turn starting switch OFF. * Disconnect C05.
qeplace
Defective contact or disconnection in wiring larness between CO2(female) :8)- H12 (5) -CO5 (female)(l), Jr defective contact, short :ircuit with grond, or lisconnection in wiring aarness between CO2(female’ (18) - HI2 (7) -CO5 (female) (2)
YES
Is resistance between CO5 (female ) (3) and (4), (4) and chassis as shown in Table l?
Replace
A
NO
4
Remedy
Defective contact or disconnectio in wiring harness between CO5 (female) (3) - H12 (3) - Cl3 (female) (l), or disconnection in wiring harness between CO5 (female) (4) - H12 (4) -Cl3 (female) (2)
IO
?epair or .eplace
Replace
Repair or replace
1 Troubleshooting
No. 2
Troubleshooting
Between
Cl3 (male)
(I) - (2)
Between
Between
Cl3 (male) (2) - chassis
No. 3
CO2 (female)
(8) - (18)
Between CO2 (female) (18) - chassis
Troubleshooting
No. 4
Between
CO5 (female)
(3) - (4)
Between
CO5 (female)
(4) -chassis
Resistance
value
IO-22n Min. 1 MR
Table 2 Troubleshooting
No. 5
Between
CO5 (male) (1) - (3). (2) - (41
Between
CO5 (male) (l)(2)(3)(4)
PC300, 350-6
- chassis
Resistance
1 1
value
Max. 1 C2 Min. 1 MD
20-469 0
c-3
TROUBLESHOOTING
C-3 Related
electric
circuit diagram
TVC prolix switch
Governor, pump controller C02(MIC21) r \ I
F-WC(+)
@
FTVCH
@-
C13(X2)
CO5(SlO)
H12(Sl6)
I
3 -@) 3 3
II
I 0
@ 0
I
@ L
3 04 05 6
/=\
-I--
II
BKFO0187
20-470 0
PC300, 350-6
TROUBLESHOOTING
C-4 Related
electric
c-4
circuit diagram
TVC prolix switch
Governor, pump controller C02(MIC21)
H12(S16)
CO5(SlO)
I 3
@
I
-3 A CO4(X2) Rear TVC valve
_ -
$J
2
BKP00188
20-472 0
PC300, 350-6
TROUBLESHOOTING
C-5
C-5 [E237] Disconnection displayed *
t Ir
t * *
in rear pump WC
solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid. If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flow to the solenoid. Always turn the TVC prolix switch OFF. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
3
YES
Is resistance YES between CO2 2 r (female) 19) and (19), -
Remedy
Defective governor, pump controller
Replace
Defective rear pump TVC solenoid (internal disconnection or defective
Replace
Is resistance YES between CO4 (male) - (I) and (21, (2) and - * Turn starting 1 chassis as shown in switch OFF. Table l? lnteiEhange * Disconnect C02. connector with -Turn starting switch OFF. front Pump TVC NO solenoid. Is fE2371 . Disconnect C04. displayed? * Interchange Cl3 with C04. * Turn starting switch ON.
t NO
YES 5p Is resistance YES between CO5 (male) - (6) and (8). (7) and (9), (6) (7) (8) (9) 4 and chassis as shown in Table 2?
From A
Is resistance between CO5 (female) (8) and (9). (9) and chassis as shwon in Table l?
=
* Turn
starting switch OFF. * Disconnect C05.
Table
NO *Turn starting switch OFF. * Disconnect C05. -Turn TVC prolix switch OFF.
Iefective contact or disconnection in wiring larness between CO2Ifemale) 9) H12 (6) - CO5(female) (6). o defective contact, short circuit Nith ground, or disconnection n wiring harness between CO2 female) (19) - H12 (8) - CO5 female) (7)
Repair or replace
Defective TVC prolix switch internal disconnection, defective contact, or short :ircuit with ground)
Replace
Iefective contact or disconnectionin wiring harness letween CO5Ifemale) (8) - H12 1) - CO4(female) (l), or defectivecontact, short circuit vith ground, or disconnection n wiring harness between CO5 female) f91- H12(2) -CO4 female) (21
NO
Repair or replace
1 Troubleshooting
No. 2
Between
CO4 (male)
(I) - (2)
Between
CO4 (male) (2) - chassis
Troubleshooting Between
No. 3
CO2 (female)
(9) - (19)
Between CO2 (female) (19) -chassis
Troubleshooting Between
CO5 (female)
Between
CO5 (female)
No. 4 (8) - (9) (9) - chassis
Resistance
value
IO-22a Min. 1 MR
Table 2 Troubleshooting
No. 5
Between
CO5 (male) (6) - (81, (7) - (9)
Between
CO5 (male) (6)(7)(8)(9) - chassis
PC300, 350-6
Resistance
value
Max. 1 L2 Min. 1 MR
20-473 0
TROUBLESHOOTING
C-5 Related
electric
c-5
circuit diagram
Governor, pump controller C02(MIC21)
\
RNC(+)
H12(S16)
CO5(SlO)
I r-B-l--
RNCk) &
Rear NC valve
1
-L :
BKP00188
20-474 0
PC300, 350-6
TROUBLESHOOTING
C-6
C-6
[E207] Short circuit in active mode (boom) solenoid system is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
3 YES 2 r
Is resistance between CO1 (female) (8) and
YES
Defective governor, pump controller
* Interchange V02 other connector. * Start engine. * Active mode switch OFF.
Defective LS select solenoid (internal short circuit or short circuit with ground)
Table
NO
Replace
Short circuit with chassis ground in wiring harness between CO1 (female) (8) and V02 (female) (2)
--with
Remedy
Repair or replace
Replace
1
Between
V02 (male)
Between
V02 (male) (2) - chassis
C-6 Related Ens
(I) - (2)
electric i ne
120 1Min.
60 R 1 MR
circuit diagram
throttle
controller
co1 (MIC13) Active mode (boom) solenoid valve
TWPOl417
PC300, 350-6
20-475 0
c-7
TROUBLESHOOTING
C-7 [E208] Disconnection displayed * -k * *
in active mode (boom) solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
4YE:
_ Is resistance between V02 (female) (I) and chassis normal?
YES 2 Is resistance between V02 (male) (1) and (2) normal?
YES
I_
Turn starting switch OFF. * Disconnect V02. *20-60R
WhenVO2(female)(21is YES groundedto chassis,is - resistancebetweenCO1 3 Ife;fe;; 181and chassis
*Turn starting switch OFF. * Disconnect COl. * Max. 1 n
_
NC
* Turn starting switch OFF. * Disconnect V02. * Max. 1 R NO
-
Remedy
GotoA
Short circuit with power ground, defective contact, or disconnection in wiring harness between CO1 (female) (8) and V02 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between V02 (female) (1) and chassis.
Repair or replace
Defective LS select solenoid (internal disconnection)
Replace
Defective gavernor, pump controller
Replace
Short circuit with power source in wiring harness between CO1 (female) (8) and V02 (female) (2)
Repair or replace
l
IIE2081 displayed? l
.J
No
I
Interchange V02 with other
NO * Turn starfing switch ON.
From A
* Disconnect COI, vo2. * Turn starting switch ON. - Max. IV
C-7 Related Enain
electric e
N(
circuit diagram
throttle
controller
v(I3 (X2)
co1 (MIC13)
Active mode (boom) solenoid valve
a a-
~03 (KES~
2)
-3 3 TWPO1417
20-476 0
PC300, 350-6
TROUBLESHOOTING
C-8 [E203]
C-8
Short circuit in swing brake solenoid system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause
3
YES
Is resistance YES between CO1 2 (female) (3) and chassis normal?
Is resistance YES between V04 _ (male) (T) and (2), _ 1 pInterchange connector with other solenoid. Is LE2031 displayed? * Interchange V04 with other connector. * Start engine. * Operate swing lever.
(2) and chassi nornal? P * Turn starting switch OFF. * Disconnect V04.
*Turn starting switch OFF. * Disconnect COl. *Turn swing lock switch OFF. *20-60R
I NO
5
chassis normlal?
switch OFF. X05. *20-60R
- Disconnect
* Turn starting switch OFF. - Disconnect X05. * Turn swing lock switch OFF. * Min. 1 MD
-
Defective governor, pump controller
Replace
Defective swing holding brake solenoid (internal short circuit or short circuit Nith ground)
xeplace
Short circuit with chassi ground in wiring harness cetween CO1 (female) (3) 126 (l)(2)- H13 (I) -X01 (7) -X05 (male) (3)
sepair or ‘eplace
GotoA
NO
Is resistance YES between X05 4 r (male) (4) and
Table
NO
Remedy
NO
YES
Short circuit with chassis ground in wiring harness between X05 (male) (4) -X01 (7) - H13 (7) -VO4 (female) (2)
Repair or replace
Defective swing lock sitch (internal short circuit with ground)
1
Between
V04 (male)
Between
V04 (male) (2) - chassis
PC300, 350-6
(1) - (2)
( 20
- 60 R
Min. 1 MR
20-477 0
TROUBLESHOOTING
C-8 Related
C-8
electric
circuit diagram
Swing
I
Engine
throttle
redundancy
switch
I
~26 (KES~ 2)
controller
co1 (MIC13)
H13 (S16)
X01 (MIC21)
x05 (M4)
g @ I D05(~w
L
@ m
20-478 0
I
vo4 (X2)
2) a
\
brake
solenoid
TWP01418
PC300, 350-6
TROUBLESHOOTING
c-9
C-9 [E213] Disconnection
in swing brake solenoid system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Note:
If the swing prolix switch is operated, this error 12131 is detected, but it does not indicate a failure. Note: When the swing prolix switch is operated, if error 12131 occurs, carry out troubleshooting (F-9) for the swing lock signal input system.
Cause
YE
Remedy
Defective governor, pump controller
Replace
Defective swing holding brake solenoid (internal disconnection or short circuit with power source)
Replace
I
* Turn starting switch OFF. * Disconnect V04. .20-600
connector with other solenoid. Is fE2131 displayed? * Interchange V04 with other connector. * Turn starting switch ON.
I
Defective contact or disconnection in wiring harness between D26 (female) (2) - HI3 - X01 (7) -X05 (male) (3)
YES 5 YES
From A
4 P Is resistance between X05 (female) (3) and (4) normal?
=
* Turn starting switch OFF. * Disconnect x05. * MAX. 1 R
Table
Is resistance between X05 (male) (4) and chassis normal? * Turn starting switch OFF. * Disconnect X05. .20-60R
Short circuit with power source, defective contact, or disconnection in wiring harness between X05 (male) (4) -X01 (6) HI3 (7) - V04 (female) (2)
NO
Defective swing lock switch (internal disconnection or short circuit with power source)
NO
Repair or replace
Repair or replace
Replace
1
Troubleshooting
No. 3
Between D26 (1) - chassis
PC300, 350-6
Measurement
Voltage 4 - 5 seconds
o-IOV 20 - 30 v
Swing
condition
after all levers are returned
lever or work equipment
lever operated
(operated
to neutral in small
movements)
20-479 0
c-9
TROUBLESHOOTING
C-9 Related
electric
circuit diagram
Swing
Engine
redundancy
~26
(KES~ 2)
H13 (S16) -3 -3
switch
Swing
lock
switch
I X01 (MIC21)
x05 hI4)
@ a
DO5 (KESl 21
e
20-480 a
TWP01418
PC300, 350-6
TROUBLESHOOTING
C-IO
C-IO [E204] Short circuit in pump merge/divider displayed Ir * * *
solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
3 Is resistance YES between CO1 2 - (female) (2) and chassis normal? Is resistance YES betweenVO3knale) p - (I) and (21, (2) and - *Turn starting switch OFF. chassis as shown in 1 * Disconnect COI. Table I? Interchange .20-60R * Turn starting connector with switch OFF. other solenoid. Is NO * Disconnect V03. [E2041 displayed?
- Interchange
V03 with other connector. * Start engine. * Operate travel independently.
Table
v NO
YES
Defective governor, pump controller
Remedy
Replace
~ NO
Short circuit with chassis ground in wiring harness between CO1 (female ) (2) and V03 (female) (2)
Defective pump merge/divider soleoid (internal short circuit or short circuit with ground)
Repair or replace
Replace
1
Between
V03 (male) (1) - (2)
Between
V03 (male) (2) - chassis
C-IO Related
electric
20 - 60 R
1Min.
1 MR
circuit diagram
Ensin e throttle controller CO1 (MIC131
TWPOl419
PC300, 350-6
20-48 1 0
TROUBLESHOOTING
C-II
C-11 E2141 Disconnection displayed
in pump merge/divider
solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
1When V03 (female) (2) i: FS resistance between CO1 (fern&l (2) and chassis
I
Interchange connector with _ other solenoid. Is IE2141 displayed? * Interchange V03 with other connector. * Turn starting switch ON.
* Turn
starting switch OFF. * Disconnect ~03. *20-60R
starting
NO
* Turn starting switch OFF. * Disconnect COl. * Max. 1 R
-
H
IL *Turn
p Is resistance YES between V03 (male) (1) and (2) 1 normal?
r
NO
GotoA Defective contact or disconnection in wirina harness between CO1 _ (female) (2) and V02 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between V03 (female) (1) and chassis
Repair or replace
Defective pump merge/divider solenoid (internal disconnection)
Replace
Defective governor, pump controller
Replace
Short circuit with power source in wiring harness between CO1 (female) (2) and V03 (female) (2)
Repair or replace
NO
t
1 NO
5YE5
From A{=[’
* Disconnect CO1 and V03. * Turn starting switch ON. . Max. 1 V
C-11 Related Engine
electric throttle
NC
circuit diagram controller
co1 (MIC13)
vo3 (x21 a @
Meree/flow divider solenoid
valve
TWP01419
20-482 0
PC300, 350-6
c-12
TROUBLESHOOTING
C-12
[E206]
Short circuit in travel speed solenoid system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
3 YES
Defective governor, pump controller
Is resistance YES 2 r
between (female)
CO1 (9) and
Short circuit with chassis ground in wiring harness between CO1 (femle) (8) and VO2 (female) (2)
* Interchange V06 other NO connector. * Start engine. * Travel speed switch at Mi or Hi - Operate the lever slightly not enough to move the machine.
Defective travel speed solenoid (internal short circuit or short circuit with ground)
--with
Table
Replace
Repair or replace
Reolace
1
Between
V06 (male)
Between
V06 (male) (2) - chassis
C-12 Related
(I) - (2)
electric
Ens i ne
throttle
120 1Min.
60 R 1 ML2
circuit diagram controller
I””
I
I
_
\AL,
lli\,. a
Travel solenoid va I ve
speed
TWP01420
PC300, 350-6
20-483 0
c-13
TROUBLESHOOTING
C-13 [E216] Disconnection displayed
in travel speed selector solenoid svstem is ,
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
4YES is 1 r YES groundedto chassis,is - resistance betweenCO1 3 (female1 (91 and chassis normal? NC * Turn starting switch OFF. * Disconnect V06. * Max. 1 R
1When
p
Yf 1 connector with other solenoid. Is
* Interchange V06 with other connecror. * Turn starting switch ON.
~ Is resistance between V06 (male) (I) and (2) normal? * Turn starting switch OFF. * Disconnect V06. .20-60R
Is resistance YES between V06 (female) (1) and 2 chassis normal? -
*Turn starting switch OFF. * Disconnect CO1 and V06. * Max. 1 R
VO6 lfemalel (2)
NO
From A
throttle
1
Defective contact or disconnection in wiring harness between V06 (female) (1) and chassis
Repair or replace
Defective governor, pump controller
Replace
Short circuit with power source in wiring harness between CO1 (female) (9) and V06 (female) (2)
NC
Repair or replace
circuit diagram
controller
V06 (X2)
CO1 (MIC13) Travel speed solenoid
Repair or replace
1-H
* Turn starting switch OFF.* Disconnect CO1 and V06. * Max. 1 V
Engine
Defective contact or disconnection in wiring harness between CO1 (female) (9) and V06 (female) (2)
Defective pump merge/divider solenoid (internal disconnection)
1 hl I.V
electric
GotoA
NO
5 YES
C-13 Related
-
Remedy
Travel solenoid valve
_
)(9;1 I
-
I
speed
m
Do7 (KES~ 2) -3 3 TWPOI420
20-484 0
PC300, 350-6
TROUBLESHOOTING
c-14
C-14 [E2311 Short circuit in active mode (swing) solenoid system is displayed * * + *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause
3 YES YES-
1
(female) (IO) and chassis normal?
YE 1 connector with other solenoid. Is [E2311 displayed?
between V07 (male) (1) and (Z), (2) and
* Turn starting switch OFF. * Disconnect V07.
. Interchange V07 I with other NO connector. * Start engine. * Swing lock switch OFF. * Active mode switch ON. * Operate swing + boom raise lever slightly at the same time.
Table
*Turn starting switch OFF. * Disconnect COI. *20-60R
Remedy
Defective governor, pump controller
Replace
7 l-l
Short circuit with chassis ground in wiring harness between CO1 (female) (IO) and V07 (female) (2)
NO
Repair or replace
NO
1
Defective LS select solenoid (internal short circuit or short circuit with ground)
Replace
1
120
Between
V07 (male)
Between
V07 (male) (2) - chassis
C-14 Related
(1) - (2)
electric
Ene i ne
throttle Ml
- 60 R
Min. 1 MR
circuit diagram
controller
h4lf?l?1
.”
I
\n,,,
a @
\
7
\
Active I \ Imode wIna, .I I solenolo valve
I
~02 (KES~ 21 -3 -3 TWPOl421
PC300, 350-6
20-485 0
TROUBLESHOOTING
c-15
C-15 [E2351 Disconnection displayed
in active mode (swing)- solenoid system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
c ToA
Is resrstance YES between V07 (male) (1) and (2)
r-l
connector with other solenoid. Is fE2351 displayed? * Interchange V07 with other connector. * Turn starting switch ON.
switch OFF. . Disconnect V07.
*Turn starting switch OFF. * Disconnect COI. * Max. 1 R
+Max.
1R
NO
-l
Defective contact or disconnection in wiring harness between CO1 (female) (10) and V07 (female) (2)
Repair or replace
Defective contact or disconnection in wiring harness between V07 (female) (1) and chassis
Repair or replace
Defective active mode (swing) solenoid (intern: disconnection)
Replace
Defective governor, pump controller
Replace
Short circuit with power source in wiring harness between CO1 (female) (10) and V07 (female) (2)
Repair or replace
NO
11 NO
5YES
From A{=[
* Disconnect CO1 and V07. * Turn starting switch ON. * Max. 1 V
C-15 Related Ena
electric in e
NO
circuit diagram
throttle
controller
co1 (MIC13) Active mode (sw i ns) solenoid valve
Do2 (KEY
2)
-3 3 TWP01421
20-486 0
PC300, 350-6
TROUBLESHOOTING
C-16
C-16 [E2171Model selection input error is displayed *
Ir * *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
Defective governor, pump controller
1
t
1Is monitoring I mode disolav as shown in Table
1 1
I’? * Turn
~~yff&,~
I
“~l-l
starting N switch ON. * Set to monitorir 19 codes 102, 031 and I21, 221.
Table
Defective model selection connector, or disconnection, short circuit with ground, or short circuti in witing harness where voltage is defective
NO
* Turn si:arting switch ON.
1 Monitoring Model
Model
codes 02, 03
Monitoring
(
3 BKP00193
1t
Ir
Repair or replace
code display
code display
Monitoring
Remedy
selection
signal
input display
code 21
Monitoring
code 22
_---_ PP_ +
BKP00194
BKP00195
The diagram shows monitoring code 02. Check the bit pattern display marked with t.
Table 2 Voltage Cl? Voltage
PC300, 350-6
of wiring
Between
harness
(5) - chassis
20 - 30 v
Between
(6)
Max.
chassis 1V
Between
(7)
- chassis
Max. 1 V
Between
(13) - chassis
Max. 1 V
Between
(14) - chassis
20 - 30 v
20-487 0
TROUBLESHOOTING
C-16 Related
C-16
electric
Engine
circuit diagram
throttle
controller
Cl7 (04016) I I
Machine
select
connector
?a co9 1
2 3
4
H14 (M6)
TfT-
20-488 0
TWP01422
PC300,350-6
c-17
TROUBLESHOOTING
C-17 [E2221 Short circuit in LS-EPC solenoid system is displayed *
* * *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
I 2 YES
Is resistance
Is resistance
YES between CO2 - (female) (7) and (17), 1 (71and chassisas shown in Table I?
-
between Cl0
(male) (1) and (2). (1) and chassis as shown in Table I? _ * Turn starting switch OFF. * Disconnect CIO.
Table
* Turn starting switch OFF. Disconnect CO2
Cause
Remedy
Defective governor, pump controller
I
Short circuit with ground or short circuit with power source in wiring harness between CO2 (female) (7) - Cl0 (female) (I), or short circuit with power source in wiring harness between CO2 (female) (17) - Cl0 (female) (2)
NO
l
Repair or replace
Defective LS-EPC solenoid (internal short circuit with ground or short circuit with power source)
NO
1
Troubleshooting
No. 1
Troubleshooting
No. 2
Between Cl0 (male) (I) - (2)
Between CO2 (female) (7) - (17)
Between Cl0 (male) (1) - chassis
Between
C-17 Related
electric
Governor,
CO2 (female)
(7) - chassis
Resistance value 7-14R
Min. 1 MR
circuit diagram
pump controller C02(MIC21) LS-EPC
solenoid valve
BKP00251
PC300, 350-6
20-489 0
C-18
TROUBLESHOOTING
C-18 [E223] Disconnection
in LS-EPC solenoid system is displayed
*
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. * If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted. Ir Always connect any disconnected connectors before going on the next step.
Remedy
Cause
2
I Is resistance
Defective governor, pump controller
YES II
Defect contact or short circuit with chassis ground in wiring harness between CO2 (female) 171and Cl0 (female) (1). or defective contact, short circuit with ground, or disconnection in wiring harness between CO2 (female) (17) - Cl0 (female) (2)
I
switch OFF. * Disconnect COZ.
* Turn starting switch OFF. * Disconnect ClO.
Table
Defective LS-EPS solenoid (internal disconnection, defective contact, or short circuit with ground)
NO
Repair or replace
Replace
1 Troubleshootinq
No. 1
Between
Cl0 (male) (1) - (2)
Between
Cl0 (male) (2) - chassis
C-18 Related
electric
I
Troubleshootina
1Betieen Between
No. 2
CO2 (female)
(7) - (17)
CO2 (female)
(17) - chassis
1 Resistance I
value
7-14R
1 I
Min. 1 M!Z
circuit diagram
Governor, DumD controller COiiMICil)
ClO(X2) cg @
BKPO0251
20-490 0
PC300, 350-6
TROUBLESHOOTING
Cl9
C-19 [E224] Abnormality displayed *
in front pump pressure sensor system is
*
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
* *
check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
I
Cause
Defective governor, pump controller
3 YES Is voltage between CO3 (3) and (16) normal?
YES -
P Is voltage between CO8 (2) and (1) normal?
* Turn starting switch ON. *18-28V
*Engine at high NO ilding _ * Operate repeatedly arm IN reliefe, lever NEUTRAL. * 0.5 - 4.5 v 4 YES Is voltage between CO8 (2) NO and chassis normal? * Disconnect C08. * Turn starting switch ON. *18-28V
l
Short circuit with powe source, defective contact, or disconnection in wiring harness between CO3 (female) (3) - CO8 (female) (3)
2-p
I
*Turn starting switch OFF. Interchange CO7 with C08. * Engine at high idling
-
1
Short circuit with ground, defective contact, or disconnection in wiring harness between CO3 (female) (16) and CO8 (female) (1)
I
NO
IO
Remedy
Replace
Repair or replace
Repair or replace
Short circuit with ground, defective contact. or disconnection in wiring harness between CO3(female;I 16)and CO8(female) (2)
Repair or replace
Defective front pump pressure sensor (internal disconnection, defective contact, short circuit, or short circuit with ground)
IReplace
C-19 Related electric circuit diagram
Governor, pump controller CO3(04020)
CO8(XO2)
Front pump pressur sensor SIG
($
Pressure sensor power source
a
Pressure sensor GN
a
PC300, 350-6
Front pump pressure sensor
20-491 0
TROUBLESHOOTING
c-20
C-20 [E225] Abnormality displayed
in rear pump pressure sensor system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
3 YES
Defective governor, pump controller
YE pHp
2 bwtween CO7 (2) and (1) normal?
YE
I
connector with
I
*Turn starting switch ON. *18-28V
NO * Engine at high idling * Operate repeatedly arm IN relief-lever NEUTRAL. * 0.5 - 4.5 v 4 YES
,pH-
* Disconnect CO7. . Turn starting switch ON. * 18-28V
electric
Short circuit with ground, defective contact, or disconnection in wirino harness between CO3fiemalel (61and CO7(female) (2)
NO
Defective rear pump pressure sensor (internal disconnection, defective /contact, short circuit, or short circuit with ground)
Replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
Governor, pump controller CO3(04020)
CO7(XO3)
Pressure sensor power source
a
Rear pump pressure sensor SIG
a
II
20-492 0
Short circuit with ground, defective contact, or disconnection in wiring harness bewtween CO3 (female) 116)and CO7(female] 11)
N
* Turn starting swtich OFF. . Interchange CO8 with C07. * Engine at high idling
C-20 Related
Short circuit with power source, defective contact, or disconnection in wiring harness between CO3 (female) (13) - CO7 (female) (3)
Remedy
Rear pump pressure sensor
@
PC300, 350-6
TROUBLESHOOTING
c-21
C-21 [E226] Abnormality displayed
in pressure sensor power source system is
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Defective front pump pressure sensor (internal short circuit or short circuit with ground)
YES 2 Is voltage YES between CO3 (6) and (16) normal?
-
Turn starting switch OFF. * Disconnect C03, C07, and C08. * Min. 1 MD
* Turn starting switch ON. * Disconnect C08. .18-28V
l
C-21 Related
3 Is voltage between CO3 (6) NO and (16) normal?
* Disconnect C07. * Turn starting switch ON. *18-28V
Defective rear pump pressure sensor (internal short circuit or short circuit with ground)
YES
-
Defective governor, pump controller
NO
Short circuit or short circuit with ground in wiring harness of system where resistance value is defective
NO
electric
Replace
~ Replace
Replace
Repair or replace
circuit diagram CO8(X3)
Governor, pump controller CO3(04020) Front pump pressure sensor SIG
Front pump pressure sensor
Pressure sensor power source Rear pump pressure sensor SIG Pressure sensor GNC . Rear pump pressure sensor
BKPW1254
PC300, 350-6
20-493 0
c-22
TROUBLESHOOTING
C-22 [E227] Abnormality
in engine speed sensor system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed, the problem has been removed. If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the problem has been removed.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
2
I
YES I r
Is resistance between E07 (male) (1) and (2) normal? Turn starting switch OFF. * Disconnect E07. *500-lOOOR
Is resistance between Cl6 (female) (I) and (2) normal?
YES
Defective governor, pump controller Short circuit with ground, defective contact, or disconnection in wiring harness between Cl6 (female) (1) - E08 (IO) - E07 (female) (2). or between Cl6 (female) (2) - E08 (9) - E07 (female) (1)
-
-k * Turn starting switch OFF. * Disconnect C16. *500-lOOOR
l
C-22 Related
Defective engine speed sensor (internal disconnection, defective contact, or short circuit with ground)
NO
electric
Replace
Repair or replace
Replace
circuit diagram
Governor, pump controller C16(MIC17)
E08(SWP14)
E07iX2)
BKPCO255
20-494 a
PC300, 350-6
TROUBLESHOOTING
C-23
C-23 Abnormality in machine push-up solenoid system (no service code displayed) * * * a)
Even if any abnormality occurs in the machine push-up solenoid system, the service code is not displayed on the monitor panel. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. If solenoid is not actuated (turned ON) when setting * Check that fuse No. 2 is not blown. * Carry out troubleshooting with the machine tion.
machine
push-up
push-up
switch
switch
is set to low-pressure
at the low-pressure
Cause
I
1 Is voltage between V05 (2) and chassis normal?
I
* Turn starting switch OFF.. * Disconnect V05. *20-60R
Defective machine push-up solenoid (internal disconnection or defective contact)
I
NO
Short circuit with ground, defective contact, or disconnection in wiring harness between M38 (male) fl)- X01 (16)-H13 (3 - V05 (female) (2)
4 YES
17
* Turn starting switch ON. * 20 - 30 v
Defective machine push-up switch (internal disconnection, defective contact, or short circuit with ground)
h * Turn starting switch ON. *20-3ov
C-23 Related
electric
. Switch
OFF: Min. 1MR
Defective fuse 2 or short circuit with ground, defective contact, or disconnection in wiring harness between fuse 2 X01 (12) -M38 (male) (2)
NO
posi-
Remedy
Defective contact or disconnection in wiring harness between V05 (female) (I) and chassis ground
YI
setting
Repair or replace
Replace
Repair or replace
Replace
Repair or replace
circuit diagram Do6 (~5.31
Fuse
2)
L=Dl H 13 (S 161
,-
a a
Machine push UP solenoid valve
TWPO1423
PC300, 350-6
20-495 0
TROUBLESHOOTING
b)
C-23
If solenoid is not canceled (turned OFF1 when setting * Carry out troubleshooting with the machine tion.
machine push-up
push-up
switch
is set to high-pressure
switch at the high-pressure
Cause
Replace
YES
Defective machine push-up switch (internal short circuit with power source)
Replace
NO
Short circuit with power source in wiring harness between M38 (male) (1) X01 (16) - HI3 (3) - V05 (female) (2)
V05 (2) 2
* Turn starting switch ON. * Max. 1 V
Is voltage between M38 (1) , and chassis N normal? * Turn starting switch ON. * Max. 1 V
C-23 Related
electric
posi-
Remedy
Defective machine push-up solenoid (internal short circuit with power source)
YES
between
setting
Repair or replace
circuit diagram Fuse
D~~(KEs~ 2)
TWP01423
20-496 0
PC300, 350-6
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)
Electrical
circuit diagram
for F mode.. .................................................................................................
20-502
F- 1
Bit pattern
20-(l)
Swing
oil pressure
switch does not light up ..........................................
.20-504
F- 2
Bit pattern
20-(2) Travel
oil pressure
switch does not light up ..........................................
.20-505
F- 3
Bit pattern
20-(3) Boom
LOWER oil pressure RAISE oil pressure
F- 4
Bit pattern
20-(4) Boom
F- 5
Bit pattern
20-(5) Arm IN oil pressure
F- 6
Bit pattern
20-(6) Arm OUT oil pressure
F- 7
Bit pattern
21-(l)
Bucket CURL oil pressure Bucket DUMP
Bit pattern
21-(2)
Bit pattern
21-(3) Swing
F-IO
Bit pattern
22-(5)
Kerosene
F-II
Bit pattern
22-(6)
L.H. knob switch
PC300, 350-6
does not light up ...............................
switch does not light up ........................................ switch does not light up.. ...................................
oil pressure
F- 8 F- 9
switch does not light up.. ........................... switch
switch switch
does not light up.. ............................. does not light up .............................
lock switch does not light up.. ...................................................... mode connection
does not light up.. ......................................
does not light up ..........................................................
20-506 20-507 .20-508 .20-509 20-510 20-51 1 .20-512 .20-513 .20-514
20-501 0
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM STARTING
SWITCH
SWING
FOR F MODE REDUNDANCY
SWITCH
TVC RESISTER
coti IMZI
L_---___-_I
M45043)
!!I’
r
I 1
NETWORK
BUS
PC300, 350-6
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
E08ISWPl4)
E07 1x2)
ENGINE SENSOR
SPEED
IzIIz@D
E THROTTLE
CONTR_OA
:R
:oI lWIC13)
TWP01416
PC300, 350-6
20-503 0
F-l
TROUBLESHOOTING
F-l
Bit pattern
20-(l)
Swing oil pressure switch does not light up
Ir
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code c,lisplay returns to normal, the problem has been removed.
A *
Turn the swing lock switch ON before operating the swing lever. If there is no display when the lever is operated on one side, the PPC shuttle valve is defective. (See H-5) (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
+ *
Cause
YES
between
Defective governor, pump controller Defective contact, or disconnection in wiring harness between SO8 (female) (1) and chassis ground
Cl6 (51 Yi
* Start engine. * Swing lever at neutral :20-3ov Swing lever opereated : Max. IV
SO8{male) D) and (2)
l
* Turn starting switch OFF. * Disconnect Cl6 and S08. * Between Cl6 and SO8 Max. 1 R * Between wiring harness and chassis: Min. 1 MR
Disconnect SOS. Start engine. * Swing lever at IO neutral : Min. 1 MR Swing lever operated: Max. 1 R * See Note 1.
l
l
Remedy
l
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl6 (female) (5) and SO8 (female) (2) Defective swing oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.
Repair or replace
Repair or replace
Replace
Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between Cl6 (5) and the chassis. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO
F-l Related
electric
circuit diagram
Governor, pump controller C16tMIC17)
SO8(X2) Swing oil pressure switch
BKPCiJ257
20-504 0
PC300, 350-6
F-2
TROUBLESHOOTING
F-2 Bit pattern
2042) Travel oil pressure switch does not light up
*
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed.
a Ir
Before operating the travel lever, check that the surrounding area is safe. If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective. (See H-5) (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
* *
Cause
YES
Defective governor, pump controller
1 1s voltage between Cl6 and chassis normal?
r (13)
Start engine. * Travel lever at neutral : 20-30V * Travel lever operated : Max. 1 V l
YES r 2 1s resrstance between SO1 (male) (1) and (2) - normal, and is circuit NO insulated from chassis?
3 Is resistance between Cl6 (female) (131 and SO1 (female) (2) normal, and is circuit insulated from chassis?
*Turn starting switch
YES
NO
Defective contact, or disconnection in wiring harness between SO1 (female) (1) and chassis ground
Repair or replace
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl6 (female) (13) and SO1 (female) (2)
Repair or replace
Defective travel oil pressure switch (If the condition does not returen to normal even when the switch is replaced, go to H-5.)
Replace
OFF.
*Disconnect C16and
Sol. Between Cl6 and Sol: Max. 1 n -Between wiring harnessand chassis: Min. 1 MQ l
* Disconnect SO1 * Start engine. * Travel lever at NO neutral : Min. 1MR * Travel lever operated : Max: 1 R * See Note 1.
Note 1: It is also posibble to fit a short connector and judge the condition. In this case, check the voltage between Cl6 (13) and the chassis. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO
F-2 Related electric circuit diagram Governor, pump controller C16(MIC17) Travel oil pressure switch
PC300, 350-6
20-505 0
F-3
TROUBLESHOOTING
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. g
Ir *
When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
YES
H
1
Is voltage between Cl7 (IO) and chassis normal?
* Stan engine. * Boom lever at neutral: 20 - 30V * Boom lever operated to LOWER: Max. IV
YE
Turn starting switch OFF. * Disconnect Cl7 and S04. * Between Cl7 and S04: Max. 1 R * Between wiring harness and chassis : Min. 1 MR l
normal, and is circuit
+ Disconnect S04. * Start engine. * Boom lever at No neutral : Min. 1 Ma * Boom lever operated to LOWER: Max. 1 42 * See Note 1.
Note 1: It is also possible to fit a short connector condition. In this case, check the voltage (IO) and the chassis. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO
F-3 Related
electric
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between SO4(female) (1) and chassis ground
Repair or replace
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl7 (female) (10) H13 illi -SO4 (female] (21
Repair or replace
Defective boom LOWER oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)
Replace
and judge the between Cl7
circuit diagram
Govermor, pump controller C17(04016)
SO4(X2) Boom LOWER pressure switch
oil
m+
BKP00259
20-506 a
PC300, 350-6
TROUBLESHOOTING
F-4
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up *
g
Ir *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
3
____
Is resistancebetween YES Cl7 (female) I21and YES SO2(female) (21 normal, and is circuit insulated from 2 Start engine. chassis? * Boom lever at is resistancebetween p NO - Turn starting switch neutral: 20 - 30V _ SO2(male)11)and (21 OFF. * Boom lever NO normal,and is circuit * Disconnect Cl7 and S02. operated to RAISE insulatedfrom chassis? d * Between Cl7 and SO2 : Max. 1 L! : Max. 1 V * Between wiring harness and chassis * Disconnect S02. : Min. 1 MR * Start engine. * Boom lever at NO neutral: Min. 1 MR * Boom lever operated to RAISE : Max. 1 R. * See Note 1. between
Cl7 (2)
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between SO2 (female) (I) and chassis ground
Repair or replace
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl7 (female) f21- H13 (9) - SO2 (female) (2)
l
Remedy
Defective boom RAISE oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)
Repair or replace
Replace
Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between C17 (2) and the chassis. * If it is 20 - 30V: Go to YES + If it is less than 1V: Go to NO
F-4 Related
electric
circuit diagram
Governor, pump controller C17(04016)
SO2(X2) H13(S16)
($
@
@
Boom RAISE oil pressure switch
m
BKF’OOZSO
PC300, 350-6
20-507 0
F-5
TROUBLESHOOTING
F-5 Bit pattern 2045) Arm IN oil pressure switch does not light up *
A
* *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
YES
Defective governor, pump controller
1
Defective contact, or disconnection in wiring harness between SO5 (female) (1) and chassis ground
Is voltage between Cl7 (3) and chassis normal?
Is resistance betwe$ YES _ Cl7 (female) 13)and YES SO5(female) (2) r normal, and is circuit insulated from 2 * Start engine. chassis7 Is * Arm lever at NO SO5(male) (1) and (2) * Turn starting neutral: 20 - 30V switch OFF. L normal, and is circuit * Arm lever NO insulated from * Disconnect Cl7 and S05. operated to IN chassis? * Between C17 and S05: Max. 1 R : Max. 1 V * Between wiring harness and chassis * Disconnect S05. : Min. 1 MR Start engine.
