SEBM025808
MACHINE MODEL
SERIAL NUMBER
PC300-7 PC300LC-7 PC350-7 PC350LC-7
40001 and up 40001 and up 20001 and up 20001 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, 300LC, PC350, 350LC-7 mount the SAA6D114E engine. For details of the engine, see the 114 Series Engine Shop Manual.
© 2005 All Rights Reserved Printed in Japan 09-05 (01)
00-1 (8)
GENERAL
CONTENTS No. of page
01 GENERAL ............................................................................................................................
01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................
10-1
20 TESTING AND ADJUSTING ........................................................................
20-1
30 DISASSEMBLY AND ASSEMBLY
...................................................... 30-1
90 OTHERS ................................................................................................................................
00-2
90-1
PC300/350(LC)-7
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(6)
90-9
(6)
90-11
(6)
90-13
(6)
90-15
(6)
90-17
(6)
90-19
(6)
PC300/350(LC)-7
00-2-5 (8)
Safety
Safety notice
Safety Safety notice Important safety notice Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. Preparations for work 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
Safety
Precautions during work 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor 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 minimum of gasoline when washing electrical parts.
00-4
Safety notice
19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
Foreword
General
Foreword General This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
Maintenance standard This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function”.
Others This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
Notice The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword
General
How to read the shop manual Volumes Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume:
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-todate information before you start any work. Filing method 1. See the page number on the bottom of the page. File the pages in correct order.
Revised edition mark W he n a m an ua l i s r ev i s e d, an e di t i on m a r k ((1)(2)(3)....) is recorded on the bottom of the pages.
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. Symbol
Item
Remarks
k
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.
4
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
Places that require special attention for the tightening torque during assembly.
2
Coat
Places to be coated with adhesives and lubricants, etc.
5
Oil, water
Places where oil, water or fuel must be added, and the capacity.
6
Drain
Places where oil or water must be drained, and quantity to be drained.
a
2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (–) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5
00-6
Added pages
20-203 12-203-1 12-203-2 12-204
Foreword
Hoisting instructions
Hoisting instructions Hoisting k
•
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 4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
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.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k
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.
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
a 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 portion of the hook.
4) 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 {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120? hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
00-7
Foreword
Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler k
k
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see “Tes ting and adjus ting”, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see “Testing and adjusting”, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
Foreword
Method of disassembling, connecting push-pull type coupler
Type 2
Type 3
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1)
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2)
Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2)
Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3)
Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3)
Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
•
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Disassembly
1)
00-9
Foreword
Coating materials
Coating materials a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list. Category
Komatsu code
Part No.
LT-1A
790-129-9030
LT-1B
790-129-9050
LT-2
09940-00030
LT-3
790-129-9060 (Set of adhesive and hardening agent)
LT-4
790-129-9040
Holtz MH 705
790-126-9120
Three bond 1735
790-129-9140
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
LG-1
790-129-9010
LG-5
790-129-9080
LG-6
790-129-9020
LG-7
790-129-9070
Three bond 1211
790-129-9090
Three bond 1207B
419-15-18131
Adhesives
Gasket sealant
00-10
Q’ty
Container
Main applications, features
• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. • Used in places requiring an immediately effective, strong adhesive. 20 g Polyethylene Used for plastics (except polyethylene, (2 pcs.) container polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and nonmetal. • Features: Polyethylene Resistance to heat and chemicals 50 g container • Used for anti-loosening and sealant purpose for bolts and plugs. Adhesive: • Used as adhesive or sealant for metal, 1 kg glass and plastic. Can Hardening agent: 500 g Polyethylene • Used as sealant for machined holes. 250 g container • Used as heat-resisting sealant for 75 g Tube repairing engine. • Quick hardening type adhesive Polyethylene • Cure time: within 5 sec. to 3 min. 50 g container • Used mainly for adhesion of metals, rubbers, plastics and woods. • Quick hardening type adhesive • Quick cure type Polyethylene 2g (max. strength after 30 minutes) container • Used mainly for adhesion of rubbers, plastics and metals. • Resistance to heat, chemicals Polyethylene 50 cc • Used at joint portions subject to high container temperatures. • Used as adhesive or sealant for gaskets 200 g Tube and packing of power train case, etc. • Used as sealant for various threads, pipe joints, flanges. 1 kg Can • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. • Features: Silicon based, resistance to heat, cold 200 g Tube • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc. • Features: Silicon based, quick hardening type 1 kg Tube • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Used as heat-resisting sealant for 100 g Tube repairing engine. • Features: Silicone type, heat resistant, vibration resistant, and impact resistant 100 g Tube sealing material • Used as sealing material for transfer case 150 g
Tube
Foreword
Molybdenum disulphide lubricant
Komatsu code
Part No.
Q’ty
Container
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
Various
Various
G2-LI
G2-CA
Grease
Primer
Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41
Adhesive
Caulking material
SUNSTAR SASH PRIMER GP-402 SUNSTAR PENGUINE SUPER 560 SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W” Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT GE TOSHIBA SILICONES TOSSEAL 381
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM
Various
Various
400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can
Main applications, features • Used as lubricant for sliding portion (to prevent from squeaking). • Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc. • General purpose type
• Used for normal temperature, light load bearing at places in contact with water or steam. • Used for heavy load portion
• Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type • Since this grease is white, it does not Can stand out against machine body.
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)
400 g 16 kg
SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
400 g 16 kg
Bellows type Can
20 ml
Glass container
20 ml
Glass container
22M-54-27230
20 ml
Glass container
22M-54-27240
150 ml
Can
22M-54-27250
20 ml
Glass container
22M-54-27210
320 ml
Ecocart (Special container)
• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months)
417-926-3910
417-926-3910
320 ml
Polyethylene container
20Y-54-39850
310 ml
Polyethylene container
417-926-3920
320 ml
Polyethylene container
20Y-54-55130
333 ml
Polyethylene container
22M-54-27220
333 ml
Cartridge
• Used as primer for glass side (Using limit: 4 months)
Adhesive for cab glass
Category
Coating materials
• Used as primer for painted surface on cab side (Using limit: 4 months) • Used as primer for black ceramiccoated surface on glass side and for hard polycarbonate-coated surface (Using limit: 4 months) • Used as primer for sash (Alumite). (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • “S” is used for high-temperature season (April - October) and “W” for low-temperature season (November April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months) • Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months)
00-11
Foreword
Standard tightening torque
Standard tightening torque Standard tightening torque table (when using torque wrench) a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190
1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5
16 18 20 22 24
24 27 30 32 36
235 – 285 320 – 400 455 – 565 610 – 765 785 – 980
23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100
27 30 33 36 39
41 46 50 55 60
1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630
118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 13 14 27
5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
Tightening torque
Sealing surface
Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. SAD00483
Thread diameter
Width across flats
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12
Tightening torque
Foreword
Standard tightening torque
Table of tightening torques for flared nuts a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter
Width across flats
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
59 – 74 98 – 123 235 – 285
6 – 7.5 10 – 12.5 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Norminal No. 02 03, 04 05, 06 10, 12 14
Thread diameter
Width across flats
mm
mm
14 20 24 33 42
Varies depending on type of connector.
Tightening torque (Nm {kgm}) Range 35 – 63 {3.5 – 6.5} 84 – 132 {8.5 – 13.5} 128 – 186 {13.0 – 19.0} 363 – 480 {37.0 – 49.0} 746 – 1010 {76.0 – 103}
Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
Table of tightening torques for o-ring boss plugs a Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter
Width across flats
Tightening torque (Nm {kgm})
mm
mm
Range
Target
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 — 36 — —
5.88 – 8.82 {0.6 – 0.9} 9.8 – 12.74 {1.0 – 1.3} 14.7 – 19.6 {1.5 – 2.0} 19.6 – 24.5 {2.0 – 2.5} 24.5 – 34.3 {2.5 – 3.5} 34.3 – 44.1 {3.5 – 4.5} 44.1 – 53.9 {4.5 – 5.5} 58.8 – 78.4 {6.0 – 8.0} 93.1 – 122.5 {9.5 – 12.5} 107.8 – 147.0 {11.0 – 15.0} 127.4 – 176.4 {13.0 – 18.0} 181.3 – 240.1 {18.5 – 24.5} 274.4 – 367.5 {28.0 – 37.5}
7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
Foreword
Standard tightening torque
Tightening torque for 102 and 114 engine series 1) Bolt and nuts Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12
10 ± 2 24 ± 4 43 ± 6 77 ± 12
1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22
2) Eye joints Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12 14
8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
3) Tapered screws Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter
Tightening torque
inch
Nm
kgm
1 / 16 1/8 1/4 3/8 1/2 3/4 1
3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9
0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type) a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm})
Nominal size of hose
Width across flats
02
19
Range
Target
Taper seal type
Face seal type
Thread size Nominal thread size Root diameter – Threads per inch, (mm) (mm) (Reference) Thread series 9 — – 18UN 14.3 16
34 – 54 {3.5 – 5.5}
44 {4.5}
34 – 63 {3.5 – 6.5}
44 {4.5}
14
—
—
22
54 – 93 {5.5 – 9.5}
74 {7.5}
—
11 – 16UN 16
17.5
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
—
—
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
13 – 16UN 16
20.6
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
1 – 14UNS
25.4
3 1 – 12UN 16
30.2
03
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
—
—
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
—
—
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
—
—
00-14
Foreword
Electric wire code
Electric wire code In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness Norminal number
Copper wire Number of strands
Dia. of Cross section strands (mm2) (mm2)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Classification by color and code Priority
1
Circuits
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
White & Black
Red & White
Rellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Black & Yellow
Red & Black
Yellow & Black
Green & Red
Blue & Yellow
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
Classification Primary
2
3
4
Auxiliary
5
6
00-15
Foreword
Conversion table
Conversion table Method of using the conversion table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
(C) (A)
00-16
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Foreword
Conversion table
Millimeters to Inches 1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound 1 kg = 2.2046 lb 0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
Foreword
Conversion table
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
Foreword
Conversion table
kgm to ft. lb 1 kgm = 7.233 ft. lb 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
Foreword
Conversion table
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
Foreword
Conversion table
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F °C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
Foreword
Units
Units In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses {
}.
Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
04-05
01
GENERAL Specification Dimension Drawings . . . 01-2 Specifications PC300-7, PC300LC-7 . . . . . . . . . . . 01-4 PC350-7, PC350LC-7 . . . . . . . . . . . 01-6 Weight Table PC300-7, PC300LC-7 . . . . . . . . . . . 01-8 PC350-7, PC350LC-7 . . . . . . . . . . 01-10 Fuel, Coolant, And Lubricants. . . . . . . 01-12
PC300-7
01-1
GENERAL
SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS DIMENSIONS
WORKING RANGES
01-2
PC300-7
GENERAL
SPECIFICATION DIMENSION DRAWINGS
12 DIMENSIONS Item
Unit
PC300-7
PC300LC-7
PC350-7
PC350LC-7
A
Overall length
mm
11,140
11,140
11,140
11,140
B
Overall height
mm
3,280
3,280
3,280
3,280
C
Overall width
mm
3,190
3,290
3,190
3,290
D
Track shoe width
mm
600
700
600
700
E
Height of cab
mm
3,130
3,130
3,130
3,130
F
Tail swing radius
mm
3,450
3,450
3,450
3,450
G
Track overall length
mm
4,625
4,955
4,625
4,955
H
Length of track on ground
mm
3,700
4,030
3,700
4,030
Min. ground clearance
mm
498
498
498
498
Unit
PC300-7
PC300LC-7
PC350-7
PC350LC-7
WORKING RANGES Item A
Max. digging reach
mm
11,100
11,100
11,100
11,100
B
Max. digging depth
mm
7,380
7,380
7,380
7,380
C
Max. digging height
mm
10,210
10,210
10,210
10,210
D
Max. vertical wall depth
mm
6,480
6,480
6,480
6,480
E
Max. dumping height
mm
7,110
7,110
7,110
7,110
F
Min. dumping height
mm
2,640
2,640
2,640
2,640
G
Max. reach at ground level
mm
10,920
10,920
10,920
10,920
PC300-7
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS PC300-7, PC300LC-7 Machine model
PC300-7
Serial Number m³
1.4
1.4
Operating weight
kg
30,800
31,900
Max. digging depth
mm
7,380
7,380
Max. vertical wall depth
mm
6,480
6,480
Max. digging reach
mm
11,100
11,100
Max. reach at ground level
mm
10,920
10,920
Max. digging height
mm
10,210
10,210
Max. dumping height
mm
7,110
7,110
kN {kg}
211.8 {21,600}
211.8 {21,600}
kN {kg}
(226.5 {23,100})
(226.5 {23,100})
Swing speed
rpm
9.5
9.5
Swing max. slope angle
deg.
21
21
Travel speed
km/h
Working ranges Performance
40001 and up
Bucket capacity
Max. digging force (using power max. function)
Lo: 3.2 (
Mi: 4.5)
Lo: 3.2 (
Mi: 4.5)
Hi: 5.5
Hi: 5.5
deg.
35
35
kPa {kg/cm²}
62.8 {0.64}
53.0 {0.54}
[mm]
[600]
[700]
Overall length (for transport)
mm
11,140
11,140
Overall width
mm
3,190
3,190
Overall width of track
mm
3,190
3,290
Overall height (for transport)
mm
3,280
3,280
Overall height to chassis
mm
3,130
3,130
Ground clearance to bottom of upper structure
mm
1,186
1,186
Min. ground clearance
mm
498
498
Tail swing radius
mm
3,450
3,450
Min. swing radius of work equipment
mm
4,310
4,310
Height of work equipment at min. swing radius
mm
8,520
8,520
Length of track on ground
mm
3,700
4,030
Track gauge
mm
2,590
2,590
Height of machine cab
mm
3,130
3,130
Gradeability
Ground pressure [standard shoe width]
Dimensions
PC300LC-7
: The "Mi" mode is on the multi-monitor specification machine only.
01-4
PC300-7
GENERAL
SPECIFICATIONS
12 Machine model
PC300-7
Serial Number
40001 and up
Model Type
Performance
Engine
No. of cylinders - bore x stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
PC300LC-7
l {cc}
SAA6D114E 4-cycle, water-cooled, in-line, vertical, direct injection, with turbo charger and aftercooler 6 - 114 x 135 8.27 {8,270}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
180.3/1,900 {242/1,900} 1,079/1,400 {110/1,400} 2,160 900 205 {153}
mm
Starting motor Alternator Battery
24V, 7.5 kW 24V, 35 A 12V, 126 Ah x 2
Radiator core type
CF19-4 2 on each side
Track shoe
Assembly-type triple grouser, 45 on each side
Assembly-type triple grouser, 48 on each side
Hydraulic pump
8 on each side
Type x No. Delivery Set pressure
Control valve
7 on each side
Type x No. Control method
Hydraulic motor
Track roller
Travel motor
l/min MPa (kg/cm²)
HMV160ADT-2, Piston type (with brake valve, parking brake): x 2 KMF230ABE-5, Piston type (with safety valve, holding brake): x 1 reverse rotation check valve
Swing motor
Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins
Hydraulic tank Hydraulic filter Hydraulic cooler
PC300-7
HPV125+125, variable displacement, Piston type x2 267.5 x 2 37.8 {380} 6-spool type + 1-spool type x 1 Hydraulic
Type Hydraulic cylinder
Hydraulic system
Undercarriage
Carrier roller
mm mm mm mm mm
Boom
Arm
Bucket
Double acting piston
Double acting piston
Double acting piston
140 100 1,480 3,525 2,045
160 110 1,825 4,255 2,430
140 100 1,285 3,155 1,870
Closed box type Tank return side CFT-1 (Air cooled)
01-5
GENERAL
SPECIFICATIONS
PC350-7, PC350LC-7 Machine model
PC350-7
Performance
Working ranges
Serial Number
20001 and up
Bucket capacity
m³
1.4
1.4
Operating weight
kg
32,300
33,400
Max. digging depth
mm
7,380
7,380
Max. vertical wall depth
mm
6,480
6,480
Max. digging reach
mm
11,100
11,100
Max. reach at ground level
mm
10,920
10,920
Max. digging height
mm
10,210
10,210
Max. dumping height
mm
7,110
7,110
kN {kg}
212.8 {21,700}
212.8 {21,700}
(227.5 {23,200})
(227.5 {23,200})
Max. digging force (using power max. function) Swing speed
rpm
9.5
9.5
Swing max. slope angle
deg.
18
18
Travel speed
km/h
Lo: 3.2 (
Mi: 4.5)
Lo: 3.2 (
Mi: 4.5)
Hi: 5.5
Hi: 5.5
deg.
35
35
kPa {kg/cm²}
65.7 {0.67}
62.8 {0.64}
[mm]
[600]
[700]
Overall length (for transport)
mm
11,140
11,140
Overall width
mm
3,190
3,190
Overall width of track
mm
3,190
3,290
Overall height (for transport)
mm
3,280
3,280
Overall height to chassis
mm
3,130
3,130
Ground clearance to bottom of upper structure
mm
1,186
1,186
Min. ground clearance
mm
498
498
Tail swing radius
mm
3,450
3,450
Min. swing radius of work equipment
mm
4,310
4,310
Height of work equipment at min. swing radius
mm
8,520
8,520
Length of track on ground
mm
3,700
4,030
Track gauge
mm
2,590
2,590
Height of machine cab
mm
3,130
3,130
Gradeability
Ground pressure [standard shoe width]
Dimensions
PC350LC-7
: The "Mi" mode is on the multi-monitor specification machine only.
01-6
PC300-7
GENERAL
SPECIFICATIONS
Machine model
PC350-7
Serial Number
20001 and up
Model Type
Performance
Engine
No. of cylinders - bore x stroke Piston displacement Flywheel horsepower Max. torque Max. speed at no load Min. speed at no load Min. fuel consumption
PC350LC-7
l {cc}
SAA6D114E 4-cycle, water-cooled, in-line, vertical, direct injection, with turbo charger and aftercooler 6 - 114 x 135 8.27 {8,270}
kW/rpm {HP/rpm} Nm/rpm {kgm/rpm} rpm rpm g/kWh {g/HPh}
180.3/1,900 {242/1,900} 1,079/1,400 {110/1,400} 2,180 900 205 {153}
mm
Starting motor Alternator Battery
24V, 7.5 kW 24V, 35 A 12V, 126 Ah x 2
Radiator core type
CF19-4 2 on each side
Track shoe
Assembly-type triple grouser, 45 on each side
Assembly-type triple grouser, 48 on each side
Hydraulic pump
8 on each side
Type x No. Delivery Set pressure
Control valve
7 on each side
Type x No. Control method
Hydraulic motor
Track roller
Travel motor
l/min MPa (kg/cm²)
HMV160ADT-2, Piston type (with brake valve, parking brake): x 2 KMF230ABE-5, Piston type (with safety valve, holding brake): x 1 reverse rotation check valve
Swing motor
Inside diameter of cylinder Diameter of piston rod Stroke Max. distance between pins Min. distance between pins
Hydraulic tank Hydraulic filter Hydraulic cooler
PC300-7
HPV125+125, variable displacement, Piston type x2 267.5 x 2 37.8 {380} 6-spool type + 1-spool type x 1 Hydraulic
Type Hydraulic cylinder
Hydraulic system
Undercarriage
Carrier roller
mm mm mm mm mm
Boom
Arm
Bucket
Double acting piston
Double acting piston
Double acting piston
140 100 1,480 3,525 2,045
160 110 1,825 4,255 2,430
140 100 1,825 3,155 1,870
Closed box type Tank return side CFT-1 (Air cooled)
01-7
GENERAL
WEIGHT TABLE
WEIGHT TABLE This weight table is for use when handling components or when transporting the machine.
PC300-7, PC300LC-7 Unit: kg Machine model
PC300-7
Serial Number Engine assembly
PC300LC-7 40001 and up
1,148
1,148
•
Engine
860
860
•
Damper
14.3
14.3
•
Hydraulic pump
178
178
Radiator oil cooler assembly
153
153
Hydraulic tank, filter assembly (excluding hydraulic oil)
176
176
Fuel tank (excluding fuel)
238
238
2,723
2,723
Operator’s cab
292
292
Operator’s seat
35
35
Counterweight
5,470
5,470
Swing machinery
442
442
Control valve
242
242
Swing motor
88
88
Travel motor
164 x 2
164 x 2
Center swivel joint
29.9
29.9
Track frame assembly
7,311
7,979
•
Track frame
3,879
4,441
•
Swing circle
487
487
•
Idler
169 x 2
169 x 2
•
Idler cushion
287.5 x 2
287.5 x 2
•
Carrier roller
31.3 x 4
31.3 x 4
•
Track roller
52.9 x 14
52.9 x 16
•
Final drive (including travel motor)
583 x 2
583 x 2
Revolving frame
01-8
PC300-7
GENERAL
WEIGHT TABLE
12
Unit: kg Machine model
PC300-7
Serial Number
PC300LC-7 40001 and up
Track shoe assembly •
Standard triple grouser shoe (600 mm)
3,470
3,700
•
Standard triple grouser shoe (700 mm)
4,030
4,300
•
Wide triple grouser shoe (800 mm)
4,380
4,680
•
Road liner (rubber pad type) (600 mm)
—
—
Boom assembly
2,290
2,290
Arm assembly
1,105
1,105
Bucket assembly
1,015
1,015
254 x 2
254 x 2
Arm cylinder assembly
382
382
Bucket cylinder assembly
228
228
Link assembly (large)
316
316
Link assembly (small)
—
—
76 + 15 x 2 + 56 + 17 + 42
76 + 15 x 2 + 56 + 17 + 42
Arm pin
13 +17
13 +17
Bucket pin
30 x 2
30 x 2
Link pin
27 x 2
27 x 2
Boom cylinder assembly
Boom pin
PC300-7
01-9
GENERAL
WEIGHT TABLE
PC350-7, PC350LC-7 Unit: kg Machine model
PC350-7
Serial Number Engine assembly
PC350LC-7 20001 and up
1,148
1,148
•
Engine
860
860
•
Damper
14.3
14.3
•
Hydraulic pump
178
178
Radiator oil cooler assembly
153
153
Hydraulic tank, filter assembly (excluding hydraulic oil)
176
176
Fuel tank (excluding fuel)
238
238
2,828
2,828
Operator’s cab
287
287
Operator’s seat
35
35
Counterweight
6,370
6,370
Swing machinery
442
442
Control valve
242
242
Swing motor
88
88
Travel motor
164 x 2
164 x 2
Center swivel joint
29.9
29.9
Track frame assembly
7,538
8,183
•
Track frame
4,074
4,602
•
Swing circle
487
487
•
Idler
169 x 2
169 x 2
•
Idler cushion
287.5 x 2
287.5 x 2
•
Carrier roller
31.3 x 4
31.3 x 4
•
Track roller
52.9 x 8 58.3 x 6
52.9 x 8 58.3 x 8
•
Final drive (including travel motor)
583 x 2
583 x 2
Revolving frame
01-10
PC300-7
GENERAL
WEIGHT TABLE
12
Unit: kg Machine model
PC350-7
Serial Number
PC350LC-7 20001 and up
Track shoe assembly •
Standard triple grouser shoe (600 mm)
3,670
3,920
•
Standard triple grouser shoe (700 mm)
4,030
4,300
•
Wide triple grouser shoe (800 mm)
—
—
•
Road liner (rubber pad type) (600 mm)
—
—
Boom assembly
2,450
2,450
Arm assembly
1,211
1,211
Bucket assembly
1,508
1,508
254 x 2
254 x 2
Arm cylinder assembly
382
382
Bucket cylinder assembly
228
228
Link assembly (large)
316
316
Link assembly (small)
—
—
76 + 15 x 2 + 56 + 17 + 42
76 + 15 x 2 + 56 + 17 + 42
Arm pin
13 +17
13 +17
Bucket pin
30 x 2
30 x 2
Link pin
27 x 2
27 x 2
Boom cylinder assembly
Boom pin
PC300-7
01-11
GENERAL
FUEL, COOLANT, AND LUBRICANTS
12
FUEL, COOLANT, AND LUBRICANTS
RESERVOIR
KIND OF FLUID
AMBIENT TEMPERATURE -22 -4 -30 -20
14 -10
32 0
50 10
68 20
86 30
104°F 40°C
CAPACITY (l) Specified
Refill
38
35
1.3
—
13.4
13.4
8.5
8.5
Idler (1 each)
0.22 ~ 0.24
0.22 ~ 0.24
Track roller (1 each)
0.25 ~ 0.28
0.25 ~ 0.28
0.145 ~ 0.155
0.145 ~ 0.155
365
188
605
—
32
—
SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Damper case Swing machinery case Final drive case (each side)
Engine oil
SAE 30
Carrier roller (1 each) SAE 10W SAE 10W-30 Hydraulic system SAE 15W-40 Hydraulic oil
Fuel tank
H046-HM (★) ASTM D975 No. 2
Diesel fuel ASTM D975A No.1
Cooling system
Coolant
Add antifreeze
★ For the H-046-HM, use the oil recommended by Komatsu.
01-12
PC300-7
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 1252 Engine
Multi Monitor System . . . . . . . . . . 10-173 7-Segment Monitor System . . . . . 10-193 Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-200
PC300-7
10-1
Related Parts . . . . . . . . . . . . . .10-2 Radiator • Oil Cooler • Aftercooler . . .10-3 Power Train . . . . . . . . . . . . . . . . . . . . .10-4 Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6 Sprocket . . . . . . . . . . . . . . . . . . . . . . 10-7-1 Swing Machinery. . . . . . . . . . . . . . . . .10-8 Swing Circle . . . . . . . . . . . . . . . . . . . .10-10 Track Frame • Recoil Spring . . . . . . .10-12 Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 Carrier roller. . . . . . . . . . . . . . . . . . . .10-16 Track roller . . . . . . . . . . . . . . . . . . . . .10-17 Track Shoe . . . . . . . . . . . . . . . . . . . . .10-18 Hydraulic Equipment Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22 Hydraulic Tank . . . . . . . . . . . . . . . . . .10-24 Hydraulic Pump . . . . . . . . . . . . . . . . .10-26 Variable Volume Valve . . . . . . . . . . .10-47 Control Valve . . . . . . . . . . . . . . . . . . .10-50 CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-66 Self Pressure Reducing Valve. . . . . .10-69 Swing Motor . . . . . . . . . . . . . . . . . . .10-72 Reverse Prevention Valve . . . . . . . . .10-78 Center Swivel Joint . . . . . . . . . . . . . .10-80 Travel Motor . . . . . . . . . . . . . . . . . . .10-81 Travel Junction Valve . . . . . . . . . . . .10-91 Travel PPC Shuttle Valve . . . . . . . . .10-94 Valve Control . . . . . . . . . . . . . . . . . . .10-98 Work Equipment • Swing PPC Valve10-99 Travel PPC Valve . . . . . . . . . . . . . . .10-103 Service PPC Valve . . . . . . . . . . . . . .10-112 Solenoid Valve. . . . . . . . . . . . . . . . .10-115 PPC Accumulator. . . . . . . . . . . . . . .10-117 Return Oil Filter . . . . . . . . . . . . . . . .10-118 Boom Hydraulic Drift Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120 Quick Return Valve . . . . . . . . . . . . .10-126 Lift Check Valve . . . . . . . . . . . . . . . .10-128 Attachment Circuit Selector Valve .10-129 Hydraulic Cylinder . . . . . . . . . . . . . .10-132 Work Equipment . . . . . . . . . . . . . . .10-134 Air Conditioner . . . . . . . . . . . . . . . .10-140 Engine Control . . . . . . . . . . . . . . . . .10-141 Electronic Control System . . . . . . .10-149
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
1. 2. 3. 4.
Drive plate Torsion spring Stopper pin Friction plate
10-2
5. 6. 7. 8.
Damper assembly Muffler Rear engine mount Front engine mount
OUTLINE •
The damper assembly is a wet type. Oil capacity: 1.3
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
RADIATOR • OIL COOLER • AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
SWP08671
1. 2. 3. 4. 5. 6. 7. 8. 9.
Reservoir tank Oil cooler Radiator Radiator inlet hose Radiator outlet hose Net Shroud Radiator cap Aftercooler
PC300-7
SPECIFICATIONS Radiator : CF19-4 Oil cooler : CF40-1
10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
POWER TRAIN
12
POWER TRAIN
1. 2. 3. 4. 5. 6.
Idler Center swivel joint Control valve Final drive Travel motor (HMV 160ADT-2) Engine (SAA6D114E)
10-4
7. 8. 9. 10. 11. 12.
Hydraulic pump (HPV125+125) Travel speed solenoid valve Swing brake solenoid valve Swing machinery Swing motor (KMF230ABE-5) Swing circle
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
FINAL DRIVE
12
FINAL DRIVE
10-6
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
FINAL DRIVE
12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Level plug Drain plug No. 1 planetary gear (No. of teeth: 42) No. 1 sun gear (No. of teeth: 11) No. 2 sun gear (No. of teeth: 19) No. 1 planetary carrier No. 2 planetary carrier Cover Ring gear (No. of teeth: 97) Hub Sprocket Floating seal Travel motor No. 2 planetary gear (No. of teeth: 38)
SPECIFICATIONS Reduction ratio: 11+ 97 19 + 97 − × = −58.943 11 19
Unit: mm No.
15
Check item Backlash between No. 1 sun gear and No. 1 planetary gear
Criteria
Remedy
Standard clearance
Clearance limit
0.12 ~ 0.44
0.90
16
Backlash between No. 1 planetary gear and ring gear
0.18 ~ 0.62
1.20
17
Backlash between No. 2 planetary carrier and motor
0.06 ~ 0.25
—
18
Backlash between No. 2 sun gear and No. 2 planetary gear
0.15 ~ 0.51
1.00
19
Backlash between No. 2 planetary gear and ring gear
0.19 ~ 0.66
1.30
20
Backlash between No. 2 planetary carrier and No. 2 sun gear
0.39 ~ 0.80
1.60
21
Amount of wear on sprocket tooth
22
Repair limit: 6 Standard size
Repair limit
87
84
Width of sprocket tooth
PC300-7
Replace
Rebuild or replace
10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SPROCKET
12 PC300-7
SPROCKET
Unit: mm No.
1
Check item
Criteria
Remedy
Standard clearance
Clearance limit
336.5
324.5
Wear of tooth tip
2
Thickness of tooth root
20
14
3
Width of tooth
87
84
4
Wear of tooth shape
10-7-1 (6)
Build-up welding or replace
Repair limit: 6 (measure with sprocket tooth shape)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
★ The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy on an OHP sheet. PC300-7
10-7-2 (6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MACHINERY
12
SWING MACHINERY
10-8
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MACHINERY
12
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Swing pinion (No. of teeth: 13) Spacer Case No. 2 planetary gear No. 2 sun gear Ring gear No. 1 sun gear Swing motor Oil level gauge No. 1 planetary gear No. 1 planetary carrier No. 2 planetary carrier Drain plug
SPECIFICATIONS Reduction ratio: 19 + 68 24 + 68 × = 17.553 19 24
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.18 ~ 0.28
—
Backlash between No. 1 sun gear and No. 1 planetary gear
0.15 ~ 0.51
1.00
16
Backlash between No. 1 planetary gear and ring gear
0.17 ~ 0.60
1.10
17
Backlash between No. 1 planetary carrier and No. 2 sun gear
0.40 ~ 0.75
1.20
18
Backlash between No. 2 sun gear and No. 2 planetary gear
0.16 ~ 0.55
1.00
19
Backlash between No. 2 planetary gear and ring gear
0.17 ~ 0.60
1.10
20
Backlash between coupling and swing pinion
0.08 ~ 0.25
—
21
Backlash between swing pinion and swing circle
0.00 ~ 1.21
2.00
22
Clearance between plate and coupling
0.57 ~ 1.09
—
Standard size
Repair limit
23
Wear of swing pinion surface contacting with oil seal
14
Backlash between swing motor shaft and No. 1 sun gear
15
PC300-7
145
0 -0.100
—
Replace
Apply hard chrome plating, recondition, or replace
10-9
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 90) 2. Ball 3. Swing circle outer race
SPECIFICATIONS
a. Inner race soft zone S position b. Outer race soft zone S position
Reduction ratio:
−
90 = −6.923 13
Amount of grease: 33 l (G2-LI) Unit: mm No.
4
10-10
Check item Axial clearance of bearing (when mounted on chassis)
Criteria
Remedy
Standard clearance
Clearance limit
0.5 ~ 1.6
3.2
Replace
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK FRAME • RECOIL SPRING
TRACK FRAME • RECOIL SPRING
SWP08996
1 2 3 4 5 6 7 8 9
Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard
10-12
• The dimensions and the number of track rollers depend on the model, but the basic structure is not different. • Number of track rollers Model
Q’ty
PC300-7, PC350-7
7
PC300LC-7, PC350LC-7
8
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK FRAME • RECOIL SPRING
12
Standard shoe Model
PC300-7
PC300LC-7
PC350-7
PC350LC-7
Shoe width
600 mm
700 mm
600 mm
600 mm
Link pitch
216 mm
216 mm
216 mm
216 mm
45 (pieces)
49 (pieces)
45 (pieces)
48 (pieces)
Item
No. on track (one side)
Unit: mm No.
10
11
Check item
Vertical width of idler guide
Horizontal width of idler guide
Criteria
Remedy
Standard size
Tolerance
Repair limit
Track frame
123
+2 -1
127
Idler support
120
± 0.5
118
Track frame
266
+3 -1
271
Idler support
261
—
259
Standard size 12
Recoil spring
PC300-7
Rebuild or replace
Repair limit
Free length x O.D.
Installation length
Installation load
Free length
Installation load
795 X 241
648
173.3 kN (17,680 kg)
—
138.56 kN (14,140 kg)
Replace
10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
IDLER
12
IDLER
10-14 (6)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
IDLER
12
Unit: mm No.
Check item
1
Outside diameter of protruding
Criteria
Remedy
Standard size
Repair limit
635
—
2
Outside diameter of tread
590
578
3
Thickness of tread
32
26
4
Width of protrusion
102
—
5
Total width
190
—
6
Width of tread
44
50
7
Clearance between shaft and bushing
Standard size 80
8
Interference between idler and bushing
Standard size 87.6
PC300-7
Tolerance Shaft
Hole
-0.225 -0.325
+0.130 -0.024
Tolerance Shaft
Hole
+0.087 +0.037
-0.027 -0.079
Rebuild or replace
Standard clearance
Clearance limit
0.201 ~ 0.455
1.5
Standard interference
Interference limit
0.064 ~ 0.166
—
Replace bushing
10-15 (6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CARRIER ROLLER
12
CARRIER ROLLER
Unit: mm No.
1
Check item
Criteria
Remedy
Standard size
Repair limit
175
—
Outside diameter of flange
2
Outside diameter of tread
148
134
3
Width of tread
50.3
—
4
Thickness of tread
32
25
5
Width of flange
19
—
6
Interference between shaft and bushing
Standard size 50
7
Interference between roller and bushing
Standard size 57
8
Shaft
Hole
-0.250 -0.270
+0.099 -0.032
Tolerance Shaft
Hole
+0.117 +0.087
+0.040 0
Standard interference
Clearance limit
0.218 - 0.369
—
Standard interference
Interference limit
0.047 - 0.117
—
Standard clearance
Clearance limit
0.5 - 0.7
—
Replace
Axial clearance of roller
10-16 (6)
Tolerance
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK ROLLER
12
TRACK ROLLER
Unit: mm No.
1
Check item
Criteria
Remedy
Standard size
Repair limit
216
—
Outside diameter of flange
2
Outside diameter of tread
180
168
3
Thickness of tread
54
48
4
Overall width
250
—
5
Inside width
98
—
6
Width of tread
49
—
7
Width of flange
27
—
8
Clearance between shaft and bushing
Standard size 65
9
Interference between roller and bushing
Standard size 72
PC300-7
Tolerance Shaft
Hole
-0.250 -0.350
+0.186 -0.064
Tolerance Shaft
Hole
+0.108 +0.008
-0.006 -0.036
Rebuild or replace
Standard clearance
Clearance limit
0.186 - 0.536
—
Standard interference
Interference limit
0.014 - 0.144
—
Replace bushing
10-17 (6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK SHOE
12
TRACK SHOE
SWP09000
★ P portion shows the link of bushing press fitting end.
10-18
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK SHOE
12
Unit: mm No . 1
Check item
Criteria
Remedy
Standard size
Repair limit
216.3
219.3
Standard size
When turned
66.9
61.9
Standard size
Repair limit
116
107
30.7
21.7
Link pitch
2
Bushing outside diameter
3
Reverse or replace
Link height Thickness of link metal (bushing press-fitting portion)
4 5
Repair or replace
178.4
6
Shoe bolt pitch
140.4
7
Replace
76.2
8 Link
9 10
Inside width
102
Overall width
47.8
Tread width
42.6
11
Protrusion of pin
4.2
12
Protrusion of regular bushing
5.25
13
Overall length of pin
242
14
Overall length of bushing
15
Thickness of bushing metal
16
Thickness of spacer
17 18
Press-fitting force
19
Repair or replace
Adjust or replace
148.4 Standard size
When turned
10.8
5.8 —
Bushing
98 - 264.6 kN {10 - 27 ton}
Regular pin
147 - 362.6 kN {15 - 37 ton}
Master pin
98 - 215.6 kN {10 - 22 ton}
—
: Dry type track link
PC300-7
10-19 (6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK SHOE
12
Unit: mm No.
Check item
Criteria Tightening torque (Nm {kgm})
Remedy Additional tightening angle (deg.)
a. Regular link Triple shoe
393 ± 39 {40 ± 4}
120 ± 10 Retighten
Shoe bolt 20 b. Master link
Tightening torque (Nm {kgm})
Additional tightening Lower limit torque angle (deg.) (Nm {kgm})
—
22
23
Interference between bushing and link
Interference between regular pin and link
Clearance between regular pin and bushing
Standard size
Interference between master pin and bushing
Clearance between master pin and bushing
Standard interference
Hole
66.5
+0.464 +0.424
+0.074 0
0.350 ~ 0.464
44.6
+0.235 +0.085
-0.188 -0.250
0.273 ~ 0.485
Standard size
Standard size 44.6
25
Tolerance
—
Shaft
44.6
24
—
PC300-7, PC350-7: 45 PC300LC-7, PC350LC-7: 48
No. of shoes (each side)
21
—
Standard size 44.3
Tolerance Shaft
Hole
+0.235 +0.085
+0.915 +0.415
Tolerance Shaft
Hole
+0.03 0
-0.188 -0.250
Tolerance Shaft
Hole
+0.050 -0.050
+0.915 +0.415
Standard clearance 0.180 ~ 0.830
Adjust or replace
Standard interference 0.188 ~ 0.280 Standard clearance 0.365 ~ 0.965
: Dry type track link
10-20 (6)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRACK SHOE
12
TRIPLE GROUSER SHOE
Unit: mm No.
1
Check item
Criteria
Height ( )
2
Remedy
Standard size
Repair limit
36
24
30
18
Thickness
11 32
3 ( )
29
Length of base 26 Rebuild or replace
4 ( )
24 24
5 ( )
22 18
6
Length at tip ( )
16 18
7 ( )
22
: PC300-7, PC300LC-7 : 600 mm width shoe
PC300-7
10-21 (6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC EQUIPMENT LAYOUT DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING 1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Swing motor 5. Control valve 6. Oil cooler 7. Hydraulic filter 8. Hydraulic pump 9. L.H. travel motor 10. Hydraulic tank 11. Multi-pattern selector valve 12. L.H. PPC valve 13. Safety lever (electric type) 14. Center swivel joint 15. R.H. PPC valve 16. Travel PPC valve 17. Attachment circuit selector valve 18. Holding valve 19. Accumulator 20. Solenoid valve assembly 20A PPC lock solenoid 20B Travel junction solenoid 20C Pump merge/divider solenoid 20D Travel speed solenoid 20E Swing brake solenoid 20F Machine push-up solenoid 20G 2-stage relief solenoid
10-22
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC EQUIPMENT LAYOUT DRAWING
12
PC300-7
10-23
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC TANK
12
HYDRAULIC TANK
1. 2. 3. 4. 5. 6.
Sight gauge Hydraulic tank Oil filler cap Filter element Strainer Bypass valve
10-24
SPECIFICATIONS Tank capacity: 275 l Amount of oil inside tank: 188 l Pressure valve Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm²} Suction cracking pressure: 0 - 0.49 kPa {0 - 0.005 kg/cm²} Bypass Valve set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm²}
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
HYDRAULIC PUMP HPV125 + 125
1. 2. 3. 4. 5. 6.
Front main pump Rear main pump LS valve PC valve LS-EPC valve PC-EPC valve
IM ISIG PAF PFC
: : : :
PAR : PRC : PBF : PD1F: PENF:
PC mode selector current LS set selector current Front pump delivery port Front pump delivery pressure detection port Rear pump delivery port Rear pump delivery pressure detection port Pump pressure input port Case drain port Front pump control pressure detection port
PENR : Rear pump control pressure detection port PLSF : Front load pressure input port PLSFC: Front load pressure detection port PLSR : Rear load pressure input port PLSRC: Rear load pressure detection port PS : Pump suction port PLSC : LS set selector pressure detection port PM : PC set selector pressure detection port PEPC : EPC basic pressure input port
Outline • This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-26
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
1. 2. 3. 4. 5. 6.
Shaft (Front) Cradle Case (Front) Rocker cam Shoe Piston
PC300-7
7. 8. 9. 10. 11. 12.
Cylinder block Valve plate End cap Shaft (Rear) Case (Rear) Servo piston
10-27
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
SWP
Function • The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is discharged according to the load. • It is possible to change the discharge amount by changing the swash plate angle. Structure • Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. • The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing.
10-28
•
•
•
Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
Operation 1) Operation of pump i Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle α is called the swash plate angle.) ii Center line X of rocker cam (4) maintains swash plate angle α in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F - E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. iii If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)
PC300-7
10-29
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 12 2)
HYDRAULIC PUMP
Control of discharge amount • If the swash plate angle α becomes larger, the difference between volumes E and F becomes larger and discharge amount Q increases. • Swash plate angle α is changed by servo piston (12). • Servo piston (12) moves in a reciprocal movement (↔) according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction of arrow. • With servo piston (12), the area receiving the pressure is different on the left and the right, so main pump discharge pressure (self pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. • Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter end. The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).
10-30
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
LS VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Plug Locknut Sleeve Spring Seat Spool Piston Sleeve
PA : PP : PDP : PLP : PLS : PPL : PSIG :
Pump port Pump port Drain port LS control pressure output port LS pressure input port PC control pressure input port LS mode selection pilot port
PA : PA2 : PDP : PM : PPL : PPL2:
Pump port Pump pressure pilot port Drain port PC mode selector pressure pilot port PC control pressure output port LS control pressure output port
PC VALVE
1. 2. 3. 4. 5. 6. 7. 8.
Servo piston assembly Plug Pin Spool Retainer Seat Cover Wiring
PC300-7
10-31
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12 Function (1) LS valve The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to differential pressure ∆PLS (=PP - PLS) [called the LS differential pressure] (the difference between main pump pressure PP and control valve outlet port pressure PLS). Main pump pressure PP, pressure PLS {called the LS pressure} coming from the control valve output, and pressure Psig {called the LS selector pressure} from the proportional solenoid valve enter this valve. The relationship between discharge amount Q and differential pressure ∆PLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP - PLS) changes as shown in the diagram at the right according to LS pressure selector current isig of the LS-EPC valve. When isig changes between 0 and 1A, the set pressure of the spring changes according to this, and the selector point for the pump discharge amount changes at the rated central valve between 0.98 ↔ 2.5 MPa {10 ↔ 25 kg/ cm²}. (2) PC valve When the pump discharge pressure PP1 (self-pressure) and PP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below
10-32
09141
09142
the set value, the command current to the PCEPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12 OPERATION
SDP08884
(1) LS valve 1) When control valve is at neutral position • The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring changes). • Before the engine is started, servo piston (12) is pushed to the right. (See the diagram on the right) • When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa {0 kg/cm²}. (It is interconnected with the drain circuit through the control valve spool.)
PC300-7
At this point, spool (6) is pushed to the left, and port C and port D are connected. Pump pressure PP enters the large diameter end of the piston from port K and the same pump pressure PP also enters port J at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in the area of the piston (12).
10-33 (8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
SDP08885
2) Operation in increase direction for pump discharge amount • When the difference between the main pump pressure PP and LS pressure PLS, in other words, LS differential pressure ∆PLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and pump PP drops), spool (6) is pushed to the right by the combined force of LS pressure PLS and the force of spring (4). • When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D - K becomes drain pressure PT. (The operation of the PC valve is explained later).
10-34
•
For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger. If the output pressure of the EPC valve for the LS valve enters port G, this pressure creates a force to move piston (7) to the left. If piston (7) is pushed to the left, it acts to make the set pressure of spring (4) weaker, and the difference between PLS and PP changes when ports D and E of spool (6) are connected.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
SDP08886
3) Operation in decrease direction for pump discharge amount • The following explains the situation if the servo piston (12) moves to the left (the discharge amount becomes smaller). When LS differential pressure ∆PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the left. • When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large diameter end of the piston.
PC300-7
•
• •
Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed to the left. As a result, the swash plate moves in the direction to make angle smaller. If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.
10-35
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
SDP08887
4) When servo piston is balanced • Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 x PP = A1 x Pen, servo piston (11) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)
10-36
•
•
At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0 : A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP : Pen = 2:1. The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP - PLS = 2.5 MPa {25 kg/cm²}. However, if PSIG (the output pressure of 0 ↔ 2.9 MPa {0 ↔ 30 kg/cm²} of the EPC valve of the LS valve) is applied to port G, the balance stop position will change in proportion to pressure PSIG between PP - PLS = 2.5 ↔ 0.98 MPa {25 ↔ 10 kg/cm²}.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
(2) PC Valve 1) When pump controller is normal a. When the load on the actuator is small and pump pressures PP1 and PP2 are low i) Movement of PC-EPC solenoid (1) • The command current from the pump controller flows to PC-EPC solenoid (1).This command current acts on the PCEPC valve and outputs the signal pressure. When this signal pressure is received, the force pushing piston (2) is changed. • On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6) and pump pressure PP1 (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops at a position where the combined force pushing spool (3) is balanced, and
PC300-7
•
the pressure (pressure of port C) output from the PC valve changes according to this position. • The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. ★ Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure
10-37 (8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
ii) Action of spring • The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position. • If piston (9) moves to the left, spring (6) is compressed, and if it moves further to the left, spring (6) contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9) extending or compressing springs (4) and (6).
10-38 (8)
•
If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2) changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC valve solenoid command current.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
•
•
•
•
Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self pressure PP1 enters port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A. When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase. As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker. When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the right is stopped. In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.
PC300-7
10-39
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
b. When load on actuator is large and pump discharge pressure is high • When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to the left becomes larger and spool (3) moves to the position in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port B flows out through port C where the LS valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes approximately half of main pump pressure PP. • When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops.
10-40 (8)
•
•
If main pump pressure PP increases further and spool (3) moves further to the left, main pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the left, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, the opening of port C and port D becomes larger. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the left. The position in which piston (9) stops when this happens is further to the left than the position when pump pressures PP1 and PP2 are low.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
•
The relation of average pump pressure (PP1 + PP2)/2 and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (4) and (6). The relationship between average pump pressure (PP1 + PP2)/2 and pump discharge amount Q is shown in the figure at the right.
•
If command voltage X sent to PC-EPC valve solenoid (1) increases further, the relationship between average pump pressure (PP1 + PP2)/2, and pump discharge amount Q is proportional to the pushing force of the PC-EPC valve solenoid and moves in parallel. In other words, the pushing force of PC-EPC solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and Q moves from [1] to [2] in accordance with the increase in X.
PC300-7
10-41 (8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
2) When pump controller is abnormal and emergency pump drive switch is ON a. When load on main pump is light • If there is a failure in the pump controller, turn emergency pump drive switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1). • When this is done, the current becomes constant, so the force pushing piston (2) is also constant. • If the main pump pressure PP1 and PP2 are low, the combined force of the pump pressure and the force of PC-EPC valve solenoid (1) are weaker than the spring set force, so spool (3) is balanced at a position to the right.
10-42 (8)
•
At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
09147
b. When main pump load is heavy • In the same way as in the previous item, when the emergency pump drive switch is ON, the command current sent to PCEPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. • If main pump pressures PP1 and PP2 increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the diagram above. • In this case, the pressure from port A flows to port C, so servo piston (9) moves to the left (to make the discharge amount smaller) by the same mechanism as explained in item 2)-b, and stops at a position to the left of the position when the load on the pump is light. In other words, even when the emergency pump drive switch is ON, the curve for the pump pressure PP
PC300-7
and discharge amount Q is determined as shown in the diagram for the valve of the current sent to the PC-EPC valve solenoid through the resistor. The curve when the PC prolix switch is ON is curve ➁, which is to the left of curve ➀ for when the pump controller is normal.
10-43
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12
LS(PC)-EPC VALVE
1. 2. 3. 4.
Body Spool Spring Rod
10-44
5. Coil 6. Plunger 7. Connector
PSIG(PM) : To LS(PC) valve PT : To tank PEPC : From self-reducing pressure valve
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC PUMP
12O FUNCTION •
•
The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. When it receives signal current i from the pump controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS valve.
OPERATION 1. When signal current is 0 (coil de-energized) • When there is no signal current flowing from the controller to coil (5), coil (5) is deenergized. • For this reason, spool (2) is pushed to the right in the direction of the arrow by spring (3). • As a result, port PEPC 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 PSIG(PM) through port PT and is drained to the tank.
PC300-7
08890
10-45 (8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 2. When signal current is very small (coil energized) • When a very small signal current flows to coil (5), coil (5) is energized, and a propulsion force is generated which pushes plunger (6) to the left. • Push pin (4) pushes spool (2) to the left, and pressurized oil flows from port PEPC to port PSIG(PM). • When the pressure at port PSIG(PM) rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (6), spool (2) is pushed to the right. The circuit between port PEPC and port PSIG(PM) is shut off, and at the same time, port PSIG(PM) and port PT are connected. • As a result, spool (2) is moved up or down until the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port PSIG(PM). • Therefore, the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current. 3. When signal current is maximum (coil energized) • When the signal current flows to coil (5), 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 (2) is pushed fully to the left by push pin (4). • As a result, the maximum flow of pressurized oil from port PEPC flows to port PSIG(PM), and the circuit pressure between the EPC valve and LS valve becomes the maximum. At the same time, port PT closes and stops the oil from flowing to the tank.
10-46
HYDRAULIC PUMP
08891
08892
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
VARIABLE VOLUME VALVE
12
VARIABLE VOLUME VALVE
1. 2. 3. 4.
Block Plug Spring Piston
PC300-7
PM: To PC valve PT: To tank PEPC: From self-reducing pressure valve
10-47
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
VARIABLE VOLUME VALVE
FUNCTION •
This stabilizes the EPC output pressure.
OPERATION •
The output pressure from EPC flows to port PM, and when the propulsion force of piston (4) becomes larger than the load of spring (3), piston (4) is pushed to the left and the volume at port PM increases. When the propulsion force of piston (4) becomes less than the load on spring (3), piston (4) is pushed to the right and the volume at port PM goes down.
09148
10-48 (8)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12
CONTROL VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
6-spool valve Cover 1 Cover 2 Pump merge-divider valve Back pressure valve Boom lock valve Boom, arm Hi valve Service valve Quick return valve Boom Hi check valve
OUTLINE •
•
•
A1 A2 A3 A4 A5 A6 A-1 A-2 B1 B2 B3 B4 B5 B6 B-1 B-2 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
: : : : : : : : : : : : : : : : : : : : : : : :
To bucket cylinder bottom To left travel motor To boom cylinder bottom To swing motor To right travel motor To arm cylinder head To boom cylinder bottom To attachment To bucket cylinder head To left travel motor To bottom cylinder head To swing motor To right travel motor To arm cylinder bottom To arm cylinder bottom To attachment From bucket PPC valve From bucket PPC valve From left travel PPC valve From left travel PPC valve From boom PPC valve From boom PPC valve From swing PPC valve From swing PPC valve : From right travel PPC valve : From right travel PPC valve
10-50 (8)
P11 P12 P-3 P-4 BP1 PB5 BP6
This control valve consists of a 7-spool valve (6 spool valve + boom, arm Hi valve) and a service valve. A merge-divider valve, back-pressure valve, boom hydraulic drift prevention valve, quick return valve, and Hi valve check valve are installed to it. Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is small in size and easy to maintain. Since one spool of this control valve is used for one work equipment unit, its structure is simple.
: : : : : : :
PLS1 : PLS2 : PP1 : PP2 : PPS1: PPS2: PR : PS : PST : PX1 : PX2 : SA : SB : T : T1 : TS : TSW :
From arm PPC valve From arm PPC valve From service PPC valve From service PPC valve Boom RAISE PPC output pressure From 2-stage safety valve solenoid valve From attachment circuit selector solenoid valve To rear pump control To front pump control To rear pump control To front pump control From rear main pump From front main pump To solenoid valve, PPC valve, EPC valve From pump merge-divider solenoid valve From travel junction valve From 2-stage solenoid valve From 2-stage solenoid valve Pressure sensor fitting port Pressure sensor fitting port To tank To tank To tank To swing motor
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 8-spool valve (7-spool valve + 1 service valve) (1/9)
PC300-7
10-51 (8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (2/9)
S*P09099
10-52
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (3/9)
1. Unload valve 2. Pressure compensation valve (Arm OUT) 3. Pressure compensation valve (Right travel reverse) 4. Pressure compensation valve (Right swing) 5. Pressure compensation valve (Boom RAISE) 6. Pressure compensation valve (Left travel reverse) 7. Pressure compensation valve (Bucket CURL) 8. Pressure compensation valve (Boom RAISE) 9. Pressure compensation valve (Service)
PC300-7
10. 11. 12. 13. 14. 15. 16. 17. 18.
Pressure compensation valve (Service) Pressure compensation valve (Arm IN) Pressure compensation valve (Bucket DUMP) Pressure compensation valve (Left travel forward) Pressure compensation valve (Boom LOWER) Pressure compensation valve (Left swing) Pressure compensation valve (Right travel forward) Pressure compensation valve (Arm IN) Main relief valve
10-53
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (4/9)
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.
Spool (Arm) Spool (Right travel) Spool (Swing) Spool (Boom) Spool (Left travel) Spool (Bucket)
Spool (Boom Hi) Spool (Arm Hi) Spool (Service) Unload valve Main relief valve
Unit: mm No.
Check item
Criteria Standard size
12
Spool return spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
54.2 x 34.8
51.2
416.5 N {42.5 kg}
—
333.2 N {34 kg}
13
Spool return spring
54.6 x 34.8
51.2
429.9 N {42.9 kg}
—
336.1 N {34.3 kg}
14
Spool return spring
54.5 x 34.8
51.2
393 N {40.1 kg}
—
314.6 N {32.1 kg}
15
Spool return spring
54.9 x 24.2
51.2
251 N {25.1 kg}
—
201.0 N {20.5 kg}
10-54
If damaged or deformed, replace spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (5/9)
1. 2. 3. 4. 5. 6. 7. 8. 9.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Safety-suction valve (Arm OUT) Suction valve (Right travel reverse) Suction valve (Boom RAISE) Suction valve (Left travel reverse) Safety-suction valve (Service) Safety-suction valve (2-stage) (Service) Safety-suction valve (Arm IN) Safety-suction valve (Bucket DUMP) Suction valve (Left travel forward)
Safety-suction valve (2-stage) (Boom LOWER) Suction valve (Right travel forward) Safety-suction valve (Arm IN) LS shuttle valve (Arm, right travel) LS select valve LS shuttle valve (Boom, left travel, bucket) LS shuttle valve (Service) LS check valve Pressure relief plug
Unit: mm No.