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl7 (female) (3) - H13(IO) - SO5 ifemale) 12) Defective arm IN oil pressure switch (If the condition does not return to normal even when the switch is reolaced, go to H-5.)
l
* Arm lever at NO neutral : Min. 1 MQ * Arm lever operated to IN: Max. 1 R * See Note 1.
qepair or ,eplace
qepair or .eplace
Replace
Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between Cl7 (3) and the chassis. * If it is 20 - 3OV: Go to YES * If it is less than 1V: Go to NO
F-5 Related
electric
circuit diagram
Governor, pump controller C17(04016) Arm IN oil pressure switch
8
SO5(X2) H13(S16)
@ a
@
Arm IN oil pressure switch
m
BKPoo261
20-508 0
PC300, 350-6
F-6
TROUBLESHOOTING
F-6 Bit pattern
a * *
2046) Arm OUT oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
Defective governor, pump controller
YES
1
Defective contact, or disconnection in wiring harness between SO3 Eo;;l$ (1) and chassis
3 -
YES Is resistance between Cl7 (female) 111) and YES SO3 (female) (2) normal, and is circuit insulated from 2 * Start engine. chassis? resistance between ~ * Arm lever at NO SO3Imale) 11)and (2) * Turn starting neutral: 20 - 30V normal,and is circuit switch OFF. Arm lever ND insulatedfrom * Disconnect Cl7 and S03. operated to chassis? . * Between Cl7 and S03: Max. 1 R OUT: Max. 1 V * Between wiring harness and chassis * Disconnect S03. : Min. 1 MR * Start engine. - Arm lever at NO neutral : Min. 1 MD * Arm lever operated to OUT: Max. 1 R * See Note 1. between
Cl7
(II)
Remedy
-
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl7 (female) (11) - HI3 (12) SO3 (female) (2)
l
Repair or replace
Repair or replace
Defective arm OUT oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)
Note 1: It is also possible to fit a short connector and judge the condition. In this case, check the voltage between Cl7 (11) and the chassis. * If it is 20 - 3OV: Go to YES - If it is less than 1V: Go to NO
F-6 Related
electric
circuit diagram
Governor, pump controller C17(04016)
SO3(X2) H13(S16)
@
@
g
Arm OUT oil pressure switch
77-T
BKPoo262
PC300, 350-6
20-509 0
TROUBLESHOOTING
F-7
F-7 Bit pattern 21-(I) Bucket CURL oil pressure switch does not light up *
g Ir *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. When measuring with the engine running, operate the lever slightly and make sure that the work equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
VFS
1
3 YES Is voltage Is resistance between P between Cl6 (11) Cl6 (female) (11) and and chassis YES SO6(female) 12) normal, and is circuit normal? insulated from 2 Start engine. Is chassis? * Bucket lever at NO SO6(male) 11)and 12) -Turn starting neutral: 20 - 30V - normal, and is circuit switch OFF. Bucket lever NO insulated from * Disconnect Cl6 and S06. operated to chassis? * Between Cl6 and S06: Max. 1 R CURL: Max. 1 V * Between wiring harness and chassis * Disconnect SO6 : Min. 1 MD * Start engine. l
l
* Bucket lever at NCl neutral: Min. 1 ‘_MQ - Bucket lever operated to CURL: Max. 1 fi + See Note 1. Note 1: It is also possible to fit a short connector condition. In this case, check the voltage (11) and the chassis. * If it is 20 - 30V: Go to YES * If it is less than 1V: Go to NO
F-7 Related
electric
Remedy
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between SO6 (female) (1) and chassis ground
Repair or replace
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl6 (female) (11) and SO6 (female) (2) Defective bucket CURL oil pressure switch (If the condition does not return to normal even when the switch is replaced. go to H-5.)
Repair or replace
Replace
and judge the between Cl6
circuit diagram
Governor, pump controller C16(MIC17)
SO6IX2) Bucket CURL oil pressure switch
BKP00263
20-510 0
PC300, 350-6
TROUBLESHOOTING
F-8
F-8 Bit pattern 2%(2) Bucket DUMP oil pressure switch does not light up *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. , When measuring with the engine running, operate the lever slightly and make sure that the work A equipment does not move. (When measuring with the engine stopped, charge the accumulator first.) Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on the next step.
Cause
YES
Remedy
Defective governor, pump controller
Replace
Defective contact or disconnection in wiring harness between SO7(female) (21and chassis ground
Repair or replace
1
Is voltage between Cl6 (12) and chassis normal? * Start engine. Bucket lever at neutral: 20 - 30V * Bucket lever operated to DUMP: Max. 1 V l
*Turn starting switch OFF. * Disconnect Cl6 and S07. * Between Cl6 and S07: Max. 1 52 * Between wiring harness and chassis: Min. 1 MR
* Disconnect S07. * Start engine. + Bucket lever at IO neutral : Min. 1 MR * Bucket lever operated to DUMP: Max. 1 R * See Note 1.
Note 1: It is also possible to fit a short connector condition. In this case, check the voltage (12) and the chassis. * If it is 20 - 30V: Go to YES * If it is less than 1V: Go to NO
F-8 Related
electric
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl6 (female) (12) and SO7 (female) (2) Defective bucket DUMP oil pressure switch (If the condition does not return to normal even when the switch is replaced, go to H-5.)
Repair or replace
Replace
and judge the between Cl6
circuit diagram
Governor, pump controller C16(MIC17)
SO7(X2) g @
Bucket
DUMP
oil
pressure switch
BKP00264
PC300, 350-6
20-511 0
F-9
TROUBLESHOOTING
F-9 Bit pattern 2143) Swing lock switch does not light up j,
j, * *
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. If the panel display is normal. (If the swing lock lamp does not light up, go to M-21.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
Defective governor, pump controller 1 Is voltage between Cl7 (16) and chassis normal? Turn starting switch ON. * Swing lock switch ON: Max. IV OFF: 20 - 30V
l
F-9 Related
electric
Defective contact, short circuit with ground, or disconnection in wiring harness between Cl7 (female) (16) -X01 (4) X05 (male) (I)
Defective switch
swing
lock
Repair or replace
Repair or replace
Replace
circuit diagram
Governor, pump controller C17(04016)
I Monitor panel PO1(04020)
20-512 0
Defective contact, short circuit with ground, or disconnection in wiring harness between X05 (female) (2) -X01 (51- H14 (61. chassis ground
3
Is resistance between YES Cl7 (female) (161and YES X05 (female) (1) - normal, and is circuit insulated from 2 Is chassis7 P NO X05 (female) (1) and * Turn starting - (2) normal, and is switch OFF. ND circuit insulated from * Disconnect Cl7 and X05. chassis? * Between Cl7 and X05 : Max. 1 R *Turn starting . Between wirina harness and chassis switch OFF. :Min. 1 MQ * Disconnect X05. NO * Swing lock switch ON: Max. 1 R OFF: Min. 1 MR
Swing lock switch XOl(MIC21)
X05(M4)
@
-3
g
-3
H14(M6)
PC300, 350-6
F-IO
TROUBLESHOOTING
F-10 Bit pattern 2245) Kerosene mode connection *
* *
does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
YES
Defective governor, pump controller
Connected : Max. 1V
* Turn starting
Open: 20 - 30V
* Disconnect
Defective contact, or disconnection in wiring harness between M36 (male) (1) and chassis ground Defective contact or disconnection in wiring harness between Cl7 (female) (15) and M36 (female) (1)
NO
switch OFF. Cl7
Remedy
Replace
Repair or replace
Repair or replace
and M36. l
F-IO Related
Max. 1 R
electric Governor, C17(04016)
circuit diagram pump controller Kerosene
mode connector
~j..--$J~~~
l
PC300, 350-6
(connected) Diesel oil mode (open)
20-5 13 0
F-II
TROUBLESHOOTING
F-II Ir
* * *
Bit pattern 2246) L.H. knob switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the monitor code display returns to normal, the problem has been removed. When fuse No. 5 is not blown. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
* Defective governor, pump controller
YES
1 Isvoltage
3
between CO3 (9) and chassis normal? * Turn starting switch ON. * Knob switch ON: 20 - 30V OFF: Max. 1 V
Related
Defective L.H. knob switch
NO * Turn starting switch OFF. * Disconnect switch terminal. Knob switch ON: Max. 1 R OFF: Min. 1 MD
electric
NO
Repair wiring harness
Replace
Defective contact, or disconnection in wiring harness between fuse No. 5 - H12 (16) - M22 (I) - H23 (1) -knob switch
l
*Turn starting switch ON. .20-30V
F-II
Defective contact, or disconnection in wiring harness between knob switch outlet - M23 (2) M22 (2) - CO3 (female) (9)
YES
Is resistance YES between terminals of knob 2 switch normal? Is voltagebetween _ _ knobswitchinlet NO tyi;; and chassis
Replace
Repair wiring harness
circuit diagram
Governor, pump controller CO3(040)
H12(S16)
Fuse
M22IM2)
M23(M2)
L.H. knob switch I, a
a-
a
a.
I FY EKPW267
PC300, 350-6
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
actuation
logic, solenoid
Pump merge/divider Table of failure
20-553
table.. ........................................................................
20-554
and causes ......................................................................................................
modes
All work equipment,
travel,
H-l
Speeds
H-2
There
H-3
No work equipment,
swing
drop in engine
is excessive
H-4
Abnormal
H-5
Auto-deceleration
H-6
Fine control
travel,
speed,
swing
or engine
.20-560
stalls .............................................
20-561
move ...........................................................................
(around
noise generated
20-558
swing, travel are slow or lack power.. .........................
of all work equipment,
pump)
ability is poor or response
.20-561
......................................................................
20-562
PPC shuttle valve is cause) ............................
does not work (when
20-562
is poor.. ..............................................................
Work equipment H-7
Boom is slow or lacks power ..............................................................................................
20-564
H-8
Arm is slow or lacks power.. ...............................................................................................
20-566
...........................................................................................
20-568
H-9
Bucket is slow or lacks power..
H-10
Work equipment (but travel
(boom,
arm, bucket) does not move
and swing are normal)
H-l 1
Excessive
hydraulic
H-12
Excessive
time
.20-569
at low idling) ..........................................................................
20-570
drift (boom,
lag (engine
Other equipment In L/O, F/O modes,
moves when
work equipment
H-15
Defective
of machine
actuation
speed is faster than specified
push-up
function..
speed.. .................
..........................................................
In compound
H-17
In swing + boom
operations,
work equipment
RAISE, boom
with larger load is slow .............................
RAISE is slow.. ................................................................
H-18
In swing + arm, arm is slow.. ..............................................................................................
H-19
In swing + travel, travel speed drops excessively
Travel
system
H-20
Travel
deviation..
a)
When
b)
Excessive
Travel
...........................................................
...................................................................................................................
there is deviation travel deviation
in normal when
Steering Travel
speed does not switch
H-24
Travel
does not move (one side only). ...............................................................................
Swing
system
or is faster than specified
speed .....................................
Does not swing .....................................................................................................................
b)
Does not swing
Swing
acceleration
left or right ........................................................................
in one direction
PC300, 350-6
Swing
20-573
................................................................................
20-574 .20-576 20-578 20-578
20-579 20-579 20-579
is poor or swing speed is slow
(both left and right, one direction a)
20-572 .20-572
20-573
does not turn easily or lacks power.. .................................................................
Does not swing to either
20-572
20-573
speed is slow.. ...........................................................................................................
a)
20-571
..................................................................
H-23
H-26
.20-571
travel ..................................................................
starting
H-22
H-25
20-571
operations
H-16
H-21
20-570
single circuit is relieved ..................................................
H-13 H-14
Compound
20-569
...................................................................................... arm, bucket) .................................................................
accelerations
only) .............................................................................
is poor.. ......................................................................................
20-580 20-580
20-551 0
H-27
Excessive
overrun
when
a)
One direction
b)
Both directions..
stopping
swing ...........................................................................
Excessive
shock when
H-29
Excessive
abnormal
noise when
H-30
Excessive
hydraulic
drift of swing ......................................................................................
20-552 0
stopping
a)
When
swing
b)
When
swing holding
Swing
20-582
............................................................................................................
H-28
H-31
20-582
only ........................................................................................................
holding
swing
(one direction
stopping
swing
20-582
only). ..........................................
............................................................
.20-583 .20-583 20-584
brake is released.. ....................................................................
20-584
brake is applied
.......................................................................
20-584
speed ......................................................................
20-585
speed is faster than specified
PC300, 350-6
PUMP MERGE/DIVIDER LOGIC, LS SELECT LOGIC, SOLENOID ACTUATION TABLE
TROUBLESHOOTING
PUMP MERGE/DIVIDER Divide (pump 1. 2.
merge/divider
LOGIC
solenoid
ON)
Travel operated independently. Travel + work equipment (any one of boom, arm, bucket, swing, or service) + front or rear pump oil pressure 19.6 MPa 1200 kg/ cm*) or above when raised or 14.7 MPa I150 kg/cm*) or above when lowered. (See dia-
Merge
(pump
All operations
merge/divider
solenoid
OFF)
except those on left.
gram) ON ______.______
OFF
IIIIE
14.7 (150)
19.6 (200)
Pressure MPa(kg/cm2) 3.
BKP00221
Breaker mode + service (breaker) valve pressure switch ON.
SOLENOID
ACTUATION
TABLE
Name of solenoid
Brake released
Brake applied
speed
Travel motor swash plate angle at MIN
Travel motor swash plate angle at MAX
mode (boom)
STD mode
Active mode
Divided
Merged
Swing
holding
Travel Active
brake
Pump merge/divider Machine Active
OFF
ON (energized)
push-up
mode (swing)
PC300, 350-6
valve
flow
flow
High pressure
Low pressure I
1
Active mode
STD mode
20-553 0
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
(l/Z) -
-
Parts causing failure
s
Piston pump
9
F E
s -
&
r
E ij-
5 t In the failure modes, modes for compound L: When there is an abnormality
20-554 0
operations are used when independent
operations
&
e2
0” - -f2 - -
0 -
0 0 0 0 0 5 0 0 0 0 0 -
0 0 0 -
are normal
for both front and rear
PC300, 350-6
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
Control valve
Front pump
Rear pump 5 2.
Pump merge/ divider valve
AAAA
Regeneration valve
: p 5 ;5 P E
9 z Troubleshooting
code
H-l
H-10
H-30
0 0
PC300, 350-6
0
H-31
20-555 0
TABLE OF FAILURE MODES AND CAUSES
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES (2/2)
xcesswe
overrun
* In the failure modes, modes for compound A: When there is an abnormality
20-556 0
operations
are used when independent
operations
are normal
for both front and rear
PC300, 350-6
TROUBLESHOOTING
Travel
-
-
TABLE OF FAILURE MODES AND CAUSES
-
-
-
-
-
motor
-
-
l-
5 +Y
.-P
P
x
Boom
al
e i-2 .-E b z % ?
1” 2 i?
s d P 5 $ -0 h2 I J 2is 2 :: % > +6 ::0 T 2 I
s
z 5 - -u 6- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i - 3 7 7 i G
3 -
.-F
=_ -
I
I-
1” 5 z f 9
,z .-E 5 ii
-2 T 1 -
2
s
6
-
1
z ci ._
-0
-
-
-
-
-
-
-
-
-
-
-
0 -
-
-
-
-
-
-
-
-
h ::
$ -
-
G
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
7 -
C
-
Bucket
T Troubleshooting
code
2 z
-
0
ii
2
5
IL -
G G
Arm
switch
.-6
$ E 8 m -
31
--c -3
-
7
Pressure
-
-
-
C)-
5
2 t-
L 5Y
1 1
z ii -
I
H-l H-2 H-3 H-4
7 -
H-5 H-6 H-7
H-l 1 H-12
I
I
H-13 H-14 H-15 H-16 H-17
I
I
I
I
I
I
H-18 H-19
7 7 I I 7 - I(01 -
H-20 H-21 H-22 H-23 H-24
H-28 H-29 H-30
PC300, 350-6
20-557 a
H-l
TROUBLESHOOTING
H-l + Sr
Speeds of all work equipment, power
swing, travel are slow or lack
Carry out troubleshooting in the H/O mode. Check that no abnormal noise is being generated from the main pump before troubleshooting. (If there is any abnormal noise, carry out troubleshooting for H-4.)
carrying
out
YES 51 Does condition YES become normal when TVC valve is adjusted? * See TESTING AND ADJUSTING.
BYES _
Does condition become normal when ND servo assembly is replaced?
NO
approx. 2/5 of main
* Engine at high idling - Power max. mode * L.H. knob switch ON *Arm IN relief
3
YI
* 0.2 5 0.2 MPa I2 2 2 kg/cm*) . Engine at high idling * Arm IN relief
2 YE I
Is main pump relief pressure normal?
~32.34 - 35.77 MPa (330 - 365 kg/cm? * Engine at high idling * Arm IN relief
1
i * Check and measure circuit oil pressure. For details, see TESTING AND ADJUSTING.
FH_ bJO NO * Distribution of servo (LS valve) and piston pump (servo plstonj
IO
YES 8 Does condmon become normal when
P
Is control circuit pressure normal?
Is output pressure of LSEPC valve nnrmal7
7 YES
. main relief valves are 1adjusted in order from
-
9 YES Does condmon become normal when ~32.34 - 35.77 MPa _ unload valves are I339 - 365 kg/cm*} NO replaced in order from + Engine at high left to right? idling * 3.92 k 1.0 MPa NO - Arm IN relief (40 ‘-_10 kg/cm’} left to right?
* Engine at high idling . Arm IN relief
L
NO
%
The oil pressure
Ir
Measuring servo piston inlet port pressure in Item No. 4 . Measure the input pressure to the large diameter end of the servo piston when the arm is relieved in the power max. mode. (Approx. 12.74 MPa (130 kg/cm?) Basically, the pressure at the large diameter end is approx. 2/5 of the small diameter end. (For details, see TESTING AND ADJUSTING.)]
20-558 0
in the control
circuit is reduced
by the self-pressure
reducing
valve.
PC300, 350-6
H-l
TROUBLESHOOTING
(
Cause
Remedy
Defective adjustment of TVC valve
Adjust
Defective servo assembly (defective TVC valve)
Repair or replace
Defective piston pump
Repair or replace
Defective servo assembly (defective LS valve)
Repair or replace
Defective piston pump (servo piston)
Repair or replace
Defective operation of LS-EPC solenoid valve
PC300, 350-6
Defective operation of main relief assembly (valve which becomes normal when adjusted)
Adjust
Defective operation of unload valve (valve which becomes normal when replaced)
Replace
Defective operation of main relief valve
Replace
Defective self-reducing valve
Repair or replace
20-559 0
TROUBLESHOOTING
H-2
H-2 There is excessive drop in engine speed, or engine stalls * *
Carry out troubleshooting in the H/O mode. Check that the main relief pressure is normal.
Cause
YES
Remedy
Clogged throttle inside servo or clogged filter inside servo
Clean
Defective TVC valve or defective operation of LS valve
Adjust or replace servo valve assembly
Defective servo piston
Replace (piston pump assembly)
1 Is throttle inside servo or filter inside servo clogged? P Is engine speed - at arm IN relief NO normal?
* See
3 YES Doescondrtron YES becomenormalwhen - TVCvalve (servo 2 valveassembly)is replaced? NO
_
See troubleshooting engine (S mode)
Note 1.
for
-
N_
Note 1:Replace the servo valve assembly on the defective side with a new part, and if the engine speed is lower than the reference value below, carry out troubleshooting for S mode (engine). If it is higher, it can be judged that the TVC valve (servo valve assembly) is defective, so replace it. * Engine speed (reference) at arm IN relief when engine and pump are normal
20-560 0
PC300, 350-6
TROUBLESHOOTING
H-3, H-4
H-3 No work equipment,
travel, swing move
Cause
2 YES When main pump YES pressure pickup 1 - plug is removed, does oil come out? Is safety lock valve working properly?
_
NO
* Crank with starting motor.
NO
H-4 Abnormal
noise generated
Defective self-reducing valve, defective control circuit, or defective main piston pump
Replace
Defective damper
Replace
Defective operation of safety lock valve or safety linkage
Adjust
(around pump)
Cause
3
YES
YE j=y2
Remedy
Goto4
stopped?
I
I
nproper
NO
hydraulic oil
Change hydraulic oil
bubbles inside YES
4 Is suction strainer clogged by NO external object? Is hydraulic tank oil level normal?
* External object: Cloth, etc.
0
PC300, 350-6
Iogged by external lbject (cloth, etc.)
Remove
tefect inside pump
Repair or reolace
rperate for a short time nd watch for any hange in symptoms
Inspect again (depending on changes in symptoms)
ack of hydraulic oil
4dd hydraulic oil
5 Is suction strainel clogged with metal particles or Nc are metal particles stuck to drain plug?
20-56 0
1
H-5, H-6
TROUBLESHOOTING
H-5 Auto-deceleration cause) *
does not work (when PPC shuttle valve is
The control pressure for the travel and swing passes through to the pressure switch.
the PPC shuttle valve and is supplied
Cause
1 YES Does condition become normal when oressure switch is replaced? NO
Remedy
Defective pressure switch
Replace
Defective operation of PPC shuttle valve in applicable system (swing or travel)
Repair or replace
H-6 Fine control ability is poor or response is poor
Remedy
2
YES
YES Is throttle in LS circuit clogged? 1 Is output pressure of LSEPC normal? * Output pressure: 2.94 t 0.2 MPa (30 t 2 kg/cm3
20-562 0
NO
-
NO
Clogged throttle in LS circuit
Clean
Defective servo valve assembly (LS valve), or defective servo piston
Replace
Defective LS-EPC valve
Repair or replace
PC300, 350-6
H-7
TROUBLESHOOTING
H-7 Boom is slow or lacks power Ir Sr
When travel and swing speeds are normal. Carry out troubleshooting in the H/O mode.
YES
YEiS 5
I Is relief oressure when boom RAISE
Does LS shuttle valve move smoothly?
I * Check LS shuttle L for R.H. travel NO and bucket
(330 - 365 kg/cm? I NO * Engine at high idling
Does control YES valve spool for boom move smoothly? 2 . YES ls output - pressure of PPC valve normal? 1 Is pressure switch for boom RAISE, LOWER normal? * See Judgement Table. (Bit pattern 20 (3)(4)) * See Note 1.
-
. Min. 2.74 MPa (28 kg/cm21 * Engine at high idling * Operate boom.
-
* It is also possible to interchange with other compensation valve. * See Note 2.
(50 + 30 kg/cm21 * Engine at high idling NO
NO
NO
NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, system normal. Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-564 0
is
PC300, 350-6
TROUBLESHOOTING
H-7
P
Remedy
Defective operation boom lock valve
of
Defective boom cylinder piston packing
Repair or replace
Defective operation of LS shuttle valve (LS shuttle for R.H. travel or bucket)
Repair or replace
Defective boom lock valve or suction valve for boom in control valve
Replace
Defective operation boom lock valve
of
Defective operation boom regeneration
of valve
Defective operation of boom pressure compensation valve 01 pressure compensation piston (for boom RAISEend,check boom Hi also) Defective operation of control valve spool (for boom RAISE end, check boom Hi spool also) Defective
PPC valve
Defective boom RAISE or boom LOWER pressure switch
PC300, 350-6
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
Replace
20-565 0
H-8
TROUBLESHOOTING
H-8 Arm is slow or lacks power Sr When travel and swing speeds are normal. * Carry out troubleshooting in the H/O mode.
YES 6 S Does LS shuttle valve move smoothly?
YE 4 IS pressure
YES compensrrtion valvefor -
_ Does control YES valve spool for arm move
YI
* See Judgement Table. (Bit pattern 20 (5), (6)) * See Table 1.
Is output pressure of PPC valve normal? . Min. 2.74 MPa (28 kg/cm? * Engine at high idling * Operate arm.
-
3
_
arm normal, or does pressure compensation pistonmovesmoothly?
* It is also possible to interchange with other compensation valve. * See Note 2.
. 32.34 - 35.77 MPa I330 - 365 kg/cm*) * Engine at high idling
*Check LS shuttle i-4’ for L.H. travel, boom, R.H. travel and bucket
NO
uo
NO
NO
NO
Note 1: If the auto-deceleration is canceled when arm IN or arm OUT is operated, the system normal. Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-566 0
PC300, 350-6
is
TROUBLESHOOTING
H-8
Y=Is leakage from - arm cylinder normal? * Max. 20 cc/min * Engine at high idling
NO
Defective operation of arm regeneration valve
Repair or replace
Defective arm cylinder piston packing
Repair or replace
Defective operation of LS shuttle valve (LS shuttle for L.H. travel, boom, R.H. travel or bucket)
Repair or replace
Defective operation of arm oressure
PC300, 350-6
Remedy
I
Defective PPC valve
Replace
Defective arm IN or arm OUT pressure switch
Replace
20-567 0
TROUBLESHOOTING
H-9
H-9 Bucket is slow or lacks power Sr
When
travel and swing speeds
are normal.
Remedy
Cause
I -----I
Defective operation of control valve spool for bucket
Repair or replace
Defective PPC valve
Replace
Defective bucket CURL or bucket DUMP pressure switch
Replace
Defective operation of safety-suction valve for bucket
Repair or replace
Defective bucket cylinder piston packing
Repair or replace
valve normal?
switch for bucket
I
* See Judgement Table. (Bit pattern 21 (1). (2)) - See Note 1.
II
* Min. 2.74 MPa (28 kg/ems) * Engine at high idling * Operate bucket.
NO
NO
5YE! 5
I
From A- ~
rncve smoothly? * It is also possible to interchange with other compensation valve. * See Note 2.
I NO --_
Note 1: If the auto-deceleration is canceled when bucket CURL system is normal. Note 2: After inspection, do not forget to return the interchanged
20-568 0
Defective operation of compensation valve for bucket or Ipressure compensation Ipiston Ipressure
or bucket
DUMP
qepair or *eplace
is operated,
valves to the original
the
position.
PC300, 350-6
TROUBLESHOOTING
H-10 *
H-10, H-II
Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)
When boom, pendently.
arm,
and bucket
are each
operated
inde-
-7
Defective control valve spool
1 YES
output pressureof
Cause
Remedy
Repair or replace
Is
PPC valve normal?
Defective PPC valve
* Min. 2.74 MPa I28 kg/cm? - Engine at high idling
H-11
Excessive hydraulic drift (boom, arm, bucket)
1) Excessive
hydraulic
drift of boom
YES 1 Doesspeedof downwardmovement becomefasterwhen lever is operated? * See TESTING N~ AND ADJUSTING. - It is also possible to measure leakage of cylinder. - Max. 20 cc/min * At relief - Engine at high idling
2) Excessive
2
YES
Does condition become normal when safety-suction valveis Interchanged? NO
hydraulic
drift of arm or bucket
downward movement become faster when * See TESTING AND ADJUSTING. N - It is also possible to measure leakage of cylinder. * Max. 20 cclmin f At relief * Engine at high idling
YES
1Does
Remedy
Defective hydraulic cylinder piston packing
Replace
Defective operation of safety-suction valve
Replace
Defective operation of boom lock valve
Repair or replace
Cause
Remedy
Defective operation of safety-suction valve
condition
1: After inspection,
PC300, 350-6
I
Cause
Defective hydraulic cylinder piston packing
‘ES
Note
Replace
NO
* It is also possible to interchange with other compensation valve * See Note I.
do not forget to return the interchanged
Defective control valve spool
Replace
Damaged slipper seal of pressure compensation valve, or defective operation of pressure compensation piston
Repair or replace
valves to the original
position.
20-569 0
TROUBLESHOOTING
H-12
H-12,
Excessive time lag (engine at low idling)
I arm
YES 2
Is output pressure of LSEPC solenoid valve normal?
- See
H-13
Note 1.
Is YE.S compensationvalve normal,or does pressurecompensation piston move smoothly?
i
-
* It is also possible to interchange NO with other compensation valve. * See Note 2.
N0
Bucket
Cause
Remedy
Defective safety-suction valve, or defective regeneration valve
Replace
Defective valve
Replace
safety-suction
Defective operation of pressure compensation valve or pressure compensation piston
Repair or replace
Defective operation of LS-EPC solenoid valve
Repair or replace
Note 1: Output pressure of LS-EPC solenoid 2.94 + 0.2 MPa 130 f 2 kg/cm*) is output from the LS-EPC solenoid when the all lever are at neutral. Note 2: After inspection, do not forget to return the interchanged valves to the original position. l
H-13
Other equipment
moves when single circuit is relieved Cause Defective operation of pressure compensation valve slipper seal (The slipper seal in the pressure compensation valve of the circuit that moved is defective.)
20-570 0
Remedy
Replace
PC300, 350-6
H-14, H-15, H-16
TROUBLESHOOTING
H-14
speed is faster than
In L/O, F/O modes, work equipment specified speed
Cause
1 YES Is output pressure of LSEPC solenoid valve normal?
- See
NO
Note 1.
Defective LS valve
Repair or replace
Defective operation of LS-EPC solenoid valve
Repair or replace
1: Output pressure of LS control EPC solenoid (travel OFF) 2.94 + 0.2 MPa I30 + 2 kg/cm21 is output from the LS-EPC solenoid neutral.
Note
l
H-15 *
Defective
When
electrical
actuation
system
is normal.
Cause
1 YES
H
Remedy
Defective safety valve
Replace
Defective operation of solenoid valve
Repair or replace
NO * Engine at high idling . For details of the measurement procedure, see TESTING AND ADJUSTING.
Table
when the all lever are at
of machine push-up function
1soutputoressure I I of machine pushup solenoid valve as shown in Table
Remedy
1
1 Machine
push-up
switch
@ Low pressure
setting
@ High pressure
setting
H-16
(Oil pressure
(MPa {kg/cm?) 1
In compound operations, work equipment with larger load is slow Remedy
Cause Defective operation of pressure compensation valve 1 Combination
of compound
Replace (replace pressure compensation valve on side where load is lower) operation
1 Side where
load is larger
1
Boom RAISE + arm IN
Boom RAISE
2
Boom RAISE + arm OUT
Arm OUT
3
Boom RAISE + bucket CURL
I 4
I
Arm OUT + bucket CURL
1 5
1
Boom
PC300,
350-6
LOWER
+ arm OUT
1
Boom RAISE
I I
Arm OUT Arm OUT
I 20-57 1 0
TROUBLESHOOTING
H-17
H-17, H-18, H-19
In swing + boom RAISE, boom RAISE is slow
*
If swing and boom
(I)
In active mode
RAISE work normally
when
NO
1 Is output pressure of active (swing) solenoid valve normal? ~ * Min. 2.74 MPa _ YES 128 kg/cm’) * Boom lever operated fully to RAISE
2 Does valve select move
YES
PPC shuttle for LS circuit smoothly? NO
operated
independently.
Defective operation of active (swing) solenoid valve
Repair or replace
Defective operation select valve
Repair or replace
of LS
Defective operation of PPC shuttle valve for LS select circuit (PPC shuttle for boom RAISE, LS select)
Repair or replace
Defective operation select valve
Repair or replace
(2) In other mode
1 YES
I
Does valve select move
PPC shuttle for LS circuit smoothly? NO
H-18 +
Defective operation of PPC shuttle valve for LS select circuit (PPC shuttle for boom RAISE, LS select)
Repair or replace
In swing + arm, arm is slow
See H-17. (If the operation is normal when the swing and arm are operated independently. If the Cause column shows that there is defective operation of the LS shuttle valve, the cause is in the shuttle valve for the arm OUT, IN and LS select.)
H-19 *
of LS
In swing + travel, travel speed drops excessively
See H-17. (If the operation is normal when the swing and travel are operated independently. If the Cause column shows that there is defective operation of the PPC shuttle valve, the cause is in the shuttle valve for the LS select.)
20-572 0
PC300, 350-6
H-20
TROUBLESHOOTING
H-20 * *
Travel deviation
Carry out troubleshooting in the H/O mode. When swing and work equipment speeds are normal.
a) When
there
is deviation
in normal
travel Cause
3
YES
Does control YES valve spool for 2 travel move smoothly? YES Does junction - valve move smoothly? lIs differencein output pressurebetweenleft and rightPPC valves
between FORWARD and REVERSE : Within 0.39 MPa t4 kg/cm2 ) * Engine at high idling * Travel relief
Note 1:
l
l
NO
- Check
as an individual part
NO
* Same conditions as for Item 1 * See Note 1
Defective travel motor assembly
Repair or replace
Defective operation of control valve spool
Repair or replace
Defective operation of travel junction valve
Repair or replace
Defective PPC shuttle
Repair or replace
Defective PPC valve
Replace
NO
Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip. If the adapter for blocking the circuit is not available, interchange the travel PPC hoses with the PPC hoses for the bucket (CURL, DUMP), boom (LOWER), or arm (IN) at both the inlet and outlet ports of the shuttle block, and check operation.
bl Excessive
travel
deviation
when
Cause
starting
I
Remedy
Defective operation of travel counterbalance valve
Correct or replace
Clogging of throttle inside servo of front or rear pump
Correct or replace
PC300, 350-6
I
20-573 0
H-21
TROUBLESHOOTING
H-21 *
Travel speed is slow
Check that the spool of the travel PPC valve is moving shooting. Carry out troubleshooting in the H/O mode. When swing and work equipment speeds are normal.
* *
the full stroke before carrying
3 Is output YES pressure of LS2 EPC solenoid valve normal? -
Slow in both FORWARD and REVERSE
Is pressure switch normal?
_
out trouble-
YES _
NO
* See Note 2.
I
NO
YES 7IIs pressure
1 speed slow m both FORWARD and REVERSE, or is Is
- See
p Does control YES valve spool for travel move 5 smoothly? p
Note 1.
YES
* Check as individual
4
1
Slow in one direction only (FORWARD or REVERSE)
_
Is difference in output pressure between left and right PPC valves normal. or is output pressure * Difference
in
~~~~“,‘,“,‘““““‘” FORWARD and REVERSE : Within 0.39 MPa (4 kg/cm*) * Output pressure: Min. 2.74 MPa (28 kg/cm? * Engine at high idling * Travel relief
Does junction valve move smoothly?
compensation valve YES normal, or does - pressure compensation piston 6 move smoothly? + It is also possible to interchange NO with other compensation valve. * See Note 3.
-
NO
part. NO
_ 9 YES Is output pressure _ (shuttle block inlet ~0 end) of PPC valve normal?
- Same
conditions as for Item 4 * See Note 4.
_
NO
Measure the travel speed under no load or measure the time taken to travel 20 m. (See MAINTENANCE STANDARD FOR CHASSIS RELATED PARTS.) . When measuring the speed of the travel motor under no load + Remove connector of LS control EPC solenoid, and measure travel speed in Lo and Hi. Note 2: Output pressure of LS-EPC solenoid Unit: MPa {kg/cm21 Note 1:
Travel
l
speed
LS-EPC output pressure Remarks
l
l
20-574 0
Lo
Mi
Hi
0.2 f 0.2 {2.0 + 2.01
1.8 + 0.2 i18.4 + 2.01
0.2 * 0.2 I2.0 * 2.0)
Engine at high idling Operate travel lever slightly
(auto-deceleration
cancel position)
PC300, 350-6
TROUBLESHOOTING
H-21
Cause
Remedy
f
a
YES
Does condition become normal - when travel suction valve for control valve is replaced? * See Note 1.
Defective operation of LS shuttle valve (for bucket)
Repair or replace
Defective operation of LS-EPC solenoid valve
Repair or replace
Defective travel pressure switch
Replace
Defective operation of travel suction valve for control valve
Repair or replace
Defective travel motor assembly
Repair or replace
Defective pressure compensation valve, or defective operation of pressure compensation piston
Repair or replace
Defective operation of travel spool for control valve
Repair or replace
Defective operation of iunction valve
Repair or replace
Defective PPC shuttle
Repair or replace
Defective PPC valve
Replace
NO
Note 3: After inspection, do not forget to return the interchanged valves to the original position. Note 4: Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip. If the adapter for blocking the circuit is not available, interchange the travel PPC hoses with the PPC hoses for the bucket (CURL, DUMP), boom (LOWER), or arm (IN) at both the inlet and outlet ports of the shuttle block, and check operation. l
l
PC300, 350-6
20-575 0
TROUBLESHOOTING
H-22 *
Steering
H-22
does not turn easily or lacks power in the H/O mode.
Carry out troubleshooting
4YES _ Both front and rear high Both left and right
pressure
jFZ$$%r$H
of front
when relieved
on
2 Is it difficult to turn to Y ES both left and right, or is it difficult to turn in one direction only?
NO Pressure high only on side - being relieved (oil pressure is normal) Both front and rear high
L
One direction only
pump when relieved Does not turn to left or right
pressure
l
l
When steering, drive side is low tnoo~~~$te side is
switch
See Judgement Table. (Bit pattern 20 (2)) If autodeceleration is canceled when travel is operated, system is normal.
-
Does not turn to left only
L
Ni0
20-576 0
PC300,
350-6
H-22
TROUBLESHOOTING
Cause
YES 11
Doescondrtion becomenormalwhen - suctionvalveof controlvalveis interchanged?
r-J
+ Interchange
left
and right s~ools.NO
YES
NO
PC300, 350-6
8 Does condition become normal _ when suction
YES
Remedy
Defective operation of pump merge/divider valve or LS pump merge/divider valve
Repair or replace
Defective operation of main pump merge/divider solenoid valve
Repair or replace
Defective operation of travel junction valve spool
Repair or replace
Defective operation of LS circuit check valve
Repair or replace
Defective control valve suction valve
Replace
Defective travel motor check valve
Repair or replace
Defective travel motor safety valve
Replace
Defective operation of LS shuttle valve for bucket
Repair or replace
Defective travel pressure switch
Replace
_
valve of motor is interchanged? NO
20-577 0
TROUBLESHOOTING
H-23 *
H-23, H-24
Travel speed does not switch or is faster than specified speed
Carry out troubleshooting
in the H/O mode. Cause
3 Is outputpressure of travel speed selector solenoid valve normal?
YES 2
-
I Is output YES pressure of LSEPC solenoid 1 valve normal?
_
* See Table 1.
Is travel pressure switch normal?
YES
NO * Min. 2.74 MPa {28 kg/cm21 . Travel speed selector switch: Mi, Hi * Turn travel switch ON.
NO
Replace
Defective operation of travel speed selector solenoid valve
Repair or replace
Defective operation of LS-EPC solenoid valve
Repair or replace
Defective travel pressure switch
Replace
i
* See Judgement Table. (Bit No pattern 20 (2)) * If autodeceleration is canceled when travel is operated, system is normal.
Table
Defective operation of travel speed selector servo piston in travel motor
1. Output
pressure
of LS-EPC solenoid
Unit: MPa {kg/cm21
Travel speed
Lo
Mi
Hi
LS-EPC output pressure
0.2 f 0.2 12.0 * 2.01
1.8 f 0.2 i18.4 f 2.0}
0.2 f 0.2 (2.0 f 2.0)
l
Remarks
l
H-24
Engine at high idling Operate travel lever slightly
cancel position)
Travel does not move (one side only)
ti
YES
3 nne~trom final drive7
YES
1Doescondition II v~sl become normal when 1 1
11 II
If controlvalve I
- Max. : 30 --
e /min . Engine at high idling -At travel relief
20-578 0
(auto-deceleration
NO
I
Defective final drive
Repair or replace
Defective operation of suction valve of control valve
Replace
Defective operation of counterbalance valve or travel motor safety valve
Replace
Defective travel motor
Replace
PC300, 350-6
TROUBLESHOOTING
H-25
H-25
Does not swing
a) Does not swing
to either
left or right
Cause
3 YES YES 2 r Is output pressure
Is any foreign material found in oil drained from swing machinery?
YE
Remedy
Defective swing machinery
Repair or replace
Defective swing holding brake or swing motor
Repair or replace
Defective operation of holding brake solenoid valve
Repair or replace
Defective swing pressure switch
Replace
-
NO
1 Is swing pressure switch normal?
* See Judgement Table. (Bit NO pattern 20 (1 )I * If autodeceleration is canceled when swing is operated, system is normal.
* Min. 2.74 MPa I28 kg/cm? NO . Operate swing lever for operate work equipment lever).
b) Does not swing
in one direction
Cause
i YES 1 Is PPC valve output pressure normal? I
* Min. 2.74 MPa (28 kg/cm*} * Operate swing lever for operate work equipment lever).
PC300, 350-6
YES
Does control valve spool for swing move smoothly?
NO
-
Remedy
Defective swing motor safety valve or suction valve
Defective operation of control valve spool for swing
Repair or replace
J
Defective PPC valve NO
20-579 0
H-26
TROUBLESHOOTING
H-26 * *
Swing acceleration
is poor or swing speed is slow
Carry out troubleshooting in the H/O mode. If condition is normal when work equipment
al Swing
acceleration
is operated
is poor
2
-
independently.
Both left and right
YES
Does LS shuttle valve move smoothly?
-
I I
I
NO 6 YES
acceleration poor in both directions YES
YES r
-
One direction only (left or right)
Is PPC valve output pressure normal?
-
* Min. 2.74 MPa (28 kg/cm2) * Engine at high idling Operate swing
p Is output pressure (at shuttle block end) of PPC valve normal?
4 II
* Same conditions
-
4
Does control valve spool for swing move smoothly? p
Is pressure compensation valve YES for swing Norman,or does pressure 5 compensation piston move smoothlv? _
* It is also possible to
NO interchange with other compensation valve. 0 See Note 2. NO
II
as for ltem 6 * See Note 1.
NO
l
Note 1:
Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip. If the adapter for blocking the circuit is not available, interchange the swing PPC hoses with the PPC hoses for the bucket (CURL, DUMP), at both the inlet and outlet ports of the shuttle block, and check operation. Note 2: After inspection, do not forget to return the interchanged valves to the original position. l
l
20-580 0
PC300, 350-6
H-26
TROUBLESHOOTING
,
F= Defective swing motor assembly
Replace
Defective operation of LS shuttle valve (all LS shuttles)
Repair or replace
Defective operation of swing motor safetysuction valve Defective operation of pressure compensation valve or compensation piston
PC300, 350-6
Remedy
Repair or replace
Repair or replace
Defective operation of control valve spool for swing
Repair or replace
Defective operation of PPC shuttle valve
Repair or replace
Defective PPC valve
Replace
20-581 0
TROUBLESHOOTING
H-27
H-27
Excessive overrun when stopping
a) One direction
swing
only Cause
I. YES 2 _
p ~Does control valve spool for swing move smoothly?
3
problem reversed when left and right swing PPC slow return valves are interchanged? IS
Is problem reversed YES when left and right - output hoses of PPC valves are 1
YES
I
Defective swing PPC slow return valve
Repair or replace
Defective
Replace
PPC valve
NO
NO
Remedy
Defective swing motor safety valve
Replace
Defective operation of control valve spool for swing
Repair or replace
b) Both directions
Cause Defective
20-582 0
swing
Remedy motor
Repair or replace
PC300, 350-6
H-28, H-29
TROUBLESHOOTING
H-28
Excessive shock when stopping
swing (one direction
only)
Cause
1 YES
1Doescondition become
11
I
normal when leftand right swine PPCslowreturn 1valve-sare interchanged? 1 Y
I
NO
H-29
Excessive abnormal
noise when stopping
Defective swing PPC slow return valve (check valve)
Repair or replace
Defective
Replace
PPC valve
swing
Cause
1 Doescondition become 1 normal when swing motor safety-suction valve is cleaned? t
h
YES 2 Doesconditionbecome normalwhenswing motorsafetysuction valveis replaced?
3
No
Is foreign material found swing machinery?
YES
Remedy
Defective operation of swing motor safetysuction valve
Clean
Defective swing motor safety-suction valve
Replace
Defective swing machinery
Repair or replace
Defective valve
Repair or replace
in
NO
PC300, 350-6
Remedy
back pressure
20-583 0
H-30
TROUBLESHOOTING
H-30
Excessive hydraulic drift of swing
a) When
swing
holding
brake is released
Cause
2 YES
-One
1
I
direction only i~H~
NO
Is hydraulic drift excessive in both directions or one direction only?
3
YES
i I-
swing
Defective pressure compensation valve for swing, or defective operation of pressure compensation piston
holding
1 YES
* 0.2 f 0.2 MPa (2 * 2 kg/cm*) -When 5 seconds havepassed after all swing and work equipment control levers have been returned to neutral.
20-584 0
NO
Repair or replace
Defective control valve spool for swing
Replace
Defective swing motor
Repair or replace
NO
brake is applied Cause
Is output pressure of swing holding brake solenoid valve normal?
Repair or replace
Both left and right {FHP
-11 elmin * Engine at high idling - At swing relief
b) When
Defective swing motor safety-suction valve
Remedy
Remedy
Defective operation of swing holding brake
Repair or replace
Defective operation of swing holding brake solenoid valve
Repair or replace
PC300, 350-6
TROUBLESHOOTING
H-31
H-31
Swing speed is faster than specified swing speed
Cause
Is output pressure of LSEPC solenoid valve normal?
Table
1.
J
1
NO
- See Table 1.
Output
pressure
of LS-EPC solenoid
Remedy
Defective operation of LS valve
Replace servo assembly
Defective LS-EPC solenoid
Repair or replace
valve
unit: MPa {kg/cm*} H/O mode
G/O mode
F/O mode
L/O mode
0.2 * 0.2 (2.0 + 2.01
0.2 + 0.2 (2.0 f 2.0)
1.51 + 0.2 i15.4 f 2.0)
2.17 +I 0.2 (22.0 f 2.0)
l
l
Engine at high idling Travel OFF
PC300, 350-6
20-585 0
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
Action taken by monitor and problems
on machine
circuit diagram
Electrical M-l
panel when
abnormality
..._............................................................................................................
[El011 Abnormality
in error data is displayed
[El031 Short circuit in buzzer output with buzzer drive harness [El041 Air cleaner
M-4
[El061
clogging
M-5
[El081 Engine water temperature
M-6
When
Drop in engine
switch
is turned
light up for 3 seconds
M-7
detected
oil pressure
None of lamp on monitor
b)
Some
of 24V wiring
harness 20-609
...............................................................................
is displayed Hi detected
105’C detected
.20-610
............................................................. ............................................
is displayed is displayed
.20-610
..........................................
ON, none of lamps on monitor
20-61 1
panel 20-612 20-612
panel light up.. ..................................................................... panel do not light up.. .....................................................
of lamps on monitor
starting
or contact
............................................................................................................
a)
When
20-608
.................................................................................
is displayed..
M-3
starting
20-604
for M mode system . . . . .. . .. . . . . . .. . . . .. . .. . . . . . . . .. . . .. . . . . . .. . . . . . . .. . . . .. . . . . . . . . .. . . . . . . .. . . . .. . . . . 20-606
[El021 Error in clock data is displayed M-2
occurs
switch is turned
ON, monitor
panel lamps all stay lighted
.20-612
up 20-614
and do not go out.. ................................................................................................................. M-8
When
starting
different M-9
When a)
M-10
M-12
starting
M-13
panel are
ON (engine
stopped),
basic check items flash ..............
oil level) flashes.. ............................................................................................
is not being used but (preheating
starting
Alternator
b)
Engine
switch
is turned
monitor)
ON and engine
lights up ....................................
is started,
starting
switch
system ............................................................................................. is turned
ON (engine
stopped),
caution
b)
Engine
system .............................................................................................................
oil pressure
starting
switch
sensor system.. ............................................................................... is turned
ON and engine
is started,
20-617 .20-618
20-619 20-620
items,
stop items flash ...................................................................................................
Alternator
20-615
basic check items flash ...... 20-619
system .............................................................................................................
oil pressure
a)
20-614
20-616
a)
When
is turned
up on monitor
.................................................................................
oil level) flashes ..................................................................................................
(engine
(hydraulic
emergency
ON, items lighted (model)
20-615
b)
Preheating
switch
level) flashes
c)
When
is turned
......................................................................................................
(coolant
M-l 1 When
switch
from actual machine
caution
20-621 20-621 20-622
items,
emergency
stop items flash ...................................................................................................
20-623
a)
(engine
oil pressure)
flashes ...........................................................................................
20-623
b)
(coolant
level) flashes
......................................................................................................
20-623
c)
(battery
charge)
...................................................................................................
20-623
d)
(coolant
temperature)
flashes.. ........................................................................................
20-624
e)
(fuel level) flashes.. ...........................................................................................................
20-624
f)
(air cleaner
20-625
PC300, 350-6
flashes
clogging)
flashes
..........................................................................................
20-601 0
M-14
When starting switch is turned ON (engine stopped), item flashes
Caution
buzzer does not sound for 1 second .20-626
but buzzer does not sound ...............................................................
M-15
No abnormality
is displayed
M-16
Night lighting
M-17
Coolant
temperature
gauge
does not rise ..........................................................................
temperature
gauge
does not give any display.. ...................................................
on monitor
on monitor
but buzzer sounds. ............................................
panel does not light up (liquid crystal display
is normal)
20-626 ... 20-627 .20-628 .20-628
M-18
Coolant
M-19
Fuel level gauge
always
FULL.. .............................................................................
.20-629
M-20
Fuel level gauge
does not give display ................................................................................
20-629
M-21
Swing
lock switch
M-22
Swing
prolix switch
M-23
Service
M-24
When
displays
is turned
ON (LOCK) but (swing
is turned
ON (prolix),
meter does not advance starting
while
but (swing
are not displayed..
does not light up .... 20-630
lock monitor)
does not flash .... 20-630
is running .................................................
engine
switch is at OFF and time switch
time and service meter
lock monitor)
is pressed,
M-25
Defective
fuel level sensor system.. ......................................................................................
Defective
coolant
temperature
M-27
Defective
engine
oil level sensor system .............................................................................
M-28
Defective
coolant
M-29
Defective
hydraulic
M-30
Wiper
M-32
20-602 0
20-633 20-634 20-635
.................................................................................
oil level sensor system ......................................................................... is not being used but wiper
20-636
is actuated 20-638
E112, El 13). ...............................................................................................................
a)
Wiper
does not work.. ......................................................................................................
b)
Wiper
switch
Washer
20-632
sensor system.. ...................................................................
does not work or switch
(include
M-31
20-631
..........................................................................
M-26
level sensor system
motor
is not being operated
but wiper
20-631
20-638
is actuated .........................................
does not work, or switch is not being used but washer
.20-642
motor
is actuated
(include
E114) ......................................................................................................
20-643
a)
Washer
motor
does not work .........................................................................................
20-643
b)
Switch
is not being operated
but washer
is actuated ..................................................
Electric grease gun does not work.. ......................................................................................
20-644 20-645
PC300, 350-6
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User zode
Service code
Abnormal
Nature
system
of abnormality
-
El01
Abnormality data
in error
1. 2. 3. 4.
Abnormality in internal memory Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Connector has separated
-
El02
Abnormality in clock data
1. 2. 3. 4.
Abnormality in internal clock function Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Connector has separated /-
-
El03
Short circuit in buzzer output system
1. Short circuit inside buzzer 2. Power line in contact with wiring harness between monitor (PO1 (7) pin) and buzzer 3. Abnormality in monitor panel
-
El04
Air cleaner clogging detected is displayed
1. Air cleaner clogging sensor has detected clogging
-
~106
Drop in engine oil Hi pressure detected is displayed
1. Engine oil pressure Hi sensor has detected drop in oil pressure
-
El08
Engine water temperature 105’C detected is displayed
1. Coolant temperature 105°C
El12
Short circuit in wiper motor drive nOrmal rotation system
1. Short circuit with 2. Short circuit with 3. Short circuit with monitor PO2 (11) wiper motor W04
El13
Short circuit in wiper motor drive reverse rotation system
1. Short circuit with ground, short circuit inside wiper motor 2. Short circuit with ground, short circuit inside relay box 3. Short circuit with ground, short circuit in wiring harness between monitor PO2 (3) and relay box W08 (31, or between W08 (7) and wiper motor W04 (1)
El14
Short circuit in window washer drive system
1. Short circuit inside washer motor 2. Short circuit inside relay box 3. Short circuit with power source in wiring harness between monitor PO2 (2),(10) and relay box W08 (171, or between W08 (16) and M28 (1)
-
-
-
20-604 0
gauge has detected water temperature
ground, short ground, short ground, short and relay box (3)
of
circuit inside wiper motor circuit inside relay box circuit in wiring harness between W08 (21, or between W08 (6) and
PC300, 350-6
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
TROUBLESHOOTING
Condition when normal voltage, current, resistance)
.
t
Action
when is detected
by controller
abnormality
Problem that appears on machine when there is abnormality
-
1. Service code cannot be cleared 2. Time becomes 0O:OO.
-
1. Service code cannot be cleared 2. Time becomes 0O:OO. 3. Clock does not advance.
Voltage between PO1 (7) - chassis Buzzer ON: Max. IV Buzzer OFF: 20 - 30V When there is a disconnection, El03 is not displayed and the buzzer does not sound
-
1.
Buzzer does not sound
Resistance between PI1 (male) - PI2 (male): Min. 1 R (engine started)
-
1.
If abnormality detection continues, air cleaner clogging caution lamp flashes and buzzer sounds
Resistance between sensor terminal - chassis 1 MR (engine at midrange speed or above)
-
1.
If abnormality detection continues, engine oil pressure caution lamp flashes and buzzer sounds
When starting switch is turned ON, keep time switch pressed for 5 seconds to actuate clear function
Resistance (1) - (2): Min. 3.156 started)
between
1. If abnormality detection continues, coolant temperature caution lamp flashes and buzzer sounds 2. If abnormality detection continues, engine speed is reduced to low idling
PO7 -
kR (engine
l
Voltage and (5)
*
Repeats
-
Voltage and (5)
*
between
W04
(3)
1. Sets output
to relay box to 0
1. Operation
of wiper
stops
: Max. 3 V 5 20 - 30 v in regular cycle
between
W04
(1)
: Max. 3 V
Repeats
z 20 - 30 v in regular cycle
D Resistance
PC300, 350-6
of motor
:
Same
as El12
1. Sets output
Same
to washer
motor to 0
as El12
1. Operation stops
of window
washer
20-605 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM STARTING
FOR M MODE SYSTEM
FOR M MODE SYSTEM
SWITCH HEADLAMP (R.H)
WORKING LAMP (BOOM)
MONITOR
L
PANEL
I!!
!
I
NETWORK ALARM BUZZER
PO4
Ir
BUS PO9 (Xl)
(M2)
AIR CLEANER CLOGGING SENSOR
20-606 0
I
nl, RADIATOR WATER LEVEL FUEL LEVEL SENSOR SENSOR
OIL LEVEL SENSOR
TWP01424
PC300, 350-6
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
TROUBLESHOOTING
LAMP SWITCH
SWING
WIPEReWASHER
LOCK SWITCH
SWITCH
SWING REDUNDANCY
I
Ml8 (M4)
SWITCH
I
WI PER MOTOR
L-4 RELAY BOX WO8 (07018)
ENGINE THROTTLE CONTROLLER r-------1
UL a-__
a.L-L-
B___
uL__
L_______.
ENGINE OIL LEVEL SENSOR
ENGINE WATER
II lEX0
LEVEL SENSOR
Sll ENGINE OIL PRESSURE
SWITCH TWP01425
PC300, 350-6
20407 0
TROUBLESHOOTING
M-l
M-l [El011 Abnormality in error data is displayed [El021 Error in clock data is displayed *
* * *
This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting connector PO2 (for the monitor panel electrical system), fuse No. 13, connector M14, connector Mll, battery relay terminal B, or the battery terminal. (When the monitor panel power source circuit is shut off with the starting switch turned OFF.) If the service code display appears again after the system has been reset, carry out troubleshooting as follows. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
2
* After resetting system, carry out normal operations for a short time and watch the condition. (See Note 1.)
YES
II
Remedy
Defective monitor panel
Replace
Disconnection, defective contact, short circuit with ground in wiring harness between battery - battery relay B-Ml1 (l)(Z)-HI4 (I)-fuseNo.13-PO2 (female) (8)(14)
Repair or replace
-
Normal
NO
Note 1: Resetting operation: Turn the starting switch OFF. Then keep the time switch at the back of the monitor depressed, switch the starting switch ON again, and keep the time switch depressed seconds to return the system to normal. (With this operation, all the service codes in the internal memory are erased.)
M-l
Related
electric
Monitor panel
panel for 5
circuit diagram
PO2(04016)
I I
Fuse
GND
14(M6)
I
Mll(L2)
I
Power source (+24V) GND
Power source (+24V)
:
Fusible link
11 (I-11 11, BKW0272
20-608 0
PC300, 350-6
M-2
TROUBLESHOOTING
M-2 [El031 Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed * t *
If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an E service code is displayed. (If it is not displayed, the system has been reset.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Cause
2
YES
Is voltage _ YES between ~04 (2) 1’ and chassis normal? Is resistancebetween NO PO4(male)(1) - 12). _ * Turn starting (2) -chassis as shown switch ON. in the table? , * Buzzer ON: Max. 1 V * Buzzer OFF: 20 - 30 V *Turn starting l
switch OFF. Disconnect P04.
Remedy
I
Defective monitor panel
Replace
Short circuit with power source in wiring harness between PO1 (female)(7) and PO4 (female)(Z) or short circuit in wiring harness between PO4 (1) and (2)
Repair or replace
Defective buzzer
Replace
NO
Table
M-2 Related
electric
circuit diagram P04(M2)
Monitor panel
POl(O4020) a
Buzzer I
I
Buzzer
@
@ I
I Dl l(KES)
BKPW273
PC300, 350-6
20-609 0
M-3, M-4
TROUBLESHOOTING
M-3 [El041 Air cleaner clogging detected
is displayed
k YES
See M-13 f)
1 Is air cleaner clogging caution lamp on monitor flashing?
-
I 2
YES
Defective monitor panel
Replace
Failure in engine system (See Note 1)
-
Is “E” service NO code displayed? NO
* Turn starting switch ON.
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has detected symptoms of clogging in the past, so carry out troubleshooting of the engine to remove the problem.
M-4 [EI~G] Drop in engine oil Hi pressure detected
is displayed
Remedy
YES
See M-13 a)
1 Is engine oil pressure caution lamp on monitor flashing?
2
YES
-
Defective monitor panel
Replace
Failure in engine system (See Note 1)
-
Is “E’ service NO code displayed?
- Turn
starting switch ON.
NO
Note 1: The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has detected symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of the engine to remove the problem.
20-6 10
PC300, 350-6
TROUBLESHOOTING
M-5
M-5 [El081 Engine water temperature
105°C detected
is displayed
Cause
See M-13 d)
Defective monitor panel
‘Turn starting switch ON.
NO
Remedy
-
Replace
Failure in engine system (See Note 1)
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has detected symptoms of the coolant temperature reaching 105’C in the past, so carry out troubleshooting of the engine to remove the problem.
PC300, 350-6
20-611 0
TROUBLESHOOTING
M-6
M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds Ir * Ir
Check that fuses No. 10 and 13 are not blown. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.
a)
None of lamps on monitor
panel light up
Cause
YES 2 YE
1
Is voltage between PO2 (8)(14) - (l)(9) normal?
Is voltage between PO1 (9) and chassis normal? * Turn starting switch ON. *20-30V
N
Is voltage between fuse No. 13 and chassis normal?
- Turn
starting switch ON. *20-30V
b)
Some
of lamps on monitor
Defective monitor panel
3 YES ,
Is voltage between fuse No. NO 10 and chassis normal? * Turn starting switch ON. *20-30V 4 YES
* Turn starting switch ON. *20-30V
NO
I NO
Disconnection, defective contact, short circuit with ground in wiring harness between PO1 (female) (9) and fuse No. 10 Disconnection,defective contact,short circuitwith ground in wiring harness between fuse No. 10 - HO5(2) - Ml4 (2)(l) - battery relay M Disconnection, defective contact, short circuit with ground in wiring harness between PO2 (female) (8)(14) and fuse No. 13 Disconnection, defective contact, short circuit with ground in wiring harness between fuse No. 13 - H14 (2)-M11(2)(1)-battery relay B
Remedy
Replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
panel do not light up Cause
Defective monitor panel
20-612 0
inserted.
Remedy
Replace
PC300, 350-6
TROUBLESHOOTING
M-6 a) Related
Monitor oanel
M-6
electric
PO1 (04020) \ I
Starting ON signal
ly4,(L2), FIISC
switch
GND Power
circuit diagram
HO5 (L2)
I
SUPPIY
(+24V) I
GND Power
SUPP IY (+24V) I
I
PO2 (04016)
Battery
relay
TWP01426
PC300, 350-6
20-613 0
M-7, M-8
TROUBLESHOOTING
M-7 When starting switch is turned ON, monitor lighted up and do not go out
panel lamps all stay
Remedy
Cause
Defective monitor panel
Replace
M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine (model) +
immediately after replacing the monitor panel, turn the starting switch OFF, then turn it ON again and check.
Remedy
Cause
1 YES Is display of monitoring code 01 as shown in table?
* Turn
starting switch ON. * Set to monitoring code 01.
Defective monitor panel
_ Go to troubleshooting C mode (See C-14)
I NO
for
-
Table
3cc BKPGO275
20-614 0
PC300, 350-6
TROUBLESHOOTING
M-9
M-9 When starting switch is turned ON (engine stopped), items flash Ir * a)
basic check
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. )c)a
(coolant
inserted.
level) flashes
SAP00519 Ir
Check that the coolant
is at the specified
level before carrying
out troubleshooting. Remedy
Cause
Defective coolant level
sensor system (see M-261
4 YE out when short connected to PO8 + Disconnect P08. . Turn starting switch ON. _ Is there continuity between PO8 NIO (female) (2) and chassis?
- Turn -
starting switch OFF. Disconnect P08.
p Is continuity YES between Cl6 - (female j(8) and chassis as shown 2 in table?
YES IS bit (3) of - monitoring code 3 24 lighted up?
- Turn
-
- * Turn starting switch ON. to monitoring code 24.
* Set
starting switch OFF. NO * Disconnect C16, P08. . Connect ++ disconnect short connector to PO8 (female). NO
-
Defective governor, pump controller
-
N(
Defective monitor panel Defective contact, or disconnection in wiring harness between Cl6 (female) (8) - PO8 (female) (I) Defective contact, or disconnection in wiring harness between PO8 (female) (2) - chassis ground
Repair or replace
Repair or replace
Table
M-9 a1 Related
electric
circuit diagram
Governor, pump controller
Coolant level sensor
BKFW277
PC300, 350-6
20-6 15 0
M-9
TROUBLESHOOTING
bl
0
(engine
6
oil level) flashes
SAP00523 Ir
Check that the engine
oil is at the specified
level before carrying
Y‘ES
3 when PO5(female)(1)
YES
III
* Disconnect PO5 -Turn starting switch ON.
out troubleshooting.
Cause
Remedy
3efective engine oil level sensor system (see M-27:
-
Iefective governor, oump controller
3eplace
Iefective
.3eplace
monitor panel
Defective contact, or disconnection in wiring harness between Cl6 (female) (16) - E08 (5) PO5 (female) (1)
* Turn starting I NO switch OFF. * Disconnect C16, PO5. * Connect++ disconnect short connector to PO5 (female) (I).
Repair or replace
Table
1Chassis ground
M-9 b) Related
1Continuity
electric
1
circuit diagram
Engine oil level sensor
Governor, pump controller Monitor panel
C16(MIC17) E08(SWP14) 3
PO5(Xl)
.
BKPOO278
20-616 0
PC300, 350-6
M-9
TROUBLESHOOTING
cl
a 0
(hydraulic
oil level) flashes
SAP00524 *
Check that the hydraulic
oil is at the specified
level before carrying
‘ES
3 YES
when PO9(female) (1)
* Disconnect PO9. * Turn starting switch ON.
M-9 c) Related
Cause
Remedy
Defective hydraulic oil level sensor system (see M-29)
-
Defective governor, pump controller
Defective h * Turn starting I switch OFF. NO - Disconnect C16, PO9. - Connectdisconnect short connector PO9 (female) (1).
electric
out troubleshooting
monitor
Replace
panel
Defective contact, or disconnection in wiring harness between Cl6 (female) (9) and PO9 (female) (1)
Replace
Repair or replace
to
circuit diagram
Monitor panel Aetwork
Governor, pump controller C16(MIC17)
Hydraulic oil level sensor PO9(Xl) &---
BKP00279
PC300, 350-6
20-617 0
TROUBLESHOOTING
M-IO
M-10 Preheating lights up Before Always
+
+
carrying connect
is not being used but
0m
(preheating
monitor)
SAP00526
out troubleshooting, any disconnected
check that all the related connectors are properly connectors before going on the next step.
inserted.
Cause
2
YES
Defective
1V
* Disconnect terminal RI. *Turn starting switch ON. * Max. 1 V
M-10 Related
Defective
electric
panel
Short circuit with power source in wiring harness between starting switch RI -X07 (3) - HI3 (6) PO1 (femaleJ(l8) or El1 (female)(l) - E08 (3) H13 (female)(6)
~~
* Max.
monitor
-
starting
switch
Remedy
Replace
Repair or replace
Replace
circuit diagram Starting
switch B
BR Rl R2 C ACC
0
x07 (MIC 1 Monitor Pane I
PO1 (04020)
1
H13 (S16) 3
E08 (SWP14) a
El1 (X2)
Heater
-
plug
3 3
TWP01427
20-618 0
PC300, 350-6
M-l 1
TROUBLESHOOTING
M-II Ir + *
When starting switch is turned ON and engine is started, check items flash
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Check both the alternator system and the engine oil pressure system.
a) Alternator
inserted.
system
3
YES
Does monitoring YES code 43 show a _ 2 value of greater than IOO? Is voltage p YES between CO3 (12) _ *Start engine and NO and chassis run at mid-range 1 normal? or above. Is voltage between * Set to monitoring code 43. Start engine and alternator terminal run at mid-range NO R and chassis or above. normal? .20-30V Start engine and rr;;;;i,d-range NO l
l
basic
Defective governor, pump controller
Replace
Defective monitor panel
Replace
Defective contact, or disconnection in wiring harness between alternator terminal R E08 (2) - CO3 (female) (12)
Repair or replace
Defective alternator
Replace
*20-30V
M-II
a) Related
electric
Monitor panel
circuit diagram
Governor, pump controller c03(04020)
EOB(SWPl4)
Alternator
BKPC4282
PC300, 350-6
20-6 19 0
M-11
TROUBLESHOOTING
b) Engine oil pressure system * When engine oil pressure I) Low-pressure sensor
is normal.
Defective oil pressure sensor (for low pressure)
*Engine idling
Is there continuity between Cl6 II
High-pressure
N Defective monitor oanel
I
sensor
Defective oil pressure sensor (for high pressure)
YES
. Engine at high idling
2
M-II
,_ between Cl6 NO (female) (7) and chassis?
b) Related
Contact of chassis ground with wiring harness between Cl6 (female) (7) - E08 (7) sensor
YES
Is there continuity
* Turn starting switch OFF. * Disconnect sensor wiring harness Cl6
electric
Replace
NO
Engine at low idling *Set to monitoring code 24.
l
1r
When engine is runningat high idling and wiring harness of oil pressuresensor is removed,does displaygo out?
Repair or repalce
Defective governor, pump controller
* Turn starting switch OFF. * Disconnect sensor wiring harness C16.
2)
Contact of chassis ground with wiring harness beteen Cl6 (female) (15) - E08 (8) sensor
Ir
’ zat row
Replace
3 Is bit (2) of No monitoring code 24 lighted up? Engine at high idling * Set to monitoring code 24. l
YES
Remedy
Replace
Repair or replace
Defective governor, pump controller
Replace
Defective monitor panel
Replace
-
NO
circuit diagram
Governor, pump controller
E08(SWP14) Engine oil pressure sensor (high pressure)
Engine oil pressure sensor (low pressure)
BKPOO283
20-620 0
PC300, 350-6
M-12
TROUBLESHOOTING
M-12
Sr * j,
When starting switch is turned ON (engine stopped), items, emergency items flash (battery, engine oil pressure lamps do not light up)
caution
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Check both the alternator system and the engine oil pressure system.
a) Alternator
system
3
YES 1 _ Is voltage between alternator terminal R and chassis normal? * Disconnect terminal R. * Turn starting switch ON. * Max. 1 V
Is voltage between Co3 (female) (12) and chassis normal? + Disconnect C03. *Turn starting switch ON. * Max. 1V
YES
Defective governor, pump controller
Does monitoring YES code 43 show a 2 value of greater than lOO? _
,
Defective monitor panel
‘Startengineand NO run at mid-range speed or above. * Set to monitoring code 43.
Short circuit with power source in wiring harness between CO3 (femaleHl2) - E08 (2) alternator R
NO
I NO
M-12 a) Related
electric
Monitor panel
PC300, 350-6
inserted.
-
Defective alternator
Replace
Repair or replace
Replace
circuit diagram
Governor, pump controller CO3(04020)
E08(SWP14)
20-621 0
M-12
TROUBLESHOOTING
b) Engine oil pressure sensor system * When engine oil pressure is normal. 1) Low-pressure sensor
Remedy
Cause
Defective governor, pump controller
Defective
Is there continuity bstweensensor terminal and chassis?
* Turn starting switch OFF. * Disconnect Cl6 and sensor wiring harness.
* Turn starting switch OFF. Remove sensor wiring hanrness.
1
24.
NO
NO
monitor
panel
Defective contact, or disconnection in wiring harness between Cl6 (female) (15) - E08 (8) sensor
Repair or replace
Defective oil pressure sensor (low pressure)
Replace
l
2)
High-pressure
sensor
Cause
3
YES
III
Is 1
L
YE
NO
1
there continuity between sensor terminal and chassis?
* Turn starting switch OFF. * Remove sensor wiring harness.
switch OFF. * Disconnect Cl6 and sensor wiring harness.
NO
I
Defective governor, pump controller
Defective
monitor
1
Replace
panel
Defective contact, or disconnection in wiring harness between Cl6 (female) (7) - E08 (7) sensor Defective oil pressure sensor (high pressure)
UO
Remedy
Replace
Repair or replace
Replace
M-12 b) Related electric circuit diagram
Monitor panel
Governor, pump controller C16(04017) Engine oil pressure sensor (high pressure)
Engine oil pressure sensor (low pressure)
BKF’O0283
20-622 0
PC300, 350-6
M-13
TROUBLESHOOTING
M-13
* *
When starting switch is turned ON and engine is started, _ caution items, emergency items flash (when there is no abnormality in engine or items to check before troubleshooting)
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. (engine
a) 0 6
oil pressure)
inserted.
flashes
SAP00520 *
Check that the engine oil pressure carrying out troubleshooting.
is normal
before Cause
See M-II
b1 a
(coolant
b)
Remedy
-
level) flashes
SAPW519
Ir
Check that the coolant out troubleshooting.
level is normal
before carrying
I
Cause
See M-9 a)
(battery SAP00522
charge)
flashes
Cause
See M-l 1 a)
PC300, 350-6
Remedy
-
Remedy
-
20-623 0
M-13
TROUBLESHOOTING
d)
(coolant
01
temperature)
flashes
SAP00527
Check that the coolant temperature rying out troubleshooting.
*
is normal
before car-
2When PO7 is YI3 disconnected, . does only level 1 (left end) of gauge 1 display light up?
-
_ -
* Start engine.
NO
YES
3 Is resistance between CO3 (female) (1) -(16), (1) (16) -chassis normal?
* Turn starting switch OFF. * Disconnect CO3 and P07. * Max. 1 MR
I
Defective coolant temperature sensor system (see M-26)
-
Defective governor, pump controller
Replace
Short circuit of wiring harness between CO3 (female) (1) - E08 (6) PO7 (female) (1) and wiring harness between CO3 (female) (16) - EO8 (11) -PO7 (female) (2)
-
NO
* Start engine and run at mid-range or above.
Remedy
Cause
Defective monitor panel
Repair or replace
Replace
NO
M-13 dl Related
electric
circuit diagram Governor, pump controller CO3(04020)
dletwork
Coolant temperature GND
E08(SWP14)
Coolant temperature sensor
PO7(X2)
G @ BKPOO284
e)
!EB
(fuel level) flashes
*
Check that there shooting.
is fuel before
carrying
out troubleDefective fuel level sensor system (see M25)
YES 2
l
Start engine.
Remedy
Cause
SAP00528
WhenPO6(female)(1) to chassis YEiS is connected ground,do alllampsto level14 (rightend)of gaugedisplaylightup? 1 p * Start engine. * Wait for aPProx. NO 2 minutes. (The fuel level may vary, so the display is given a time delay.)
3 Is voltage between CO3 (2) and (16) normal?
Defective governor, pump controller
YES
-
Defective contact or disconnection in wiring harness between CO3 (female) (2) and PO6 (female) (1)
* ConnectPO6(female) NO (I) to chassisground. *TurnstartingswitchON. - Max. 0.3 V
Defective monitor panel
-
Replace
Repair or replace
Replace
NO
M-13 e) Related
electric
/Vlonitor p;nel
circuit diagram Governor, pump controller CO3(04020)
I
\
PO6(Xl) Fuel level sensor
hetwork
BKPO0285
20-624 0
PC300, 350-6
M-13
TROUBLESHOOTING
fl
w
c__~ a
(air cleaner
clogging)
flashes
SAP00521 *
Check that the air cleaner
is not clogged
before carrying
out troubleshooting.
Cause
Remedy
Defective air cleaner clogging sensor
when PI 1 (female) is connected to PI2 * Start engine.
h
4 YE Ir YES Is bit (6) of - monitoring code _ 3 24 lighted up? Is continuitybetween YES Cl6 (female)(17) and _ * Start engine. NI chassisas shownin * Set to monitoring 2 table? code 24. Is there continuity p . Turn starting between PI2 NO switch OFF. (male) and Disconnect C16, Pll, and P12. chassis? * Connectc*disconnect Pll (female) to * Turn starting P12 (male). ___ switch OFF. ..a IYU Disconnect P12. l
l
M-13 f) Related
electric
Monitor panel
Defective governor, pump controller
Defective monitor panel Defective contact or disconnection in wiring harness between Cl6 (female) (17) and Pll (female) Defective contact or disconnection in wiring harness between P12 (male) and chassis ground
Repair or replace
Repair or replace
circuit diagram
Governor, pump controller C16(MIC17) Pll Air cleaner clogging P12
PC300, 350-6
Air cleaner clogging sensor
20425 0
M-14,
TROUBLESHOOTING
M-14
* * *
When starting switch is turned ON (engine stopped), does not sound for ‘l second Caution item flashes but buzzer does not sound
M-15
buzzer
Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge or fuel level. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
I *
YES When PO1(female) YES (7) and chassis are connected, does buzzer sound? ,
~Is resistance between PO4 _ ‘(male) (1) and (2) normal? * Turn starting switch OFF. * Disconnect P04. *200-300 R
M-15 f
* *
*DisconnectPOI. * Turn starting switch ON.
3
YES
I
Is voltage _ between PO4 NO (female) (1) and chassis normal? * Disconnect ~04. * Turn starting switch ON. *20-30V
NO
Repair or replace
Disconnection, defective contact, short circuit with ground in wiring harness between PO4 (female) (I 1 and fuse No. 13 Defective buzzer
is displayed
on monitor
When the buzzer sounds continuously. If the buzzer sounds intermittently, carry out troubleshooting M-14.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 1 YES When PO1 is disconnected, does buzzer sound?
M-14,
Defective contact or disconnection in wiring harness between PO1 (female) (7) and PO4 (female) (2)
Repair or replace
Replace
NO
No abnormality
* Disconnect POI. * Turn starting switch ON.
Replace
Defective monitor panel
2
but buzzer sounds
Cause Contact of chassis ground with wiring harness between PO1 (female) (7) and PO4 (female) (2), or defective buzzer Defective monitor panel
Remedy
Repair or replace
Replace
NO
15 Related
electric
circuit diagram
Buzzer
TWP01428
20-626 0
PC300, 350-6
M-16
TROUBLESHOOTING
M-16 Night lighting on monitor panel does not light up (liquid crystal display is normal) *
When the front lamp and working lamp light up normally.