Check item
Criteria Standard size
19
Check valve spring
PC300-7
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
If damaged or deformed, replace spring
10-55
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (6/9)
ARM CONTROL VALVE 1. Unload valve 2. Main relief valve 3. Safety valve (Boom RAISE) 4. Lift check valve
10-56
5. Safety-suction valve 6. Spool 7. Pressure compensation valve (OUT) 8. LS shuttle valve 9. Pressure compensation valve (IN) 10. Safety-suction valve 11. Check valve for regeneration circuit
R. H. TRAVEL CONTROL VALVE 12. Suction valve 13. Spool 14. Pressure compensation valve (Reverse) 15. LS shuttle valve 16. Pressure compensation valve (Forward) 17. Suction valve
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Criteria Standard size
18
Regeneration valve spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
31.5 x 10.3
19.5
6.2 N {0.6 kg}
—
4.9 N {0.5 kg}
19
Piston return spring
48.1 x 10.8
28
17.5 N {1.8 kg}
—
14.0 N {1.4 kg}
20
Piston return spring
36.9 x 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
PC300-7
If damaged or deformed, replace spring
10-57
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
(7/9)
SWING CONTROL VALVE
BOOM CONTROL VALVE
1. Spool 2. Pressure compensation valve (Right) 3. LS select valve 4. Pressure compensation valve (Left)
5. Suction valve 6. Spool 7. Pressure compensation valve (RAISE) 8. Hydraulic drift prevention valve 9. LS shuttle valve 10. Pressure compensation valve (Lower) 11. Safety-suction valve 12. Check valve for regeneration circuit
10-58
L. H. TRAVEL CONTROL VALVE 13. Pump merge-divider valve (Travel junction valve) 14. Return spring 15. Suction valve 16. Spool 17. Pressure compensation valve (Reverse) 18. LS shuttle valve 19. Pressure compensation valve (Forward) 20. Suction valve
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Criteria Standard size
21
Regeneration valve spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
31.5 x 10.3
19.5
6.2 N {0.6 kg}
—
4.9 N {0.5 kg}
—
14.0 N {1.4 kg}
22
Piston return spring
48.1 x 10.8
28
17.5 N {1.8 kg}
23
Piston return spring
36.9 x 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
24
Spool return spring
30.7 x 20.5
23
50.0 N {5.1 kg}
—
40.0 N {4.1 kg}
PC300-7
If damaged or deformed, replace spring
10-59
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (8/9)
BUCKET CONTROL VALVE
BOOM, ARM HI VALVE
SERVICE VALVE
1. Safety-suction valve 2. Spool 3. Pressure compensation valve (CURL) 4. LS shuttle valve 5. Pressure compensation valve (DUMP) 6. Safety-suction valve
7. Boom Hi spool 8. Pressure compensation valve (Boom RAISE) 9. Boom Hi check valve 10. Quick-return valve 11. Pressure compensation valve (Arm IN) 12. Arm Hi spool 13. Safety-suction valve
14. 15. 16. 17. 18. 19.
Safety-suction valve Spool Pressure compensation valve LS shuttle valve Pressure compensation valve Safety-suction valve
Unit: mm No.
Check item
Criteria Standard size
20
21
Piston return spring
Piston return spring
10-60
Free length x Outside diameter
Remedy Repair limit
Installed length
Installed load
Free length
Installed load
28
17.5 N {1.8 kg}
—
14.0 N {1.4 kg}
48.1 x 10.8 36.9 x 11.1
28
29.4 N {3 kg}
—
23.5 N {2.4 kg}
If damaged or deformed, replace spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12 (9/9)
1. 2. 3. 4. 5. 6. 7. 8.
Unload valve Main relief valve Pump merge-divider valve (Main) Return spring Pump merge-divider valve (For LS) Return spring Valve (Sequence valve) Spring (Sequence valve)
10-62
9. 10. 11. 12. 13. 14. 15. 16.
LS bypass plug Screw Poppet Spring (Pressure reducing valve pilot) Spring (Pressure reducing valve main) Valve (Pressure reducing valve) Spring (Safety valve) Ball
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
Unit: mm No.
Check item
Criteria Standard size
17
Check valve spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N {0.15 kg}
—
1.2 N {0.12 kg}
—
125.5 N {12.8 kg}
18
Spool return spring
46.6 x 21.8
3.3
156.8 N {16.0 kg}
19
Spool return spring
64.5 x 32.3
63
177.5 N {18.1 kg}
—
142.0 N {14.5 kg}
20
Sequence valve spring
70.9 x 18.0
59
199.8 N {20.4 kg}
—
160.0 N {16.3 kg}
PC300-7
If damaged or deformed, replace spring
10-63
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
MAIN RELIEF VALVE
1. Spring 2. Poppet
FUNCTION •
The relief valve set pressure is set to 2 stages. When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.
OPERATION • •
The relief valve set pressure is determined by the installed load of spring (1). (First stage) It is unnecessary to set the first and second stage individually. The second stage is set when the first stage is set.
1.
When pilot pressure P is OFF: Low-pressure setting The set pressure is determined by the installed load of spring (1).
2. When pilot pressure P is ON: High-pressure setting In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter d1, so the set pressure becomes higher.
10-64
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CONTROL VALVE
12
VARIABLE PRESSURE COMPENSATION VALVE
PC300-7
10-65
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CLSS
12
CLSS OUTLINE OF CLSS
FEATURES
STRUCTURE
•
CLSS stands for Closed center Load Sensing System, and has the following features.
•
1) Fine control not influenced by load 2) Control enabling digging even with fine control 3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations 4) Energy saving using variable pump control
•
10-66
The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. The main pump body consists of the pump itself, the PC valve and LS valve.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CLSS
Basic principle 1) Control of pump swash plate • The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure ∆PLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (LS pressure ∆PLS = Pump discharge pressure PP – LS pressure PLS)
•
If LS differential pressure ∆PLS 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.
PC300-7
10-67
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
2) 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 ∆P between the upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
10-68
CLSS
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of each valve.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE FUNCTION •
This value reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, PPC valves, etc.
OPERATION 1. When engine is stopped • Poppet (11) is pressed by spring (12) against the seat and port PR is not connected to TS. • Valve (14) is pressed by spring (13) against the left side and port P2 is connected to PR. • Valve (7) is pressed by spring (8) against the left side and port P2 is not connected to A2.
PC300-7
10-69
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
2. When in neutral or load pressure P2 is low (When boom is lowered and arm is in IN position and they are moving down under own weight) Note: When load pressure A2 is lower than self-pressure reducing valve output pressure PR.
•
•
Valve (7) receives the force of spring (8) and PR pressure (which is 0 MPa {0 kg/cm²} when the engine is stopped) in the direction to close the circuit between ports P2 and A2. If the hydraulic oil flows in port P2, the φdx P2 pressure becomes equal to the total of the force of spring (8) and the value of area of ∅d x PR pressure, then the area of the pass between ports P2 and A2 is so adjusted that the P2 pressure will be kept constant above the PR pressure. If the PR pressure rises above the set level, puppet (11) opens and the hydraulic oil flows from the PR port through orifice "a" in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice "a" in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
3. When load pressure P2 is high • If load pressure A2 rises and the pump discharge increases because of operation of the work equipment, the φdx P2 pressure rises higher than the total of the force of spring (8) and the value of ∅d x PR pressure, and then valve (7) moves to the right stroke end. • As a result, the area of the pass between ports P2 and A2 increases and the pass resistance lowers and the loss of the engine power is reduced. • If the PR pressure rises above the set pressure, poppet (11) opens and the hydraulic oil flows from the PR port through orifice "a" in spool (14) and open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated between before and after orifice "a" in spool (14) and then spool (14) moves to close the pass between port P2 and PR. The P2 pressure is controlled constant (at the set pressure) by the area of the oil pass at this time and supplied as the PR pressure.
10-70
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SELF PRESSURE REDUCING VALVE
12 4. When abnormally high pressure is generated • If the PR pressure on the self-pressure reducing valve rises high abnormally, ball (16) separates from the seat against the force of spring (15) and the hydraulic oil flows from output port PR to TS. Accordingly, the PR pressure lowers. By this operation, the hydraulic devices (PPC valves, solenoid valves, etc.) are protected from abnormal pressure.
PC300-7
10-71
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MOTOR
12
SWING MOTOR KMF230ABE-5
B : S : T : MA : MB :
From swing lock solenoid valve From control valve To tank From control valve From control valve
SPECIFICATIONS
Model
KMF230ABE-5
Theoretical displacement
229.4 cm³/rev
Safety valve set pressure
10-72
27.9
+0.5 0
MPa {285 0+0.5 kg/cm2 }
Rated revolving speed
1,130 rpm
Brake release pressure
1.9 ± 0.4 MPa {19 ± 4 kg/cm²} PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MOTOR
12
1. 2. 3. 4. 5. 6. 7.
Brake spring Drive shaft Spacer Case Disc Plate Brake piston
10-74
8. 9. 10. 11. 12. 13. 14.
Housing Piston Cylinder block Valve plate Reverse prevention valve Center shaft Center spring
15. Safety valve 16. Check valve 17. Shuttle valve
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MOTOR
12
Unit: mm No.
Check item
Criteria Standard size
18
19
Check valve spring
Shuttle valve spring
PC300-7
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
66.5 x 25.6
45
6.96 N {0.71 kg}
—
5.59 N {0.57 kg}
24.5 x 11.6
14
7.7 N {0.79 kg}
—
6.18 N {0.63 kg}
If damaged or deformed, replace spring
10-75
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MOTOR
RELIEF VALVE PORTION 1) Outline The relief portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormally high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage. 3. Operation 1) When starting swing • When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA through the control valve and returns to the tank. (Fig. 1) 2) When stopping swing • When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. • If the pressure at port MB becomes higher than the pressure at port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig.2) • When relief valve (1) is being actuated, the relief oil and oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.
10-76
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SWING MOTOR
12
Operation of swing lock 1. When swing lock solenoid valve is deactivated When the swing lock solenoid valve is deactivated, the 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 (1), discs (5) and plates (6) are pushed together, and the brake is applied.
09149
2. When swing lock solenoid valve is excited When the swing lock solenoid valve is excited, the valve is switched and the pressure oil from the main pump enters port B and flows to brake chamber a. The pressure oil entering chamber a overcomes brake spring (1) and pushes brake piston (7) up. As a result, discs (5) and plates (6) are separated and the brake is released.
09150
PC300-7
10-77
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE Operation diagram
1. Valve body 2. Spool (MA side) 3. Spring (MA side) 4. Plug 5. Spool (MB side) 6. Spring (MB side) 7. Plug
Explanation of effect
10-78
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
REVERSE PREVENTION VALVE
12
Outline This valve reduces the swing back generation 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.
Operation 1) 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 D1 > 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 (2), 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.
PC300-7
10-79
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
1. Cover 2. Body 3. Slipper seal 4. O-ring 5. Shaft
T2. To tank T1. From L.H. and R.H. travel motors port T D2. From control valve port B5 B1. To L.H. travel motor port PA C2. From control valve port A5
A1. To L.H. travel motor port PB A2. From control valve port A2 C1. To R.H. travel motor port PA B2. From control valve port B2 D1. To R.H. travel motor port PB E. To L.H. and R.H. travel motors port P
Unit: mm No.
Check Item
6
Clearance between rotor and shaft
10-80
Criteria
Remedy
Standard Size
Standard clearance
Repair limit
80
—
—
Replace
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
TRAVEL MOTOR HMV160ADT-2
P T PA PB
: : : :
From travel speed solenoid valve To tank From control valve From control valve
PC300-7
SPECIFICATIONS Type Theoretical Delivery
HMV160ADT-2 Min.
103.5 cm³/rev
Max.
160.8 cm³/rev
Brake releasing pressure
1.2 MPa {12 kg/cm²}
Travel speed switching pressure
0.8 MPa {8 kg/cm²}
Differential pressure
10-81
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
12
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Output shaft Motor case Rocker cam Piston Cylinder Valve plate End cover Slow return valve Brake spring Brake piston
10-82
11. 12. 13. 14. 15. 16. 17. 18. 19.
Plate Disc Regulator piston Check valve spring Counterbalance valve Safety valve Ball Regulator valve Spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
12
Unit: mm No.
Check item
Criteria Standard size
20
Spool return spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
58.43 x 30.0
42.0
426.3 N {43.5 kg}
—
341 N {34.8 kg}
21
Check valve spring
33.0 x 13.8
23.0
1.27 N {0.13 kg}
—
1.0 N {0.10 kg}
22
Regulator piston spring
61.6 x 23.2
30.0
398.9 N {40.7 kg}
—
319.5 N {32.6 kg}
PC300-7
If damaged or deformed, replace spring
10-83
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
OPERATION OF MOTOR 1) At low speed (motor swash plate angle at maximum)
09151
•
•
•
The solenoid valve is deactivated, so the pilot pressure oil from the main pump does not flow to port P. For this reason, regulator valve (21) is pushed to the right by spring (22). Because of this, it pushes slow return valve (8), 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 force b of the combined force of the propulsion force of cylinder (5), 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.
10-84
•
•
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.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
12
2) At high speed (motor swash plate angle at minimum)
09152
•
•
•
When the solenoid valve is excited, 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 (13) at the bottom, 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.
PC300-7
10-85
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
OPERATION OF PARKING BRAKE 1) When starting to travel 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 the brake piston (10). It overcomes the force of spring (9), and pushes piston (10) to the left. When this happens, the force pushing plate (11) and disc (12) together is lost, so plate (11) and disc (12) separate and the brake is released.
2) 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 (10) is pushed to the right in the direction of the arrow 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 still effective after the machine stops.
10-86 (8)
TRAVEL MOTOR
09153
09154
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL MOTOR
OPERATION OF BRAKE VALVE • The brake valve consists of 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 pressure oil is supplied • When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It pushes open suction safety valve (18a) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by suction safety valve (18b) and spool (19), so the pressure at the supply side rises. (Fig. 2)
•
The pressurized oil at the supply side flows from orifice E1 and E2 in spool (19) to chamber S1. When the pressure in chamber S1 goes above the spool switching pressure, spool (19) is pushed to the right in the direction of the arrow. 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)
PC300-7
09155
09156
09157
10-87
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 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 S1 through orifices E1 and E2 will also drop. When the pressure in chamber S1 drops below the spool switching pressure, spool (19) is returned to the left, in the direction of the arrow 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 the 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) 2) Safety valve (2-direction operation, 2stage 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 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. 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 the inertia. (Fig. 5) • If the pressure goes above the set pressure, the force produced by the difference in are between D1 and D2 [π4(D12 - D22) x pressure] overcomes the force of the spring and moves the poppet to the left, so that the oil flows to chamber MA in the circuit on the opposite side. (Fig. 6)
10-88
TRAVEL MOTOR
09158
09160
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
2) 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. 7)
•
If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [π4(D32 - 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)
TRAVEL MOTOR
09161
09162
Operation of mechanism for varying set pressure 1) When starting travel (high-pressure setting) • When the travel lever is operated, the pressurized oil from the pump actuated counterbalance valve spool (19), 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.
09163
PC300-7
10-89
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
2) When stopping travel (low-pressure setting) • When the travel lever is placed in 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.
TRAVEL MOTOR
09164
[Set pressure of safety valve] When starting, when traveling: High-pressure setting
When stopping: Lowpressure setting
40.2 MPa {410 kg/cm2}
27.5 MPa {280 kg/cm2}
10-90
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE Function • This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors and the machine will travel straight. • When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering performance.
Operation When pilot pressure is turned ON • If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right travel circuit) is closed.
09165
PC300-7
10-91
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
When pilot pressure is turned OFF • If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against the right side and the pass between ports PTL and PTR is open.
•
TRAVEL JUNCTION VALVE
If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.
09166
10-92
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE Function • If boom RAISE or arm IN are operated when the machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC pressure and this limits the flow of oil to the boom and arm cylinders. • When the boom and arm stroke is controlled, the travel PPC pressure passes through the circuit inside the control valve to actuate the system. Operation 1 When travel is at neutral • Stroke limit signal chambers a and b are connected to the travel PPC valve through orifices (5) and (6) in pistons (3) and (4) inside the travel spring case, and the is drained. •
•
When arm IN is operated, spool (1) moves to the right by stroke (st0) to a point where it contacts the end face of spring case (2). When boom RAISE is operated, spool (9) moves to the left by stroke (st3) to a point where it contacts the end face of spring case (10).
10-94
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
09167
PC300-7
10-95
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
12 2. When travel is operated • When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC pressure pushes spool (7) to the left (or right). • Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of the travel PPC valve. • At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on the right end face of piston (8), and pushes piston (8) to the left. • If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of movement st2 of piston (8) and becomes st1. • If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal chamber b, so the spool does not move.
10-96
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC SHUTTLE VALVE
09168
PC300-7
10-97
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
VALVE CONTROL
VALVE CONTROL
1. Travel PPC valve 2. Service PPC valve 3. Service pedal 4. L.H. travel lever 5. R.H. travel lever 6. R.H. PPC valve 7. R.H. work equipment control lever
10-98 (8)
8. Solenoid valve 9. Accumulator 10. Control valve 11. Hydraulic pump 12. Junction box 13. L.H. work equipment control lever 14. L.H. PPC valve
Lever positions A. Hold B. Boom "RAISE" C. Boom "LOWER" D. Bucket "DUMP" E. Bucket "CURL" F. Hold G. Arm "IN" H. Arm "OUT"
J. K. L. M. N.
Swing "RIGHT" Swing "LEFT" Neutral Travel "REVERSE" Travel "FORWARD"
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
P: From main pump T: To tank
PC300-7
P1: P2: P3: P4:
Left: Arm OUT / Right: Boom LOWER Left: Arm IN / Right: Boom RAISE Left: Swing RIGHT / Right: Bucket CURL Left: Swing LEFT / Right: Bucket DUMP
10-99
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
12
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11.
Spool Metering spring Centering spring Piston Disc Nut (For connection of lever)
Joint Plate Retainer Body Filter Unit: mm
No.
Check item
Criteria Standard size
12
Centering spring (For P3 and P4)
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
42.5 x 15.5
34
17.6 N {1.8 kg}
—
13.7 N {1.4 kg}
13
Centering spring (For P3 and P4)
44.5 x 15.5
34
29.4 N {3.0 kg}
—
23.5 N {2.4 kg}
14
Metering spring
26.5 x 8.2
24.9
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
10-100
If damaged or deformed, replace spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
OPERATION 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2) During fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), 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, 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 P1 to port A. When the pressure at port P1 becomes higher, spool (1) 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 P1. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (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 (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 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 P1) and the force of the control valve spool return spring are balanced. (Fig. 2)
PC300-7
10-101
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT • SWING PPC VALVE
12 3) 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 P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), 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 P1 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)
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), 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 P1, 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)
10-102
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump T : To tank P1 : Left reverse P2 : Left forward
PC300-7
P3 P4 P5 P6
: Right reverse : Right forward : Travel signal : Steering signal
10-103
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12
1. 2. 3. 4. 5.
Plate Body Piston Collar Metering spring
10-104
6. 7. 8. 9. 10.
Centering spring Valve Damper Steering signal Steering signal valve spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12
Unit: mm No.
Check item
Criteria Standard size
Metering spring
1
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
26.5 x 8.15
24.7
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
2
Centering spring
48.1 x 15.5
32.5
108 N {11 kg}
—
86.3 N {8.8 kg}
3
Steering signal spring
12.8 x 7.3
8.5
8.8 N {0.9 kg}
—
7.1 N {0.72 kg}
PC300-7
If damaged or deformed, replace spring
10-105
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12 OPERATION 1) At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
2) Fine control (neutral → fine control) When piston (4) starts to be pushed by disc (5), 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 P1. When the pressure at port P1 rises, spool (1) 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 P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port P1. The relationship of the position of spool (1) and body (10) (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 (1). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the spool of the control valve spool moves to a position where the pressure of chamber A (same as pressure at port P1) and the force of the return spring of the control valve spool are balanced. (Fig. 2)
10-106
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12
3) Fine control (control lever returned) When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port P1 is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring (2), 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 P1 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)
4) At full stroke Lever (5) pushes down piston (4), and retainer (9) pushes down on spool (1). 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 P1 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)
PC300-7
10-107
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
2. Travel signal/Steering function • Travel signal If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5. • Steering signal If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the PPC output pressures on both sides is output as the steering signal. Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral. Accordingly, if the machine is being steered is judged by the signal of port P6. Operation 1) While in NEUTRAL The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not output.
10-108
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
2) While travelling straight (The following drawing shows the circuit for traveling straight forward.) While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port P6) is not output.
PC300-7
10-109
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12 3) When steered or pivot-turned (The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.) If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal. In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure in right spring chamber (l) is P4. If (P4 - P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
10-110
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
TRAVEL PPC VALVE
12 4) When pivot-turned (The following drawing shows the circuit for left reverse and right forward operation.) While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).
PC300-7
10-111
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SERVICE PPC VALVE
SERVICE PPC VALVE
1. Spool 2. Metering spring 3. 4. 5. 6. 7. 8.
Centering spring Piston Lever Plate Retainer Body
T P P1 P2
: To tank : From main pump : Port : Port
Unit: mm No.
Check item
Criteria Standard size
9
10
10-112
Centering spring
Metering spring
Remedy Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
33.9 x 15.3
28.4
124.5 N {12.7 kg}
—
100 N {10.2 kg}
22.7 x 8.1
22
16.7 N {1.7 kg}
—
13.7 N {1.4 kg}
If damaged or deformed, replace spring
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SERVICE PPC VALVE
OPERATION At neutral • The pressurized oil from the main pump enters from port P and is blocked by spool (1). • 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 (1).
WHEN OPERATED •
•
When lever (5) is moved, metering spring (2) is pushed by piston (4) and retainer (7), and spool (1) is pushed down by this. As a result, 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.
PC300-7
10-113
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
•
•
•
SERVICE PPC VALVE
When the pressure at port a becomes higher, spool (1) is pushed back by the force acting on the end of the spool, and fine control portion Y closes. As a result, spool (1) moves up and down to balance the force at port a and the force at metering spring (2). Therefore, metering spring (2) 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.
10-114
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SOLENOID VALVE
SOLENOID VALVE PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves
1. PPC lock solenoid valve 2. Travel junction solenoid valve 3. Merge-divider solenoid valve 4. Travel speed solenoid valve 5. Swing brake solenoid valve 6. Machine push-up solenoid valve 8. 2-stage relief solenoid valve
PC300-7
T : To tank A1 : To PPC valve A2 : To main valve (Travel junction valve) A3 . To main valve (Mergedivider valve) A4 : To both travel motors A5 : To swing motor A6 : To 2-stage safety valve at boom cylinder head
A8 : To main valve (2-stage relief valve) P1 : From main pump ACC: To accumulator
10-115
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SOLENOID VALVE
12 1. 2. 3. 4. 5. 6.
Connector Moving core Coil Spool Block Spring
OPERATION
WHEN SOLENOID IS TURNED OFF •
Since the signal current does not flow from the controller, solenoid (3) is turned off. Accordingly, spool (4) is pressed by spring (6) against the left side. By this operation, the pass from P to A is closed and the hydraulic oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON The signal current flows from the controller to solenoid (3), and the latter is turned on. Accordingly, spool (4) is pressed against to the right side. By this operation, the hydraulic oil from the main pump flows through port P and spool (4) to port A, then flows into the actuator. At this time, port T is closed and the oil does not flow into the tank.
10-116
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
PPC ACCUMULATOR
PPC ACCUMULATOR 1
1. 2. 3. 4. 5. 6.
2
Gas plug Shell Poppet Holder Bladder Oil port
SPECIFICATIONS Gas capacity:300 cc (for PPC)
3
4
5
6
SBP00290
PC300-7
10-117
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
RETURN OIL FILTER
RETURN OIL FILTER FOR BREAKER
SPECIFICATIONS 1. 2. 3. 4. 5.
Drain plug Element Case Head cover Relief valve
10-118
Rated pressure: 6.9 MPa {70 kg/cm2} Flow : 200 l/min. Relief valve cracking pressure: 0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2} Filter mesh size: 6 µm Filtering area : 4,570 cm2
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE Function •
When the boom lever is not being operated, these valves act to prevent the oil at the boom bottom from leaking from spool (1) and prevent the boom from moving down.
Operation 1. Boom RAISE When the boom RAISE is operated, the main pressure oil acts in the left direction on ringshaped area A (= Area of ∅d1 - Area of ∅d2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. When it overcomes the force of spring (4), poppet (5) moves to the left. In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force of spring (4), valve (6) moves to the right. As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
10-120
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION VALVE
09169
PC300-7
10-121
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION VALVE
2. Boom at HOLD • When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped area A (= Area of ∅d1 - Area of ∅d2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. • In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of valve (6). • Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at the bottom of the boom cylinder are shut off. As a result, the boom is held in position.
10-122
PC300-7
BOOM HYDRAULIC DRIFT PREVENTION VALVE
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
09170
PC300-7
10-123
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
BOOM HYDRAULIC DRIFT PREVENTION VALVE
3. Boom LOWER • When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B goes to port A and flows to the control valve.
10-124
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 4. When abnormally high pressure is generated • If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check valve (6) open, then safety valve (3) operates.
•
BOOM HYDRAULIC DRIFT PREVENTION VALVE
If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6) open, then safety valve (3) operates.
09171
PC300-7
10-125
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
QUICK RETURN VALVE
QUICK RETURN VALVE FUNCTION When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom. OPERATION 1.
Arm at OUT When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from chamber b inside the poppet is drained through orifice c. The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber b drops. When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring -shaped area C (= Area of ∅d1 - Area of ∅d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the tank.
10-126
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
QUICK RETURN VALVE
2. Arm at HOLD The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of ∅d1 - Area of ∅d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the force of spring (3), so port A and port B are shut off.
PC300-7
10-127
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
LIFT CHECK VALVE
LIFT CHECK VALVE Function This valve applies back pressure to the drain circuit to prevent generation of negative pressure on the hydraulic devices for the work equipment (motors, cylinders, etc.) Operation 1. While engine is stopped Any oil is not supplied from the pump to the self-pressure reducing valve and valve (1) is pressed by only the force of spring (2) toward the right and drain circuit "a" of the control valve is connected through orifice "b" of valve (1) to port T.
2. While engine is running • Output pressure PR of the self-pressure reducing valve is applied through the control valve to spring chamber "c" of the back pressure valve. • Output pressure PR applied to spring chamber "c" is applied to the left end of valve (1) (area of ∅d) to push valve (1) to the right. • At this time, pressure PA of drain circuit "a" of the control valve is applied to the right end of valve (1) (area of ∅d1) to push valve (1) to the left. • Valve (1) is balanced so that the back pressure PA will be as follows. PA = {(Area of ∅d) x PR + Force of spring (2)} / (Area of ∅d1)
10-128
09174
09175
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ATTACHMENT CIRCUIT SELECTOR VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
V : T : ATT: ACC: P1 : TS :
1. Spool 2. Spring
To control valve To hydraulic tank To attachment To accumulator From attachment circuit selector solenoid valve To hydraulic tank Unit: mm
No.
Check item
Criteria
Remedy
Standard size
3
Spool return spring
PC300-7
Repair limit
Free length x Outside Dia.
Installed length
Installed load
Free length
Installed load
132.0 x 29
114.5
833 N {85.0 Kg}
--
666 N {68.0 Kg}
Replace spring if any damages or deformations are found
10-129
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ATTACHMENT CIRCUIT SELECTOR VALVE
Function When a breaker is installed, the return oil from the breaker does not pass through the main valve, but returns directly to the hydraulic tank. When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation 1. When attachment other than breaker is installed Spool (1) is pushed fully to the left by the force of spring (2), ATT port and port V are interconnected, and ATT port and port T are shut off, so the attachment and main valve are interconnected.
2. When breaker is installed When the pilot pressure from the attachment circuit selector solenoid valve overcomes the force of spring (2), the spool (1) moves fully to the right. ATT port and port V are shut off and ATT port and port T are interconnected, so the oil returning from the breaker does not pass through the main valve, but passes through port T and returns directly to the hydraulic tank.
10-130
08901
08902
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-132
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
HYDRAULIC CYLINDER
12
Unit: mm No.
Check item
Criteria
Cylinder
1
2
3
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Clearance between cylinder bottom support pin and bushing
PC300-7
Standard size
Tolerance Shaft
Hole
Remedy
Standard clearance
Clearance limit
Boom
100
-0.036 -0.090
+0.035 +0.005
0.041 ~ 0.125
0.412
Arm
110
-0.036 -0.090
+0.261 +0.047
0.083 ~ 0.351
0.412
Bucket
100
-0.030 -0.076
+0.257 +0.047
0.083 ~ 0.347
0.447
Boom
100
-0.030 -0.060
+0.190 +0.070
0.100 ~ 0.250
—
Arm
100
-0.030 -0.076
+0.190 +0.070
0.105 ~ 0.251
—
Bucket
90
-0.030 -0.076
+0.190 +0.070
0.100 ~ 0.246
—
Boom
90
-0.030 -0.060
+0.190 +0.070
0.075 ~ 0.225
—
Arm
100
-0.030 -0.076
+0.190 +0.070
0.105 ~ 0.251
—
Bucket
90
-0.030 -0.060
+0.190 +0.070
0.100 ~ 0.230
—
Replace bushing
Replace pin or bushing
10-133
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
10-134
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
1
Check item
Clearance between connecting pin and bushing of revolving frame and boom
Criteria Standard size
Tolerance
Remedy
Standard clearance
Clearance limit
+0.157 +0.079
0.115 ~ 0.247
1.0
Shaft
Hole
110
-0.036 -0.090
2
Clearance between connecting pin and bushing of boom and arm
110
-0.036 -0.090
+0.179 +0.081
0.117 ~ 0.269
1.0
3
Clearance between connecting pin and bushing of arm and link
90
-0.036 -0.090
+0.165 +0.072
0.108 ~ 0.255
1.0
4
Clearance between connecting pin and bushing of arm and bucket
90
-0.036 -0.090
+0.145 +0.083
0.119 ~ 0.235
1.0
5
Clearance between connecting pin and bushing of link and bucket
90
-0.036 -0.090
+0.165 +0.072
0.108 ~ 0.255
1.0
6
Clearance between connecting pin and bushing of link and link
90
-0.036 -0.090
+0.163 +0.069
0.105 ~ 0.253
1.0
7
Bucket clearance (a)
0.5 ~ 1.0
8
Bucket clearance (b)
2.0
Replace
Adjust shims
PC300-7
10-135
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT
1. DIMENSION OF ARM
10-136
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm
Model No.
φ 100
1 2
119.3
3
320
+0.1 0
+1.5 0 +0.5 0
φ 110
4
/
/ 116 ± 1.2 / 316 -0.3 − 0.8
0 − 0.5
/
−0.036 − 0.090
+0.1 0
φ 100
/
−0.036 −0.071
119.3
+1.5 0
/ 116 ± 1.2
320
+0.5 0
/ 316 -0.3 − 0.8
φ 110
0 − 0.5
/
−0.036 − 0.090
470.6 ± 1
470.6 ± 1
6
236.5 ± 0.5
236.5 ± 0.5
7
1022.4 ±1
1022.4 ±1
8
3,178 ± 3
3,178 ± 3
9
2,975.6 ± 1
2,975.6 ± 1
10
472.5
472.5 ± 1.0
11
731.0 ± 0.2
731.0 ± 0.2
12
728.0 ± 0.5
728.0 ± 0.5
13
513.6
513.6
14
1,670
1,670
16 17 Arm as individual part When pressfitting bushing
+0.2 0
φ 90
/
−0.036 − 0.090
345.0 ± 0.5
φ 80
+0.2 0
330
/
−0.036 −0.090
0 −0.5
φ 90
+0.2 0
/
−0.036 − 0.090
345.0 ± 0.5
φ 80
+0.2 0
330
/
−0.036 −0.090
0 −0.5
345
345
Min.
1,870
1,870
Max.
3,155
3,155
19
PC300-7
−0.036 −0.071
PC350-7, PC350LC-7
5
15
18
PC300-7, PC300LC-7
10-137
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 12 2.DIMENSION
10-138
WORK EQUIPMENT
OF BUCKET
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
WORK EQUIPMENT
12
Unit: mm
Model
PC300-7, PC300LC-7
PC350-7, PC350LC-7
1
512.2 ± 0.5
512.2 ± 0.5
2
37.9 ± 0.5
37.9 ± 0.5
3
94° 19’
94° 19’
4
513.6
513.6
5
1,658
1,666
6
193
208
7
—
—
8
50°
42°
No.
9
φ 90
10
346
+0.2 0 +1 0
11
68
68
12
138
138
13
525.5 ± 0.5
525.5 ± 0.5
∅
14
∅
26
26
A
∅
165
∅
165
B
∅
150
∅
150
16
∅
200
∅
200
17
146.1
135.5
18
137.6
142.0
19
R115
R115
20
R100
R100
15
370
21 22
PC300-7
60
+2 0
60
10-139
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING
1. 2. 3. 4. 5. 6. 7. 8.
Hot water pickup piping Receiver tank Hot water return piping Condenser Air conditioner compressor Refrigerant piping Air conditioner unit Duct
10-140
A. Fresh air B. Recirculated air C. Hot air/cold air
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery relay Battery Starting switch Fuel control dial Linkage Starting motor Engine throttle and pump controller Fuel injection pump Governor motor
PC300-7
OUTLINE • •
The engine can be started and stopped with only starting switch (3). The engine throttle and pump controller(7) receives the signal of fuel control dial (4) and transmits the drive signal to governor motor (9) to control the governor lever angle of fuel injection pump (8) and control the engine speed.
10-141
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
12 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 engine throttle 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. • If the engine stop solenoid (shut-off valve) is not driven before starting the engine, the engine will not start. (At the same time as the starting signal for the starting motor is input from the controller, the drive signal is output for 3 seconds.) Engine speed control • The fuel control dial sends a signal to the engine throttle and pump controller according to the position of the dial. The engine throttle 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 engine throttle and pump controller, so that it can observe the operation of the governor motor. Stopping engine • When the engine throttle and pump controller detects that the starting switch has been turned to the STOP position, it drives the governor motor so that it is set to the low idling angle position. The engine stop solenoid signal (HOLD) which drives directly from the ACC signal is turned OFF and the engine stops. • When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle and pump controller itself drives the battery relay.
10-142
09176
09177
09178
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
12 1. COMPONENT Fuel control dial
1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector
Function • The fuel control dial is installed under the monitor panel, and a potentiometer is installed under the knob. The potentiometer shaft is turned by turning the knob. • As the potentiometer shaft is turned, the resistance of the variable resistor in the potentiometer changes and a throttle signal is sent to the engine throttle and pump controller. The hatched area in the graph shown at right is the abnormality detection area.
PC300-7
10-143
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
Governor motor
1. 2. 3. 4. 5. 6. 7. 8.
Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector
Function • The motor is turned according to the drive signal from the engine throttle and pump controller to control the governor lever of the fuel injection pump. This motor used as the motive power source is a stepping motor.
10-144
• •
A potentiometer for feedback is installed to monitor the operation of the motor. Revolution of the motor is transmitted through the gear to the potentiometer.
Operation While motor is stopped • Electric power is applied to both phases A and B of the motor. While motor is running • The engine throttle and pump controller supplies a pulse current to phases A and B, and the motor revolves, synchronizing to the pulse.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
Engine throttle and pump controller
10-146
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ENGINE CONTROL
12 Input and output signals CN-1
CN-2
Pin No. 1 —
Signal name
Input/ output
CN-3
Pin No. 1 NC
2
R pump pressure sensor
3
—
Input
4
Signal GND
Input
5
Abnormality in auto-greasing controller
Input
6
NC
Input
7
Overload sensor (analog)
Input
8
8
F boom pressure sensor
Input
9
9
—
10
Signal name
Input/ output Output
Pin Signal name No. 1 VB (controller power)
Input/ output Input
2
Swing emergency switch
Input
2
VIS (solenoid power)
3
NC
Input
3
SOL_COM (solenoid common gnd)
Input
4
232C_RxD
Input
4
Battery relay drive
Output
5
Overload sensor (ON/OFF)
Input
5
Governor motor A phase (+)
Output
6
Overload alarm valid switch
Input
6
LS-EPC
Output
7
Model selection 4
Input
7
Travel junction SOL
Output
Attachment circuit selector signal
Output
8
Engine stop solenoid (Pull)
Output
NC
Output
9
Bucket CURL pressure SW
Input
NC
Input
10
Boom RAISE pressure SW
Input
Output
11
VB (controller power)
Input
12
VIS (solenoid power)
Input
Input
13
SOL_COM (solenoid common gnd)
10
Signal GND
Input
11
NC
11
Knob SW
Input
12
CAN shield
12
NC
Input
13
Model selection 5
13
Governor motor FB potentiometer
Input
14
232C_TxD
Output
14
KEY_SIG
14
—
15
NC
Input
15
Governor motor A phase (-)
Output
15
NC
Output
16
SENS_PWR
17
Key Switch (Terminal C)
Input
Input
16
Travel steering signal pressure SW
Input
16
PC-EPC
Output
17
Model selection 3
Input
17
Pump merge/divider solenoid
Output
Input
18
—
18
Heater relay drive
Output
18
NC
Input
19
NC
Output
19
Bucket DUMP pressure switch
Input
19
Throttle potentiometer
Input
20
NC
Input
20
Boom LOWER pressure switch
Input
20
NC
Input
GND (controller GND)
GND (analog GND)
S_NET
21
21
Input/ output
22
VIS (solenoid PWR)
22
POT_PWR
SOL_COM (solenoid common gnd)
Key switch (terminal ACC)
CAN0_L
23
23
Input/ output
24
KEY_SIG
CAN1_L
Input/ output
25
Governor motor B phase (+)
26
Service flow adjustment EPC (1)
Output
27
Travel Hi/Lo selector solenoid
Output Output
24
—
Output Input
21 22 23
Input Output
24
—
28
2-stage relief solenoid
25
NC
Input
29
Swing pressure switch
Input
26
NC
Input
30
Arm IN pressure switch
Input
27
Model selection 2
Input
31
GND (controller GND)
28
NC
Input
32
GND (controller GND)
29
GND (pulse GND)
33
GND (controller GND)
30
NC
Input
34
NC
31
GND (S_NET GND)
Input
35
Governor motor B phase (-)
Output
CAN0_H
Input/ output
36
NC
Output
37
Swing parking brake solenoid
Output
CAN1_H
Input/ output
38
NC
Output
39
Travel pressure switch
Input
40
Arm OUT pressure switch
Input
32 33 34
PC300-7
Input
GND (232C GND)
35
Service valve pressure switch
Input
36
NC
Input
37
Model selection switch 1
Input
38
Swing lock switch
Input
39
GND (pulse GND)
40
Engine speed sensor
Input
10-147
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM
Control function
1 Engine/Pump composite control function 2 Pump/Valve control function 3 One-touch power maximizing function Machine push-up function 4 Auto-deceleration function 5 Auto-warm-up/Overheat prevention function
Electronic control system 6 Swing control function 7 Travel control function 8 ATT flow control, circuit selector function (option)
Self-diagnosis function
★ For the self-diagnosis function, see "TROUBLE SHOOTING".
PC300-7
10-149
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
10-150
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
09179
PC300-7
10-151
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
1. Engine and Pump control function
SJP09121 OR 08908
10-152
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
FUNCTION •
The operator can set the work mode switch on the monitor panel to mode A, E, or B (or L) and select proper engine torque and pump absorption torque according to the type of work. • The engine throttle and pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed and controls them so that the pump will absorb all the torque at each output point of the engine, according to the pump absorption torque set in each mode. : The L mode is on the multi-monitor specification machine only.
SJP08755 OR 08909
SJP09180
SJP08757 OR 08911
PC300-7
10-153
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
1) Control method in each mode Mode A, Mode E • Matching point in mode A: Rated speed
•
Mode A (Work)
180.2 kW/1,950 rpm {242 HP/1,950 rpm}
Mode A (Travel)
180.2 kW/1,900 rpm {242 HP/1,900 rpm}
Mode E
154.4 kW/1,750 rpm {207 HP/1,750 rpm}
If the pump load increases and the pressure rises, the engine speed lowers. At this time, the controller lowers the pump discharge so that the engine speed will be near the full output point. If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near the full output point. By repeating these operations, the controller constantly uses the engine near the full output point.
09181
09182
SJP08760 OR 08914
10-154
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
Mode B / (Mode Mode Partial output point
L) Mode B 82%
Mode
L
61% 09183
•
Mode B
147.1 kW/1,800 rpm {197 HP / 1,800 rpm}
(Mode ❈L)
110.3 kW/1,550 rpm {148 HP / 1,550 rpm}
At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine speed by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area. : The L mode is on the multi-monitor specification machine only.
09184
09185
PC300-7
10-155
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12 2) Function to control pump during travel • When the travel is operated in A operation, or E or B working mode, the working mode stays as it is, and the pump absorption torque and engine speed rise to A travel mode. 09186
•
If the machine travels in mode L, the working mode and engine speed do not change, but the pump absorption torque is increased. : The L mode is on the multi-monitor specification machine only.
3) Function to control when emergency pump drive switch is turned ON • Even if the controller or a sensor has a trouble, the functions of the machine can be secured with pump absorption torque almost equivalent to mode E by turning on emergency pump drive switch (10). In this case, a constant current flows from the battery to the EPC valve for PC and the oil pressure is sensed by only the EPC valve for PC.
4) Function of engine drive switch when emergency occurs • If there is a failure in the controller or any problem in the chassis wiring or relays, and the engine cannot be started because the engine stop solenoid cannot drive, turn the switch ON for approx. 5 seconds before the starting signal comes ON. This makes it possible to drive the solenoid forcibly. (However, if current flows through this solenoid continuously for more than 30 seconds, there is danger that it will burn out, so correctly control the time that the current flows.)
10-156
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12 2. Pump/Valve control function
SJP08765 OR 08921
Function • The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
PC300-7
10-157
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
1) LS control function • The change point (LS set differential pressure) of the pump discharge in 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. • By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. 2) Cut-off function • When the cut-off function is turned on, the PC-EPC current is increased to near the maximum value. By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function
09187
Condition •
The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm²} and the one-touch power maximizing function is not turned on
The cut-off function does not work, however, while the machine is travelling in mode A or the arm crane operation width swing lock switch is turned on. 1. 2-stage relief function • The relief pressure in the normal work is 34.8 MPa {355 kg/cm²}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 37.2 MPa {380 kg/cm²}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function Condition • • • • •
During travel When swing lock switch is turned on When boom is lowered When one-touch power maximizing function is turned on When
Relief pressure
34.8 MPa {355 kg/cm²} ⇓ 37.2 MPa {380 kg/cm²}
L mode is operated
: The L mode is on the multi-monitor specification machine only.
10-158
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
3. One-touch power maximizing/machine push-up function
09188
FUNCTION • •
Power can be increased for a certain time by operating the left knob switch. When the machine push-up switch is operated, the boom pushing force is increased.
PC300-7
10-159
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force. • If the left knob switch is turned on in working mode "A" or "E", each function is set automatically as shown below.
⇓ Software cut-off function Working mode
A, E
Engine/Pump control
2-stage relief function
Operation time
Software cut-off function
Matching at rated output point
34.8 MPa {355 kg/cm²} ⇓ 37.2 MPa {380 kg/cm²}
Automatically reset at 8.5 sec
Cancel
2) Machine push-up function • Operate switch (1) to increase the boom pushing force when digging ditches or holes on hard ground.
10-160
Switch
2-stage safety valve function
OFF
Setting of safety valve at boom cylinder 14.7 MPa {150 kg/cm²}
ON
Setting of safety valve at boom cylinder 28.4 MPa {290 kg/cm²}
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
4. Auto-deceleration function
SJP08767 OR 08924
FUNCTION •
•
If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the medium level automatically to reduce the fuel consumption and noise. If any lever is operated, the engine speed rises to the set level instantly.
PC300-7
10-161
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
OPERATION WHEN CONTROL LEVERS ARE SET IN NEUTRAL •
•
If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,400 rpm), the engine speed lowers instantly to the first deceleration level about 100 rpm lower than the set speed. If 4 more seconds pass, the engine speed lowers to the second deceleration level (about 1,400 rpm) and keeps at that level until any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED •
If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.
10-162
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
5. Auto-warm-up/Overheat prevention function
SJP08768 OR 08925
FUNCTION •
After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. If the engine cooling water temperature rises too high during work, the pump load is reduced to prevent overheating.
PC300-7
10-163
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12 1) Auto-warm-up function • After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All)
Operated
⇒
Water temperature: Below 30°C. Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
⇓ Resetting condition (Any one)
Reset
⇒
Water temperature: Above 30°C Auto Auto-warm-up operation time: Min. 10 minutes Manual
Fuel control dial: Kept at 70% of full level for 3 sec. or longer
2) Overheat prevention function • If the engine cooling water temperature rises too high during work, the pump load and engine speed are reduced to prevent overheating.
Operating condition
Water temperature: Above 105°C
⇒
Operating condition Water temperature: Above 102°C
⇒
Operating condition Water temperature: Above 100°C
10-164
This function is turned on when the water temperature rises above 95°C.
Operation/Remedy
Resetting condition
Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Water temperature: Below 105°C Fuel control dial: Return to low idle position once. • Under above condition, controller is set to condition before operation of function. (Manual reset)
⇒
Operation/Remedy
Resetting condition
Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge.
Water temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
⇒
Operation/Remedy
⇒
Operating condition Water temperature: Above 95°C
•
Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.
Resetting condition
⇒
Operation/Remedy
⇒
Engine speed: Any level
Work mode: Travel Engine speed: Keep as is. Lower travel speed.
Water temperature: Below 100°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
Resetting condition
⇒
Water temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
6. Swing control function
SJP08769 OR 08926
FUNCTION The swing lock and swing holding brake functions are installed.
PC300-7
10-165
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
1) Swing lock and swing holding brake functions • The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake function (automatic) is used to prevent hydraulic drift after the machine stops swinging. • Swing lock switch and swing lock/holding brake Lock switch
OFF
ON
•
Lock lamp
Function
Operation
OFF
Swing holding brake
If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is operated, brake is released and machine can swing freely.
Swing lock
Swing lock operates and machine is locked from swinging. Even if swing lever is operated, swing lock is not reset and machine does not swing.
ON
2) Quick hydraulic oil warm-up function when swing lock switch is turned on • If swing lock switch (4) is turned on, the pump-cut function is cancelled and the relief pressure rises from 34.8 MPa {355 kg/cm²} to 37.2 MPa {380 kg/cm²}. If the work equipment is relieved under this condition, the hydraulic oil temperature rises quickly and the warm-up time can be shortened.
Operation of swing holding brake release switch If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing, the swing lock can be reset with the swing holding brake release switch.
Swing holding brake release switch Swing lock switch Swing brake
ON (When control has trouble) ON
OFF
OFF (When controller is normal) ON
OFF
Swing Swing Swing lock Swing holdlock is lock is is turned ing brake is turned on. canceled. on. turned on.
★ Even if the swing holding brake release switch is turned on, if the swing lock switch is turned on, the swing brake is not released. ★ If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if swinging is stopped on a slope, the upper structure may drift hydraulically.
10-166
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
7. Travel control function
SJP08770 OR 08927
FUNCTION •
The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance matched to the type of work and jobsite during travel.
PC300-7
10-167
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12 1) Pump control function during travel • If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. ★ For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION. 1. Travel speed change function i) Manual change with travel speed switch If the travel speed switch is changed between Lo, ( Mi), and Hi, the governor/ pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to change the travel speed. Travel speed switch
Lo (Low speed)
(
Mi) (Middle Speed)
Hi (High speed)
Pump capacity (%)
90
82
100
Motor capacity
Max.
Max.
Min.
3.2
4.5
5.5
Travel speed (km/h)
ii) Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200 rpm: • When traveling in Lo, it will not switch even when set to Hi or Mi. • When traveling in Hi or Mi, it will switch automatically to Lo. iii) Automatic changes according to pump discharge pressure When traveling with the travel speed switch set to Hi or Mi, it the load increases, such as when traveling uphill, and the travel pressure goes above 3.23 MPa {330 kg/cm²} for more than 0.5 sec, the travel motor capacity will automatically change to low speed (equivalent to Lo). (The travel speed switch will stay at Hi or Mi.) After continuing to travel in Lo, if the load increases, such as when traveling on level ground or traveling downhill, and the travel pressure goes below 18.6 MPa {190 kg/cm²} for more than 0.5 sec, the travel motor capacity will automatically change and will return to Hi or Mi. : The "Mi" mode is on the multi-monitor specification machine only.
10-168
09189
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
8. ATT flow control, circuit selector function (if equipment)
FUNCTION This function is available only with the ATT specification. The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the ATT PPC pressure and controls the flow when the pedal is depressed fully. 2) In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes). : The ATT flow control adjustment function is on the multi-monitor specification machine only.
PC300-7
10-169
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
9. System component parts 1) Engine revolution sensor
1. 2. 3. 4.
Sensor Locknut Wiring harness Connector
FUNCTION •
•
The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller. A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.
10-170
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
2) PPC oil pressure switch
1. Plug 2. Switch 3. Connector
SPECIFICATIONS Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm²} Resetting (OFF) Pressure: 0.3 ± 0.5 MPa {3.0 ± 0.5 kg/cm²} FUNCTION •
The junction block has 9 pressure switches, which check the operating condition of each actuator by the PPC pressure and transmit it to the engine throttle and pump controller.
PC300-7
10-171
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
ELECTRONIC CONTROL SYSTEM
12
3) Pump pressure sensor
1. Sensor 2. Connector FUNCTION •
The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a voltage and transmits it to the engine throttle and pump controller.
OPERATION •
•
•
•
The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is deformed. The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier). The amplifier amplifies the received voltage and transmits it to the engine throttle and pump controller. Relationship between pressure P (MPa {kg/ cm²}) and output voltage (V) is as follows. V = 0.08 [0.008] x P + 0.5
10-172
SJP08774 OR 08930
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
MULTI MONITOR SYSTEM
SJP08775 OR 08931
•
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
PC300-7
•
The monitor panel also has various mode selector switches and functions to operate the machine control system.
10-173
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
12
1. Monitor panel
OUTLINE •
The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-174
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
Input and output signals CN-1
CN-2
Pin No. 1 Key ON
Signal name
2
Key ON
3
Washer motor output
4
Input/ output Input
CN-3
Pin Signal name No. 1 Engine water temperature
Input/ output Input
Pin No. 1 NC
Signal name
Input/ output Input
Input
2
Fuel level
Input
2
NC
Output
3
Radiator water level
Input
3
NC
Input
Starting signal
Input
4
(Hydraulic oil level)
Input
4
NC
Input
5
Limit switch (W)
Input
6
GND
7
GND
8
VB +
9
Wiper motor (+)
Output
10
Wiper motor (-)
Output
11
Buzzer ON signal
Input
12
Limit switch (P)
Input
PC300-7
Input
Input
5
Air cleaner clogging
Input
5
NC
Input
6
NC
Input
6
NC
Input
7
Engine oil pressure
Input
7
RS230C CTS
Input
8
Engine oil level
Input
8
RS230C RXD
Input
9
N/W signal
Input/ Output
9
RS230C RXD
Input/ Output
10
N/W signal
Input/ Output
10
RS230C RXD
Input/ Output
11
Battery charge
Input
11
BOOTSW
Input
12
Hydraulic oil temperature (analog)
Input
12
NC
Input
13
GND (for analog signal)
13
GND
14
Buzzer drive
Input
14
CAN (SHIELD)
Input
15
Limit SW (window)
Input
15
CAN (+)
Input
16
Buzzer cancel
Input
16
CAN (-)
Input
17
Swing lock
Input
18
Preheat
Input
19
Light switch
Input
20
N/W GND
10-175
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION
08932
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Wiper motor Preheating monitor Swing lock monitor Engine water temperature monitor Hydraulic oil temperature gauge Engine water temperature gauge Working mode monitor Service monitor Travel speed monitor Fuel gauge
10-176
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fuel level monitor Hydraulic oil temperature monitor Power max. monitor Auto-deceleration monitor Radiator water level caution Battery charge caution Engine oil pressure caution Engine oil level caution Air cleaner clogging Maintenance time warning caution
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
MONITOR ITEMS AND DISPLAY
Symbol
Display item
Swing lock
Display method
Swing lock switch
Swing holding brake release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Power Max. switch status
Power max. monitor status
Being pressed
Lights up but goes out after approx. 9 sec. when kept pressed
Not being pressed
Flashes
Preheating
Power Max.
Engine water temperature Hydraulic oil temperature
See gauge display on the next page
Fuel level
PC300-7
10-177
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
Gauge
Engine water temperature (°C)
Hydraulic oil temperature (°C)
MULTI MONITOR SYSTEM
Range
Temperature, volume
Indicator
Buzzer sound
A1
105
Red
❍
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
417
Green
C2
347.5
Green
C3
277.5
Green
C4
139
Green
C5
100
Green
C6
62
Red
Fuel level (L)
10-178
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
Checks before starting (caution lamps all light up), when maintenance interval is exceeded. If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Symbol
Display item
Check before starting item
When engine is stopped
When engine is running
Engine oil pressure
●
--
When abnormal, lights up and buzzer sounds
Battery charge
●
--
Lights up when abnormal
Radiator water level
●
Lights up when abnormal
When abnormal, lights up and buzzer sounds
Engine oil level
●
Lights up when abnormal
--
Air cleaner clogging
●
--
Lights up when abnormal
Maintenance
Lights up when there is a warning. Lights up for only 30 sec. after key is turned ON, then goes out.
The problems that have occurred are displayed in order from the left. When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.
Condition of hydraulic oil
Color of symbol
Low temperature (below B6 or equivalent)
Black on white background
Normal (B6 - B2)
No display
High temperature (below B2)
White on red letters
PC300-7
10-179
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
Display category
Symbol
Display item
MULTI MONITOR SYSTEM
Display range ON
INT
Display method OFF
Wiper
Displays set condition
Working mode
Displays set mode
Travel speed
Displays set speed
Monitor
Service meter
10-180
Auto-deceleration
ON ⇔ OFF
Displays actuation status
Service meter indicator
When service meter is working
Lights up when service meter is working
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
SWITCHES
1. 2. 3. 4. 5. 6. 7. 8. 9.
Working mode selector switch Selector switch Display brightness, contrast adjustment switch Control switch Window washer switch Wiper switch Maintenance switch Travel speed selector switch Auto-deceleration switch
PC300-7
10-181
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD •
Working mode selector switch The condition of the machine changes according to the switch that is pressed (A, E, L, B). It is possible to check the condition on the working mode monitor display. The relationship between each working mode and the monitor display is shown in the table on the right.
•
Selector switch This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL FUNCTION for modes A and E.)
•
Maintenance switch Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)
•
Auto-deceleration switch Each time the auto-deceleration switch is pressed, the auto-deceleration function is switched ON/OFF. Use the auto-deceleration monitor display to check the present condition. When the working mode switch is operated to switch the working mode, it is automatically set to ON.
•
Travel speed selector switch Each time the travel speed selector switch is pressed, the travel speed changes. Lo → Mi → Hi → Lo. . . . . . Use the travel speed monitor display to check the present condition. The relationship between the set speed and the monitor display in the table on the right.
•
Wiper switch Each time the wiper switch is pressed, the wiper setting changes OFF → INT → ON → OFF → . . . . . . Use the wiper monitor display to check the present condition. The relationship between the wiper setting and the monitor display is as shown in the table on the right.
10-182
MULTI MONITOR SYSTEM
Switch that is pressed
Display
Working mode status after setting
[A]
A
A mode (default)
[E]
E
E mode
[L]
L
L mode
[B]
B
B mode
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Mi
Medium speed
Crawler symbol + Hi
High speed
Display
Setting
Wiper actuation status
None
OFF
Stowing stopped or now stowing
Wiper symbol + INT
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
•
Window washer switch While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
•
Control switch This is used for control when using the maintenance function or select function. (For details, see each function.)
•
Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For details, see each function.)
PC300-7
MULTI MONITOR SYSTEM
10-183
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
SELECT MODE FUNCTION •
•
This is used when setting the flow in each working mode. It is possible to make the setting when genuine attachment piping is installed and the initial value setting function on the service menu has been used to set to ATTACHMENT INSTALLED. It is possible to check on the working mode monitor if this function can be set.
Working mode
Monitor display
A mode
[A] + crusher symbol
E mode
[E] + crusher symbol
B mode
[B] + flow symbol
METHOD OF USE ★ Carry out the setting on the normal screen 1. A mode, E mode 1) Press select switch (1) on the monitor to move to the adjustment screen. 2) Press control switch (2) to select the flow level. Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
3) After completing the level selection, press input confirmation switch (3). The selection flow level is confirmed and the screen moves to the normal screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right.
10-184
Flow level
Flow (L/min.)
Remarks
8
530
❈ Default
7
430
6
370
5
300
4
230
3
165
2
100
1
30
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
2. B mode 1) Press select switch (1) on the monitor to move to the screen for selecting the 3stage flow level. 2) Press control switch (2), or input [01] - [03] with the numeral 10-key pad to choose one on the three flow levels. No.
10-key pad operation
01
02
03
3) After completing the level selection, press input confirmation switch (3). The selected flow level is selected. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, so press return switch (4) to return to the operator screen. This function can be used to return to the previously set flow. 4) After the flow level is confirmed, the screen changes to the screen shown in the diagram on the right. With this screen, it is possible to make fine adjustment to the flow.
No.
Flow level (L/min.)
Remarks
01
230
❈ Default
02
190
03
150
5) Press control switch (2) and select the flow level.
Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
PC300-7
10-185
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
6) After completing the level selection, press input confirmation switch (3). The selected flow level is confirmed and the screen moves to the operator screen. From the moment that the flow level is selected, the content of the selection is reflected for the attachment flow. ★ Before the input confirmation switch is pressed, the flow level is not confirmed, se press return switch (4) to return to the normal screen. This function can be used to return to the previously set flow. The relationship between the set flow level and the flow value is as shown in the table on the right. 7) Check the set value with the working mode monitor. The relationship between the display level and the set value is as shown in the table on the right, and it is possible to check the level of the flow that can be set.
10-186
MULTI MONITOR SYSTEM
Flow level
When flow is 100 l/ min.
When flow is 140 l/ min.
When flow is 180 l/ min.
7
180
220
250
6
170
210
250
5
160
200
240
4
150
190
230
3
140
180
220
2
130
170
210
1
120
160
200
Remarks
❈ Default
Display level
Set value (ll/min.)
8
250 or 260
7
230 or 240
6
210 or 220
5
190 or 200
4
170 or 180
3
150 or 160
2
130 or 140
1
120
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
MAINTENANCE FUNCTION When the maintenance time for replacement, inspection, or filling has approached for the 10 maintenance items, press maintenance switch (1) and the caution display (yellow or red) appears on the monitor display for 30 seconds after the key is turned ON to remind the operator to carry out lubrication maintenance. ★ Maintenance items No.
Item
Replacement interval (hours)
01
Engine oil
500
02
Engine oil filter
500
03
Fuel filter
500
04
Hydraulic filter
1000
05
Hydraulic tank breather
500
06
Corrosion resistor
❈ (1000)
07
Damper case oil
1000
08
Final case oil
2000
09
Machinery case oil
1000
10
Hydraulic oil
5000
❈ Option, so not set
★ The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the table below.
Display
Condition
None
Remaining time for maintenance for all items is more than 30 hours
Notice display (black symbol displayed on yellow background)
There is one or more items with less than 30 hours remaining time for maintenance
Warning display (wiper symbol displayed on red background)
There is one or more items with less than 0 hours remaining time for maintenance
PC300-7
10-187
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
METHOD OF CHECKING STATUS MAINTENANCE ITEMS ★ Operate as follows when on the operator screen. 1. Press maintenance switch (1) and switch to the maintenance list display screen. ★ The maintenance items are displayed as symbols on the screen. 2. Press control switch (2), or use the 10-key pad to input the number (01 - 10) of the maintenance item to select the item. ★ The cursor moves and the item is highlighted. ★ The display method is the same as described on the previous page (relationship between remaining time and caution display). If the remaining time is less than 30 hours, the item is displayed in yellow, and if it is less than 0 hours, it is displayed in red. MAINTENANCE OPERATION 1.
After completing the selection, press input confirmation switch (3). The screen will change to the maintenance reset screen. 2. Use the maintenance reset screen to check the content, and if there is any problem, press input confirmation switch (3) to move to the check screen. If the wrong item is selected, press return switch (4) to return to the maintenance list screen. 3. Check the content on the check screen, and if there is no problem, press input confirmation switch (3) to reset the maintenance time. After the reset is completed, the screen returns to the maintenance list display screen. To check the remaining time, or if the wrong item is selected, press return switch (4) to return to the maintenance list screen. ★ The check screen shows the symbol for the maintenance item and the set time in large letters. ★ The background color of the symbol for the item where the maintenance item was reset is the same as the background of the screen, so it is possible to check that it has been reset.
10-188
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION This function is used to adjust the brightness and contrast of the display. ADJUSTMENT METHOD ★ Operate as follows when on the operator screen. 1. Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen. ★ Relationship between menu symbol and content. No.
Symbol
Content
01
Return mark
Return
02
Contrast
03
Brightness
2. Press control switch (2), or use the 10-key pad to input the number (00 - 02) to select either contrast or brightness. After completing the selection, press input confirmation switch (3) and return to the adjustment screen. Then press return switch (4) or use the 10-key pas to set to [00] and press input confirmation switch (3) to return to the normal screen. 3. Press control switch (2) and adjust the brightness and contrast as desired. Control switch
Actuation Flow level bar graph extends to the right
Flow level bar graph retracts to the left
PC300-7
08937
10-189
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
SERVICE METER CHECK FUNCTION •
•
When the starting switch is at the OFF position, keep return switch (1) and control switch (2) of the monitor pressed at the same time, and the service meter is shown on the display. This display is shown only while the two switches are being pressed. When the switches are released, the display goes out. Note that it takes 3 - 5 seconds after the switches are pressed for the service meter display to appear.
DISPLAY LCD CHECK FUNCTION •
•
On the password input screen or on the normal screen, if monitor return switch (1) and working mode (A) switch are kept pressed at the same time, all the LCD display will light up and the whole screen will become white, so the display can be checked. If any part of the display is black, the LCD is broken.
10-190
4
08943
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
MULTI MONITOR SYSTEM
USER CODE DISPLAY FUNCTION •
•
•
If there is any problem in operating the machine, the user code is displayed on the monitor to advise the operator of the steps to take. This code display appears on the operator screen. On the operator screen, the user code is displayed on the portion for the hydraulic oil temperature gauge.
If more than one user code is generated at the same time, the user codes are displayed in turn for 2 seconds each to display all the user codes. 08945
PC300-7
10-191 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
•
While the user code is being displayed, if the input confirmation switch is pressed, the service code and failure code can be displayed.
•
If there is more than one service code or failure code, the display switches every 2 seconds and displays all the service codes/failure codes that caused the user code to be displayed. Even if service codes/failure codes have occurred, if they did not cause the user code to be displayed, this function does not display them.
•
If the telephone number has been set using the telephone number input on the service menu, it is possible to switch on the service code/failure code and display the telephone symbol and telephone number. For details of inputting and setting the telephone number, see SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING AND ADJUSTING section.
10-192 (6)
MULTI MONITOR SYSTEM
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775 OR 08931
•
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It processes and immediately displays the obtained information on the panel notifying the operator of the condition of the machine. The panel is roughly divided as follows. 1. Monitor section to output alarms when the machine has troubles 2. Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
PC300-7
•
The monitor panel also has various mode selector switches and functions to operate the machine control system.
10-193 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
12 1. Monitor panel
OUTLINE •
The monitor panel has the functions to display various items and the functions to select modes and electric parts. The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information. The monitor display unit consists of LCD (Liquid Crystal Display) and LED (Light Emitting Diode). The switches are flat sheet switches.
10-194
4
INPUT AND OUTPUT SIGNALS CN-P01 Pin No.
CN-P02 Signal name
Pin No.
Signal Name Engine water temperature
1
Key switch (Battery)
1
2
Key switch (Battery)
2
Fuel
3
Washer motor output
3
Radiator water level
4
Key switch (Terminal C)
4
NC
5
Wiper contact W
5
Air cleaner clogging sensor
6
GND
6
NC
7
GND
7
Engine oil pressure sensor
8
VB + (24 V)
8
Engine oil level sensor
9
Wiper motor (+)
9
Network signal
10
Wiper motor (-)
10
Network signal
11
(Buzzer ON signal input)
11
Charge level
12
Wiper contact P
12
NC
13
GND (For analog signal)
14
NC
15
Wind limit switch
16
Buzzer cancel
17
Swing lock
18
Preheating
19
Limit switch
20
Network (GND)
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Display section of monitor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
PC300-7
Service meter display Coolant temperature gauge Coolant temperature caution Digital meter display (Service code and user code are displayed when trouble occurs Fuel level caution Fuel level gauge Engine 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
10-195 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
Monitored items and display Symbol
When engine is stopped Lights when normal. (Goes off when engine is started.)
Displayed item
Display range
Engine oil pressure
Max. 1,500 rpm Max. 0.05 MPa {0.5 kg/cm²} Min. 1,500 rpm Max. 0.15 MPa {1.5 kg/cm²}
Air cleaner clogging
When clogged
Goes off.
Flashes when abnormal.
Charge level
When charge is abnormal
Lights when normal. (Goes off when engine is started.)
Flashes when abnormal.
Engine oil level
Below low level
Flashes when abnormal.
Packing (Swing lock)
When swing is locked
Lights up when swing is locked. Flashes when swing holding brake release switch is turned on.
Oil maintenance
See "OIL MAINTENANCE FUNCTION" on next page.
Preheating
When preheated
Coolant temperature
Flashes at 102°C or higher. Flashes and buzzer sounds at 105°C or higher.
Fuel level
Flashes when below low level.
While engine is running
Flashes and buzzer sounds when abnormal.
SAP00521
SAP00523
SAP00526
10-196
4
Goes off.
Lights up for 30 sec. when starting switch is set to HEAT. Then, flashes for 10 sec. to indicated completion of preheating.
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
12
Oil maintenance function 1. Function and operation At a set time after the engine oil is replaced, the oil maintenance function is turned on to notify the operator by the LED lamp on the monitor panel that it is time to replace the oil. The function to indicate the phone number of the place to make contact for service on the LCD unit is installed, too. 1) Check of elapsed time Nothing is displayed normally until point B shown in the figure at right after this function is reset. If the key is turned on with the buzzer cancel switch processed (for 2.5 seconds), however, the elapsed time is displayed on the service meter section. 2) Display of replacement of oil If time passes point B after this function is reset, the elapsed time is displayed on the service meter section and the LED flashes when the key is turned on. 2. Setting of time interval 1) The time interval is set in the interval setting mode. It can be set to "125h", "250h", "500h", "Not set", or "Demo-mode". The default is "Not set". 2) To enter the interval setting mode, press and hold the clock switch for 2.5 seconds. 3) If the buzzer cancel switch is pressed in the interval setting mode, the clock display section changes to "—" → "125" → "250" → "500" → "d" in order. ("—" corresponds to "Not set" and "d" corresponds to "Demo-mode".) 4) To save the time interval, set a desired time (mode) on the monitor panel and press and hold the clock switch for 2.5 seconds.
PC300-7
10-197 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
12
3. Timing and contents of display 1) When replacement of oil is displayed The elapsed time is displayed for 10 seconds after all segments are turned on. Phone number is displayed for the next 10 seconds. If the phone number has not been input, however, the elapsed time is displayed for 20 seconds after all segments are turned on. 2) When elapsed time is checked The elapsed time is displayed for 10 seconds after all segments are turned on. 4. Resetting elapsed time 1) When the replacement of oil and elapsed time are displayed, press the buzzer cancel switch 10 seconds after all segments are turned on (while the elapsed time is displayed) and hold for 3 seconds. The elapsed time is reset. After this operation, "0h" is displayed for 1 second. 2) When the set time is changed, the elapsed time is reset to "0h". 5. Demo-mode 1) In the demo-mode, the time is set to 250h, the elapsed time is set to 240h, and replacement of oil is displayed when the key is turned on. The elapsed time does not increase, however. The time can be reset in this mode. Turn on the key 3 times in this mode, and the time interval is automatically set to "Not set" at the 4th time and after. The elapsed time is set to "0h" and counting of elapsed time is started.
10-198
4
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
7-SEGMENT MONITOR SYSTEM
12 Mode selector switches 1. Travel speed switch 2. Auto-deceleration switch 3. Wiper switch 4. Work mode selector switch (Including setting switch)
•
There are 4 sets of the mode selector switches on the switch section. Each time one switch is pressed, the machine condition changes. The current condition is indicated by the lighting of the LED above the switch.
•
The initial setting of only the work mode after the starting switch is turned on can be changed. ★ For how to change the setting, see "Work mode default setting mode" in TROUBLESHOOTING-Display and special functions of monitor panel.
PC300-7
Operations table of switch section ★ The bold letters are the positions of the switches reset when the starting switch is turned on. Item
Operation
Work mode
A↔E↔B
Auto-deceleration
ON↔OFF
Wiper Travel speed
OFF↔Intermittent↔ON Hi↔Lo
10-199 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SENSOR
SENSOR •
The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground.
Sensor name
Type of sensor
When normal
When abnormal
Engine oil level
Contact
ON (Closed)
OFF (Open)
Engine oil pressure
Contact
OFF (Open)
ON (Closed)
Hydraulic oil temperature
Resistance
—
—
Coolant temperature
Resistance
—
—
Fuel level
Resistance
—
—
Contact
OFF (Closed)
ON (Open)
Air cleaner clogging
10-200
4
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SENSOR
12
Engine oil level sensor 1. Connector 2. Bracket 3. Float 4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug 2. Contact ring 3. Contact 4. Diaphragm 5. Spring 6. Terminal
Coolant temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
PC300-7
4. Tube 5. Wire 6. Connector
10-201 4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SENSOR
12
Fuel level sensor
1. Float 2. Connector 3. Cover 4. Variable resistor
Air cleaner clogging sensor
10-202
4
PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SENSOR
12
Engine oil level sensor 1. Connector 2. Bracket 3. Float 4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug 2. Contact ring 3. Contact 4. Diaphragm 5. Spring 6. Terminal
Coolant temperature sensor Hydraulic oil temperature sensor
1. Thermistor 2. Body 3. Tube
PC300-7
4. Tube 5. Wire 6. Connector
10-203
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD
SENSOR
12
Fuel level sensor
1. Float 2. Connector 3. Cover 4. Variable resistor
Air cleaner clogging sensor
10-204
PC300-7
20 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 3 TESTING AND ADJUSTING ...................................................................................................................... 20-101 TROUBLESHOOTING ................................................................................................................................ 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or troubleshooting. 1. 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. 2. 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. 3. These standard values are not the standards used in dealing with claims. k k k k
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. 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. Be careful not to get caught in the fan, fan belt or other rotating parts.
PC300/350(LC)-7
20-1
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Item
Applicable model
PC300, 300LC, 350, 350LC-7
Engine
SAA6D114E-2
Measurement condition
Standard value for new machine
Service limit value
2,160±70
2,160±70
25 900 –+ 50
25 900 –+ 50
1,900
1,900
kPa {mmHg.}
133–160 {1,000–1,200}
Max. 120 {Max. 900}
Bosch index
Max. 4.5
Max. 6.5
Max. 1.0
Max. 2.0
0.30 ± 0.05
—
0.56 ± 0.05
—
Unit
High idle Engine speed
Low idle
rpm
Rated speed Intake air pressure (boost pressure) Exhaust gas color Valve clearance (Normal temperature)
At rated output At sudden acceleration At high idle Intake valve Exhaust valve
mm
Compression pressure
Oil temperature: 40–60ºC Engine speed: 250–300rpm
MPa {kg/cm2}
Min. 2.4 {Min. 24.6}
Difference between cyinders Min. 2.0 {Min. 20.5} Max. 0.7 {Max. 6.9}
Blow-by pressure
(Coolant temperature: operating range) At rated output
kPa {mmH2O}
Max. 1.0 {Max. 100}
20 {200}
0.36–0.61 {3.5–6.0} Min. 0.10 {Min. 1.0}
0.18 {1.8} 0.07 {0.7}
°C
90–120
120
°(degree)
9.5
9.5
Oil pressure (SAE15W-40)
(Coolant temperature: operating range) At high idle
MPa {kg/cm2}
At low idle Oil temperature
Whole speed range (inside oil pan)
Fuel injection timing
Before Top Dead Center
Fan belt tension
Deflection when pressed with finger force of approx. 58.8 N{6 kg}
mm
8
Min. 6, Max. 10
Air conditioner compressor belt tension
Deflection when pressed with finger force of approx. 63.7 N {6.5 kg}
mm
5–8
5–8
20-2 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model
Operating force of control levers
Travel of control levers
Spool stroke
Engine speed
Category
Item
Measurement Condition
2 pumps at relief
• Engine water temperature: Within operation range • Hydraulic oil temperature: Within operation range • Engine at high idling • Arm in relief condition
At 2-pump relief + one touch power up
• Engine water temperature: Within operation range • Hydraulic oil temperature: Within operation range • Engine at high idling • Arm relief + One-touch power max. switch in ON condition
Speed when autodeceleration is operated
• Engine at high idling • Auto-deceleration switch in ON condition • All control levers in NEUTRAL condition
PC300, 300LC, 350, 350LC-7 Unit
rpm
Standard value
Permissible value
1,980±100
1,980±100
1,870±100
1,870±100
1,400±100
1,400±100
9.5±0.5
9.5±0.5
85±10
85±10
85±10
85±10
Boom control valve Arm control valve Bucket control valve
mm
Swing control valve Travel control valve Boom control lever • Engine stopped • At center of control lever grip • Max. reading up to stroke end (excepting lever play in NEUTRAL position)
Arm control lever Bucket control lever Swing control lever Travel control lever
mm
85±10
85±10
85±10
85±10
115±12
115±12
Play of control lever
Max. 10
Max. 15
Boom control lever
15.7±3.9 {1.6±0.4}
Max. 24.5 {Max. 2.5}
Arm control lever
15.7±3.9 {1.6±0.4}
Max. 24.5 {Max. 2.5}
12.7±2.9 {1.3±0.3}
Max. 21.6 {Max. 2.2}
12.7±2.9 {1.3±0.3}
Max. 21.6 {Max. 2.2}
Lever
24.5±5.9 {2.5±0.6}
Max. 39.2 {Max. 4.0}
Papel
74.5±18.6 {7.6±1.9}
Max. 107.6 {Max. 11}
• Hydraulic oil temperature: Within operation range • Engine at high idling • At center of control lever grip • At tip in case of pedal • Max. reading up to stroke end
Bucket control lever Swing control lever
Travel control lever
PC300/350(LC)-7
N{kg}
20-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
Unload pressure
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Hydraulic pump output pressure with all control levers in NEUTRAL position
RAISE • Hydraulic oil temperature: Within At low-presoperation range sure setting • Engine at high idling At high-pres• Working mode: A sure setting mode • Hydraulic pump output pressure with all measurement circuits relieved • Values inside parenthesis: Hydraulic oil pressure with one-touch power max. switch in ON mode (reference only)
Hydraulic pressure
Arm Bucket Swing
Swing
20-4
3.9±1.0 {40±10}
34.81 +1.47 –0.98
33.34–37.23
(37.26 +1.47 –0.98 )
(35.80–39.23)
18.13±0.98 {185±10}
16.66–19.6 {170–200}
31.36±1.47 {320±15}
29.4–33.32 {170–200}
34.81 +1.47 –0.98
33.34–37.23
(37.26 +1.47 –0.98 )
(35.80–39.23)
+2.94 37.27 –0.98
{380 +30 –10 } • Hydraulic oil temperature: Within operation range • Engine running at high idling • Self-reducing pressure valve output pressure with all control levers in NEUTRAL position
• Hydraulic oil temperature: Within operation range Self-reducing pres- • Engine at high idling sure valve • Working mode: A mode • Traveling speed: Hi • Hydraulic oil pump pressure - LS pressure
Swing brake angle
3.9±1.0 {40±10}
+15 {340–375(365–400)} {355 +15 –10 (380 –10 )} MPa {kg/cm2} 30.87 +1.47 28.42–32.85 –2.45 +15 {285–335} {315 –25 }
Travel
Control circuit source pressure
Permissible value
+15 {340–375(365–400)} {355 +15 –10 (380 –10 )}
LOWER
Boom
Standard value
35.80–40.70 {365–415}
3.23±0.2 {33±2}
2.84–3.43 {29–35}
When all control levers in NEUTRAL position
3.9±1.0 {40±10}
3.9±1.0 {40±10}
When traveling at half stroke (without load)
2.45±0.1 {25±1}
2.45±0.1 {25±1}
PC300, 300LC: Max. 110 PC350, 350LC: Max. 120
PC300, 300LC: Max. 140 PC350, 350LC: Max. 150
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Swing circle misalignment amount when stopping after one turn
deg. (mm)
PC300/350(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
Standard value
Permissible value
3.3±0.4
Max. 4.2
4.7±0.5
Max. 5.7
sec.
31.6±2.9
Max. 38
mm
0
0
¶/min
Max. 5.5
Max. 11
90°
Time taken to start swing
Swing
Time taken to swing
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required for passing points 90 and 180 degrees from starting point
sec.
180°
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required for 5 more turns after making initial one turn
15
BKP00103
Hydraulic drift of swing
Leakage from swing motor
PC300/350(LC)-7
• Hydraulic oil temperature: Within operation range • Engine stopped • Keeping upper structure transverse on slope of 15 degrees • Notching a mating mark on inner and outer races of swing circle • Mating mark misalignment amount during 5 minutes • Hydraulic oil temperature: Within operation range • Engine running at high idling • Swing lock switch: ON • Leakage amount for one minute during swing relief
20-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
Standard value
Permissible value
Lo
PC300, 350: 55.0±11.0 PC300LC, 350LC: 58.0±11.5
PC300, 350: 42.0–70.0 PC300LC, 350LC: 45.0–74.5
( Mi)
PC300, 350: 39.0±5.5 PC300LC, 350LC: 41.5±6.0
PC300, 350: 31.5–48.5 PC300LC, 350LC: 34.0–51.5
Hi
PC300, 350: 32.0±2.0 PC300LC, 350LC: 34.0±2.0
PC300, 350: 28.0–39.0 PC300LC, 350LC: 32.0–41.5
Lo
23.3±4.4
18.9–31.0
( Mi)
16.7±2.2
14.4–21.0
Hi
13.1±0.7
12.1–15.1
Max. 200
Max. 300
BKP00104
Travel speed (1)
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required for track shoes to make 5 turns after making one initial idle turn
sec.
45˚
BKP00105
Travel
Travel speed (2)
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Flat ground • Time required for traveling 20 m after 10 m trial run 45˚
BKP00105
Travel deviation
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Travel speed: Lo • Solid and flat ground • Swerving amount while traveling 20 m (X) after initial 10 m trial run
mm
20m
10m
BKP00107
: The “Mi” mode is on the multi-monitor specification machine only.
20-6
PC300/350(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
Standard value
Permissible value
mm
0
0
¶/min
Max. 15
Max. 30
PC300, 300LC: Max. 450 PC350, 350LC: Max. 550
PC300, 300LC: Max. 675 PC350, 350LC: Max. 825
PC300, 300LC: Max. 25 PC350, 350LC: Max. 30
PC300, 300LC: Max. 38 PC350, 350LC: Max. 45
PC300, 300LC: Max. 135 PC350, 350LC: Max. 165
PC300, 300LC: Max. 203 PC350, 350LC: Max. 248
PC300, 300LC: Max. 20 PC350, 350LC: Max. 25
PC300, 300LC: Max. 30 PC350, 350LC: Max. 38
12˚ BKP00108
Travel
Hydraulic drift of travel
Hydraulic drift of work equipment
Work equipment
Leakage of travel motor
• Hydraulic oil temperature: Within operation range • Engine stopped • Parking machine on slope of 12 degrees with sprocket facing upslope • Sliding distance for 5 minutes • Hydraulic oil temperature: Within operation range • Engine at high idling • Traveling with sprocket locked • Oil leakage amount for one minute with traveling in relief condition
Whole work equipment (tooth tip fall amount)
Boom cylinder (cylinder retraction amount)
Arm cylinder (cylinder extension amount)
Bucket cylinder (cylinder retraction amount)
PC300/350(LC)-7
BKP00110
• Hydraulic oil temperature: Within operation range • Flat and level ground • Work equipment in measurement posture as illustrated above • Bucket load: 2,160 kg • Engine stopped • Work equipment control lever in NEUTRAL position • Fall amount for 15 minutes as measured every 5 minutes starting immediately after initial setting
mm
20-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
RAISE
PC300, 300LC: 3.7±0.4 PC350, 350LC: 3.8±0.4
PC300, 300LC: Max. 4.5 PC350, 350LC: Max. 4.6
LOWER
Measurement Condition
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground
Permissible value
2.5±0.3
Max. 3.0
IN
Work equipment speed
Work equipment
Boom
Standard value
3.8±0.4
Max. 4.5
OUT
Item
PC300, 300LC: 2.9±0.3 PC350, 350LC: 3.1±0.4
PC300, 300LC: Max. 3.5 PC350, 350LC: Max. 3.7
CURL
Category
PC300, 300LC, 350, 350LC-7
3.2±0.3
Max. 3.8
DUMP
Applicable model Unit
2.3±0.3
Max. 2.9
Max. 3.0
Max. 3.6
Arm • Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end
sec.
Bucket
Time lag
• Hydraulic oil temperature: Within operation range • Engine running at high idling • Working mode: A mode • Time required from dumping stroke end to digging stroke end
20-8
BKP00114
Boom
• Hydraulic oil temperature: Within operation range • Engine running at low idling • Working mode: A mode • Time required from raise stroke end till bucket touches ground and pushes up machine front
sec.
PC300/350(LC)-7
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
BKP00115
Time lag
Work equipment
Arm
• Hydraulic oil temperature: Within operation range • Engine running at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again
PC300, 300LC: Max. 3.0 PC350, 350LC: Max. 4.0
PC300, 300LC: Max. 3.6 PC350, 350LC: Max. 4.6
Max. 3.0
Max. 5.0
4.5
20
10
50
Max. 400
Max. 440
BKP00116
Internal leackage Performance in compound operation
Permissible value
sec.
• Hydraulic oil temperature: Within operation range • Engine running at low idling • Working mode: A mode • Time required from dumping stroke end till bucket stops momentarily after control lever is tilted to digging and starts to move again • Hydraulic oil temperature: Within operation Cylinders range • Engine running at high idling cc/min • Leakage amount for one minute with cylinCenter der or travel to be measured in relief condiswivel joint tion Bucket
Performance of hydraulic pump
Standard value
Swerving amount in simultaneous operation of work equipment and travel
• Hydraulic oil temperature: Within operation range • Engine at high idling • Working mode: A mode • Traveling speed: Lo • Flat and level ground • Swerving amount (X) when traveling 20 m after initial trial run of 10 m
10m
Hydraulic pump delivery
PC300/350(LC)-7
mm
20m
See next page
BKP00107
¶/min
See next page
20-9
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Applicable model Category
Item
PC300, 300LC, 350, 350LC-7
Measurement Condition
Unit
Standard value
Permissible value
Standard value for discharge amount Q (¶/min)
Judgement standard lower limit Q (¶/min)
See graph
See graph
Performance of hydraulic pump
Discharge amount of hydraulic pump (A mode)
• Pump speed: At 1,950 rpm, PC current 280 mA
Check point
As desired
Test pump discharge pressure (MPa {kg/cm2})
Discharge pressure of other pump (MPa {kg/cm2})
P1
P2
Average pressure (MPa {kg/cm2}) P1+P2 2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
20-10
when measuring. The error is large near the point where the graph curves, so avoid measuring at this point. When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC300/350(LC)-7
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ........................................................ 20-101-1 INSPECTION AND ADJUSTMENT OF ENGINE SPEED .......................................................................... 20-102 MEASUREMENT OF AIR BOOST PRESSURE......................................................................................... 20-104 MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-105 ADJUSTMENT OF VALVE CLEARANCE................................................................................................... 20-106 MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-108 MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-109 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20- 110 MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 112 ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 113 INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20- 113 EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 114 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20- 115 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20- 116 INSPECTION OF WEAR ON SPROCKET ................................................................................................. 20- 116 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20- 117 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-121 INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-122 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-125 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE .............................................................. 20-129 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-132 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-133 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-134 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-135 MEASUREMENT OF OIL LEAKAGE AMOUNT ......................................................................................... 20-136 AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-138 INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-140 SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-141 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL .................................................................. 20-165 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-178
PC300/350(LC)-7
20-101 (8)
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Part No.
Intake pressure (boost pressure)
1 2 1 B 2
799-205-1100 795-790-2600 799-201-2202 799-101-5210
Exhaust gas color
C
Test, measurement item Engine speed
A
1 2 1 Engine valve clearance
Compression pressure Blow-by pressure Fuel injection timing
D 2 3 1 E 2 1 F 2 1 G 2 3
Part name
Tachometer kit Take off drive Boost gauge kit Nipple Handy smoke 799-201-9001 checker Commercially Smoke meter available 795-799-1131 Gear Commercially Thickness gauge available 795-799-1900 Pin assembly 795-790-3610 Compression gauge 795-790-3710 Tester 799-201-1504 Blow-by kit 795-790-3300 Tool (Nozzle) 795-799-1131 Gear 795-799-1900 Pin assembly 795-799-1950 Lock pin 799-101-5002 Hydraulic tester
1
Engine oil pressure
Q’ty
Symbol
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
1 Digital indication: 6 – 99,999.9 rpm 1 1 –101 – 200 kPa {–760 – 1,500 mmHg} 1 R1/4 1 Bosch index: 0 – 9 1 1 1 1 1 1 1 0 – 4.9 kPa {0 – 500 mmH2O} 1 1 1 1 Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 1 {25, 60, 400, 600 kg/cm2}
Hydraulic tester (Digital type) 2 799-401-2320 Hydraulic tester 6732-81-3170 Joint 3 6215-81-9710 O-ring Commercially J Dial gauge available K 796-627-1130 Wear gauge
1
Hydraulic tester
1
790-261-1204
H
Swing circle bearing clearance Sprocket wear Work equipment, swing, 799-101-5002 travel circuit hydraulic oil 1 pressure 790-261-1204 L Control circuit oil pressure 799-101-5220 Pump PC control circuit 2 07002-11023 oil pressure
1 Pressure gauge: 58.8 MPa {600 kg/cm2} 1 Pressure gauge: 0.98 MPa {10 kg/cm2} 1 1 1
1 10 x 1.25 mm
O-ring
1
1 Pressure gauge: 58.8 MPa {600 kg/cm2}
1
1
20-101-1 (8)
Hydraulic tester (Digital type) M 799-101-5220 Nipple 2 07002-11023 O-ring Differential pressure 3 799-401-2701 gauge 790-261-1204
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
Hydraulic tester (Digital type) Nipple
799-101-5002 Hydraulic tester Pump LS control circuit oil pressure
Remarks
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 58.8 MPa {600 kg/cm2} 1 10 x 1.25 mm 1 1
PC300/350(LC)-7
Part No.
Part name
799-101-5002 Hydraulic tester Solenoid valve output pressure
PPC valve output pressure Internal oil leakage inside hydraulic cylinder Coolant temperature, oil temperature Operating force Stroke, hydraulic drift Work equipment speed Voltage, resistance
Troubleshooting of sensors and wiring harnesses
PC300/350(LC)-7
Q’ty
Test, measurement item
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
TESTING AND ADJUSTING
Remarks
1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25, 60, 400, 600 kg/cm2}
1
N
Hydraulic tester (Digital type) 2 790-401-3100 Adapter 3 799-401-3200 Adapter 790-261-1204
799-101-5002 Hydraulic tester P 799-261-1204
Hydraulic tester (Digital type)
1 Pressure gauge: 58.8 MPa {600 kg/cm2} 1 02 size 1 03 size Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 1 {25, 60, 400, 600 kg/cm2} 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Q
Commercially Cylinder available
R
799-101-1502 Digital thermometer 1 –99.9 – 1,299 ºC
79A-264-0021 79A-264-0091 Commercially T available Commercially U available Commercially V available 799-601-7400 799-601-7310 799-601-7320 799-601-7330 1 799-601-7340 W 799-601-7350 799-601-7360 799-601-7520 2 799-601-9000 3 799-601-9300 S
1
Push-pull scale Push-pull scale
1 0 – 294 N {0 – 30 kg} 1 0 – 490 N {0 – 50 kg}
Scale
1
Stopwatch
1
Tester
1
T-adapter assembly Adapter Adapter Adapter Adapter Adapter Adapter Adapter T-adapter assembly T-adapter assembly
1 1 For SWP-12 1 For SWP-16 1 For S-16(white) For M-8 1 For S-12(white) 1 For relay (5-pin) 1 For AMP070-12 1 For DT connector 1 For DT connector (for 24, 40-pin)
20-101-2 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF ENGINE SPEED
INSPECTION AND ADJUSTMENT OF ENGINE SPEED a Engine inspection and maintenance tools Mark 1 A 2
Part No. 799-205-1100 795-790-2600
Part name Tachometer kit Take off drive
Inspection 1. Open up the engine hood and take off cover (1). a Remove cover using filter wrench.
a Engine speed may be detected using a monitoring function in the monitor panel (special function furnished to the monitor panel). •
Multi monitor
2. Fit take off drive A2, and connect pickup set [1] and tachometer [2] of tachometer kit A1.
•
7-Segment monitor
k Be careful not to touch the strongly heated por-
tion of the engine by accident while installing a measurement equipment.
20-102 (8)
3. Measure the engine speed after setting each measurement condition. 1) Engine speed at low idle: i) Set the fuel dial at low idle (MIN). ii) Move all the control levers of work equipment, swing and travel to the NEUTRAL position. 2) Engine speed at high idle: i) Turn the auto-decelerator OFF. ii) Set the fuel dial at high idle (MAX). iii) Operate any of the work equipment, swing and travel control levers. a Operate the lever lightly enough to turn on the PPC hydraulic switch, but not to start the work equipment, swing or travel. 3) Engine speed at fuel pump relief i) Set the fuel dial at high idle (MAX) ii) Put the arm in the digging relief position.
PC300/350(LC)-7
TESTING AND ADJUSTING
4) Engine speed when 2 pump relief and onetouch power max. switch are set (near rated engine speed) i) Set the fuel dial at high idle (MAX). ii) Put the arm in digging relief position and keep the one-touch max. power switch depressed. a The one-touch power max. function is automatically released in 8.5 seconds, even if the knob switch is kept depressed. Take measurement during the period. 5) Engine speed when auto-decelerator is set i) Turn the auto-decelerator ON. ii) Set the fuel dial at high idle (MAX). iii) Move all the control levers of work equipment, swing and travel to the NEUTRAL position. a Approx. 5 seconds after all the control levers are moved to the NEUTRAL position, the engine speed falls automatically. That is when the engine speed with the auto-decelerator in motion should be measured.
INSPECTION AND ADJUSTMENT OF ENGINE SPEED
Adjustment 1. Adjustment of engine speed at low idle a If the engine speed at low idle deviates from the standard value, make adjustment using the adjustment function provided in the monitor panel. a For the adjustment procedures, refer to the section, "Special Function of Monitor Panel" 2. Adjustment of Governor Spring a If the engine speed at high idle deviates from the standard value, or it is unsteady (hunting), adjust the governor spring securing dimensions, using the adjustment function in the monitor panel. a For the adjustment procedures, refer to the section, "Special Function of Monitor Panel"
4. Detach all the measurement tools after the inspection, and make sure that the machine is back to normal condition.
PC300/350(LC)-7
20-103 (8)
TESTING AND ADJUSTING
MEASUREMENT OF AIR BOOST PRESSURE
MEASUREMENT OF AIR BOOST PRESSURE a Air boost pressure measurement tool Mark 1 B 2
Part No. 799-201-2202 799-101-5210
Part name Boost gauge kit Fitting (R1/4)
1. Open up the engine hood.
6. Take measurement of air boost pressure at high idle after setting the following measurement conditions. • Working mode: A mode • Swing lock switch: ON (High pressure relief) • Work equipment, swing and travel: Arm digging relief
2. Remove air boost pressure measurement plug (1).
7. Detach the measurement tool after the measurement, and return the machine to the normal condition. 3. Install fitting B2 and connect it with gauge [1] of air boost gauge kit B1.
4. Start the engine and wait for the engine coolant temperature and hydraulic oil temperature to rise to the operation range. 5. Run the engine at a medium speed and drain oil in the hose. a Oil can be drained by inserting the gauge into the hose halfway and then repeating to open and close the self- seal on the hose side. a If Pm Kit (A) is available, an air bleeding coupling (790-261-1130) included in the kit may well be used. a Be sure to drain oil thoroughly. If there is oil remaining in the hose, the gauge does not function properly.
20-104 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR a Exhaust gas color measurement tool Mark Part No. 1 799-201-9001 C 2 Commercial product
Part name Handy smoke checker Smoke meter
k Be careful not to touch the highly heated parts,
while fitting and detaching a measurement tool. a If no compressed air or power is not available in the field, use Handy Smoke Checker C1. For recording official data, use Smoke Meter C2. 1. Measurement with Handy Smoke Checker C1 1) Fit a filtering paper to Handy Smoke Checker C1. 2) Insert the exhaust gas intake pipe into the exhaust pipe. 3) Start the engine and keep it running until the engine coolant temperature comes within the operating range. 4) Let the exhaust gas stay on the filtering paper by operating a handle of Handy Smoke Checker C1, when the engine speed is suddenly accelerated or kept at high idle.
5) Take out the filtering paper and compare it with the attached scale for judgement. 6) Detach the measurement tool after the measurement, and make sure the machine is back to normal condition. 2. Measurement with Smoke Meter C2 1) Insert probe [1] of the Smoke Meter C2 into the exhaust gas pipe outlet, and fasten it to the outlet with a clip.
PC300/350(LC)-7
2) Connect the probe hose, accelerator switch outlet and air hose to the Smoke Meter C2. a Keep the pressure of the supplied compressed air below 1.5 MPa {15 kg/cm2}. 3) Connect the power cable to an outlet of AC socket. a Confirm that the Smoke Meter power switch is in the OFF position, before connecting the power cable to an outlet. 4) Fit a filtering paper by loosening the suction pump cap nut. a Fit the filtering paper securely so that air may not leak. 5) Move the Smoke Meter C2 power switch to the ON position.
6) Start the engine and keep it running until the engine coolant temperature rises to the operating range. 7) Let the exhaust gas stay on the filtering paper by depressing the accelerator pedal of Smoke Meter C2, when the engine speed is suddenly accelerated or kept at high idle. 8) Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets) in the filtering paper holder, and read the indicated value. 9) Detach the measurement tool after the measurement, and make sure that the machine is back to normal condition.
20-105 (8)
TESTING AND ADJUSTING
ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE a Valve clearance adjustment tools Mark Part No. 1 795-799-1131 D 2 Commercial product 3 795-799-1900
Part name Gear Thickness gauge Pin assembly
a After setting the No. 1 cylinder to the top dead center, stamp a counter mark on the crank pulley and the front cover.
1. Open up the engine hood and remove air intake connector (1). 2. Remove cylinder head covers (2).
5. When No. 1 cylinder is at the top dead center, adjust valve clearances indicated with a black bullet mark (z) in the valve layout chart in the following manner. •
Valve layout chart
3. Take off cap (3) and fit gear D1.
4. Turn the crankshaft clockwise (normal rotation) with gear D1 until yellow paint mark "a" on the crank pulley comes up to the top. Then set the No. 1 cylinder to the top dead center with timing pin (4). a When No. 1 cylinder is at the top dead center, its rocker arm can be manually moved as much as the valve clearance. If it cannot be moved, that means that No. 1 cylinder is not yet at the top dead center. In that case, rotate it by one more turn. a Timing pin push-in depth: 8 mm a If it proves difficult to make this check with the timing pin installed in the engine, metallic pin assembly D3 may be used instead.
20-106 (8)
1) Insert thickness gauge D2 in between rocker arm (5) and valve stem (6), and adjust the valve clearance "b" with adjusting screw (7). a For the adjustment, turn the adjusting screw with filler gauge D2 inserted to the extent that filler gauge D2 can be lightly moved. 2) Fix adjusting screw (7) and then tighten lock nut (8). 3 Lock nut: 24±4 Nm{2.45±0.41kgm} a Check the valve clearance again after tightening lock nut (8). a Return timing pin (4) to the original position and proceed to the next step, once all the measurements of valve clearance indicated with a black bullet mark (z) have been completed.
PC300/350(LC)-7
TESTING AND ADJUSTING
ADJUSTMENT OF VALVE CLEARANCE
6. Turn the crankshaft clockwise (normal rotation) with gear D1 so as to match the counter marks on the crank pulley and the front cover, and bring up No. 6 cylinder to the top dead center. 7. When No. 6 cylinder is at the top dead center, adjust valve clearances indicated with a white bullet mark ({) in the valve layout chart. a The adjustment procedures are the same as introduced in Item 5 above. 8. After the adjustment, make sure that the machine is back to normal condition. 3 Cylinder head cover securing bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
PC300/350(LC)-7
20-107 (7)
TESTING AND ADJUSTING
MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE a Compression pressure measurement tools Mark 1 E 2
Part No. 795-790-3610 795-790-3710
Part name Compression gauge Tester
k Be careful not to get burnt by touching the ex-
haust manifold or muffler, or get caught with a rotating parts, while taking measurement of compression pressure. 1. Adjust the valve clearances. a For the adjustment, refer to the section, "Adjustment of Valve Clearance".
7. Crank up the engine with the engine starting motor, and measure the compression pressure. a Read off the value, when the needle of the compression gauge steadies itself. a When taking measurement of the compression pressure, be sure to measure the engine rpm, too, so that it stays within the range of designated measurement conditions. 8. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition. 2 Nozzle holder rubber boot: Engine oil (EO10-CD)
2. Make preparations for measuring the engine rpm. a For the preparations, refer to the section, "Inspection and adjustment of engine speed". 3. Warm up the engine until the engine oil temperature rises up to 40 – 60°C. 4. Detach nozzle holder (1) of a cylinder to be measured.
5. Fit compression gauge E1 to the nozzle holder mounting. 6. Disconnect E10 connector (2) of the engine stop solenoid.
20-108 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF BLOW-BY PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE a Blow-by pressure measurement tools Mark 1 F 2
Part No. 799-201-1504 795-790-3300
Part name Blow-by kit Tool (Nozzle)
1. Remove the engine under cover. 2. Fit tool F2 to blow-by hose (1) and connect it with gauge [1] of blow-by kit F1.
3. Start the engine and keep it running until the engine coolant temperature rises to the operating range. 4. Measure the blow-by pressure at high idle and under the following conditions. • Working mode: A mode • Swing lock switch: ON (High pressure relief) • Work equipment, swing and travel: Arm IN relief a Read off the blow-by pressure value, when the needle of the gauge steadies itself.
5. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition.
PC300/350(LC)-7
20-109 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING a Fuel injection timing inspection and adjustment tools Mark 1 G 2 3
Part No. 795-799-1131 795-799-1900 795-799-1950
Part name Gear Pin assembly Lock pin
Inspection 1. Open up the engine hood. 2. Take off cover (1) and fit gear G1.
3. Turn the crankshaft clockwise (normal rotation) with gear G1 until yellow paint mark "a" on the crank pulley comes up to the top. Then set the No. 1 cylinder to the top dead center with timing pin (2). a Remove the head cover and check that No. 1 cylinder rocker arm moves as much as the valve clearance. If not, that means that the No. 1 cylinder is not yet at the top dead center. In that case, turn the crankshaft by one more turn. a Timing pin push-in depth: 8 mm a If the pin cannot be pushed in, turn the crankshaft slightly back and forth with gear G1. a If it proves difficult to make this checking with the pin installed in the engine, metallic pin assembly G2 may be used instead.
20-110 (8)
4. Disconnect plug (3) of the fuel injection pump. 5. Reverse and push in timing pin (4) of the fuel injection pump, and confirm its cut-out portion matches with protruding portion "b" inside the pump. a If timing pin (4) can be pushed in smoothly, then injection timing is correct. a If timing pin (4) cannot be pushed in smoothly, injection timing is incorrect and requires adjustment. a If it is found difficult to confirm the push-in depth with timing pin (4) as installed in the engine, metallic pin ass'y G3 may well be used instead.
6. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition. 3 Cylinder head cover securing bolt: 24 ± 4 Nm {2.45 ± 0.45 kgm} k Do not forget to bring driving gear timing pin (4) and injection pump timing pin (4) back to the pre-inspection condition. a In case the adjustment follows, leave gear G1 and timing pin (2) as they are.
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
Adjustment a If fuel injection timing is found incorrect, adjust it in the following manner. 1. Confirm that drive gear injection timing is fixed with driving gear timing pin (2). a If timing pin was pulled back after the inspection had been completed, push it in again following the foregoing inspection procedures.
4. Mount the fuel injection pump. a For mounting the pump, refer to the same section mentioned in Item 2 above. 5. Detach the measurement tools after the adjustment, and make sure that the machine is back to normal condition. k Before starting the engine again, check that driving gear timing pin (2) and fuel injection pump timing pin (4) have been brought back to the pre-adjustment condition.
2. Dismantle the fuel injection pump. a For dismantling the fuel injection pump, refer to the section, "FUEL INJECTION PUMP ASSEMBLY" in the chapter of "DISASSEMBLY AND ASSEMBLY". 3. Reverse and push in timing pin (4) of the fuel injection pump, then match the pin cut-out portion and protruding portion "b" inside the fuel injection pump by turning the shaft. a After fuel timing has been set, fix it by fitting plug (3).
PC300/350(LC)-7
20-111
TESTING AND ADJUSTING
MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE a Engine oil pressure measurement tools Mark 1 H
Part No. 799-101-5002 790-261-1204
2
799-401-2320
3
6732-81-3170 6215-81-9710
Part name Hydraulic tester Digital type hydraulic tester Hydraulic tester (1.0 MPa {10 kg/cm2}) Joint O-ring
4. Measure engine oil pressure at low idle as well as at high idle.
1. Remove hydraulic measurement plug (1) on the cylinder block. 5. Detach the measurement tools after the measurement, and make sure that the machine is back to normal condition.
2. Install joint H3, then fix nipple [1] and connect it with hydraulic tester H2.
3. Start the engine and keep it running until the engine coolant temperature rises to the operating range.
20-112 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
ADJUSTMENT OF ENGINE SPEED SENSOR INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
ADJUSTMENT OF ENGINE SPEED SENSOR
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
a Detach engine speed sensor (1) before the adjustment, then check that there is no metal dust stuck or damage at the tip and fit it again.
Inspection Check belt deflection amount "a" when depressing the mid point between the fan pulley and the compressor with a thumb. • Belt depressing force: Equivalent to 63.7 N {6.5 kg}
1. Screw in sensor (1) until its tip comes to contact with the tip of flywheel ring gear teeth (2). 3 Threaded portion: Gasket sealant (LG-6) 2. Screw back sensor (1) from that position by the prescribed angle. a Screw-back angle: 1±1/6 turn a Adjust clearance "a" between the sensor tip and gear tooth tip to be 1.25–1.75 mm. 3. Fasten sensor (1) with nut (3). 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
Adjustment a If the belt deflection amount is not proper, adjust it in the following manner. 1. Loosen two compressor bracket securing bolts (1) (upper and lower). 2. Shift compressor mounting bracket (1) to adjust the belt tension. 3. Tighten two compressor bracket (1) securing bolts. a Check the belt tension again after the adjustment.
4. After the adjustment, confirm that correct engine speed is displayed in the monitor panel, using the special monitoring function. a For monitoring engine speed, refer to the section, "Special function of monitor panel".
PC300/350(LC)-7
20-113 (8)
TESTING AND ADJUSTING
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM a If a failure occurs on any of the engine control devices like fuel dial, governor pump controller or governor motor • potentiometer, and the engine gets out of control, first fix the engine speed and take the following steps to avoid the immediate danger. a The suggested steps are provisional ones. Identify the cause for the failure and carry out repairs promptly thereafter.
3. Remove bolt (4), connect governor spring (3) and fix it at the original position. a Tilt the governor motor lever to the fuel injection pump side, but stop short of the governor spring. a The governor lever of the fuel injection pump is fixed at a near-idle position.
1. Disconnect E11 connector (1) of the governor motor from E10 connector (2) of the governor potentiometer. k If the governor motor • potentiometer connector is left connected, the governor motor will be suddenly activated while the engine is running, causing a mechanical damage. Be sure to disconnect it.
4. Start the engine again and travel the machine to a safe place. 5. Disconnect E10 connector (5) of the engine stop solenoid. k Operation of stopping the engine is to be carried out while the engine is running at high speed. Be careful not to touch the parts of high temperature or get caught in rotating parts. 2. Detach governor spring (3) on the governor motor side.
20-114 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS a Swing circle bearing clearance measurement tools Mark Part No. J Commercial product
Part name Dial gauge
a Follow the steps explained below, when measuring clearance in the swing circle bearing in the actual machine. k Be careful not to put a hand or foot under the undercarriage, while taking measurement.
4. Hold the arm nearly perpendicular to the ground, and lower the boom until the track shoes will be lifted at the machine front. a The upper structure is raised at the front and lowered at the rear at that time. 5. Read off the value in dial gauge J in this condition. a The value indicated in dial gauge J expresses clearance in the bearings.
1. Fasten dial gauge J to swing circle outer race (1) or inner race (2), and contact the probe with the end surface of inner race (2) or outer race (1) on the opposite side. a Set dial gauge J at the machine front or rear.
6. Return the machine to the posture in Item 2 above, and confirm reading of dial gauge J is zero. a If zero value is not indicated, repeat the steps in Items 3 through 5.
2. Keep the work equipment in the max. reach posture and keep the height of the bucket teeth tip level with the lower height of the revolving frame. a The upper structure is lowered at the front and raised at the rear at that time. 3. Set dial gauge J at zero point.
PC300/350(LC)-7
20-115 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION INSPECTION OF WEAR ON SPROCKET
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION OF WEAR ON SPROCKET
Inspection 1. Travel the machine forward by the length of track on ground, keeping the engine at low idle, and stop the machine slowly.
a Inspection tool for sprocket wear Mark K
Part No. 796-627-1130
Part name Wear gauge
2. Place straight bar [1] on the track shoe between the idler and the 1st carrier roller. a L beam is recommended for bar [1], because of its deflection-free nature. 3. Measure max. clearance "a" between bar [1] and the track shoe. • Max. standard clearance a: 10 – 30 mm
Adjustment a If the track shoe tension is not proper, adjust it in the following manner. 1. When the tension is too strong Discharge grease by loosening valve (1). k Do not loosen valve (1) by more than one turn, because grease will spurt out due to its internal high pressure. 2. When the tension is too weak Add grease through grease fitting (2). a If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.
20-116 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL a Inspection and adjustment tools for hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel Mark 1
Part No. 799-101-5002 790-261-1204
L 2
799-101-5220 07002-11023
Part name Hydraulic tester Digital type hydraulic tester Nipple (10 x 1.25 mm) O-ring
a Hydraulic oil pressure in the hydraulic circuit for work equipment, swing and travel (hydraulic pump output pressure) may be also confirmed with a monitoring function in the monitor panel (special function of monitor panel). Measurement 1. Pre-measurement work k Lower the work equipment to the ground, then release the remaining pressure in the piping by operating the control lever several times after stopping the engine, and release the pressure inside the hydraulic tank by gradually loosening the oil filler cap. 1) Remove hydraulic oil pressure measuring plugs (1) and (2). • Plug (1): For the circuit of front hydraulic pump (at the machine rear part) • Plug (2): For the circuit of rear hydraulic pump (at the machine front part)
PC300/350(LC)-7
2) Fit nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use an oil pressure gauge with the capacity of 58 MPa {600 kg/cm2}.
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
20-117 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
2. Combination of pump, actuator and valve a You will know that when oil flow from the pumps is divided, the front and rear pumps work independently of each other for each actuator, as well as that different relief valves are activated then. a Oil flow from the pumps is merged in the single pressure relief when the work equipment swings, while it is divided in the single pressure relief when the machine travels. a The actuators in the table below are arranged in the order that the control valves are viewed from the machine front. Pump
Actuator Relieved valve (Front unload valve) (Front main relief valve) Service Service safety valve Boom Hi Front main relief valve Arm Hi Front Bucket Front main relief valve Left travel Front main relief valve Raise: Front main relief valve Boom Lower: Safety-suction valve (Merge-divider valve) (Travel junction valve) (Self-reducing pressure valve) Swing Swing motor safety valve Rear Right travel Rear main relief valve Arm Lo Rear main relief valve (Rear unload valve) (Rear main relief valve) (Centralized safety valve) (Back pressure valve)
a Except in boom LOWER, the constant 2stage relief solenoid valve is turned ON and the relief pressure of high pressure is indicated, when the swing lock switch is turned ON. For this reason, keep the swing lock switch in the OFF position, while in the measurement. a In boom LOWER, pressure when the safety valve is relieved is indicated. a The relief pressure in boom LOWER is lower than the main relief pressure. a In boom LOWER, the relief pressure of low pressure is indicated if the machine push-up switch is turned OFF, and the relief pressure of high pressure is indicated if it is turned ON. 5. Measurement of swing relief pressure 1) Start the engine and move the swing lock switch to the ON position. 2) Measure hydraulic oil pressure when the engine is running at high idle and the swing circuit is relieved. a Hydraulic oil pressure when the swing motor safety valve is relieved is displayed. a The swing motor relief pressure is lower than the main relief pressure. 6. Measurement of travel circuit relief pressure 1) Start the engine and lock travel. k Put pin [2] in between the sprocket and the track frame to make sure locking travel.
3. Measurement of Unload Pressure 1) Start the engine. 2) Measure hydraulic oil pressure, when the engine is running at high idle and all the control levers are moved to the NEUTRAL position. a Hydraulic oil pressure when the unload valve unloads is displayed. 4. Measurement of work equipment relief pressure 1) Start the engine and move the cylinder to be measured to its stroke end. 2) Measure hydraulic oil pressure, when the engine is running at high idle and the cylinder is in relief condition. a Except in boom LOWER, the relief pressure of the main relief valve is indicated. a Except in boom LOWER, the relief pressure of low pressure is indicated when the onetouch power max. switch is not depressed and the relief pressure of high pressure is indicated, when it is depressed.
20-118 (8)
2) Measure hydraulic oil pressure when the engine is running at high idle and the travel circuit is relieved. a Hydraulic oil pressure with the main relief valve in relief condition is displayed. In the travel circuit relief, the pressure is high pressure relief all the time.
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
Adjustment a The unload valve cannot be adjusted. 1. Adjustment of main relief pressure a If relief pressure in the work equipment and travel circuits is not normal, adjust the high pressure setting side of main relief valves (3) and (4) in the following manner. • (3): For the front main relief valve • (4): For the rear main relief valve a The main relief valve adjusts the relief pressure of high pressure. (When the relief pressure of low pressure is adjusted, the relief pressure of high pressure is also adjusted automatically) a The relief pressure of low pressure is such condition that the 2-stage relief solenoid valve is in the OFF position and no pilot pressure is applied to the switching port.
1) Disconnect the pilot hose. 2) Fix holder (6) and loosen lock nut (5). 3) Adjust the pressure by turning holder (6). a If the holder is turned to the right, the pressure rises. If the holder is turned to the left, the pressure falls. a Adjustment amount per turn of holder: Approx. 20.5 MPa{approx. 209 kg/cm2} 4) Fix holder (6) and tighten lock nut (5). 3 Lock nut: 49.0–58.8 Nm{5–6 kgm}
PC300/350(LC)-7
5) Connect the pilot hose. 6) Check the pressure again after the adjustment, following the aforementioned steps for measurement. 2. Adjustment of relief pressure in boom LOWER (High pressure setting side) a If the relief pressure of high pressure in boom LOWER is not normal, adjust the high pressure setting side of safety and suction valve (7) for boom LOWER in the following manner. a The relief pressure of high pressure is such condition that the machine push-up switch is in the ON position, and the switching port and the pilot pressure do not function.
1) Disconnect pilot hose. 2) Fix holder (9) and loosen lock nut (8). 3) Adjust the pressure by turning holder (9). a If the holder is turned to the right, the pressure rises. If the holder is turned to the left, the pressure falls. a Adjustment amount per turn of holder: Approx. 21.8 MPa{approx. 222 kg/cm2} 4) Fix holder (9) and tighten lock nut (8). 3 Lock nut: 93–123 Nm{9.5–12.5 kgm}
20-119 (7)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
5) Connect the pilot hose. 6) Check the pressure again after the adjustment, following the aforementioned steps for measurement. a If high pressure setting side is adjusted, low pressure setting side is also affected, so adjust it, too. 3. Adjustment of relief pressure in boom LOWER (Low pressure setting side) a If the relief pressure of low pressure in boom LOWER is not normal, or the high pressure setting side has been adjusted, adjust the low pressure setting side of safety and suction valve for boom LOWER in the following manner. a The relief pressure of low pressure is such condition that the machine push-up switch is in the OFF position, and the pilot pressure is applied to the switching port. 1) Disconnect the pilot hose. 2) Fix holder (11) and loosen lock nut (10). 3) Adjust the pressure by turning holder (11). a Turn the holder: • To the right to increase the pressure • To the left to lower the pressure a Adjustment volume of holder per turn: Approx. 21.8 MPa{Approx. 222 kg/cm2} 4) Fix holder (11) and tighten lock nut (10). 3 Lock nut: 78–93 Nm{8.0–9.5 kgm}
5) Connect the pilot hose. 6) Check the pressure again after the adjustment, following the aforementioned steps for measurement.
20-120 (7)
4. Adjustment of swing relief pressure a If the swing relief pressure is not normal, adjust it with swing motor safety valve (12) in the following manner.
1) Fix adjusting screw (14) and loosen lock nut (13). 2) Adjust the pressure by turning adjusting screw (14). a If the holder is turned to the right, the pressure rises. If the holder is turned to the left, the pressure falls. a Adjustment amount per turn of adjusting screw: Approx. 4.70 MPa{approx. 47.9 kg/cm2} 3) Fix adjusting screw (14) and tighten lock nut (13). 3 Lock nut: 147–196 Nm{15–20 kgm}
4) Check the pressure again after the adjustment, following the aforementioned steps for measurement.
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE a Control circuit oil pressure inspection and adjustment tools Mark 1
Part No. 799-101-5002 790-261-1204
L 2
799-101-5220 07002-11023
Part name Hydraulic tester Digital type hydraulic tester Nipple (10 x 1.25 mm) O-ring
3. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. 4. Measure oil pressure with the engine running at high idle and all the control levers in the NEUTRAL position.
Measurement k Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank. 1. Remove oil pressure measurement plug (1).
5. Detach all the measurement tools after the measurement, and make sure that the machine is back to normal condition. a Do not attempt to adjust the control circuit oil pressure relief valve.
2. Fit nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.
PC300/350(LC)-7
20-121 (8)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE a Pump PC control circuit oil pressure inspection and adjustment tools Mark 1
Part No. 799-101-5002 790-261-1204
L 2
799-101-5220 07002-11023
1. Measurement of PC valve output pressure (servo piston inlet pressure) a Measure PC valve output pressure (servo piston inlet pressure) and pump delivery pressure together, and compare the two pressures. 1) Remove oil pressure measurement plugs (1), (2), (3) and (4). • Plug (1): For measuring the front pump delivery pressure (at the machine rear part) • Plug (2): For measuring the rear pump delivery pressure (at the machine front part)
(8)
•
Part name Hydraulic tester Digital type hydraulic tester Nipple (10 x 1.25 mm) O-ring
Measurement a Implement measuring the pump PC control circuit oil pressure after confirming that the work equipment, swing and travel circuit oil pressure as well as the control circuit original oil pressure are normal. k Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank.
20-122
•
Plug (3): For measuring the front pump PC valve delivery pressure Plug (4): For measuring the rear pump PC valve delivery pressure
2) Fit nipple L2 and connect to oil pressure gauge [1] of hydraulic tester L1. a Use an oil pressure gauge with the capacity of 58.8 MPa {600 kg/cm2}. •
Photo shows pump delivery pressure side.
•
Photo shows PC valve output pressure side.
PC300/350(LC)-7
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
2. Measurement of PC-EPC output pressure 1) Remove oil pressure measurement plug (5). a The plug is fitted at the machine front.
4) Measure the pump delivery pressure and PC valve output pressure (servo piston inlet pressure) together with the engine running at high idle, after setting the machine at the following conditions. • Working mode: A mode • Swing lock switch: ON (switched to high pressure relief with 2-stage relief turned ON) • Work equipment, swing and travel circuit: Arm digging relief a Judgement method: When the ratio between the pump delivery pressure and PC valve output pressure (servo piston output pressure) reaches the following values, both pressures are judged normal.
2) Fit nipple L2 and connect it to oil pressure gauge [1] of hydraulic tester L1. a Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.
Pressure to be measured Pump delivery pressure PC valve outlet pressure
Pressure ratio 1
3) Start the engine and keep it running until the hydraulic oil pressure rises to the operating range.
Approx. 0.6
a If there is any abnormality with PC valve or servo piston, the PC valve output pressure (servo piston output pressure) equals to the pump delivery pressure, or approximates to 0 pressure.
PC300/350(LC)-7
20-123 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE
4) Measure the hydraulic oil pressure with all the control levers kept in the NEUTRAL position and the engine running at high idle and at low idle. a If PC-EPC valve output pressure changes to the following values, it is judged normal. Engine speed
Control lever
Low idle Neutral High idle
Hydraulic oil pressure 2.9 MPa {30 kg/cm2} 0 MPa {0 kg/cm2}
Adjustment a If any of the phenomena mentioned below occurs and PC valve malfunctioning is suspected, adjust PC valves (6) and (7) in the following manner. • As workload increases, the engine speed sharply drops. • While the engine speed is normal, the work equipment moves slowly. • (6): Front pump PC valve • (7): Rear pump PC valve a The width across flats of the locknut for the PC valve is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not turn any other locknut or adjustment screw since it has effects on the performance of the hydraulic pumps.
2. Turn adjustment screw (9) to the right or left to adjust. a Turn the adjustment screw in the following directions. • In the work equipment speed is low, turn the adjustment screw to the right (to increase the pump absorption torque). • If the engine speed lowers, turn the adjustment screw to the left (to decrease the pump absorption torque). 3. Tighten lock nut (8). 3 Lock nut: 27.50 – 34.3 Nm {2.8–3.5 kgm}
4. Confirm that the PC valve output pressure (servo piston inlet pressure) is normal after the adjustment, following the measurement steps explained earlier.
1. Loosen lock nut (8). a Before loosening the lock nut, make match marks at the adjustment screw end so that you can see the position of the lock nut before the adjustment (and you can return the lock nut to its original position after turning it in reverse).
20-124 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE a Pump LS control circuit oil pressure inspection and adjustment tools Mark 1 M
2
Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023
3
799-401-2701
•
Part name Hydraulic tester Digital type hydraulic tester Nipple (10 x 1.25 mm) O-ring Differential pressure gauge
Measurement a Measure pump LS control circuit oil pressure after confirming that the work equipment, swing and travel circuit oil pressure as well as control circuit original pressure are normal. k Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank. 1. Measurement of LS valve output pressure (servo piston inlet pressure) a Measure LS valve output pressure (servo piston inlet pressure) and pump delivery pressure together, and compare both pressures thereafter. 1) Remove oil pressure measurement plugs (1), (2), (3) and (4). • Plug (1): For measuring the front pump delivery pressure (at the machine rear part) • Plug (2): For measuring the rear pump delivery pressure (at the machine front part)
PC300/350(LC)-7
•
Plug (3): For measuring the front pump LS valve delivery pressure Plug (4): For measuring the rear pump LS valve delivery pressure
2) Fit nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1. a Use an oil pressure gauge with the capacity of 58.5 MPa {600 kg/cm2}. •
Photo shows pump delivery pressure side.
•
Photo shows LS valve output pressure side.
20-125 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE
3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • For measuring oil pressure in front circuit: Right track shoe • For measuring oil pressure in rear circuit: Left track shoe k Provide a working area of sufficient space, as the raised track shoe will be idly rotated.
4) Measure pump delivery pressure and PC valve output pressure (servo piston inlet pressure) together with the machine set at the following conditions and the engine running at high idle. • Working mode: A mode • All the control levers of the work equipment, swing and travel are kept in the NEUTRAL position and the travel control lever is kept at half stroke (one side of the track shoes idly rotates). a Let the raised track shoe idly rotate, paying enough attention to the surroundings for safety. a Judgement method: When the ratio between the pump delivery pressure and LS valve output pressure (servo piston output pressure) reaches the following values, both pressures are judged normal. Oil pressure ratio Oil pressure to be All control levers Travel at half measured in NEUTRAL stroke Pump delivery 1 pressure Nearly equal pressure LS valve delivery Approx. 0.6 pressure 5) Detach all the measurement tools after the measurement and make sure that the machine is back to normal condition.
20-126 (8)
2. Measurement of LS differential pressure a LS differential pressure can be obtained by measuring pump delivery pressure and LS pressure (actuator loaded pressure) at the same time and computing the difference of both pressures. 1) Remove oil pressure measurement plugs (1), (2), (5) and (6). • Plug (1): For measuring the front pump delivery pressure (at the machine rear part) • Plug (2): For measuring the rear pump delivery pressure (at the machine front part)
• •
Plug (5): For measuring the front pump LS pressure (at the machine rear part) Plug (6): For measuring the rear pump LS pressure (at the machine rear part)
2) Fit nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1 or differential pressure gauge M3. a When using a differential pressure gauge: Connect pump delivery pressure to the high pressure side and LS pressure to the low pressure side. A differential pressure gauge requires DC 12V power. Connect it with one battery. a When using an oil pressure gauge: Use an oil pressure gauge with the capacity of 58.8 MPa{600 kg/cm2}.
PC300/350(LC)-7
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE
The max. differential pressure is no more than approx. 3.9 MPa {40 kg/cm2}. The same gauge may be used throughout the measurement. •
Photo shows pump delivery pressure side.
•
Photo shows LS pressure side.
4) Measure pump delivery pressure and LS pressure (actuator loaded pressure) together with the machine set at the following conditions and the engine running at high idle. • Working mode: A mode • Traveling speed: Hi • All the control levers of the work equipment, swing and travel are kept in the NEUTRAL position and the travel control lever is kept at half stroke (one side of the track shoes idly rotates). a Let the raised track shoe idly rotate, paying enough attention to the surroundings for safety. a Calculation of LS differential pressure: LS differential pressure = Pump delivery pressure – LS pressure a If LS differential pressure is in the following conditions, it is judged normal. Control lever position LS differential pressure All levers in Unload pressure NEUTRAL (see standard value table) Travel lever at half Max. LS differential pressure stroke (Run track idle) (see standard value table) 5) Detach all the measurement tools after the measurement, and make sure that the machine is back to normal condition.
3) Run the engine and raise the hydraulic oil temperature to the operating range and push up the track shoe on the side to be measured with the work equipment. • For measuring oil pressure in front circuit: Left track shoe • For measuring oil pressure in rear circuit: Right track shoe k Provide a working area of sufficient space, as the raised track shoe will be idly rotated.
PC300/350(LC)-7
3. Measurement of LS-EPC valve output pressure 1) Remove oil pressure measurement plug (7). a The plug is fitted on the rear pump.
20-127 (8)
TESTING AND ADJUSTING
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE
2) Fit nipple M2 and connect it with oil pressure gauge [1] of hydraulic tester M1. a Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.
3) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
Adjustment a When LS differential pressure is not normal, adjust it with LS valves (8) and (9). • (8): Front pump LS valve • (9): Rear pump LS valve
1. Fix adjusting screw (11) and loosen lock nut (10). 2. Adjust the pressure by turning adjusting screw (11). a If the adjusting screw is turned to the right, the differential pressure rises. If the adjusting screw is turned to the left, the differential pressure falls. a Adjustment amount (LS differential pressure) per turn of adjusting screw: 1.3 MPa {13.3 kg/cm2} 3. Fix adjusting screw (11) and tighten lock nut (10). 3 Lock nut: 49 – 64 Nm {5–7 kgm}
4) Measure the oil pressure when the engine is running at high idling and the travel speed switch and travel lever are operated. a If LS-EPC valve output pressure changes to the following values, the pressure is normal. Travel speed
Travel control lever
Lo
Neutral
Hi
Fine control (Note)
Hydraulic pressure Approx. 1.4 MPa {approx. 14 kg/cm2} 0 MPa {0 kg/cm2}
Note: Operate the travel control lever slightly to the extent that the PPC hydraulic oil pressure is turned ON. (Stop the operation short of starting the machine) 5) Detach all the measurement tools after the measurement, and make sure that the machine is back to normal condition.
20-128 (8)
4. After the adjustment, confirm that LS differential pressure is normal, following the steps for measurement explained earlier.
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE a Solenoid valve output pressure measurement tools Mark 1 N 2 3
Part No. 799-101-5002 790-261-1203 799-401-3100 799-401-3200
Part name Hydraulic tester Digital type hydraulic tester Adapter (Size 02) Adapter (Size 03)
a Measure solenoid valve output pressure after confirming that control circuit original pressure is normal. k Lower the work equipment to the ground and stop the engine. After the engine stops, operate the control lever several times to release the remaining pressure in the piping. Then loosen the oil filler cap to release the pressure inside the hydraulic tank.
2. Fix adapter N2 or N3 and connect the disconnected hose again. 3. Fit nipple [1] of hydraulic tester N1 and connect it to oil pressure gauge [2]. a Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.
1. Disconnect the hoses of solenoid valve to be measured at the outlet side. No. 1 2 3 4 5 6 7
Solenoid valve to be measured PPC lock solenoid valve Travel interconnection solenoid valve Merge/divide solenoid valve Travel speed shifting solenoid valve Swing and parking brake solenoid valve Machine push-up solenoid valve 2-stage relief solenoid valve a Hose (1) is installed at the rear of operator's cab, and hoses (2) through (7) are installed at the center of revolving frame.
PC300/350(LC)-7
4. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
20-129 (8)
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
5. Run the engine at full throttle, then turn each solenoid valve ON or OFF by operating the control lever switch, and measure the pressure. a For conditions for turning each solenoid valve ON or OFF, refer to the ensuing "Table for Functioning Conditions" for each solenoid valve. a How each solenoid valve functions can be confirmed with monitoring function in the monitor panel. (Special Function of Machine Monitor) a When each output pressure shows the following values, it is judged normal. Solenoid valve OFF (Demagnetization)
Output pressure 0 MPa {0 kg/cm2}
ON (Excitation)
3 MPa {30 kg/cm2}
6. Detach all the measurement tools after the measurement, and make sure that the machine is back to normal condition. Table for Functioning conditions - Swing and parking brake solenoid
Table for Functioning conditions - PPC lock solenoid valve Functioning condition Locked Safety lock lever Released
Functioning OFF ON
Table for Functioning conditions - Machine push-up solenoid valve Functioning condition OFF ON
Machine push-up switch
Functioning condition When all of them Work equipment, is OFF swing, travel, When any of signaling them is ON
Functioning OFF ON
Functioning ON OFF
Table for Functioning conditions - Travel interconnection solenoid valve Functioning condition When the travel steering signal is ON When the travel steering signal is OFF
20-130 (8)
Functioning ON
If front or rear pump pressure is over 24.5 MPa {250 kg/cm2} In conditions other than above Traveling operation only
ON OFF
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
Table for Functioning conditions - Travel speed shifting solenoid valve Functioning condition When overheat setting of the 2nd stage is ON When the fuel dial indicates less than 1,200 rpm When the travel speed switch is at Lo (or Mi (*1)) The travel signal is OFF If front or rear pump pressure is When the travel speed switch is at Hi The travel 32.3 MPa {330 kg/cm2} signal is ON If front or rear pump pressure is 18.6 MPa {190 kg/cm2} In conditions other than above
Functioning
OFF
ON
*1: The "Mi" mode is on the multi-monitor specification machine only.
Table for Functioning conditions - 2-stage relief solenoid valve Functioning condition Functioning When overheat setting of the 1st stage is ON OFF When all the signals for work equipment, swing and travel are OFF When swing lock switch is ON When travel signal is ON When working mode is L mode (*2) ON When boom LOWER signal is ON When working mode is A or E When left knob If signals other than swing operation only is ON mode switch is ON If swing operation only is ON OFF In conditions other than above Table for Functioning conditions - Merge/divide solenoid valve When working mode is B mode When travel signal only is ON
Functioning condition When service signal is ON
When F or R pump pressure is higher than 2 Other than L 19.6 MPa {200 kg/cm } When F or R pump pressure is lower than When the work mode 14.7 MPa {150 kg/cm2} When the travel equipment and signal is ON swing signals When F or R pump pressure is higher than are ON 16.7 MPa {170 kg/cm2} L mode (*2) When F or R pump pressure is lower than 11.8 MPa {120 kg/cm2} In conditions other than above
Functioning ON
OFF ON OFF
*2: The "L" mode is on the multi-monitor specification machine only.
PC300/350(LC)-7
20-131 (8)
TESTING AND ADJUSTING
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE a PPC valve output pressure measurement tools Mark P
Part No. 799-101-5002 790-261-1204
Part name Hydraulic tester Digital type hydraulic tester
2. Fit nipple [1] of hydraulic tester P and connect oil pressure gauge [2]. a Use an oil pressure gauge with the capacity of 5.9 MPa {60 kg/cm2}.
a Measure PPC valve output pressure after confirming that control circuit original pressure is normal. 1. Remove PPC oil pressure switches (1) through (10) in the hydraulic circuits to be measured. No. 1 2 3 4 5 6
Circuit to be No. measured Boom, RAISE (S06) 7 Boom, LOWER (S02) 8 Arm, DIGGING (S04) 9 Arm, DUMPING (S08) 10 Bucket, DIGGING (S01) Bucket, DUMPING (S05)
Circuit to be measured Swing, left (S03) Swing, right (S07) Travel (black) (S30) Steering (red) (S31)
3. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range.
a Oil pressure switches (1) through (8) are installed in the PPC relay block, and (9) and (10) are installed at the rear of operator's cab.
4. Measure the pressure when the engine is running at high idling and the control lever of the circuit to be measured is kept in the NEUTRAL position and at the full stroke. a If PPC valve output pressure is at the level shown below, it is judged normal. Lever control In NEUTRAL At full stroke
Hydraulic pressure 0 MPa {0 kg/cm2} Nearly equal to control original pressure (see standard value table)
5. Detach all the measurement tools, and make sure that the machine is back to normal condition.
20-132 (8)
PC300/350(LC)-7
TESTING AND ADJUSTING
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE a If there is excessive play in the work equipment or swing lever, adjust it in the following manner. 1. Remove work equipment and swing PPC valve ass'y. 2. Take off boot (1). 3. Loosen lock nut (2) and screw in disc (3) until it contacts the heads of four pistons (4). a Do not move the piston while doing this work. 4. Keep disc (3) in place and tighten lock nut (2) to the specified tightening torque. 3 Lock nut: 98 – 127 Nm {10 – 13 kgm} 5. Install boot (1). 6. Install work equipment and swing PPC valve assembly.
PC300/350(LC)-7
20-133 (8)
TESTING AND ADJUSTING
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT a If there is any hydraulic drift in the work equipment (cylinders), check in the following manner to determine if the cause is in the cylinder packing or in the control valve.
2. Inspection of arm cylinder 1) Operate the arm cylinder to move the arm to the position 100 mm before the digging stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders 1) Set the work equipment in the same posture as when measuring hydraulic drift, and stop the engine. a Fill the bucket with earth or apply the rated load to the bucket.
2) Operate the control lever to the RAISE position or the bucket control lever to the CURL position. • If the lowering speed increases, the cylinder packing is defective. • If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again.
20-134
2) Operate the arm control lever to move the arm to the digging side. • If the lowering speed increases, the cylinder packing is defective. • If there is no change, the control valve is defective. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again. [Reference]If the cause of the hydraulic drift is in the defective packing, and the above operation is carried out, downward movement is accelerated 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 small than the volume at the bottom end by the volume of the rod end, 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(LC)-7
TESTING AND ADJUSTING
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 3. Inspection of boom lock valve 1) Set the work equipment at the maximum reach and the boom top horizontal. Then stop the engine. k Lock the work equipment control levers and release the pressure inside the hydraulic tank. k Do not allow anyone to come under the work equipment during the work. 2) Disconnect drain hose (1) of the control valve, and install a blind plug in the hose. • Part No. for the blind hose: 07376-70210 a Leave the control valve end open. a If any oil leaks out from the port that is left open, following hydraulic drift of the work equipment, the boom lock valve is defective (loose contact).
k If the piping between the hydraulic cylinders or
the hydraulic motor and control valves is to be disconnected, release the remaining pressure in the following manner. a There is no pressure remaining in the swing motor circuit and travel motor circuit, but the internal pressure in the hydraulic tank affects them. So open the oil filler cap of the hydraulic tank. 1. Stop the engine, and loosen the oil filler cap gradually to release the pressure inside the tank. 2. Turn the engine starting switch to the ON position and operate the control levers several times. a There must be power supply to the PPC lock valve. Be sure to operate the control levers with the engine starting switch in the ON position. a 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. 10 seconds to accumulate pressure in the accumulator, then stop the engine. 4. Repeat the steps in Item 2 to 3 above several times.
4. Inspection of PPC valve Measure the amount of hydraulic drift of the work equipment when the accumulator is charged with pressure and the safety lock lever is put to the LOCK and FREE positions. a Operate the control lever with the engine starting switch in the ON position. a If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again. a If there is any difference in the hydraulic drift between LOCK and FREE positions, the PPC valve is defective (some internal failure).
PC300/350(LC)-7
20-135
TESTING AND ADJUSTING
MEASUREMENT OF OIL LEAKAGE AMOUNT
MEASUREMENT OF OIL LEAKAGE AMOUNT 1. Measurement of oil leakage amount from boom cylinder 1) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the boom cylinder to the stroke end. k Release the pressure remaining in the piping, referring to the foregoing section of "Release of remaining pressure in hydraulic circuit". 2) Disconnect hose (1) at the cylinder head end and block the hose end with a plate. k Be careful not to disconnect the hose at the cylinder bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine running at high idle. 4) Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.
5) After the measurement, make sure that the machine is back to normal condition. 2. Measurement of oil leakage amount from arm cylinder 1) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the arm cylinder to the digging stroke end. k Release the pressure remaining in the piping, referring to the foregoing section of "Release of remaining pressure in hydraulic circuit". 2) Disconnect hose (2) on the cylinder head end and block the hose end with a plate. k Be careful not to disconnect the hose at the cylinder bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine running at high idle.
20-136 (8)
4) Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.
5) After the measurement, make sure that the machine is back to normal condition. 3. Measurement of oil leakage amount from bucket cylinder 1) Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the bucket cylinder to the digging stroke end. k Release the pressure remaining in the piping, referring to the foregoing section of "Release of remaining pressure in hydraulic circuit". 2) Disconnect hose (3) at the cylinder head end block the hose end with a plate. k Be careful not to disconnect the hose at the cylinder bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine running at high idling. 4) Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.
5) After the measurement, make sure that the machine is back to normal condition.
PC300/350(LC)-7
TESTING AND ADJUSTING
MEASUREMENT OF OIL LEAKAGE AMOUNT
4. Measurement of oil leakage amount from swing motor 1) Disconnect drain hose (4) and fit a blind plug in the hoses. 2) Turn the swing lock switch to the ON position. 3) Start the engine. Apply the swing relief pressure with the engine running at high idle and measure an oil leakage amount under such conditions. a After keeping the conditions in 3) above for 30 seconds, measure the oil leakage amount for one minute. a After the first measurement, turn the upper structure by 180 degrees and take measurement again in the same way.
3) Disconnect drain hose (5) of the travel motor and fit a blind plug in the hose end. 4) Start the engine and apply the travel relief pressure with the engine running at high idle, then measure an oil leakage amount under such conditions. kIn this measurement, an erroneous operation of the control lever will likely lead to a serious accident. Make sure that all the signals and confirmations are followed without fail. a After keeping the conditions in 4) above for 30 seconds, measure the oil leakage amount for one minute. a Repeat the measurement several times, slightly rotating the motor, i.e. shifting the position of valve plate and cylinder, and the position of cylinder and piston, and take measurement several times.
4) After the measurement, make sure that the machine is back to normal condition. 5. Measurement of oil leakage amount from travel motor 1) Take off the travel motor cover. 2) Start the engine and lock the travel. k Put pin [1] in between the sprocket and the track frame to block the travel.
PC300/350(LC)-7
5) After the measurement, make sure that the machine is back to normal condition.
20-137 (8)
TESTING AND ADJUSTING
AIR BLEEDING OF VARIOUS PARTS
AIR BLEEDING OF VARIOUS PARTS Air bleeding item
Contents of Work • Change of hydraulic oil • Cleaning of strainer
Steps for air bleeding 1
2
3
4
Hydraulic pump air bleeding
Engine start
Cylinder air bleeding
Swing motor air bleeding
{
{
{
{
6
Travel Operation motor air start bleeding
(Note)
{
(Note)
{
• Replacement of return filter element • Repair or replacement of hydraulic pump • Removing suction pipe
5
{
{ {
{
{
{
• Repair or replacement of control valve
{
{
{
• Replacement of cylinder • Removing cylinder piping
{
{
{
• Replacement of swing motor • Removing swing motor piping
{
• Replacement of travel motor swivel • Removing travel motor swivel piping
{
{
{ {
{
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained. 1. Air bleeding from hydraulic pump 1) Loosen air bleeding plug (1) and confirm that oil seeps out from the plug. 2) If the oil seepage is confirmed, tighten air bleeding plug (1). 3 Air bleeding plug: 7.8 – 9.8 Nm {0.8 – 1.0 kgm} a Precautions for starting engine When starting the engine after the air bleeding work explained above, run the engine at low idle for 10 minutes. If the engine cooling water temperature is low and an automatic engine warming-up function is relied on, use the fuel dial, when it becomes necessary to cancel it.
20-138 (8)
2. Air bleeding from hydraulic cylinder 1) Start the engine and kept it running at low idle for 5 minutes. 2) Raise and lower the boom 4 to 5 times with the engine running at low idle. a Be careful not to apply the relief pressure, stopping the piston rod approx. 100 mm before its stroke end. 3) Repeat the steps in Item 2) above, but this time with the engine running at high idle. 4) Apply the relief pressure by extending the piston rod to its stroke end and with the engine running at low idle. 5) For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in Item 2) through 4) above. a In case a cylinder is replaced with new one, it is advised to bleed air from the new one before mounting the work equipment. It is especially so with the boom cylinder, because its rod does not extend to the stroke end of LOWER side, after the work equipment is mounted.
PC300/350(LC)-7
TESTING AND ADJUSTING
AIR BLEEDING OF VARIOUS PARTS
3. Air bleeding from swing motor 1) Start the engine and run it at low idle. 2) Bleed air from the motor by swinging the upper structure slowly. 4. Air bleeding from travel motor 1) Start the engine and run it at low idle. 2) Loosen air bleeding plug (2) and confirm that oil seeps out from the plug. 3) If the oil seepage is confirmed, tighten air bleeding plug (2). 3 Air bleeding plug: 27.5 – 35.3 Nm {2.8 – 3.6 kgm}
PC300/350(LC)-7
20-139 (8)
TESTING AND ADJUSTING
INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE a Check an assembled-type diode (8 pins) and single diode (2 pins) in the following manner. a The continuity direction of an assembled-type diode is as shown in the diagram below. a The continuity direction of a single diode is shown on the diode surface.
1. When using digital type circuit tester 1) Switch the testing mode to diode range and confirm the indicated value. a Voltage of the battery inside is displayed with conventional circuit testers. 2) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode, and confirm the displayed value.
20-140 (8)
3) Determine if a specific diode is good or no good with the indicated value. • No change in the indicated value: No continuity (defective). • Change in the indicated value: Continuity established (normal) (Note) Note: A silicon diode shows a value between 400 and 600.
2. When using analog type circuit tester 1) Switch the testing mode to resistance range. 2) Check the needle swing in case of the following connections. i) Put the red probe (+) of the test lead to the anode (P) and the black probe (–) to the cathode (N) of diode. ii) Put the red probe (+) of the test lead to the cathode (N) and the black probe (–) to the anode (P) of diode. 3) Determine if a specific diode is good or no good by the way the needle swings. • If the needle swings in Case i), but does not swing in Case ii): Normal (but the breadth of swing (i.e. resistance value) will differ depending on a circuit tester type or a selected measurement range) • If the needle swings in either case of i) and ii): Defective (short-circuited internally) • If the needle does not swing in any case of i) and ii): Defective (short-circuited internally)
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
[1] Figure input switch 1
[6] Figure input switch 6
[
] Return switch
[2] Figure input switch 2
[7] Figure input switch 7
[
] Upward move switch
[3] Figure input switch 3
[8] Figure input switch 8
[
] Downward move switch
[4] Figure input switch 4
[9] Figure input switch 9
[
] Input confirmation switch
[5] Figure input switch 5
[0] Figure input switch 0
PC300/350(LC)-7
20-141
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Monitor panel functions - conventional and special The monitor panel is provided with conventional and special functions, and various kind of information are shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel and others that are shown by switch operations. 1. Conventional function: Operator's Menu This is a function by which an operator can set or show displays by switch operations. The display contents are those which are normally shown. 2. Special function: Service Menu This is a function by which a service mechanic can set or show displays by special switch operations. The display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trouble-shooting or special setting of machines. Operator's Menu 1
Function for inputting and setting password
2
Function for showing Komatsu's logo
3
Function for machine inspection before starting day's work
4
Function for showing machine maintenance
5
Function for showing precaution items
6
Function for confirming working mode and travel speed
7
Function for display of ordinary items
8
Function for adjusting display luminance and contrast
9
Function for adjusting breaker and attachment flow rate
10
Function for confirming maintenance information
11
Function for showing service meter reading
12
Function for checking display LCD
13
Function for showing occurrence of caution item
14
Function for showing users' code No.
15
Function for showing service code No. and failure code No.
20-142
Service Menu 16
Function for monitoring [01]
17
Function for fail- Electrical system ure history [02] Mechanical system
18
Function for maintenance history [03]
19
Function for maintenance mode change [04]
20
Function for recording phone No. [05]
21
Function for initial value setting and default [06]
Mode with key ON Language Unit Attachment installed/No attachment installed Adjustment of governor lever stroke 22
Function for adjustment [07]
Fuel pump absorbin torque RPM at low idling Adjustment of oil flow to attachment
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Operation of Operator's Menu and Display (Outline) This section introduces only the outline of the operator's menu. For details on the contents and operation steps of each menu, refer to the operation and maintenance manual or the chapter of "STRUCTURE AND FUNCTION" in this shop manual. 1. Function for inputting and setting password When the engine starting switch is turned ON, the password inputting display is shown. This display is shown only when a password is registered. 2. Function for showing KOMATSU logo When a password is inputted, or when the engine starting switch is turned ON, KOMATSU logo is shown for two seconds.
3. Function for machine inspection before starting day's work Following the KOMATSU logo, the display of machine inspection before starting day's work is shown for 2 seconds.
4. Function for machine maintenance Following the display of machine inspection before starting day's work, the maintenance mark appears for 30 seconds, if there is an oil filter whose maintenance time is approaching or has just passed. This display appears only when the maintenance function is set.
PC300/350(LC)-7
20-143
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
5. Function for showing precaution items If there is any item of machine inspection before starting day's work that indicates some abnormality, a corresponding symbol mark is shown after the display of machine inspection before starting day's work.
6. Function for confirming working mode and travel speed After the display of machine inspection before day's work, amplified symbol marks for working mode and travel speed are shown for two seconds to urge an operator to confirm the setting.
7. Function for display of ordinary items The display of confirming working mode and travel speed is switched to this display of ordinary items. If the working mode setting or travel speed setting is changed, or auto-deceleration or windshield wiper setting is activated while this is in display, an amplified corresponding symbol mark is shown for two seconds. In this display, a symbol mark for preheat monitor is shown only when preheating is carried out. 8. Function for adjusting display luminance and contrast Luminance as well as contrast of the display can be adjusted by operating the display adjusting switch.
20-144
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
9. Function for adjusting breaker and attachment flow rate (For machines equipped with breaker attachment) When a breaker or other attachments are used, hydraulic pump flow rate can be adjusted by operating the select switch. Note that the symbol mark and contents of display partially differ between the breaker and the other attachments.
10. Function for confirming maintenance information Detailed information on maintenance items (set time and elapse of time) can be confirmed and resetting after the confirmation is feasible by operating the maintenance switch. Use service Menu for setting or releasing maintenance items and setting maintenance time.
11. Function for showing service meter reading Only the service meter reading can be shown by the following switching operation, when the engine starting switch is turned OFF. • Switching operation: [ ] + [ ] (synchronized switching operation)
12. Function for checking display LCD Display of the Display LCD can be confirmed by the following switching operation in the display of inputting and setting password as well as in the display of ordinary items • Switching operation: [ ] + [A] (synchronized switching operation) All the LCD light up, turning the entire screen white. If there is no showing in black, the display is normal. This display returns to the immediately preceding one, if making any other switching operation.
PC300/350(LC)-7
20-145
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
13. Function for showing occurrence of caution item If any of the caution items occurs, the magnified corresponding symbol mark is shown for two seconds and thereafter stays on the display as a small symbol mark until it is dissolved.
14. Function for showing users' code No. When a trouble occurs on the machine, the user's code is automatically displayed depending on the magnitude of the trouble to call attention of the operator for a proper action. This display turns to the display of service code and failure code, if operating the switch (Refer to Item No. 15)
Relation between User Code and Action Directed to Operator User Code
Failed System
Action Directed to Operator
E02
PC-EPC Valve
Ordinary work may be resumed by turning the emergency pump drive switch ON, but call for the inspection service immediately.
E03
Swing Brake
Release the brake after turning emergency swing and parking brake switch ON. When applying the swing brake, operate the swing lock switch manually. The swing brake may not be released depending on the nature of the trouble. In either case, call for the inspection service immediately.
E05
Governor
The governor control has become inoperable. Operate the governor control lever manually. For fixing the lever at full throttle position, use a fixing bolt provided at the bracket. In this case, call for the inspection service immediately.
20-146
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
15. Function for showing service code No. and failure code No. If the following switching operation is made while the users' code No. is shown, a phone symbol (if registered), phone numbers (if registered), service code No. and failure code No. are shown in turn. • Switching operation: [ ] (keep the switch depressed) a The following items are repeatedly displayed in order according to the operation of the switch. Telephone symbol mark Ø Telephone No. Ø Service code No. and failure code No. a The telephone symbol mark and telephone No. are shown only when they are registered in the monitor panel. For registration, correction and deletion of telephone No., use Service Menu. a For details on the displayed service code No. and failure code No., refer to the Table for Service and Failure Code Nos.
PC300/350(LC)-7
20-147 (7)
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Code No.
Content
– E101 Abnormal data in error history Short circuit in wiper motor drive, normal rotation system Short circuit in wiper motor drive, reverse rotation system Short circuit in windshield washer drive Abnormality of windshield wiper in motion Abnormality of windshield wiper in retraction
Failure Code Code No.
Location
DAF0KT Failure history
Windshield wiper motor (normal rotation) Windshield wiper motor – E113 DY2EKB (reverse rotation) – E114 DY2CKB Windshield washer motor – E115 DY20KA Windshield wiper motor – E116 DY20MA Windshield wiper motor Travel interlocking solenoid – E201 Short circuit in travel interconnection solenoid DW91KB valve E03 E203 Short circuit in swing holding brake solenoid DW45KB Swing holding solenoid valve – E204 Short circuit in merge/divide solenoid DWJ0KB Merge solenoid valve – E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Travel Hi-Lo shifting solenoid – E206 Short circuit in travel speed shifting solenoid DW43KB valve Travel interlocking solenoid – E211 Disconnection in travel interlocking solenoid DW91KA valve E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve – E214 Disconnection in merge/divide solenoid DWJ0KA Merge solenoid valve – E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Travel Hi-Lo shifting solenoid – E216 Disconnection in travel speed shifting solenoid DW43KA valve – E112
DY2DKB
– E217 Abnormality in model code input
DA2SKQ S_NET
– – – – –
DA2SKA S_NET DXE0KB LS-EPC solenoid valve DXE0KA LS-EPC solenoid valve DHPAMA F pump pressure sensor DHPBMA R pump pressure sensor
E218 Disconnection in S_NET signal E222 Short circuit in LS-EPC solenoid E223 Disconnection in LS-EPC solenoid E224 Abnormality in F pump pressure sensor E225 Abnormality in R pump pressure sensor
– E226 Abnormality in pressure sensor power source – E227 Abnormality in engine revolution sensor – E228 Short circuit in ATT return switching relay E02 E232 Short circuit in PC-EPC solenoid E02 E233 Disconnection in PC-EPC solenoid – E238 Disconnection in ATT return switching relay – E245 Short circuit in ATT flow rate adjusting EPC – E246 Disconnection in ATT flow rate adjusting EPC – E256 Incorrect nonvolatile memory data – E304 Short circuit in engine stop solenoid relay – E306 Abnormality in motor potentiometer
20-148
DA25KP Governor pump controller DLE2MA D196KB DXA0KB DXA0KA D196KA
Phenomenon
Failure Classification
Service Code
Abnormality in data Short circuit Short circuit Short circuit Disconnection Malfunctioning Short circuit Short circuit Short circuit Short circuit Short circuit Disconnection Disconnection Disconnection Disconnection Disconnection Nonconformance in model selecting signal Disconnection Short circuit Disconnection Malfunctioning Malfunctioning Lowering in output voltage Malfunctioning Short circuit Short circuit Disconnection Disconnection
Electrical system
User Code No.
Table for Service and Failure Code Nos.
Engine revolution sensor ATT switching relay TVC solenoid valve TVC solenoid valve ATT switching relay ATT flow rate throttling EPC DXE4KB Short circuit valve ATT flow rate throttling EPC DXE4KA Disconnection valve Abnormality in DA20KT Nonvolatile memory data DY45KB Engine stop solenoid relay Short circuit Governor motor feedback DK54KZ Malfunctioning potentiometer
PC300/350(LC)-7
Service Code Code No.
Content
E05 E308 Abnormality in throttle potentiometer – E314 Disconnection in engine stop solenoid relay – E315 Short circuit in battery relay output – E316 Abnormality in governor motor step-out E05 E317 Disconnection in both governor motors A and B E05 E318 Short circuit in both governor motors A and B – None Engine high idling out of rate
Failure Code Code No. DK10KZ DY45KA D110KB DY10K4 DY10KA DY10KB A000N1
Location Throttle potentiometer Engine stop solenoid relay Battery relay Governor motor Governor motor Governor motor Engine
Phenomenon Malfunctioning Disconnection Short circuit Out of control Disconnection Short circuit Overrunning Low idling out of rate Clogging Insufficient charging Oil pressure lowered Oil level lowered Overheating Cooling water level lowered Overheating
– None Engine low idling out of rate
A000N2 Engine
– None Air cleaner clogged
AA10NX Air cleaner element
– None Charging voltage abnormally low
AB00KE Alternator
– None Engine oil pressure abnormally low
B@BAZG Engine oil
– None Engine oil level abnormally low – None Engine cooling water overheated
B@BAZK Engine oil B@BCNS Engine cooling water
– None Radiator water level abnormally low
B@BCZK Engine cooling water
– None Hydraulic oil overheated
B@HANS Hydraulic oil Auto-lubrication system conDA80MA Malfunction troller
– None Auto-lubrication system abnormal
Failure Electrical system Classification
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Mechanical system
User Code No.
TESTING AND ADJUSTING
This table is arranged in the sequence of Service Code No. In case there is no number assigned in the column of User Code No., or in case "none" is described in the column of Code No. of Service Code, the corresponding service code or failure code is not shown in the display of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in electrical system or mechanical system) of Service Menu. History Classification indicates that a specific failure is classified as belonging to either electrical system or mechanical system, when it is recorded in Service Menu. "E" at the head of Code No. of Service Code means the following status of a specific failure. • With "E": The failure is yet to be dissolved and continues. • Without "E": The failure has already been dissolved.
PC300/350(LC)-7
20-149
TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Operation and Display of Service Menu Way of switching to Service Menu When using Service Menu, change the display to Service Menu display through the following special operation. 1) Confirmation of display Confirm that the display of ordinary items is shown. Changing to Service Menu cannot be made from displays other than this. 2) Switch operation Operate the switch as instructed below. • Switch operation: [ ] + [1] [2] [3] (Enter a figure, depressing [
])
3) Showing Service Menu display The display is changed to the initial display of Service Menu program. Select an appropriate item from among the menu. No.
Service Menu
00
Return (Termination of Service Menu)
01
Monitoring
02
Abnormality Record
03
Maintenance Record
04
Maintenance Mode Change
05
Phone Number Entry
06
/ Default
07
Adjustment
08
–
4) Termination of Service Menu function When terminating the initial display or any subsequent display of Service Menu, do that through any one of the following methods. Depress [ ] switch. (This method may be used for terminating any display) If "Return" switch is shown, depress it. If "Return" menu is shown, call that menu and depress [ ] switch.
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16. Function of monitoring [01] The monitor panel monitors signals from an assortment of switches, sensors and actuators installed in various parts of the machine. Monitored information can be put in display or confirmed on a real time basis through the following operations. 1) Selection of menu Select "01 Monitoring" in the initial display of Service Menu and depress [ ] switch. 2) Setting of monitoring item Select or register an item to be monitored through the following switch operation. • [ ] switch: Selection • [ ] switch: Selection • [ ] switch: Registration A monitoring item can be set in any number between the min. one to the max. four. (Depending upon the selected item, the max. number is less than four) In case of monitoring 1 to 3 items, move to the monitored information display through any of the following switch operations, after the registration work has been completed. • Keep [ ] switch depressed. (For about 3 seconds) • Select Menu 999 and depress [ ] switch. The display automatically moves to the display of monitored information, when all of the registrable items have been duly registered. Monitored information are transmitted via communication circuits. Thus the number of selected items can impact the communication speed. If truly real time monitoring is required, reduce the selected items to the minimum. For details on the monitoring items, display unit, etc., refer to the Table for Monitoring Items.
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3) Monitoring operation Call the monitoring information display and confirm the monitored information, while operating the machine.
4) Monitored information holding function If [ ] switch is depressed while monitoring, all the monitored information are put on hold. If [ ] switch is depressed in this condition, information holding is released.
5) Machine setting mode switching function If it becomes necessary to change settings of working mode, select mode, travel speed and auto-decel while monitoring, depress the corresponding switch, then the mode confirmation display is shown. An illustration at right shows the display in A mode and E mode. Symbol marks are partially different in B mode. When a specific setting is confirmed, depress [ ] switch, then the display returns to that of monitoring. In case a specific setting has been changed while monitoring, the new setting is still maintained when returning from Service Menu to Operator's Menu after the monitoring is finished.
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Table for Monitoring Items Code No.
Item to be monitored
000
Return
999
To Display Screen
002 003 010 011
Controller Model Select Controller Model Select Engine Speed F Pump Pressure
012 013 015 016 017
R Pump Pressure PC-EPC Sol. Curr. LS-EPC Sol. Curr. 2nd Eng. Speed Command Service Sol. Curr. Swing Travel Boom Lower Pressure Switch 1 Boom Raise Arm Curl Arm Dump Bucket Curl Bucket Dump Pressure Switch 2 Service Travel Steering Lever Sw. Switch Input 1 Swing Release Sw. Swing Brake Sw. Travel Junction Swing Brake Solenoid valve 1 Merge-divider 2-stage Relief Travel Speed Solenoid valve 2 Service Return Model Select 1 Model Select 2 Model Select 3 Switch Input 2 Model Select 4 Model Select 5 Fuel Dial Vol. Gov. Motor Potentio Vol. Battery Voltage Gov. Motor Phase A Curr. Gov. Motor Phase B Curr. Battery Relay O/P Vol. Switch Input 3 Key Switch Batt. Relay Dr. Controller Output Engine Stop SOL. Engine Water Temperature Fuel Lever Sensor Vol.
019
021
022
023
024
027
030 031 032 033 034 035 036 037 041 042
PC300/350(LC)-7
Unit (Default: ISO) ISO Meter Inch (Not displayed) (Not displayed)
r/min MPa MPa mA mA r/min mA
V V V mA mA V
ºC V
Figure Figure rpm kg/cm
2
kg/cm2 mA mA rpm mA ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF V V V mA mA V ON/OFF ON/OFF ON/OFF ºC V
Remark Termination menu Execute Command menu
rpm PSI PSI mA mA rpm mA
V V V mA mA V
ºF V
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Code No. 043 044
045
046
049
200 201
Item to be monitored Battery Charge Vol. Hydr. Oil Temperature Key Switch Start Preheat Monitor Input 1 Light Rad. level Hydr. Oil Level Aircleaner Eng. Oil Press. Monitor Input 2 Eng. Oil Level. Spare Battery Charge Swing Brake Sw. Buzzer cancel Sw. Window Limit Sw. Monitor Input 3 W Limit Sw. P Limit Sw. Monitor Prog. Version Controller Prog. Version
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
Unit (Default: ISO) ISO Meter Inch V V V ºC ºC ºF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ABN•NOR ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF Figure Figure
Remark
Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu. Abbreviations, ABN and NOR, stand for the following conditions. ABN: Abnormal, NOR: Normal It cannot be monitored how the machine push-up solenoid valve works.
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17. Function for Abnormality Record [02] The monitor panel records failures that occurred on the machines in the past after classifying them into failures in the electric system and those in the mechanical system. Information on them can be displayed through the following operation. 1) Selection of menu Select 02 Abnormality Record in the initial display of Service Menu and depress [ ] switch. 2) Selection of Submenu Select an appropriate item from Submenu in the Abnormality Record display and depress [ ] switch. No. 00 01 02
Abnormality Record Submenu Return (termination of Abnormality Record) Electrical System Mechanical Systems
3) Information shown in display of Abnormality Record in the electrical system : The numerator expresses sequence of failure occurrence, counting from the latest one. The denominator expresses the total number of a specific failure recorded. : Service Code : Abnormality Code No. (system in 4 digits and phenomenon in 2 digits) : Time elapsed since the occurrence of the first failure : Contents of failure Refer to "Table for Service Code and Abnormality Code" in Operator's Menu. 4) Information shown in display of Failure History in the mechanical systems : Record No. : Contents of Abnormality : Abnormality Code No. (system in 4 digits and phenomenon in 2 digits) : Total number of occurrence : Service meter reading at the initial occurrence Refer to "Table for Service Code and Abnormality Code" in Operator's Menu.
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5) Resetting Electrical Systems Resetting Electrical Systems (deletion) is possible only with the electrical system. The failure history in the mechanical system cannot be reset. For resetting any specific or all information in the Electrical Systems, follow the operation explained below. i) Through the following switch operation, call the resetting display in the display of Electrical Systems. • Switch operation: [ ] +[1] [2] [3] This is the same switch operation in changing the display to Service Menu. ii) Operate the switch, following the instructions shown in the resetting display. When resetting specific information only, call the display of that specific information and reset it with either [ ] switch or [ ] switch. When resetting all the information, a display of any information will do.
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18. Function for Maintenance Record [03] The monitor panel records information on the maintenance of filters and oils. The stored information can be displayed through the following switch operation. 1) Selection of menu Select 03 Maintenance Record in Service Menu and depress [ ] switch.
2) Information to be displayed : Name of oils and filters : Times of replacement to date : Service meter reading at the latest replacement
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19. Function for Maintenance Mode Change [04] Conditions set for controlling maintenance display function can be changed in the following manner. • Turn the function effectual or ineffectual. • Change the set interval for replacement. 1) Selection of menu Select 04 Maintenance Mode Change in the initial display of Service Menu, and depress [ ] switch.
2) Selection of item to be changed Select an item to be changed in the display of Maintenance Mode Change Selecting Menu. No. 00 01 02 03 04 05 06 07 08 09 10 11 12
Maintenance mode change item Return Maintenance Mode On/Off Engine Oil Exch. Int. Engine Oil Filter Exch. Int. Fuel Filter Exch. Int. Hydr. Oil Filter Exch. Int. H/Tank Breather Exch. Int. Corro. Resis. Exch. Int. PTO Oil Service Int. Final Drive Oil Exch. Int. S/Machinery Oil Exch. Int. Hydraulic Oil Exch. Int. Use Default Values
01 and 12 menus are provided for setting the whole maintenance mode, while those from 02 through 11 are for setting individual items. 3) Contents of Maintenance Mode On/Off • Use: The maintenance display function of all oil and filter-related items are turned effectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails) • Do not use: The maintenance display function of all oil and filter-related items are turned ineffectual. (Irrespective of whether "On" or "Off" set for individual items, this setting prevails)
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4) Set contents of individual items : Default: The maintenance time set in the monitor (recommended by the manufacturer and cannot be changed). : Set: Maintenance time that can be freely set. The maintenance mode program functions based on this maintenance time. (The maintenance time can be increased or decreased by 50 hours with [ ] or [ ] switch) : On: Maintenance display function with this instruction becomes effectual. : Off: Maintenance display with this instruction becomes ineffectual. The lowest maintenance time is 50 h. 5) Set contents of "Use Default Values" When selecting this menu and depressing the switch [ ], all individual time settings are reduced to the initial settings.
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SPECIAL FUNCTION OF MULTI-MONITOR PANEL
20. Function for Phone Number Entry [05] In the display of User Code, a telephone number and Service Code are shown alternately. Phone number can be inputted or modified in the following manner. If there is no Phone number registered, the display for Phone numbers does not appear. 1) Selection of menu Select 05 Phone Number Entry menu in the display of Service Menu, and depress [ ] switch. 2) Changing the display Select Entry next to change the display to the Phone Number Entry display. Even if a Phone number is already inputted, it is deleted, upon switching to the Phone Number Entry display.
3) Entry and setting Phone number Following the method explained below, Entry a Phone number in the Phone Number Entry display. (Entry automatically begins with a cursor at the left end) i) Enter a number into a cursor at the left end with a ten-key. ii) Depress [ ] switch when all the numbers have been entered. Numbers can be entered up to the max. 12 digits, but omit unnecessary digits. When entering a wrong number, depress [B] switch, then the cursor goes back by one digit. When input is finished, the display changes to Entry display shown above. If the inputted Phone number is shown in this display, the input is normal.
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21. Function for /Default [06] It is possible to change the following settings for the monitor panel as well as the machine. Make a change as is required. • Working mode when the engine starting switch is in the ON position. • Display language in Service Menu • Display unit in the monitoring function • With/Without Service Cir. 1) Selection of menu Select 06 "/Default menu" in the initial display of Service Menu, and depress [ ] switch. 2) Selection of submenu Select an item to change from the submenu, and depress [ ] switch. No. 00 01 02 03 04
/Default submenu Return (termination of /Default) Key-on Mode /Language Unit With/Without Service Cir.
3) Function for Key-on Mode When the engine starting switch is turned ON, a working mode can be set that is shown in the monitor panel. • A, E, L and B Modes: If any of them is set, the machine always ramps up with that working mode, when turning the engine starting switch ON. • Mode at Previous Key-off: If this mode is set, the machine ramps up with the working mode that was last used in the previous machine operation. • Default Value: If this mode is set, the machine ramps up with the default mode (A mode) that was originally set at the time of delivery from the factory. Irrespective of this setting mode, a machine "With attachment" always ramps up with B mode, when the engine starting switch is turned ON at the subsequent operation, if that was the working mode used in the last machine work.
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4) Function for /Language In Service Menu, the language in use can be changed between Japanese and English. English is used as the language for default setting in the monitor panel. If the monitor panel for spare parts is to be used in a Japanese-speaking region or organization, change the language from English to Japanese, using this function.
5) Function for unit selection As the unit to be used in the monitoring function display of Service Menu, three kinds of unit are provided. Unit used for default setting in the monitor panel is SI, i.e. International System of Units.
6) Function for selecting distinction of With/ Without Service Cir. It is possible in this function to set a distinction between with or without attachment. • With Service Circuit: When an attachment is installed. • Without Service Circuit: When no attachment is installed. If "With Service Circuit" setting is not made in this display, while it is actually installed on a specific machine, SELECT function in Operator's Mode (attachment oil flow rate adjustment) cannot be utilized.
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22. Function for Adjustment [07] The monitor panel has a function of making various adjustments of the machine. 1) Selection of menu Select 07 adjustment in the initial display of Service Menu, and depress [ ] switch.
2) Selection of submenu Select an item to change from the submenu and depress [ ] switch. No. 00 01 02 03 04
Adjustment submenu Return (termination of adjustment) Governor Motor Adjustment Pump Absorption Torque Low Idle Speed Service Current Adjust.
3) Function for Governor Stroke Adjustment a If the governor actuator, fuel injection pump, or governor spring is removed and installed or the high idling speed is low or the engine speed is unstable, adjust the governor lever stroke according to the following procedure. i) Call the display of governor lever stroke adjustment and set the fuel dial at MAX. a Under this condition, the governor actuator lever moves to the FULL position. Keep this display until adjustment is finished. a The engine speed is indicated in 10 rpm at the center of the display. a The turning direction of the governor spring when the fuel injection pump is seen from the governor actuator is indicated.
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TESTING AND ADJUSTING
ii) iii)
iv)
v)
vi)
vii)
Loosen locknuts (2) of rod (1). a Locknut (2) has left-hand threads. Turn rod (1) counterclockwise to increase installed length (a) of governor spring (3) and return governor lever (4) of the fuel injection pump to a position at which it will not touch the full stop. a Take care that the outer cylinder of governor spring (3) will not be dragged and the water drain hole will not be moved from the bottom. Turn rod (1) clockwise to decrease installed length (a) of governor spring (3). If governor lever (4) touches the full stop, stop turning the rod. • Standard installed length (a): 261.75 mm (Reference) Turn rod (1) 3 more turns to compress the spring in governor spring (3). a Since the internal spring is compressed, only the outside cylinder of governor spring (3) moves about 3.75 mm toward the governor actuator (The installed length does not change). Fixing rod (1), tighten locknuts (2). a Before tightening the locknuts, check that the water drain hole of the governor spring is directed down. 3 Nut: 11.8 – 19.6 Nm {1.2 – 2.0 kgm} Return the fuel control dial to the MIN position, and then turn it toward the MAX side gradually. At this time, check that governor spring (3) is lengthened about 3.75 mm after governor lever (4) touches the full stop.
20-163-1 (7)
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
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TESTING AND ADJUSTING
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
4) Function for Pump Absorption Torque adjustment The pump absorption torque can be adjusted within the range shown in the table below. Adjustment value Torque adjustment value 220 +4.0 kgm 221 +3.0 kgm 222 +2.0 kgm 223 +1.0 kgm 224 0.0 kgm 225 –1.0 kgm 226 –2.0 kgm 227 –3.0 kgm 228 –4.0 kgm 5) Function for Low Idle Speed adjustment The engine rotation at low idling can be adjusted within the range shown in the table below. Adjustment value 320 321 322 323
Low idling rotation 900 rpm 1,000 rpm 1,100 rpm 1,200 rpm
6) Function for Service Current Adjust. When a machine is used for a compound operation, distribution of hydraulic pump oil flow can be adjusted within the range shown in the table below. Adjustment value 370 371 372 373
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Distribution of oil flow to attachment 0.5 Time 0.7 Time 1.0 Time 0.4 Time
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SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display special functions
Section to operate special function 1 (Basic operation)
Section to operate special function 2 (Selecting operation and special operation)
1. Display section
3. Caution buzzer stop switch
7. Working mode selector (UP) switch
2. Service meter section
4. Auto-decelerator switch
8. Working mode selector (DOWN) switch
5. Setting switch (Black switch) 6. Travel speed shifting switch
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Ordinary functions and special functions of monitor panel The monitor panel has the ordinary functions and special functions and displays various pieces of information on display section (1) and service meter section (2). Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by operating switches. 1. Ordinary functions: Operator menu The items in this menu are displayed normally or displayed automatically when a trouble occurs. 2. Special functions: Service menu The items in this menu are not displayed normally. Each serviceman can display them by operating special switches. These functions are used for special setting, testing, adjusting, or troubleshooting. Flow of each function
1 Function of displaying service meter O
2 Function of displaying user code
Special functions (Service menu) O
Ordinary functions (Operator menu)
3 Function of displaying service code [01] 4 Monitoring function [02] 5 Function of adjusting governor [03] 6 Function of selecting maintenance period [04] 7 Function of selecting default working mode [05] 8 Function of setting installation of attachment [16] 9
Special function of monitoring replacement of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
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Display of operator menu a Only outline of the operator menu is described in this section. For details of each menu, see OPERATION MANUAL or the volume of STRUCTURE AND FUNCTION.
1. Function of displaying service meter While the machine is used normally, the monitor panel displays the following information. • Display section (1): Nothing is displayed • Service meter section (2): Service meter
2. Function of displaying user code If the machine has any trouble, the corresponding user code is displayed automatically in display section (1) and the caution buzzer is turned ON to urge the operator to take a proper remedy, depending on the degree of the trouble. a Service meter section (2) continues displaying the service meter. a For displayed user codes and the remedies shown to the operator, see "User codes and remedies shown to operator". a Each user code simply shows occurrence of a trouble to the operator. To find out the cause of the trouble, a serviceman must check the service code with the "Function of displaying service code [01]" in the service menu. A user code is displayed only when a serious trouble occurs. Even if a user code is not displayed, a trouble may have occurred. If you feel any abnormality, be sure to check for a service code with the "Function of displaying service code [01]" in the service menu. a User codes and remedies shown to operator
User code
Error mode
E02
Error in pump control system
Error in swing E03 brake system E05
Remedy (shown to operator)
Caution buzzer
If the emergency pump drive switch is set in the upper position, the machine can operate normally. Have the machine inspected immediately, however.
q
Set the swing holding brake release switch in the upper position to release the brake. When applying the swing brake, operate the swing lock switch manually. The brake may not be released, depending on the cause of the failure. In this case, have the machine inspected immediately.
q
Error in governor Have the machine inspected immediately. system
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Operation and display of service menu How to select service menu a When using the general functions in the service menu, perform the following switch operation to change the screen of the monitor panel. 3. Function of displaying service code [01] 4. Monitoring function [02] 5. Function of adjusting governor [03] 6. Function of selecting maintenance period [04] 7. Function of selecting default working mode [05] 8. Function of setting installation of attachment [16] 1) Operating switches While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds. 2) Displaying display section and service meter section If the switches are operated as shown above, the first menu No. [01] (Monitoring function) is displayed in service meter section (2). a Nothing is displayed in display section (1). 3) Selecting menu While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a menu you will use. • UP switch (7): Increase Menu No. • DOWN switch (8): Decrease Menu No. Menu No. 01 02 03 04 05 16
Service menu (Excluding special functions) Function of displaying error code Monitoring function Function of adjusting governor Function of selecting maintenance period Function of selecting default working mode Function of setting installation of attachment
4) Executing menu Select a menu you will use and press set switch (5), and the menu is executed. 5) Finishing service menu While holding caution buzzer stop switch (3), hold auto decelerator switch (4) for 2.5 seconds (similarly to the selecting operation). a The service menu is finished and the ordinary screen appears. a The service menu can be also finished by turning the starting switch OFF while the service menu is selected. (In this case, the ordinary screen appears when the starting switch is turned ON again.)