Cause
Blown bulb or defective contact of bulb
YES
is there defective
Remedy
Replace bulb, or clean (defective contact)
Defective monitor panel
Replace
Defective contact, or disconnection in wiring harness between PO1 (female) (8) -X01 (1) MO7 (female) (I)
Repair or replace
* Remove bulb. . Check visually h for blown bulb.
code 49.
M-16
Related
electric
Monitor
* Turn starting switch ON. . Turn light switch ON. l20-30V
circuit diagram
panel Light switch
PO1(04020)
I
NO
\ Light
I @
XOl(MIC21) a @
M07(M2) (OFF/ ON/ 01 2
Fuse
BKPOO287
PC300, 350-6
20-627 0
M-17. M-18
TROUBLESHOOTING
M-17 *
Coolant temperature
gauge does not rise
If the coolant temperature actually does not rise, check the engine system. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
* *
Remedy
Defective coolant temperature sensor system (see M-26)
YES
Id When short connector is connected to PO7
3 YES Does monitoring YES_ code 41 show a _ value of less than 2 50?
(female), do level lamps on gauge go up in turn and then all lamps go out? * Disconnect P07. - Turn starting switch ON.
Is therecontinuity betweenCO3 (female) - (1) and (1s)when
NO
~0
*TurnstartingswitchON. *Set to monitoring
short connector is connected to PO7
* Turn starting switch OFF. * Disconnect CO3 and P07.
. Connect short connector to PO7 (female). code 41.
4 YES Is there continuity between CO3 NO (female) (1) and PO7 (female) fl)?
*
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between CO3 (female) (16) - E08 (11) PO7 (female) (2)
Repair or replace
Repair or replace
Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
*
Replace
Defective contact or disconnection in wiring harness between CO3 (female) (1) - E08 (6) PO7 (female) (1)
* Turn starting switch NO OFF. * Disconnect CO3 and PO7.
M-18
Defective monitor panel
YES 1 When PO7is disconnected,does coolanttemperature gauge display appear?
2
3 YES
l
* Turn starting switch OFF. * Disconnect C03, PO7.
Remedy
Iefective coolant emperature sensor system (see M-26) Iontact of chassis rround with wiring rarness between CO3 female) (I) - E08 (6) ‘07 (female) (1)
YES
Is there continuity . Disconnect P07. between CO3 Turn starting NO (female) (I) and switch ON. chassis?
Cause
Does monitoring code 41 show a NO value of less than 50? * Turn starting switch ON. * Set to monitoring code 41.
Xepair or .eplace
Defective governor, pump controller
Replace
Defective monitor panel
Replace
NO
M-17, 18 Related electric circuit diagram Monitor panel
I
I
Governor, pump controller CO3(04020) I 1 I Coolant @ temperature GND @
E08(SWP14)
I
\I
PO7(X2) I/
I
Coolant temperature sensor
BKP00284
20-628 0
PC300, 350-6
M-19,
TROUBLESHOOTING
M-19
M-20
Fuel level gauge always displays FULL
Jc
Check that there is actually remaining fuel before carrying out troubleshooting. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on the next step.
Defective fuel level sensor system (see M-25)
YES
YES
2 *Turn starting switch ON. N *Wait for approx. 2 minutes. (The fuel level may vary, so the display is given a time delay.)
M-20 j, * *
Cause
Is there continuity
chassis?
r
H
. Turn starting switch OFF. - Disconnect C03, P06.
Repair or replace
Defective monitor panel
Replace
Defective governor, pump controller
NO
* Turn starting switch ON. * Set to monitoring code 42.
Contact of chassis ground with wiring harness between CO3 (female) (2) and PO6 (female) (I)
Fuel level gauge does not give display
Check that there is actually remaining fuel before carrying out troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
Remedy
Cause
Defective fuel level sensor system (see M25)
-
1 3 when PO6Ifemale)
* Disconnect P06. *Turn starting switch ON.
F
M-19, 20 Related
Monitor r----T
YES
Does monitoring YES code 42 show a 2 value of less than Is there conttnurty408? between co3 (femaleI A 1 (21and chassiswhen _ * Turn starting switch ND ’ PO6(female)(l) and ON. chassisground are connected7 , * Set to monitoring code 42. *Turn starting NO switch OFF. * Disconnect C03, P06.
electric
Replace
Defective monitor panel
Replace
Defective contact, or disconnection in wiring harness between CO3 (female) (2) and PO6 (female) (1)
Repair or replace
circuit diagram Governor, oumo controller C03id4026)
anel
r-----T /Newark
Defective governor, pump controller
2
Fuel level
PO6(Xl) II
Fuel level sensor
2
BKP00285
PC300, 350-6
20-629 0
M-21,
TROUBLESHOOTING
M-21 * * *
Swing lock switch is turned ON (LOCK) but monitor) does not light up
Carry out this troubleshooting only if the swing lock is actually Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.
M-22
8 (swing lock SAT00098
being actuated.
II Defective monitor panel Is voltage betweenP05and chassis as shown in table?
Defective contact disconnection in harness between (female) (5) -X01 X05 (male)
NO
* Turn starting switch ON.
M-21 Related
electric
circuit diagram
* * *
II
I
YI 1 between Cl7 (8) and chassis as shown in table? * Turn starting switch ON.
.
Is bit (6) of monitoring code 21 lighted up?
BKFQ0288
-
8 (swing lock
Swinq prolix switch is turned ON (prolix), but moniio;) does not flash
Carry out this troubleshooting only if the swing prolix is actually being actuated. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 2 YES
Repair or replace
Swing lock switch
-775 M-22
or wiring PO1 (4) -
Replace
SAT00098
Cause
Remedy
Defective monitor panel
Replace
Defective governor, pump controller
Replace
-
NO Turn starting switch ON. * Set to monitoring code 21. l
Defective contact or disconnection in wiring harness between Cl7 (female) (8) and prolix switch (4)
NO
Table
M-22 Related
Swing
prolix switch
ON
Swing
prolix switch OFF
Max.
electric
circuit diagram
Repair or replace
Swing prolix switch
1 V
20 - 30 V
BKPW289
20-630 0
PC300, 350-6
TROUBLESHOOTING
M-23
M-23, M24
Service meter does not advance while engine is running
Cause
YES See M-13 d)
1 Does battery charge caution lamp flash?
-
* Start engine and NO run at mid-range or above. - Set to monitoring code 43.
Defective monitor panel
Replace
Defective governor, pump controller
Replace
When starting switch is at OFF and time switch is pressed, time and service meter are not displayed
Cause
1 YES When starting switch is ON, is panel display normal? * Turn starting switch ON.
PC300,
-
2 YES
Does monitoring . Start engine and _ code 43 show a NO value of greater run at midthan IOO? range or above.
M-24
Remedy
350-6
Remedy
Replace
_
NO
See M-6
-
20-63 1 0
M-25
TROUBLESHOOTING
M-25 Sr
Defective fuel level sensor system
Remove
the fuel level sensor when
carrying
out the troubleshooting.
3 YES
Cause
Remedy
Interference with sensor inside tank
Replace (See Note 2)
Defective contact of connector
Clean connector or replace
YES Is there any large -
2
crack, chip, or damage to float?
YES Does arm move smoothly?
-
NO
1 When float
Defective sensor (See Note 2)
is
moved up and
NO
down, is resistance between connector (1) and flange as shown in table?
YES
4
Check wiring - harness visually. NO Is it broken?
-
Replace
Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)
Replace sensor
Defective sensor
Replace
NO
Table Top (FULL) stopper Bottom
(EMPTY)
position
stopper
position
Approx. Approx.
12 Q or below 85 - 110 Q
p$p~.;
r:
TOPFULL) Bottom (EMPTY) ELPOO290
Note 1: Difference between fuel level and gauge display For gauge display position 14 (FULL), the amount of fuel is 78-100%; and for display position 1 (EMPTY) it is below 14.5%. If the chassis is at an angle, the displayed amount of fuel will be different from the actual amount. Therefore, when checking, stop the machine at a horizontal place and wait for at least 2 minutes before checking the gauge. (The display is given a time delay so that the gauge can deal with sudden changes in the fuel level.) Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be careful when installing. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
20-632 a
PC300, 350-6
TROUBLESHOOTING
M-26
M-26
Defective
coolant temperature
sensor system
I
temperature sensor
2 YES Check wiring - harness visually. NO IS it broken?
-
NO
Cause
I
Remedy
Defective contact of connector (See Note 1)
Clean connector or replace sensor
Disconnection in wiring harness (See Note 2) (defective clamp) (external force applied)
Replace sensor
Defective
Replace
sensor
Table Normal
temperature 100°C
(25°C)
Approx. Approx.
37 - 50 kR 3.5 - 4.0 kR
Note
1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
PC300, 350-6
20-633 0
M-27
TROUBLESHOOTING
M-27 *
Defective engine oil level sensor system
Remove
the engine
oil level sensor when
carrying
out troubleshooting.
Remedy
Cause
Defective movement float due to dirt
YES 2 Is any foreign YES material (dirt) stuck to moving part of float? 1 When float is moved up anddown,is resistance betweenconnector (1) andflangeasshownin Table l?
_ 3 YES Is there any large - crack, chip, or NO damage to float? NO
4 YES Check wiring - harness visually. (r ) Is it broken?
-
of
Clean
Resonance of mount (See Note 2)
Replace senso (See Note 4)
Defective contact of connector (See Note 2)
Clean connector or replace
Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)
Replace senso
Defective sensor
Replace
NO
Table Float UP
Max. 1 Q
Float DOWN
Min. 1 MQ
UP
I
Note 1: Variations in oil level The oil level may change according to the angle of the machine, the engine speed, or the temperature of the oil, so if there is any display, check the oil level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
20-634 0
PC300, 350-6
M-28
TROUBLESHOOTING
M-28 Defective coolant level sensor system * Remove the coolant level sensor when carrying out troubleshooting.
Remedy
Cause
YES
Defective movement float due to dirt
2
YES
Is any foreign material (dirt) stuck to moving
3 YES
of
Clean
Resonance of mount (See Note 2)
Replace sensor (See Note 4)
Defective contact of connector (See Note 2)
Clean connector or replace
crack. chio. or
1
NO[damage to’float? resistance between connector (1)and(2)as showninTablel?
11 NO
4 YES
harness visually.
Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)
Defective sensor
Replace sensor
Replace
NO
Table -1
BLP00293
Note 1: Variations in coolant level The coolant level may change according to the angle of the machine, or the swaying of the machine, so if there is any display, check the coolant level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
PC300, 350-6
20-635 0
M-29
TROUBLESHOOTING
M-29 Ir
Defective
Remove
hydraulic oil level sensor system
the hydraulic
oil level sensor when
carrying
out troubleshooting.
Remedy
Cause
Defective movement float due to dirt
YE
~
of
Clean
Resonance of mount (See Note 2)
Replace sensor (See Note 4)
Defective contact of connector (See Note 2)
Clean connector or replace
1
resistance
between
NO
4 YES lCheckwiring= ,,I harness visually. kUI Is it broken?
H
Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied)
Replace sensor
11 Defective sensor
Replace
NO
UP
t
1 DOWN
BLFOO292
Note 1: Variations in hydraulic oil level The hydraulic oil level may change according to the angle of the machine, or the swaying of the machine, so if there is any display, check the hydraulic oil level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action.
20-636 0
PC300, 350-6
M-30
TROUBLESHOOTING
M-30 * *
Wiper does not work, or switch is not being used but wiper is actuated (include E112, El131
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
a) Wiper does not work
+ *
Check that fuse 7 is normal. Carry out this troubleshooting
if service code [El121 or [El131 is displayed.
YE.S
I -
Do bits (31or (4) of ES monitoringcode I471 liaht UDunder same c&dit/ons as Item Z?
I
Same as Item 2.
Do bits (I) and (2) of monitoring YES code 1481 go out Iwhen wiper
I
* Turn starting switch ON. Turn wiper switch to ON or INT. * Set to monitoring code I481.
* Front window: Closed position * Turn starting switch ON. Set to monitoring code 1481. l
20-638 a
Iurns
;~~~
switch * Turn starting switch OFF. * Disconnect P02, W04, W08. YES
I
6
II
Is service code [El 121 or [El 131 hIO being displayed? p *Turn starting switch ON. * Set to service code display mode.
-
YES pDo bits (2) or (3) ’ ,of monitoring _ code f4CI light up _ NO when wiper switch is turned OFF? * Turn starting switchN$N. * Turn wiper switch OFF. * Set to monitoring code [4Cl.
9 YES
l
monitoring code
1
Is resistancebetween YES pins of PO2 (female1 and W04 (male) as 8r shown in Table 2?
,
* Turn starting switch OFF.* Disconnect M 18.
*Turn starting switch OFF. . Disconnect P02, WOA
‘NO
NO
11 YES Is resistance between
YES wtc k”&) (31- p02 - tfemaleli13l, WlOImale 10 (4)- PO2(fern&JIll pprmat? Is resistance NO * Turn starting between WlO switch OFF. NO (female) (3) and * Disconnect W04, P02. (4) normal? . Max. 1 R *Turn starting switch OFF. NO * Disconnect WlO.
PC300, 350-6
M-30
TROUBLESHOOTING
Cause
tReplace
Defective relay box
Defective contact or disconnection in wiring harness with defective resistance Short circuit with power source in wiring harness between PO2 (female) (3) and W08 (female) (3). or between PO2 (female) (11) and W08 (female) (2) Defective contact or disconnection in above wiring harness
Repair or replace
Repair or replace
Repair or replace
Defective monitor panel
Replace
Defective monitor panel
Replace
Defective contact or disconnection in wiring harness with defective resistance
Repair or replace
Defective wiper, washer switch
Defective monitor panel Defective contact or disconnection in wiring harness between PO2 (female) (13) and WlO (male) (3), or between PO2 (female) (1) - H14 (2) chassis, or between WlO (male) (4) - H15 (1) chassis Defective rear limit switch, or front window is open
PC300, 350-6
Replace
Repair or replace
Inspect or replace
20-639 0
TROUBLESHOOTING
Table 1 Timing chat-t when
M-30
wiper
switch
is at ON
Item
Set time
Symbol
Length of pause until next actuation
Tla
Safety circuit during operation of wiper [safety + function (l)l
Tsa
Length of pause when
1.5sec
Safety circuit during stowing of wiper [safety function (2)I
1Osec
TKP00827
Timing Actuation of wiper snitch
chart when wiper
switch
is at INT
ON OFF
Item
Symbol
I
____________________--__--------_____________
Set time
I
Length of pause until next actuation
Tla
4sec
Safety circuit during operation of wiper [safety function (l)]
Tsa
1 Osec
Safety circuit during stowing of wiper [safety function (2)I
TSP
1Osec
----I Tlr[ NO,.,, rot,ti0n ON R%% OFF rotltion 08 ON
TI1 -------
----_______
I
OFF: Max. 3 V ON: 20 - 30 V
Table 3 Resistance value
W,i;y;Itech
Between W04 (female) (3) and W08 (female) (6) Between W04 (female) (4) and PO2 (female) (5)
Max. 1 R
Between W04 (female) (5) and PO2 (female) (1)
OFF mode
Min. 1 MR
Between W08 (female) (2) and PO2 (female) (11) Between W08 (female) (3) and PO2 (female) (3)
0
Max. 1 R
Ml8
1
(female)
(1) - (4)
(1) - (4)
Between (1) - (12)
Between
(2) - (4)
Between (4) - (12)
-
(2)
Between
(1)
-
(1) - (4)
1 Between
(1) - (12)
1Between
(2) - (4)
1 Between
(4) - (12)
-
(2)
Between
(1)
-
(4)
Between (1) - (4)
Between (1) - (12)
Between
Between (4) - (12)
(2) - (4)
Min. 1 MR
(4)
Between
Between (1) ON mode
) feRe;,yc
PO2 (female) Between
Between
Between (1)
Between W04 (female) (6) and PO2 (female) (6) and GND
(
Between (1) - (2)
Between W04 (female) (1) and W08 (female) (7)
20-640
I
TKP00828
Table 2
Between W04 (female) (l).(3),(4).(5),(6)
1
Min. 1 M&2
1 Max. 1 R Min. 1 MR
PC300, 350-6
I
M-30
TROUBLESHOOTING
M-30 Related
electric
circuit diagram
MOTOR DRIVE (REVERSE) WIPER SWITCH (ON) WIPER SWITCH (WASHER) LIMIT SWITCH (WI POWER SUPPLY WASHER DRIVE MOTOR DRIVE (NORMAL) WIPER SWITCH (INT) LIMIT SWITCH (WINDOW) POWER SUPPLY LIMIT SWITCH (P) HI2 616)
WIPER. WASHER
RELAY BOX
PC300, 350-6
SWITCH
TWP01429
20-641 0
M-30
TROUBLESHOOTING
b)
Wiper
switch
is not being operated
but wiper
is actuated
Remedy
Cause
Ir
4YEI I IS resistance between
Defective
monitor
panel
Replace
YE
YE 2
;
Do bits (1) or (2) of monitoring code 1481 go out?
. Turn starting switch OFF. * Disconnect M18.
rt
1
r
Does bit (4) of monitoring code f481 light up?
* Turn starting switch ON. * Set to monitorin< code 1481.
I Is resistance between pins of Ml8 (female) (1). (2). (4) as shown in Table l?
NC * Turn starting switch OFF. * Disconnect P02, W04 W08. NO
YES
IDo bits (3) or (4) 1 1 of monitoring YES , code I471 light 6 up? ~ Do bits (2) or (3) * Turn starting of monitoring switch ON. NO code [4CI light 7 YES - Set to up? Is voltage between monitoring code W06 (female) (1) and * Turn starting 1471. NE (61,or between (1) switch ON. and (7) normal? * Set to monitoring code * Disconnect W06. NC [4Cl. * Turn starting
2
Table
1 Between W04 (female) (I) and W08 (female) (7)
1
1 Between W04 (female) (3) and W08 (female) (6)
1
1 Between W04 (female) (4) and PO2 (female) (5)
1
Wiper
Defective
monitor
Replace
panel
Replace
switch
Max. 1 a OFF mode
and GND
Min. 1 MD
Between W08 (female) (2) and PO2 (female) (11) Between W08 (female) (3) and PO2 (female) (3)
Repair or replace
Defective
Replace
relay box
Short circuit with power source in wiring harness between W08 (female) (6) and W04 (male) (l), or between W08 (female) (71 and W04 (male) (3)
Ml8 (female) Between (1)
Between W04 (female) (6) and PO2 (female) (6) Between W04 (female) (1).(3),(4L(5).(6)
Short circuit with ground in wiring harness between PO2 (female) (3) and W08 (female) (3), or between PO2 (female) (11) and W08 (female) (2)
Repair or replace
3
INT mode
Between W04 (female) (5) and PO2 (female) (1)
0
wiper, washer
5
Resistance value
20-642
Defective switch
Repair or replace
* Turn starting switch ON. * Set to monitoring code 1481.
switch ON. * Max. 1 V
Table
Defective contact or disconnection in wiring harness with defective resistance
ON mode
-
PO2 (female) (2)
Between
(1)
-
Resistance (4)
Min. 1 MD
Between (1) - (4)
Between (1) - (12)
Max. 1 R
Between
(2) - (4)
Between (4) - (12)
Min. 1 MR
Between
(1)
-
(2)
Between
(1)
-
(4)
-1Between
(1) - (4)
Between (1) - (12)
Between
(2) - (4)
Between (4) - (12)
Between
(1) - (2)
Between
Max. 1 R
(1) - (41
Between (1) - (4)
Between (1) - (12)
Between (2l-
Between (4) - (12)
Max. 1 R (4)
Min.1M.Q
Min. 1 MR
PC300,
350-6
M-31
TROUBLESHOOTING
M-31
Washer motor does not work, or switch is not being used but washer motor is actuated (include El141
*
Before carrying out troubleshooting, check that all the related Always connect any disconnected connectors before going on to the next step. a) Washer motor does not work Ir Check that fuse 5 is normal. a)-1 When El14 is displayed
connectors
are properly
inserted.
*
2 YES YES 1 Is voltage between PO2 (female) (2). (10). M28 (female) (1) and chassis normal?
Is resistance of washer motor normal? p * Turn starting
NO
switch OFF. * Disconnect W28. . Check as nindividual part. *5-20R
* Turn starting switch OFF. * Disconnect P02, No M28. * Connect T-adapter to PO2 (female) or M28 (female). * Turn starting switch to ON or OFF. Max. 1 V
Remedy
Cause
-
Defective monitor panel
Replace
Defective washer motor (internal short circuit)
Replace
Short circuit in wiring harness between PO2 (female) (2), (9) and M28 (female) (I)
Replace
Remedy
Cause
l
a)-2 When
El 14 is not displayed YES
Defective monitor panel
Replace
Defective switch
Replace
3
Y
2
(female) (21, (IO) and (9) normal?
box W08 (16) and
I
* Turn starting switch OFF. . Disconnect W08. * Max. 1 !J
* Turn starting switch OFF. * Insert T-adapter in P02. * Turn starting switch ON. -Wiper washer switch at [WASH II or [WASH III: Max. 1 V *Wiper washer switch at [OFF]: 20-30V
Is voltage between PO2 (female) (5) and (9) normal?
4 To1 _
* Turn starting switch OFF. * Insert T-adapter in P02. * Turn starting switch ON. *Wiper washer switch at [WASH I] or [WASH III: Max. 1 V *Wiper washer switch at [OFF]: 20-30V
6
Is resistance between Ml8 NO (female) (1) and (3) normal? * Turn starting switch OFF. . Disconnect M18. * Check as individual part. *Wiper washer switch at [WASH II or [WASH III: Max. 1 R Wiper washer switch at [OFF]: Min. 1 Ma YES
EH_
5YE
From A jGJ%&q[
N Turn starting switch OFF. * Disconnect M18. * Max. 1 Q l
Short circuit with ground or disconnection in wiring harness between PO2 (female) (21, (10) and M28 (I) Short circuit with ground or disconnection in wiring harness between fuse 5 and M28 (16)
NO * Disconnect M28. * Connect T-adapter. Turn starting switch ON. *20-30V
NO
PC300, 350-6
washer
l
l
,
wiper
Repair or replace
Repair or replace
Defective relay box (internal disconnection)
Replace
Short circuit with power source or defective contact in wiring harness between PO2 (5) -X01 (IO) - Ml8 (3)
Repair or replace
Disconnection in wiring harness between Ml8 (male) -X01 (21) chassis ground
Repair or replace
20-643 0
TROUBLESHOOTING
b)
Switch +
M-31
is not being operated
For this failure 1
mode,
El14
but washer
is actuated
Cause
Remedy
is not displayed.
YES
Defectivemonitor panel
Is resistance
PO2 (female) (3). Ml8 (male)(3),WO8(13) and chassis normal?
Replace
between
Short circuit with ground inwiring harness between PO2 (female)(5) -M18(male)-W08 (female)(13)
starting NO switch OFF.- DisconnectP02,M18,W08. - Min.1 MR CauseRemedy *Turn
M-31
Related
electric
Repair or replace
circuit diagram CONNECTOR FOR CHECK M46 CM31
MOTOR DRIVE (REVERSE) WIPER SWITCH (ON) WIPER SWITCH (WASHER) LIMIT SWITCH (WI POWER SUPPLY WASHER DRIVE MOTOR DRIVE (NORMAL) WIPER SWITCH (INT) LIMITSWITCH (WINDOW) POWER SUPPLY MIT SWITCH (PI H12 LSI 61
DOI HI5 (LZI
(KESI
WASHER MOTOR
WIPER. WASHER
RELAY BOX
20-644 0
SWITCH
TWP01429
PC300, 350-6
M-32
TROUBLESHOOTING
M-32 * Ir * 1:
Electric grease gun does not work
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Check that there is grease before starting troubleshooting. Check that fuse No. 1 for the electric grease gun is normal.
inserted.
Cause
Defective
2 YES YES 1 Is voltage between electric grease gun _ connector CN (I) and chassis normal? * Turn starting switch ON. *20-28V
M-32 Related
Turn starting switch OFF. Disconnect CN. . Max. 1R
l
electric grease
gun
Is resistance between electricgrease gun connector CN (female1 (2)andchassisnormal? NO
Repair or replace
Defective contact or disconnection in wiring harness between CN (female) (2) and chassis
Repair or replace
Defective contact or disconnection in wiring harness between CN (female) (1) and fuse No.
Repair or replace
l
NO
electric
circuit diagram
Battery
Cable Special fuse (20A) for electric grease gunA
Electric grease gun
(Inside battery case)
PC300, 350-6
20-645 a
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................. PRECAUTIONS WHEN CARRYING OUT OPERATION .......................................... SPECIAL TOOL LIST.. ................................. SKETCHES OF SPECIAL TOOLS ............... STARTING MOTOR ASSEMBLY Removal and Installation .................... ALTERNATOR ASSEMBLY Removal and Installation .................... ENGINE OIL COOLER ASSEMBLY Removal and Installation .................... FUEL INJECTION PUMP ASSEMBLY Removal ................................................. Installation ............................................ WATER PUMP ASSEMBLY Removal and Installation .................... NOZZLE HOLDER ASSEMBLY Removal and Installation .................... TURBOCHARGER ASSEMBLY Removal and Installation .................... THERMOSTAT ASSEMBLY Removal and Installation .................... ENGINE FRONT SEAL Removal ................................................. Installation ............................................ ENGINE REAR SEAL Removal and Installation .................... GOVERNOR MOTOR ASSEMBLY Removal and Installation .................... CYLINDER HEAD ASSEMBLY Removal ................................................. Installation ............................................ AFTERCOOLER ASSEMBLY Removal and Installation .................... HYDRAULIC COOLER ASSEMBLY Removal ................................................. RADIATOR, HYDRAULIC COOLER ASSEMBLY Removal ................................................. Installation ............................................ ENGINE, MAIN PUMP ASSEMBLY Removal ................................................. Installation ............................................
PC300, 350-6
30- 3 30- 5 30- 7 30-10 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-25 30-26 30-28 30-31 30-32
30-33 30-34 30-35 30-38
DAMPER ASSEMBLY Removal and Installation .................... FUEL TANK ASSEMBLY Removal and Installation .................... CENTER SWIVEL JOINT ASSEMBLY Removal and Installation .................... Disassembly and Assembly.. .............. FINAL DRIVE ASSEMBLY Removal and Installation .................... Disassembly ......................................... Assembly .............................................. SPROCKET Removal and Installation .................... SWING MOTOR ASSEMBLY Removal and Installation .................... SWING MACHINERY ASSEMBLY Removal and Installation .................... Disassembly ......................................... Assembly .............................................. REVOLVING FRAME ASSEMBLY Removal ................................................ Installation ............................................ SWING CIRCLE ASSEMBLY Removal and Installation .................... IDLER, RECOIL SPRING ASSEMBLY Removal and Installation .................... IDLER ASSEMBLY Disassembly ......................................... Assembly .............................................. RECOIL SPRING ASSEMBLY Disassembly ......................................... Assembly .............................................. TRACK ROLLER ASSEMBLY Removal and Installation .................... Disassembly ......................................... Assembly .............................................. CARRIER ROLLER ASSEMBLY Removal and Installation .................... Disassembly ......................................... Assembly .............................................. TRACK SHOE ASSEMBLY Removal and Installation ....................
30-39 30-40 30-41 30-42 30-43 30-44 30-48 30-54 30-55 30-56 30-57 30-61 30-66 30-67 30-68 30-69 30-70 30-71 30-73 30-74 30-75 30-76 30-77 30-79 30-80 30-82 30-84
30-l 0
HYDRAULIC TANK ASSEMBLY Removal ..................... ... .......... ...... ...... Installation .. ........ ..... ............. .............. MAIN PUMP ASSEMBLY Removal .... ............ .............. ................ Installation ................. ..... .................... MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation ...... ............ CONTROL VALVE ASSEMBLY Removal .... ........ .......... ..... .. ................. Installation ............. ... .................. ........ Disassembly .......... ............ ........ ......... Assembly .... ...... .. .......... .................. ... . PUMP MERGE/DIVIDER VALVE ASSEMBLY Disassembly and Assembly .. .. ......... . PRESSURE COMPENSATION VALVE ASSEMBLY Disassembly and Assembly .......... .... SERVO VALVE ASSEMBLY FOR FRONT PUMP Removal and Installation . ................. SERVO VALVE ASSEMBLY FOR REAR PUMP Removal and Installation .... .............. LS-EPC SOLENOID VALVE ASSEMBLY Removal and Installation .. ........ ........ SOLENOID VALVE ASSEMBLY Removal and Installation ....... ... ..... .. . WORK EQUIPMENT PPC VALVE ASSEMBLY Removal and Installation .......... ........ Disassembly .... .................. .......... .. ..... Assembly ... ............_........................ TRAVEL PPC VALVE ASSEMBLY Removal and Installation ............... ... Disassembly ...................... ................. Assembly .... .................. .................. .. .. PPC SHUTTLE VALVE ASSEMBLY Removal .......... ...... ... ... ..... .. ................. Installation .... ......... ..... .... .................. .. Disassembly .......... ......... ... ............... .. Assembly ...................... ............. ..... .... BOOM LOCK VALVE ASSEMBLY Removal and Installation ................ .. Disassembly and Assembly .... .......... BOOM CYLINDER ASSEMBLY Removal ................. .......... ................... Installation .......... .............................. ..
30-2 0
30- 85 30- 86 30- 87 30- 88 30- 89 30303030-
90 92 93 99
30-106
30-107
30-I 08
30-109 30-I 10 30-I 11
30-I 12 30-l 13 30-l 14 30-I 15 30-I 16 30-I 17 30-I 18 30-I 19 30-120 30-121 30-122 30-123
ARM CYLINDER ASSEMBLY Removal .......... ............ ...... ..... ... .... ... ... 30-I 26 Installation ............. ......... .. ........ .. ........ 30-127 BUCKET CYLINDER ASSEMBLY Removal .................. ........ .. ............ ...... 30-I 28 Installation ................ ............ ........ ...... 30-129 HYDRAULIC CYLINDER ASSEMBLY Disassembly .......... ........... ............. ..... 30-130 Assembly ............................ ............. ... 30-I 33 WORK EQUIPMENT ASSEMBLY Removal .......... ........................ ......... ... 30-137 Installation ........... ........... ............ ........ 30-138 BUCKET ASSEMBLY Removal ................ .................... .......... 30-I 39 Installation . ... ............ ........... ... .... ... ... .. 30-I 40 ARM ASSEMBLY Removal ......... ............... ....... ............... 30-I 41 Installation ...................... .. .......... ........ 30-I 42 BUCKET, ARM ASSEMBLY Removal ... ............. .......... ............... ..... 30-I 43 Installation .......... ................. ............. .. 30-I 44 BOOM ASSEMBLY Removal .......... ............ .. ........ .............. 30-145 Installation .......... .. ........ .. ..... ............... 30-146 OPERATOR’S CAB ASSEMBLY Removal .... .......... ... ....... .......... ............ 30-I 47 Installation .... ......... ......... ...... ...... ...... .. 30-I 48 COUNTERWEIGHT ASSEMBLY Removal and Installation ... ............. .. 30-I 49 AIR CONDITIONER COMPRESSOR ASSEMBLY Removal and Installation .... .............. 30-I 50 AIR CONDITIONER CONDENSER ASSEMBLY Removal and Installation .... ............ .. 30-151 RECEIVER TANK ASSEMBLY Removal and Installation .......... ........ 30-152 AIR CONDITIONER UNIT ASSEMBLY Removal .... ...... ...... ............ ............. ..... 30-I 53 Installation ................ .. .......... .............. 30-I 54 GOVERNOR, PUMP CONTROLLER ASSEMBLY Removal and Installation ..._............ 30-155 MONITOR PANEL ASSEMBLY Removal and Installation .......... ........ 30-I 56 CONTROL STAND CASE Removal ................ .............................. 30-I 57 Installation .... .......... .................... ...... .. 30-I 58
30-124 30-125
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
METHOD
OF USING MANUAL
1.
METHOD OF USING MANUAL
When removing or installing unit assemblies @ When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. @ Any special techniques applying only to the installation procedure are marked a, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 0 ASSEMBLY .......... .. Title of operation g ................. ........ ......... ......... ......... .................. Precautions related to safety when carrying out the operation 1. XXXX(1) ................... ... ..... ... ........ .. ............. Step in operation * .............. .. ...... ................. ............. ...... .. ....... Technique or important point to remember when removing XXXX (1). 2. n n a a (2): .................................. ............. a Indicates that a technique is listed for use during installation 3. 0 0 0 0 assembly (3) 4 & ..*. ................ .. .......*............... ............... Quantity of oil or water drained INSTALLATION OF 0 0 0 0 ASSEMBLY . ...Title of operation Carry out installation in the reverse order to removal. m ......... ............. ............ .................. .......... Technique used during installation * ................ .................. .................. ........ ....... Technique or important point to remember when installing a a a n (2). . Adding water, oil ................ ................. Step in operation * ................ ...... .................. .................. .. Point to remember when adding water or oil l
ti
................ ....................... .......... ........ Quantity when filling with oil and water
2.
General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation.
3.
Listing of special tools @ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC300, 350-6
30-3 0
DISASSEMBLY
4. *
AND ASSEMBLY
METHOD OF USING MANUAL
General tightening torque table (when using torque wrench) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flats
mm
mm
6 8 10 12 14
SAD00481
SAD00482
Nm
10 13 17 19 22
kgm 1.35 + 0.15 3.2 + 0.3 6.7 f 0.7 11.5 * 1.0 18.0 2 2.0
13.2 31.4 65.7 112 177
+ 1.4 + 2.9 -c 6.8 + 9.8 * 19
16 18 20 22 24
24 27 30 32 36
28.5 -c 3 39 + 4 56 f 6 76 2 8 94.5 f 10
279 383 549 745 927
f + A f +
27 30 33 36 39
41 46 50 55 60
135 175 225 280 335
f + + + 2
-c 140 k 190 + 240 + 290 2 340
1320 1720 2210 2750 3280
15 20 25 30 35
29 39 58 78 98
surface
Seal
SAD00483
5. Ir
Table of tightening torques for flared nuts In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter mm 14 18 22 24 30 33 36 42
6. *
F
Width across flats mm 19 24 27 32 36 41 46 55
Ti htenin kgm 2.5 -c 0.5 5-c2 8&2 14 f 3 18 +. 3 20 + 5 25 + 5 30 f 5
torque
----I
Nm 24.5 f 4.9 49 f 19.6 78.5 -c 19.6 137.3 + 29.4 176.5 -c 29.4 196.1 + 49 245.2 + 49 294.2 f 49
Table of tightening torques for split flange bolts In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter mm 10 12 16
30-4 0
Width across flats mm 14 17 22
Tightening torque Nm kgm 6.7 & 0.7 65.7 +. 6.8 112 r 9.8 11.5 + 1 279 f 29 28.5 f 3
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
PRECAUTIONS
PRECAUTIONS WHEN CARRYING OUT OPERATION
WHEN CARRYING
OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] . 1. Pre&tions when carrying out removal-w&k . If the coolant contains antifreeze, dispose of it correctly. . After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
. . . . . . . . *
entering.
When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number
Plug (nut end)
02 03 04 05 06 10 12
07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234
2)
Sleeve nut (elbow end) 07221-20210 07221-20315 07221-20422 07221-20522 07221-20628 07221-21034 07221-21234
(Nut), (Nut), (Nut), (Nut), (Nut), (Nut), (Nut),
Use the two items below as a set
07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219
(Plug) (Plug) (Plug) (Plug) (Plug) (Plug) (Plug)
Split flange type hoses and tubes
Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04 05
07379-00400 07379-00500
07378-10400 07378-10500
0737 I-30400 07371-30500
3)
If the part is not under hydraulic pressure, the following corks can be used. Part Number
A
n a
I Taper l/8
‘0 a 1
L
DEW00401
PC300, 350-6
30-5 0
DISASSEMBLY
AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-PI. After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the 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. Ir When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. * For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 0
PC300, 350-6
DISASSEMBLY
SPECIAL TOOL LIST
AND ASSEMBLY
SPECIAL TOOL LIST Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured). New/remodel: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Component Engine assembly Swing machinery assembly
I
T 790-331-I 110
F
796T-626- 1110 1
Final drive assembl) I
.