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a To use the following special function, you must operate the switches differently from the above. See details of this function "9. Special function of monitoring replacement of engine oil".
3. Function of displaying service code [01] With this function, you can check the service code of a trouble which is occurring at present or has occurred in the past. 1) Selecting and executing function i) Select menu No. [01] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Information displayed in display section and service meter section 1 (When service code is recorded) If a service code is recorded, the following information is displayed in display section (1) and service meter section (2). (a): Service code (b): Service meter reading increased after trouble occurred (c): Mark [E] to indicate that trouble is occurring at present a Mark [E] to indicate that a trouble is occurring at present indicates that the service code is being detected now. It is not displayed if the trouble has been repaired or the service code is not detected. a For the service codes which the monitor panel and engine throttle and pump controller can detect, see the "Service codes table". 3) Information displayed in display section and service meter section 2 (When service code is not recorded) If a service code is not recorded, display section (1) and service meter section (2) display as shown in the figure. 4) Number of recorded service codes and display order of them This function can record up to 20 service codes, which are displayed in order from the latest one. a If a new trouble occurs while 20 service codes are recorded, the oldest service code is deleted and the service code of the new trouble is recorded.
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5) Change of displayed service codes While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to change the displayed service codes. • UP switch (7): Next service code appears. • DOWN switch (8): Previous service code appears. 6) How to delete service code i) While holding caution buzzer stop switch (3), turn the starting switch OFF and keep holding caution buzzer stop switch (3). ii) Under the above condition, turn the starting switch ON again and hold caution buzzer stop switch (3) for 5 seconds. a A service code having the mark [E] is not deleted.
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Service codes table User code
Service code
Trouble
—
E101
Abnormality in error history data
—
E104
Clogging of air cleaner (Equivalent to error code [AA10NX])
—
E108
Overheating of engine coolant (Equivalent to error code [B@BCNS])
—
E112
Short circuit in wiper motor drive forward system
—
E113
Short circuit in wiper motor drive reverse system
—
E114
Short circuit in windshield washer drive system
—
E115
Trouble in operation of windshield wiper
—
E116
Trouble in storage of windshield wiper
—
E201
Short circuit in travel junction solenoid
E03
E203
Short circuit in swing holding brake solenoid
—
E204
Short circuit in merge-divider solenoid
—
E205
Short circuit in 2-stage relief solenoid
—
E206
Short circuit in travel speed shifting solenoid
—
E211
Disconnection in travel junction solenoid
E03
E213
Disconnection in swing holding brake solenoid
—
E214
Disconnection in merge-divider solenoid
—
E215
Disconnection in 2-stage relief solenoid
—
E216
Disconnection in travel speed shifting solenoid
—
E217
Abnormality in input model code
—
E218
Disconnection in S-NET signal line
—
E222
Short circuit in LS-EPC solenoid
—
E223
Disconnection in LS-EPC solenoid
—
E224
Abnormality in F pump pressure sensor
—
E225
Abnormality in R pump pressure sensor
—
E226
Abnormality in pressure sensor power supply
—
E227
Abnormality in engine speed sensor
—
E228
Short circuit in ATT return selector relay
E02
E232
Short circuit in PC-EPC solenoid
E02
E233
Disconnection in PC-EPC solenoid
—
E238
Disconnection in ATT return selector relay
—
E256
Illegal non-volatile memory data
—
E304
Short circuit in engine stop solenoid relay
—
E306
Abnormality in governor potentiometer
E05
E308
Abnormality in fuel control dials
—
E313
Abnormality in auto grease system (Equivalent to error code [DA80MA])
—
E314
Disconnection in engine stop solenoid relay
—
E315
Short circuit in battery relay output line
—
E316
Abnormality in step-out of governor motor
E05
E317
Disconnection in phases A and B of governor motor
E05
E318
Short circuit in phases A and B of governor motor
a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the section of the corresponding "Error code of mechanical system". a "E" at the head of each service code indicates the following condition. • With E: The trouble has not been repaired. • Without E: The trouble has been repaired.
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4. Monitoring function [02] With this function, you can monitor the revolution speed, oil pressure, current, voltage, input condition, output condition, etc. in real time by the signals from the sensors, switches, and solenoids installed to various parts of the machine. 1) Selecting and executing function i) Select menu No. [02] in the menu selection mode. ii) Press set switch (5) to execute this function. 2) Selecting and executing monitoring code While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select a monitoring code displayed in service meter section (1). • UP switch (7): Increase code No. • DOWN switch (8): Decrease code No. a This function displays monitoring code [001] and its information first. a For the items and code Nos. which you can monitor, see the "Monitoring codes table".
3) Information displayed in display section and service meter section 1 (When numeral code is displayed) If a numeral monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (Value is displayed)
4) Information displayed in display section and service meter section 2 (When 6-bit code is displayed) If a 6-bit monitoring code is selected, the following information is displayed in display section (1) and service meter section (2). (a): Monitoring code (b): Monitoring information (6 pieces of information are displayed in bits) a In the 6-bit display mode, only the top and bottom of the 7-segments mark are used to display. "Solid black" indicates the ON state, and "white on black background" indicates the OFF state. a For the No. of each bit, see the "Monitoring codes table" and the drawing attached to it.
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Monitoring codes table Code
Monitoring item
Unit
002
Engine throttle and pump controller model code
Numeral
003
Engine throttle and pump controller model code
Numeral
010
Engine speed
10 rpm
011
F pump discharge pressure
kg/cm2
012
R pump discharge pressure
kg/cm2
013
PC-EPC solenoid output current
10 mA
015
LS-EPC solenoid output current
10 mA
016
2nd throttle speed
10 rpm
017
(Unused)
019
021
022
023
024
Input condition 1 of switch
Input condition 2 of switch
Input condition 3 of switch
Drive condition of solenoid valve 1
Drive condition of solenoid valve 2
PC300/350(LC)-7
Remarks
— a Swing oil pressure switch (ON)
(6 bit)
b Travel oil pressure switch (ON)
(6 bit)
c Boom LOWER oil pressure switch (ON)
(6 bit)
d Boom RAISE oil pressure switch (ON)
(6 bit)
e Arm IN oil pressure switch (ON)
(6 bit)
f Arm OUT oil pressure switch (ON)
(6 bit)
a Bucket CURL oil pressure switch (ON)
(6 bit)
b Bucket DUMP oil pressure switch (ON)
(6 bit)
c (Unused)
(6 bit)
d Service oil pressure switch (ON)
(6 bit)
e Travel differential pressure switch
(6 bit)
f (Unused)
(6 bit)
a (Unused)
(6 bit)
b (Unused)
(6 bit)
c One-touch power maximizing switch (ON)
(6 bit)
d Swing holding brake release switch (RELEASE)
(6 bit)
e Swing lock switch (LOCK)
(6 bit)
f (Unused)
(6 bit)
a (Unused)
(6 bit)
b Travel junction solenoid (ON)
(6 bit)
c Swing holding brake solenoid (ON)
(6 bit)
d Merge-divider solenoid (ON)
(6 bit)
e 2-stage relief solenoid (ON)
(6 bit)
f Travel speed shifting solenoid (ON)
(6 bit)
a (Unused)
(6 bit)
b (Unused)
(6 bit)
c (Unused)
(6 bit)
d ATT return selector relay (ON)
(6 bit)
e (Unused)
(6 bit)
f (Unused)
(6 bit)
20-173 (5)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Code
027
Monitoring item
Input condition of model selection signal
Unit
a Model selection 1 (Connected to ground)
(6 bit)
b Model selection 2 (Connected to ground)
(6 bit)
c Model selection 3 (Connected to ground)
(6 bit)
d Model selection 4 (Connected to ground)
(6 bit)
e Model selection 5 (Connected to ground)
(6 bit)
f Kerosene mode (Connected to ground)
(6 bit)
030
Fuel control dial input voltage
10 mV
031
Governor potentiometer input voltage
10 mV
032
Controller power source voltage
100 mV
033
Governor motor phase A output current
10 mA
034
Governor motor phase B output current
10 mA
035
Battery relay BR output voltage
100 mV
036
037
Input condition of signal
Output condition of signal
a (Unused)
(6 bit)
b (Unused)
(6 bit)
c (Unused)
(6 bit)
d (Unused)
(6 bit)
e Starting switch signal C (START)
(6 bit)
f (Unused)
(6 bit)
a Battery relay (DRIVEN)
(6 bit)
b (Unused)
(6 bit)
c Engine stop solenoid relay (DRIVEN)
(6 bit)
d (Unused)
(6 bit)
e (Unused)
(6 bit)
f (Unused)
(6 bit)
041
Engine coolant sensor input voltage
10 mV
042
Fuel level sensor input voltage
10 mV
043
Alternator input voltage
100 mV
044
Hydraulic oil temperature sensor input voltage
10 mV
045
046
Input condition of switch 4
Input condition of sensor
20-174 (5)
a Starting switch signal ACC (ON)
(6 bit)
b Starting switch signal C (START)
(6 bit)
c Starting switch signal R1 (HEAT)
(6 bit)
d Lamp switch (ON)
(6 bit)
e Radiator coolant level switch (OPEN)
(6 bit)
f (Unused)
(6 bit)
a Air cleaner clogging switch (OPEN)
(6 bit)
b (Unused)
(6 bit)
c Engine oil pressure switch (OPEN)
(6 bit)
d Engine oil level switch (OPEN)
(6 bit)
e (Unused)
(6 bit)
f Alternator (Normal generation)
(6 bit)
Remarks
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Code
049
Monitoring item
Input condition of switch 5
Unit
a Swing lock switch (LOCK)
(6 bit)
b Caution buzzer stop switch (ON)
(6 bit)
c Windows limit switch (ON)
(6 bit)
d Wiper contact W (ON)
(6 bit)
e Wiper contact P (ON)
(6 bit)
f (Unused)
(6 bit)
200
Monitor panel program version
Numeral
201
Engine throttle and pump controller program version
Numeral
Remarks
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or (d) and (e) light up.
Display of numeral code
PC300/350(LC)-7
Display of 6-bit code
20-175 (5)
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
5. Function of adjusting governor [03] This function is used to adjust the governor lever stroke after the governor actuator, fuel injection pump, or governor spring is removed and installed or replaced, or when the high idling speed is low or engine speed is not stabilized. 1) Selecting and executing function i) Select menu No. [03] in the menu selection mode. ii) Press set switch (5) to execute this function.
2) Condition of governor motor If this function is executed, all the governor control functions are cancelled, and then the operating angle of the governor actuator follows up only the operation signal of the fuel control dial. a While this function is executed, [GOV] is displayed in display section (1) and [gSET] is displayed in service meter section (2).
3) Adjusting governor lever stroke i) Keep the fuel control dial to the MAX position. ii) Loosen nuts (2) and (3) of governor spring (1). a Nut (2) is left-handed. iii) Turn and adjust rod (5) so that governor lever (4) of the fuel injection pump will touch the full stopper. iv) Tighten rod (5) a little less than 1 turn to compress governor spring (1) by 2.0 mm. a At this time, distance (a) between the pins does not change but the spring in the governor spring is compressed. v) Tighten nuts (2) and (3). 3 Nut: 11.8 – 19.6 Nm {1.2 – 2.0 kgm} vi) Return the fuel control dial to the MIN position, and then turn it again slowly toward the MAX position. At this time, check that governor spring (1) expands by about 2.0 mm after it reaches the full stopper.
20-176 (5)
PC300/350(LC)-7
TESTING AND ADJUSTING
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
6. Function of selecting maintenance period [04] With this function, you can adjust the maintenance period of the engine oil for the function of the engine oil replacement monitor. 1) Selecting and executing function i) Select menu No. [04] in the menu selection mode. ii) Press set switch (5) to execute this function.
2) Selecting maintenance period The current display mode or maintenance period is displayed in service meter section (2). Press set switch (5) to select a maintenance period. a Nothing is displayed in display section (1). a Each time the set switch is pressed, the display mode or maintenance period changes in the following order. Display
Display mode/ Maintenance period
0
Maintenance function is reset.
125
125-hour interval
250
250-hour interval
500
500-hour interval
d
Demonstration mode
3) Settling maintenance period The display or maintenance period becomes effective when it is selected. Accordingly, perform the ordinary finishing operation. a For the method of displaying the engine oil replacement monitor, method of checking the elapsed time after replacement of engine oil, method of clearing the elapsed time, and method of displaying demonstration mode, see "9. Special functions of engine oil replacement monitor".
PC300/350(LC)-7
20-177 (5)
TESTING AND ADJUSTING
7. Function of selecting default working mode [05] With this function, you can freely select the working mode which is set automatically when the starting switch is turned ON (When the machine is delivered, mode A is set). 1) Selecting and executing function i) Select menu No. [05] in the menu selection mode. ii) Press set switch (5) to execute this function.
2) Selecting default working mode The currently set working mode is displayed in service meter section (2). Press working mode selector switches (7) and (8) to select a working mode. • UP switch (7): Next mode is displayed. • DOWN switch (8): Previous mode is displayed. a Nothing is displayed in display section (1). a The working mode changes in the following order: A o E o B 3) Settling default working mode Press set switch (5) to settle the selected working mode.
20-177-1 (5)
PC300/350(LC)-7
TESTING AND ADJUSTING
8. Function of setting installation of attachment [16] With this function, you can set installation of attachment. a When an attachment is installed, if INSTALLED is not set with this function, the Bmode function (automatic single/double operation selecting function) cannot be used. 1) Selecting and executing function i) Select menu No. [16] in the menu selection mode. ii) Press set switch (5) to execute this function. a While this function is executed, [16SET] is displayed in the service meter section (2) and [0] or [1] is displayed in display section (1). 2) Selecting installation of attachment i) The current setting is displayed in service meter section (1). Check the actual installation of attachment and setting. • [0]: Attachment is not installed. • [1]: Attachment is installed. ii) While holding caution buzzer stop switch (3), operate working mode selector switches (7) and (8) to select [0] or [1]. • UP switch (7): [1] is selected. • DOWN switch (8): [0] is selected. 3) Settling installation of attachment Press set switch (5) to settle the selected setting of installation of attachment.
PC300/350(LC)-7
20-177-2 (5)
TESTING AND ADJUSTING
9. Special functions of engine oil replacement monitor 1) Ordinary display of engine oil replacement monitor If the rest of time before the set engine oil replacement time is 10 hours or shorter, engine oil replacement monitor (10) lights up and display the elapsed time in service meter section (2) for 20 seconds each time the starting switch is turned ON. 2) Checking elapsed time To check the elapsed time while engine oil replacement monitor (10) is OFF, turn the starting switch OFF and press set switch (5) and then turn the starting switch ON and keep holding set switch (5). 3) Clearing elapsed time To clear the elapsed time after replacing the engine oil, hold set switch (5) for 3 seconds while the elapsed time is displayed in service meter section (2). a If the above operation is performed, the elapsed time in the monitor panel is set to 0 hours. 4) Function of demonstration mode If the demonstration mode is selected, you can perform demonstration of the oil maintenance function when teaching the operation to a customer. The functions and display of the demonstration mode are as follows. i) The internally set interval is recognized as 250 hours and the elapsed time is recognized as 240 hours. ii) When the starting switch is turned ON after the demonstration mode is set, the ordinary display is repeated up to 3 times (number of the times of turning the starting switch ON). iii) After the demonstration is finished, resetting of maintenance setting [0] is recognized. a When the demonstration is repeated 3 times, resetting of maintenance setting is recognized. If setting is necessary at this time, see "Function of selecting maintenance period".
20-177-3 (5)
PC300/350(LC)-7
TESTING AND ADJUSTING
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 a When diagnosing electric circuits related to the monitor panel and governor pump controller, first open up the connector portions in the following manner.
2. Governor pump controller a The governor pump controller is installed under a cover behind the operator's seat. 1) Remove three caps (1) and then three securing bolts. a When removing the caps, use of a thin flat-head screw driver is recommended. 2) Take off cover (2).
1. Monitor panel 1) Take off cover (1). a The cover is fixed with two upper and lower clips. Pull it up for the removal. a If a sunlight sensor is equipped for an air conditioner, detach P15 connector at the cover rear side.
2) Remove three securing screws and take monitor panel (2) off the mount. a Be careful not to let fall the securing screws inside the console. 3) Insert or connect a T-adaptor for diagnosis with P01, P02 and P70 (multi-monitor only) connectors.
20-178 (7)
3) Insert or connect a T-adapter for diagnosis with C01, C02 and C03 connectors of governor pump controller (3). a The connectors are fixed with screws. Loosen the screws and detach the connectors. a When putting the connectors back into position, tighten them to the specified torque. 3 Screw: 2.82 Nm{0.288 kgm}
PC300/350(LC)-7
TESTING AND ADJUSTING
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up a When diagnosing electric circuits related to the monitor panel and governor pump controller, first open up the connector portions in the following manner.
2. Governor pump controller a The governor pump controller is installed under a cover behind the operator's seat. 1) Remove three bolts and then cover (5).
1. Monitor panel 1) Take off cover (1). a The cover is fixed with two upper and lower clips. Pull it up for the removal. a If a sunlight sensor is equipped for an air conditioner, detach P15 connector at the cover rear side.
2) Insert or connect a T-adapter for diagnosis with C01, C02 and C03 connectors of governor pump controller (6). a The connectors are fixed with screws. Loosen the screws and detach the connectors. a When putting the connectors back into position, tighten them to the specified torque. 3 Screw: 2.82 Nm {0.288 kgm} 2) Remove three securing screws and take monitor panel (2) off the mount. a Be careful not to let fall the securing screws inside the console. 3) Insert or connect a T-adaptor for diagnosis with P01, P02 and P70 (multi-monitor only) connectors.
PC300/350(LC)-7
20-178-1 (7)
PC300/350(LC)-7
20-179
20-180
PC300/350(LC)-7
Engine
Hydraulic system
PC300/350(LC)-7
20-181
Full
Low
Full
Fuel dial
A
Full
Fuel dial
E ( L)
Boom and arm held level
Boom held level Bucket DIGGING
Arm DIGGING
Fully extended
1
No.
Engine stop
Fuel dial
Swing (5 turns)
Boom and arm held level, Bucket loaded
Hydraulic drift amount at bucket tooth tip (15 min.)
Hydraulic oil temperature (45 – 55oC) Condition setting Measurement item Working mode Work equipment posture
3. Work equipment hydraulic drift amount
7
mm
Unit
Sec.
Unit
All control levers in NEUTRAL
Arm (extended) relief
Right Left Right Lo Left A Right Track shoe raised Travel ( Mi) 8 at one side Left (5 turns) Right Hi Left : The "Mi" and "L" modes are on the multi-monitor specification machine only.
1 2 3 4 5 6
No.
OFF
ON
All control levers in NEUTRAL
Operating travel control lever (Do not travel machine)
Hydraulic oil temperature (45 – 55oC) Condition setting Working Work equipment posture Measurement item mode Boom RAISE No load, fully extended Arm DUMPING A
ON
OFF
OFF
rpm MPa{kg/cm2} rpm MPa{kg/cm2} rpm kPa{mmH2O} rpm
Engine rotation Engine oil pressure Engine rotation Engine oil pressure Engine rotation Blow-by pressure Engine rotation
2,090 – 2,230 0.36 – 0.61{3.5– 6.0} 850 – 925 Min. 0.10{Min. 1.0} 1,770 – 1,970 Max. 1.0{Max. 100} 1,300 – 1,500
New machine — 0.18{1.8} — 0.07{0.7} — 2.0{200} —
Failure judgement
Standard value
Implemented on:
PC300: 28.0 – 39.0 PC300LC: 32.0 – 41.5 PC300: 31.5 – 48.5 PC300LC: 34.0 – 51.5 PC300: 42.0 – 70.0 PC300LC: 45.0 – 74.5
PC300: 30.0 – 34.0 PC300LC: 32.0 – 36.0 PC300: 33.5 – 44.5 PC300LC: 35.5 – 47.5 PC300: 44.0 – 66.0 PC300LC: 46.5 – 69.5
PC350: 33.5 – 44.5 PC350LC: 35.5 – 47.5 PC350: 44.0 – 66.0 PC350LC: 46.5 – 69.5
PC350: 30.0 – 34.0 PC350LC: 32.0 – 36.0
28.7 – 34.5
3.4 – 4.2 2.7 – 3.5 3.4 – 4.2 3.5 – 4.5 4.4 – 5.4 2.9 – 3.5
PC350: 31.5 – 48.5 PC350LC: 34.0 – 51.5 PC350: 42.0 – 70.0 PC350LC: 45.0 – 74.5
PC350: 28.0 – 39.0 PC350LC: 32.0 – 41.5
Max. 30
Max. 4.6 Max. 3.7 Max. 4.5 Max. 4.8 Max. 5.7 Max. 3.8
450
Max. 675
550
Max. 825
Standard value PC350, 350LC-7 PC300, 300LC-7 Failure judgement New model Failure judgement New model
Max. 30
Max. 4.5 Max. 3.5 Max. 4.5 Max. 4.9 Max. 5.7 Max. 3.8
28.7 – 34.5
3.3 – 4.1 2.6 – 3.2 3.4 – 4.2 3.6 – 4.6 4.4 – 5.4 2.9 – 3.5
Standard value PC350, 350LC-7 PC300, 300LC-7 New model Failure judgement New model Failure judgement
Unit
Client user's name
Measurement item
Service meter reading
Work equipment operation
Serial No.
Condition setting Working Auto One-touch pomode decelerator wer max. switch
2. Work equipment speed
1 2 3 4 5 6 7
No.
1. Engine
Model
Measured value
Measured value
Measured value
Good / No good
Judgement
Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good
Judgement
Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good Good / No good
Judgement
Inspected by:
20-182
PC300/350(LC)-7
Part to be checked
Servo
Part to be checked
PC-EPC valve
6
No.
7
No.
8
Full
Full
Low
Fuel dial
Full
Fuel dial
Full
Fuel dial
(
(
A
B
E
A
L)
L)
Working mode
A
Working mode
A
Working mode
: The "L" mode is on the multi-monitor specification machine only
LS-EPC valve
Main relief valve, Travel safety valve, Travel interlocking valve
5
9
Swing safety valve
4
Self-decompression valve Main relief valve (When power increased)
Part to be checked
LS valve (LS differential pressure valve)
3
2
1
No.
4. Inspection of hydraulic circuit
Condition setting
OFF
Condition setting
OFF
Left reverse
Left forward
Right reverse
Right forward
Left relief
Right relief
Left
Right
Arm dumping relief
Work equipment operation
Track shoe locked
Swing lock switch ON
Travel without load, engine at Hi idling and control lever at half stroke
Neutral
Arm dumping relief
Work equipment operation
OFF
OFF
OFF
OFF
Right lever at halfway position Left lever at halfway position Right lever at halfway position Left lever at halfway position
Neutral Neutral
Neutral
➀
➁
➀ F main pump
600 kg/cm2
R main pump
600 kg/cm2
➁
R main pump
600 kg/cm2
600 kg/cm2 F main pump
➁
R main pump
600 kg/cm2
➀
F main pump
600 kg/cm2
Do not travel the machine.
Arm IN relief
Arm dumping relief
Neutral
Neutral
AutoOne-touch po- Work equipment Travel lever decelerator wer max. switch operation
OFF
AutoOne-touch podecelerator wer max. switch
OFF
ON
OFF
Auto-dece- One-touch polerator wer max. switch
Condition setting
➂
➃
➄
➄
Control circuit pressure
60 kg/cm2
600 kg/cm2
60 kg/cm2
➂” PC EPC
60 kg/cm2
Remarks
LS EPC
60 kg/cm2
➃”
Control circuit pressure
60 kg/cm2
➄
When one pump relieved: 1.5 MPa {15 kg/cm2}
At neutral: 2.9 MPa {30 kg/cm2} When 2 pumps relieved: 0 MPa {0 kg/cm2}
<11> <10>
< 0> <10>
<32>
Remarks
Connection to be changed to hoses ➂ and ➃, and gauge to be replaced with one with 60 K capacity.
Main servo pressure balance ➂ / ➀ = ➃ / ➁ = 3/5
Remarks
38.2 MPa {390 kg/cm2}
30.9 MPa {315 kg/cm2}
Main–LS=2.5 MPa{25.0 kg/cm2} (LS pressure)
Main–LS=2.9 MPa{30 kg/cm2} (LS differential pressure = Unload pressure)
Circuit pressure 3.2 MPa {33 kg/cm2} 34.8 → 37.3 MPa {355 → 380 kg/cm2}
Connection to be changed to hoses ➂ and ➃
➃
R pump LS
600 kg/cm2
circuit F pump servo R pump servo Control pressure
600 kg/cm2
➂
F pump LS
600 kg/cm2
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204 CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236 TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
PC300/350(LC)-7
20-201
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING k k k k k k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release 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. 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. 2. 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? 3. 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. 4) Check the stroke of the control valve spool.
20-202
5) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. 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. 5. 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. 6. 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(LC)-7
TESTING AND ADJUSTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC300/350(LC)-7
20-203
TESTING AND ADJUSTING
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 when handling electric equipment 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. Main failures occurring in wiring harness 1) 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.
2) 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.
20-204
PC300/350(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) 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.
4) 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 short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) 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(LC)-7
20-205
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors and wiring harnesses •
Disconnecting connectors 1) Hold the connectors when disconnecting. 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. 2) 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.
3) 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. If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206
PC300/350(LC)-7
TESTING AND ADJUSTING
•
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Connecting connectors 1) Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective 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. 2) 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. 3) 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 easily, remove the clamp and adjust the position. 4) If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
•
Connecting connectors (DT type connector) Since the DT 8-pole and 12-pole DT type connectors have 2 latches respectively, push them in until they click 2 times. 1. Male connector, 2. Female connector • Normal locking state (Horizontal): a, b, d • Incomplete locking state (Diagonal): c
PC300/350(LC)-7
20-207
TESTING AND ADJUSTING
•
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. 1) 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. 2) Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. ★ 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.
3) 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 reassemble.
20-208
PC300/350(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box 1) 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. 2) Do not open the cover of the control box unless necessary.
3) Do not place objects on top of the control box. 4) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 5) During rainy weather, do not leave the control box in a place where it is exposed to rain.
6) 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). 7) 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) Always turn the power OFF before disconnecting or connect connectors. 2) 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. 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(LC)-7
20-209
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic equipment 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. 1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2) 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.
4) 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.
20-210
PC300/350(LC)-7
TESTING AND ADJUSTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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. (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. 6) 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.
7) Cleaning operations After repairing the hydraulic equipment (pump, c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he 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 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
PC300/350(LC)-7
20-211
TESTING AND ADJUSTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Electrics, electrical equipment
Hydraulic, Electrical mechanical equipment equipment
Lubricating oil, coolant
Item
Judgement value
Action
— — — — — — — — — —
Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace Replace Add oil
1. Check for looseness, corrosion of battery terminal, wiring 2. Check for looseness, corrosion of alternator terminal, wiring 3. Check for looseness, corrosion of starting motor terminal, wiring
— — —
Tighten or replace Tighten or replace Tighten or replace
1. Check for abnormal noise, smell 2. Check for oil leakage 3. Carry out air bleeding
— — —
Repair Repair Bleed air
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Check fuel level, type of fuel Check for impurities in fuel Check hydraulic oil level Check hydraulic oil strainer Check swing machinery oil level Check engine oil level (oil pan oil level) Check coolant level Check dust indicator for clogging Check hydraulic filter Check final drive oil level
20 – 30V Check battery voltage (engine stopped) — Check battery electrolyte level — Check for discolored, burnt, exposed wiring — Check for missing wiring clamps, hanging wiring — Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) — 6. Check for blown, corroded fuses 7. Check alternator voltage (engine running at 1/2 throttle or above) After running for several minutes : 27.5 – 29.5V — 8. Check operating sound of battery relay (when switch is turned ON/OFF) 1. 2. 3. 4. 5.
20-212
Replace Add or replace Replace Repair Disconnect connector and dry Replace Replace
Replace
PC300/350(LC)-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING Classification of troubleshooting Mode
Content
Code display
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical system) are displayed.
E mode
Troubleshooting of electrical system
H mode
Troubleshooting of hydraulic and mechanical systems
S mode
Troubleshooting of engine assembly
Steps for troubleshooting If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed to the explanations for diagnosis. 1. Troubleshooting steps when calling User Code display in the monitor panel In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Service Code for the electrical system, carry out the troubleshooting along the corresponding code display. 2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code is recorded in the failure history: If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical system Failure Code, using the failure history function of the monitor panel. ★ If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to check if the same abnormality still persists. ★ Failure Code in the mechanical system cannot be deleted. 3. Troubleshooting steps without User Code display and no failure history is available If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC300/350(LC)-7
20-213 (7)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Failure-looking Phenomenon and Troubleshooting No. Troubleshooting No.
Failure-looking phenomenon
Code display
E mode H mode S mode
Action to be taken concerning Service Code, User Code and Failure Code 1 Display User Code in monitor panel Display Service Code in electrical system after checking failure 2 history 3
Display Failure Code in mechanical system after checking failure history
According to displayed code
Engine-related failure 4
Engine does not start up easily. (It always takes some time to start up the engine)
5 6
Engine does not rotate Engine does not start
7
S-1 E-1
S-2 (1)
Engine rotates, but there is no exhaust gas
S-2 (2)
There is exhaust gas, but engine does not start
S-2 (3)
8 Engine pickup is poor. (Engine does not follow acceleration)
S-3
9 Engine stops while in operation
E-2
10 Engine rotation is irregular. (There is hunting)
E-3
11 Engine is short of output, or lacks power
H-2
S-4 S-5
H-1
S-6
12 Color of exhaust gas is too dark. (Incomplete combustion)
S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue
S-8
14 Premature engine oil contamination
S-9
15 Excessive fuel consumption
S-10
16
Engine cooling water is mixed with engine oil, spurts out or decreases
S-11
17 Engine oil amount increases. (Water or fuel gets in)
S-13
18 Abnormal noises are heard
S-15
19 Excessive vibrations are caused
S-16
20 Engine does not stop
E-4
21 Auto-decelerator does not work
E-5
22 Engine auto warming-up device does not work
E-6
23 Engine preheater does not work
E-7
H-5
Failure related to work equipment, swing and travel 24
Speeds of all work equipment, travel and swing are slow, or they lack power
25 Engine rotation drops sharply or stalls 26 All work equipment, travel and swing do not move
E-8
H-1
S-6
H-2
S-4
H-3
27 There are abnormal noises from around hydraulic pump
H-4
28 Fine control mode function works poorly, or shows slow response
H-6
20-214 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Failure-looking phenomenon
Code display
E mode H mode S mode
Work equipment-related failure 29 Boom moves slowly or lacks power
E-21, 22
H-7
30 Arm moves slowly or lacks power
E-23, 24
H-8
31 Bucket moves slowly or lacks power
E-25, 26
H-9
32 Work equipment does not move singly
H-10
33 Natural drift of work equipment is too fast
H-11
34 Work equipment time lag is too big
H-12
35
Other work equipment moves, when specific work equipment is relieved
H-13
36 One-touch power max. switch does not work
E-9, 21–26
H-14
Compound operation-related failure 37
In compound operation, work equipment with larger load moves slowly
H-15
38 In swing + boom RAISE operation, boom moves slowly
H-16
39 In swing + travel operation, travel speed drops sharply
H-17
Travel-related failure 40 Machine tends to swerve while in travel
H-18
41 Travel speed is slow 42 Machine is difficult to steer, or lacks power 43 Travel speed cannot be shifted or is slow or fast
E-28
H-19
E-28, 29
H-20
E-28
H-21
44 Track shoe does not move (only on one side)
H-22
Swing-related failure 45 Machine does not swing
E-27
H-23
46 Swing acceleration is poor, or swing speed is slow
H-24
47 Upper structure overruns excessively, when stopping swing
H-25
48 There is a big shock caused when stopping swing
H-26
49 There is abnormal noise generated when stopping swing
H-27
50 Hydraulic drift of swing is large
H-28
Monitor panel-related failure (Operator's Menu: ordinary display) 51 No display appears in monitor panel at all
E-10
52 Part of display is missing in monitor panel
E-11
53 Descriptions on monitor panel do not apply to the machine model
E-12
In startup inspection, radiator water level monitor lamp lights up red ( )
B@BCZK
55 In startup inspection, engine oil level monitor lamp lights up red
B@BAZK
54
: The multi-monitor specification machine only.
PC300/350(LC)-7
20-215 (7)
TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Troubleshooting No.
Failure-looking phenomenon
56 In startup inspection, maintenance hour monitor lamp lights up red 57
Code display
E mode H mode S mode
Refer to Operation and Maintenance Manual
While engine is running, battery charging level monitor lamp lights AB00KE up red
58 While engine is running, fuel level monitor lamp lights up red
E-13
59
While engine is running, air cleaner clogging monitor lamp lights up AA10NX red
60
While engine is running, engine cooling water temperature monitor B@BCNS lamp lights up red
61
While engine is running, hydraulic oil temperature monitor lamp lights up red ( )
B@HANS
62 Engine cooling water temperature gauge does not display correctly
E-14
63 Hydraulic oil temperature gauge does not display correctly ( )
E-15
64 Fuel gauge does not display correctly
E-16
65 Swing lock monitor does not display correctly
E-17
66 When operating monitor switch, no display appears
E-18
67 Windshield wiper does not work
E-19
68 Warning buzzer cannot be stopped
E-20
Monitor panel-related failure (Service Menu: Special Function Display) 69
In monitoring function, "Boom RAISE" cannot be displayed correctly
E-21
70
In monitoring function, "Boom LOWER" cannot be displayed correctly
E-22
71
In monitoring function, "Arm DIGGING" cannot be displayed correctly
E-23
72
In monitoring function, "Arm DUMPING" cannot be displayed correctly
E-24
73
In monitoring function, "Bucket DIGGING" cannot be displayed correctly
E-25
74
In monitoring function, "Bucket DUMPING" cannot be displayed correctly
E-26
75 In monitoring function, "Swing" cannot be displayed correctly
E-27
76 In monitoring function, "Travel" cannot be displayed correctly
E-28
77
In monitoring function, "Travel Differential Pressure" cannot be displayed correctly
78 In monitoring function, "Service" cannot be displayed correctly
E-29 E-30
Other failure 79 Air conditioner does not work
E-31
80 Travel alarm does not sound
E-32
: The multi-monitor specification machine only.
20-216 (7)
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM Connector table PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 Address
Connector No.
Type
No. of pin
A01
X
4
Intermediate connector
T-1
H-6
I-6
A02
X
4
Intermediate connector
T-2
H-6
I-5
A03
D
12
Intermediate connector
N-1
H-6
I-2
A04
SWP
12
Intermediate connector
O-1
A05
SWP
14
Intermediate connector
T-1
H-5
I-7
A06
SWP
14
Intermediate connector
N-1
H-5
I-5
A07
SWP
16
Intermediate connector
S-1
H-4
A09
SWP
8
Intermediate connector
N-2
A10
Terminal
1
Revolving frame grounding
H-1
H-1
A11
Terminal
1
Revolving frame grounding
H-2
I-1
A12
Terminal
1
Revolving frame grounding
H-2
I-1
A13
Terminal
1
Revolving frame grounding
I-2
I-1
A14
Terminal
1
Revolving frame grounding
C-2
I-1
A15
Terminal
1
Revolving frame grounding
I-2
I-1
J-4
A16
Terminal
1
Revolving frame grounding
I-2
I-1
J-4
A20
Terminal
1
Battery relay (E terminal)
C-1
J-5
J-5
A21
Terminal
1
Battery relay (BR terminal)
C-2
J-6
J-5
A22
Terminal
1
Battery relay (M terminal)
C-1
J-5
K-5
A23
Terminal
1
Battery relay (B terminal)
C-2
J-6
K-5
A30
YAZAKI
2
Air conditioner outside air temperature sensor
L-4
A31
D
2
Air cleaner clogging sensor
K-4
K-4
A33
X
2
Radiator water level sensor
K-4
K-5
A34
L
2
Fusible link (65A)
A-5
K-6
K-6
A35
M
2
Fusible link (30A)
A-4
K-6
K-6
A36
M
2
Fusible link (30A)
A-5
A40
AMP
1
Alarm horn (low tone)
H-1
A41
AMP
1
Alarm horn (high tone)
H-1
A42
X
1
Intermediate connector
G-9
A43
X
2
Travel alarm
J-2
A44
M
1
Front right lamp
A-5
20-218 (7)
Name of device
Stereo M G P -gram circuit circuit circuit I-8 I-8 I-7
I-4
I-4 I-3
J-3
J-4
J-6
J-8
K-6
J-7 K-4 K-7
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Address
Connector No.
Type
No. of pin
A50
KES0
2
Window washer monitor (tank)
K-3
A51
D
3
F pump hydraulic oil pressure sensor
J-3
K-5
A52
D
3
R pump hydraulic oil pressure sensor
J-3
K-4
A60
X
1
Fuel level sensor
D-9
K-4
A61
D
2
Hydraulic oil temperature sensor
L-5
K-5
A80
D
8
Intermediate connector
S-1
C01
DRC
24
Governor pump controller
V-9
C02
DRC
40
Governor pump controller
W-9
C03
DRC
40
Governor pump controller
W-9
C09
S
8
Model selection connector
W-6
D01
SWP
8
Assembled type diode
W-7
A-9
D-1
D02
SWP
8
Assembled type diode
W-7
A-8
D-1
D03
SWP
8
Assembled type diode
P-1
D04
SWP
8
Assembled type diode
Q-1
E06
M
3
Fuel dial
O-8
E07
D
2
Engine speed sensor
L-8
E08
D
12
Intermediate connector
K-9
E10
D
3
Fuel shut-off valve
E10
D
3
Governor potentiometer
J-9
K-2
E11
D
4
Governor motor
J-9
K-2
F02
YAZAKI
2
Revolving warning lamp
AA-9
FB1
–
–
Fuse box
W-5
H-9
H08
M
8
Intermediate connector
W-4
J-8
H09
S
8
Intermediate connector
W-4
J-8
H10
S
16
Intermediate connector
T-9
D-6
I-8
H11
S
16
Intermediate connector
S-9
D-5
I-8
H12
S
12
Intermediate connector
S-9
D-5
I-7
H15
S090
20
Intermediate connector
N-7
C-2
G-2
PC300/350(LC)-7
Name of device
Stereo M G P -gram circuit circuit circuit K-5
I-3 A-3 A-3
A-8
A-8
A-7
A-7
A-4
A-4
C-9 G-1 H-1 A-8
I-1 H-1 L-8
J-3
J-3
K-8
K-3
C-4
F-9
B-9 C-2
20-219 (7)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address Connector No.
Type
No. of pin
J01
J
20
Junction connector (black)
W-8
C-9
D-9
C-9
J02
J
20
Junction connector (black)
W-8
D-9
D-9
D-9
J03
J
20
Junction connector (green)
W-8
D-9
E-9
D-9
J04
J
20
Junction connector (green)
W-7
D-9
E-9
E-9
J05
J
20
Junction connector (pink)
W-6
E-9
F-9
E-9
J06
J
20
Junction connector (orange)
W-6
F-9
J07
J
20
Junction connector (orange)
U-9
F-9
J08
J
20
Junction connector (pink)
U-9
K19
M
2
Pump resistor (for driving emergency pump)
U-2
K30
D
3
CAN terminating resistor
S-9
A-2
C-1
K31
D
3
CAN terminating resistor
N-4
A-4
K-7
M02
D
2
Starting motor
L-7
K-3
M07
M
3
Lamp switch
O-8
C-1
M09
M
1
Working lamp (front right)
E-9
K-7
M13
KES0
2
Speaker (right)
AC-8
M19
YAZAKI
2
Cigarette lighter
N-3
M21
PA
9
Radio
U-2
M22
Y090
2
Horn switch
N-7
M23
Y090
2
One-touch power max. switch
T-1
M26
S
12
Air conditioner unit
W-5
M27
SWP
16
Air conditioner unit
W-5
M28
SWP
12
Air conditioner unit
W-4
M29
040
20
Air control panel
W-3
M30
040
16
Air control panel
W-3
M31
M
2
Option power source (2)
U-2
M32
M
2
Option power source (1)
S-9
M33
M
2
Option power source (3)
–
M33
SWP
8
Air conditioner unit
W-4
M34
X
2
Air compressor electromagnetic clutch
W-8
M38
M
2
Machine push-up switch
Q-9
M40
YAZAKI
2
Working lamp
Z-8
K-8
M41
YAZAKI
2
Working lamp (additional)
Y-7
K-8
M42
M
1
Intermediate connector
J-3
J-7
M43
M
1
Working lamp (rear)
–
K-7
M45
D
12
Intermediate connector
U-2
M46
S090
4
RS232C relaying connector
U-9
M71
M
2
Room lamp
Z-8
M72
M
4
DC/AC converter
U-2
M73
KES0
2
Speaker (left)
M79
YAZAKI
2
12V electrical equipment socket
20-220
Name of device
Stereo M G P -gram circuit circuit circuit
G-9 G-9
H-9
H-9
H-9 E-3
B-9
D-2
C-9
AD-8 V-9
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address Connector No.
Type
No. of pin
P01
070
12
Monitor panel
N-6
A-7
K-8
P02
040
20
Monitor panel
N-5
A-6
K-8
P03
M
2
Buzzer canceling switch
P-9
D-1
P05
M
2
Revolving warning lamp switch
W-3
P05
D
2
Engine oil temperature switch
K-9
K-2
P07
D
2
Engine cooling water switch
L-8
K-1
P15
Y050
2
Air conditioner sun light sensor
N-6
P70
040
16
Monitor panel
N-4
A-5
R10
R
5
Lamp relay
O-8
E-1
R11
R
5
Engine starting motor cutting relay (PPC lock)
P-8
E-1
R13
R
5
Engine starting motor cutting relay (personal code)
P-9
F-1
R20
R
5
Attachment circuit switching relay
W-6
R22
R
5
Engine stop solenoid relay
L-8
S01
X
2
Bucket digging oil pressure switch
L-7
K-2
S02
X
2
Boom lowering oil pressure switch
L-7
K-3
S03
X
2
Swing oil pressure switch, left
L-6
K-2
S04
X
2
Arm digging oil pressure switch
L-6
K-3
S05
X
2
Bucket dumping oil pressure switch
L-5
K-2
S06
X
2
Boom raise oil pressure switch
L-5
K-3
S07
X
2
Swing oil pressure switch, right
K-3
K-2
S08
X
2
Arm dumping oil pressure switch
J-3
K-3
S09
X
2
Service oil pressure switch (intermediate connector)
K-3
K-1
S10
X
2
Service oil pressure switch, front
–
K-1
S11
X
2
Service oil pressure switch, rear
–
K-1
S14
M
3
Safety lever lock switch
S-1
S21
Terminal
6
Pump emergency driving switch
R-9
E-2
S22
Terminal
6
Swing and parking brake emergency releasing switch
Q-9
F-2
S23
Terminal
6
Emergency engine starting switch
R-9
S25
S090
16
Intermediate connector
R-9
S30
X
2
Travel hydraulic switch
O-1
A-1
S31
X
2
Travel steering hydraulic switch
O-1
A-1
T05
Terminal
1
Floor frame grounding
W-3
T06
Terminal
1
Radio body grounding
–
T06A
M
1
Intermediate connector
T-2
T11
Terminal
1
Operator's cab grounding
PC300/350(LC)-7
Name of device
Stereo M G P -gram circuit circuit circuit A-9
K-7
C-9 D-1
K-9
F-8
F-1
J-8
AD-3
20-221
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TESTING AND ADJUSTING
Address Connector No.
Type
No. of pin
V01
D
2
PPC hydraulic lock solenoid valve
L-3
K-6
V02
D
2
Travel interlocking solenoid valve
L-3
K-6
V03
D
2
Merge/divide valve solenoid valve
L-2
K-7
V04
D
2
Travel speed solenoid valve
L-2
K-5
V05
D
2
Swing and parking brake solenoid valve
L-2
K-6
V06
D
2
Machine push-up solenoid valve
L-1
K-5
V08
D
2
2-stage relief solenoid valve
L-1
K-6
V12
D
2
Attachment return switching solenoid valve
G-9
K-4
V21
D
2
PC-EPC solenoid valve
V22
D
2
LS-EPC solenoid valve
L-6
K-7
V30
X
2
Attachment oil flow rate adjusting EPC solenoid valve
P-1
A-1
W03
X
2
Rear limit switch (window)
W04
M
6
X05
M
4
Name of device
K-7
AB-9
K-8
Windshield wiper motor
Y-4
B-9
Swing lock switch
Q-9
D-1
Connector No. D or DT
Stereo M G P -gram circuit circuit circuit
C-2
Detailed information Japanese and German makes DT type connector (08192-XXXXX)
L
Product of Yazaki Corporation L type connector (08056-2XXXX)
J
Product of Sumitomo Wiring Systems 090 type splice
M
Product of Yazaki M type connector (08056-0XXXX)
R
Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S
Product of Yazaki S type connector (08056-1XXXX)
X
Product of Yazaki X type connector (08055-0XXXX)
PA
Product of Yazaki PA type connector
SWP
Product of Yazaki SWP type connector (08055-1XXXX)
DRC
Japanese and German makes DRC type connector
040
Product of Japan AMP 040 type connector
070
Product of Japan AMP 070 type connector
Y050
Product of Yazaki 050 type connector
S090
Product of Sumitomo 090 type connector
Y090
Product of Yazaki 090 type connector
YAZAKI KES0
Yazaki-made connector KESO type connector (08027-0XXXX)
Terminal
Round pin type single terminal connector
Terminal
Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
20-222
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up Address
Connector No.
Type
No. of pin
A01
X
4
Intermediate connector
T-1
H-6
I-6
A02
X
4
Intermediate connector
T-1
H-6
I-5
A03
D
12
Intermediate connector
N-2
H-6
I-2
A04
SWP
6
Intermediate connector
O-1
A05
SWP
14
Intermediate connector
T-1
H-5
I-7
A06
SWP
14
Intermediate connector
O-1
H-5
I-5
A07
SWP
16
Intermediate connector
S-1
H-4
A09
SWP
8
Intermediate connector
N-2
A10
Terminal
1
Revolving frame grounding
H-1
H-1
A11
Terminal
1
Revolving frame grounding
H-2
I-1
A12
Terminal
1
Revolving frame grounding
H-2
I-1
A13
Terminal
1
Revolving frame grounding
I-2
I-1
A14
Terminal
1
Revolving frame grounding
C-2
I-1
A15
Terminal
1
Revolving frame grounding
I-2
I-1
J-4
A16
Terminal
1
Revolving frame grounding
I-2
I-1
J-4
A20
Terminal
1
Battery relay (E terminal)
C-1
J-5
J-5
A21
Terminal
1
Battery relay (BR terminal)
C-2
J-6
J-5
A22
Terminal
1
Battery relay (M terminal)
C-1
J-5
K-5
A23
Terminal
1
Battery relay (B terminal)
C-2
J-6
K-5
A31
D
2
Air cleaner clogging sensor
K-4
K-4
A33
X
2
Radiator water level sensor
K-4
K-5
A34
L
2
Fusible link (65A)
A-5
K-6
K-6
A35
M
2
Fusible link (30A)
A-4
K-6
K-6
A36
M
2
Fusible link (30A)
A-5
A40
AMP
1
Alarm horn (low tone)
H-1
A41
AMP
1
Alarm horn (high tone)
H-1
A42
D
1
Intermediate connector
G-9
A43
X
2
Travel alarm
J-2
A44
M
1
Front right lamp
A-5
PC300/350(LC)-7
Name of device
Stereo M G P -gram circuit circuit circuit I-8 I-8 I-7
I-4
I-4 I-3
J-3
J-4
J-6
J-8
K-6
J-7 K-4 K-7
20-222-1 (7)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Address
Connector No.
Type
No. of pin
A50
KES0
2
Window washer monitor (tank)
K-3
A51
D
3
F pump hydraulic oil pressure sensor
J-3
K-5
A52
D
3
R pump hydraulic oil pressure sensor
J-3
K-4
A60
X
1
Fuel level sensor
D-9
K-4
A61
D
2
Hydraulic oil temperature sensor
L-5
K-5
A70
D
3
Boom cylinder bottom pressure sensor (Overload alarm)
G-1
A80
D
4
Intermediate connector
S-1
C01
DRC
24
Governor pump controller
U-9
C02
DRC
40
Governor pump controller
U-9
C03
DRC
40
Governor pump controller
V-9
C09
S
8
Model selection connector
W-9
D01
SWP
8
Assembled type diode
W-7
A-9
D-1
D02
SWP
8
Assembled type diode
W-5
A-8
D-1
D04
SWP
8
Assembled type diode
W-5
A-8
E06
M
3
Fuel dial
O-7
E07
D
2
Engine speed sensor
L-8
E08
D
12
Intermediate connector
K-9
E10
D
3
Fuel shut-off valve
E10
D
3
Governor potentiometer
J-9
K-2
E11
D
4
Governor motor
J-9
K-2
F02
YAZAKI
2
Revolving warning lamp
FB1
–
–
Fuse box
V-2
H-9
H08
M
8
Intermediate connector
W-6
J-8
H09
S
8
Intermediate connector
W-6
J-8
H10
S
16
Intermediate connector
T-9
D-6
I-8
H11
S
16
Intermediate connector
S-9
D-5
I-8
H12
S
12
Intermediate connector
S-9
D-5
I-7
H15
S090
20
Intermediate connector
N-7
C-2
G-2
20-222-2 (7)
Name of device
Stereo M G P -gram circuit circuit circuit K-5
I-3 A-3 A-3
A-8
A-8
A-7
A-7
A-4
A-4
C-9 G-1 I-1 H-1 L-8 J-3
J-3
K-8
K-3
AA-9 C-4
F-9
B-9 C-2
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Address
Connector No.
Type
No. of pin
J01
J
20
Junction connector (black)
T-9
C-9
D-9
C-9
J02
J
20
Junction connector (black)
T-9
D-9
D-9
D-9
J03
J
20
Junction connector (green)
U-9
D-9
E-9
D-9
J04
J
20
Junction connector (green)
V-2
D-9
E-9
E-9
J05
J
20
Junction connector (pink)
V-3
E-9
F-9
E-9
J06
J
20
Junction connector (orange)
V-3
F-9
J07
J
20
Junction connector (orange)
W-5
F-9
J08
J
20
Junction connector (pink)
W-5
K19
M
2
Pump resistor (for driving emergency pump)
W-5
K30
D
3
CAN terminating resistor
K31
D
3
CAN terminating resistor
M02
D
2
M07
M
M09
Name of device
Stereo M G P -gram circuit circuit circuit
G-9 G-9
H-9
H-9
H-9 E-3
A-2
C-1
N-4
A-4
K-7
Starting motor
L-7
K-3
3
Lamp switch
P-8
C-1
M
1
Working lamp (front right)
E-9
K-7
M13
KES0
2
Speaker (right)
AC-8
M19
YAZAKI
2
Cigarette lighter
N-3
M21
PA
9
Radio
U-2
M22
Y090
2
Horn switch
O-7
M23
Y090
2
One-touch power max. switch
T-1
M26
S
12
Air conditioner unit
W-4
B-9
M27
Y090
18
Air conditioner unit
W-4
M29
040
20
Air control panel
U-2
M30
040
16
Air control panel
U-2
M31
M
2
Option power source (2)
W-7
M32
M
2
Option power source (1)
W-6
M33
M
2
Option power source (3)
V-9
M33
SUMITOMO
4
Air conditioner unit
W-4
M34
X
2
Air compressor electromagnetic clutch
M38
M
2
Machine push-up switch
Q-8
M40
YAZAKI
2
Working lamp
Z-8
K-8
M41
YAZAKI
2
Working lamp (additional)
Y-7
K-8
M42
M
1
Intermediate connector
J-3
J-7
M43
M
1
Working lamp (rear)
–
K-7
M45
D
12
Intermediate connector
W-7
M46
S090
4
RS232C relaying connector
V-9
M71
M
2
Room lamp
Z-8
M72
M
4
DC/AC converter
U-2
M73
KES0
2
Speaker (left)
M79
YAZAKI
2
12V electrical equipment socket
PC300/350(LC)-7
D-2
C-9
AD-8 V-9
20-222-3 (7)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Address
Connector No.
Type
No. of pin
P01
070
12
Monitor panel
N-6
A-7
K-8
P02
040
20
Monitor panel
N-5
A-6
K-8
P03
M
2
Buzzer canceling switch
P-8
D-1
P05
M
2
Revolving warning lamp switch
U-2
P05
D
2
Engine oil temperature switch
K-9
K-2
P07
D
2
Engine cooling water switch
L-8
K-1
P15
Y050
2
Air conditioner sun light sensor
N-5
P17
090
2
Air conditioner high-low pressure switch
P70
040
16
Monitor panel
N-5
A-5
R10
R
5
Lamp relay
P-8
E-1
R11
R
5
Engine starting motor cutting relay (PPC lock)
P-8
E-1
R13
R
5
Engine starting motor cutting relay (personal code)
Q-8
F-1
R20
R
5
Attachment circuit switching relay
W-7
R22
R
5
Engine stop solenoid relay
W-6
R30
SUMITOMO
5
Air conditioner blower relay
W-4
R31
AMP
4
Air conditioner compressor relay
W-3
S01
X
2
Bucket digging oil pressure switch
L-7
K-2
S02
X
2
Boom lowering oil pressure switch
L-7
K-3
S03
X
2
Swing oil pressure switch, left
L-6
K-2
S04
X
2
Arm digging oil pressure switch
L-6
K-3
S05
X
2
Bucket dumping oil pressure switch
L-5
K-2
S06
X
2
Boom raise oil pressure switch
L-5
K-3
S07
X
2
Swing oil pressure switch, right
K-3
K-2
S08
X
2
Arm dumping oil pressure switch
J-3
K-3
S09
X
2
Service oil pressure switch (intermediate connector)
K-3
K-1
S10
X
2
Service oil pressure switch, front
–
K-1
S11
X
2
Service oil pressure switch, rear
–
K-1
S14
M
3
Safety lever lock switch
S-1
S21
Terminal
6
Pump emergency driving switch
R-9
E-2
S22
Terminal
6
Swing and parking brake emergency releasing switch
Q-8
F-2
S23
Terminal
6
Emergency engine starting switch
R-9
S25
S090
16
Intermediate connector
R-9
S30
X
2
Travel hydraulic switch
O-1
A-1
S31
X
2
Travel steering hydraulic switch
P-1
A-1
T05
Terminal
1
Floor frame grounding
V-3
T06
Terminal
1
Radio body grounding
S-9
T06A
M
1
Intermediate connector
T-2
T11
Terminal
1
Operator's cab grounding
20-222-4 (7)
Name of device
Stereo M G P -gram circuit circuit circuit A-9
K-7
C-9 D-1
K-9
F-8
F-1
J-8
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
TROUBLESHOOTING
Address
Connector No.
Type
No. of pin
V01
D
2
PPC hydraulic lock solenoid valve
L-3
K-6
V02
D
2
Travel interlocking solenoid valve
L-3
K-6
V03
D
2
Merge/divide valve solenoid valve
L-2
K-7
V04
D
2
Travel speed solenoid valve
L-2
K-5
V05
D
2
Swing and parking brake solenoid valve
L-2
K-6
V06
D
2
Machine push-up solenoid valve
L-1
K-5
V08
D
2
2-stage relief solenoid valve
L-1
K-6
V12
D
2
Attachment return switching solenoid valve
G-9
K-4
V21
D
2
PC-EPC solenoid valve
V22
D
2
LS-EPC solenoid valve
L-6
K-7
V30
X
2
Attachment oil flow rate adjusting EPC solenoid valve
P-1
A-1
W03
X
2
Rear limit switch (window)
W04
M
6
X05
M
4
Name of device
K-7
AB-9
K-8
Windshield wiper motor
Y-4
B-9
Swing lock switch
Q-9
D-1
Connector No. D or DT
Stereo M G P -gram circuit circuit circuit
C-2
Detailed information Japanese and German makes DT type connector (08192-XXXXX)
L
Product of Yazaki Corporation L type connector (08056-2XXXX)
J
Product of Sumitomo Wiring Systems 090 type splice
M
Product of Yazaki M type connector (08056-0XXXX)
R
Product of Ryosei Electro-Circuit Systems PH166-05020 type connector
S
Product of Yazaki S type connector (08056-1XXXX)
X
Product of Yazaki X type connector (08055-0XXXX)
PA
Product of Yazaki PA type connector
SWP
Product of Yazaki SWP type connector (08055-1XXXX)
DRC
Japanese and German makes DRC type connector
040
Product of Japan AMP 040 type connector
070
Product of Japan AMP 070 type connector
Y050
Product of Yazaki 050 type connector
S090
Product of Sumitomo 090 type connector
Y090
Product of Yazaki 090 type connector
YAZAKI KES0
Yazaki-made connector KESO type connector (08027-0XXXX)
Terminal
Round pin type single terminal connector
Terminal
Round terminal
Y090 AMP
PC300/350(LC)-7
Product of Yazaki Y090
type connector
Japan AMP-made connector
20-223 (7)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION STEREOGRAM PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
20-224 (7)
PC300/350(LC)-7
TROUBLESHOOTING
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-225 (7)
TROUBLESHOOTING
20-226
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC300/350(LC)-7
TROUBLESHOOTING
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-227 (7)
TROUBLESHOOTING
20-228
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION STEREOGRAM PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-229-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-229-2 (7)
TROUBLESHOOTING
20-229-3 (7)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC300/350(LC)-7
TROUBLESHOOTING
PC300/350(LC)-7
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
20-229-4 (7)
TROUBLESHOOTING
20-229-5 (7)
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Monitor Panel System Circuit Diagram (M Circuit) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
20-230 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the monitor panel system and engine starting system from the overall electrical circuit diagram.
PC300/350(LC)-7
20-231
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Monitor Panel System Circuit Diagram (M Circuit) PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-231-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the monitor panel system and engine starting system from the overall electrical circuit diagram.
PC300/350(LC)-7
20-231-2 (7)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
20-232 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the governor•pump controller system (power source, governor control, model selection and communication) from the overall electrical circuit diagram.
PC300/350(LC)-7
20-233
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-233-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the governor•pump controller system (power source, governor control, model selection and communication) from the overall electrical circuit diagram.
PC300/350(LC)-7
20-233-2 (7)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
20-234 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC lock system, machine push-up system and backup alarm system from the overall electrical circuit diagram.
PC300/350(LC)-7
20-235 (7)
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-235-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
★ This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC lock system, machine push-up system and backup alarm system from the overall electrical circuit diagram.
PC300/350(LC)-7
20-235-2 (7)
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
X type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08055-00181
Part No.: 08055-00191
799-601-7010
2
799-601-7020
Part No.: 08055-00282
Part No.: 08055-00292
3
799-601-7030
Part No.: 08055-00381
Part No.: 08055-00391
4
799-601-7040
Part No.: 08055-00481
Part No.: 08055-00491
—
Terminal part No.: 79A-222-3370 • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
Terminal part No.: 79A-222-3390 • Electric wire size: 0.85 • Grommet: Black • Q’ty : 20
—
—
Terminal part No.: 79A-222-3380 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20
Terminal part No.: 79A-222-3410 • Electric wire size: 2.0 • Grommet: Red • Q’ty: 20
—
20-236
PC300/350(LC)-7
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector Male (female housing)
Female (male housing)
6
T-adapter Part No.
799-601-7050
Part No.: 08055-10681
Part No.: 08055-10691
8
799-601-7060
Part No.: 08055-10881
Part No.: 08055-10891
12
799-601-7310
Part No.: 08055-11281
Part No.: 08055-11291
14
799-601-7070
Part No.: 08055-11481
PC300/350(LC)-7
Part No.: 08055-11491
20-237
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
SWP type connector
No. of pins
Male (female housing)
Female (male housing)
16
T-adapter Part No.
799-601-7320
Part No.: 08055-11681
Part No.: 08055-11691
—
Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
Terminal part No.: • Electric wire size: 0.85 • Grommet: Black • Q’ty: 20
—
—
Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20
Terminal part No.: • Electric wire size: 1.25 • Grommet: Red • Q’ty: 20
—
20-238
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
1
Part No.: 08056-00171
Part No.: 08056-00181
799-601-7080
2
799-601-7090
Part No.: 08056-00271
Part No.: 08056-00281
3
799-601-7110
Part No.: 08056-00371
Part No.: 08056-00381
4
799-601-7120
Part No.: 08056-00471
Part No.: 08056-00481
6
799-601-7130
Part No.: 08056-00671
Part No.: 08056-00681
8
799-601-7340
Part No.: 08056-00871
PC300/350(LC)-7
Part No.: 08056-00881
20-239 (7)
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
8
799-601-7140
Part No.: 08056-10871
Part No.: 08056-10881
10 (White)
799-601-7150
Part No.: 08056-11071
Part No.: 08056-11081
12 (White)
799-601-7350
Part No.: 08056-11271
Part No.: 08056-11281
16 (White)
799-601-7330
Part No.: 08056-11671
20-240
T-adapter Part No.
Part No.: 08056-11681
PC300/350(LC)-7
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector Male (female housing)
Female (male housing)
10 (Blue)
—
—
—
12 (Blue)
799-601-7160
Part No.: 08056-11272
Part No.: 08056-11282
16 (Blue)
799-601-7170
Part No.: 08056-11672
PC300/350(LC)-7
T-adapter Part No.
Part No.: 08056-11682
20-241
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector
No.of pins
Male (female housing)
Female (male housing)
T-adapter Part No.
7
Body part No.: 79A-222-2640 (Q’ty: 5)
Body part No.: 79A-222-2630 (Q’ty: 5)
—
11
Body part No.: 79A-222-2680 (Q’ty: 5)
Body part No.: 79A-222-2670 (Q’ty: 5)
—
5
799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5)
Body part No.: 79A-222-2610 (Q’ty: 5)
9
799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5)
Body part No.: 79A-222-2650 (Q’ty: 5)
13
799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2)
20-242
Body part No.: 79A-222-2690 (Q’ty: 2)
PC300/350(LC)-7
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MIC type connector Male (female housing)
Female (male housing)
17
T-adapter Part No.
799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2)
Body part No.: 79A-222-2720 (Q’ty: 2)
21
799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2)
Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 (Q’ty: 50)
Terminal part No.: 79A-222-2760 (Q’ty: 50)
PC300/350(LC)-7
—
20-243
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP040 type connector Male (female housing)
Female (male housing)
8
T-adapter Part No.
799-601-7180
—
Housing part No.: 79A-222-3430 (Q’ty: 5)
12
799-601-7190
—
Housing part No.: 79A-222-3440 (Q’ty: 5)
16
799-601-7210
—
Housing part No.: 79A-222-3450 (Q’ty: 5)
20
799-601-7220
—
Housing part No.: 79A-222-3460 (Q’ty: 5)
Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-244
PC300/350(LC)-7
TROUBLESHOOTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
AMP070 type connector Male (female housing)
Female (male housing)
10
799-601-7510
—
Part No.: 7821-92-7330
12
799-601-7520
—
Part No.: 7821-92-7340
14
799-601-7530
—
Part No.: 7821-92-7350
18
799-601-7540
—
Part No.: 7821-92-7360
20
799-601-7550
—
PC300/350(LC)-7
T-adapter Part No.
Part No.: 7821-92-7370
20-245 (8)
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector Male (female housing)
Female (male housing)
2
—
—
No.of pins
—
Connector for PA Male (female housing)
Female (male housing)
9
—
Bendix MS connector Male (female housing)
Female (male housing)
10
T-adapter Part No.
799-601-3460
—
20-246
T-adapter Part No.
—
—
No.of pins
T-adapter Part No.
—
PC300/350(LC)-7
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector Male (female housing)
Female (male housing)
2
T-adapter Part No.
—
Part No.: 08027-10210 (Natural color) 08027-10220 (Black)
Part No.: 08027-10260 (Natural color) 08027-10270 (Black)
3
—
Part No.:08027-10310
Part No.:08027-10360
4
—
Part No.: 08027-10410 (Natural color) 08027-10420 (Black)
Part No.: 08027-10460 (Natural color) 08027-10470 (Black)
6
—
Part No.: 08027-10610 (Natural color) 08027-10620 (Black)
PC300/350(LC)-7
Part No.: 08027-10660 (Natural color) 08027-10670 (Black)
20-247
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
KES 1 (Automobile) connector
No.of pins
Male (female housing)
Female (male housing)
8
T-adapter Part No.
—
Part No.: 08027-10810 (Natural color) 08027-10820 (Black)
No.of pins
Part No.: 08027-10860 (Natural color) 08027-10870 (Black)
Connector for relay (Socket type) Male (female housing)
Female (male housing)
5
799-601-7360
—
—
6
799-601-7370
—
20-248
T-adapter Part No.
—
PC300/350(LC)-7
TESTING AND ADJUSTING
No.of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector Male (female housing)
Female (male housing)
4
—
—
PC300/350(LC)-7
T-adapter Part No.
—
20-249
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9210
18-8 (1)
Part No.: 08191-11201, 08191-11202, 08191-11205, 08191-11206 Pin (female terminal)
Part No.: 08191-14101, 08191-14102, 08191-14105, 08191-14106 Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, 08191-12205, 08191-12206 Pin (male terminal)
Part No.: 08191-13101, 08191-13102, 08191-13105, 08191-13106 Pin (female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202, 08191-21205, 08191-12206 18-14 (2) Pin (female terminal)
Part No.: 08191-24101, 08191-24102, 08191-24105, 08191-24106 Pin (male termial)
799-601-9220
Part No.: 08191-22201, 08191-22202, 08191-22205, 08191-22206
20-250
Part No.: 08191-23101, 08191-23102, 08191-23105, 08191-23106
PC300/350(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9230
18-20 (3)
Part No.:08191-31201, 08191-31202
Part No.:08191-34101, 08191-34102
Pin (female terminal)
Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202
Part No.:08191-33101, 08191-33102
Pin (male terminal)
Pin (female termial)
799-601-9240
18-21 (4)
Part No.:08191-41201, 08191-42202
Part No.:08191-44101, 08191-44102
Pin (female terminal)
Pin (male termial)
799-601-9240
Part No.:08191-42201, 08191-42202
PC300/350(LC)-7
Part No.:08191-43101, 08191-43102
20-251
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9250
24-9 (5)
Part No.:08191-51201, 08191-51202
Part No.:08191-54101, 08191-54102
Pin (female terminal)
Pin (male termial)
799-601-9250
Part No.:08191-52201, 08191-52202
Part No.:08191-53101, 08191-53102
Pin (male terminal)
Pin (female termial)
799-601-9260
Part No.: 08191-61201, 08191-62202, 08191-61205, 08191-62206 24-16 (6) Pin (female terminal)
Part No.: 08191-64101, 08191-64102, 08191-64105, 08191-64106 Pin (male termial)
799-601-9260
Part No.: 08191-62201, 08191-62202, 08191-62205, 08191-62206
20-252
Part No.: 08191-63101, 08191-63102, 08191-63105, 08191-63106
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female termial)
T-adapter Part No.
799-601-9270
24-21 (7)
Part No.: 08191-71201, 08191-71202, 08191-71205, 08191-71206 Pin (female terminal)
Part No.: 08191-74101, 08191-74102, 08191-74105, 08191-74106 Pin (male termial)
799-601-9270
Part No.: 08191-72201, 08191-72202, 08191-72205, 08191-72206 Pin (male terminal)
Part No.: 08191-73101, 08191-73102, 08191-73105, 08191-73106 Pin (female termial)
799-601-9280
Part No.: 08191-81201, 08191-81202 08191-81203, 08191-81204 08191-81205, 08191-80206 24-23 (8) Pin (female terminal)
Part No.: 08191-84101, 08191-84103, 08191-84105,
08191-84102 08191-84104 08191-84106
Pin (male termial)
799-601-9280
Part No.: 08191-82201, 08191-82203, 08191-82205,
PC300/350(LC)-7
08191-82202 08191-82204 08191-82206
Part No.: 08191-83101, 08191-83103, 08191-83105,
08191-83102 08191-83104 08191-83106
20-253 (7)
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] HD30 Series connector
Type (shell size code)
Body (plug)
Body (receptacle)
Pin (male termial)
Pin (female terminal)
T-adapter Part No.
799-601-9290
24-31 (9)
Part No.: 08191-91203, 08191-91204, 08191-91205, 08191-91206 Pin (female terminal)
Part No.: 08191-94103, 08191-94104, 08191-94105, 08191-94106 Pin (male termial)
799-601-9290
Part No.: 08191-92203, 08191-92204, 08191-92205, 08191-92206
20-254
Part No.: 08191-93103, 08191-93104, 08191-93105, 08191-93106
PC300/350(LC)-7
TESTING AND ADJUSTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
799-601-9020
Part No.: 08192-12200 (normal type) 08192-22200 (fine wire type)
Part No.: 08192-12100 (normal type) 08192-22100 (fine wire type)
3
799-601-9030
Part No.: 08192-13200 (normal type) 08192-23200 (fine wire type)
Part No.: 08192-13100 (normal type) 08192-23100 (fine wire type)
4
799-601-9040
Part No.: 08192-14200 (normal type) 08192-24200 (fine wire type)
Part No.: 08192-14100 (normal type) 08192-24100 (fine wire type)
6
799-601-9050
Part No.: 08192-16200 (normal type) 08192-26200 (fine wire type)
PC300/350(LC)-7
Part No.: 08192-16100 (normal type) 08192-26100 (fine wire type)
20-255
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DT Series connector
No.of pins
Body (plug)
Body (receptacle)
T-adapter Part No.
8GR: 8B: 8G: 8BR:
8
799-601-9060 799-601-9070 799-601-9080 799-601-9090
Part No.: 08192-1820
(normal type) Part No.: 08192-1810
(normal type) 08192-2820
(fine wire type) 08192-2810
(fine wire type)
12GR: 12B: 12G: 12BR:
12
799-601-9110 799-601-9120 799-601-9130 799-601-9140
Part No.: 08192-1920
(normal type) Part No.: 08192-1910
(normal type) 08192-2920
(fine wire type) 08192-2910
(fine wire type)
20-256 (7)
PC300/350(LC)-7
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] DTM Series connector
No.of pins
Body (plug)
Body (receptacle)
T-adapter Part No.
799-601-9010
2
Part No.: 08192-02200
Part No.: 08192-02100
[The pin No. is also marked on the connector (electric wire insertion end)] DTHD Series connector
No.of pins
Body (plug)
Body (receptacle)
2
T-adapter Part No.
—
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12) 08192-41200 (Contact size #8) 08192-41100 (Contact size #8) 08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC300/350(LC)-7
20-257
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)] No.of pins
DRC26 Series connector Body (plug)
Body (receptacle)
24
799-601-9360
—
Part No.:7821-93-3110
40 (A)
799-601-9350
—
Part No.:7821-93-3120
40 (B)
799-601-9350
—
20-258 (7)
T-adapter Part No.
Part No.:7821-93-3130
PC300/350(LC)-7
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2600 799-601-3100 799-601-3200 799-601-3300 799-601-3360 799-601-3370 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780 799-601-2790 799-601-2810 799-601-2820 799-601-2830 799-601-2840 799-601-2850 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340
20-260 (7)
Measurement box Measurement box Measurement box Measurement box Plate Plate Plate BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) BENDIX (MS) Case MIC MIC MIC MIC MIC ECONO ECONO ECONO ECONO ECONO DLI DLI DLI Additional cable Case X X X X SWP SWP SWP SWP SWP M M M M M M
Econo-21P Q MS-37P MS-37P Econo-24P For MS box For MS box For MS box 24P 24P 17P 17P 5P 10P 5P 14P 19P 14P
Q Q
Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q
5P 13P 17P 21P 9P 2P 3P 4P 8P 12P 8P 12P 16P 1P 2P 3P 4P 6P 8P 12P 14P 16P 1P 2P 3P 4P 6P 8P
Q Q
Q Q
Q
Q Q Q Q Q Q Q Q Q
Q Q Q
—
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
799-601-2500
★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of Harness Checker Ass'y.
Q
Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q
Q Q Q Q Q
Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q
Q
Q
Q Q Q Q Q
Q Q Q Q Q
Q Q
Q
PC300/350(LC)-7
PC300/350(LC)-7
10P 12P 14P 18P 20P 5P 6P 2P 2P 2P 3P 4P 6P 8P-Gray 8P-Black 8P-Green 8P-Brown 12P-Gray 12P-Black 12P-Green 12P-Brown 18-8 18-14 18-20 18-21 24-9 24-16 24-21 24-23 24-31 For HD30 For DT, HD 40P 24P 2P
Q Q Q Q Q Q Q Q Q Q Q Q Q Q
—
799-601-9300
799-601-9200
799-601-9100
Q Q Q Q
799-601-9000
Q Q Q Q
799-601-8000
Q Q Q Q
799-601-7500
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-7400
8P 10P-White 12P-Blue 16P-Blue 16P-White 12P-White 8P 12P 16P 20P X-2
799-601-7100
S S S S S S AMP040 AMP040 AMP040 AMP040 Short connector Case Case 070 070 070 070 070 Relay connector Relay connector JFC connector DTM DT DT DT DT DT DT DT DT DT DT DT DT HD30 HD30 HD30 HD30 HD24 HD30 HD30 HD30 HD30 Plate Measurement box Case Case DRC26 DRC26 For NE, G sensor For fuel, boost 799-601-9420 press. 799-601-9430 PVC socket
799-601-7000
799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410
799-601-2800
Connector type or No. of pins part name
799-601-2700
Part No.
T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
TROUBLESHOOTING
Q Q Q Q
Q
Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q
Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
Q
3P
Q
2P
Q
20-261 (7)
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304 Service Code in Electrical System E101 (Abnormal data in Error History) ................................................ 20-306 Service Code in Electrical System E112 (Short-circuiting in normal rotation system of windshield wiper motor drive)............................................................................................................... 20-308 Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of windshield wiper motor drive)............................................................................................................... 20-310 Service Code in Electrical System E114 (Short-circuiting in window washer drive system) ...................... 20-312 Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion) ........................................ 20-314 Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) .............................. 20-316 Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) ......................... 20-318 Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid in governor • pump controller system).................................................................................................. 20-320 Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)................................. 20-322 Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)................................. 20-324 Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ..................... 20-326 Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)........................... 20-328 Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)..................... 20-330 Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) .................................. 20-332 Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) .................................. 20-334 Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid)....................... 20-336 Service Code in Electrical System E217 (Abnormality in inputting model code)........................................ 20-338 Service Code in Electrical System E218 Disconnection of S-NET signal) ................................................. 20-340 Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) ........................................ 20-342 Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) ............................. 20-343 Service Code in Electrical System E224 (Abnormality in F pump pressure sensor).................................. 20-344 Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) ................................. 20-346 Service Code in Electrical System E226 (Abnormality in Pressure sensor power source) ........................ 20-348 Service Code in Electrical System E227 (Abnormality in engine rotation sensor in governor • pump controller system).................................................................................................. 20-350 Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ............... 20-351 Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid ........................................ 20-352 Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)............................. 20-354 Service Code in Electrical System E238 (Disconnection in attachment return switching relay) ................ 20-356 Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only)............................................................................................................................... 20-358 Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)............................................................................................................................... 20-359 Service Code in Electrical System E256 (Incorrect nonvolatile memory data) .......................................... 20-360 Service Code in Electrical System E304 (Short circuit of engine stop solenoid relay)............................... 20-362 Service Code in Electrical System E306 (Abnormality in governor potentiometer).................................... 20-364 PC300/350(LC)-7
20-301
TESTING AND ADJUSTING
Service Code in Electrical System E308 (Abnormality in fuel dial)............................................................. 20-366 Service Code in Electrical System E314 (Disconnection of engine stop solenoid relay) ........................... 20-368 Service Code in Electrical System E315 (Short-circuiting in battery relay) ................................................ 20-370 Service Code in Electrical System E316 (Step-out in governor motor) ...................................................... 20-372 Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-374 Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-376 Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-378 Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-378 Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379 Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380 Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382 Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383 Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-384 Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-385 Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302
PC300/350(LC)-7
Defective battery relay
Service code Failure code
E101 E112 E113 E114 E115 E116 E201 E203 E204 E205 E206 E211 E213 E214 E215 E216 E217 E218 E222 E223 E224 E225 E226 E227 E228 E232 E233 E238 E245 E246 E256 E304 E306 E308 E314
DAF0KT DY2DKB DY2EKB DY2CKB DY20KA DY20MA DW91KB DW45KB DWJ0KB DWK0KB DW43KB DW91KA DW45KA DWJ0KA DWK0KA DW43KA DA2SKQ DA2SKA DXE0KB DXE0KA DHPAMA DHPBMA DA25KP DLE2MA D196KB DXA0KB DXA0KA D196KA DXE4KB DXE4KA DA20KT DY45KB DK54KZ DK10KZ DY45KA
20-303-1
(7)
q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
q q q q q q q
q q
q
Lowering of engine oil level
Lowering of engine oil pressure
Defective fuel control of engine
Defective adjustment of governor lever
Defective mechanical system of engine
Defective alternator
Defective air cleaner clogging switch
Defective radiator coolant level switch
Defective engine coolant temperature sensor
Defective engine oil level switch
Defective engine oil pressure switch
Defective engine speed sensor (including adjustment)
Defective engine stop solenoid relay
Defective governor potentiometer
Defective governor motor
Defective fuel control dial
Defective emergency pump drive switch
Defective swing lock switch
Defective windshield washer motor
Defective wiper motor
Defective sensor power supply (5 V)
Defective engine throttle and pump controller
Defective monitor panel
Defective fuse or fusible link
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Error codes, failure codes, and possible causes Possible causes
q q
q q q
q
q q
q
q
q q
q
q
q
PC300/350(LC)-7
q
PC300/350(LC)-7
q
q q
q
q
q
q
q q q q
q q
q q q q
q q
q
q q q q q q q q
q q q q q q q q q q q q q q q q q
Short circuit with power source in wiring harness
Grounding fault in wiring harness
Disconnection in wiring harness
Defective concentrated diodes
Overheating of hydraulic oil
Defective hydraulic oil temperature sensor
R pump pressure sensor
F pump pressure sensor
Defective attachment flow control EPC solenoid
Defective attachment return selector relay
Defective travel speed shifting solenoid
Defective 2-stage relief solenoid
Defective pump merge-divider solenoid
Defective swing holding brake solenoid
Defective travel junction solenoid
Defective LS-EPC Solenoid
Defective PC-EPC Solenoid
Clogging of air cleaner
Lowering of water level in radiator sub tank
Overheating of engine
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Possible causes
q q q q
q q q
q q q q q
q q q q q
q
q q q
q q
q q q q q q q q
q q q q q q q q q
20-303-2
(7)
Service code
20-303-3
(7) Failure code
E315 D110KB q E316 DY10K4 E317 DY10KA E318 DY10KB — 989EKX — A000N1 — A000N2 — (E104) AA10NX — AB00KE — B@BAZG — B@BAZK — (E108) B@BCNS — B@BCZK — B@HANS — (E313) DA80MA q q q q q q q q q q q q q q q q q q q
q q
Lowering of engine oil level
Lowering of engine oil pressure
Defective fuel control of engine
Defective adjustment of governor lever
Defective mechanical system of engine
Defective alternator
Defective air cleaner clogging switch
Defective radiator coolant level switch
Defective engine coolant temperature sensor
Defective engine oil level switch
Defective engine oil pressure switch
Defective engine speed sensor (including adjustment)
Defective engine stop solenoid relay
Defective governor potentiometer
Defective governor motor
Defective fuel control dial
Defective emergency pump drive switch
Defective swing lock switch
Defective windshield washer motor
Defective wiper motor
Defective sensor power supply (5 V)
Defective engine throttle and pump controller
Defective monitor panel
Defective fuse or fusible link
Defective battery relay
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Possible causes
q q
q q
q q q
q q
q
★ Service codes (E104), (E108), and (E313) are displayed in only the 7-segment monitor panel. They are not displayed in the multi-monitor panel.
PC300/350(LC)-7
PC300/350(LC)-7 q
q q q q
Short circuit with power source in wiring harness
Grounding fault in wiring harness
Disconnection in wiring harness
Defective concentrated diodes
Overheating of hydraulic oil
Defective hydraulic oil temperature sensor
R pump pressure sensor
F pump pressure sensor
Defective attachment flow control EPC solenoid
Defective attachment return selector relay
Defective travel speed shifting solenoid
Defective 2-stage relief solenoid
Defective pump merge-divider solenoid
Defective swing holding brake solenoid
Defective travel junction solenoid
Defective LS-EPC Solenoid
Defective PC-EPC Solenoid
Clogging of air cleaner
Lowering of water level in radiator sub tank
Overheating of engine
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Possible causes
q
q q
q q q q q q q q
20-303-4
(7)
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Connection table of fuse box ★ This connection table shows the devices to which each power supply of the fuse box supplies power directly (A switch power supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a device which supplies power while the starting switch is at the OFF position). ★ When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to see if the power is supplied normally. Type of power supply
Fuse No.
Fuse capacity
Destination of power Engine throttle and pump controller (Controller power supply)
1
10A
Emergency pump drive resistor Swing holding brake release switch
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Switch power supply (Fusible link: A34)
Constant power supply (Fusible link: A35)
20-303-5 (7)
Engine throttle and pump controller (Solenoid power supply) 2
20A
Machine push up switch Attachment return switching relay (Coil side and contact side)
3
10A
Work equipment lock switch
4
10A
5
10A
Horn switch
6
10A
(Spare)
7
10A
Rotary lamp switch
8
10A
Light relay (Contact side)
9
10A
10
10A
(Spare)
11
20A
Air conditioner unit
12
20A
13
20A
Light switch
14
10A
Service power supply (M32 connector)
15
10A
16
10A
Radio
17
10A
Monitor panel
18
10A
Starting switch
19
10A
Room lamp
20
10A
(Spare)
Cigarette lighter Windshield washer motor
One-touch power maximizing switch Radio
Starting motor cut-out (Personal code) relay (Coil side) Monitor panel
Travel alarm DC/DC converter
PC300/350(LC)-7
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Problems which occur when solenoid power supply of engine throttle and pump controller is defective ★ The solenoid power supply (FB1-2) of the engine throttle and pump controller is used by the controller to drive the solenoids and relays. ★ Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error codes are displayed simultaneously. • [E211]: Disconnection in travel junction solenoid • [E213]: Disconnection in swing holding brake solenoid • [E214]: Disconnection in pump merge-divider solenoid • [E215]: Disconnection in 2-stage relief solenoid • [E216]: Disconnection in travel speed shifting solenoid • [E223]: Disconnection in LS-EPC solenoid • [E233]: Disconnection in PC-EPC solenoid ★ If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the engine throttle and pump controller. 1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side. 2) Turn the starting switch ON. 3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33). Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins. If the voltage is 20 – 30 V, it is normal. Power supply connector (C03) of engine throttle and pump controller
PC300/350(LC)-7
20-303-6 (7)
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ★ The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. User Code
Service Code
Failure Code
Display in monitor panel
Display in monitor panel
Display in monitor panel
Failure phenomenon
Title of failure phenomenon shown in failure history
Failure content
Failure status as detected by monitor panel or controller
Response from monitor panel or controller
Action taken by the monitor panel or controller to protect an affected system or equipment, when they detect some failure.
Phenomenon occurring on machine
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or controller
Relative information
Information on the failure occurred as well as the troubleshooting Cause
Presumed cause and standard value in normalcy
1
2
Cause that presumably triggered failure in question 3 (The assigned No. is for filing purpose only. It does not stand for any priority)
4
5
20-304
Standard value in normalcy and references for troubleshooting • Standard value in normalcy by which to pass "Good" or "No good" judgement over the presumed cause • Reference for passing the above "Good" or "No Good" judgement • Disconnection There is a faulty contact at the connector or disconnection of wiring harness occurred. • Defective grounding A wiring harness that is not connected with a grounding circuit has a contact with the grounding circuit. • Short-circuiting A wiring harness that is not connected with a 24 V electric circuit has a contact with the electric circuit. 1) Connector No. display method and handling of T-adapter Insert or connect T-adapters in the following manner before starting troubleshooting unless otherwise instructed. • If there is no indication of "male" or "female" in a specific connector No., disconnect the connector and insert the T-adapter into both male and female sides. • If there is an indication of "male" or "female" in a specific connector No., disconnect the connector and connect the T-adepter with only one side of either "male" or "female". 2) Entry sequence of pin No. and handling of circuit tester lead Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the following manner unless otherwise instructed. • Connect the positive (+) lead with the pin No. indicated at the front or the wiring harness. • Connect the negative (–) lead with the pin No. indicated at the front or the wiring harness.
PC300/350(LC)-7
TROUBLESHOOTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
PC300/350(LC)-7
20-305
TROUBLESHOOTING
E101
Service Code in Electrical System E101 (Abnormal data in Error History) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E101
DAF0KT
Failure phenomenon
Abnormal data in the error history (in Monitor Panel system)
Failure content
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or exceeded 36 V.
Response from Monitor Panel
• None in particular
Phenomenon occurring on machine
• A display for information on the failure history (in the electrical system) cannot be called. Cause
1 Fuse No. 17 defective
Presumed cause and standard value in normalcy
2
Fusible link No. A35 defective
Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that the circuit has a grounding fault. (See Cause 4) If the fusible link is blown, there is a big possibility that the circuit has a grounding fault. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting.
Disconnection of wiring harness 3 (Disconnection or connector contact fault)
Resistance value
Above 1 Ω
Wiring harness between FB1-17 inlet and A35 (male)
Resistance value
Above 1 Ω
Wiring harness between A35 (male) nal)
Resistance value
Above 1 Ω
Wiring harness from P01 (female) let
to J07 to FB1-17 out-
and A23 (B termi-
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Resistance value
Above 1 MΩ
Between wiring harness between FB1-17 inlet and A35 (male) and grounding
Resistance value
Above 1 MΩ
Between wiring harness between A35 (male) (B terminal) and grounding
Resistance value
Above 1 MΩ
Between wiring harness between P01 (female) and FB1-17 outlet and grounding
to J07
and A23
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 5 Monitor Panel defective
C03 Between
20-306 (7)
and
Voltage 20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E101
Monitor Panel Power Source Electric Circuit Diagram
PC300/350(LC)-7
20-307 (7)
TROUBLESHOOTING
E101
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E101
DAF0KT
Failure phenomenon
Abnormal data in the error history (in Monitor Panel system)
Failure content
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or exceeded 36 V.
Response from Monitor Panel
• None in particular
Phenomenon occurring on machine
• A display for information on the failure history (in the electrical system) cannot be called. Cause
1 Fuse No. 18 defective
Presumed cause and standard value in normalcy
2
Fusible link No. A35 defective
Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that the circuit has a grounding fault. (See Cause 4) If the fusible link is blown, there is a big possibility that the circuit has a grounding fault. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting.
Disconnection of wiring harness 3 (Disconnection or connector contact fault)
Resistance value
Above 1 Ω
Wiring harness between FB1-18 inlet and A35 (male)
Resistance value
Above 1 Ω
Wiring harness between A35 (male) nal)
Resistance value
Above 1 Ω
Wiring harness from P01 (female) let
to J07 to FB1-18 out-
and A23 (B termi-
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Grounding fault of wiring harness 4 (Contact with grounding circuit)
Resistance value
Above 1 MΩ
Between wiring harness between FB1-18 inlet and A35 (male) and grounding
Resistance value
Above 1 MΩ
Between wiring harness between A35 (male) (B terminal) and grounding
Resistance value
Above 1 MΩ
Between wiring harness between P01 (female) and FB1-18 outlet and grounding
to J07
and A23
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. 5 Monitor Panel defective
C03 Between
20-307-1 (7)
and
Voltage 20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E101
Monitor Panel Power Source Electric Circuit Diagram
PC300/350(LC)-7
20-307-2 (7)
TROUBLESHOOTING
E112
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of windshield wiper motor drive) User Code
Service Code
Failure Code
—
E112
DY2DKB
Failure phenomenon
Short-circuiting in normal rotation system of windshield wiper motor drive (in monitor panel system)
Failure content
• Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from Monitor Panel
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Phenomenon occurring on machine
• The windshield wiper stops moving.
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between Between
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Continuity and resistance value Continued
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) W04 (male) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01
3 Monitor panel defective
20-308
Between
and grounding
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V⇔20 – 30 V (at constant cycle)
PC300/350(LC)-7
TROUBLESHOOTING
E112
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-309 (7)
TROUBLESHOOTING
E113
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of windshield wiper motor drive) User Code
Service Code
Failure Code
—
E113
DY2EKB
Failure phenomenon
Short-circuiting in reverse rotation system of windshield wiper motor drive (in Monitor Panel system)
Failure content
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the windshield wiper was set in motion.
Response from Monitor Panel
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Phenomenon occurring on machine
• The windshield wiper stopped moving.
Presumed cause and standard value in normalcy
Cause Windshield wiper motor defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between Between
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Continuity and resistance value Continued
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Between wiring harness between P01 (female) W04 (male) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01
3 Monitor panel defective
20-310
Between
and grounding
Windshield wiper switch
Voltage
OFF
Below 3 V
ON
Below 3 V⇔20 – 30 V (at constant cycle)
PC300/350(LC)-7
TROUBLESHOOTING
E113
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-311 (7)
TESTING AND ADJUSTING
E114
Service Code in Electrical System E114 (Short-circuiting in window washer drive system) User Code
Service Code
Failure Code
E114
DY2CKB
—
Failure phenomenon
Short-circuiting in window washer drive system (in Monitor Panel system)
Failure content
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was switched ON.
Response from Monitor Panel
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Phenomenon occurring on machine
• The window washer stopped moving.
Presumed cause and standard value in normalcy
Cause Window washer drive 1 motor defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. A50 (male) Between
Short-circuiting of wiring harness 2 (Contact with 24 V circuit)
Resistance value 5 – 20
and
Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. Between wiring harness from P01 (female) to J04 to A50 (female) and grounding, or between wiring harness between P01 (female) and D04 (female) and grounding
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01
3 Monitor panel defective
20-312
Between
and grounding
Window washer switch
Voltage
OFF
20 – 30 V
ON
Below 1 V
PC300/350(LC)-7
TESTING AND ADJUSTING
E114
Monitor Panel Window Washer Motor Electrical Circuit Diagram
PC300/350(LC)-7
20-313
TESTING AND ADJUSTING
E115
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion) User Code
Service Code
Failure Code
—
E115
DY20KA
Failure phenomenon
Abnormal operation of windshield wiper (in Monitor Panel system)
Failure content
• A W signal is not inputted at both ends of movement, when it is in motion.
Response from Monitor Panel
• Power to the windshield wiper motor is turned OFF.
Phenomenon occurring on machine
• The windshield wiper motor does not work.
Relative information
• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Windshield wiper motor 1 defective (Internal disconnection)
W04 (female)
Between
Disconnection of wiring harness 2 (Disconnection or faulty contact with connector)
and
Windshield wiper blade
Resistance value
At upper end of operation range
Below 1
Outside upper end of operation range
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. Wiring harness between P01 (female)
Wiring harness between W04 (male)
and W04 (male)
and grounding
Resistance value
Below 1
Resistance value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the ON position for the troubleshooting. P01 3 Monitor panel defective Between
20-314
and grounding
Windshield wiper blade
Voltage
At upper end of operation range
Below 1 V
Outside upper end of operation range
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E115
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-315 (7)
TROUBLESHOOTING
E116
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) User Code
Service Code
Failure Code
—
E116
DY20MA
Failure phenomenon
Abnormal operation of retracting windshield wiper (in Monitor Panel system)
Failure content
• P signal in the retraction range is not inputted, when the wiper is retracted.
Response from Monitor Panel
• Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted.
Phenomenon occurring on machine
• The windshield wiper cannot be retracted completely.
Relative information
• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation range is inputted or not. (Code No. 049: Monitor Input 3)
Presumed cause and standard value in normalcy
Cause Windshield wiper motor 1 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position for the troubleshooting. W04 (female) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
and
Windshield wiper blade
Resistance value
Retraction range
Below 1 Ω
Operation range
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P01 (female)
Between wiring harness W04 (male)
and W04 (male)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P01
3 Monitor panel defective Between
20-316
and grounding
Windshield wiper blade
Voltage
Retraction range
Below 1V
Operation range
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E116
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-317 (7)
TROUBLESHOOTING
E201
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
E201
DW91KB
—
Failure phenomenon
Short-circuiting in travel interlocking solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the travel interlocking circuit is switched OFF. • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits cannot be disconnected.)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid)
Presumed cause and standard value in normalcy
Cause Travel interlocking solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male) Between Between
Assembled-type diode 2 D03 defective (Internal short-circuiting)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) to J06 to V02 (female) and grounding, or between wiring harness between C03 (female) and D03 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4
Governor • pump controller defective
C03 Between
20-318 (7)
20 – 60 Ω
and
and grounding
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
and grounding
Travel control lever
Voltage
Straight forward
Below 1 V
Steering
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E201
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-319
TROUBLESHOOTING
E201
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E201
DW91KB
Failure phenomenon
Short-circuiting in travel interlocking solenoid (in governor • pump controller system)
• Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the travel interlocking circuit is switched OFF. • Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits cannot be disconnected.)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid)
Presumed cause and standard value in normalcy
Failure content
Cause Travel interlocking solenoid defective 1 (Internal short-circuiting or grounding fault)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male) Between Between
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value 20 – 60 Ω
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (female) and grounding
to V02
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Governor • pump controller defective
20-319-1 (7)
Standard value in normalcy and references for troubleshooting
C03 Between
and grounding
Travel control lever
Voltage
Straight forward
Below 1 V
Steering
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E201
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-319-2 (7)
TROUBLESHOOTING
E203
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid - in governor • pump controller system) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
E03
E203
DW45KB
Failure phenomenon
Short-circuiting in swing and parking brake solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the swing and parking brake solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the swing and parking brake solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the swing and steering brake does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The upper structure cannot swing. (The swing holding brake cannot be released.)
Relative information
• Operation of the swing and parking brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the emergency swing brake releasing switch to the FREE position. (In this case, however, the parking brake does not work, when stopping the machine)
Presumed cause and standard value in normalcy
Cause Swing and parking brake solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male) Between Between
Assembled-type diode 2 D03 defective (Internal short-circuiting)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to D01 to J02 to X05 to J06 to V05 (female) , or between wiring harness between C03 (female) and D03 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4
Governor • pump controller defective
C03 Between
20-320 (7)
20 – 60 Ω
and
and grounding
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
and grounding
Swing control lever
Voltage
NEUTRAL
Below 1 V
Swing
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E203
Electrical Circuit Diagram for Swing and Parking Brake of Governor • Pump Controller
PC300/350(LC)-7
20-321
TROUBLESHOOTING
E203
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
E03
E203
DW45KB
Failure phenomenon
Short-circuiting in swing holding brake solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the swing holding brake solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The upper structure cannot swing. (The swing holding brake is not released)
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the emergency swing brake releasing switch to the FREE position. (In this case, however, the swing holding brake does not work, when stopping the machine)
Presumed cause and standard value in normalcy
Cause Swing holding brake solenoid defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V05 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (37) to D01 to J02 to X05 to V05 (female) (2), or between wiring harness between C03 (female) (37) and grounding
Resistance value
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Governor • pump controller defective
20-321-1 (7)
Standard value in normalcy and references for troubleshooting
C03 Between (37) and grounding
Swing control lever
Voltage
NEUTRAL
Below 1 V
Swing
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E203
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC300/350(LC)-7
20-321-2 (7)
TROUBLESHOOTING
E204
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E204
DWJ0KB
Failure phenomenon
Short-circuiting in merge/divide solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the merge/divide solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (Front and rear pumps cannot be disconnected.)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between Between
Assembled-type diode 2 D03 defective (Internal short-circuiting)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to J06 to V03 (female) , or between wiring harness between C03 (female) and D03 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4
C03
Governor • pump controller defective Between
20-322 (7)
20 – 60 Ω
and
and grounding
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
and grounding
Travel control lever
Voltage
NEUTRAL
Below 1 V
When operating one side only
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E204
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-323
TROUBLESHOOTING
E204
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E204
DWJ0KB
Failure phenomenon
Short-circuiting in merge/divide solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the merge/divide solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation. (Front and rear pumps are not separated)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause Merge/divide solenoid defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2), or between wiring harness between C03 (female) (17) and grounding
Resistance value
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Governor • pump controller defective
20-323-1 (7)
Standard value in normalcy and references for troubleshooting
C03
Travel control lever
Voltage
NEUTRAL
Below 1 V
Between (17) and grounding
When operating one side only
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E204
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-323-2 (7)
TROUBLESHOOTING
E205
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E205
DWK0KB
Failure phenomenon
Short-circuiting in 2-stage relief solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the 2-stage relief solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between Between
Assembled-type diode 2 D03 defective (Internal short-circuiting)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D03 (male)
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to J06 to V06 (female) , or between wiring harness between C03 (female) and D03 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
Governor • pump controller defective
C03 Between
20-324 (7)
20 – 60 Ω
and
and grounding
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
and grounding
Working mode
Voltage
Other than L mode
Below 1 V
L mode
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E205
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-325 (7)
TROUBLESHOOTING
E205
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E205
DWK0KB
Failure phenomenon
Short-circuiting in 2-stage relief solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Response from controller
• Power supply to the 2-stage relief solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause 2-stage relief solenoid defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (28) to V08 (female) (2), or between wiring harness between C03 (female) (28) and grounding
Resistance value
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3
Governor • pump controller defective
20-325-1 (7)
Standard value in normalcy and references for troubleshooting
C03 Between (28) and grounding
Working mode
Voltage
Other than L mode
Below 1 V
L mode
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E205
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-325-2 (7)
TROUBLESHOOTING
E206
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
E206
DW43KB
—
Failure phenomenon
Short-circuiting in travel speed shifting solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
Response from controller
• Power supply to the travel speed shifting solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The travel speed does not turn to Hi. (The travel motor swash plate angle does not turn to minimum.)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between Between
Assembled-type diode 2 D04 defective (Internal short-circuiting)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D04 (male)
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to J06 to V04 (female) , or between wiring harness between C03 (female) and D04 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4
Governor • pump controller defective
C03 Between
20-326 (7)
20 – 60 Ω
and
and grounding
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
and grounding
Travel speed
Voltage
Lo
Below 1 V
Hi + Travel operation
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E206
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-327
TROUBLESHOOTING
E206
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E206
DW43KB
Failure phenomenon
Short-circuiting in travel speed shifting solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
Response from controller
• Power supply to the travel speed shifting solenoid circuit is switched OFF. • Even after the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The travel speed does not turn to Hi. (The travel motor swash plate angle is not set to the minimum)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1)
Presumed cause and standard value in normalcy
Cause Travel speed shifting solenoid defective 1 (Internal short-circuiting or grounding fault)
Grounding fault of wiring harness 2 (Contact with grounding circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
Between (1) and grounding
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2), or between wiring harness between C03 (female) (27) and grounding
Resistance value
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 3
Governor • pump controller defective
20-327-1 (7)
Standard value in normalcy and references for troubleshooting
C03 Between (27) and grounding
Travel speed & Travel lever
Voltage
Lo + Neutral
Below 1 V
Hi + Travel
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E206
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-327-2 (7)
TROUBLESHOOTING
E211
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E211
DW91KA
Failure phenomenon
Disconnection in travel interlocking solenoid (in governor • pump controller system)
Failure content
• No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)
Presumed cause and standard value in normalcy
Cause Travel interlocking 1 solenoid defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
(7)
20 – 60 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (female)
to J06 to V02
Wiring harness between V02 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J06 to V02 (female) , or between wiring harness C03 (female) and D03 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
20-328
Resistance value
and grounding
Resistance value 20 – 60 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E211
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-329
TROUBLESHOOTING
E211
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E211
DW91KA
Failure phenomenon
Disconnection in travel interlocking solenoid (in governor • pump controller system)
Failure content
• No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• It is difficult to steer the machine while traveling. (The right and left travel circuits are not separated from each other)
Relative information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)
Presumed cause and standard value in normalcy
Cause Travel interlocking 1 solenoid defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
20-329-1 (7)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V02 (male)
Resistance value
Between (1) and (2)
20 – 60 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) (13) (23) and V02 (female) (1)
Resistance value
Below 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (7) to V02 (female) (2), or between wiring harness C03 (female) (7) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (7) and grounding
20 – 60 z
PC300/350(LC)-7
TROUBLESHOOTING
E211
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-329-2 (7)
TROUBLESHOOTING
E213
Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code E03 Failure content Response from controller Phenomenon occurring on machine
Presumed cause and standard value in normalcy
Relative information
Service Code E213
Failure Code DW45KA
Failure phenomenon
Disconnection in swing and parking brake solenoid (in governor • pump controller system)
• No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit. • None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy. • The machine's upper structure does not swing. (The swing holding brake cannot be released.) • Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing by moving the emergency swing brake release switch to the FREE position. (In this case, however, the parking brake does not work, when stopping the machine) ★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the OFF position. ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)
Cause
Standard value in normalcy and references for troubleshooting
Swing parking brake solenoid defective 1 (Internal disconnection)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Swing lock switch defective 2 (Internal disconnection) Assembled-type diode D01 defective 3 (Internal disconnection)
V05 (male) Between and
Resistance value 20 – 60 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between
Swing lock switch OFF
and
Resistance value Below 1 Ω
LOCK Above 1 MΩ ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between and
Digital type circuit tester Diode mode
Continuity Continued
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
Short-circuiting of Wiring harness 5 (Contact with 24V circuit)
6
Governor • pump controller defective
Wiring harness between C03 (female)
(7)
Resistance value
Below 1 Ω
Resistance Below 1 Ω value Resistance Wiring harness from X05 (male) to J06 to V05 (female) Below 1 Ω value Resistance Wiring harness between V05 (female) and grounding Below 1 Ω value ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from D01 (female)
to J02 to X05 (male)
Between wiring harness between C03 (female) (female) and grounding
and D01
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
20-330
and D01 (female)
and grounding
Disconnect D01 and connect pins and of the male side.
Resistance value 20 – 60 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E213
Electrical Circuit Diagram for Swing and Parking Brake Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-331
TROUBLESHOOTING
E213
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
E03
E213
DW45KA
Failure phenomenon
Disconnection in swing holding brake solenoid (in governor • pump controller system)
• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The machine's upper structure does not swing. (The swing holding brake is not released)
Relative information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) • If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing by moving the emergency swing brake release switch to the FREE position. (In this case, however, the parking brake does not work, when stopping the machine) ★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the OFF position. ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)
Presumed cause and standard value in normalcy
Failure content
Cause
Standard value in normalcy and references for troubleshooting
Swing holding brake solenoid defective 1 (Internal disconnection)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Swing lock switch defective 2 (Internal disconnection) Assembled-type diode D01 defective 3 (Internal disconnection)
V05 (male)
Resistance value
Between (1) and (2)
20 – 60 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between (3) and (4)
Swing lock switch
Resistance value
OFF
Below 1 z
LOCK
Above 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male)
Digital type circuit tester
Continuity
Between (7) and (3)
Diode mode
Continued
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 4 (Disconnection or defective contact with connector)
Short-circuiting of Wiring harness 5 (Contact with 24V circuit)
6
Governor • pump controller defective
20-331-1 (7)
Wiring harness between C03 (female) (37) and D01 (female) (7)
Resistance value
Below 1 z
Wiring harness from D01 (female) (3) to J02 to X05 (male) (3)
Resistance value
Below 1 z
Wiring harness from X05 (male) (4) to V05 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) (13) (23) and V05 (female) (1)
Resistance value
Below 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (37) and D01 (female) (7) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between (37) and (3) (13) (23)
Disconnect D01 and connect pins (3) and (7) of the female side.
Resistance value 20 – 60 z
PC300/350(LC)-7
TROUBLESHOOTING
E213
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-331-2 (7)
TROUBLESHOOTING
E214
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E214
DWJ0KA
Failure phenomenon
Disconnection in merge/divide solenoid (in governor • pump controller system)
Failure content
• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• In L mode, speeds of the work equipment and swing in its single operation are too fast (Front and rear pumps cannot be disconnected.)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)
Presumed cause and standard value in normalcy
Cause Merge/divide solenoid 1 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
(7)
20 – 60 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (female)
to J06 to V03
Wiring harness between V03 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J06 to V03 (female) , or between wiring harness between C03 (female) and D03 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
20-332
Resistance value
and grounding
Resistance value 20 – 60 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E214
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-333
TROUBLESHOOTING
E214
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E214
DWJ0KA
Failure phenomenon
Disconnection in merge/divide solenoid (in governor • pump controller system)
Failure content
• No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• In L mode, speeds of the work equipment and swing in its single operation are too fast (Front and rear pumps are not separated)
Relative information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)
Presumed cause and standard value in normalcy
Cause Merge/divide solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
20-333-1 (7)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V03 (male)
Resistance value
Between (1) and (2)
20 – 60 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2)
Resistance value
Below 1 z
Wiring harness between C03 (female) (3) (13) (23) and V03 (female) (1)
Resistance value
Below 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (17) to V03 (female) (2) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (17) and (3) (13) (23)
20 – 60 z
PC300/350(LC)-7
TROUBLESHOOTING
E214
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-333-2 (7)
TROUBLESHOOTING
E215
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 User Code
Service Code
Failure Code
—
E215
DWK0KA
Failure phenomenon
Disconnection in 2-stage relief solenoid (in governor • pump controller system)
Failure content
• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set.)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)
Presumed cause and standard value in normalcy
Cause 2-stage relief solenoid 1 defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
(7)
20 – 60 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (female)
to J06 to V06
Wiring harness between V06 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J06 to V06 (female) , or between wiring harness between C03 (female) and D03 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
20-334
Resistance value
and grounding
Resistance value 20 – 60 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E215
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-335 (7)
TROUBLESHOOTING
E215
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E215
DWK0KA
Failure phenomenon
Disconnection in 2-stage relief solenoid (in governor • pump controller system)
Failure content
• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The one-touch power max. switch does not work. (The main relief valve cannot be set to high-pressure set)
Relative information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)
Presumed cause and standard value in normalcy
Cause 2-stage relief solenoid 1 defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
20-335-1 (7)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V08 (male)
Resistance value
Between (1) and (2)
20 – 60 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (28) and V08 (female) (2)
Resistance value
Max. 1 z
Wiring harness between C03 (female) (3) (13) (23) and V08 (female) (1)
Resistance value
Max. 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (28) to V06 (female) (1) and grounding
Voltage
Max. 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (28) and (3) (13) (23)
20 – 60 z
PC300/350(LC)-7
TROUBLESHOOTING
E215
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-335-2 (7)
TROUBLESHOOTING
E216
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) User Code
Service Code
Failure Code
E216
DW43KA
—
Failure phenomenon
Disconnection in travel speed shifting solenoid (in governor • pump controller system)
Failure content
• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The travel speed does not shift to Hi. (The travel motor swash plate angle does not turn to minimum.)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)
Presumed cause and standard value in normalcy
Cause Travel speed shifting 1 solenoid defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
(7)
20 – 60 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (female)
to J06 to V04
Wiring harness between V04 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J06 to V04 (female) , or between wiring harness between C03 (female) and D04 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
20-336
Resistance value
and grounding
Resistance value 20 – 60 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E216
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-337
TROUBLESHOOTING
E216
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up User Code
Service Code
Failure Code
—
E216
DW43KA
Failure phenomenon
Disconnection in travel speed shifting solenoid (in governor • pump controller system)
Failure content
• No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The travel speed does not shift to Hi. (The travel motor swash plate angle does not turn to minimum)
Relative information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function. (Code No. 023: Solenoid 1) ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)
Presumed cause and standard value in normalcy
Cause Travel speed shifting 1 solenoid defective (Internal disconnection)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
20-337-1 (7)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V04 (male)
Resistance value
Between (1) and (2)
20 – 60 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) (27) and V04 (female) (2)
Resistance value
Max. 1 z
Wiring harness between C03 (female) (3) (13) (23) and V04 (female) (1) and grounding
Resistance value
Max. 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) (27) to V04 (female) (2) and grounding
Voltage
Max. 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (27) and (3) (13) (23)
20 – 60 z
PC300/350(LC)-7
TROUBLESHOOTING
E216
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-337-2 (7)
TROUBLESHOOTING
E217
Service Code in Electrical System E217 (Abnormality in inputting model code) User Code
Service Code
Failure Code
—
E217
DA2SKQ
Failure phenomenon
Abnormality in inputting model code (in governor • pump controller system)
Failure content
• A model code signal was inputted which indicates another model that is not registered in the controller.
Response from controller
• The controller treats it as a default-set model (PC300). • Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• None in particular
Relative information
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring function. (Code No. 002 and 003: Controller Model Code) ★Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.(Code No. 027:Switch Input 2) Cause
Presumed cause and standard value in normalcy
Model selecting connector defective 1 (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C09 (female)
Resistance value
Between
,
and
Below 1 Ω
Between
,
and
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Wiring harness between C02 (female) (male)
and C09
Resistance value
Below 1 Ω
Wiring harness between C02 (female) (male)
and C09
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
Between wiring harness between C09 (male) and grounding
and J05
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 3 (Contact with grounding circuit)
Between wiring harness between C02 (female) C09 (male) and grounding
and
Resistance value
Above 1 MΩ
Between wiring harness between C02 (female) C09 (male) and grounding
and
Resistance value
Above 1 MΩ
Between wiring harness between C02 (female) C09 (male) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
Governor • pump controller defective
20-338 (7)
C02 Between
,
or
and grounding
Between
,
and grounding
Voltage 20 – 30 V Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E217
Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC300/350(LC)-7
20-339 (7)
TROUBLESHOOTING
E218
Service Code in Electrical System E218 Disconnection of S-NET signal) User Code
Service Code
Failure Code
E218
DA2SKA
—
Failure phenomenon
Disconnection in S-NET signal (in governor • pump controller system)
Failure content
• A failure occurred in S-NET communication between the monitor and controller in the past. (The machine operation returned to normalcy, when the display was resumed)
Response from controller
• While the failure is still continuing, the machine operation is controlled by the following default setting. 1) Working mode: E mode 2) Travel speed: Lo 3) Auto-decelerator: ON 4) Attachment oil flow rate: Minimum ( ) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• • • •
Relative information
• This Service Code No. is displayed to inform that there was a failure occurred in the past, when S-NET communication between the monitor panel and the governor • pump controller is returned to normalcy. • The communication has already returned to normalcy by the time this Service Code No. is displayed. But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a failure in order to prevent recurrence of failures.
The working mode cannot be changed. (The display changes normally in the monitor panel) The travel speed cannot be shifted. (The display changes normally in the monitor panel) The auto-decelerator cannot be released. (The display changes normally in the monitor panel) The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
: The multi-monitor specification machine only.
Presumed cause and standard value in normalcy
Cause Disconnection of wiring harness 1 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 2 (Contact with grounding circuit) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female) (female) Wiring harness between P02 (female) (female)
and C02 and C02
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) C02 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) C02 (female) and grounding
and
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4 Monitor panel defective
P02 (male) Between
5
Governor • pump controller defective
6–9V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C02 (male) Between
20-340
and
Voltage
and
Voltage 6–9V
PC300/350(LC)-7
TROUBLESHOOTING
E218
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor • Pump Controller
PC300/350(LC)-7
20-341
TROUBLESHOOTING
E222
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) User Code
Service Code
Failure Code
—
E222
DXE0KB
Failure phenomenon
Disconnection in LS-EPC solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the LS-EPC solenoid circuit.
Response from controller
• The controller reduces the output to the LS-EPC solenoid circuit to 0. • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The travel speed is slow at Mi and Lo, or in Lmode, speed of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.)
Relative information
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 015: LS-EPC solenoid current)
Presumed cause and standard value in normalcy
Cause LS-EPC solenoid defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male) Between Between
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value 7 – 14 Ω
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) V22 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3
Governor • pump controller defective
C03 (female) Between Between
Resistance value
and and grounding
7 – 14 Ω Above 1 MΩ
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
20-342 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E223
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) User Code
Service Code
Failure Code
—
E223
DXE0KA
Failure phenomenon
Disconnection in LS-EPC solenoid (in governor • pump controller system)
Failure content
• No current flows to the LS-EPC solenoid circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon occurring on machine
• The travel speed is slow at Mi and Lo, or in Lmode, speeds of the work equipment and swing are too fast. (The LS valve set pressure cannot be controlled.)
Relative information
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 015: LS-EPC solenoid current)
Presumed cause and standard value in normalcy
Cause LS-EPC solenoid defec1 tive (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V22 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
Resistance value 7 – 14 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) V22 (female) and grounding Wiring harness between C03 (female) (female)
and and V22
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) V22 (female) and grounding
and
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
Resistance value
and
7 – 14 Ω
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-343 (7)
TROUBLESHOOTING
E224
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor) User Code
Service Code
Failure Code
—
E224
DHPAMA
Failure phenomenon
Abnormality in F pump pressure sensor (in governor • pump controller system)
Failure content
• Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from controller
• The controller controls the F pump pressure at 0 MPa{0 kg/cm2}. • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon occurring on machine
• The travel speed does not shift automatically.