Idler assembly
Track roller assembly
2
IQ’tyl ,gze,ISketchI
Nature of work, remarks Tightening of cylinder head bolt
-c
Erasssftting of Removal, installation of round nut
796-627-1210 1
796T-627- 1230
2
790-101-2510
3
792- 104-3940
4
01580-I 1613
5
790-101-2570
6
01643-31645
7
790-105-2100
8
790-101-I 102
Disassembly, assembly
3
790-331-I 110
4
791-580-1510
1
796-570-1020
Installer
1
2
791-601-1000
Oil pump
1
3
796-670-1010
Installer
1
4
791-601-1000
Oil pump
1
790-302-I 500
Wrench kit
1
5
l
Carrier roller assembly
Part Name
09003-05560
6
796-670-I 020
7
796T-630-1130
8
791-601-1000
Disassembly, assembly Disassembly, assembly
Pushing of bearing inner race
Tightening of cover bolt Installation of Floating seal Installation of floating seal Charging with oil Installation of Floating seal Charging with oil Removal, installation of nut installation of floating seal Press fitting of ring
Oil oumo
1
Charging with oil
791-685-8005 Recoil spring assembly
1 790-101-1600 790-101-1102
PC300, 350-6
Removal, installation of recoil spring
791-635-3160 F
Oil pump
I 1 I
30-7 0
DISASSEMBLY
AND
Component
Recoil spring assembly
Track shoe assembl)
ASSEMBLY
I
SPECIAL
Symbol
Part No. ~790-201-1500
pump
1Push tool kit
790-201-1650
l
Plate
1
l
790-101-5021
l
Grip
1
l
01010-50816
l
Bolt
1
R
I
791-646-3000
Remover, installer
790-101-1300
Cylinder
790-101-I
102
Pump
796-660-I
200
Oil stopper assembly
rez$el 1
Sketch I
Nature I Disassembly
Installation of assembly piston dust seal
Oil stopper
1
l
796-660-1210
l
Rod
1
l
2OY-60-21330
l
Rod assembly
1
790-201-2740
I79O-IOl-2501
Push tool kit
I
l
Soacer
I Push tool kit
N
1
l
l
remarks
Removal Removal, press installa- fitting of master tion pin
796-460-1210
S
of work,
LIST
1
l
790-20;-2700
Shutting off Removal hydraulic oil installation
N
1
III
I
I
Ill
I
I
Press fitting of shaft oil seal
c
Disconnection of shaft and rotor
1
I*790-101-2630 1 Leg l
30-8 0
1 1
l
2
Center swivel joint assembly
Q’ty
2
1 Hydraulic assembly
Part Name
TOOL
I2
IrI
PC300,
350-6
DISASSEMBLY
AND ASSEMBLY
Component
3
Symbol
Part No. I
Center swivel joint assembly
SPECIAL TOOL LIST
T
1
l
790-101-2570
l
l
Part Name I
Q’ty
re$$e,
l
Plate
I41 I
I
790-101-2560
l
Nut
I 2
I
790-101-2650
l
I
790-502-1003
Adapter
Sketch Nature of work, remarks
I
I
I
Dis-
Disconnection of
assembh If assembli I shaft and rotor
2 Securing of
Cylinderrepairstand 1
cvlinder
Installation of piston ring
pF;J;tting g
U
Born, Hydraulic assembly
of coil
bucket
I 1
cylinder I* 790-101-5021
1 Grip
I J-
1 01010-50816
I* Bolt
Ill
~790-201-1500
1Push tool kit
l
l
I
l 1l
I
I I
Installation dust seal
of
Boom.1 U
Arm
5
I* 01010-50816
I* Bolt
Ill
1Remover assembly] 1 1 796-670-I I 10 1 Sleeve IIINI
1796-670-1100 l
I
I-1 N
I
I
1
l
Work equipment assembly, boom assembly
Removal of boom foot pin
I* 01803-13034
I* Nut
III
~790-101-4000
I Puller
I 1
~790-101-1102
( Pump
I799-703-1200
I Service toot kit III
799-703-I
Components related to air conditioner
100
X
1
1
Ill
1
Vacuum pump (1OOV)
I
I
I
799-703-l
110
Vacuum pump (22OV)
1
799-703-I
120
Vacuum pump l24OV)
1
Gas leak detector
1
799-703-1400
PC300, 350-6
I
I
I
1
I
I
I
I
I
I
Removal. installation
tCharging with 1ireon gas (R134a)
30-9 0
DISASSEMBLY
SKETCHES OF SPECIAL TOOLS
AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS Note:
F
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Push tool
1
t
/
1
co.5
co.5 70 100
CDPOO506
-
n
796T-626- 1110 J2-1
Push tool
-_-M
---M
-t---t
140
HEAT TREATMENT -__
MATERIAL
PART NAME PUSH TOOL
cm 1
796T-627-1230
30-l 0 0
STKMlBA
A
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
L7 Push tool
Cl -~-
i
HEAT TREATMENT -__
MATERIAL
PART NAME
QN 1
PUSH TOOL
796T-630-1130
PC300, 350-6
STKM 13A
n
30-H 0
DISASSEMBLY
STARTING MOTOR
AND ASSEMBLY
REMOVAL OF STARTING MOTOR ASSEMBLY g
Disconnect the cable from the negative minal of the battery.
1.
Open engine
2.
Remove
engine
3.
Remove
starting
4.
Disconnect starting motor harnesses and connector (3) EN-M2).
5.
Remove 3 mounting bolts, then remove starting motor assembly (4). * The two mounting bolts at the top are also used for tightening the cover mounting bracket in Step 3.
(-1 ter-
hood. undercover. motor wiring
harness cover. (1) and (21,
CEP00301
INSTALLATION OF STARTING MOTOR ASSEMBLY J l
Carry out installation removal.
30-l 2 0
in the
reverse
order
I
I
CEP00302
to
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ALTERNATOR
REMOVAL OF ALTERNATOR ASSEMBLY a
Disconnect the cable from the negative minal of the battery.
1.
Open engine
2.
Disconnect
3.
Remove
4.
Loosen lock bolt (5) and mount
5.
Loosen tension adjustment bolt (71, then remove belt (8) from alternator pulley.
6.
(-1 ter-
hood.
alternator
wiring
(I), (21, and (3).
fan guard (4). bolt (6).
Remove lock bolt (5) and mount remove alternator assembly (9).
I
’ \
L
uuuuuuuuu~
I
CEFUO303
\
\
//
//
bolt (61, then a
INSTALLATION OF ALTERNATOR ASSEMBLY l
Carry out installation removal.
in the
reverse
order
to
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting of alternator belt tension.
PC300, 350-6
30-l 3 0
DISASSEMBLY
AND ASSEMBLY
ENGINE
OIL COOLER
REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1.
Drain coolant.
2.
Remove fuel injection pump assembly. For details, see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY.
3.
Disconnect engine oil pressure sensor harnesses (I) and (2) from sensor.
4.
Remove
5.
Disconnect
6.
Remove
oil cooler assembly
7.
Remove
oil cooler core (7) from cover (6).
oil filter (3) together bottom
wiring
with bracket.
m
3
1
i
CEW0310
part of tube (4). (5).
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY l
Carry out removal.
m
installation
in the
reverse
order
Mounting bolt of oil filter marked with %: 18.68 + 4.9 Nm II.9 + 0.5 kgm}
5 -4
to
I
I
CEFQO311
7
_
CEP00312
CEFO0313
30-14 0
PC300, 350-6
DISASSEMBLY
FUEL INJECTION PUMP
AND ASSEMBLY
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY a
Disconnect the cable from the negative (-1 terminal of the battery.
1. Open engine hood. 2.
Disconnect governor motor wiring connector (I) (CN-E05).
3.
Disconnect governor motor spring rod (2). a * Do not rotate the shaft of the governor motor suddenly. * Always disconnect governor motor connector CN-E05 before disconnecting the rod. + Check the position of the lever hole.
4.
Remove fuel filter (3) together with bracket and hose. * Disconnect the hose at the injection pump m end.
5.
Disconnect fuel supply hose (4) and return hose a (5). Ir There is no stop valve installed to the supply hose, so stop the fuel.
6.
Remove boost compensation tube (6) and injec1141 tion pump lubrication tube (7).
7.
Disconnect 6 delivery tubes (8).
8.
Remove bracket (9).
9.
Remove mounting bolts, then remove fuel inm jection pump assembly (IO).
-n-n\
II I
8
a
I
PC300, 350-6
7
IO
CEPo0317
30-15 0
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY l
Carry out installation removal.
*
Ir
in the reverse order to
Adjust the spring rod. For details, see TESTING AND ADJUSTING, Adjusting governor motor lever stroke. Connect the spring rod before connecting the connector (CN-E05).
If w
Joint bolt (width across flats: 22 mm): 17.2 t 2.5 Nm Il.75 t 0.25 kgm}
w
Joint bolt (width across flats: 22 mm): 17.2 2 2.5 Nm Il.751 t 0.25 kgm)
w
Boost compensation tube nut . Intake manifold end: 24.5 t. 9.8 12.5 + 1.0 . Injection pump end: 10.3 t 2.5 (I.05 t 0.25 Lubrication tube joint bolt: 11.3 f 1.5 Nm Il.15 t 0.15
w
w
Nm kgm} Nm kgm} kgm}
Delivery tube sleeve nut: 22.1 + 2.5 Nm (2.25 + 0.25 kgm}
Align the spline notch, then align the line on the fuel injection pump with the line on the gear case, and install the coupling. Adjust the injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing. Bleed the air from the fuel circuit.
CDP00318
30-16 0
DISASSEMBLY
AND ASSEMBLY
WATER PUMP
REMOVAL OF WATER PUMP ASSEMBLY 1. 2. 3.
4.
5. 6.
Drain coolant. Open engine hood. Loosen adjustment bolt (2) and mount bolts (3) of tension pulley (I), and remove belt (4) from m water pump pulley. Disconnect bypass hose (51, aeration tube (61, heater hose (71, and clamps (8) and (9). * Check the angle of the clamps. Disconnect water pump inlet hose (IO). Remove mounting bolts, then remove water m pump assembly (II). Ir There is one mounting bolt at the cylinder block end.
INSTALLATION OF WATER PUMP ASSEMBLY l
Carry out installation removal.
in the reverse order to
a
l
*
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting of water pump belt tension.
*
Set one mounting bolt at the fan pulley end installed to the water pump (it will not go in later).
Refilling with water -k Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
CEFW322
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
NOZZLE HOLDER
REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.
Open engine hood.
2.
Disconnect delivery tube (I).
3.
Disconnect spill hose (2).
4.
Remove bolder(3).
5.
Remove nozzle assembly (4).
INSTALLATION OF NOZZLE HOLDER ASSEMBLY .
Carry out installation removal.
in the reverse order to
Delivery tube sleeve nut: 22.1 + 2.5 Nm I2.25 z 0.25 kgm} CEPO0324
Nozzle holder mounting bolt : 44.1 s 4.9 Nm 14.5 + 0.5 kgm1
30-18 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF TURBOCHARGER 1. 2. 3. 4. 5. 6. 7. 8. 9.
TURBOCHARGER
ASSEMBLY
Open engine hood. Remove top adiabatic cover (I) together with stay. Remove intake hose (2). Remove turbocharger outlet hose (3). Remove bottom adiabatic cover (4). Remove clamp (7) and bolts and nuts of cona necting clamp (6) of exhaust pipe (5). Remove turbocharger lubrication inlet tube (8). Disconnect turbocharger lubrication return hose (9). Remove turbocharger assembly (IO) while pulling out exhaust pipe (5). m
CWPOGI03
INSTALLATION OF TURBOCHARGER ASSEMBLY l
Carry out installation removal.
in the reverse order to
u Ir &
w
m
Do not use the connection clamp again. Replace it with a new part. Exhaust pipe connection: Coat with thermosetting agent (Nihon Holt Fire Gum or equivalent) Tightening nut of connecting clamp (6): 83.4 2 14.7 Nm I8.5 z 1.5 kgm}
Turbocharger mounting nut: 36.8 + 7.4 Nm I3.75 + 0.75 kgm}
PC300, 350-6
30-l 9 0
DISASSEMBLY
AND ASSEMBLY
THERMOSTAT
REMOVAL OF THERMOSTAT ASSEMBLY 1.
Drain engine coolant.
2.
Open engine hood.
3.
Disconnect aeration tube (IL
4.
Disconnect water pump inlet hose (2). * The mounting bolts (inside bottom bolts) of the thermostat cover cannot be removed, so disconnect the hose.
-1
5.
Remove thermostat cover (3). * There are two clamps, so check the mounting angle.
6.
Remove thermostat (4).
CEPoO328
INSTALLATION OF THERMOSTAT ASSEMBLY .
Carry out installation removal.
.
Refilling with water * Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
30-20 0
in the reverse order to
PC300, 350-6
DISASSEMBLY
REMOVAL SEAL
AND ASSEMBLY
ENGINE FRONT SEAL
OF ENGINE FRONT
1.
Remove radiator and hydraulic cooler assembly. For details, see REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.
2.
Remove fan (I).
3.
Remove fan guard (2).
m
CEPOO330
4.
Loosen tension of alternator (3), tension pulley (4), and air conditioner compressor (5), and remove belts (6), (7), and (8). m * For details, see REMOVAL OF ALTERNATOR, WATER PUMP, AIR CONDITIONER COMPRESSOR.
5.
Remove damper (9). m Ir The compressor drive pulley will also come off at the same time.
6.
Remove front pulley washer (I 1).
7.
Using puller 0, remove front pulley (12). Ir The collar will also come off at the same time.
PC300, 350-6
mounting
bolt (IO) and m
30-21 0
DISASSEMBLY AND ASSEMBLY
8.
ENGINE FRONT SEAL
Remove front oil seal (12).
CEPoo334
INSTALLATION OF ENGINE FRONT SEAL l
Carry out installation removal.
m
in the reverse order to
Fan mounting bolt: 88.2 t 2.5 Nm 16.75 z 0.25 kgm}
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting alternator belt, water pump belt, and air conditioner compressor belt tension.
Damper mounting bolt: 88.2 t 2.5 Nm i6.75 + 0.25 kgm)
Front pulley mounting bolt: 451.1 t 29.4 Nm I46 t 3 kgm}
Ir &
30-z 0
Press fit the front seal until it is level with the surface of the front cover. Lip of oil seal: Grease (G2-LI) (approx. 2 cc.)
PC300, 350-6
DISASSEMBLY
REMOVAL SEAL 1.
AND ASSEMBLY
ENGINE REAR SEAL
OF ENGINE REAR
Remove main pump assembly. For details, see REMOVAL OF MAIN SEMBLY.
2.
Remove
damper
3.
Remove
flywheel
assembly
assembly
PUMP
AS-
(1).
(2).
CWPO6165
4.
Remove rear seal (3). * Be careful not to damage when removing.
INSTALLATION REAR SEAL 1.
Installation
the
crankshaft
OF ENGINE
of rear seal
1) Install rear seal with TOP mark facing up. 2) Press fit 20 mm from end face of crankshaft. 3)
If there is wear of lip contact face of crankshaft (fingernails catch: more than 0.1 mm), move rear seal approx. 3 mm to rear when assembling. & Lip of oil seal : Grease (G2-LI) CWP06167
PC300, 350-6
30-23 0
DISASSEMBLY
2.
3.
AND ASSEMBLY
ENGINE REAR SEAL
Installation of flywheel 1) Coat flywheel mounting bolts, thread portion, seat face, and washer with engine oil. & Mounting bolt: Engine oil (EO#30) 2) Install mounting bolts in order shown in diagram on right. w Mounting bolt : 1st step: 88.3 Nm (9 kgm} 2nd step: 188.3 Nm I19 kgm} 3) Measurement of face runout, radial runout Face runout: Max. 0.20 mm Radial runout: Max. 0.15 mm -k If the measurement is not within the standard value, take the action given in the MAINTENANCE STANDARD. Installation of damper w Damper mounting
bolt:
110 t 12.3 Nm (II.25
30-24 0
CWPO6188
t 1.25 kgm}
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
GOVERNOR MOTOR
REMOVAL OF GOVERNOR MOTOR ASSEMBLY A
Disconnect the cable from the negative (-1 terminal of the battery.
1.
Open engine hood.
2.
Disconnect wiring connectors (I) (CN-E04) and (2) KN-E051.
3.
Remove cover (3).
4.
Disconnect spring rod (4).
5.
Remove governor motor assembly (5).
CEP00341
a
INSTALLATION OF GOVERNOR MOTOR ASSEMBLY l
Carry out installation removal.
in the reverse order to
CEP00342
*
Adjust the spring rod. For details, see TESTING AND ADJUSTING, Testing and adjusting of governor motor lever stroke.
PC300, 350-6
30-25 0
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
REMOVAL OF CYLINDER HEAD ASSEMBLY A 1. 2. 3. 4. 5. 6.
Disconnect the cable from the negative (-) terminal of the battery. Open engine hood. Drain coolant. Remove intake connector (2). Remove clamp (31, and disconnect spill hose (4). Disconnect fuel filter (5) at bracket end, then move it towards counterweight. Disconnect heater relay (6) at bracket end. Ir One connector clamp and one wiring harness clamp are tightened together.
7. Disconnect wiring harness clamp (71, then return bolt to its original position. 8. Disconnect bypass hose (8) and aeration tube (9). 9. Disconnect block (10) from cylinder head.
10. Disconnect oil filter bracket (11) from intake manifold. m 11. Remove boost compensation tube (12). 12. Disconnect both ends of delivery tube (13). m /GJ 13. Remove intake manifold (14). * There is a wiring clamp at the bolt at the bottom of the No. 6 cylinder.
14. Loosen tension of alternator belt, then remove plate mounting bolt (15). a 15. Disconnect turbocharger outlet hose (16) and remove inlet hose (171. 16. Remove top adiabatic cover (18) and bottom adiabatic cover (19). * Remove the top adiabatic cover together with the stay.
30-26 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
17. Disconnect turbocharger lubrication inlet tube (21) and outlet tube (22). Ir Loosen the nut at the bottom, then move the inlet tube towards the control valve. 18. Remove mounting bolts and nuts of connecting clamp (23) of exhaust pipe (201, then remove m clamp (24). 19. Disconnect level gauge clamp (25).
20. Lift off turbocharger and exhaust manifold as116 sembly (26). m 21. Remove exhaust pipe (20).
22. Remove wiring harness (28) and lead (29I.m a 23. Remove 6 glow plugs (30). 24. Disconnect spill hose (311, remove holder (321, @ZJ then remove 6 nozzle holders (33). 25. Disconnect blow-by hose (341, and remove head cover (35). m
11121 26. Remove rocker arm assembly (36). * Loosen the locknut, then loosen the adjustment screw 2 - 3 turns.
PC300, 350-6
CYLINDER HEAD
DISASSEMBLY
AND ASSEMBLY
CYLINDER HEAD
27. Remove push rods (37). 28. Remove cylinder head bolts (38).
29. Lift off cylinder head assembly (39). &I kg
Cylinder head assembly: 65 kg
INSTALLATION OF CYLINDER HEAD ASSEMBLY l
Carry out installation removal.
m
in the reverse order to
Boost compensation tube nut. . Intake manifold end: 24.5 t 9.8 I2.5 t 1.0 . Injection pump end: 10.3 t 2.5 Il.05 t 0.25
Nm kgm} Nm kgm)
m
Delivery tube sleeve nut: 22.1 t 2.5 Nm I2.25 t 0.25 kgm}
m
Intake manifold mounting bolt: 24.5 t 9.8 Nm 12.5 t 1.0 kgm}
*
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting alternator belt tension.
30-28 0
f’C300,350-6
DISASSEMBLY
AND ASSEMBLY
CYLINDER HEAD
m *
Do not use the connection clamp again. Replace it with a new part. m Connecting clamp (23) tightening nut: 83.4 + 14.7 Nm I8.5 + 1.5 kgm}
w
Exhaust manifold mounting bolt: 44.1 + 9.8 Nm 14.5 t. 1.0 kgm}
&
Exhaust pipe connection: Coat with thermosetting
w agent
m
Wiring harness and lead mounting nut: 1.5 t 0.5 Nm IO.15 t 0.05 kgm}
w
Glow plug: 17.2 + 2.5 Nm II.75 z 0.25 kgm}
* w
Clean the mounting portion. Nozzle holder mounting bolt: 44.1 t 4.9 Nm (4.5 t 0.5 kgm}
m
Head cover mounting nut: 8.8 + 1.0 Nm IO.9 t 0.1 kgm1
11121 * When tightening
* .
m
the nuts and bolts, start from the center and work towards the outside. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance. Mounting bolt, nut: 24.5 + 4.9 Nm i2.5 t 0.5 kgm}
PC300, 350-6
30-29 0
DISASSEMBLY AND ASSEMBLY
& *
CYLINDER HEAD
If any rust of more than 5 mm square is found on the shaft or the thread of the bolt, replace the head bolt with a new bolt. Be careful to check that there is no dirt or dust on the mounting surface of the cylinder head or inside the cylinder. When installing the gasket, check that the grommets have not come out. Coat the thread and seat of the bolt, and the seat of the cylinder head holes completely with molybdenum disulphide (LM-P). Mounting bolt: Anti-friction compound (LM-PI. Tighten the cylinder head mounting bolts 2 - 3 turns by hand, then tighten in the order given in the diagram. w Cylinder head mounting bolt: 1st pass:
Front Exhaust side
CEPOO353
Tighten to 98.1 + 9.8 Nm IlO t 1 kgm}
2nd pass: Tighten to 147.1 2 4.9 Nm (15 t 0.5 kgm}
3rd pass: 1. When using tool A. Using an angle tightening wrench, tighten bolt 90““8’. 2. When not using tool A. I) Using the angle of the bolt head as the base, make start marks on the cylinder head and socket. 2) Make an end mark at a point 90’?from the start mark. 3) Tighten so that the start mark on the socket is aligned with the end mark on the cylinder head at the 90”+? position. l
CEP00354
Cylinder head start mark Socket 1 start mark CI,
End mark / Socket
After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. . If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt.
I,
cylinder head start mark
So\cket start mark
( Make mark with punch
Refilling with water * Refill to the specified level, and run the en-
gine to circulate the water through the system. Then check the water level again.
I
30-30 0
CErn0356
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
AFTERCOOLER
REMOVAL OF AFTERCOOLER ASSEMBLY 1.
Open aftercooler
front cover.
2.
Loosen clamps of aftercooler outlet hose (2).
3.
Remove mounting bolts, pull out from hose, and remove aftercooler assembly (3).
INSTALLATION AFTERCOOLER l
Carry out installation removal.
PC300, 350-6
inlet hose (I) and
OF ASSEMBLY in the
reverse
order
to
30-3 1 0
DISASSEMBLY AND ASSEMBLY
HYDRAULIC COOLER
REMOVAL OF HYDRAULIC COOLER ASSEMBLY A
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic tank.
2.
:
Hydraulic tank: Approx. 200 !J
Lift off engine hood (1). * Loosen the hinge mounting bolts before lifting. & kg
Engine hood assembly: 85 kg
3.
Remove aftercooler top cover, and open front cover.
4.
Remove aftercooler assembly. For details, see REMOVAL OF AFTERCOOLER ASSEMBLY.
5.
Disconnect hose (2) and tube (3). * Set a container under the cooler assembly to catch the oil.
6.
Sling hydraulic cooler assembly (41, remove mounting bolts, then lift off hydraulic cooler assem bly. & kg
Hydraulic cooler assembly: 90 kg
INSTALLATION OF HYDRAULIC COOLER ASSEMBLY Carry out installation removal.
in the reverse order to CEFOO361
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-32 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
RADIATOR, HYDRAULIC COOLER
REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY A
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil from hydraulic tank. - :
Hydraulic tank: Approx. 200 .Q
2. Drain coolant 3. Lift off engine hood (1). * Loosen the hinge mounting bolts before lifting. & kg
CEW0359
Engine hood assembly: 85 kg
4. Remove aftercooler top cover, and open front cover. 5. Remove radiator undercover. 6. Remove aftercooler assembly. For details, see REMOVAL OF AFTERCOOLER ASSEMBLY. Disconnect hydraulic cooler hose (2) and tube (3). Ir Set a container under the cooler assembly to catch the oil. Remove shroud left cover (4). Ir The shroud mounting bolts cannot be removed, so remove the cover.
9. Disconnect radiator outlet hose (5). * Disconnect the clamps at two places at the same time.
6
10. Disconnect sub-tank hose (6). 11. Remove 2 mounting
bolts of shroud (7) from
below.
PC300, 350-6
30-33 0
DISASSEMBLY AND ASSEMBLY
RADIATOR, HYDRAULIC COOLER
12. Disconnect radiator inlet hose (8). 13. Remove top 2 mounting bolts of shroud (71, and move it towards engine.
14. Sling radiator and hydraulic cooler assembly (91, remove top and bottom mount bolts, then lift off radiator and hydraulic cooler assemb1y.a Ir Check the direction of the holder plate at the bottom of the top mount. I+ kg
Radiator, hydraulic cooler assembly: 160 kg
365
INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY l
Carry out installation removal.
w
.
l
in the reverse order to
Mount bolt: 110.3 t. 12.3 Nm III.25 t 1.25 kgm}
Refilling with water Ir Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-34 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ENGINE, MAIN PUMP
REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY A
Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the qround and stoo the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Remove hydraulic tank strainer, and using tool Sl, stop oil. . When not using tool Sl, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. -
:
CEP00268
Hydraulic tank : Approx. 200 .r?
2. Drain coolant. 3. Remove main pump undercover undercover.
and engine
4. Open engine hood. 5. Remove main pump top cover (II, tions (2) and (3).
and parti-
6. Remove muffler drain tube (4). 7. Disconnect chassis ground cable (5). 8. Remove bracket (6) of pump branch hose. Ir Do not disconnect the branch hose. 9. Disconnect suction tube (7). 10. Disconnect cooling hose (8).
-
11. Disconnect LS control hose (9). 12. Disconnect rear pump LS pressure detection hose (IO). 13. Disconnect rear pump delivery pressure detection hose (I 1). 14. Disconnect TVC wiring connectors (12) (C13, 14). 15. Disconnect NC wiring clamp (13). 16. Disconnect front pump LS pressure detection hose (14). 17. Disconnect front pump delivery pressure detection hose (15). * After disconnecting the hoses, fit tags to distinguish them.
PC300, 350-6
II I
/
\\ CWPO6108
DISASSEMBLY
ENGINE, MAIN PUMP
AND ASSEMBLY
18. Disconnect hose (16) going to self-reducing pressure valve. 19. Disconnect hose (17) going to control valve. 20. Disconnect drain hose (18).
21. Disconnect fuel return hose (19) and supply hose m (20). Ir There is no stop valve installed to the supply hose, so stop the fuel. 22. Disconnect car heater hose (21). 23. Disconnect spill hose clamp (22). 24. Disconnect water pump inlet hose (23).
26 _
23
- 22 U
CEW0370
25. Remove aftercooler joint tube (241 together with bracket. 26. Disconnect governor motor wiring connectors (251, (261, and (E04, 05).
CWPO61
I I
27. Remove clamps (27) (2 places), then disconnect spill hose (28). 28. Disconnect engine coolant outlet hose (29). 29. Remove fan guard (301, then remove fan (31). m
30-36 0
PC300, 350-6
DISASSEMBLY
30. 31. 32. 33.
ENGINE, MAIN PUMP
AND ASSEMBLY
Disconnect hose (32) going to aftercooler. Remove hose (33) coming from air cleaner. Disconnect hose (34) going to dust indicator. Remove air cleaner assembly (35) together with bracket.
--
/ 32
co)
35 -
\
34
c9
CWP06113
34. Disconnect air conditioner compressor wiring connector (36) (M34). m 35. Disconnect air conditioner hose (37). -f Before disconnecting the hose, use tool Xl to collect the refrigerant (R134a). 36. Disconnect wiring cable (38) from starting motor. 37. Disconnect wiring connector (39) (E08) and clamp (40). *CWPO6114
CWPO6115
38. Remove engine mount bolts (41) and (42I.m
4L CWPO61 16
39. Lift off engine and main pump assembly (43).
Ir m
Check that all wiring and piping has been disconnected, then lift off slowly. Engine and main pump assembly: 1062 kg
/
PC300, 350-6
7
CWPO6117
30-37 0
DISASSEMBLY AND ASSEMBLY
ENGINE. MAIN PUMP
INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY l
Carry out installation removal.
in the reverse order to
w
Joint bolt: 17.2 2 2.5 Nm t1.75 t 0.25 kgm}
m
Fan mounting bolt: 66.2 t 7.4 Nm (6.75 t 0.75 kgml
m
l
l
l
l
*
Check that there is no damage or deterioration of the O-ring, then connect the hose.
m
Engine mount bolt (front): 384.9 L 41.7 Nm 139.25 t 4.25 kgm} (rear): 926.7 t 103.0 Nm (94.5 f 10.5 kgm)
Refilling with water * Add water up to the water filler port. Run the engine to circulate the water through the system. Then check the water level again at the reserve tank. Charging air conditioner with gas * Using tool Xl, charge the air conditioner circuit with refrigerant (R134a). Refilling with oil * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air * Bleed the air from the main pump. For details, see TESTING AND ADJUSTING, Bleeding air.
30-38 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
DAMPER
REMOVAL OF DAMPER ASSEMBLY 1.
Remove main pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY.
2.
Remove damper assembly (1).
INSTALLATION ASSEMBLY l
Carry out installation removal.
w
m
OF DAMPER
in the reverse order to
Damper mounting bolt: 110.3 2 12.3 Nm III.25 + 1.25 kgm)
PC300, 350-6
30-39 0
DISASSEMBLY
AND ASSEMBLY
FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY &
Disconnect the cable from the negative (-1 terminal of the battery.
1.
Open drain valve of fuel tank and drain fuel. - :
Fuel tank: Approx. 470 I? (when tank is full)
2.
Remove air conditioner condenser top cover.
3.
Remove handrail (I 1, front cover (2), and battery case cover (3).
4.
Disconnect fuel level sensor connector (4) (CNPO6).
5.
Disconnect fuel supply hose (51, return hose (61, spill hose (71, and clamp (8).
6.
Remove mounting assembly (9).
CEPUO112
& kg
bolts, and lift off fuel tank a
Fuel tank assembly: 210 kg
I
INSTALLATION ASSEMBLY l
Carry out installation removal.
m
CEPO0113
OF FUEL TANK
in the reverse order to
Fuel tank mounting bolt: 277.0 + 31.9 Nm i28.25 + 3.25 kgm} CEPO0114
30-40 0
CEPOOllE
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY a
g + 1. 2. 3.
4. 5. 6. 7.
Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Mark all the piping with tags to prevent mistakes in the mounting position when installing. Disconnect travel motor hoses (I) and (21. Disconnect speed selector hose (3). Disconnect drain hose (41, and remove elbow (5). + Install a blind plug in the drain hose. Disconnect drain hoses (7) and (8). * Install a blind plug in the drain hose. Disconnect travel hoses (9) and (IO), and speed selector hose (11). Pull out pin (121, and disconnect plate (13). Sling center swivel joint assembly (141, remove mounting bolts from below, then lift off. Center swivel joint assembly: 40 kg
INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY l
Carry out installation removal.
in the reverse order to
m Sr Assemble the center swivel as shown in the diagram below. l
.
Refilling with oil (hydraulic tank) li Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air li Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.
Sprocket
dB PC300, 350-6
hD
CEPoo404
30-41 0
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.
Remove cover (1).
2.
Remove snap ring (2).
3.
Using puller T, pull out swivel rotor (4) and ring (3) from swivel shaft (5).
4.
Remove O-ring (6) and slipper seal (7) from swivel rotor.
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.
Assemble slipper seal (7) and O-ring (6) to swivel rotor.
2.
Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. & Contact surface of rotor, shaft: Grease (G2-LI) Ir When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.
3.
Install ring (3) and secure with snap ring (2).
4.
Fit O-ring and install cover (I). m Mounting bolt: 31.4 t 2.9 Nm f3.2 t 0.3 kgm}
30-42 0
CEP00381
PC300, 350-6
DISASSEMBLY
REMOVAL
1.
2. a 3. 4. 5.
6. 7.
AND ASSEMBLY
FINAL DRIVE
OF FINAL DRIVE
Remove the track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. Using work equipment, push up track frame and set block between track frame and link. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove sprocket. For details, see REMOVAL OF SPROCKET. Remove cover (1). Disconnect drain hose (2). * Set a container to catch the oil, then disconnect the hose and install a blind plug. Disconnect speed selector hose (3) and motor hoses (4) and (5). Sling final drive assembly (61, and remove mounting bolts, then remove. m & kg
Final drive assembly: 550 kg
INSTALLATION OF FINAL DRIVE ASSEMBLY l
Carry out installation removal.
w
in the reverse order to
Final drive mounting bolt: 549.1 + 58.8 Nm I56 + 6 kgm}
.
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
.
Bleeding air + Bleed the air from the travel motor (hydraulic tank). For details, see TESTING AND ADJUSTING, Bleeding air.
PC300,350-6
30-43 0
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1.
Draining
oil
Remove drain plug and drain oil from final drive case. - : 2.
Final drive case: Approx. 11 t
Cover
1) Remove mounting
bolts, then use forcing screws @ to disconnect cover (I) from ring gear.
204
2) Use eyebolts @ to remove cover (1).
CEFU0472
3.
Spacer
Remove spacer (2).
4.
No. 1 carrier assembly I) Remove No. 1 carrier assembly (3).
30-44 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
2) Disassemble
No. 1 carrier
FINAL DRIVE
assembly
as fol-
lows. i) Push in pin (41, and knock out shaft (5) from carrier (6). + After removing
shaft (51, remove
8
4
7
6
pin
(4). ii)
Remove thrust washer (71, gear (81, bearing (91, and thrust washer (IO).
5.
No. 1 sun gear shaft Remove No. 1 sun gear shaft (11).
6.
No. 2 sun gear Remove No. 2 sun gear (12).
CWPO6120
7.
Thrust washer Remove thrust washer (13).
8.
Ring gear Using eyebolts 0, remove ring gear (14).
PC300,
350-6
CWPO6121 I
DISASSEMBLY
9.
FINAL DRIVE
AND ASSEMBLY
No. 2 carrier assembly, I) Remove No. 2 carrier assembly (15).
2)
Disassemble No. 2 carrier assembly as follows. i) Push in pin (16) and pull out shaft (17) from carrier (18). After removing the shaft, remove pin * (16). ii) Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22).
20 \
2i
I,’
16
19 /
18 I
22 CEfO0481
10. Nut 1) Remove lock plate (23).
2)
30-46 0
Using tool Jl, remove nut (24).
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
11. Hub assembly I) Using eyebolts @, remove hub assembly (25) from travel motor.
2)
Disassemble hub assemblv as follows. i) Remove floating seal (iSI.
I
CWPO6125
ii)
3)
Remove bearings (27) and (28) from hub (29).
Remove floating seal (30) from travel motor (31).
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
FINAL DRIVE
OF FINAL DRIVE
-k
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Hub assembly
1) Assemble i)
ii)
hub assembly as follows. Using push tool, press fit bearings and (29) to hub.
(28)
Using tool 54, install floating seal (26). * Remove all oil and grease from the O-ring and O-ring contact surface, and dry the parts before installing the floating seal. Ir After installing the floating seal, check that the angle of the floating seal is within 1 mm. * After installing the floating seal, coat the sliding surface thinly with engine oil.
‘J4 CUP06128
2)
Using tool J4, install floating seal (30) to travel motor (31). * The procedure for installation is the same as in Step II-ii) above.
J4
3)
Using eyebolts 0, set hub assembly (25) to travel motor, then using push tool, tap to press fit bearing portion.
30-48 0
PC300, 350-6
DISASSEMBLY
2.
AND ASSEMBLY
FINAL DRIVE
Nut
1) Using tool 52, push inner race portion of bearing (27). Ir Pushing force: 14.7 - 18.6 kN (1.5 - 1.9 ton) Ir Rotate the hub 2 - 3 times before applying the pushing force to the bearing inner race.
2)
Measure dimension a in the condition in Step 1) above.
27
a
CEFUO491
Measure thickness b of nut (24) as an individual part. 4) Calculate a - b = c 5) Using tool Jl, tighten nut (24) until c portion dimension is as follows. c portion dimension = c _y mm 3)
24 “b
CEFUO492
6) Using push-pull scale 0, measure tangential force in direction of rotation of hub in relation to motor case. * Tangential force: Max. 490 N (50 kg) + The tangential force is the maximum force when starting rotation.
CEP00493
PC300, 350-6
30-49 0
DISASSEMBLY
7)
FINAL DRIVE
Install lock plate (23).
Ir &
m
3.
AND ASSEMBLY
Install the lock plate as shown in the diagram on the right. Thread of mounting bolt: Thread tightener (LT-2) * Do not coat the threaded portion of the nut with thread tightener (LT-2). Mounting bolt: 66.2 f 7.4 Nm (6.75 + 0.75 kgm)
No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. -)r There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (21) to gear (20), fit top and bottom thrust washers (19) and (22), and set gear assembly in carrier (18).
of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (17). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iii) Insert pin (16). * After inserting the pin, caulk the pin portion of the carrier. * After assembling the carrier assembly, check that gear (20) rotates smoothly. ii)
\
Casting notch Install to place where there is no casting notch. Bring lock plate and spline of motor into tight contact.
CEW0494
20
18
21
19
h
22 CEPO0495
Align with position
20
16 CEP00496
30-50 0
PC300, 350-6
DISASSEMBLY
2)
4.
AND ASSEMBLY
FINAL DRIVE
Install No. 2 carrier assembly (15). * Align the position so that the three tips of the gear shafts of carrier assembly (15) enter the three hollows in the end face of the motor case, then install.
Ring gear Fit O-ring to hub end, then using eyebolts 0, install ring gear (14). Ir Install so that the side with two grooves machined in the outside circumference of the ring gear is at the top (cover end). Ir Remove all grease and oil from the mating surface of the ring gear and hub. * Do not put any gasket sealant on the mating surface of the ring gear and hub under any circumstances.
5.
Thrust washer Install thrust washer
6.
(13).
No. 2 sun gear Install No. 2 sun gear (12).
CWPO6122
7.
No. 1 carrier assembly 1) Assemble No. 1 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (9) to gear (81, fit top and bottom thrust washers (7) and (IO) and set gear assembly to carrier (6).
8
h
7
CWPO6121
6
CEW0499
PC300, 350-6
30-51 0
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
ii)
Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (5). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iii) Insert pin (4). After inserting the pin, caulk the pin * portion of the carrier. * After assembling the carrier assembly, check that gear (8) rotates smoothly.
8
5 CEW0499
2)
8.
Install No. 1 carrier assembly (3).
No. 1 carrier assembly I) Assemble No. 1 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (9) to gear (8), fit top and bottom thrust washers (7) and (IO) and set gear assembly to carrier (6).
8
9
h
7
6
10 CEFO04998
9.
No. 1 sun gear shaft Install No. 1 sun gear shaft (11).
CEW0501
30-52 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
FINAL DRIVE
IO. Spacer Install spacer (2).
11. Cover 1) Using eyebolts 0, install cover (I). & Mounting surface of cover: Gasket sealant (LG-6)
CEPOO472
2)
.
Using tool 53, tighten mounting bolts. m Mounting bolt: Initial torque: 98.1 Nm {lo kgm1 Additional tightening angle: 100 - 110”
Refilling with oil Ir Tighten drain plug through oil filler.
and add engine
I
J3
oil
Final drive case: Approx. 11 !?. %9 * Carry out a final check of the oil level at the determined position after installing the final drive assembly to the chassis.
PC300, 350-6
30-53 0
DISASSEMBLY AND ASSEMBLY
SPROCKET
REMOVAL OF SPROCKET 1.
Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2.
Swing work equipment SO”, then push up chassis with work equipment and set block 0 between track frame and track shoe.
3.