Relative information
• Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function. (Code No. 011: F pump pressure) Cause
1
Sensor power source fault
Standard value in normalcy and references for troubleshooting If the Service Code No. [E226] is displayed, troubleshoot the failure first. ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
Presumed cause and standard value in normalcy
F pump pressure sensor 2 defective (Internal failure)
A51
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit) Short-circuiting of wiring harness 5 (Contact with 24 V circuit)
Wiring harness from C01 (female) (22) to J07 to A51 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and A51 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (8) and A51 (female) (C)
Resistance value
Max. 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (8) and A51 (female) (C) and grounding
Resistance value
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C01 (female) (22), J07 and A51 (female) (B) and grounding
Voltage
Max. 1 V
Between wiring harness between C01 (female) (8) and A51 (female) (C) ang grounding
Voltage
Max. 1 V
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6
Governor • pump controller defective
20-344 (7)
C01
Voltage
Between (22) and (10)
Power supply
4.5 – 5.5 V
Between (8) and (10)
Signal
0.5 – 4.5 V
PC300/350(LC)-7
TROUBLESHOOTING
E224
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor • Pump Controller
PC300/350(LC)-7
20-345 (7)
TROUBLESHOOTING
E225
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) User Code
Service Code
Failure Code
—
E225
DHPBMA
Failure phenomenon
Abnormality in R pump pressure sensor (in governor • pump controller system)
Failure content
• Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from controller
• The controller controls the R pump pressure as 0 MPa {0 kg/cm2}. • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon occurring on machine
• The travel speed does not shift automatically.
Relative information
• Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function. (Code No. 012: R pump pressure) Cause
1
Sensor power source fault
Standard value in normalcy and references for troubleshooting If the Service Code No. [E226] is displayed, troubleshoot the failure first. ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting.
Presumed cause and standard value in normalcy
R pump pressure sen2 sor defective (Internal failure)
A52
Voltage
Between (B) and (A)
Power supply
4.5 – 5.5 V
Between (C) and (A)
Signal
0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for another cause of the trouble, and then judge. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit) Short-circuiting of wiring harness 5 (Contact with 24 V circuit)
Wiring harness from C01 (female) (22) to J07 to A52 (female) (B)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (10) and A52 (female) (A)
Resistance value
Max. 1 z
Wiring harness between C01 (female) (2) and A52 (female) (C)
Resistance value
Max. 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding
Resistance value
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C01 (female) (22), J07 and A52 (female) (B) and grounding
Voltage
Max. 1 V
Between wiring harness between C01 (female) (2) and A52 (female) (C) and grounding
Voltage
Max. 1 V
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 6
Governor • pump controller defective
20-346 (7)
C01
Voltage
Between (22) and (10)
Power supply
4.5 – 5.5 V
Between (2) and (10)
Signal
0.5 – 4.5 V
PC300/350(LC)-7
TROUBLESHOOTING
E225
Electrical Circuit Diagram for R Pump Pressure Sensor in Governor • Pump Controller
PC300/350(LC)-7
20-347 (7)
TROUBLESHOOTING
E226
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source) User Code
Service Code
Failure Code
—
E226
DA25KP
Failure phenomenon
Abnormality in pressure sensor power source (in governor • pump controller system)
Failure content
• Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
Response from controller
• The controller turns OFF power supply to the power source circuit (5 V). • Even when the failure cause disappears of itself, the current does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• Signals from the pressure sensors and potentiometer are not inputted correctly. • The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at the same time.
Presumed cause and standard value in normalcy
Cause
Pressure sensor or 1 potentiometer defective (Internal short-circuit)
Disconnect the parts shown at right in order. If the error code goes off when one of those parts is disconnected, that part is defective.
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Fuel dial
E06 Connector
Governor motor potentiometer
E10 Connector
F pump pressure sensor
A51 Connector
R pump pressure sensor
A52 Connector
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Grounding fault of wiring harness 2 (Contact with grounding circuit)
3
Governor • pump controller defective
20-348 (7)
Standard value in normalcy and references for troubleshooting
Between wiring harness from C01 (female) (22) to J07 to E06 (female) (1) and grounding [Fuel dial system]
Resistance value
Min. 1 Mz
Between wiring harness from C01 (female) (22) to J07 to E10 (female) (A) and grounding [Governor potentiometer system]
Resistance value
Min. 1 Mz
Between wiring harness from C01 (female) (22) to J07 to A51 (female) (B) and grounding [F pump pressure sensor system]
Resistance value
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C01
Voltage
Between (22) and (10) (21)
4.5 – 5.5 V
PC300/350(LC)-7
TROUBLESHOOTING
E226
Electrical Circuit Diagram for Sensor Power Source in Governor • Pump Controller
PC300/350(LC)-7
20-349
TROUBLESHOOTING
E227
Service Code in Electrical System E227 (Abnormality in engine rotation sensor in governor • pump controller system) User Code
Service Code
Failure Code
E227
DLE2MA
—
Failure phenomenon
Abnormality in engine rotation sensor (in governor • pump controller system)
Failure content
• A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from controller
• The controller exercises a control equivalent to E mode. • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon occurring on machine
• The machine lacks power a bit.
Relative information
• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine RPM)
Presumed cause and standard value in normalcy
Cause Engine rotation sensor fault 1 (Internal short-circuiting or disconnection)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E07 (male) Between Between
2
Engine rotation sensor adjustment improper
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
4
Short-circuiting of wiring harness
Resistance value 500 – 1,000 Ω
and
Above 1 MΩ
and grounding
For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation Sensor" in this manual. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) (female) Wiring harness between C02 (female) (female)
and E07 and E07
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
(Contact with 24 V cir- Between wiring harness between C02 (female) cuit) E07 (female) and grounding
and
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Governor • pump controller defective
C02 (female) Between Between
and and grounding
Resistance value 500 – 1,000 Ω Above 1 MΩ
Electrical Circuit Diagram for Engine Rotation Sensor in Governor • Pump Controller System
20-350 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E228
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) User Code
Service Code
Failure Code
E228
D196KB
—
Failure phenomenon
Short-circuiting in attachment return switching relay (in governor • pump controller system)
• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from controller
• The controller turned OFF power to the attachment return switching relay circuit. • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon occurring on machine
• The hydraulic circuit for attachments is not switched to the single operation circuit. (The switching valve is not switched to the tank circuit.)
Relative information
• In this code, a failure is diagnosed only when the setting mode is "with ATT". (Check the setting mode shown in the monitor panel) ★This code detects only failures occurring on the primary ATT return switching relay (coil side). If the ATT return switching solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the secondary relay (contact side). • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No. 024:Solenoid 2)
Presumed cause and standard value in normalcy
Failure content
Cause Attachment return 1 switching relay defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male) Between
Short-circuiting of wiring harness 2 (Contact with 24 V circuit)
Resistance value 100 – 500 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C02 (female) R20 (female) and grounding
and
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 3
Governor • pump controller defective
C02 Between
and grounding
Working mode
Voltage
Other than B mode
20 – 30 V
B mode
Below 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC300/350(LC)-7
20-351 (7)
TROUBLESHOOTING
E232
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid User Code
Service Code
Failure Code
E02
E232
DXA0KB
Failure phenomenon
Disconnection in PC-EPC solenoid (in governor • pump controller system)
Failure content
• Abnormal current flew to the PC-EPC solenoid circuit.
Response from controller
• The controller reduces the output to the PC-EPC solenoid circuit to 0. • Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled)
Relative information
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 013: PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency drive switch ON. (At that time the monitor panel continues to display service code No. [E232], but this is not abnormal) ★Turn the emergency driving switch ON during the troubleshooting.
Presumed cause and standard value in normalcy
Cause PC-EPC solenoid defective 1 (Internal short-circuiting or grounding fault)
Emergency pump driving switch defective 2 (Internal short-circuiting or grounding fault)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)
Resistance value
Between (1) and (2)
7 – 14 z
Between (1) and grounding
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S25 (male)
Emergency pump drive switch
Between (3) and (4) Between (3) and grounding
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Normal
Resistance value Min. 1 Mz Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) (16) to S25 (female) (3) and grounding
Resistance value
Min. 1 Mz
Between wiring harness from S25 (female) (2) to V21 (female) (1) and grounding
Resistance value
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Governor • pump controller defective
20-352 (7)
Standard value in normalcy and references for troubleshooting
C03 (female)
Resistance value
Between (16) and (3) (13) (23)
7 – 14 z
Between (16) and grounding
Min. 1 Mz
PC300/350(LC)-7
TROUBLESHOOTING
E232
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-353
TROUBLESHOOTING
E233
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system) User Code
Service Code
Failure Code
E02
E233
DXA0KA
Failure phenomenon
Disconnection in PC-EPC solenoid (in governor • pump controller system)
Failure content
• No current flows to the PC-EPC solenoid circuit.
Response from controller
• None in particular (The solenoid does not function as there is no current flowing to it) • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon occurring on machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls. (The pump absorption torque cannot be controlled)
Relative information
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function. (Code No. 013: PC-EPC solenoid current) • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the monitor panel continues to display Service Code No. [E233], but this is not abnormal) Cause
PC-EPC solenoid 1 defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V21 (male)
Resistance value
Between (1) and (2)
7 – 14 z
Presumed cause and standard value in normalcy
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump driving 2 switch defective (Internal disconnection)
Emergency pump driving switch
Resistance value
Normal
Max. 1 z
Emergency
Min. 1 Mz
Between (2) and (5) Between (5) and (6)
Normal
Max. 1 z
Emergency
Min. 1 Mz
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 4 (Contact with 24 V circuit)
5
Governor • pump controller defective
20-354 (7)
S25
Wiring harness between C03 (female) (16) and S25 (female) (3)
Resistance value
Max. 1 z
Wiring harness between S25 (female) (2) and V21 (female) (1)
Resistance value
Max. 1 z
Wiring harness between C03 (female) (3) (13) (23) and S25 (female) (6)
Resistance value
Max. 1 z
Wiring harness between S25 (female) (5) and V21 (female) (2)
Resistance value
Max. 1 z
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) (16) and S25 (female) (3) and grounding
Voltage
Max. 1 V
Between wiring harness between S25 (female) (2) and V21 (female) (1) and grounding
Voltage
Max. 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
Resistance value
Between (16) and (3) (13) (23)
7 – 14 z
PC300/350(LC)-7
TROUBLESHOOTING
E233
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-355
TROUBLESHOOTING
E238
Service Code in Electrical System E238 (Disconnection in attachment return switching relay) User Code
Service Code
Failure Code
E238
D196KA
—
Failure phenomenon
Disconnection in attachment return switching relay (in governor • pump controller system)
Failure content
• When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage is not generated.
Response from controller
• None in particular • If the failure cause disappears, the governor returns to normalcy.
Phenomenon occurring on machine
• The hydraulic circuit for attachments cannot be switched to the single operation (The switching valve is not switched to the tank circuit.)
Relative information
• In this code, a failure is diagnosed only when the setting mode is "with ATT". (Check the setting mode shown in the monitor panel) ★This code detects only failures occurring on the primary ATT return switching relay (coil side). If the ATT return switching solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the secondary relay (contact side). • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF). (Code No. 024:Solenoid 2) Cause
Presumed cause and standard value in normalcy
1 Fuse No. 2 fault Attachment return 2 switching relay defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting If the fuse has been blown, there is a big possibility that grounding fault occurred in the relay circuit. (See Cause 4) ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R20 (male) Between
100 – 500 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Emergency pump driving 3 switch defective (Internal disconnection)
Wiring harness between C02 (female) (female) Wiring harness from R20 (female) outlet
Grounding fault of wiring harness 4 (Contact with grounding circuit)
and R20
Resistance value
Below 1 Ω
to J03 to FB1-2
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C02 (female) R20 (female) and grounding Between wiring harness from R20 (female) FB1-2 outlet and grounding
and
to J03 to
Resistance value
Above 1 MΩ
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Governor • pump controller defective
C03 Between
20-356 (7)
Resistance value
and grounding
Working mode
Voltage
Other than B mode
20 – 30 V
B mode
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E238
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-357
TROUBLESHOOTING
E245
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only) User Code
Service Code
Failure Code
E245
DXE4KB
—
Failure phenomenon
Short-circuiting in attachment oil flow rate adjusting EPC (in governor • pump controller system)
• Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from controller
• The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit. • Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relative information
• In this code, a failure is diagnosed only when the setting mode is "with ATT". (Check the setting mode shown in the monitor panel) • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Presumed cause and standard value in normalcy
Failure content
Cause Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male) Between Between
Grounding fault of wiring harness 2 (Contact with grounding circuit)
Resistance value 7 – 14 Ω
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) V30 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3
Governor • pump controller defective
C03 (female) Between Between
and and grounding
Resistance value 7 – 14 Ω Above 1 MΩ
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump Controller
20-358 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E246
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only) User Code
Service Code
Failure Code
E246
DXE4KA
—
Failure phenomenon
Disconnection in attachment oil flow rate adjusting EPC (in governor • pump controller system)
Failure content
• No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from controller
• None in particular (The solenoid does not work, as there is no current flowing to it) • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon occurring on machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relative information
• In this code, a failure is diagnosed only when the setting mode is "with ATT". (Check the setting mode shown in the monitor panel) • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)
Presumed cause and standard value in normalcy
Cause Attachment oil flow rate adjusting EPC defective 1 (Internal short-circuiting or grounding fault) Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
4
Governor • pump controller defective
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V30 (male) Between
Resistance value 7 – 14 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C03 (female) V30 (male) and grounding
and
Between wiring harness between C03 (female) and V30 (male) and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between C03 (female) V30 (female) and grounding
and
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female) Between
and
Resistance value 7 – 14 Ω
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7
20-359 (7)
TESTING AND ADJUSTING
E256
Service Code in Electrical System E256 (Incorrect nonvolatile memory data) User Code
Service Code
Failure Code
—
E256
DA20KT
Failure phenomenon
Incorrect nonvolatile memory data (in governor • pump controller)
Failure content
• The data in the nonvolatile memory in the controller cannot be updated.
Response from controller
• None in particular • Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• In some cases control parameters of the machines change, resulting in increase or decrease of the machine's power.
Relative information
• Recorded in the nonvolatile memory are part of the machine control parameters
Presumed cause and standard value in normalcy
20-360
1
Cause
Standard value in normalcy and references for troubleshooting
Governor • pump controller defective
As it is an internal failure, troubleshooting is impossible. (There is no problem with continuing with use of the controller, so long as no failure is visually evident)
PC300/350(LC)-7
TESTING AND ADJUSTING
E304
Service Code in Electrical System E304 (Short circuit of engine stop solenoid relay) User Code
Service Code
Failure Code
—
E304
DY45KB
Failure phenomenon
Short circuit of engine stop solenoid relay (in governor • pump controller system)
Failure content
• Abnormal current flew to the engine stop solenoid relay circuit, when power is supplied to the circuit.
Response from controller
• Switch OFF power to the engine stop solenoid relay circuit. • Even when the failure dissolves itself, the circuit does not return to normalcy, if the engine starting switch is not turned off once.
Phenomenon occurring on machine
• The engine cannot be started.
Relative information
• This code detects only failures occurring on the primary engine stop solenoid relay (coil side). If the engine stop solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the secondary relay (contact side). • It can be checked in the monitoring function how the engine stop solenoid relay works (ON and OFF). (Code 023: Controller output) • If there is nothing abnormal with the relay or wiring harness, the engine can be started again by moving the emergency fuel solenoid driving switch to the EMERGENCY side.
Presumed cause and standard value in normalcy
Cause Fault of engine stop 1 solenoid relay (Internal short circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R22 (male) Between
Fault of emergency fuel 2 solenoid driving switch (Internal short circuiting)
100 – 500
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S25 (male)
Resistance value
and
Above 1 M
Between Grounding fault of wiring harness 3 (Contact with grounding circuit)
Resistance value
grounding
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to J01 to R22 (female) , or between wiring harness between C03 (female) and S25 (female).
Resistance value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. 4
Governor • pump controller defective
C03 Between
20-362
and grounding
Engine starting switch
Voltage
ON
Below 1 V
Engine start-up
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E304
Electrical Circuit Diagram for Engine Stop Solenoid and Relay in Monitor Panel PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-363 (7)
TROUBLESHOOTING
E304
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-363-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E306
Service Code in Electrical System E306 (Abnormality in governor potentiometer) User Code
Service Code
Failure Code
—
E306
DK54KZ
Failure phenomenon
Abnormality in governor potentiometer (in governor • pump controller)
Failure content
• Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
Response from controller
• The controller exercises control by computing the motor position through voltage right before a failure occurred. • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• • • • • •
Relative information
• Input from the governor potentiometer (voltage) can be confirmed in the monitor function. (Code No. 031: Governor potentiometer voltage)
The engine cannot attain the specified rotation at high idling. (A bit lower) The engine cannot attain the specified rotation at low idling (A bit higher) The auto-decelerator or automatic warming-up function does not work. There is hunting while the engine is running. The engine stalls. The engine does not stop.
Cause 1
Sensor power source defective
Standard value in normalcy and references for troubleshooting If Service Code No. [E226] is displayed, troubleshoot the failure first. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Governor potentiometer 2 defective (Internal failure)
E10 (male)
Resistance value
Between
and
4.0 – 6.0 kΩ
Between
and
0.25 – 5.0 kΩ
Between
and
0.25 – 5.0 kΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Short-circuiting of wiring harness 5 (Contact with 24 V circuit)
Wiring harness from C01 (female) (female)
to J07 to E10
Resistance value
Below 1 Ω
Wiring harness between C01 (female) (female)
and E10
Resistance value
Below 1 Ω
Wiring harness between C01 (female) (female)
and E10
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) E10 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C01 (female) E10 (female) and grounding
to J07 to
Between wiring harness between C01 (female) E10 (female) and grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 6
Governor • pump controller defective
20-364 (7)
C01
Resistance value
Between
and
Power supply
4.5 – 5.5 V
Between
and
Signal
0.5 – 4.5 V
PC300/350(LC)-7
TROUBLESHOOTING
E306
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC300/350(LC)-7
20-365
TROUBLESHOOTING
E308
Service Code in Electrical System E308 (Abnormality in fuel dial) User Code
Service Code
Failure Code
E05
E308
DK10KZ
Failure phenomenon
Abnormality in governor fuel dial (in governor • pump controller)
Failure content
• Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
Response from controller
• The controller exercises control by computing the fuel dial position through voltage right before a failure occurred. • If the failure cause disappears, the fuel dial returns to normalcy.
Phenomenon occurring on machine
• • • •
Relative information
• Input from the fuel dial (voltage) can be confirmed in the monitor function. (Code No. 030: Fuel dial voltage)
If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL. If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL. There is hunting while the engine is running. The engine cannot attain the specified rotation at high idling and lacks power.
Cause Sensor power source 1 defective
Presumed cause and standard value in normalcy
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Standard value in normalcy and references for troubleshooting If Service Code No. [E226] is displayed, troubleshoot the failure first. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E06 (male)
Resistance value
Between
and
4.0 – 6.0 kΩ
Between
and
0.25 – 5.0 kΩ
Between
and
0.25 – 5.0 kΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
Grounding fault of wiring harness 4 (Contact with grounding circuit)
Short-circuiting of wiring harness 5 (Contact with 24 V circuit)
Wiring harness from C01 (female) (female)
to J07 to E06
Resistance value
Below 1 Ω
Wiring harness between C01 (female) (female)
and E06
Resistance value
Below 1 Ω
Wiring harness between C01 (female) (female)
and E06
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) E06 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness from C01 (female) E06 (female) and grounding
to J07 to
Between wiring harness between C01 (female) E06 (female) and grounding
and
Voltage
Below 1 V
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 6
Governor • pump controller defective
20-366 (7)
C01
Resistance value
Between
and
Power supply
4.5 – 5.5 V
Between
and
Signal
0.5 – 4.5 V
PC300/350(LC)-7
TESTING AND ADJUSTING
E308
Electrical Circuit Diagram for Fuel Dial in Governor • Pump Controller
PC300/350(LC)-7
20-367
TESTING AND ADJUSTING
E314
Service Code in Electrical System E314 (Disconnection of engine stop solenoid relay) User Code
Service Code
Failure Code
—
E314
DY45KA
Failure phenomenon
Disconnection of engine stop (in governor • pump controller system)
Failure content
• No current flows to the engine stop solenoid relay, when power is supplied to it.
Response from controller
• No response in particular (The solenoid does not function without current) • When the failure dissolves itself, the relay returns to the normalcy.
Phenomenon occurring on machine
• The engine cannot be started.
Relative information
• This code detects only failures occurring on the primary engine stop solenoid relay (coil side). If the engine stop solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the secondary relay (contact side). • It can be checked in the monitoring function how the engine stop solenoid relay works (ON and OFF). (Code 023: Controller output) • If there is nothing abnormal with the relay or wiring harness, the engine can be started again by moving the emergency fuel solenoid driving switch to the EMERGENCY side. +The solenoid detects disconnection with power ON. Be sure to make a test for checking after the repair with power ON. (For the operation with power ON and OFF, refer to Diagnosis of Service Code [E201].
Presumed cause and standard value in normalcy
Cause Fault of engine stop 1 solenoid relay (Internal disconnection)
Standard value in normalcy and references for troubleshooting +Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R22 (male) Between
Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Short-circuiting of wiring harness 3 (Contact with 24 V circuit)
6
Governor • pump controller defective
100 – 500 :
and
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) (female)
to J01 to R22
Wiring harness between R22 (female) to J08 to J04 and grounding
Resistance value
Below 1 :
Resistance value
Below 1 :
+Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J01 to R22 (female) , or between wiring harness C03 (female) and S25 (female) and grounding.
Voltage
Below 1 V
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 Between
20-368
Resistance value
and grounding
Resistance value 100 – 500 :
PC300/350(LC)-7
TROUBLESHOOTING
E314
Electrical Circuit Diagram for Engine Stop Solenoid and Relay in Monitor Panel PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-369 (7)
TROUBLESHOOTING
E314
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-369-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E315
Service Code in Electrical System E315 (Short-circuiting in battery relay) User Code
Service Code
Failure Code
—
E315
D110KB
Failure phenomenon
Short-circuiting in battery relay (in governor • pump controller)
• Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
Response from controller
• The controller turns OFF power to the battery drive circuit. • Even when the failure cause disappears, the relay does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The engine does not stop.
Relative information
• It can be confirmed in the monitor function how the battery relay works (ON or OFF). (Code No. 037: Controller output)
Presumed cause and standard value in normalcy
Failure content
Cause
1
Battery relay defective (Internal failure)
Battery relay
Continuity & Resistance value
Between A21 (BR terminal) and A20 (E terminal)
Continued
Between A21 (BR terminal) and grounding Grounding fault of wiring harness 2 (Contact with grounding circuit)
3
Governor • pump controller defective
20-370 (7)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from C03 (female) J01 to A21 (BR terminal) and grounding
to D01 to
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. C03 Between
and grounding
Engine starting switch
Voltage
ON → OFF
20 – 30 V (for 4 to 7 seconds)
PC300/350(LC)-7
TROUBLESHOOTING
E315
Electrical Circuit Diagram for Battery Relay in Governor • Pump Controller
PC300/350(LC)-7
20-371 (7)
TESTING AND ADJUSTING
E316
Service Code in Electrical System E316 (Step-out in governor motor) User Code
Service Code
Failure Code
—
E316
DY10K4
Failure phenomenon
Step-out in governor motor (in governor • pump controller)
Failure content
• There is a big difference between signals from the potentiometer and the set values in the controller.
Response from controller
• The controller repeats the same controlling motions (step-out). • Even when the failure cause disappears, the governor motor does not return to normalcy, unless the engine starting switch is once turned OFF.
Phenomenon occurring on machine
• The engine rotation cannot be controlled. • There is hunting in the rotation. • The engine does not stop.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1 Fuel dial defective
If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective
If Service Code [E306] is displayed, troubleshoot that failure first.
3 Governor motor defective (disconnection)
If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first. 5 Governor lever adjustment improper
Refer to the section of "Inspection and Adjustment - Special Function of Monitor Panel" in this manual.
6 Engine fuel control system defective
Refer to Engine Shop Manual.
7 Governor • pump controller defective
As this is an internal failure, no troubleshooting can be carried out. (If there is none of the failures listed above, the controller is judged as defective)
20-372
PC300/350(LC)-7
TESTING AND ADJUSTING
E317
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) User Code
Service Code
Failure Code
E05
E317
DY10KA
Failure phenomenon
Disconnection in governor motor Phase A and B (in governor • pump controller)
Failure content
• No current flew to the governor motor, when power was supplied to the motor.
Response from controller
• None in particular. • If the failure cause disappears, the governor returns to normalcy.
Phenomenon occurring on machine
• • • •
Relative information
• Operation of the governor motor (current) can be confirmed in the monitor function. (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
The engine rotation drops to low idling. There is hunting in the rotation The engine does not stop. The governor motor steps out.
Presumed cause and standard value in normalcy
Cause
Governor motor defec1 tive (Internal disconnection)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E11 (male)
Resistance value
Between
and
2.5 – 7.5
Between
and
2.5 – 7.5
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Wiring harness between C03 (female) (female)
and E11
Resistance value
Below 1
Wiring harness between C03 (female) (female)
and E11
Resistance value
Below 1
Wiring harness between C03 (female) (female)
and E11
Resistance value
Below 1
Wiring harness between C03 (female) (female)
and E11
Resistance value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 3
Governor • pump controller defective
20-374
C03 (female)
Resistance value
Between
and
2.5 – 7.5
Between
and
2.5 – 7.5
PC300/350(LC)-7
TESTING AND ADJUSTING
E317
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC300/350(LC)-7
20-375
TESTING AND ADJUSTING
E318
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) User Code
Service Code
Failure Code
E318
DY10KB
E05
Failure phenomenon
Disconnection in governor motor Phase A and Phase B (in governor • pump controller system)
Failure content
• Abnormal current flew to the governor motor, when power is supplied to the motor.
Response from controller
• None in particular • If the failure cause disappears, the governor motor returns to normalcy.
Phenomenon occurring on machine
• • • •
Relative information
• Operation of the governor motor (current) can be confirmed in the monitor function. (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)
The engine rotation cannot be controlled. The engine rotation drops to low idling. There is hunting in the rotation. The engine does not stop.
Cause
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
Governor motor defective 1 (Internal short-circuiting or grounding fault)
E11 (male)
Resistance value
Between
and
2.5 – 7.5
Between
and
2.5 – 7.5
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Disconnection of wiring harness 2 (Disconnection or defective contact with connector)
Between wiring harness between C03 (female) E11 (female) and grounding
and
Resistance value
Above 1 M
Between wiring harness between C03 (female) E11 (female) and grounding
and
Resistance value
Above 1 M
Between wiring harness between C03 (female) E11 (female) and grounding
and
Resistance value
Above 1 M
Between wiring harness between C03 (female) E11 (female) and grounding
and
Resistance value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. C03 (female)
3
Governor • pump controller defective
20-376
Resistance value
Between
and
2.5 – 7.5
Between
and
2.5 – 7.5
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
Between
and grounding
Above 1 M
PC300/350(LC)-7
TESTING AND ADJUSTING
E318
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC300/350(LC)-7
20-377
TROUBLESHOOTING
A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) User Code
Service Code
Failure Code
—
—
A000N1
Failure phenomenon
Out-of-rate engine rotation at high idling (in mechanical system)
Failure content
• Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
Response from controller
• None in particular • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon occurring on machine
• There is a possibility that the engine is damaged, if is used continuously without adjustment.
Relative information
• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine rotation) Cause
Presumed cause and standard value in normalcy
Standard value in normalcy and references for troubleshooting
1
Check if there has been an internal or external factor that would cause Failure in engine mechanthe engine to overrun at high idling, and troubleshoot the mechanical ical system system of the engine.
2
Governor • pump controller defective
As this is an internal failure, troubleshooting cannot be conducted. (Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling) User Code
Service Code
Failure Code
—
—
A000N2
Failure phenomenon
Out-of-rate engine rotation at low idling (in mechanical system)
Failure content
• Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from controller
• None in particular • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon occurring on machine
• There is a possibility that the engine is damaged, if it is used continuously without adjustment.
Relative information
• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function. (Code No. 010: Engine rotation) Cause
Presumed cause and standard value in normalcy
20-378 (7)
Standard value in normalcy and references for troubleshooting
1
Check if there has been an internal or external factor that would cause Failure in engine mechanthe engine to overrun at high idling, and troubleshoot the mechanical ical system system of the engine.
2
Governor • pump controller defective
As this is an internal failure, troubleshooting cannot be conducted. (Unless there is any visible trouble found in the machine, use of the controller may be continued as it is)
PC300/350(LC)-7
TROUBLESHOOTING
AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging) User Code
Service Code
Failure Code
—
— (E104)
AA10NX
Failure phenomenon
Air cleaner clogged (in mechanical system)
Failure content
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. disconnected from grounding circuit).
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the engine is damaged, if it is used continuously without corrective action.
Relative information
• Service code (E104) is displayed in the 7-segment monitor panel. • This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor panel while the engine is running. • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel. (Code No. 046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause Air cleaner clogged 1 (when the system is in normal condition) Air cleaner clogging 2 switch defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Check the air cleaner for clogging. If it is clogged, clean or replace it with new one. ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. A31 (male) Between
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
and
Air cleaner
Resistance value
When in normal condition
Below 1 Ω
When clogged
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. Wiring harness between P02 (female) (female)
and A31
Between wiring harness A31 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P02
4 Monitor panel defective Between
and grounding
Air cleaner
Voltage
When in normal condition
Below 1 V
When clogged
20 – 30 V
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC300/350(LC)-7
20-379 (7)
TROUBLESHOOTING
AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage) User Code
Service Code
Failure Code
—
—
AB00KE
Failure phenomenon
Charging voltage abnormally lowered (in mechanical system)
Failure content
• Generation signal from the alternator is not inputted, while the engine is running.
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the battery may not be charged, if charging is continued without corrective action.
Relative information
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the engine is running. • Input from the alternator (voltage) can be confirmed in the monitor function. (Code No. 043: Charging voltage)
Presumed cause and standard value in normalcy
Cause
1
Alternator defective (short generating output)
Disconnection of wiring harness 2 (Disconnection or defective contact with connector) Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it running during the troubleshooting. E12 (male)
Engine rotation
Voltage
Between terminal R and grounding
Above medium speed
27.5 – 29.5 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from P02 (female) terminal R.
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from P02 (female) to J02 to alternator terminal R, or between P02 (female) and D01 (female) , or between P02 (female) to M02 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. 4 Monitor panel defective
P02 Between
20-380 (7)
to J02 to alternator
and grounding
Engine rotation
Voltage
Above medium speed
27.5 – 29.5 V
PC300/350(LC)-7
TROUBLESHOOTING
AB00KE
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-381 (7)
TROUBLESHOOTING
AB00KE
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-381-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) User Code
Service Code
Failure Code
—
—
B@BAZG
Failure phenomenon
Engine oil pressure abnormally lowered (in mechanical system)
Failure content
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the engine was running.
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the engine may seize, if the engine is kept running without corrective action.
Relative information
• This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel, while the engine is running. • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function. (Code No. 046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause Engine oil pressure low1 ered (the system in normal condition) Engine oil pressure 2 switch defective (Internal short-circuiting)
Grounding fault of wiring harness 3 (Contact with grounding circuit)
Standard value in normalcy and references for troubleshooting ★Check the failure cause and damage to the engine, and then make repairs. ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. E02 (on switch side)
Engine oil pressure
Resistance value
Between terminal and grounding
When in normal condition
Above 1 MΩ
When lowered
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (7) and E02 (terminal) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. P02
4 Monitor panel defective Between
and grounding
Engine oil pressure
Voltage
When in normal condition
20 – 30 V
When lowered
Below 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382 (7)
PC300/350(LC)-7
TROUBLESHOOTING
B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level) User Code
Service Code
Failure Code
—
—
B@BAZK
Failure phenomenon
Engine oil level abnormally lowered (in mechanical system)
Failure content
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the engine is stopped (with the starting switch in the ON position).
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the engine seizes if it is kept running without a corrective action.
Relative information
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is stopped (with the starting key in the ON position). • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No. 046: Monitor input 2)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
Engine oil level lowered ★Check the engine oil level, and refill oil. 1 (System in normal condi(If the phenomenon occurs frequently, check the cause) tion) Engine oil level switch 2 defective (Internal disconnection)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P05 (male) Between
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
and grounding
Engine oil level
Resistance value
When in normal condition
Below 1 Ω
When lowered
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female)
and P05 (female)
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
4 Monitor panel defective Between
and grounding
Engine oil pressure
Voltage
When in normal condition
Below 1 V
When lowered
20 – 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC300/350(LC)-7
20-383 (7)
TROUBLESHOOTING
B@BCNS
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating) User Code
Service Code
Failure Code
—
— (E108)
B@BCNS
Failure phenomenon
Engine cooling water overheated (in mechanical system)
Failure content
• The engine cooling water sensor inputted a signal of 102°C, while the engine was running.
Response from monitor panel
• Response from controller
Phenomenon occurring on machine
• There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative information
• Service code (E108) is displayed in the 7-segment monitor panel. • This Failure Code is recorded, if the engine cooling water temperature gauge is displayed in the red range, when the engine is running. • Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor function. (Code No. 041: Engine cooling water temperature)
Presumed cause and standard value in normalcy
Cause Engine Overheating 1 (system in normal condition)
Engine cooling water temperature sensor 2 defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting ★Check the engine for the cause and damage, and repair it. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P07 (male) Between Between
Grounding fault of wiring harness 3 (Contact with grounding circuit)
and
and grounding
Engine cooling water temperature
Resistance value 90 – 3.5kΩ
10 – 100 °C
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) P07 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective
P02 (female) Between Between
and
and grounding
Engine water temperature 10 – 100 °C
Resistance value 90 – 3.5kΩ Above 1 MΩ
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor in Monitor Panel
20-384 (7)
PC300/350(LC)-7
TROUBLESHOOTING
B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) (Multi-monitor only) User Code
Service Code
Failure Code
—
—
B@BCZK
Failure phenomenon
Radiator water level abnormally lowered (in mechanical system)
Failure content
• The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative information
• This Failure Code is recorded, if the radiator water level caution symbol is displayed in the monitor panel, when the engine is running. • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function. (Code No. 045: Monitor input 1)
Presumed cause and standard value in normalcy
Cause Radiator water level low1 ered (system in normal condition) Radiator water level 2 switch defective (Internal disconnection)
Standard value in normalcy and references for troubleshooting ★Check the water level and refill cooling water. (If this phenomenon occurs frequently, check the cause) ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A33 (male) Between
Disconnection of wiring harness 3 (Disconnection or defective contact with connector)
and
Engine cooling water level
Resistance value
When in normal condition
Below 1 Ω
When lowered
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female)
and A33 (female)
Wiring harness between A33 (female)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02
4 Monitor panel defective Between
and grounding
Engine water temperature
Resistance value
When in normal condition
Below 1 V
When lowered
20 – 30 V
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC300/350(LC)-7
20-385 (7)
TROUBLESHOOTING
B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating) (Multi-monitor only) User Code
Service Code
Failure Code
—
—
B@HANS
Failure phenomenon
Hydraulic oil overheated (in mechanical system)
Failure content
• The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from monitor panel
• None in particular
Phenomenon occurring on machine
• There is a possibility that the engine seizes, if it is kept running without a corrective action.
Relative information
• This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when the engine is running. • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function. (Code No. 044: hydraulic oil temperature)
Presumed cause and standard value in normalcy
Cause Hydraulic oil overheat1 ing (system in normal condition)
Hydraulic oil temperature 2 sensor defective (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting ★Check the cause and damage to the hydraulic equipment, and repair it. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A61 (male) Between Between
Grounding fault of wiring harness 3 (Contact with grounding circuit)
and
and grounding
Hydraulic oil temperature
Resistance value 90 – 3.5kΩ
10 – 100 °C
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) A61 (female) and grounding
and
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4 Monitor panel defective
P02 (female) Between Between
and
and grounding
Engine water temperature 10 – 100 °C
Resistance value 90 – 3.5kΩ Above 1 MΩ
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-386 (7)
PC300/350(LC)-7
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502 E-1 Engine does not start........................................................................................................................ 20-503 E-2 Engine stops while in operation ........................................................................................................ 20-508 E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-510 E-4 Engine does not stop ........................................................................................................................ 20-512 E-5 Auto-decelerator does not work ........................................................................................................ 20-514 E-6 Auto engine warm-up device does not work ..................................................................................... 20-515 E-7 Preheater does not work................................................................................................................... 20-516 E-8 All work equipment, swing and travel do not move........................................................................... 20-518 E-9 One-touch Power Max. Switch does not work .................................................................................. 20-520 E-10 No display in monitor panel at all ................................................................................................... 20-521-1 E-11 Part of display on monitor panel is missing ...................................................................................... 20-522 E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-522 E-13 Fuel level monitor red lamp lights up while engine is running .......................................................... 20-523 E-14 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-524 E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-525 E-16 Fuel gauge does not display correctly .............................................................................................. 20-526 E-17 Swing lock monitor does not display correctly .................................................................................. 20-527 E-18 When the monitor switch is operated, no display appears ............................................................... 20-528 E-19 Windshield wiper does not work ....................................................................................................... 20-530 E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-532 E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-533 E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-534 E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-535 E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-536 E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-537 E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-538 E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-540 E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-542 E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-544 E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-546 E-31 Air Conditioner does not work........................................................................................................... 20-548 E-32 Travel alarm does not sound ............................................................................................................ 20-561
PC300/350(LC)-7
20-501 (7)
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE The following information are edited and contained in the "Information Contained in Troubleshooting Table". You are required to proceed with troubleshooting after fully grasping the contents. Failure information
Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting Cause
• The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy
1
2
3
Standard value in normalcy and references for troubleshooting
Cause for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)
4
5
• Failure due to disconnection Defective contact with connector or disconnection of wiring harness has occurred. • Grounding fault A wiring harness that is not originally connected with a grounding circuit is in contact with it. • Failure due to short-circuiting A wiring harness that is not originally connected with a power source circuit (24 V) is in contact with it. 1) Connector denotation method and handling of T-adapters Insert or connect T-adapters in the following manner, unless specifically otherwise instructed. • If there is no indication of (male) or (female) in the connector No., pull off a connector and insert a T-adapter into both sides of male and female. • If there is an indication of (male9 and (female) in the connection No., pull off a connector and insert a T-adapter into only one side of (male) or (female). 2) Description sequence of pin No. and handling of circuit tester leads Connect the positive lead (+) and negative lead (–) for troubleshooting in the following manner unless specifically otherwise instructed. • Connect the positive lead (+) to a pin No. marked at the front or wiring harness. • Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred. • Connector No.: Indicates (Type - numbers of a pin) (color) • Arrow: Roughly indicates the location in the machine where it is installed.
20-502
PC300/350(LC)-7
TESTING AND ADJUSTING
E-1
E-1 Engine does not start Failure information (1)
• The engine does not start (the engine does not rotate).
Relative information
• The following two engine start locking mechanisms are provided in the engine starting circuit. 1) Engine start locking by means of password in the monitor panel ( ) 2) Engine start locking by means of safety lock lever
: The multi-monitor specification machine only.
Presumed cause and standard value in normalcy
Cause 1
Shortage in battery capacity
2
Fuse Nos. 3 and 18 and Fusible Link A35 fault
3
Engine starting switch fault (Internal disconnection)
4
5
6
Safety lock switch fault (Internal short-circuiting)
Engine starting motor cut relay, R11 and R13 defective (Internal disconnection or short-circuiting)
Engine starting motor fault (Internal disconnection or damage)
Standard value in normalcy and references for troubleshooting Battery voltage
Battery electrolyte specific gravity
Above 24 V
Above 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in the circuit. If a monitor lamp does not light up in the monitor panel, check the power source circuit between the battery and the specific fuse. Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. H15 (male) Between
Position
Resistance value
OFF
Above 1 M
Start
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. S14 (female) Between
Lock lever
and
Release
Below 1
LOCK
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. R11 (female) & R13 (male) and
100 – 500
Between
and
Above 1 M
Between
and
Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. (If all of the power source, grounding (GND), generation signal and engine start input are normal and yet the engine start output is not normal, the engine starting motor relay is defective) Engine starting motor
Engine start input: C terminal and grounding Alternator fault (Internal short-circuit)
PC300/350(LC)-7
Resistance value
Between
Power source: B terminal and grounding
7
Resistance value
Engine startVoltage ing switch Start
20 – 30 V 20 – 30 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position or running during the troubleshooting. Alternator
Voltage
R terminal and grounding
Below 1 V
20-503
TESTING AND ADJUSTING
Cause
E-1
Standard value in normalcy and references for troubleshooting +Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
8
Wiring harness between FB1-18 outlet and H15 (female)
Resistance value
Below 1 :
Wiring harness from H15 (female)
Resistance value
Below 1 :
Resistance value
Below 1 :
Resistance value
Below 1 :
to J01 to R11 (female)
Disconnection of wirWiring harness between R11 (female) and M02 (female) ing harness (Disconnection or defective contact Wiring harness between FB1-3 and S14 (female) with connector) Wiring harness between S14 (female)
and R11 (female)
Resistance value
Below 1 :
Wiring harness between R11 (female)
and R13 (female)
Resistance value
Below 1 :
Resistance value
Below 1 :
Wiring harness from R13 (female)
to J04 to grounding
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
9
Grounding fault of wiring harness (Contact with grounding circuit)
Between wiring harness from battery relay B terminal (A23) to A35 to FB1-18 and grounding
Resistance value
Above 1 M:
Between wiring harness between FB1-18 outlet and H15 (female) and grounding
Resistance value
Above 1 M:
Between wiring harness from H15 (female) (female) and grounding
Resistance value
Above 1 M:
Resistance value
Above 1 M:
Between wiring harness between FB1-3 and S14 (female) and grounding
Resistance value
Above 1 M:
Between wiring harness between S14 (female) (female) and grounding
Resistance value
Above 1 M:
Resistance value
Above 1 M:
Between wiring harness between R11 (female) (female) and grounding
Between wiring harness from R13 (female) (female) and grounding Short-circuiting of wiring harness 10 (Contact with 24 V circuit)
20-504
to J01 to R11 and M02
and R11
to J05 to P02
+Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from P02 (female) to J02 to M02 (female) , or wiring harness between P02 (female) and D01 (female) , or between wiring harness between P02 (female) and alternator R terminal and grounding
Voltage
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Start and Battery Charging PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-505 (7)
TROUBLESHOOTING
E-1
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-505-1 (7)
PC300/350(LC)-7
TESTING AND ADJUSTING
E-1
Failure information (2)
• The engine cannot be started. (The engine can be rotated)
Relative information
— Cause
Presumed cause and standard value in normalcy
1
Fault of engine stop solenoid (Internal disconnection)
Standard value in normalcy and references for troubleshooting +Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. E10 (male)
Resistance value
Between
and
0.6 – 1.0 :
Between
and
37 – 46 :
2
Fault of engine stop solenoid relay
Check by replacing it with another relay
3
Fault of fusible link A36
When the fusible link is blown, there is a big possibility that grounding fault has occurred in the circuit.
4
Fault of assembledtype diode (Internal short-circuiting)
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D02 (male) Between
Resistance value Above 1 M:
and
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
5
Wiring harness disconnected (Disconnection or defective contact of connector)
Wiring harness from battery relay M terminal (A22) to A36 to R22 (female)
Resistance value
Below 1 :
Wiring harness between R22 (female)
Resistance value
Below 1 :
Wiring harness from the engine starting switch ACC terminal to J07 to J03 to E10 (female)
Resistance value
Below 1 :
Wiring harness between E10 (female)
Resistance value
Below 1 :
and E10 (female)
and grounding
+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
6
7
Grounding fault of wiring harness (Contact with GND circuit)
Fault of governor • pump controller
20-506
Wiring harness from battery relay M terminal (A22) to A36 to R22 (female) , or between wiring harness from battery relay M terminal (A22) to A34 to FB1 inlet and grounding
Resistance value
Above 1 M:
Between wiring harness between R22 (female) (female) and grounding
Resistance value
Above 1 M:
Resistance value
Above 1 M:
and E10
Wiring harness from engine starting switch ACC terminal to J07 to J03 to E10 (female) , or wiring harness between engine starting switch ACC terminal and C01 (female) , or wiring harness between the engine starting switch ACC terminal and D02 (female) , or wiring harness between S25 (female) and grounding
If the engine can be started with the engine starting switch ON, after the emergency fuel solenoid driving switch is once moved to the EMERGENCY side, then the governor • pump controller is defective.
PC300/350(LC)-7
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Start and Battery Charging PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-507 (7)
TROUBLESHOOTING
E-1
Electrical Circuit Diagram for Engine Start and Battery Charging PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-507-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-2
E-2 Engine stops while in operation Failure information
• The engine suddenly stopped while in operation.
Relative information
• Input from the governor potentiometer (voltage) can be confirmed in the monitor function. (Code No. 031: governor potentiometer voltage) Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 1
Governor potentiometer fault (Internal failure)
E06 (male)
Resistance value
Between
and
4.0 – 6.0 kΩ
Between
and
0.25 – 5.0 kΩ
Between
and
0.25 – 5.0 kΩ
2
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position ing harness during the troubleshooting. (Disconnection or Wiring harness between C01 (female) and E10 (female) Resistance defective contact Below 1 Ω value with connector)
3
Grounding fault of wiring harness (Contact with grounding circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) (female) and grounding
and E10
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
Governor • pump controller defective
C01
Voltage
Between
and
4.5 – 5.5 V
Between
and
0.5 – 4.5 V
Electrical Circuit Diagram for Fuel Dial
20-508 (7)
PC300/350(LC)-7
TESTING AND ADJUSTING
E-3
E-3 Engine speed is irregular, or there is hunting Failure information
• Engine speed is irregular at low idling. • There is hunting. • Engine speed is lower than specified at high idling.
Relative information
• Engine rotation can be confirmed in the monitor function. (Code No. 010: Engine rotation) Cause
Standard value in normalcy and references for troubleshooting If the monitor display is not normal, proceed to Service Code [E217].
Presumed cause and standard value in normalcy
1
Model code signal fault (Internal failure)
Monitoring Code
Item
Normal display
002 003
Controller model code
200
2
Governor lever improperly adjusted
Refer to the section "Special Function of Monitor Panel" in this manual.
3
Governor motor improperly working
If the governor motor lever moves smoothly in the following operations, it is judged as normal. • The fuel dial is operated between low idling and high idling. • The engine is stopped with the fuel dial.
4
Engine fuel control system defective
Refer to the Engine Shop Manual.
5
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position ing harness during the troubleshooting. (Disconnection or Wiring harness from C01 (female) to J07 to H15 (female) Resistance defective contact Below 1 value with connector)
6
Grounding fault of wiring harness (Contact with grounding circuit)
7
Governor • pump controller defective
20-510
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between C01 (female) H15 (female) and grounding
to J17 and
Resistance value
Above 1 M
As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
PC300/350(LC)-7
TROUBLESHOOTING
E-3
Electrical Circuit Diagram for Engine Start and Battery Charging PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-511 (7)
TESTING AND ADJUSTING
E-4
E-4 Engine does not stop Failure information
• The engine does not stop.
Relative information
— Cause
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
Presumed cause and standard value in normalcy
1
Fault of engine stop solenoid (Internal fault)
E10 (male)
Resistance value
Between
and
0.6 – 1.0
Between
and
37 – 46
If the plunger rod can be moved smoothly by hand, then the engine stop solenoid is normal. 2
Fault of engine stop solenoid relay
3
Fault of emergency fuel solenoid driving switch (Internal short-circuiting)
Check by replacing it with another relay. Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. S25 (male) Between
and
Switch
Resistance value
In normalcy
Above 1 M
In emergency
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between R22 (female) (female) and grounding
4
and E10
Wiring harness short-circuited (Con- Wiring harness from the engine starting switch ACC terminal tact with 24 V circuit) to J07 to J03 to E10 (female) , or wiring harness between the engine starting switch ACC terminal and C01 (female) , or wiring harness between the engine starting switch ACC terminal and D02 (female) , or wiring harness between S25 (female) and grounding
20-512
Voltage
Below 1 V
Voltage
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-4
Electrical Circuit Diagram for Engine Stop PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7
20-513 (7)
TROUBLESHOOTING
E-4
Electrical Circuit Diagram for Engine Stop PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-513-1 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-5
E-5 Auto-decelerator does not work Failure information
• The auto-decelerator does not work.
Relative information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the auto-decelerator does not work. • Confirm the display on the monitor panel, when the engine is running. Cause
1
Boom RAISE signal fault
Standard value in normalcy and references for troubleshooting Monitoring code
Item
Normal display
019
Boom RAISE
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-21 Troubleshooting.
2
Boom LOWER signal fault
Monitoring code
Item
Normal display
019
Boom LOWER
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-22 Troubleshooting.
Presumed cause and standard value in normalcy
3
Arm DIGGING signal fault
Monitoring code
Item
Normal display
019
Arm DIGGING
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-23 Troubleshooting.
4
Arm DUMPING signal fault
Monitoring code
Item
Normal display
019
Arm DUMPING
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-24 Troubleshooting.
5
Bucket DIGGING signal fault
Monitoring code
Item
Normal display
021
Bucket DIGGING
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-25 Troubleshooting.
6
Bucket DUMPING signal fault
Monitoring code
Item
Normal display
021
Bucket DUMPING
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-26 Troubleshooting.
7
Swing signal fault
Monitoring code
Item
Normal display
019
Swing
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-27 Troubleshooting.
8
Travel signal fault
Monitoring code
Item
Normal display
019
Travel
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-28 Troubleshooting.
9
Attachment signal fault
Monitoring code
Item
Normal display
021
Service
Lever operation: ON Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-30 Troubleshooting. Governor • pump 10 controller defective
20-514 (7)
As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the causes listed in Item 1 through 9, the controller is judged as defective.
PC300/350(LC)-7
TROUBLESHOOTING
E-6
E-6 Auto engine warm-up device does not work • The auto engine warm-up device does not work.
Relative information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C, and raise the engine rotation up to 1,200 rpm. • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
Presumed cause and standard value in normalcy
Failure information
Cause
1
2
Engine cooling water temperature signal fault
Governor • pump controller defective
PC300/350(LC)-7
Standard value in normalcy and references for troubleshooting If the display on the monitor panel is not normal, proceed to No. E-14 Troubleshooting. Monitoring code 041
Item
Normal display
Engine cooling water temperature
Compare with the actual engine cooling water temperature.
As this is an internal failure, troubleshooting cannot be conducted. (If the fault mentioned in the above item is not found, the Governor • pump controller is judged as defective)
20-515 (7)
TESTING AND ADJUSTING
E-7
E-7 Preheater does not work Failure information (1)
• Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not light up.
Relative information
• Input of the preheating signal (ON or OFF) can be confirmed in the monitor function. (Code No. 045: Monitor input 1)
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
Engine starting switch fault
If preheating does not occur (the heater is not warmed up), refer to Failure Phenomenon (2) below.
2
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ing harness (Disconnection or Resistance defective contact Below 1 Wiring harness between P02 (female) and J02 value with connector) Turn the engine starting switch OFF for the preparations.
3
P02
Monitor panel fault Between
Engine starting switch
Voltage
OFF
Below 1 V
HEAT
20 – 30 V
and grounding
Failure information (2)
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
Relative information
• In low cooling water temperature (lower than 30°C), the governor • pump controller drives the heater relay for 100 seconds after the engine is started and automatically warms up the engine. Cause
Presumed cause and standard value in normalcy
1
2
3
4
20-516
Engine starting switch fault (Internal disconnection)
Heater relay fault (Internal disconnection)
Electrical intake air heater (Internal disconnection)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations. H15 (male) Between
Engine starting switch
Resistance value
OFF
Above 1 M
HEAT
Below 1
and
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Heater relay
Continuity and resistance value
Between coil terminal and grounding
Continued
Between contact terminals
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between heater terminals
Normal if continuity is established.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posiDisconnection of wirtion during the troubleshooting. ing harness Resistance Wiring harness from H15 (female) to J02 to heater (Disconnection or Below 1 value relay terminal defective contact Wiring harness between battery relay M terminal (A22) Resistance with connector) Below 1 and heater relay terminal value
PC300/350(LC)-7
TESTING AND ADJUSTING
E-7
Electrical Circuit Diagram for Engine Preheater
PC300/350(LC)-7
20-517
TROUBLESHOOTING
E-8
E-8 All work equipment, swing and travel do not move Failure information
• All the work equipment, swing and travel do not move.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Fuse No. 3 fault
2
Safety switch lock defective (Internal disconnection)
3
4
PPC lock solenoid fault (Internal disconnection or short-circuiting) Assembled-type diode D01 fault (Internal short-circuiting)
Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. (See Cause 6) S14 (female) Between
Safety control lever
Resistance value
Lock
Above 1 MΩ
Release
Below 1 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. V01 (male) Between Between
20 – 60 Ω
and
Above 1 MΩ
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. D01 (male) Between
Resistance value Above 1 MΩ
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
5
Disconnection of wirWiring harness between FB1-3 outlet and S14 (male) ing harness (Disconnection or defective contact Wiring harness from S14 (male) to J02 to V01 (female) with connector) Wiring harness between V01 (female)
6
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
20-518 (7)
Resistance value
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-3 outlet and S14 (male) and grounding
Resistance value
Above 1 MΩ
Wiring harness from S14 (male) to J02 to V01 (female) , or between wiring harness between S14 (male) and D01 (female) and grounding
Resistance value
Above 1 MΩ
PC300/350(LC)-7
TROUBLESHOOTING
E-8
Electrical Circuit Diagram for PPC Lock Solenoid
PC300/350(LC)-7
20-519
TROUBLESHOOTING
E-9
E-9 One-touch Power Max. Switch does not work Failure information
• The one-touch power max. switch does not work.
Relative information
• If the one-touch power max. switch is depressed, while the engine is running and the work equipment is operated in either A mode or E mode, the symbol mark is displayed in the monitor panel. • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function. (Code No. 022: Switch input 1)
Presumed cause and standard value in normalcy
Cause 1
Fuse No. 9 fault
2
One-touch power max. switch fault (Internal disconnection)
Standard value in normalcy and references for troubleshooting If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. (See Cause 4) M23 (male) Between
One-touch power max. switch
Resistance value
Release
Above 1 MΩ
Depress
Below 1 Ω
and
3
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Above 1 MΩ Wiring harness between FB1-9 outlet and M23 (female) value defective contact Resistance with connector) Above 1 MΩ Wiring harness between M23 (female) and C01 (female) value
4
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-9 outlet and M23 (female) and grounding, or related circuits
Resistance value
Above 1 MΩ
Between wiring harness between M23 (female) (female) and grounding
Resistance value
Above 1 MΩ
and C01
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Governor • pump controller defective
C01 Between
One-touch power max. switch
Voltage
Release
Below 1 V
Depress
20 – 30 V
and grounding
Electric Circuit Diagram for One-Touch Power Max. Switch
20-520 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-10
E-10 No display in monitor panel at all Failure information
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Fuse No. 12 fault
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. (See Cause 3) ing harness Resistance Below 1 Ω (Disconnection or Wiring harness from P01 (female) to J07 to FB1-12 value defect contact with Resistance connector) Below 1 Ω Wiring harness between P01 (female) and grounding value
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness from P01 (female) FB1-12 outlet and grounding
to J07 to
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
Monitor panel defective
20-521-1 (7)
Standard value in normalcy and references for troubleshooting
P01
Voltage and resistance value
Between
and grounding
Voltage: 20 – 30 V
Between
and grounding
Resistance value: Below 1 Ω
PC300/350(LC)-7
TROUBLESHOOTING
E-10
Electrical Circuit Diagram for Power Source in Monitor Panel PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-521-2 (7)
TESTING AND ADJUSTING
E-11, E-12
E-11 Part of display on monitor panel is missing • Part of the display in the monitor panel is missing.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Monitor panel LCD fault
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the following switching operation, then the monitor panel is normal. • Switching operation: [ ] + [ A ] (simultaneous switching operation)
2
Monitor panel defective
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the controller is judged as defective)
E-12 Monitor panel displays contents irrelevant to the model • The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting If the display on the monitor panel is normal, proceed to Service Code [E217].
1
2
20-522
Model code signal fault (Internal failure)
Monitor panel defective
Monitoring code
Item
Normal display
002 003
Controller model code
300
As this is an internal failure, troubleshooting cannot be conducted. (If there is no problem with the above switching operation, the monitor panel is judged as defective)
PC300/350(LC)-7
TESTING AND ADJUSTING
E-13
E-13 Fuel level monitor red lamp lights up while engine is running Failure information
• The fuel level monitor red lamp lighted up while the engine was running.
Relative information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red. • (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No. 042: Fuel level sensor)
Presumed cause and standard value in normalcy
Cause 1
Fuel level lowered (system in normal condition)
2
Fuel level sensor fault (Internal disconnection)
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
Standard value in normalcy and references for troubleshooting Refill fuel. Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male) Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 – 110
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between P02 (female)
and A60 (female)
Resistance value
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 4
Monitor panel defective
P02 (female) Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 – 110
Electrical Circuit Diagram for Fuel Level Sensor
PC300/350(LC)-7
20-523
TESTING AND ADJUSTING
E-14
E-14 Engine cooling water temperature gauge does not indicate correctly Failure information
• The engine cooling water rises normally, but the display does not exceed the white range (C). • The engine cooling water temperature remains stable, but the display rises to the red range (H).
Relative information
• Input from the engine cooling water temperature sensor can be confirmed in the monitor function. (Code No. 041: Engine cooling water temperature) Cause
Presumed cause and standard value in normalcy
1
Engine cooling water temperature sensor fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Engine cooling water temperature
P07 Between Between
and
10 – 100 °C
and grounding
Resistance value 90 – 3.5 k Above 1 M
2
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Wiring harness between P02 (female) and P07 (female) value defective contact Resistance with connector) Below 1 Wiring harness between P02 (female) and P07 (female) value
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
4
Short-circuiting of wiring harness (Contact with 24 V circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and P07
Resistance value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and P07
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Monitor panel defective
Engine cooling water temperature
P02 Between Between
and
10 – 100 °C
and grounding
Resistance value 90 – 3.5 k Above 1 M
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor
20-524
PC300/350(LC)-7
TESTING AND ADJUSTING
E-15
E-15 Hydraulic oil temperature gauge does not display correctly (Multi-monitor only) Failure information
• Hydraulic oil temperature rises normally, but the display does not exceed the white range (C). • Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative information
• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function. (Code No. 044: Hydraulic oil temperature) Cause
Presumed cause and standard value in normalcy
1
Hydraulic oil temperature sensor fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Engine cooling water temperature
A61 Between Between
and
10 – 100 °C
and grounding
Resistance value 90 – 3.5 k Above 1 M
2
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Wiring harness between P02 (female) and A61 (female) value defective contact Resistance with connector) Below 1 Wiring harness between P02 (female) and A61 (female) value
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
4
Short-circuiting of wiring harness (Contact with 24 V circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and A61
Resistance value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and A61
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Monitor panel defective
Engine cooling water temperature
P02 Between Between
and
10 – 100 °C
and grounding
Resistance value 90 – 3.5 k Above 1 M
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC300/350(LC)-7
20-525
TESTING AND ADJUSTING
E-16
E-16 Fuel gauge does not display correctly Failure information
• Though fuel was refilled, the display does not exceed the red range (E). • Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative information
• Input from the fuel level sensor (voltage) can be confirmed in the monitor function. (Code No. 042: Fuel sensor voltage) Cause
Presumed cause and standard value in normalcy
1
Fuel level sensor fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. A60 (male) Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 – 110
2
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. ing harness (Disconnection or Resistance defective contact Below 1 Wiring harness between P02 (female) and A60 (female) value with connector)
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
4
Short-circuiting of wiring harness (Contact with 24 V circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and A60
Resistance value
Above 1 M
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (female) and grounding
and A60
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. 5
Monitor panel defective
P02 Between
and grounding
Fuel level
Resistance value
FULL (Upper limit)
Approx. 12
EMPTY (Lower limit)
85 – 110
Electrical Circuit Diagram for Fuel Level Sensor
20-526
PC300/350(LC)-7
TROUBLESHOOTING
E-17
E-17 Swing lock monitor does not display correctly Failure information
• Though the swing lock switch was turned ON, the swing lock monitor does not light up. • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative information
• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause
Presumed cause and standard value in normalcy
1
Swing lock switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. X05 (female) Between
and
Swing lock switch
Resistance value
OFF
Above 1 MΩ
ON
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness from P02 (female) to J02 to X05 (male) value defective contact Resistance with connector) Below 1 Ω Wiring harness from X05 (male) to J05 to grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness from P02 (female) to J02 to X05 (male) , or C02 (female) and grounding
Between wiring harness from P02 (female) to J02 to X05 (male) , or C02 (female) and grounding
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 5
Monitor panel defective
P02 Between
and grounding
Swing lock switch
Voltage
OFF
20 – 30 V
ON
Below 1 V
Electrical Circuit Diagram for Swing Lock Switch
PC300/350(LC)-7
20-527 (7)
TESTING AND ADJUSTING
E-18
E-18 When the monitor switch is operated, no display appears Failure information (1)
• When operating the working mode changing switch, the working mode monitor does not appear.
Relative information
—
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information (2)
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
Relative information
If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information (3)
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
Relative information
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information (4)
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
Relative information
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
Presumed cause and standard value in normalcy
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
Failure information (5)
• When operating the select switch, the adjustment display does not appear. • When operating the LCD monitor adjusting switch, the adjustment display does not appear. • When operating the maintenance switch, the item display does not appear.
Relative information
—
Presumed cause and standard value in normalcy
20-528
Cause 1
Monitor panel defective
Standard value in normalcy and references for troubleshooting As this is an internal failure, troubleshooting cannot be conducted.
PC300/350(LC)-7
TESTING AND ADJUSTING
E-19
E-19 Windshield wiper does not work Failure information
• The windshield wiper does not work.
Relative information
• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3) Cause
1
Presumed cause and standard value in normalcy
2
Window rear limit switch fault (Internal disconnection or short-circuiting) Windshield wiper motor fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W03 (Switch side) Between
and
Front window
Resistance value
When installed at front
Above 1 M
When retracted at rear
Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. W04 (male) Between Between
Continuity and resistance value Continued
and
Above 1 M
and grounding
3
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Wiring harness between P01 (female) and W04 (female) value defective contact Resistance with connector) Below 1 Wiring harness between P01 (female) and W04 (female) value
4
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. wiring harness (Contact with Resistance grounding (GND) cir- Between wiring harness between P02 (female) Above 1 M and W03 value cuit)
Monitor panel fault (Rear limit switch system)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. P02 Between
and grounding
Front window
Voltage
When installed at front
20 – 30 V
When retracted at rear
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
5 Monitor panel fault (Windshield wiper motor system)
20-530
P02 Between Between
and grounding and grounding
Windshield wiper switch
Resistance value
OFF
Below 3 V
ON
Below 3 V 20 – 30 V (Constant cycle)
PC300/350(LC)-7
TESTING AND ADJUSTING
E-19
Electrical Circuit Diagram for Windshield Wiper Motor
PC300/350(LC)-7
20-531
TESTING AND ADJUSTING
E-20
E-20 Alarming buzzer cannot be cancelled Failure information
• The alarming buzzer cannot be cancelled.
Relative information
• Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function. (Code No. 049: Monitor input 3)
Presumed cause and standard value in normalcy
Cause
1
Alarming buzzer cancellation switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. P03 (female) Between
and
Alarming buzzer cancellation switch
Resistance value
Release
Above 1 M
Depress
Below 1
2
Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Wiring harness between P02 (female) and P03 (male) value defective contact Resistance with connector) Below 1 Wiring harness from P03 (male) to J05 to grounding value
3
Short-circuiting of wiring harness (Contact with 24 V circuit)
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Between wiring harness between P02 (female) (male) and grounding
and P03
Voltage
Below 1 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. 4
P02
Monitor panel fault Between
and grounding
Alarming buzzer cancellation switch
Voltage
Release
20 – 30 V
Depress
Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-532
PC300/350(LC)-7
TROUBLESHOOTING
E-21
E-21 "Boom RAISE" is not correctly displayed in monitor function Failure information
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
1
Boom RAISE PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S06 (male) Between
and
Boom control lever
Resistance value
NEUTRAL
Above 1 MΩ
RAISE
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S06 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S06 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S06
and S06
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Boom control lever
Voltage
NEUTRAL
20 – 30 V
RAISE
Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC300/350(LC)-7
20-533 (7)
TROUBLESHOOTING
E-22
E-22 "Boom LOWER" is not correctly displayed in monitor function Failure information
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
1
Boom LOWER PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S02 (male) Between
and
Boom control lever
Resistance value
NEUTRAL
Above 1 MΩ
LOWER
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S02 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S02 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S02
and S02
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Boom control lever
Voltage
NEUTRAL
20 – 30 V
LOWER
Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-534 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-23
E-23 "Arm DIGGING" is not correctly displayed in monitor function Failure information
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
1
Arm DIGGING PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S04 (male) Between
and
Arm control lever
Resistance value
NEUTRAL
Above 1 MΩ
DIGGING
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S04 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S04 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S04
and S04
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Arm control lever
Voltage
NEUTRAL
20 – 30 V
DIGGING
Below 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC300/350(LC)-7
20-535 (7)
TROUBLESHOOTING
E-24
E-24 "Arm DUMPING" is not correctly displayed in monitor function Failure information
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
—
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
Arm DUMPING PPC ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. hydraulic switch defect S08 (male) Arm control lever Resistance value (Internal disconnecNEUTRAL Above 1 MΩ tion and short-circuitBetween and ing) DUMPING Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S08 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S08 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S08
and S08
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Arm control lever
Voltage
NEUTRAL
20 – 30 V
DUMPING
Below 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-536 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-25
E-25 "Bucket DIGGING" is not correctly displayed in monitor function Failure information
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
—
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
★Turn the engine starting switch OFF for the preparations, and keep the engine running durBucket DIGGING ing the troubleshooting. PPC hydraulic switch fault S01 (male) Bucket control lever Resistance value (Internal disconnecNEUTRAL Above 1 MΩ tion and short-circuitBetween and ing) DIGGING Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S01 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S01 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S01
and S01
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Bucket control lever
Voltage
NEUTRAL
20 – 30 V
DIGGING
Below 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC300/350(LC)-7
20-537 (7)
TROUBLESHOOTING
E-26
E-26 "Bucket DUMPING" is not correctly displayed in monitor function Failure information
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
—
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
★Turn the engine starting switch OFF for the preparations, and keep the engine running durBucket DUMPING ing the troubleshooting. PPC hydraulic switch fault S05 (male) Bucket control lever Resistance value (Internal disconnecNEUTRAL Above 1 MΩ tion and short-circuitBetween and ing) DUMPING Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C03 (female) and S05 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness between S05 (female) and grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C03 (female) (female) and grounding
Between wiring harness between C03 (female) (female) and grounding
and S05
and S05
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
and grounding
Bucket control lever
Voltage
NEUTRAL
20 – 30 V
DUMPING
Below 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-538 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-27
E-27 "SWING" is not correctly displayed in monitor function Failure information
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
1
Presumed cause and standard value in normalcy
2
Swing PPC hydraulic switch, left, fault (Internal disconnection or short-circuiting) Swing PPC hydraulic switch, right, fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S03 (male) Between
Swing control lever
Resistance value
NEUTRAL
Above 1 MΩ
Left
Below 1 Ω
and
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S07 (male) Between
Swing control lever
Resistance value
NEUTRAL
Above 1 MΩ
Right
Below 1 Ω
and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Disconnection of wir- Wiring harness between C03 (female) and S03 (female) , or wiring harness between C03 (female) and S07 (female) ing harness (Disconnection or defective contact Wiring harness between S03 (female) and grounding with connector) Wiring harness between S07 (female)
4
5
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
and grounding
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C03 (female) and S03 (female) , or wiring harness between C03 (female) and S07 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C03 (female) and S03 (female) , or wiring harness between C03 (female) and S07 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 6
Governor • pump controller defective
C03 Between
20-540 (7)
and grounding
Swing control lever
Voltage
NEUTRAL
20 – 30 V
Right or left
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-27
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC300/350(LC)-7
20-541
TROUBLESHOOTING
E-28
E-28 "TRAVEL" is not correctly displayed in monitor function Failure information
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
Presumed cause and standard value in normalcy
1
Travel PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S30 (male) Between
and
Travel control lever
Resistance value
NEUTRAL
Above 1 MΩ
Forward or reverse
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness from C03 (female) to J01 to S30 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness from S30 (female) to J05 to grounding value
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
4
Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness from C03 (female) to J01 to S30 (female) , or between wiring harness between C03 (female) and A43 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness from C03 (female) to J01 to S30 (female) , or between wiring harness between C03 (female) and A43 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C03 Between
20-542 (7)
and grounding
Travel control lever
Voltage
NEUTRAL
20 – 30 V
Forward or backward
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-28
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
PC300/350(LC)-7
20-543 (7)
TROUBLESHOOTING
E-29
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function Failure information
• "Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
• When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential mechanism is turned ON. Cause
Presumed cause and standard value in normalcy
1
Travel steering PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S31 (male) Between
and
Travel control lever
Resistance value
NEUTRAL
Above 1 MΩ
One side of right or left only
Below 1 Ω
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between C02 (female) and S31 (female) value defective contact Resistance with connector) Below 1 Ω Wiring harness from S31 (female) to J05 to grounding value ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting.
4
Between wiring harness between C02 (female) (female) and grounding
Between wiring harness between C02 (female) (female) and grounding
and S31
and S31
Resistance value
Voltage
Above 1 MΩ
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 5
Governor • pump controller defective
C02 Between
20-544 (7)
and grounding
Travel control lever
Voltage
NEUTRAL
20 – 30 V
One side of right or left only
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-29
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC300/350(LC)-7
20-545
TROUBLESHOOTING
E-30
E-30 "Service" is not correctly displayed in monitor function If attachment equipped Failure information
• "Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
— Cause
1
Presumed cause and standard value in normalcy
2
Service (front) PPC hydraulic switch fault (Internal disconnection or short-circuiting) Service (rear) PPC hydraulic switch fault (Internal disconnection or short-circuiting)
Standard value in normalcy and references for troubleshooting ★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S10 (male) Between
and
Service pedal
Resistance value
NEUTRAL
Above 1 MΩ
Front
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running during the troubleshooting. S11 (male) Between
and
Service pedal
Resistance value
NEUTRAL
Above 1 MΩ
Rear
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting.
3
4
5
Disconnection of wirWiring harness between C02 (female) and S10 (female) ing harness (Disconnection or , or wiring harness between C02 (female) and S11 defective contact (female) with connector) Wiring harness between S10 (female) and grounding Grounding fault of wiring harness (Contact with grounding (GND) circuit) Short-circuiting of wiring harness (Contact with 24 V circuit)
Resistance value
Below 1 Ω
Resistance value
Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Wiring harness between C02 (female) and S10 (female) , or between wiring harness between C02 (female) and S11 (female) and grounding
Resistance value
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. Wiring harness between C02 (female) and S10 (female) , or between wiring harness between C02 (female) and S11 (female) and grounding
Voltage
Below 1 V
★Turn the engine starting switch OFF for the preparations, and start the engine during the troubleshooting. 6
Governor • pump controller defective
C02 Between
20-546 (7)
and grounding
Service pedal
Voltage
NEUTRAL
20 – 30 V
Front or rear
Below 1 V
PC300/350(LC)-7
TROUBLESHOOTING
E-30
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC300/350(LC)-7
20-547
TROUBLESHOOTING
E-31
E-31 Air Conditioner does not work PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000 • The air conditioner does not work.
Relative information
• For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND FUNCTION - Air Conditioner in this manual.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Fuse No. 11 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
2
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. (See Cause 3) ing harness Resistance (Disconnection or Below 1 Ω Wiring harness between FB1-11 outlet and M26 (male) value defective contact Resistance with connector) Below 1 Ω Wiring harness between M26 (male) and grounding value
3
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
4
Air conditioner unit defective
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-11 outlet and M26 (male) and grounding
(7)
Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position during the troubleshooting. M26 Between
20-548
Voltage
Voltage and
20 – 30 V
PC300/350(LC)-7
TROUBLESHOOTING
E-31
Electrical Circuit Diagram for Air Conditioner
PC300/350(LC)-7
20-549 (7)
TROUBLESHOOTING
E-31
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up Troubleshooting procedure for air conditioner system ★ The control panel of the air conditioner constantly monitors the sensors and other devices in the system . When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially. ★ If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to the procedure for “Troubleshooting by self-diagnosis notice”, and then; • If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”. • If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice ★ Check the “Self-diagnosis notice” on the control panel according to the following procedure. •
How to display “Self-diagnosis notice” 1) Turn the starting switch ON. 2) Press OFF switch (1) and check that anything is not displayed on display monitor (2). 3) Hold the UP switch ( ) and DOWN switch ( ) of temperature setting switch (3) simultaneously for 3 seconds or more. 4) Check the “Self-diagnosis notice” displayed on display monitor (2).
•
How to select “Self-diagnosis notice” If multiple “Self-diagnosis notices” are recorded, press the UP switch ( ) or DOWN switch ( ) of temperature setting switch (3) to select another notice.
•
How to delete “Self-diagnosis notice” When reproducing the “Self-diagnosis notices” or after removing the cause of a failure, press the switches on both sides of recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the “Self-diagnosis notices” are deleted.
•
Finishing display of “Self-diagnosis notice” To finish display of the “Self-diagnosis notice”, press OFF switch (1) or turn the starting switch OFF.
20-550 (7)
Self-diagnosis Failure mode notice E-No failures Disconnection in recirculated air E11 sensor E12 Short-circuit in recirculated air sensor Disconnection in water temperature E15 sensor Short-circuit in water temperature E16 sensor E18 Short-circuit in daylight sensor E43 Abnormality in air outlet damper E44 Abnormality in air mix damper Abnormality in recirculated and fresh E45 air damper
PC300/350(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Disconnection in recirculated air sensor
E11 Contents of trouble Action of control panel
• Disconnection in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated 1 air sensor (Internal disconnection)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and TH I (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Short circuit in recirculated air sensor
E12 Contents of trouble Action of control panel
• Short circuit in the recirculated air sensor system is detected. • Fixes the recirculated air temperature for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause Defective recirculated air 1 sensor (Internal short circuit)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
PC300/350(LC)-7
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THI (male)
Resistance
Between (1) and (2)
300 z – 430 kz
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (12) and TH I (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and TH I (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-551 (7)
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Disconnection in water temperature sensor
E15 Contents of trouble Action of control panel
• Disconnection in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting without turning Defective water temperastarting switch ON. 1 ture sensor (Internal disTHW (male) Resistance connection) Between (1) and (2) 95 z – 455 kz Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Short circuit in water temperature sensor
E16 Contents of trouble Action of control panel
• Short circuit in the water temperature sensor system is detected. • Ignores the warm-up control and fixes the engine water temperature at 60°C for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause Defective water tempera1 ture sensor (Internal short circuit)
Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
20-552 (7)
Defective air conditioner system
Standard value in normal state/Remarks on troubleshooting ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. THW (male)
Resistance
Between (1) and (2)
95 z – 455 kz
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (14) and THW (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (11) and THW (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC300/350(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Short circuit in daylight sensor
E18 Contents of trouble Action of control panel
• Short circuit in the daylight sensor system is detected. • Assumes that the daylight sensor is not installed for control. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective daylight sen1 The daylight sensor may be defective. Check it directly. sor (Internal short circuit) Disconnection of wiring harness (Disconnection 2 or defective contact with connector)
3
Defective air conditioner system
Self-diagnosis notice
Trouble
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between M30 (female) (16) and P15 (female) (2)
Resistance
Max. 1 z
Wiring harness between M30 (female) (3) and P15 (female) (1)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Abnormality in air outlet damper
E43 Contents of trouble
• Abnormality in air outlet servomotor system is detected.
Action of control panel
• Stops the air outlet servomotor. • When the following condition is satisfied, the operation returns to normalcy. • + + +
Related information
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Standard value in normalcy and references for troubleshooting
Possible causes and standard value in normal state
Defective air outlet servo1 The air outlet servomotor may be defective. Check it directly. motor (Internal defect) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
3
Defective air conditioner system
PC300/350(LC)-7
Wiring harness between MV1 (female) (1) and M30 (female) (3)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (3) and M29 (female) (11)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (5) and M30 (female) (9)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (6) and M29 (female) (8)
Resistance
Max. 1 z
Wiring harness between MV1 (female) (7) and M29 (female) (9)
Resistance
Max. 1 z
If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-553 (7)
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Abnormality in air mix damper
E44 Contents of trouble
• Abnormality in air mix servomotor system is detected.
Action of control panel
• Stops the air mix servomotor. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils. Cause
Possible causes and standard value in normal state
Defective air mix servo1 motor (Internal defect)
The air mix servomotor may be defective. Check it directly. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
3
20-554 (7)
Standard value in normal state/Remarks on troubleshooting
Defective air conditioner system
Wiring harness between MAM (female) (1) and M29 (female) (11)
Resistance
Max. 1 z
Wiring harness between MAM (female) (3) and M30 (female) (3)
Resistance
Max. 1 z
Wiring harness between MAM (female) (5) and M30 (female) (2)
Resistance
Max. 1 z
Wiring harness between MAM (female) (6) and M29 (female) (4)
Resistance
Max. 1 z
Wiring harness between MAM (female) (7) and M29 (female) (5)
Resistance
Max. 1 z
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC300/350(LC)-7
TROUBLESHOOTING
Self-diagnosis notice
Trouble
E-31
Abnormality in recirculated and fresh air damper
E45 Contents of trouble
• Abnormality in recirculated and fresh air servomotor system is detected.
Action of control panel
• Stops the recirculated and fresh air servomotor. • When the following condition is satisfied, the operation returns to normalcy. + + +
Related information
★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Possible causes and standard value in normal state
Cause
Standard value in normal state/Remarks on troubleshooting
Defective recirculated 1 and fresh air servomotor (Internal defect)
The recirculated and fresh air servomotor may be defective. Check it directly.
2 Defective fuse (in unit)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 3 in wiring harness or defective contact in connector)
4
Defective air conditioner system
PC300/350(LC)-7
Wiring harness between MRF (female) (1) and M29 (female) (6)
Resistance
Max. 1 z
Wiring harness between MRF (female) (3) and M29 (female) (7)
Resistance
Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit, and M33 (female) (3)
Resistance
Max. 1 z
If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-555 (7)
TROUBLESHOOTING
E-31
Electrical Circuit Diagram for Air Conditioner
20-556 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-31
Troubleshooting by failure phenomenon Trouble
• The air conditioner does not operate.
(1) The air conditioner does not operate at all.
Related information Cause 1 Defective fuse No. 11
Standard value in normal state/Remarks on troubleshooting If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.) ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes and standard value in normal state
Disconnection in wiring harness (Disconnection 2 in wiring harness or defective contact in connector)
Short circuit with chassis ground in wiring harness 3 (Contact with ground circuit)
Wiring harness between fuse 11 outlet and M33 (male) (3)
Resistance
Max. 1z
Wiring harness between M27 (female) (14) and M30 (female) (6)
Resistance
Max. 1z
Wiring harness between M33 (male) (3) and chassis ground
Resistance
Max. 1z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1z
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Between wiring harness between circuit breaker fuse 11 outlet and M33 (male) (3) and chassis ground
Resistance
Min. 1 Mz
Between wiring harness between M27 (female) (14) and M30 (female) (6) and chassis ground
Resistance
Min. 1 Mz
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 4
Defective air conditioner unit
M33
Voltage
Between (2) and (3)
20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective. ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. 5 Defective control panel
M30, M29
Voltage
Between M30 (6) and M29 (12)
20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control panel is defective.
PC300/350(LC)-7
20-557 (7)
TROUBLESHOOTING
Trouble
E-31
• The air conditioner does not operate.
(2) Air does not come out (Air flow is insufficient).
Related information Cause 1 Defective fuse (in unit)
2
3
Defective blower relay (on coil side)
Defective blower relay (on contact side)
Possible causes and standard value in normal state
Defective power transis4 tor (Internal defect)
★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R30 (male)
Resistance
Between (1) and (3)
140 – 340 z
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. R30
Fan switch
Voltage
Between (4) and chassis ground
ON (Operated)
20 – 30 V
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Fan switch
If air flow can be changed with fan switch, Operate in range of Low, Medium, and High power transistor is normal. ★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting.
5
Defective blower motor (Internal defect)
MB (female)
Fan switch
Voltage
Between (1) and (2)
ON (Operated)
20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 6 in wiring harness or defective contact in connector)
7
20-558 (7)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
Defective air conditioner system
Wiring harness between fuse 11 outlet, fuse in unit, R30 (3), R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between M29 (female) (3) and R30 (female) (1)
Resistance
Max. 1 z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1 z
Wiring harness between MB (female) (1) and R30 (female) (4)
Resistance
Max. 1 z
Wiring harness between MB (female) (2) and PTR (female) (3)
Resistance
Max. 1 z
Wiring harness between PTR (female) (1) and chassis ground
Resistance
Max. 1 z
Wiring harness between PTR (female) (2) and M30 (female) (7)
Resistance
Max. 1 z
Wiring harness between PTR (female) (4) and M30 (female) (8)
Resistance
Max. 1 z
If none of causes 1 – 6 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC300/350(LC)-7
TROUBLESHOOTING
Trouble
E-31
• The air conditioner does not operate.
(3) Air is not cooled (Cooling capacity is low).
Related information Cause 1 Defective fuse (in unit)
2
3
Possible causes and standard value in normal state
4
Defective compressor relay (on coil side)
Defective compressor relay (on contact side)
Defective thermostat (Internal defect)
Defective high/low pres5 sure switch (Internal disconnection)
Standard value in normal state/Remarks on troubleshooting If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. R31 (male)
Resistance
Between (1) and (2)
140 – 340 z
★ Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position). R31
Fan switch
Voltage
Between (4) and chassis ground
ON (Operated)
20 – 30 V
The thermostat may be defective. Check it directly. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. P17 (male)
Resistance
Between (1) and (2)
Max. 1 z
6
Defective compressor clutch (Internal defect)
The compressor clutch may be defective. Check it directly.
7
Defective compressor (Internal defect)
The compressor may be defective. Check it directly. ★ Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection 8 in wiring harness or defective contact in connector)
9
Defective air conditioner system
PC300/350(LC)-7
Wiring harness between M30 (female) (4) and P17 (female) (1)
Resistance
Max. 1 z
Wiring harness between P17 (female) (2) and chassis ground
Resistance
Max. 1 z
Wiring harness between fuse 11 outlet, R31 (female) (2), fuse in unit, R31 (female) (1), and M30 (female) (6)
Resistance
Max. 1 z
Wiring harness between ST1 (female) (1) and R31 (female) (3)
Resistance
Max. 1 z
Wiring harness between M29 (female) (2) and ST1 (female) (2)
Resistance
Max. 1 z
Wiring harness between M29 (female) (12) and chassis ground
Resistance
Max. 1 z
Wiring harness between R31 (female) (4) and M34 (female) (1)
Resistance
Max. 1 z
If none of causes 1 – 8 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
20-559 (7)
TROUBLESHOOTING
E-31
Electrical Circuit Diagram for Air Conditioner
20-560 (7)
PC300/350(LC)-7
TROUBLESHOOTING
E-32
E-32 Travel alarm does not sound If travel alarm equipped Failure information
• The travel alarm does not sound while the machine is traveling. • The alarm begins to sound when the machine is at a standstill.
Relative information
—
Presumed cause and standard value in normalcy
1
Cause
Standard value in normalcy and references for troubleshooting
Fuse No. 15 fault
When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. (See Cause 4) If the monitor display is not correct, proceed to No. E-21 Troubleshooting.
2
Travel signal fault
Monitoring code
Item
Normal display
019
Travel
Control lever operation: ON Control lever NEUTRAL: OFF
3
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position Disconnection of wirduring the troubleshooting. ing harness Wiring harness between FB1-15 outlet to J03 and A43 Resistance (Disconnection or Below 1 Ω value (female) defective contact Resistance with connector) Below 1 Ω Wiring harness between A43 (female) and J01 value
4
Grounding fault of wiring harness (Contact with grounding (GND) circuit)
5
Travel alarm fault
PC300/350(LC)-7
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position during the troubleshooting. Between wiring harness between FB1-15 outlet to J03 and A43 (female) and grounding
Resistance value
Above 1 MΩ
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
20-561 (7)
TROUBLESHOOTING
E-32
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
20-562 (7)
PC300/350(LC)-7
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-602 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-604 H-1 All work equipment lack power, or travel and swing speeds are slow .............................................. 20-605 H-2 Engine speed sharply drops or engine stalls .................................................................................... 20-606 H-3 No work equipment, travel or swing move ........................................................................................ 20-607 H-4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-607 H-5 Auto-decelerator does not work ........................................................................................................ 20-608 H-6 Fine control mode does not function................................................................................................. 20-608 H-7 Boom moves slowly or lacks power .................................................................................................. 20-609 H-8 Arm moves slowly or lacks power..................................................................................................... 20-610 H-9 Bucket moves slowly or lacks power ................................................................................................ 20- 611 H-10 Work equipment does not move in its single operation .................................................................... 20-611 H-11 Work equipment has a bit too fast hydraulic drift .............................................................................. 20-612 H-12 Work equipment has big time lag...................................................................................................... 20-613 H-13 Other work equipment moves when relieving single circuit .............................................................. 20-613 H-14 One-touch power max. switch does not operate .............................................................................. 20-613 H-15 In compound operation, work equipment with larger load moves slowly .......................................... 20-614 H-16 In swing + boom RAISE operation, boom moves slowly .................................................................. 20-614 H-17 In swing + travel, travel speed drops sharply.................................................................................... 20-614 H-18 Machine swerves in travel ................................................................................................................ 20-615 H-19 Machine travels slowly ...................................................................................................................... 20-616 H-20 Machine cannot be easily steered or lacks power ............................................................................ 20-617 H-21 Travel speed does not shift, or it is too slow or fast. ......................................................................... 20-618 H-22 Track shoe does not turn (on one side only)..................................................................................... 20-618 H-23 Machine does not swing ................................................................................................................... 20-619 H-24 Swing acceleration is poor, or swing speed is slow .......................................................................... 20-620 H-25 Excessive overrun when stopping swing .......................................................................................... 20-621 H-26 There is big shock when stopping swing .......................................................................................... 20-622 H-27 There is big abnormal noise caused when stopping swing .............................................................. 20-622 H-28 Swing natural drift is too big.............................................................................................................. 20-623
PC200/220(LC)-7
20-601
TESTING AND ADJUSTING
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-602
PC200/220(LC)-7
TESTING AND ADJUSTING
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
PC200/220(LC)-7
20-603
TESTING AND ADJUSTING
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out troubleshooting work after fully grasping their contents. Phenomena occurring on machine
Relative information
Information on occurred failures and troubleshooting
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
2
3
Cause for presumed failure (The attached No. for filing and reference purpose only. It does not stand for any priority)
• The standard values in normalcy by which to judge "good" or "no good" about presumed causes. • References for making judgement of "good" or "no good"
4
5
20-604
PC200/220(LC)-7
TESTING AND ADJUSTING
H-1
H-1 All work equipment lack power, or travel and swing speeds are slow Failure information
• All the work equipment lack power, or their travel and swing speeds are slow.
Relative information
• Set the working mode at A mode for troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of unload valve
Control lever
Unload pressure
All control levers in NEUTRAL
3.9 ± 1.0 MPa {40 ± 10kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
2
Improper adjustment or malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.34 – 37.23 MPa {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal failure is suspected. In that case, check the valve itself.
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling. 3
Malfunctioning of self pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 – 3.43 MPa {29 – 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure to be measured 4
Improper adjustment or malfunctioning of PC valve
Pump delivery pressure PC valve output pressure
Measurement condition
Oil pressure ratio
Swing lock: ON Arm digging relief
Approx. 3/5
1
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of PC valve or its internal failure is suspected. In that case, check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling. 5
Malfunctioning of LS-EPC valve
Travel speed
Travel control lever
LS-EPC output pressure
Lo
NEUTRAL
Approx. 1.4 MPa {Approx. 14 kg/cm2}
Hi
Travel control lever
0{0}
Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured 6
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL Nearly equal pressure
Travel without load (control lever held at half stroke) 1 Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal failure is suspected. In that case, check the valve itself. 7
Malfunctioning of servo piston
Malfunctioning of servo piston is suspected. Check the piston itself.
8
Piston pump defective
If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance, malfunctioning or internal failure.
PC200/220(LC)-7
20-605
TESTING AND ADJUSTING
H-2
H-2 Engine speed sharply drops or engine stalls Failure information
• The engine speed sharply drops or the engine stalls.
Relative information
• Relative Information
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Improper adjustment or malfunctioning of main relief valve
Control lever
Main relief pressure
Arm, DIGGING
33.34 – 37.23 MPa {340 – 375kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve or its internal failure is suspected. In that case, check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure to be measured 2
Improper adjustment or malfunctioning of PC valve
Pump delivery pressure PC valve output pressure
Measurement condition
Oil pressure ratio
Swing lock: ON Arm digging relief
1 Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its internal failure is suspected. In that case, check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured 3
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL Nearly equal pressure
Travel without load (control lever held at half stroke) 1 Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4
Orifice or filter in servo equipment clogged
The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.
5
Malfunction of servo piston
The servo piston is suspected of malfunction. Check the piston itself.
20-606
PC200/220(LC)-7
TESTING AND ADJUSTING
H-3, H-4
H-3 No work equipment, travel or swing move • No work equipment nor travel and swing functions can be set in motion.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of PPC lock solenoid valve
Safety lock lever
Main relief pressure
Locked
0{0}
Released
2.84 – 3.43 MPa {29 – 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling. 2
Malfunctioning of self pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL position
2.83 – 3.43 MPa {29 – 35kg/cm2}
3
Piston pump defective
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner. • Remove the oil pressure measurement plug and crank the engine. If oil flows out, it is in normal condition.
4
Damper defective
It is presumed that the pump shaft does not rotate due to some internal failure of the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump • An abnormal noise is heard from around the hydraulic pump.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Hydraulic oil level lowered
Make a visual check.
2
Quality of hydraulic oil bad
Air may have get mixed with the oil. Make a visual check.
3
Hydraulic tank cap breather clogged
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside the tank. Make a visual check.
4
Hydraulic tank strainer clogged
It is presumed that the strainer in the hydraulic tank is clogged, thereby causing negative pressure in the suction circuit. Make a visual check.
5
Piston pump defective
The piston pump is suspected of an internal failure. Check the pump itself.
PC200/220(LC)-7
20-607
TESTING AND ADJUSTING
H-5, H-6
H-5 Auto-decelerator does not work • The auto-decelerator does not work.
Relative information
• This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually located inside PPC valve) • Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Travel control lever
PPC valve output pressure
NEUTRAL
0{0}
Operation
Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of travel PPC valve (shuttle valve)
H-6 Fine control mode does not function Failure information
• The fine control mode poorly functions or its response is slow.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
2
Malfunctioning of LS-EPC valve
Orifice in LS circuit clogged
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.4 MPa {Approx. 14 kg/cm2}
Hi
Travel control lever
0{0}
The orifice in the LS circuit is presumed to be clogged. Check the orifice itself. Stop engine for preparations. Start troubleshooting at engine high idling. Oil pressure ratio Oil pressure to be measured
3
Improper adjustment or malfunctioning of LS valve
Pump delivery pressure PC valve output pressure
All control levers in NEUTRAL Nearly equal oil pressure
Travel without load (control lever held at half stroke) 1 Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal failure is suspected. In that case, check the valve itself. 4
20-608
Malfunctioning of servo piston
Malfunctioning of the servo piston is suspected. Check the piston itself.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-7
H-7 Boom moves slowly or lacks power Failure information
• The boom moves slowly or lacks power
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of right PPC valve (in boom circuit)
Boom lever
PPC valve output pressure
NEUTRAL
0{0}
RAISE or LOWER
Above 2.7 MPa {Above 28 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
Malfunction of merge/divide solenoid valve
Travel lever
Solenoid output pressure
NEUTRAL
0{0}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
3
Malfunctioning of merge/divide valve (main and LS valves)
The merge/divide valve (main and LS valves) is presumed to malfunction. Check the valve itself.
4
Malfunctioning of boom control valve (spool)
The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
5
Malfunctioning of boom control valve (pressure compensation valve)
The pressure compensation valve in the boom control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
6
Malfunctioning of boom control valve (regeneration valve)
The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve itself.
7
Malfunctioning of boom control valve (lock valve)
The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.
8
Malfunctioning of boom control valve (check valve)
The check valve in the boom control valve (Hi) is presumed to malfunction. Check the valve itself.
9
Malfunctioning of safety valve for lock valve or seal defective
The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself.
Malfunctioning of boom control 10 valve (suction valve) or seal defective
The suction valve in the boom control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective.
Malfunctioning of boom control 11 valve (safety and suction valves) or seal defective
The safety and suction valves in the boom control valve (Lo) are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves.
Malfunctioning of LS shuttle 12 valve (left travel, bucket and service valves)
LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to malfunction. Check those valves themselves. Stop engine for preparations. Start troubleshooting at engine high idling.
13 Boom cylinder defective
PC200/220(LC)-7
Boom lever
Amount oil leakage from cylinder
Raise relief
20 cc/min
20-609
TESTING AND ADJUSTING
H-8
H-8 Arm moves slowly or lacks power Failure information
• The arm moves slowly, or lacks power.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting +Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of left PPC valve (arm circuit)
Arm lever
PPC valve output pressure
NEUTRAL
0{0}
DIGGING or DUMPING
Above 2.7 MPa {Above 28 kg/cm2}
Presumed cause and standard value in normalcy
+Stop engine for preparations. Start troubleshooting at engine high idling. 2
Malfunctioning of merge/divide solenoid valve
Travel lever
Solenoid output pressure
NEUTRAL
0{0}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
3
Malfunctioning of merge/divide valve (main and LS valves)
The merge/divide valve (main and LS valves) is presumed to malfunction. Check the valve itself.
4
Malfunctioning of arm control valve (spool)
The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
5
Malfunctioning of arm control valve (pressure compensation valve)
The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to malfunction. Check the valve itself.
6
Malfunctioning of arm control valve (regeneration valve)
The regeneration valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be defective. Check the valve itself.
7
Malfunctioning of arm control valve (safety and suction valves) or seal defective
The safety and suction valves in the arm control valve (Lo • Hi) are presumed to malfunction, or the seal is suspected of defect. Check those valves themselves.
8
Malfunctioning of arm control valve (quick return valve)
The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself.
9
Malfunctioning of LS shuttle valve (right travel, boom, left travel, bucket and service valves)
LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control valve and service valve are presumed to malfunction. Check those valves themselves. +Stop engine for preparations. Start troubleshooting at engine high idling.
10 Arm cylinder defective
20-610
Arm lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
PC200/220(LC)-7
TESTING AND ADJUSTING
H-9, H-10
H-9 Bucket moves slowly or lacks power Failure information
• The bucket moves slowly, or lacks power.
Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Malfunctioning of right PPC valve (bucket circuit)
Bucket lever
PPC valve output pressure
NEUTRAL
0{0}
DIGGING or DUMPING
Above 2.7 MPa {Above 28 kg/cm2}
2
Malfunctioning of bucket control valve (spool)
The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
3
Malfunctioning of bucket control valve (pressure compensation valve)
The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve itself.
4
Malfunctioning of bucket control valve (safety and suction valves) or seal defective
The safety and suction valves in the bucket control valve are presumed to malfunction, or the seal is suspected to be defective. Check those valves themselves.
5
Malfunction of LS shuttle valve (service valve)
The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself.
6
Bucket cylinder defective
Stop engine for preparations. Start troubleshooting at engine high idling. Bucket lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
H-10 Work equipment does not move in its single operation • The boom does not move when operated independently. • The arm does not move when operated independently. • The bucket does not move when operated independently.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
2
Malfunctioning of PPC valve
Malfunctioning of work equipment control valve (spool)
PC200/220(LC)-7
Work equipment control lever
PPC valve output pressure
NEUTRAL
0{0}
Operation
Above 2.7 MPa {Above 28 kg/cm2}
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
20-611
TESTING AND ADJUSTING
H-11
H-11 Work equipment has a bit too fast hydraulic drift Failure information (1) • Hydraulic drift of the boom is a bit too fast.
Presumed cause and standard value in normalcy
Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling. Boom control lever
Amount oil leakage from cylinder
Raise relief
20 cc/min
1
Boom cylinder defective
2
Boom control lever (lock valve) seal defective
The seal at lock valve in the boom control valve (Lo) is suspected to be defective. Check the valve itself.
3
Seal at safety valve for lock valve defective
The seal at the safety valve in the lock valve is suspected to be defective. Check the valve itself.
Failure information (2) • Hydraulic drift of the arm is a bit too fast. Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Arm cylinder defective
Arm control lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
2
Arm control valve (safety and suction valves) seal defective
The seal for safety and suction valves in the arm control valve (Lo • Hi) is suspected to be defective. Check the valve itself. Whether the seal is defective or not may well be determined by changing for other safety and suction valves. (Do not attempt to change them for the safety and suction valves for the boom LOWER and the lock valve, because the set pressure differs)
3
Arm control valve (spool) seal defective
The seal for spool in the arm control valve (Lo • Hi) is suspected to be defective. Check the seal itself.
4
Arm control valve (pressure compensation valve) seal defective
The seal for pressure compensation valve in the arm control valve (Lo • Hi) is suspected to be defective. Check the seal itself.
Failure information (3) • Hydraulic drift of the bucket is a bit too fast. Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Bucket cylinder defective
Bucket control lever
Amount oil leakage from cylinder
Digging relief
20 cc/min
2
Bucket control valve (safety and suction valves) seal defective
The seal for the safety and suction valves in the bucket control lever is suspected to be defective. Check the seal itself. Whether the seal is defective or not may well be determined by changing for other safety and suction valves. (Do not attempt to change them for the safety and suction valves for the boom LOWER and the lock valve, because the set pressure differs)
3
Bucket control valve (spool) seal defective
The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.
4
Bucket control valve (pressure compensation valve) seal defective
The seal for pressure compensation valve in the bucket control valve is suspected to be defective. Check the seal itself.
20-612
PC200/220(LC)-7
TESTING AND ADJUSTING
H-12, H-13, H-14
H-12 Work equipment has big time lag Failure information
• The work equipment has a big time lag.
Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Malfunctioning of LS-EPC valve
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.4 MPa {approx. 14 kg/cm2}
Hi
Operation
0{0}
Malfunctioning of control valve (regeneration valve) - with boom and arm only
The regeneration valve in the control valve is presumed to malfunction. Check the valve itself.
3
Malfunctioning of control valves (safety & suction valve)
The safety and suction valves of the control valve are presumed to malfunction. Check those valves themselves directly. For the arm and boom, whether they are defective or not may well be determined by changing them for other safety and suction valves. (Do not attempt to change them for the safety and suction valves for the boom LOWER and the lock valve, because each set pressure differs)
4
Malfunctioning of control valve (pressure compensation valve)
The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.
2
H-13 Other work equipment moves when relieving single circuit • Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
1
Standard value in normalcy and references for troubleshooting
Control valve (pressure comThe seal for pressure compression valve in the control valve is suspected to pensation valve) seal defective be defective. Check the seal itself.
H-14 One-touch power max. switch does not operate • The one-touch power max. switch does not operate.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
2
Malfunctioning of 2-stage solenoid valve
Malfunctioning of main relief valve
PC200/220(LC)-7
Swing lock switch
Solenoid valve output pressure
OFF
0{0}
ON
2.84 – 3.43 MPa {29 – 35kg/cm2}
The main relief valve is presumed to malfunction. Check the valve itself.
20-613
TESTING AND ADJUSTING
H-15, H-16, H-17
H-15 In compound operation, work equipment with larger load moves slowly • In a compound operation, work equipment with larger load tends to move slowly.
Relative information
—
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting The pressure compensation valve for the work equipment with larger load is presumed to malfunction. Check the valve itself.
1
Malfunctioning of pressure compensation valve for work equipment with larger load
Combination of compound operation
Work equipment with larger load
Boom RAISE + arm DIGGING
Boom RAISE
Boom RAISE + arm DUMPING
Arm DUMPING
Boom RAISE + bucket DIGGING
Boom RAISE
Arm DUMPING + bucket DIGGING
Arm DUMPING
Boom LOWER + arm DUMPING
Arm DUMPING
H-16 In swing + boom RAISE operation, boom moves slowly • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information
• If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Presumed cause and standard value in normalcy
Failure information
1
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS select valve or seal defective
The LS select valve is presumed to malfunction, or the seal is suspected to be defective. Check the valve and seal themselves.
H-17 In swing + travel, travel speed drops sharply • In a compound operation of swing + travel, the travel speed drops sharply.
Relative information
• If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
Presumed cause and standard value in normalcy
Failure information
1
20-614
Cause
Standard value in normalcy and references for troubleshooting
Malfunctioning of LS shuttle valve (left travel and swing)
The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction. Check both of them directly.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-18
H-18 Machine swerves in travel Failure information
• The machine tends to swerve while traveling.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of travel PPC valve
Travel control lever
PPC valve output pressure
Forward or reverse
Above 2.7 MPa {Above 28 kg/cm2}
Differential output between right and left sides
Below 0.4 MPa {Below 4 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
Malfunctioning of self-pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 – 3.43 MPa {29 – 35 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling. Oil Pressure ratio 3
Improper adjustment or malfunctioning of LS valve
Oil pressure to be measured Pump delivery pressure LS valve output pressure
All control levers in NEUTRAL Nearly equal pressure
Travel without load (control lever held at half stroke) 1 Approx. 3/5
Stop engine for preparations. Start troubleshooting at engine high idling. 4
Malfunctioning of travel interlocking solenoid valve
Travel control lever
Solenoid valve output pressure
Operating one side only
0 {0}
Operating both sides
2.84 – 3.43 MPa {29 – 35 kg/cm2}
5
Malfunctioning of travel interlocking valve
The travel interlocking valve is presumed to malfunction. Check the valve itself.
6
Malfunctioning of travel control valve (spool)
The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself. Stop engine for preparations. Start troubleshooting at engine high idling.
7
8
Malfunction of travel motor
Final drive defective
PC200/220(LC)-7
Travel control lever
Amount of oil leakage from travel motor
Travel relief
30 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final drive directly. An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.
20-615
TESTING AND ADJUSTING
H-19
H-19 Machine travels slowly Failure information
• The machine's travel speed is slow.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of travel PPC valve
Travel control lever
PPC valve output pressure
Forward or reverse
Above 2.7 MPa {Above 28 kg/cm2}
Output differential between right and left or front and rear
Below 0.4 MPa {Below 4 kg/cm2}
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling. 2
Malfunctioning of self-pressure decompression valve
Control lever
Control circuit source pressure
All control levers in NEUTRAL
2.83 – 3.43 MPa {29 – 35kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
3
Malfunctioning of LS-EPC valve
Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.4 MPa {approx. 14 kg/cm2}
Hi
Travel control lever
0 {0}
4
Malfunction of travel control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
5
Malfunctioning of travel control valve (pressure compensation valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
6
Malfunctioning of travel control valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
7
Malfunctioning of LS shuttle valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
7
Malfunction of travel motor
Stop engine for preparations. Start troubleshooting at engine high idling.
8
Final drive defective
20-616
Travel control lever
Amount of oil leakage from travel motor
Travel relief
30 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final drive directly. An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or metal chip or dust contained in the drained oil.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-20
H-20 Machine cannot be easily steered or lacks power Failure information
• The machine cannot be easily steered.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of travel PPC valve (steering spool)
Travel control lever
PPC valve output pressure (steering)
NEUTRAL on both sides
0 {0}
Operating one side only
Above 2.7 MPa {Above 28 kg/cm2}
Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
2
3
Malfunctioning of travel interlocking solenoid valve
Malfunctioning of travel interlocking valve
Travel control lever
Solenoid valve output pressure
Operating both sides
0 {0}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The travel interlocking valve is presumed to malfunction. Check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling.
4
Malfunctioning of merge/divide solenoid valve
Travel control lever
Solenoid valve output pressure
Operating both sides
0 {0}
Operating one side only
2.84 – 3.43 MPa {29 – 35 kg/cm2}
5
Malfunctioning of merge/divide valve
The merge/divide valve is presumed to malfunction. Check the valve itself.
6
Malfunction of travel control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
7
Malfunctioning of travel control valve (pressure compensation valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
8
Malfunctioning of travel control valve (suction valve)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
9
Malfunctioning of LS shuttle valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
10
Check valve seal defective at LS oil pressure pickup port
The seal in the check valve of LS oil pressure pickup port is suspected to be defective. Check the seal itself.
Malfunctioning of travel motor 11 (safety valve)
The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.
Malfunctioning of travel motor 12 (check valve)
The seal in the check valve of the travel motor is suspected of defect. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the motors between forward and reverse, or right and left.
PC200/220(LC)-7
20-617
TESTING AND ADJUSTING
H-21, H-22
H-21 Travel speed does not shift, or it is too slow or fast. Failure information
• Travel speed does not shift, or it is either too fast or slow.
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed
Travel control lever
Monitoring [15]
Lo
Fine control (to the extent that the decelerator is released)
690 mA
( 1
Malfunctioning of LS-EPC valve
Mi) Hi
740 mA 0 mA
Stop engine for preparations. Start troubleshooting at engine high idling. Travel speed
Travel control lever
LS-EPC valve output pressure
Lo
NEUTRAL
Approx. 1.4 MPa {approx. 14 kg/cm2}
Hi
Operation
0 {0}
Stop engine for preparations. Start troubleshooting at engine high idling.
2
3
Malfunctioning of travel speed solenoid valve
Malfunctioning of travel motor (speed shifting)
Travel speed
Travel control lever
Solenoid valve output pressure
Lo
NEUTRAL
0 {0}
Hi
Operation
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
: The "Mi" mode is on the multi-monitor specification machine only.
H-22 Track shoe does not turn (on one side only) • A track shoe does not turn (only on one side).
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Travel control valve (suction valve) seat defective
The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.
2
Travel motor (safety valve) seat defective
The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
3
Travel motor (check valve) seat defective
The check valve seat in the travel motor is suspected of defect. Check the seat itself. Stop engine for preparations. Start troubleshooting at engine high idling.
4
5
Travel Motor speed reduced
Final drive defective
20-618
Travel control lever
Amount of oil leakage from travel motor
Travel relief
30 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final drive directly. A failure inside the final drive may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.
PC200/220(LC)-7
TESTING AND ADJUSTING
H-23
H-23 Machine does not swing Failure information (1) • The machine swings neither to the right nor to the left. Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
2
Malfunctioning of swing parking brake solenoid valve
Malfunctioning of swing motor (parking brake)
Swing
Solenoid valve
NEUTRAL
0 {0}
Operation
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The parking brake portion of the swing motor is presumed to malfunction. Check it directly. Stop engine for preparations. Start troubleshooting at engine high idling.
3
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.42 – 32.85 MPa {285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling.
4
5
Swing motor defective
Swing machinery defective
Swing control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 ¬/min
The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly. A failure inside the swing machinery may well be determined by an abnormal noise from within, abnormal heat generated or metal dust or chips contained in the drained oil.
Failure information (2) • The machine does not swing in one direction.
Presumed cause and standard value in normalcy
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of PPC valve
Left control lever
PPC valve output pressure
NEUTRAL
0 {0}
Swing operation
Above 2.7 MPa {Above 28 kg/cm2}
2
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the spool itself.
3
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching if there is any change.
4
Swing motor (check valve) seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.
PC200/220(LC)-7
20-619
TESTING AND ADJUSTING
H-24
H-24 Swing acceleration is poor, or swing speed is slow Failure information (1) • Swing acceleration is poor, or swing speed is slow.
Presumed cause and standard value in normalcy
Relative information
• Set the working mode at A mode for the troubleshooting.
Cause
Standard value in normalcy and references for troubleshooting
1
Malfunctioning of LS shuttle valve (all LS shuttles)
The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly.
2
Malfunctioning of swing motor (parking brake)
The parking brake portion of the swing motor is presumed to malfunction. Check it directly. Stop engine for preparations. Start troubleshooting at engine high idling.
3
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.42 – 32.85 MPa {285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. Stop engine for preparations. Start troubleshooting at engine high idling.
4
Swing motor defective
Swing control lever
Amount of oil leakage from swing motor
Swing relief
Below 11 ¬/min
Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow. Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
Malfunctioning of PPC valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
2
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve itself.
3
Malfunctioning of swing motor (pressure compensation valve)
The pressure compensation valve in the swing motor is presumed to malfunction. Check the valve itself.
4
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.
5
Swing motor (check valve) seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.
20-620
PC200/220(LC)-7
TROUBLESHOOTING
H-25
H-25 Excessive overrun when stopping swing Failure information (1) • The work equipment overruns excessively when stopping swing. Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting
Presumed cause and standard value in normalcy
★Stop engine for preparations. Start troubleshooting at engine high idling.
1
Improper adjustment or malfunctioning of swing motor (safety valve)
Swing lock switch
Swing control lever
Swing relief pressure
ON
Swing relief
28.9 – 32.9 MPa {295 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself. ★Stop engine for preparations. Start troubleshooting at engine high idling.
2
Swing motor defective
Control lever
Amount of oil leakage from swing motor
Swing relief
Below 10 l/min
Failure information (2) • The work equipment overruns excessivery only one side when stopping swing. Relative information
• Set the working mode at A mode for the troubleshooting. Cause
Standard value in normalcy and references for troubleshooting ★Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy
1
Malfunctioning of PPC valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
2
Swing PPC slow return valve clogged
The PPC slow return valve is suspected of clogging. Check the valve itself. ★Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching the result.
3
Malfunctioning of swing control valve (spool)
The spool in the swing control valve is resumed to malfunction. Check the valve itself.
4
Swing motor (suction valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself. ★Whether the seal is defective or not may well be determined by swapping the right and left suction valves and watching the result.
5
Swing motor (check valve) seal defective
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself. ★Whether the seal is defective or not may well be determined by swapping the right and left check valves and watching the result.
PC300/350(LC)-7
20-621 (7)
TROUBLESHOOTING
H-26, H-27
H-26 There is big shock when stopping swing • There is a big shock caused when stopping a swing motion.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting ★Stop engine for preparations. Start troubleshooting at engine high idling.
1
2
Malfunctioning of swing PPC valve
Malfunctioning of swing PPC slow return valve
Swing control lever
PPC valve output pressure
NEUTRAL
0 {0}
Left or right
Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valve is presumed to malfunction. Check the valve itself. ★Whether the valve malfunctions or not may well be determined by swapping the right and left valves and watching the result.
H-27 There is big abnormal noise caused when stopping swing • There is a big abnormal noise caused when stopping a swing motion.
Relative information
• Set the working mode at A mode for the troubleshooting.
Presumed cause and standard value in normalcy
Failure information
Cause
Standard value in normalcy and references for troubleshooting
1
Malfunctioning of backpressure valve
The backpressure valve is presumed to malfunction. Check the valve itself.
2
Malfunction of swing motor (safety valve)
The safety valve in the swing motor is presumed to malfunction. Check the valve itself.
3
Malfunction of swing motor (suction valve)
The seal in suction valve of the swing motor is suspected of defect. Check the seal itself. ★Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the result.
Swing machinery defective
The swing machinery is suspected of an internal failure. Check the inside of the machinery itself. ★A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat generated or metal dust or chips contained in the drained oil.
4
20-622 (7)
PC300/350(LC)-7
TESTING AND ADJUSTING
H-28
H-28 Swing natural drift is too big Failure information (1) • Natural drift of the swing is too big (when the parking brake is activated).
Presumed cause and standard value in normalcy
Relative information
• When the emergency swing release switch is in the OFF position (this is a normal condition), the swing and parking brake is activated and the swing is fixed with a disc brake. Cause
Standard value in normalcy and references for troubleshooting Stop engine for preparations. Start troubleshooting at engine high idling.
1
2
Swing and parking brake solenoid valve malfunctioned
Swing motor (parking brake portion) malfunctioned
Swing control lever
Solenoid valve output pressure
NEUTRAL
0 {0}
Left or right
2.84 – 3.43 MPa {29 – 35 kg/cm2}
The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that portion directly.
Failure information (2) • Natural drift of the swing is too big (when the parking brake is released). Relative information
• When the emergency swing release switch is in the ON condition (this is an emergent condition), the swing and parking brake is released and the swing is retained only hydraulically.
Presumed cause and standard value in normalcy
Cause
Standard value in normalcy and references for troubleshooting
1
Swing control valve (spool) malfunctioned
The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
2
Swing control valve (pressure compensation valve) malfunctioned
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself directly.
3
Swing motor (safety valve) defective
The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.
4
Swing motor (suction valve) defective
The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.
5
Swing motor (check valve) defective
The check valve seal in the swing motor is suspected of defect. Check the valve itself directly.
PC200/220(LC)-7
20-623
TROUBLESHOOTING OF ENGINE (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-702 S-1 Starting performance is poor (Starting always takes time) ............................................................... 20-706 S-2 Engine does not start........................................................................................................................ 20-708 (1) Engine does not turn ................................................................................................................