Remove mounting (I). I+ kg
bolts, then lift off sprocket )I
Sprocket : 70 kg
,i
CEP00050
INSTALLATION OF SPROCKET l
Carry out installation removal.
& w
30-54 0
in the reverse order to
Thread of sprocket mounting bolt: Thread tightener (LT-21 Sprocket mounting bolt: 637.4 t 49.1 Nm I65 r 5 kgm)
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
SWING MOTOR
REMOVAL OF SWING ASSEMBLY A
A
* 1. 2. 3. 4. 5.
MOTOR
Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Fit blind plugs in the disconnected hoses and tubes. Disconnect suction hose (I). Disconnect swing hoses (2). Disconnect drain hoses (3) and (4). Disconnect swing holding brake hose (5). Remove mounting bolts, and lift off swing motor assembly (6).
el kg
Swing
motor assembly:
110 kg
INSTALLATION OF SWING MOTOR ASSEMBLY l
l
Carry out removal.
installation
in the
reverse
order
to
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
.
Bleeding air * Bleed the air from the swing motor. For details, see TESTING Bleeding air.
PC300, 350-6
AND ADJUSTING,
30-55 0
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
REMOVAL OF SWING MACHINERY ASSEMBLY 1.
Remove swing motor assembly. For details, see REMOVAL OF SWING MOTOR ASSEMBLY.
2.
Remove mounting bolts (1).
3.
Sling swing machinery assembly (21, screw in forcing screws @ to separate swing machinery from frame, then lift off. I+ kg
m
Swing machinery assembly: 331 kg
INSTALLATION OF SWING MACHINERY ASSEMBLY l
Carry out installation removal.
w
30-56 0
in the reverse order to
Swing machinery case mounting bolt: 927 t 103 Nm t94.5 t 10.5 kgm1
PC300, 350-6
DISASSEMBLY
SWING
AND ASSEMBLY
MACHINERY
DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1. Draining
oil
Loosen drain plug and drain oil from swing machinery. 2.
:
Swing machinery case: Approx. 12.5 rJ
Cover
Remove mounting bolts, then lift off cover (1).
3.
4.
No. 1 carrier assembly.
I) 2)
Remove thrust washer (2). Remove No. 1 sun gear (3).
3)
Remove No. 1 carrier assembly (4).
Disassemble No. 1 carrier assembly as follows. 1) Push in pin (5), and knock out shaft (6) from carrier (7). Ir After removing the shaft, remove pin (5). 2) Remove thrust washer (81, gear (91, bearing (IO), and thrust washer (II).
9
11
6 CEPOOZOS
PC300, 350-6
DISASSEMBLY AND ASSEMBLY
5.
SWING MACHINERY
Ring gear Lift off ring gear (12).
CWPO6136
6.
No. 1 sun gear I) Remove thrust washer (13) and collar (14). 2) Remove No. 1 sun gear (15).
31 Remove thrust washer (16). * Remove No. 2 carrier assembly (17) before removing the thrust washer.
7.
No. 2 carrier assembly Lift off No. 2 carrier assembly (17).
30-58 0
PC300, 350-6
DISASSEMBLY
8.
AND ASSEMBLY
Disassemble No. 2 carrier assembly as follows. I) Push in pin (181, and knock out shaft (19) from carrier (17). * After removing the shaft, remove pin (18). 2) Remove thrust washer (201, gear (21), bearing (221, and thrust washer (23).
SWING
19
MACHINERY
22
17
21 -------23
18
9.
CEP00213
Pinion shaft assembly.
1) Remove bolt (241, then remove holder (25). 2)
Remove
gear (26).
3)
Turn over case and pinion assembly, then remove mounting bolts (28) of cover assembly (27).
27
28
CEPO0215
4)
Turn over case and pinion assembly (29), and set on press stand, then using push tool 0, remove pinion shaft assembly (30) with press. * Set a wooden block under the press, and be careful not to damage the pinion shaft assembly when removing it.
CEPOO216
PC300, 350-6
CEFOOZl;
DISASSEMBLY
AND ASSEMBLY
SWING MACHINERY
10. Disassemble pinion shaft assembly as follows. 1) Using push tool 0, remove cover assembly (27) and bearing (31) from shaft (32). 2) Remove oil seal (33) from cover (27).
3 27 CEP00219
11. Bearing Using push tool, remove
bearing
(34) from case
35
34
(35).
CEFOo220
30-60 0
PC300, 350-6
DISASSEMBLY
SWING MACHINERY
AND ASSEMBLY
ASSEMBLY OF SWING MACHINERY ASSEMBLY *
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
1.
Bearing Using push tool 0, press fit bearing (31) to case (35).
CEW0221
2.
Cover assembly 1) Using push tool 0, press fit oil seal (33) to cover (27). & Outside circumference of oil seal: Gasket sealant (LG-61 * Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.
27
CWPO6140
2)
Fit cover assembly (27) to case (351, and tighten mounting bolts (28). * Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting. & Cover mounting surface: Gasket sealant (LG-61 m Mounting bolt: 66.2 + 7.4 Nm 16.75 t 0.75 kgm} a Lip of oil seal: Grease (G2-LII
27 35
CWPO6141
3.
Case assembly 1) Set case assembly (35) to shaft (321, then using push tool 0, press fit bearing inner race portion. * When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.
35’
-32
I I
PC300, 350-6
CWPO6142
30-61 0
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
2) Bearing Using tool F, press fit bearing (34). Jr Press the bearing inner race and outer race at the same time when press fitting. Do not press only the inner race when press fitting. + After press fitting the bearing, check that the case rotates smoothly.
-
3)
4.
-
CWP06143
Gear, holder Assemble gear (261, then fit holder (25) and tighten bolt (24). & Mounting bolt: Thread tightener (LT-2) m Mounting bolt: 380 t: 46.6 Nm (38.75 + 4.75 kgm}
Assemble No. 2 carrier assembly as follows * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1) Assemble bearing (22) to gear (211, fit top and bottom thrust washers (23) and (20) and set gear assembly to carrier (17).
22 20
I
17 /
21 23
h CEP00226
2) Align with position of pin holes of shaft and
3)
carrier, then tap with a plastic hammer to install shaft (19). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. Insert pin (18). f After inserting the pin, caulk the pin portion of the carrier. -k After assembling the carrier assembly, check that gear (21) rotates smoothly.
I
18 I
30-62 0
CEPO0227
PC300, 350-6
DISASSEMBLY
SWING MACHINERY
AND ASSEMBLY
5.
No. 2 carrier assembly Raise No. 2 carrier assembly (17) and install. * Align the position so that the tip of the gear shaft enters at 4 places, then install.
6.
No. 2 sun gear I) Assemble thrust washer (16). * Assemble thrust washer (16) before installing No. 2 carrier assembly (17).
2)
7.
Install No. 2 sun gear (15) to No. 2 carrier, then install collar (14) and thrust washer (13).
Ring gear
Raise ring gear (12) and install. * Align with the drain hole and assemble. & Mating surface of ring gear and case: Gasket
sealant
(LG-6)
CUP06136
PC300, 350-6
DISASSEMBLY
8.
AND ASSEMBLY
SWING MACHINERY
Assemble No. 1 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. 11 Assemble bearing (IO) to gear (91, fit top and bottom thrust washers (8) and (11) and set gear assembly to carrier (7).
h
10
7
2) Align position of pin holes of shaft and car-
3)
9.
rier, then tap with a plastic hammer to install shaft (6). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. Insert pin (5). Ir After inserting the pin, caulk the pin portion of the carrier. * After assembling the carrier assembly, check that gear (9) rotates smoothly.
9
6
No. 1 carrier assembly Install No. 1 carrier assembly (4).
10. No. 1 sun gear I) Assemble No. 1 sun gear (3) to carrier assem bly. 2) Install thrust washer (2).
30-64 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
SWING MACHINERY
11. Cover
Install cover (I). & Cover mounting surface: Gasket sealant (LG-6) w Wlounting bolt: 1st pass: 98 Nm II0 kgm) 2nd pass: 80 - 90”
12. Refilling with oil
Tighten drain plug and add engine oil through oil filler. Q
Swing machinery case: Approx. 12.5 I?
PC300, 350-6
30-65 0
DISASSEMBLY
REVOLVING FRAME
AND ASSEMBLY
REMOVAL OF REVOLVING FRAME ASSEMBLY 1.
g
2.
Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. When disconnecting the hydraulic hoses, release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Disconnect boom cylinder hoses (I). * Fit blind plugs in the hoses and make it possible to swing the upper structure.
3.
Raise boom cylinder assembly (21, then pull out foot pin (3) and lift off. -f Remove the right cylinder assembly in the same way. Boom cylinder assembly: 300 kg kg &I
4.
Remove counterweight assembly. For details, see REMOVAL OF COUNTERWEIGHT ASSEMBLY.
5.
Remove engine hood (41, cover (51, and frame (6). + For details of the method of removing the engine hood, see REMOVAL OF HYDRAULIC COOLER ASSEMBLY.
6.
Leave 3 mounting bolts each at front and rear of revolving frame, and remove other mounting bolts. 1: Swing the upper structure and set to a position where it is easy to remove the mounting bolts.
7.
Disconnect drain hoses (7) and (8). Ir Install blind plugs in the drain hoses.
8.
Disconnect travel hoses (9) and (IO), and speed selector hose (I I).
9.
Pull out pin (12), and disconnect plate (13) from swivel joint.
30-66 0
6
CEFfJo393
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
REVOLVING FRAME
IO. Sling revolving
frame assembly (141, then remove mounting bolts, and lift off revolving frame assembly. Ir Use 2 lever blocks. * Loosen the mounting bolts remaining at the front and rear and adjust the center of gravity with the lever block while lifting off.
A kg
Revolving frame assembly: 7000 kg
INSTALLATION OF REVOLVING FRAME ASSEMBLY l
Carry out installation removal.
in the reverse order to
pJ Mating surface of swing circle: Gasket sealant (LG-41 & Thread of revolving frame mounting bolt: Thread tightener (LT-2) -Revolving frame mounting bolt: 926.7 + 103 Nm (94.5 t 10.5 kgml &
PC300, 350-6
30-67 0
DISASSEMBLY
SWING CIRCLE
AND ASSEMBLY
REMOVAL OF SWING ASSEMBLY
CIRCLE
1.
Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY.
2.
Sling swing circle assembly (I) at three points, then remove mounting bolts, and lift off swing circle assembly. & kg
Swing
circle assembly:
500 kg
INSTALLATION OF SWING 3 CIRCLE ASSEMBLY l
Carry out removal.
installation
in the
reverse
Inner race
order
to Front of machine +
a
Thread
of swing circle mounting
Thread tightener w *
&
bolt:
(LT-2)
circle mounting bolt: 926.7 * 103 Nm 194.5 t 10.5 kgm} Set the soft zone S mark on the inside ring of the inner race facing the right side of the machine as shown in the diagram, then install to the track frame. Swing circle: Grease (G2-LI) 33 e
30-68 0
Swing
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
IDLER, RECOIL SPRING
REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY 1.
Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. * Remove lubricator (I).
CEW0534
2.
Sling idler and recoil spring assembly (21, and pull out to the front to remove. * Fit wire to the idler and spring of the idler and recoil spring assembly, and adjust the balance when removing. & kg
3.
CEFWO
Idler, recoil spring assembly: 430 kg
Disconnect recoil spring assembly (4) from idler assembly (3). &I kg
Idler assembly: 170 kg
& kg
Recoil spring assembly: 260 kg
INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY l
Carry out installation removal.
*
in the reverse order to
When installing the idler assembly and recoil spring assembly, assemble so that the position of the greasing plug on the idler is on the outside for the right side of the machine and on the inside for the left side of the machine.
PC300, 350-6
30-69 0
DISASSEMBLY
IDLER
AND ASSEMBLY
DISASSEMBLY ASSEMBLY
OF IDLER
1.
Remove pin (21, then remove support (3).
2.
Remove floating seal (4) from support (3) and idler (5).
3.
Pull out shaft and support assembly (6) from idler (5). + It is filled with approx. 230 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.
6
CEPGQ540
4.
Remove floating seal (7) on opposite side from idler (5) and shaft and support assembly (6).
I 5.
Remove pin (91, then remove support (10) from shaft (I 1).
6.
Remove bushing (12) from idler (5).
L
30-70 0
CEPo0066
CEP00069
9
CEPOO550
PC300, 350-6
DISASSEMBLY AND ASSEMBLY
IDLER
ASSEMBLY OF IDLER ASSEMBLY 1.
Press fit bushing (12) to idler (5).
2.
Fit O-ring and install support (10) to shaft (Ill, then install pin (9). * After inserting the pin, caulk the pin portion of the support.
CEW0071
3.
Using tool Ll, install floating seal (7) to idler (5) and shaft and support assembly (6). * Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. * Remove all grease and oil from the contact surface of the O-ring and the floating seal.
9
CEPOO550
6
CEPO0063
I 4.
CEF-30073
Assemble shaft and support assembly (6) to idler (5).
PC300, 350-6
30-71 0
DISASSEMBLY
5.
AND ASSEMBLY
IDLER
Using tool Ll, install floating seal (4) to idler (5) and support (3). * Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. * Remove all grease and oil from the contact surface of the O-ring and the floating seal.
CEP00080
6.
Install O-ring, then assemble support (3) and install pin (2). li After inserting the pin, caulk the pin portion of the support.
7.
Add oil and tighten plug. Oil: Approx. 230 cc IEOSO-CD) Plug: 152 t. 24.5 Nm 115.5 I 2.5 kgm}
30-72 0
PC300, 350-6
DISASSEMBLY
RECOIL SPRING
AND ASSEMBLY
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
1.
2.
Remove piston assembly (2) from recoil spring assembly (II.
1
Ml
Disassembly of recoil spring assembly 1) Set tool Ml to recoil spring assembly (1).
g
2)
3)
4.
The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. * Installed load of spring: 173.3 kN (17,680 kg) Apply hydraulic pressure slowly to compress spring, then remove lock plate (31, and remove nut (4). * Compress the spring to a point where the nut becomes loose. * Free length of spring: 795 mm Remove yoke (61, cylinder (71, and dust seal (8) from spring (5).
Disassembly
1) 2)
Remove remove Remove ing (13)
PC300, 350-6
I
CEFOOO55
of piston assembly
lock plate (IO) from piston (91, then valve (I I). snap ring (121, then remove U-packand ring (14).
30-73 0
DISASSEMBLY AND ASSEMBLY
ASSEMBLY ASSEMBLY
RECOIL SPRING
OF RECOIL SPRING M2
1.
2.
3.
Assembly of piston assembly I) Assemble ring (14) and U-packing (13) to piston (9), and secure with snap ring (12). 2) Tighten valve (11) temporarily, and secure with lock plate (IO).
/8
‘7
Assembly of recoil spring assembly 11 Using tool M2. assemble dust seal (8) to cylinder (7). 2) Assemble cylinder (7) and yoke (6) to spring (51, and set in tool Ml. & Sliding portion of cylinder: Grease (G2-LI) 3) Apply hydraulic pressure slowly to compress spring, and tighten nut (4) so that installed length of spring is dimension “a”, then secure with lock plate (3) Ir Installed length “a” of spring: 648 mm 4) Remove recoil spring assembly (I) from tool Ml. Assemble piston assembly (2) to recoil spring assembly (I). 6 Piston sliding portion and wear ring: Grease IG2-Ll) * Assemble the cylinder assembly so that the mounting position of the valve is 90” to the side. Ir Fill the inside of the cylinder with approx. 200 cc of grease (G2-LI), then bleed the air and check that grease comes out of the grease hole.
30-74 0
CEPOO062
1
CEP00063
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
TRACK ROLLER
REMOVAL OF TRACK ROLLER ASSEMBLY 1.
Lower work equipment to ground, then loosen lubricator (I), and relieve track tension. m g The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards.
2.
Remove mounting bolts of track roller guard (2). then swing work equipment 90”, jack up machine with work equipment, and remove track roller guard (2) towards outside of machine.m &I kg
3.
CEP00534
CEPOOOB
Track roller guard: 35 kg
Lower chassis completely, remove mounting bolts of track roller assembly (3), then jack up machine with work equipment, and remove track roller assembly (3) to outside of machine. a & kg
Track roller assembly: 55 kg
INSTALLATION OF TRACK ROLLER ASSEMBLY l
Carry out installation removal.
*
in the reverse order to
Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. CEPOOQ83
6 m
& m
Roller guard mounting bolt: Thread tightener (LT-21 Roller guard mounting bolt: 926.7 t 103 Nm f94.5 t 10.5 kgm}
Track roller mounting bolt: Thread tightener (LT-2) Track roller mounting bolt: 1st pass: 196.1 2 19.6 Nm I20 + 2 kgmj 2nd pass: Tighten an additional 105 + 5”
PC300, 350-6
30-75 0
DISASSEMBLY
AND ASSEMBLY
TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER ASSEMBLY 785 I
1
1.
Remove pin (I), then remove collar (2).
2.
Remove floating seal (3) from collar (2) and roller (4).
3.
Pull out roller (4) from shaft (5). * It is filled with 250 - 280 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.
CEPOooRd
CEPOOa95
4.
Remove floating seal (6) on opposite side from roller (4) and collar (8).
CEP00087
5.
Remove pin (71, then remove collar (8) from shaft (5).
6.
Remove bushings (9) and (IO) from roller (4).
CEPOOOE9
6
7
30-76 0
CEFUO090
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY ASSEMBLY
OF TRACK ROLLER
1.
Using push tool 0, (IO) to roller (4).
2.
Assemble
collar
TRACK ROLLER
press fit bushings
(9) and
(8) to shaft (5), and install pin
(7). 3.
Using
tool L3, install floating
6
seal (6) to shaft
(5). * When assembling the floating seal, clean the contact surface of O-ring (6~) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. * After inserting the floating seal, check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 - 7 mm.
CEFOOOSl
Remove all oil and grease from hatched portion.
a, CEPOO093
4.
5.
Using tool L3, install floating seals (6) and (3) to roller (4). Ir For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see the precautions marked * for Step 3. Assemble
CEPOO092
Protrusion
of seal
5-7mm
-i
1
CEWOO94
I
b dI
shaft (5) to roller (4). 3 CEPOO095
6. 7.
CEPOcm6
Turn over roller (4) and shaft (5) assembly. Using tool L3, install floating
seal (3) to collar
(2). Ir For details of the precautions when installing floating seals (3a) and (3c), see the precautions marked * for Step 3.
CEPO0097
PC300, 350-6
CEFUW96
DISASSEMBLY
TRACK ROLLER
AND ASSEMBLY
8.
Assemble collar (2) to shaft (5), and install pin (1).
9.
Using tool L4, apply standard pressure to roller oil filler port, and check for leakage of air from seal. * Standard pressure: 0.1 MPa (1 kg/cm21 * Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
CEPOOlOO
10. Using tool L4, fill track roller assembly with oil, then tighten plug (II). Track roller oil: 250 - 280 cc (E030-CD) w
Plug: 14.7 t 4.9 Nm U.5 + 0.5 kgml
i To oil pump
r”
To vacuum tank CEPO0201
CEFO0202
30-78 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
CARRIER ROLLER
REMOVAL OF CARRIER ROLLER ASSEMBLY 1.
Lower work equipment to ground, then loosen lubricator (11, and relieve track tension. a A The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
CEP00534
2.
CEPO0051
Using hydraulic jacks 0, push up track to a position where carrier roller assembly can be removed, then remove carrier roller assembly (2). m r&Ikg
Carrier roller assembly:
35 kg
2
CEPO0203
INSTALLATION OF CARRIER ROLLER ASSEMBLY .
Carry out installation removal.
*
in the
reverse
order
to
Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension.
PC300, 350-6
30-79 0
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY
CEP00231
1.
Remove -
:
plug (I) and drain oil. Carrier
roller assembly:
2.
Set carrier
3.
Remove cover (2).
4.
Remove
roller assembly
450 - 500 cc
on stand 0.
ring (3).
CEP00233
5.
Using tool L5, remove
nut (4).
6.
Using push tool 0, pull out shaft assembly (5) from roller (6) with press, then remove inner race (7).
CEP00234
7.
Remove
8.
Disassembly of shaft assembly.
outer races (8) and (9) from roller (6). 6
I)
CEPO0235
Using puller 0,
remove
8
inner race (IO).
I
CEW0236
30-80 0
1
CEFW237
PC300, 350-6
CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY
2) 3)
Remove floating seals (11). Using push tool 0, remove shaft (13).
collar (12) from
L-l o
4
12
13 -
CEPO0238
PC300, 350-6
+-
CEP00239
30-81 0
DISASSEMBLY
CARRIER ROLLER
AND ASSEMBLY
ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1.
Using push tool 0, (9) to roller (6).
press fit outer races (8) and
0
L7 2.
Assembly of shaft assembly. 1) Using tool L7, press fit collar (12) to shaft (13). f When press fitting, be careful that there is no scuffing. & Fitting portion of shaft: Engine oil (E030-CD] 2)
3)
12 13 8 E+d ’
CEW0240
Using tool L6, assemble floating seals (11). * When assembling the floating seal, clean the contact surface of O-ring (11~) and floating seal Illa), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. * After inserting the floating seal, check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 - 7 mm. Assemble floating seals (I I), then using push tool 8, press fit inner race (IO). Ir For details of the precautions when installing floating seals (I 1b) and (I Id), see the precautions marked * for Step 2).
CEP00242
Remove all oil and grease from hatched portion.
CEP00241
CEP00243
Protrusion of seal
Jc!J ,P 5-7mm
CEFWJ093
3.
Assemble roller (6) to shaft assembly (5).
4.
Using push tool 0, press fit inner race (7). * When press fitting the bearing, rotate the roller, and press fit to a point where the rotation becomes slightly heavier.
5.
Using tool L5, tighten nut (4) to a point where drill hole in shaft is aligned with drill hole in nut.
I 30-82 0
CEPOO244
CEPOO094
CEPOO234
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
6.
Install ring (3).
7.
Using push-pull tates smoothly.
scale 8,
CARRIER ROLLER
check that roller ro-
CEPO0233
8.
CEW0247
Fit O-ring and install cover (2).
CEP00249
9.
Using tool L8, apply standard pressure to roller oil filler port, and check for leakage of air from seal. * Standard pressure: 0.1 MPa {I kg/cm21 * Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.
I
CEPO0249
10. Using tool L8, fill carrier roller assembly with
oil, then tighten plug (1). I&
Carrier roller oil: 450 - 599 cc (E030CD)
m
Plug: 14.7 + 4.9 Nm il.5
+ 0.5 kgm)
t To oil pump To vacuum pump CEPU0250
PC300,350-6
DISASSEMBLY
AND ASSEMBLY
TRACK SHOE
REMOVAL OF TRACK SHOE ASSEMBLY 1.
Positioning track shoe * Stop the machine at a point where it is easy to set master pin removal tool R, and where master pin is in the middle of the track frame, then loosen lubricator (I), and relieve the m track tension. g The adjustment cylinder is under extremely high pressure, so never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
2.
Using tool R, pull out master pin (2).
3.
Lay out track as follows. 1) Move machine forward so that position of temporary pin is at front of id!er, set block @ in position, then remove temporary pin 0, and remove dust seal. m 2) Drive machine in reverse to lay out track.
CEPO0051
CEP00534
(12(
INSTALLATION OF TRACK SHOE ASSEMBLY l
Carry out installation removal.
in the reverse order to
Adjust the track tension. For details, see TESTING AND ADJUSTING, Testing and adjusting track tension. m *
&
CEPO0297
Use tool R and press fit so that the protrusion of the master pin is dimension “a”. Protrusion “a” of master pin: 4.2 f 2 mm
When assembling the dust seal,coat the bushing contact surface with grease IG2-LI).
a
I I
30-84 0
II
CDPOOZ30
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANK ASSEMBLY l
A
Swing the upper structure to set the position of the hydraulic tank drain and mounting bolt outside the track. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic tank.
- : 2.
3. 4. 5. 6.
Hydraulic tank: Approx. 200 e
Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. Remove control valve top cover, hydraulic tank undercover, and main pump undercover. Open main pump side cover, then remove partitions (II and (2). Remove covers (3) and (4). Remove air conditioner air suction port (5).
CEFO0406
7.
Disconnect drain hoses (61, (71, and (8).
8.
Disconnect hydraulic oil filter inlet hose (9) and outlet hose (IO).
PC300, 350-6
30-85 0
DISASSEMBLY
HYDRAULIC TANK
AND ASSEMBLY
9. Disconnect hydraulic oil cooler return hose (1 I). IO. Disconnect drain hoses (121, (131, and (14). 11. Disconnect hydraulic oil level sensor connector
(15) (CN-PO9).
12. Remove main pump suction tube (16). Ir A box wrench cannot be fitted on the center rear mount bolt, so disconnect both sides of tube (16) and offset them.
,
I
CEFO0410
13. Remove mounting bolts, and lift off hydraulic m tank assembly (17). &I kg
Hydraulic tank assembly: 230 kg
INSTALLATION OF HYDRAULIC TANK ASSEMBLY l
Carry out installation removal.
w l
.
in the reverse order to
Hydraulic tank mounting bolt: 277 t 31.9 Nm 128.25 f 3.25 kgm}
Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air + Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
30-86 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
MAIN PUMP
REMOVAL OF MAIN PUMP ASSEMBLY -G g
Disconnect the cable from the negative (-1 terminal of the battery. A Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Remove hydraulic tank strainer, and using tool Sl, stop oil. * When not using tool Sl, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. - :
-kid!-
CEP00268
Hydraulic tank: Approx. 200 e
2. Drain coolant. 3. Remove main pump undercover.
undercover
and engine
4. Open engine hood. 5. Remove main pump top cover (I), tions (2) and (3).
and parti-
6. Remove muffler drain tube (4). 7. Disconnect chassis ground cable (5). 8. Remove bracket (6) of pump branch hose. Ir Do not disconnect the branch hose. 9. Disconnect suction tube (7). 16. Disconnect cooling hose (8).
-
II I
/
CWPO6106
11. Disconnect LS control hose (9). 12. Disconnect rear pump LS pressure
detection hose (IO). 13. Disconnect rear pump delivery pressure detection hose (I I). 14. Disconnect TVC wiring connectors (12) (C13, 14). 15. Disconnect TVC wiring clamp (13). 16. Disconnect front pump LS pressure detection hose (14). 17. Disconnect front pump delivery pressure detection hose (15). * After disconnecting the hoses, fit tags to distinguish them.
PC300, 350-6
30-87 0
DISASSEMBLY
AND ASSEMBLY
MAIN PUMP
18. Disconnect
hose (16) going to self-reducing pressure valve. 19. Disconnect hose (17) going to control valve. 20. Disconnect drain hose (18). 21. Sling main pump assembly (191, remove mounting bolts, then lift off. &I kg
Main pump assembly:
250 kg
INSTALLATION OF MAIN PUMP ASSEMBLY l
Carry out installation removal.
&
Involute
6
Mating
in the
reverse
order
to
spline of main pump:
Anti-friction
compound (LM-G)
surface of main pump case:
Gasket sealant (LG-6) l
Refilling with oil (damper case) * Add oil through the oil filler to the specified level. Run the engine, then stop the engine, wait for 15 minutes, and check the oil level again.
l
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
l
Bleeding air Ir Bleed the air. For details, see TESTING Bleeding air.
30-88 0
AND ADJUSTING,
PC300, 350-6
DISASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
AND ASSEMBLY
REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL 1.
Remove main pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY.
2.
Remove snap ring (I), then remove spacer (2).
3.
Lever up oil seal (3) with a screwdriver to rem move. * When removing the oil seal, be extremely careful not to damage the shaft.
F
CEPOO400
INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL .
Carry out installation removal.
& 6
*
in the reverse order to
Lip of oil seal: Grease (G2-LI) Coat the outside circumference of the oil seal with grease (G2-LI) thinly, then press fit. Using tool S2, press fit oil seal (3).
PC300, 350-6
CEP00401
30-89 0
DISASSEMBLY
CONTROL VALVE
AND ASSEMBLY
REMOVAL OF CONTROL VALVE ASSEMBLY a
g
* *
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. Make match marks before disconnecting the PPC circuit hoses. Fit blind plugs in the disconnected hoses and tubes. 1. Open engine hood. 2. Remove control valve top cover. 3. Disconnect turbocharger outlet port hose (I), and remove inlet port hose (2). 4. Disconnect air cleaner clogging sensor hose (3). 5. Disconnect air cleaner assembly (4) together with bracket. 6. Disconnect wiring harness (51, and remove partition (6).
7. Disconnect 9 bottom PPC hoses (7). 8. Disconnect pump merge/divider solenoid hose (8).
7
8
fi
CEFO0129
9. Disconnect pressure sensor connectors (9) and (IO) (CN-CO8 and CN-C07). 10. Disconnect main pump outlet hoses (11) and (12).
30-90 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
11. Disconnect
hoses (131, (141, (151, (16), (171, and
(18). * Hose (13): For arm boost PPC
Hoses (14) and (15): For R.H. straight travel Hoses (16) and (17): For L.H. straight travel Hose (18): For drain circuit
CONTROL VALVE
I
17
,I4
12. Disconnect hoses (19) and (20). + Hose (19): For drain circuit Hose (20): For high-pressure circuit 13. Remove elbows (211, (221, and (23). 14. Set hose mounts of elbows (24) and (25) facing down. 15. Disconnect control valve return hose (26).
16. Disconnect drain hose (27). 17. Disconnect 10 top PPC hoses (28). 18. Disconnect safety valve hose (29).
19. Disconnect high-pressure
circuit hose (30) and
LS pressure hoses (31).
I
PC300, 350-6
CEPO0134
30-91 0
DISASSEMBLY
AND ASSEMBLY
CONTROL VALVE
20. Disconnect swing motor suction hose (32). 21. Disconnect bucket hoses (331. 22. Disconnect 2 R.H. travel hoses (34). 23. Disconnect arm hoses (35). 24. Disconnect L.H. travel hoses (36).
:wPo614.4
25. Remove swing motor hoses (37). 26. Remove boom tubes (38) and (39). 27. Disconnect LS select valve hose (401.
28. Sling control valve assembly (411, then remove mounting bolts, and lift off control valve assembly. Ir Move slightly to the front and pass through the bracket to lift off. &I kg
Control valve assembly: 260 kg
INSTALLATION OF CONTROL VALVE ASSEMBLY l
l
Carry out installation removal.
in the reverse order to
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-92 0
PC300, 350-6
DISASSEMBLY
CONTROL VALVE
AND ASSEMBLY
DISASSEMBLY
OF CONTROL VALVE ASSEMBLY
(l/3)
89 W-J
2 ,106
//
Boom. arm-high Bucket R.H.travf Boom-low Swine
’
L.H.trave Arm-low
\ 90
t Z
27 25 23 21
I! 17 X DWPOO716
PC300, 350-6
30-93 0
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
15
16
13
14
II
I2
9
IO
7
0
5
6
3
Boom, arm-high Bucket R.H.travel Boom-low Swine L.H.travel Arm-low
4 I
2 A-A
26 24
23 21
‘22 19
20
17
I8
‘32
c-c
J-J
37
34 L-L
K-K
35
EE-EE
36 DWP00717
30-94 0
PC300,
350-6
DISASSEMBLY
CONTROL VALVE
AND ASSEMBLY
60
N-N (For
boom.
(For
(For
arm-high)
F-F sw ins)
54
53
bucket)
87/ E-E (For
travel)
AA-AA (For travel)
74 75 if \73
76
G-G (For
PC300,
350-6
boom)
DWPOO718
30-95 0
DISASSEMBLY
*
.
CONTROL
AND ASSEMBLY
VALVE
The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. The following procedure is for the 7-spool valve.
1.
Main relief valve 1) Remove main relief valve (2).
2.
Unload valve, safety-suction
valve, suction valve,
plug
1) Remove unload valve (1). 2) Remove safety-suction valves (17), (18), (22), and (26). 3) Remove suction valves (19), (201, (23, and (24). 4) Remove plugs (27) and (28). 3.
Pressure compensation valves * Before removing any pressure compensa-
tion valve, check and mark its mounting position. 1) Remove arm Hi IN pressure compensation valve (15), bucket DUMP pressure compensation valve (13), R.H. travel REVERSE pressure compensation valve (II), boom RAISE pressure compensation valve (9), right swing pressure compensation valve (7), L.H. travel REVERSE pressure compensation valve (5), and arm OUT pressure compensation valve (3). 2) Remove boom Hi RAISE pressure compensation valve (16), bucket CURL pressure compensation valve (14), R.H. travel FORWARD pressure compensation valve (12), boom LOWER pressure compensation valve (IO), left swing pressure compensation valve (8), L.H. travel FORWARD pressure compensation valve (6), and arm IN pressure compensation valve (4). * After removing the pressure compensation valves, remove check valve (88) from each pressure compensation valve mount. 4.
LS select valve Remove LS select valve (29).
30-96 0
PC300, 350-6
DISASSEMBLY
5.
6.
AND ASSEMBLY
CONTROL
LS shuttle valves, pump merge/divider valve, boom regeneration valve, block I) Remove LS shuttle valves (30) and (31). valve (32), 2) Remove pump merge/divider then remove boom regeneration spring (85) and boom regeneration valve (86). valve body (35) 3) Remove merge/divider and plugs (37) and (381, then remove spools (33) and (341, and springs (36) and (39). 4) Remove block (87). Arm control valve 1) Remove plug (40), then remove piston (42) and spring (41). 2) Remove case (43), then remove spring (44) and retainer (45). 3) Remove case (46), then remove spring (47) and retainer (48). 4) Remove spool assembly (49). * Do not disassemble spool assembly (49).
7.
Swing control valve 1) Remove case (501, then (51) and retainer (52). 2) Remove plug (531, then 3) 4) 5)
(54). Remove case (551, then (56) and retainer (57). Remove plug (581, then
remove
spring
remove
piston
remove
spring
remove
piston
VALVE
9. Boom control valve I) Remove case (681, then remove spring (69) and retainer (70). 2) Remove plug (711, then remove piston (72) and spring (73). 3) Remove case (74), then remove spring (75) and retainer (76). 4) Remove spool assembly (77). * Do not disassemble spool assembly (77). 10. Bucket control valve I) Remove case (781, then remove spring (79) and retainer (80). 2) Remove case (811, then remove spring (82) and retainer (83). 31 Remove spool assembly (84). Ir Do not disassemble spool assembly (84). 11. Arm regeneration valve . Remove plate (911, then remove arm regeneration spring (92) and arm regeneration valve (93).
(5% Remove spool assembly (60). * Do not disassemble spool assembly (60).
6.
R.H. travel control valve, L.H. travel control valve 1) Remove case (61), then remove spring (62) and retainer (63). Remove case (641, spring (651, and re2) tainer (66). 3) Remove spool assembly (67). Ir Do not disassemble spool assembly (67).
PC300, 350-6
30-97 0
DISASSEMBLY
AND ASSEMBLY
CONTROL
12. Boom Hi, arm Hi control valves Arm Hi control valve * Mark with tags to prevent mistakes in the mounting position when assembling the springs and spools. Remove case (1031, then pull out spool assembly to position shown in diagram on right. To prevent damage to spool assembly, hold position @ shown in diagram on right with a wrench (width across flats: 24mm), remove plug (951, then disassemble into retainer (96), springs (97a) and (97b), retainer (981, and spool (94).
VALVE
7a
CWPO6153
Boom Hi control valve * Mark with tags to prevent mistakes in the mounting position when assembling the springs and spools. 3) Remove case (1041, then remove spring (105) and plate (99). 41 To prevent damage to spool assembly, hold position @ shown in diagram on right with a wrench (width across flats: 24mm), remove plug (IOO), then disassemble into valve (IOI), plate (991, and spool (102). 13. Remove covers (89) and from valve body.
(90) and valve
(106)
O/ CWPO6154
30-98 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ASSEMBLY
CONTROL VALVE
OF CONTROL VALVE ASSEMBLY
(l/3)
Swing L. H. travel Arm-low
28
27
26
25
24
23
22
21
20
19 17 X DWP00716
PC300, 350-6
30-99 0
DISASSEMBLY
AND ASSEMBLY
CONTROL
VALVE
(Z/3)
15
16
13
14
11
12
9
IO
7
8
5
6
Boom, arm-hioh Bucket
3
4
R. H. travel Boom-low Swing L. H. travel Arm-low
I
2 A-A
B-B
26 ,24
23 21
c-c
J-J
DWP00717
30- 100 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
CONTROL VALVE
103 55 56 57
/ 25
87'
boom.
60
50 59
N-N (For
54 53
F-F (For
arm-high)
swins)
(For-.buc.ket)
(For
E-E travel)
64
42 AA-AA (For travel)
II 40
74 V-V
91
75
92
(For
arm)
76
G-G (For boom)
PC300, 350-6
DWP00718
30-101 0
DISASSEMBLY
Ir
1.
Check the spools and valves for dirt, damage, or burrs. Coat the sliding surfaces of all parts with engine oil before installing.
Covers Install valve (1061, and covers (89) and (90) to valve body. * Check that there is no damage to the O-ring, then install securely to the mating surface of the cover and valve. Ir Tighten the mounting bolts of covers (89) and (90) in the order shown in the diagram on the right. w Cover mounting bolt: 166.6 2 9.8 Nm I17 + 1 kgm}
2.
CONTROL VALVE
AND ASSEMBLY
B
AY++f D
c& CDFfJo544
Boom Hi, arm Hi control valve spools . Boom Hi control valve spool * Check the mounting position of the spring
1) 2)
and spool assembly carefully before installing. Fit seal to spool (1021, and install seal to valve (101). Assemble spool (102) to position shown in diagram on right, install plate (99) and valve (101) to spool (1021, then hold position @ shown in diagram on right with a wrench (width across flats: 24mm), and tighten plug
(411. w Plug: 13.2 + 1.5 Nm {I.35 = 0.15 kgm} 3) Push spool assembly into body, fit spring (105), then fit O-ring to case (104) and install. w Case mounting bolt: 30.9 = 3.4 Nm (3.15 + 0.35 kgm}
. +
1)
2)
3)
Arm Hi control valve spool Check the mounting position of the spring and spool assembly carefully before installing. Assemble spool (94) to position shown in diagram on right, install retainer (981, springs (97a) and (97b), and retainer (961, then install plug (95). Hold spool (94) at position @ shown in diagram on right with a wrench (width across flats: 24mm), and tighten plug (32). w Plug: 17.2 2 2.5 Nm Il.75 t 0.25 kgm} Push spool assembly into body, then fit Oring to case (103) and install. w Case mounting bolt: 30.9 2 3.4 Nm 6.15 + 0.35 kgm)
7a
CWPOBl
30-102 0
PC300, 350-6
DISASSEMBLY
3.
AND ASSEMBLY
Bucket control
valve
CONTROL
spool assembly (84) to valve
Swing control valve I) Assemble spool assembly (60) to valve
2) Assemble retainer (83) and spring (82),
2) Assemble piston (59), and install plug
I) Assemble
6.
body.
3)
4.
body.
then fit O-ring to case (81) and install. w Case mounting bolt: 30.9 t 3.4 Nm (3.15 t 0.35 kgm) Assemble retainer (80) and spring (79), then fit O-ring to case (78) and install. m Case mounting bolt: 30.9 + 3.4 Nm (3.15 2 0.35 kgm)
Boom control 1) Assemble
(58). m
Plug: 107.8 + 14.7 Nm Ill.0 t 1.5 kgm) 3) Assemble retainer (57) and spring (56), then fit O-ring to case (55) and install. w Case mounting bolt: 30.9 t 3.4 Nm 13.15 + 0.35 kgm) 4) Assemble piston (54), and install plug (53). w Plug: 107.8 a 14.7 Nm Ill.0 t 1.5 kgm} 5) Assemble retainer (52) and spring (51), then fit O-ring to case (50) and install. w Case mounting bolt: 30.9 + 3.4 Nm (3.15 + 0.35 kgm}
valve
spool assembly (77) to valve
body. Assemble retainer (76) and spring (75), then fit O-ring to case (74) and install. w Case mounting bolt: 30.9 t 3.4 Nm I3.15 z 0.35 kgm) 3) Assemble spring (73) and piston (72), and install plug (71). w Plug: 107.8 + 14.7 Nm III.0 + 1.5 kgm) 4) Assemble retainer (70) and spring (69), then fit O-ring to case (68) and install. m Case mounting bolt: 30.9 t 3.4 Nm t3.15 + 0.35 kgm) 2)
5.
VALVE
R.H. travel control valve, L.H. travel control valve I) Assemble spool assembly (67) to valve
2)
3)
body. Assemble retainer (66) and spring (65), then fit O-ring to case (64) and install. Q~EI Case mounting bolt: 30.9 t: 3.4 Nm 13.15 = 0.35 kgm) Assemble retainer (63) and spring (62), then fit O-ring to case (61) and install. m Case mounting bolt: 30.9 + 3.4 Nm 13.15 +. 0.35 kgm1
PC300, 350-6
7.
Arm control
valve
1) Assemble spool assembly (49) to valve body. Assemble retainer (48) and spring (47), then fit O-ring to case (46) and install. w Case mounting bolt: 30.9 2 3.4 Nm 13.15 t 0.35 kgm1 3) Assemble retainer (45) and spring (44), then fit O-ring to case (43) and install. w Case mounting bolt: 30.9 2 3.4 Nm 13.15 t 0.35 kgm) 4) Assemble spring (41) and piston (42), and install plug (40). m Plug: 2)
107.8 L 14.7 Nm Ill.0
+ 1.5 kgm)
30-103 0
DISASSEMBLY
CONTROL VALVE
AND ASSEMBLY
8. LS shuttle valve, pump merge/divider boom regeneration valve, block
valve,
1) Assemble
2)
3)
4)
springs (36) and (39) and spools (33) and (34) in merge/divider valve (351, then install plugs (37) and (38). m Plug (38): 39.2 + 4.5 Nm I4.0 +. 0.5 kgm} m Plug (37): 151.9 = 24.5 Nm (15.5 + 2.5 kgm} Assemble boom regeneration valve (86) and spring (85) in valve body, then install merge/ divider valve assembly (32). * Tighten the mounting bolts in the order shown in the diagram on the right. w Mounting bolt: 166.6 t 9.8 Nm {I7 f 1 kgm} Install LS shuttle valves (30) and (31). w Mounting bolt: 66.2 +. 7.4 Nm I6.75 +10.75 kgm} Install block (87). w Mounting bolt: 30.9 + 3.4 Nm I3.15 2 0.35 kgm}
9. LS select valve Install LS select valve (29). m LS select valve: 127.4 + 19.6 Nm I13 = 2 kgm}
CWPO6155
B
A+l-q+ D
c& CDP00544
10. Pressure compensation valves . Check the marks made on each
pressure compensation valve during disassembly, and install in the correct position. pressure compensation 11 Before installing valves below, install check valve (88). 2) Fit O-rings and install arm IN pressure compensation valve (41, L.H. travel FORWARD pressure compensation valve (61, left swing pressure compensation valve (8), boom LOWER pressure compensation valve (IO), R.H. travel FORWARD pressure compensation valve (121, bucket CURL pressure compensation valve (141, and boom Hi RAISE pressure compensation valve (16). m Pressure compensation valve: 392 3 19.6 Nm I40 r 2 kgm} 3) Fit O-rings and install arm OUT pressure compensation valve (31, L.H. travel FORWARD pressure compensation valve (51, right swing pressure compensation valve (71, boom RAISE pressure compensation valve (91, R.H. travel REVERSE pressure compensation valve (II), bucket DUMP pressure compensation valve (131, and arm Hi IN pressure compensation valve (15). w Pressure compensation valve: 392 t 19.6 Nm 140 + 2 kgm}
30-104 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
CONTROL
VALVE
11. Arm regeneration valve Assemble arm regeneration valve (93) and spring (921, then install plate (91). Sr Tighten the mounting bolts in the order shown in the diagram on the right. w Plate mounting bolt: 66.2 t 7.4 Nm I6.75 + 0.75 kgm} l
12. Unload valve, safety-suction valve, suction valve I) Fit O-rings and install plugs (27) and (28). w Plug: 49 + 9.8 Nm (5 t 1 kgm} 2) Fit O-rings and install suction valve assemblies (191, (20), (211, (231, and (24). w Suction valve: 147 t 9.8 Nm I15 t 1 kgm} 3) Fit O-rings and install safety-suction valves
4)
CKP00820
(171, (181, (221, and (26). w Safety-suction valve assembly: 147 + 9.8 Nm 115 t 1 kgm} Fit O-ring and install unload valve assembly (I). w
Unload
valve assembly: 166.6 + lg.6 Nm I17 t 2 kgml
13. Main relief valve . Fit O-ring and install main relief valve assembly (2). m Main relief valve assembly: 53.9 + 4.9 Nm (5.5 t 0.5 kgm}
PC300, 350-6
30-105 0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
OF PUMP MERGE/DIVIDER
PUMP MERGE/DIVIDER
VALVE
VALVE ASSEMBLY
CEFO0547
1. 2. 3. 4. *
Remove plug (2) from valve body (II, then remove spring (3) and spool (4). Remove plate (5). Remove plug (61, then remove spring (7) and spool (8). Remove plug (9). After disassembling, if there is any abnormality in body (I 1 or spools (4) or (81, replace the whole pump merge/divider valve assembly.
ASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY .
Before assembling, engine oil.
1.
Fit O-ring to plug (9) and install to valve body (1). m Plug (9): 39.2 + 5.9 Nm I4.0 = 0.6 kgm}
2.
Assemble spool (8) and spring (71, then fit Oring to plug (6) and install. w Plug (6): 39.2 t 5.9 Nm I4.0 + 0.6 kgm}
3.
Fit O-ring to plate (5) and install valve body.
4.
Assemble spool (4) and spring (31, then fit Oring to plug (2) and install. w Plug (2): 152 f 24.5 Nm 115.5 + 2.5 kgm}
30-106 0
coat the sliding surface with
PC300, 350-6
DISASSEMBLY AND ASSEMBLY
PRESSURE COMPENSATION
VALVE
DISASSEMBLY OF PRESSURE COMPENSATlOhi VALVE ASSEMBLY
CEPOO548
l
‘I.
2.
The structure of the parts for pressure compensation valves A - I is the same, but the part numbers for the component parts is different, so be careful when assembling. Remove piston sub-assembly (2) and piston (3) from sleeve (I), then remove seal (4). Ir Sub-piston assembly (2) is assembled to pressure compensation valves A-C, E-I, and piston (3) is assembled to pressure compensation valves D. Remove spring (51, then remove ring (6) and Orings (7) and (8) from sleeve (1). * After disassembling, if there is any abnormality in sleeve (I), seal (41, piston sub-assembly (21, or piston (3), replace the whole pressure compensation valve assembly.
Pressure compensation valves A: Arm IN Hi B: Boom RAISE Hi C: Boom LOWER D: R.H. travel REVERSE, L.H. travel REVERSE R.H. travel FORWARD, L.H. travel FORWARD E. Boom RAISE F: Arm OUT G: Bucket CURL H: Arm IN I: Right swing, left swing, bucket dump
ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY .
Before assembling, coat the sliding surface with engine oil. 1. Install O-rings (8) and (7) and ring (6) to sleeve (I). 2. Assemble spring (5), then assemble seal (4) to piston sub-assembly (2) and piston (3), and install to sleeve.
PC300, 350-6
30-107 0
DISASSEMBLY
AND ASSEMBLY
REMOVAL OF SERVO VALVE ASSEMBLY FOR FRONT PUMP g
Disconnect the cable from the negative (-1 terminal of the battery. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect TVC solenoid connector (I) (CN-C13). Disconnect clamp (2). Disconnect LS-EPC hose (31, LS pressure hose (41, and pump circuit pressure hose (5). * Fit blind plugs in the disconnected hoses. Remove servo valve assembly (6) for front pump. m
A 1. 2. 3.
4.
SERVO VALVE FOR FRONT PUMP
I
,
I
CEP00412
INSTALLATION OF SERVO VALVE ASSEMBLY FOR FRONT PUMP Carry out installation removal.
l
* * m Ir
l
in the reverse order to
Be careful not to let the O-ring or filter fall out when installing. Tighten the mounting bolts gradually on opposite sides in turn. Servo valve mounting bolt: 66.2 + 7.4 Nm 16.75 + 0.75 kgm} Check the performance of the work equipment, travel, and swing. For details, see TESTING AND ADJUSTING.
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-l 08 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
LS-EPC SOLENOID VALVE
REMOVAL OF LS-EPC SOLENOID VALVE ASSEMBLY a g
Disconnect the cable from the negative (-) terminal of the battery. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Open main pump side cover.
2.
Disconnect wiring connector (CN-CIO). * It is installed at the bottom of the EPC solenoid valve mounting bracket.
3.
Disconnect hose (I) going to main pump.
4.
Disconnect hose (2) going to hydraulic tank.
5.
Disconnect hose (3) coming from solenoid valve. * Fit blind plugs in the disconnected hoses.
6.
Remove LS-EPC solenoid valve assembly (4).
INSTALLATION OF LS-EPC SOLENOID VALVE ASSEMBLY l
Carry out installation removal.
30-l 10 0
in the reverse order to
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
SOLENOID VALVE
REMOVAL OF SOLENOID VALVE ASSEMBLY a A
Disconnect the cable from the negative (-) terminal of the battery. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. * Make match marks on the hoses and connectors.
1.
Disconnect solenoid wiring connectors (I). * Disconnect all connectors (VO2, 03, 04, 05, 06, and 07).
2. 3. 4. 5. 6.
Disconnect hose (2) coming from PPC. Disconnect hose (3) going to control valve. Disconnect drain hose (4). Disconnect hose (5) coming from accumulator. Disconnect hose (6) coming from self-pressure reducing valve. Disconnect outlet hoses (7) coming from each solenoid valve. Remove mounting bolts, then remove solenoid valve assembly (8).
7. 8.
.
When removing solenoid valve as an individual part I) Remove mounting bolts (91, then remove coil m (10). 2) Remove movable iron core (11) and O-ring (12). 31 Remove sleeve (13) and spool (14). 4) Remove washer (151, spring (161, and stopper (171, then clean valves.
3
.v/
CWPO6159
INSTALLATION OF SOLENOID VALVE ASSEMBLY l
Carry out installation removal.
in the reverse order to
m m
Mounting
bolt: 3.92 t 0.4 Nm IO.4 2 0.04 kgm}
CWPO6161
PC300, 350-6
CWPOG 162
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT PPC VALVE
REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY g
Lower the work equipment completely to the . . . ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Remove case. For details, see REMOVAL OF CONTROL STAND CASE.
2.
Disconnect wiring connector (I I.
3.
Remove joint bolt (21, and disconnect hose (3). m f Make match marks on the hoses.
4.
Remove mounting bolts, raise PPC valve assembly (41, then disconnect hoses (5) .and (61, and a remove.
CEP00419
INSTALLATION OF WORK EQUIPMENT, PPC VALVE ASSEMBLY l
Carry out installation removal.
in the reverse order to
w
Hose mount joint bolt: 29.4 3 4.9 Nm (3.0 + 0.5 kgml
w
Hose mount joint bolt: 39.2 + 4.9 Nm (4.0 2 0.5 kgm}
Ir
If there is excessive play in the control levers, adjust the PPC valve. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
30-l 12 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1.
Remove nut (I), then remove disc (2) and boot (3).
2.
Remove bolts, then remove plate (5). * Do not remove joint (4) unless it is to be replaced.
3.
Remove seal (6) and collar (7).
4.
Pull out piston (8), and remove retainer (91, springs (IO) and (II), and shim (12). * Spring (IO) consists of two springs each of two types with different installed loads, so check the mounting position (hydraulic port) and mark with tags to prevent mistakes when installing.
5.
Pull out valve (13) from body (14).
WORK EQUIPMENT
PPC VALVE
cl---’
8
U CEW0424
PC300, 350-6
30-l 13 0
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
PPC VALVE
ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1.
2.
3.
Assemble valve (13) to body (14). Assemble shim (12) and spring (II) to valve (13). Ir When assembling spring (II), set the end with the small coil diameter (inside diameter) at shim (12) end. Assemble spring (IO), retainer (9). and piston (8). * The number of loops in the coil for spring (IO) is different for each of the hydraulic ports below, so be careful when installing. Position of port
Free length of spring (mm)
~~ Ir
4. 5.
6.
7.
The position of each port is marked at the bottom of the valve body. & Piston: Grease (G2-LI) Ir When assembling piston (81, coat the outside of the piston and the inside of the hole in the body with grease. Fit O-ring to collar (7) and assemble in body (141, then install seal (6). Install plate (5). w Mounting bolt: 13.2 + 1.5 Nm (I.35 t 0.15 kgm} Install joint (4). & Sliding portion of joint: Grease (G2-LI) & Female thread of body: Thread tightener (LT-21 Ir Coat two places on the female thread with one drop of Loctite each as shown in the diagram on the right. w Joint: 44.1 + 4.9 Nm (4.5 t 0.5 kgm} * Keep strictly to the tightening torque. Assemble boot (3) and disc (21, and tighten with nut (I). w Nut: 112.8 + 14.7 Nm III.5 + 1.5 kgm} * After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.
30-114 0
CEP00425
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC VALVE ASSEMBLY a
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1.
Remove travel PPC valve undercover.
2.
Remove floor mat.
3.
Remove pedals (I) and levers (2).
4.
Remove cover (3).
5.
Remove covers (41, then remove springs (5).
6.
Disconnect 6 PPC hoses (71, and remove travel PPC valve assembly (8). m
INSTALLATION
111
CEW0426
a
-‘“\--r_
OF TRAVEL
PPC VALVE ASSEMBLY l
Carry out installation removal.
in the reverse order to
w
Cover mounting bolt: 19.6 + 2.0 Nm i2.0 r 0.2 kgm}
m
Hose mounting joint bolt (width across flats: 30mm): 39.2 t 4.9 Nm I4.0 + 0.5 kgm1
w
Hose mounting joint bolt (width across flats: 22mm): 29.4 d 4.9 Nm 13.0 t 0.5 kgm} 8
PC300, 350-6
30-l 15
DISASSEMBLY
AND ASSEMBLY
TRAVEL PPC VALVE
DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove screw (I), then remove lever (2).
2.
Remove mounting bolts (31, then remove case and shaft assembly (4).
3.
Remove mounting bolts (51, then remove plate (6) together with damper assembly (7). * Check the thickness and mounting position of washer (18).
4.
Remove mounting bolts (81, then remove damper assembly (7) from plate (6).
5.
Remove seal (9) and collar (IO).
6.
Pull out piston (II), and remove retainer (121, springs (13) and (141, and shims (1.5). * Check the number and thickness of shims (15) for each mounting position, and keep in a safe place.
7.
Pull out valve (16) from body (17).
CEPOO533
30-l 16 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
TRAVEL PPC VALVE
ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. 2.
3.
4. 5.
6.
7.
8.
Assemble valve (16) in body (17). Assemble shim (15) and spring (14) to valve (16). * Assemble the same number and thickness of shim (15) as was removed during disassembly. Standard shim thickness: 0.3 mm * Spring (14) is not symmetrical at the top and bottom, so assemble with the small coil diameter (inside diameter) at the shim end. Assemble spring (131, retainer (121, and piston (II). 6 Outside circumference of piston, body hole: Grease (G2- LI) Fit O-ring to collar (IO) and assemble in body (171, then install seal (9). Install damper assembly (7) to plate (61, then tighten mounting bolts (8). 6 Mounting bolt: Thread tightener (LT-2) w Mounting bolt: 4.4 t 0.5 Nm (0.45 t 0.05 kgm} Install plate (6) and damper assembly (7) as one unit, then tighten mounting bolts (5). * Temporarily assemble standard washer (1.6 mm) for washer (18). After completing the assembly, measure the difference in the angle when the left and right levers are operated fully. If the angle is greater than 0.7”, change the thickness of washer (18) to make the difference less than 0.7”. Ir Washer thickness: 1.0, 1.3, 1.6 mm * If the washer is thinner by 0.3 mm, the angle of the full stroke is 0.39” greater. m Mounting bolt: 30.9 a 3.4 Nm i3.15 * 0.35 kgm1 Install case and shaft assembly (41, then tighten mounting bolts (3). & Rocking portion of shaft, contact portion of lever and piston: Grease (G2-LII w Mounting bolt: 27.9 + 3.4 Nm (2.85 + 0.35 kgm} Install lever (21, then tighten screw (I). 6 Rocking portion of lever pin and plate: Grease (G2-LI) w Screw: 8.8 t 1.0 Nm (0.9 i 0.1 kgm)
CEPo0533
PC300, 350-6
30-117 0
DISASSEMBLY
AND ASSEMBLY
PPC SHUlTLE
VALVE
REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY A
A * *
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect the cable from the negative (-1 terminal of the battery. Make match marks at the male and female ends of the oil pressure switch connectors. Before disconnecting any hoses, check the distinguishing tape stuck to the hose, or make match marks.
1.
Disconnect
8 oil pressure
2.
Disconnect
12 PPC hoses (2).
3.
Disconnect 15 control valve hoses (3) (quick joint connection). Jg
4.
Disconnect 4 straight-travel hoses (4). Ir The elbows on the front two hoses are long, so hold the elbow with a wrench when disconnecting the hoses.
30-118 0
switch connectors
(1). m
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
5.
Disconnect clamp (5).
6.
Remove mounting bolts, then remove PPC shuttle valve assembly (6).
PPC SHUTTLE VALVE
INSTALLATION OF PPC SHUlTLE VALVE ASSEMBLY l
Carry out installation removal.
in the reverse order to
pg l
l
Check that the quick joint does not come out when the hose is pulled. Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC300, 350-6
30-119 0
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY
OF PPC SHUTTLE VALVE ASSEMBLY
1.
Disconnection of valve Remove mounting bolts (I), and disconnect shuttle valve assembly (21, travel junction valve assembly (3) and plate (4).
2.
Disassembly of shuttle valve assembly I) Remove 8 oil pressure switches (5). 2) Remove 2 slow return valves (6). 3) Remove shuttle valve (71. 4) Remove plugs (81, then remove balls (9). * There are 6 plugs and 6 balls.
3.
Disassembly of travel junction valve assembly 1) Remove 2 each of plug (IO), spring (II), and retainer (12). 2) Remove spool (13). 3) Remove 2 plugs (14).
30-l 20 0
PPC SHUTTLE VALVE
PC300, 350-6
DISASSEMBLY
ASSEMBLY
1.
2.
PPC SHUTTLE VALVE
AND ASSEMBLY
OF PPC SHUTTLE VALVE ASSEMBLY
Assembly of travel junction valve assembly. 1) Fit O-ring and install 2 plugs (14). m Plug: 17.2 * 2.5 Nm (1.75 t 0.25 kgm} 2) Assemble spool (131, and install 2 retainers (12) and springs (II). 3) Fit O-ring and install 2 plugs (10). w Plug: 107.9 t 14.7 Nm Ill.0 t 1.5 kgm1
4) 3.
Install 8 oil pressure switches (5).
Connection of valve Fit O-ring and assemble shuttle valve assembly (21, travel junction valve assembly (3) and plate (41, then tighten mounting bolts (I). QECI Mounting bolt: 66.2 + 7.4 Nm 16.75 + 0.75 kgm)
Assembly of shuttle valve assembly 1) Fit O-ring and assemble balls (91, then install plugs (8). Ir There are 6 plugs and 6 balls. m Plug: 34.3 t. 4.9 Nm 13.5 2 0.5 kgm} 2) Fit O-ring and install shuttle valve (7). Ir If the shuttle valve has been disassembled, be careful of the direction of installation of the poppet when assembling. 3) Fit O-ring and install 2 slow return valves (6). If the slow return valve has been dis* assembled, be careful of the direction of installation of the poppet when assembling.
PC300, 350-6
30-l 21 0
DISASSEMBLY AND ASSEMBLY
BOOM LOCK VALVE
REMOVAL OF BOOM LOCK VALVE ASSEMBLY A
1.
Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Drain hydraulic oil. - :
Hydraulic oil: Approx. 200 e
2.
Disconnect drain hose (I) and PPC hose (2). * Install blind plugs in the disconnected hoses.
3.
Remove tube clamp (3).
4.
Disconnect tube (4) coming from control valve.
5.
Disconnect tube (5) coming from boom cylinder.
6.
Remove mounting bolts (6). then remove boom lock valve assembly (7). -kWPO6164
INSTALLATION OF BOOM LOCK VALVE ASSEMBLY l
.
l
Carry out installation removal.
in the reverse order to
Refilling with oil * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air * Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
30- 122 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
BOOM LOCK VALVE
OF BOOM LOCK VALVE ASSEMBLY DISASSEMBLY
1.
Remove safety valve assembly (I). Ir The safety valve assembly cannot be adjusted when it is mounted on the machine, so do not disassemble it.
2.
Remove body (2), then remove spring (3) and check valve (4).
3.
Remove plug (51, then remove spacer (6L spring (71, seat (81, and spool (9).
ASSEMBLY OF BOOM LOCK VALVE ASSEMBLY *
Coat the sliding assembling.
1.
Assemble spool (91, seat (81, spring (71, and washer (6) to body (21, then fit O-ring and install plug (5). w Plug: 39.2 + 4.9 Nm (4.0 + 0.5 kgm1
2.
Assemble check valve (4) and spring (3) to body (IO), then fit O-ring and install body (2).
3.
Fit O-ring and install safety valve assembly (I). w Safety valve: 225.5 t 9.8 Nm I23 + 1 kgm)
PC300, 350-6
parts with engine oil before
30- 123 0
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
REMOVAL OF BOOM CYLINDER ASSEMBLY a
Extend the arm and bucket fully, lower the work equipment completely to the ground, and put the safety lock lever in the LOCK position.
1.
Disconnect grease hose (I).
2.
Sling boom cylinder assembly (21, and remove m lock bolt (3).
3.
Remove plate (41, then remove head pin (5j.m * There are shims installed, so check the number and thickness, and keep in a safe place.
4.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. + Set stand 0 under the cylinder assembly, and adjust the position for slinging the cylinder assembly. g Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.
5.
Disconnect hoses (6).
6.
Remove plate, then using forcing screws 0, remove bottom pin (71, and remove boom cylinder assembly (2). a Ir There are shims installed, so check the number and thickness, and keep in a safe place. & kg
I
_ -.
CEPO0056
CEPlW057
Boom cylinder assembly: 300 kg CEPO0056
30- 124 0
PC300,350-6
DISASSEMBLY
BOOM
AND ASSEMBLY
CYLINDER
INSTALLATION OF BOOM CYLINDER ASSEMBLY l
Carry out installation removal.
in the reverse order to
u *
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm. 0
&
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-G)
&
CEWO059
aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1.0 mm. Standard shim thickness: 1.0 mm, 1.5 mm
&When
*
l
&
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI
&
Greasing
g
*
after assembling
pin: Grease
(LM-G)
When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (2) and bracket (8) is less than 1.0 mm. Standard shim thickness: 1.0 mm, 1.5 mm l
.
Bleeding air * Bleed the air.
For details, see TESTING AND ADJUSTING, Bleeding air. .
4 2
/ CDPoo060
W’
R
mm
,8
comoo6i
Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
PC300, 350-6
30- 125 0
DISASSEMBLY
AND ASSEMBLY
ARM CYLINDER
REMOVAL OF ARM CYLINDER ASSEMBLY a
Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, lower the work equipment completely to the ground, then set the remaining safety lock lever to the LOCK position.
1. Set block @ between arm cylinder and boom.
2.
Remove plate (I), then remove head pin (2). m
3.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. & Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.
4.
Disconnect hoses (3).
5.
Disconnect grease hose (4).
6.
Raise arm cylinder assembly (51, remove plate (6), then remove bottom pin (7), and remove arm cylinder assembly (5). m + There are shims installed, so check the number and thickness, and keep in a safe place. & kg
30- 126 0
Arm cylinder assembly: 430 kg (PC300) 440 kg (PC3501
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ARM CYLINDER
INSTALLATION OF ARM CYLINDER ASSEMBLY l
Carry out installation removal.
& & a
& & g *
in the reverse order to
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole.
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-GI When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (5) and bracket (8) is less than 1.0 mm. Standard shim thickness: 1.0 mm
.8
l
l
l
Bleeding air * Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Bun the engine to circulate the oil through the system. Then check the oil level again.
PC300, 350-6
30-127 0
DISASSEMBLY
AND ASSEMBLY
BUCKET CYLINDER
REMOVAL OF BUCKET CYLINDER ASSEMBLY g
Extend the bucket cylinder piston rod to a point approx. 200 mm before the end of the DUMP stroke, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.
1.
Set block @ under arm top, block @ between link and arm, and block @I between bucket cylinder and arm.
2.
Remove lock bolt (I).
3.
Remove plate (21, then remove head pin (3). m
4.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.
5.
Disconnect hoses (4).
6.
Raise bucket cylinder assembly (51, remove plate (61, then remove bottom pin (71, and remove bucket cylinder assembly (5). B * There are shims installed, so check the number and thickness, and keep in a safe place. &I kg
m
Bucket cylinder assembly: 270 kg
CEPOOO77
30- 128 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
BUCKET CYLINDER
INSTALLATION OF BUCKET CYLINDER ASSEMBLY l
a
Carry out installation removal.
*
in the reverse order to
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm. 0 CEPOO059
A *
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between link (8) and link (9) is less than 1.0 mm. Standard shim thickness: 0.8 mm
Max. 1 mm
l
6 & A *
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the-. position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (5) and bracket (IO) is less than 1.0 mm. Standard shim thickness: 1.0 mm
l
.
Bleeding air Ir Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
.
Refilling with oil (hydraulic tank) -k Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
PC300,350-6
30-129 0
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1.
Piston rod assembly
1) Remove piping irom cylinder assembly. 2) Remove mounting bolts, and disconnect 3)
head assembly (I). Pull out piston rod assembly (2). Ir Place a container under the cylinder catch the oil.
to
CLPO3941
4)
Disassemble
i)
piston rod assembly
Set piston rod assembly
as follows.
(2) to tool Ul.
CLP03179
ii)
Remove piston assembly stopper screw (3). Screw size: Ml2 x pitch 1.75: Boom, Arm, Bucket
rlP03779
Ir
If screw (3) has been caulked strongly be removed, screw it in fully, then fit a tap to the thread and pull it out. and cannot
Tao
DKP00498
30-130 0
PC300, 350-6
DISASSEMBLY
HYDRAULIC CYLINDER
AND ASSEMBLY
iii) Using tool U6, remove piston assembly (4). . When not using tool U6, use the drill holes ($10: 4 places) and loosen the piston assembly.
DWP00715
iv) Remove . Arm v) Remove Arm vi) Remove l
plunger (5). and boom cylinder only collar (6). and boom cylinder only head assembly (71.
CLPO3762
vii) Remove cap (81, and pull out 12 balls (9), then remove cushion plunger (IO). Arm cylinder only l
J CWPO6166
2.
Disassembly 1) Remove 2) Remove 3) Remove 4) Remove
of piston assembly ring (III. wear ring (12). piston ring (13). O-ring and backup ring (14).
I
PC300, 350-6
CLP03764
30431 0
DISASSEMBLY
3.
HYDRAULIC CYLINDER
AND ASSEMBLY
Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) 3) 4) 5)
Remove seal (17). Remove Remove Remove
snap
ring (16). then
rod packing (18). buffer ring (19). bushing (20).
remove
dust
20
19 II
CLP02322
30-132 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY * *
1.
Be careful not to damage the packings, dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 - 60°C) before fitting it. Assembly of cylinder head assembly 1) Using tool U4, press fit bushing (20). 21 Assemble buffer ring (19). 31 Assemble rod packing (18). 4) Using tool U5, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).
CWPO6161
CWPO6162
20 I5 19 17 18
CLP02322
2.
Assembly of piston assembly 1) Using tool U2, expand piston ring (13). Ir Set the piston ring on tool U2, and turn the handle 8 - 10 times to expand the ring. 2) Set tool U3 in position, and compress piston ring (13).
CWPO6183
3) 4) 5)
Install backup ring and O-ring (14). Assemble wear ring (12). Assemble ring (11). Ir Be careful not to open the end gap of the ring too wide. & Ring groove : Grease (G2-LII
II
CWPO6164
12
13
I1
12 CLPO3764
PC300, 350-6
30- 133 0
HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY
3.
Piston rod assemblv I) Set piston rod assembly (2) to tool Ul.
CLPO3179
2) 3)
4) .
Assemble head assembly (7). Fit O-ring and backup ring to collar (6), then assemble. Boom and arm cylinder only Assemble plunger (5). Boom and arm cylinder only Ir Check that there is a small amount of play at the tip of the plunger.
CLPO3762
5)
6)
Set cushion plunger (IO) to piston rod, then assemble 12 balls (9), and secure with cap (8). . Arm cylinder only
.I0
Assemble piston assembly (4) as follows. When using rod and piston assembly (2) again Ir Wash thoroughly and remove all metal particles and dirt. i) Screw in piston assembly (4), then use tool U6 to tighten piston assembly (2) so that position of screw thread hole matches. * Remove all burrs and flashes with a file. ii) Tighten screw (3). m Screw (3): 66.2 2 7.35 Nm (6.75 t 0.75 kgm1 l
I 30- 134 0
DWP00715
PC300, 350-6
DISASSEMBLY
l
HYDRAULIC CYLINDER
AND ASSEMBLY
iii) Caulk thread at 2 places with punch. When using a new part for either or both of rod or piston assembly (2) * For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. . Arm cylinder only
I i)
Screw in until piston assembly (4) contacts end face of rod, then use tool U6 to tighten. w Piston assembly (4): 294 z 29.4 Nm I30 t 3.0 kgml Ir After tightening the piston, check that there is play in plunger (51. . Boom, arm cylinder only
ii)
Machine one hole used to install screw (3). * Align a drill horizontal with the V-groove of the thread of rod (2) and piston (41, then carry out machining. Ir For the cylinder with bottom cushion (arm cylinder), avoid the cushion plug position when machining. Screw machining dimension (mm)
DKP00500
DKP00501
l
Drill Bottom Tap Tap diameter hole depth I used I depth 10.3
27
12x1.75
20 CLPO3792
iii) After machining, wash thoroughly to remove all metal particles and dust. iv) Tighten screw (3). m Screw (3): 99.2 t 7.35 Nm 16.75 t 0.75 kgml VI Caulk thread at 2 places with punch.
CLPO3779
PC300, 350-6
DISASSEMBLY
7)
AND ASSEMBLY
HYDRAULIC CYLINDER
Assemble piston rod assembly (2). & Seal portion: Grease (G2-LI) * Set the end gap of the ring at the horizontal (side) position, align the axial center of shaft and cylinder tube, then insert. * After inserting, check that the ring is not broken and has not come out, then push in fully.
DLP00502
8)
Tighten head assembly (I) with mounting bolts. w Mounting bolt : Cylinder
Tightening torque
Bucket 373 + 84.0 Nm t38.0 * 5.5 kgml Arm
530 i 78.5 Nm I54.0 t 8.0 kgm)
Boom
373 t 54.0 Nm (38.0 * 5.5 kgm} CLPO394
1
9) Install piping.
30-136
0
PC300, 350-6
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
REMOVAL OF WORK EQUIPMENT ASSEMBLY g
Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position.
1. 2.
Disconnect grease hose (I). Sling boom cylinder assembly (21, and remove m lock bolt (3). Remove plate (41, then remove head pin (5j.m * There are shims installed, so check the number and thickness, and keep in a safe place. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out, and lower cylinder onto stand. * Disconnect the boom cylinder on the opposite side in the same way. g Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (71, and secure to valve with rope. Disconnect wiring connector (8) for working lamp.
3.
4.
5. 6.
7. 8.
Remove plate, and set tool V to boom foot pin (9). Raise work equipment assembly (IO), then remove boom foot pin (9) using tool V, and remove work equipment assembly (IO). If * There are shims installed, so check the number and thickness, and keep in a safe place. r3 kg
Work equipment assembly: 5700 kg
I
f’C300, 350-6
CDFOO280
DISASSEMBLY
AND ASSEMBLY
WORK EQUIPMENT
INSTALLATION OF WORK EQUIPMENT ASSEMBLY l
Carry out installation removal.
in the reverse order to
a *
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm.
&
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1.0 mm. Standard shim thickness: 1.0 mm, 1.5 mm
& a *
CEW0059
l
&
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) &I& Grease after assembling pin: Grease (LM-G) A When aligning the position of the pin hole, never insert your fingers in the pin hole. * Adjust the shim thickness so that the clearance between the end face of the foot of boom (11) and bracket (12) is less than 1.0 mm. Standard shim thickness: 0.8 mm, 1.5 mm
Max. I mm
l
l
l
Bleeding air + Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-138 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
BUCKET
REMOVAL OF BUCKET ASSEMBLY A
Set the back of the bucket facing down, lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position.
1.
Remove lock bolt (1).
2.
Remove connecting pin (2) between link and bucket. a Ir There are shims installed, so check the number and thickness, and keep in a safe place.
a
3.
Start engine, and retract piston rod, then tie link to arm with wire to prevent piston rod from coming out.
4.
Remove lock bolt (3).
5.
Remove plate (41, then remove connecting pin (5) between arm and bucket. m * There are shims installed, so check the number and thickness, and keep in a safe place.
6.
Start engine, then raise work equipment swing to remove bucket assembly (6). r&Ikg
CEFU0285
a
and
Bucket assembly: 1050 kg
6 CEP00287
PC300, 350-6
30- 139 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation removal.
II, *
& 6 A *
BUCKET
OF BUCKET
in the reverse order to
E3j When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm.
CEP00059
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the boss of bucket (6) and link (7) is less than 1.0 mm. Standard shim thickness: 0.8 mm
l
& & A * *
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Insert the O-ring at the end face of the bucket boss securely. Adjusting bucket clearance. 1) Measure clearance a between arm (8) and bushing (9). It is easier to measure if the bucket * is moved to one side so that all the play is in one place. 2) Select shim thickness b so that clearance a is 0.5 - 1.0 mm. Ir Standard shim thickness: 0.5 mm, 1.0 mm 3) Install selected shim, then install plate (4).
30- 140 0
-!-Max.
1 mm CDP00288
a
b
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
ARM
REMOVAL OF ARM ASSEMBLY 1.
Remove bucket assembly. For details, see REMOVAL OF BUCKET ASSEMBLY.
2.
Secure link to arm with wire. a Extend the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke, then lower the arm on to block @ and stand 0, and set the safety lock lever to the LOCK position.
3.
Set block @ between arm cylinder and boom.
4.
Remove plate (11, then remove arm cylinder head pin (2). If
5.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. g Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.
6.
Disconnect 2 bucket cylinder hoses (3).
7.
Remove plate (41, then remove connecting pin (5) between arm and boom. m * There are shims installed, so check the number and thickness, and keep in a safe place.
8.
Start engine, then raise boom and swing to remove arm assembly (6). & kg
Arm assembly: 1500 kg
PC300, 350-6
30-141 0
DISASSEMBLY
AND ASSEMBLY
INSTALLATION ASSEMBLY l
Carry out installation removal.
& & g
ARM
OF ARM
in the reverse order to
Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-GI When aligning the position of the pin hole, never insert your fingers in the pin hole.
&
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) && Grease after assembling pin: Grease (LM-G) a When aligning the position of the pin hole, never insert your fingers in the pin hole. * Adjust the shim thickness so that the clearance between the end face of the bottom of arm (6) and boom (7) is below 1.0 mm. Ir Standard shim thickness: 1.0 mm .
l
Max. 1 mm I
Bleeding air * Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-142 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
BUCKET, ARM
REMOVAL OF BUCKET, ARM ASSEMBLY g
Extend the bucket cylinder piston rod to the end of the CURL stroke, and the arm cylinder piston rod to a point approx. 200 mm before the end of the IN stroke. Then lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position.
1.
Set block @ to bucket cylinder bottom mounting boss portion of arm.
2.
Remove plate (I), then remove arm cylinder head pin (2). m
3.
Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.
4.
Disconnect 2 bucket cylinder hoses (3).
5.
Remove plate (41, then remove connecting pin (5) between arm and boom. a Ir There are shims installed, so check the number and thickness, and keep in a safe place.
6.
Start engine, then raise boom and swing to remove bucket and arm assembly (6). &I kg
CEP00294
Bucket, arm assembly: 2600 kg
CEPWZ95
PC300, 350-6
30-143 0
DISASSEMBLY
AND ASSEMBLY
BUCKET, ARM
INSTALLATION OF BUCKET, ARM ASSEMBLY .
Carry out installation removal.
& & A
& & A +
in the reverse order to
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole.
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the bottom of arm (6) and boom (7) is less than 1.0 mm. Standard shim thickness: 1.0 mm
Max. 1 mm I
l
l
.
Bleeding air * Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-l 44 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
BOOM
REMOVAL OF BOOM ASSEMBLY 1.
2. 3. 4.
5.
6. 7. 8. 9.
Remove bucket and arm assembly For details, see REMOVAL OF BUCKET, ARM ASSEMBLY. A Lower the boom assembly completely to the ground, and set the safety lock lever to the LOCK position. Disconnect grease hose (1). Sling boom cylinder assembly (2), and remove lock bolt (3). m Remove plate (41, then remove head pin (5). m * There are shims installed, so check the number and thickness, and keep in a safe place. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out, and lower it onto stand. Ir Disconnect the boom cylinder on the opposite side in the same way. A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (71, and secure to valve with rope. Disconnect wiring connector (8) for working lamp Remove plate, and set tool V to boom foot pin (9). Raise boom assembly (IO), remove boom foot pin (9) using tool V, then remove boom assembly (IO). B * There are shims installed, so check the number and thickness, and keep in a safe place. r+ kg
Boom assembly: 3000 kg CDPOO280
CEPO0299
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
INSTALLATION
BOOM
OF BOOM
ASSEMBLY l
Carry out installation removal.
in the reverse order to
m Ir
When tightening the locknut, tighten so that the clearance between the plate and nut is 0.5 - 1.5 mm. 0.5
& & g *
+
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1.0 mm. Standard shim thickness: 1.0 mm, 1.5 mm
CEPOOO59
l
’
& & g *
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that the clearance between the end face of the foot of boom (IO) and bracket (11) is less than 1.0 mm. Standard shim thickness: 0.8 mm, 1.5 mm
II
I I
2
CDPOOO60
Max. 1 mm ,
l
.
.
Bleeding air Ir Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.
11 CDP00900
Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-l 46 0
Pc300, 350-6
DISASSEMBLY
AND ASSEMBLY
OPERATOR’S CAB
REMOVAL OF OPERATOR’S CAB ASSEMBLY a
Disconnect the cable from the negative (-) terminal of the battery.
1.
Remove floor mat.
2.
Remove operator’s seat (I). * Be careful not to damage the covers.
3.
Remove knob (2).
4.
Remove 4 bolts and 1 clip, then remove panels (3) and (4).
5.
Disconnect window washer hose (5).
6.
Remove plate (61, then remove left cover (7).
CEPOO440
7.
CEFU0441
Disconnect hose (8) and speaker wiring connector, then remove right cover (9). * Lift up right cover (9) slightly before disconnecting the speaker wiring connector.
442
Pc300,350-6
30- 147 0
DISASSEMBLY
AND ASSEMBLY
OPERATOR’S CAB
8. Remove cover (IO) and duct (II). 9. Disconnect air conditioner cable (12).
10. Disconnect duct (13) at front. 11. Disconnect 11 connectors (14). * Panel: CN-X07 (MIC211 Ir Controller: CN-CO1 (MIC13) : CN-CO2 (MIC21) : CN-CO3 (MIC20) : CN-Cl6 (MIC17) * Wiring harness intermediate : CN-HI2 (S16) White : CN-HI3 (S16) Blue : CN-HI4 (M6) : CN-HIS (L2) Ir Speaker: CM-Ml3 (KES-2) Ir Air conditioner: No connector No.
CEPO0443
12- Y\‘/
I ‘is
12. Remove 4 mounting nuts and 6 mounting bolts, then lift off operator’s cab assembly (15). /GJ Operator’s cab assembly: 300 kg &I kg . %: Nut A: Bolt * Check the length of the bolts.
CEF’O0445
INSTALLATION OF OPERATOR’S CAB ASSEMBLY l
Carry out installation removal.
w
in the reverse order to
Mounting nut: 277.0 t 31.9 Nm 128.25 t 3.25 kgm) -
30-148 0
CEPC0446
Pc300, 350-6
DISASSEMBLY
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
1.
Set lifting hook chains of counterweight bly in position, and sling.
2.
Remove mounting bolts (I). * Check the location of the shims.
3.
Lift off counterweight & kg
COUNTERWEIGHT
AND ASSEMBLY
Counterweight
assem-
assembly (2).
m
assembly: 5500 kg 1
CEPCO536
INSTALLATION OF COUNTERWEIGHT ASSEMBLY l
Carry out installation removal.
& w
in the reverse order to
Adjust the stepped difference (top and bottom clearance) from the bodywork with shims. Install so that the clearance between the door and counterweight and the clearance between the revolving frame and the counterweight are a uniform IO + 5 mm. Thread of counterweight mounting bolt: Thread tightener (LT-2) Counterweight mounting bolt: 1814.1 + 98.1 Nm (185 t 10 kgm}
PC300, 350-6
30-149 0
DISASSEMBLY
AND ASSEMBLY
REMOVAL
OF AIR
AIR CONDITIONER COMPRESSOR
CONDITIONER COMPRESSOR ASSEMBLY a
Disconnect the cable from the negative (-1 terminal of the battery.
1.
Open engine hood, then install tool Xl to portion @ of air cqnditioner compressor hose, and collect refrigerant (R134a).
2.
Remove fan guard (I).
3.
Loosen lock bolts (2) and (3).
4.
Remove drive belt (4) from pulley.
m
5.
Disconnect hose (6).
a
6.
Remove lock bolts (2) and (3), then remove air conditioner compressor assembly (7). * It is difficult to remove the compressor mounting bolts, so remove together with the bracket.
CWPO6166
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY l
Carry out installation removal.
in the reverse order to
Check that the O-rings are not damaged or deteriorated, then connect the hoses.
Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting belt tension for air conditioner compressor. l
Charging air conditioner with gas * Using tool Xl, charge the air conditioner circuit with refrigerant (R134a).
30- 150 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER CONDENSER
REMOVAL OF AIR CONDITIONER
CONDENSER
ASSEMBLY g a
Disconnect the cable from the negative (-1 terminal of the battery. Collect refrigerant (R134a). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY.
1.
Remove control valve top cover and disconnect condenser wiring connector (I 1 (M35).
2.
Open air conditioner condenser side cover.
3.
Disconnect hose (2) coming from air conditioner compressor.
4.
Disconnect hose (3) going to receiver tank.= Ir The connection at the condenser end breaks easily, so always use 2 wrenches: one wrench to hold the connection and the other to loosen the hose.
5.
Remove mounting bolts, then remove air conditioner condenser assembly (4).
INSTALLATION OF CONDENSER ASSEMBLY l
Carry out installation removal.
*
l
in the reverse order to
Check that the O-rings are not damaged or deteriorated, then connect the hoses.
Charging air conditioner with gas * Using tool Xl, charge the air conditioner circuit with refrigerant (R134a).
PC300, 350-6
30-l 51 0
DISASSEMBLY
AND ASSEMBLY
RECEIVER TANK
REMOVAL OF RECEIVER TANK ASSEMBLY a g
Disconnect the cable from the negative (-) terminal of the battery. Collect refrigerant (R134a). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY.
1.
Open air conditioner condenser side cover.
2.
Disconnect hose (I) coming from air conditioner condenser.
3.
Disconnect hose (2) going to air conditioner unit.
4.
Disconnect clamp (3) of hose (1).
5.
Remove 2 U-bolts (41, then remove receiver tank assembly (5).
INSTALLATION OF RECEIVER TANK ASSEMBLY l
Carry out installation removal.
*
l
in the reverse order to
Check that the O-rings are not damaged or deteriorated, then connect the hoses.
Charging air conditioner with gas * Using tool Xl, charge the air conditioner circuit with refrigerant (R134a).
30-l 52 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY g
Disconnect the cable from the negative (-1 terminal of the battery.
1.
Collect refrigerant (R134a). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY.
2.
Close heater warm water outlet valve at engine end.
3.
Remove operator’s seat.
4.
Remove plate (I), then remove cover (2).
5.
Remove cover (3). * The speaker is installed to the cover, so disconnect the wiring connector (M73) of the speaker.
6.
Remove hose (4) from duct.
7.
Remove cover (5) and duct (6).
8.
Remove duct (7).
PC300,350-6
CEWOlO5
DISASSEMBLY
AND ASSEMBLY
AIR CONDITIONER
UNIT
9. Disconnect wiring connector (8) (M26). IO. Disconnect wiring connector (9) (AC-I). 11. Disconnect cable (IO) from receiver.
12. Disconnect heater hose (II). 13. Disconnect air conditioner hose (12). 14. Remove air conditioner unit (13). + Check that all the connectors have been disconnected.
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY l
l
l
Carry out installation removal.
in the reverse order to
Refilling with water * Add water up to the water filler port. Run the engine to circulate the water through the system. Then check the water level again at the reserve tank. Charging air conditioner with gas Ir Using tool Xl, charge the air conditioner circuit with refrigerant (R134a).
30-154 0
PC300, 350-6
DISASSEMBLY
AND ASSEMBLY
GOVERNOR, PUMP CONTROLLER
REMOVAL OF GOVERNOR, PUMP CONTROLLER ASSEMBLY A
Disconnect the cable from the negative (-1 terminal of the battery.
1. Slide operator’s seat fully forward.
2.
Remove plate (I), then remove cover (2).
3.
Remove cover (3). Ir The speaker is installed to the cover, so disconnect the wiring connector (M73) of the speaker.
4.
Disconnect hose (4) from duct.
5.
Disconnect 5 connectors (5). * Connectors = (COI, 02, 03! 16, 17)
6.
Remove governor and pump controller assemm bly (6).
NSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY l
Carry out installation removal.
in the reverse order to
pJ l
Check the performance of the work equipment, travel, and swing. For details, see TESTING AND ADJUSTING.
PC300, 350-6
30-155 0
DISASSEMBLY AND ASSEMBLY
MONITOR PANEL
REMOVAL OF MONITOR PANEL ASSEMBLY A
Disconnect the cable from the negative (-) terminal of the battery.
1. Remove 4 screws (I),
and disconnect monitor panel assembly (2) from bracket.
2.
Disconnect connectors (31, then remove monitor panel assembly (2). m CEP00436
INSTALLATION OF MONITOR PANEL ASSEMBLY l
Carry out installation removal.
in the reverse order to
m l
Check the mode setting and display function. For details, see TESTING, ADJUSTING, AND TROUBLESHOOTING. I
30-156 0
-
CEPO0437
PC300, 350-6
DISASSEMBLY
CONTROL STAND CASE
AND ASSEMBLY
REMOVAL OF CONTROL STAND CASE 1.
Tray 1) Insert a thin flat-headed screwdriver into notch at rear of tray (I) and lever up lightly to release rear claw (2). * The claw can only be released from the rear.
1
9 (ry,
Pull tray (I) to rear to remove.
Boot 1) Insert a thin flat-headed screwdriver between boot (3) and upper case (4), remove claw (5) at front of boot from upper case, then raise front. 2)
Pull boot (3) to front to remove claw at rear jFJ of boot.
3)
Disconnect wiring connector (7) from hole for removed tray. Push boot up, remove bolt (81, then remove lever (9) and boot (3). * Check the direction of the lever.
PC300, 350-6
CEPO608
CEW0609
$ 5
CEFQ0604
4)
L’ -
a
I 2.
/
II CEPOO607
2)
\\
DISASSEMBLY
3.
AND ASSEMBLY
CONTROL STAND CASE
Upper case 1) Remove 4 upper case mounting screws (IO).
CEP00421
2)
CEW0422
Push bottom center of upper case (11) from both sides, and lift up to release claws at both sides.
I 3)
Use a screwdriver from front of upper case (11) to release claws (12) at front of case.
4)
Remove upper case (I I).
CEP00423
II
CEP00602
INSTALLATION OF CONTROL STAND CASE l
Carry out installation removal.
in the reverse order to
Jr When installing the boot, insert the claw at the rear first. m Ir
When installing the tray and upper case, insert the claws at the front first.
30-158 0
CEWOW3
PC300, 350-6
40
MAINTENANCE
STANDARD
Engine mount ............................................... Swing machinery ........................................ Swing circle ................................................. Final drive .................................................... Track frame and recoil spring ................... Idler ............................................................... Carrier roller ................................................ Track roller.. ................................................. Track shoe.. .................................................. Hydraulic pump.. ........................................ Control valve ............................................... Self-reducing pressure valve ...................... Suction-safety valve. .................................. Swing motor.. .............................................. Travel motor ................................................ Work equipment swing PPC valve ........ Travel PPC valve ........................................ Service PPC valve ...................................... PPC shuttle valve, travel junction valve . . LS-EPC valve.. .............................................. Solenoid valve ............................................ Center swivel joint ..................................... Boom holding valve.. ................................... Hydraulic cylinder ...................................... Work equipment.. ......................................... Dimensions of work equipment ................ l
PC300, 350-6
40- 2 40- 4 40- 6 40- 8 40-10 40-12 40-14 40-15 40-16 40-20 40-22 40-29 40-30 40-31 40-32 40-33 40-34 40-35 40-36 40-37 40-38 40-40 40-41 40-42 40-44 .40-46
40-l
MAINTENANCE
ENGINE
STANDARD
MOUNT
ENGINE MOUNT
swP00401
B-B
A-A
Unit: mm
No.
Check item
,
Free height of front mount rubber
Remedy
Criteria Standard 84
size
Repair
limit
Replace
2
Free height rubber
40-2
of rear mount
126
-
PC300, 350-6
MAINTENANCE
SWING
STANDARD
SWING MACHINERY
MACHINERY
I
m
III
’
927*103Nm f94.5*10.5koml
--It=, -_
I
SWPO4806
40-4
PC300, 350-6
MAINTENANCE
STANDARD
SWING
MACHINERY
Unit:
NO
Check
item
Criteria
mm
Remedy
Standard
clearance
Clearance
1
Backlash between swing motor shaft and No. 1 sun gear
2
Backlash between No. 1 sur gear and No. 1 planet gear
0.15 - 0.49
3
Backlash between No. 1 planet gear and ring gear
0.17 - 0.57
4
Backlash between No. 2 planet carrier and coupling
0.06 - 0.25
5
Backlash between No. 1 planet carrier and No. 2 sun gear
0.38 - 0.66
6
Backlash between No. 2 sur gear and No. 2 planet gear
0.15 - 0.49
7
Backlash between No. 2 planet gear and ring gear
0.17 - 0.57
8
Backlash between and swing pinion
0.07 - 0.23
-
9
Backlash between pinion and swing
0 - 1.21
2.00
10
Clearance between and coupling
11
Wear of swing pinion seal contact surface
coupling
limit
-
0.18 - 0.29
I
1.00
1.10
-
1.20 Replace
I
0.90
1 .oo
swing circle plate
Standard
-
PC300,
350-6
oil
-
0.38 - 0.82
0
size
I 4o-0.100
Reoair
I
limit
-
Repair hard chrome plating or replace
40-5
MAINTENANCE
SWING
STANDARD
SWING CIRCLE
CIRCLE
-_
---..
L___i
;_
I
-__-
__
I
I
I
I
I
Unit: mm No.
1
40-6
Check item Clearance of bearing in axial direction (when mounted on machine)
Criteria Standard
clearance
0.5 - 1.6
Remedy Clearance 3.2
limit Replace
PC300, 350-6
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
m
Is 2n
\
1
3:’ _’ ! /
F’
1 4 I-_-_
____
2
40-8
-L-L& ______
5
i
el
j
‘._..-._-..-_.
1
z..T-.K-_._._--.-, _______-____________ SWPO4807
PC300, 350-6
MAINTENANCE
FINAL DRIVE
STANDARD
Unit: mm
Check item
No
Criteria
Remedy
-
1
Backlash between No. 1 sun gear and No. 1 planet gear
2
Standard
Clearance
clearance
limit
0.17 - 0.50
1 .oo
Backlash between No. 1 planet gear and ring gear
0.24 - 0.64
1.00
3
Backlash between No. 2 planet carrier and motor
0.06 - 0.24
4
Backlash between No. 2 sun gear and No. 2 planet
0.17 - 0.52
-
1.oo Replace
gear 5
Backlash between No. 2 planet gear and ring gear
0.21 - 0.64
1.00
6
Backlash between No. 1 planet carrier and No. 2 sur aear
0.38 - 0.78
1 .oo
7
End play of sprocket
shaft
0.10 - 0.15 I
8
Wear
of sprocket
teeth
Repair Standard
9
Sprocket
-
PC300, 350-6
size
limit: 6 Repair
limit qebuild or peplace
tooth width
I
40-9
MAINTENANCE
STANDARD
TRACK FRAME AND
RECOIL SPRING
TRACK FRAME AND RECOIL SPRING +
The
diagram
shows
the
PC300-6
_-__-_____-_______-_____________________ r---i--______ I _._____ __.. _____.__________ I
I
I
1 *
SAP00409
Unit: mm
Check
No
item
Criteria
Remedy
Standard size
1
Top-to-bottom idler guide
width
of
!
Track frame
idler support
I
Track frame Left-to-right 2
width
123
120
1
Repair
limit
I +2 -1
I
~0.5
/
127
118 Rebuild replace
+3 -1
266
of idler
or
271
guide Idler support
Standard
‘lecoil spring
40-10
-
261 I
3
Tolerance
I
I
size
259 I
I
Repair
limit
Replace
PC300,
350-6
MAINTENANCE
STANDARD
IDLER
IDLER
-I-
6 m
152.0k24.5Nm
Ilk--L-4
llr 7
2
6
8
L_
_
_I
SBP00411
40-12
PC300, 350-6
MAINTENANCE
STANDARD
IDLER
Unit: mm
Check
No.
item
Outside diameter of proruding portion
Outside
Width
diameter
101
-
width
190
-
of tread
44.5
Clearance between and bushing
Clearance between and support
8
578
590
of protrusion
Overall
Width
of tread
shaft
shaft
Interference between and bushing
idler
Rebuild replace
50.5 Tolerance
Shaft
Hole
Standard clearance
80
-0.225 -0.325
+o. 130 -0.010
0.215 0.455
80
-0.225 -0.290
-0.085 -0.195
0.03 - 0.205
-
Replace
+0.087 +0.037
-0.027 -0.079
0.064 0.166
-
Replace
Standard size
or
1.5
Standard size 87.6
bushing Standard 9
Side clearance (both sides)
clearance
Clearance
limit
of idler 0.68 - 1.22
I
2
I
-
PC300,
350-6
40-13
MAINTENANCE
STANDARD
CARRIER ROLLER
CARRIER ROLLER l--------I
- - ---
---
;
I
‘J-7----_ --
‘1
f
-- +
-__
3
:I li
__-__ t
ti
2
1
I
r ’
)..-A’ .-
f
iameter
c **-\,..
-_-.
Y
SBPOO415
Unit: mm
of flange
PC300, 350-6
MAINTENANCE
STANDARD
TRACK ROLLER
TRACK ROLLER (6727kgm)
_ I
P-l-4 Unit: mm
I No
Check
item
Criteria Standard
1
Outside diameter (outside)
of flange
Outside
of tread
diameter
size
Remedy Repair
216
-
180
168
I
Width
of tread
49
55
Width
of flange
27
-
Clearance between and bushing
shaft
Tolerance
Standard size 65
Standard Side clearance (both sides)
PC300, 350-6
Shaft
Hole
Standard clearance
-0.215 -0.315
+0.186 -0.064
0.151 0.501
clearance
Clearance
of idler
limit
Rebuild replace
or
Clearance limit 1.5
Replace bushing
limit Replace
0.41 - 0.95
1.5
40-l 5
MAINTENANCE
STANDARD
TRACK SHOE
TRACK SHOE TRIPLE GROUSER
SHOE
’?
?I
F
5
12
II
24
16
13 I
IL,
2
20a
Ir
P portion
40-16
shows the link of bushing
18
\
I
7
17
25
I!
\ 15
SWPO4808
press fitting end.
PC300, 350-6
MAINTENANCE
TRACK SHOE
STANDARD
Unit:
Check item
No
Standard 1
Remedy
Criteria
I
Repair
size
limit
Link pitch 219.3
216.3 I
When Standard 2
Bushing
outside
Normal
diameter
I
Impact
load
-
Standard
size
I
Repair
Link height
load
limit 107
Thickness of link metal (bushing press-fitting portion)
or
61
116 4
Reverse replace
turned
size
66.5
3
mm
Repair or replace
30.8 178.4
5
Replace 6
Shoe
bolt
pitch
76.2
I
19
7 I
9
width
102
Overall width
47.8
Inside
8 Link
10 Protrusion
12
Protrusion
13
Overall
length
of pin
14
Overall
length
of
15
Thickness
of bushing
16
Thickness
of spacer
4.2
of pin of
5.25
regular bushing
242
Press-fitting force
I Regular
Adjust or replace
148.3
bushing metal
10.8 -
98 - 264.6
kN {IO - 27 ton1
I
147 - 362.6
kN {15 - 37 ton1
I
98 - 215.6
kN I10 - 22 ton1
Bushing
17 18
42.6
pwidth
11
Repair or replace
pin
x 19/
Master
% : Dry
type
PC300, 350-6
track
link
40-17
MAINTENANCE
STANDARD
TRACK SHOE
Unit: mm
NCh. -
Check item Tightening torque (Nm {kgml)
a. Regular link
Triple shoe Shoe bolt 20 b. Master link
22
Interference between regular pin and link
-
23
Clearance between regular pin and bushing
24
nterference between master pin and link
-
-
-
Shaft
Hole
66.5
+0.424 +0.464
+0.074 0
0.350 - 0.464
44.6
+0.235 +0.085
-0.188 0
0.273 - 0.485
Shaft
Hole
Standard clearance
+0.235 +0.085
+0.915 +0.415
L
Standard size
Standard size
Standard size 44.3
% : Dry type
40-18
track
I
Standard size
44.6
Clearance between naster pin and bushing
Tolerance
Tolerance
Tolerance Shaft
Hole
+0.03 0
-0.188 -0.250 Tolerance
Shaft
Hole
+0.050 -0.050
+0.930 +0.530
Retighten
I
PC300, 350-6: 45 PC300, 35OLC-6: 48
% 25
120+10 Lower limit torque (Nm Ikgm))
44.6
-
196.1k19.6 12OZ21 Additional tightening angle (deg.)
I
21
Additional tightening angle (deg.)
Tightening torque (Nm {kgm))
No. of shoes (each side)
Interference between bushing and link
Remedy
Criteria
-
Standard interference
0.180 - 0.830
Adjust or replace
Standard. interference 0.188 - 0.280 Standard clearance 0.480 - 0.980
link
PC300,
350-6
MAINTENANCE
TRACK SHOE
STANDARD
TRIPLE GROUSER
SHOE
SDD01629
Unit: mm
Standard 1
2
Height
3 -
Repair
size
36
Thickness
limit
24 11 32
Length
of base
4
26
5
24
6
Remedy
Criteria
Check item
No.
Length
at tip
7
PC300, 350-6
- Rebuild replace
or
18 18
40-19
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC PUMP
PUMP
HPVIGO + 160
40-20
PC300, 350-6
MAINTENANCE
STANDARD
CONTROL
VALVE
CONTROL VALVE IO-spool valve (l/6) Ir
For details of the 9, 8, and 7-spool IO-SPOOL VALVE.
valves,
see
When tightening the bolts at the places marked *, always use 2 washers on top of each other.
166.7*9.8Nm 17*lkml
SWPO4810
40-22
PC300, 350-6
MAINTENANCE
STANDARD
CONTROL VALVE
B-B
SWPO481 I
Unit: mm
No
1
Remedy
Spool
return
spring
Spool return
spring
Spool return
spring
jpool
return
spring
Replace spring if there is damage or /deformation
53.3 x 37.1
40 x 12.3
49.5
38
358.7 N l36.6 kg}
-
50 N
-
15.1 kg}
PC300, 350-6
287.1
N
(29.3 kg} 40.2 N (4.1 kg)
40-23
MAINTENANCE
STANDARD
CONTROL
VALVE
(316)
74.04*8.34Nm ~7.55*0.85koml
K-K
SWPO4812
40-24
PC300, 350-6
MAINTENANCE
STANDARD
CONTROL VALVE
392.3* 19.6Nm (40*2knmI
,”
(40*2k9ml w
2knml
147.1*9.8Nm fI5*lkPml
iNm
E-E
F
392.3* 19.6Nm (40~2ksm)
.4+9.8Nm Ikpml
392.3+ 19.6Nm 140+2kaml LEI
F-F
PC300, 350-6
w
147.1* 9.8Nm ~l5~lkPml
SWPO4813
40-25
MAINTENANCE
STANDARD
CONTROL VALVE
392.3* 19.6Nm (40*2koml
E/6)
392.3* 19.6Nm (40*2koml
NA-NA
SWPO4814
Unit: mm
I
No.
Check
item
IA
Regeneration
valve spring
1B
Regeneration
valve spring
2
Piston return
spring
3
Piston return
spring
4
Piston return
spring
Piston return
spring
40-26
Criteria
Remedy
Replace spring if there is damage or deformation
PC300, 350-6
MAINTENANCE
STANDARD
CONTROL VALVE
,kom23.55*3.95Nm
1 f
J-J 152.25*24.75Nm 15.5*2.5kamI
23.55i3.95Nm 2.4f 0.4kom)
JJ-JJ SWPO4815
Unit: mm No -
Check item
Criteria
1
Standard size
1 Check valve spring
Free length x O.D. 11.5 x
Spool return spring
Spool return spring
PC300, 350-6
4.6
65.5 x 27.2
13.6 x 5.5
Repair limit
Installed length
Installed load
8.5
1.5 N IO.15 kg}
-
1.2 N IO.12 kg}
167.6 N i17.1 kg}
-
134.3 N i13.7 kg}
2N IO.2 kg}
-
1.5 N IO.15 kg]
50
10
Remedy
Free length
Installed load Replace spring if there is damage or deformation
40-27
MAINTENANCE
VARIABLE
CONTROL VALVE
STANDARD
PRESSURE
COMPENSATION
VALVE
SDPOll24
Unit: mm No.
Remedy
Criteria
Check item Standard size
1
Piston return spring
FrT$;gth 32.76 x 8.5
Installed length 20.5
Repair limit installed load
Free length
9.8 N
-
11.0 kg) 2
Relief valve spring
40-28
17.1 x 9
15.5
74.5 N 17.6 kg}
Installed load 7.8 N
IO.8 kg) -
Replace spring if any damages or deformations are found.
59.8 N 16.1 kg)
PC300, 350-6
MAINTENANCE
STANDARD
SELF-REDUCING
SELF-REDUCING PRESSURE VALVE
PRESSURE VALVE
SWPO4816
Unit: mm
No
Check
item Standard
1
2 3 4
PC300,
Spring. bmcay;;rng pressure
valve,
Spring (reducing pressure valve, pilot) Spring Spring
350-6
Remedy
Criteria
(safety valve)
Free length x O.D.
Installed length
19.2 x 7.2
16.1
size
Repair installed load
Free length
limit Installed load
19.6 N {2 kg1
-
17.7 N II.8 kg}
20.6 N (2.1 kg}
-
18.6 N il.9 kg1
If%5 x 7.2
12.7
71 x 18
59
199.8 N 120.4 kg)
-
186.2 N 119 kg1
16.1 x 7.8
13.4
61.7 N 16.3 kg}
-
58.8 N 16 kg)
Replace spring if any damages or deformations are found.
40-29
MAINTENANCE
STANDARD
SUCTION-SAFETY FOR SERVICE
SUCTION-SAFETY
VALVE
VALVE
VALVE
Unit: mm
No -
Check
item
Criteria Standard
1
Suction valve spring
2
Piston spring
size
Remedy Reoair limit
-
40-30
PC300, 350-6
MAINTENANCE
SWING MOTOR
STANDARD
SWING MOTOR KMFl60ABE-3
A -
A
SWPO4817
Unit: mm No.
Remedy
Criteria
Check item
Repair limit
Standard size 1
Check valve spring
PC300, 350-6
Free length x O.D.
Installed length
installed load
46.9 x 9.2
31
15 N {l.S kg1
Free length
-
Installed load 12.6 N (1.28 kg}
Replace spring if there . is damage or deformation
40-31
MAINTENANCE
STANDARD
TRAVEL MOTOR
TRAVEL MOTOR HMVl60ADT-2
14.7Nm .5bml
419*46.6Nm (42.6*4.7komI
swPo4818 Unit: mm
NC
Check item
Criteria
Remedy I
Standard 1
Spool return spring
2
Check valve spring
3
Regulator
40-32
piston spring
size
ReDair limit
Free length x O.D.
Installed length
Installed load
61.1 x 23.2
30.0
398.9 N 140.7 kg}
Free length
-
Installed load
319.5 N I32.6 kg}
PC300, 350-6
MAINTENANCE
STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
l
SWING
l
SWING PPC VALVE
PPC VALVE
13.2*1.5Nm 11.35*0.15kPml
*4.9Nm 0.5koml
A-A
E-E
SAP02751
Unit: mm
No. -
Check
item
~
1 Centering
spring (for P3, P4)
2
Centering spring (for Pl, P2)
3
Metering
PC300,
350-6
spring
26.5 x 8.2
16.7 N (1.7 kg1
13.7 N -
Il.4
kg}
40-33
MAINTENANCE
STANDARD
TRAVEL PPC VALVE
TRAVEL PPC VALVE
SAP01255
Unit: mm
No.
Check item
Criteria Standard
1
2
Metering
spring
Centering spring
40-34
size
Free length x O.D.
Installed length
26.5 x 8.15
24.9
48.1 x 15.5
32.5
Remedy Repair
Installed load
Free length
16.7 N
limit Installed load 13.7 N
Il.7 kg}
-
0.4 kg}
108 N (11 kg1
-
86.3 N (8.8 kg}
_ Replace if there is damage or deformation spring
PC300, 350-6
MAINTENANCE
STANDARD
SERVICE PPC VALVE
SERVICE PPC VALVE
I
J SBPO0436
Unit: mm No.
Check item
Criteria Standard size
1
2
Centering spring
Metering spring
PC300, 350-6
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
64.8 x 16.6
40.5
46.1 N 14.7 kg}
(62.9)
44.1 N 14.5 kg1
26.0 x 10.5
25.0
25.5 N t2.6 kg}
(25.2)
24.5 N 12.5 kg1
Replace spring if any damages or deformations are found.
40-35
MAINTENANCE
STANDARD
PPC SHUTTLE VALVE, TRAVEL JUNCTION
PPC SHUTTLE VALVE, TRAVEL JUNCTION
VALVE
VALVE
34.3 f 4.9N m /~3.5~0.5kml
34.3*4.9Nm
SDP01353
Unit: mm
No.
Check item
Criteria
Remedy
Standard size 1
Spool return spring
40-36
Repair limit
Free length x O.D.
Installed length
Installed load
23.6 x 13.3
20
14.7 N (1.5 kg}
Free length
-
Installed load 11.8 N Il.2 kg)
Replace spring if there is damage or deformation
PC300, 350-6
MAINTENANCE
STANDARD
LS-EPC VALVE
LS-EPC VALVE
SBPOO43S
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Return spring
PC300, 350-6
Repair limit
Free length x O.D.
Installed length
Installed load
9.0 x 11.4
7.9
3.1 N (0.32 kg}
Free length
-
Installed load -
Replace EPC valve ass’y if any damages or deformations are found.
MAINTENANCE
SOLENOID
STANDARD
SOLENOID VALVE
VALVE
SWP04676
40-38
PC300, 350-6
MAINTENANCE
CENTER SWIVEL JOINT
STANDARD
CENTER SWIVEL JOINT
\ -
SBPOO439
Unit: mm
,
Clearance between and shaft
40-40
Remedy
Criteria
Check item
No.
Standard size
Standard clearance
Clearance limit
90
0.056 - 0.105
0.111
rotor
Replace
PC300, 350-6
MAINTENANCE
BOOM HOLDING VALVE
STANDARD
BOOM HOLDING
VALVE
m
147Lmm-
(15tl
I-*
A-A
kgm)
Unit: mm
No.
I
I
I
Standard 1
2
Pilot valve spring
Check valve spring
PC300, 350-6
Remedy
Criteria
Check item
Repair limit
size
Free length x O.D.
Installed length
Installed load
26.5 x 11.2
25.0
4.7 N lo.48 kg}
-
{o.38 kg1
35.3 N I3.6 kg}
-
28.4 N 12.9 kg1
37.2 x 16.2
30.0
Free length
Installed load 3.7 N
Replace spring if there is damage or deformation
MAINTENANCE
HYDRAULIC CYLINDER
STANDARD
HYDRAULIC
CYLINDER
BOOM CYLINDER 3
2
ARM CYLINDER
BUCKET CYLINDER
1
40-42
\
I
294*29.4Nm (30*3.Okoml
3
PC300, 350-6
MAINTENANCE
STANDARD
HYDRAULIC CYLINDER
Unit: mm
Nt -
1
2
Check item
Criteria
Remedy
Clearance between piston rod
Clearance between piston rod support shaft and bushing
Replace bushing
Arm (for pc300)
100
-
+0.457 +0.370
-
1.0
Arm (for PC3501
100
-
+0.457 +0.370
-
1.0
qeplace pin, 3ushing
-
3
Clearance between cylinder bottom support shaft and
PC300, 350-6
40-43
MAINTENANCE
STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
SBPO0443
D-D A-A
I
B-B
I
b
E-E
F-F
G-G
40-44
SAP00444
PC300, 350-6
MAINTENANCE
WORK EQUIPMENT
STANDARD
Unit: mm C-
No
1
Check
Criteria
item
Clearance between bushing and mounting pin of boom and revolving frame
Standard size 110
Tolerance
1
Remedy
T
Shaft
Hole
Standard clearance
-0.036 -0.090
+0.161 +0.074
0.110 0.251
1.0
Clearance limit
2
Clearance between bushing and mounting pin of boom and arm
+0.354 +0.275
0.311 0.444
1.0
3
Clearance between bushing and mounting pin of boom and link
+0.338 +0.272
0.308 0.428
1.0
4
Clearance between bushing and mounting pin of boom and bucket
5
Clearance between bushing and mounting pin of link and bucket
6
Clearance between bushing and mounting pin of link and link
7
Bucket clearance
(a)
8
Bucket clearance
(b)
-
c 90
-0.036 -0.090
+0.337 +0.27 1
0.307 0.427
1.0
90
-0.036 -0.090
+0.346 +0.275
0.311 0.436
1.0
90
-0.036 -0.090
+0.346 +0.275
0.311 0.436
1.0
Replace
0.5 - 1.0 Adjust
PC300,
350-6
2.0
1
shims
40-45
MAINTENANCE
STANDARD
DIMENSIONS ‘I.
DIMENSIONS
OF WORK EQUIPMENT
OF WORK EQUIPMENT
ARM
9
I
I!
1 J
t-A
18
x-x z-z
SAP00446
40-46
PC300, 350-6
MAINTENANCE
STANDARD
DIMENSIONS
OF WORK EQUIPMENT
Unit: mm PC300-6 1
@
+0.1 /-0.036 -0.090
loo 0
@l17.3+;5/116 320
3
PC350-6
2 1.2
$Jl17.3+;5/l16 f 1.2 320
+0.5 -0.3 0 Ll.8
4
4J‘IO
+O.l , -0.036 0 -0.090
428.4 + 1.0
468 f 1
6
219 + 0.5
234.0 f 0.5
935.7 + 1.0
1022.8 f 1.0
8
3179 k 3
3179 f 3
9
3095.7 + 1.0
3095.7 + 1.0
IO
468 + 1
472.5 + 1.0
11
I
I
731.0 5 0.2
I
731.0 2 0.2
12
728.0 f 0.5
728.0 + 0.5
13
513.6
513.6
14
1670
1670
15 16 17
18
+0.5 -0.3 0 '-0.8
5
7
Arm
+O.l , -0.036 0 -0.090
4 loo
as individual
tJ go
I I
+0 2
-0.036 0' '-0.090
345.0 + 0.5 490
+02 -0.036 0' '-0.090
4 go
I I
+02 -0.036 0' Lo90
345.0 f 0.5 Q go
+0.2/-0.036 0 -0.090
3304.5
3302.5
345
345
Min.
1990
1990
Max.
3275
3275
part When press fittingbushing
19
PC300, 350-6
40-47
MAINTENANCE
2.
STANDARD
DIMENSIONS
OF WORK EQUIPMENT
BUCKET
2 ,
I6
I6
I5
I5
‘I
’
l-J--A-A
40-48
5
’ I SWPO4822
PC300, 350-6
MAINTENANCE
STANDARD
DIMENSIONS
OF WORK
EQUIPMENT
Unit: mm PC300-6
PC350-6
512.2 + 0.5
512.2 f 0.5
2
37.9 f 0.5
37.9 f 0.5
3
94”19’
93”12’
4
513.6
513.6
5
I
1658
I
1663 173
8
I
50”
I
42”
9
0 90+,0.2
c#l9o+y
10
346+:,
346 +;
11
68
68
12
138
138
13
525.5 2 0.5
525.5 f 0.5
14
@J 26
9 26
qI 170
f#J170
4 200
l#J200
17
146.1
135.5
18
137.6
142.0
RI15
RI15
RIO0
RIO0
16
19 20
22
PC300, 350-6
!
I I
I
60
I
60
40-49
90
OTHERS
Hydraulic circuit diagram .............................. Electric circuit diagram (l/3) ........................ Electric circuit diagram (2/3) ........................ Electric circuit diagram (3/3) .........................
PC300,
350-6
90-3 .90-5 .90-7 90-9
90-l
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:
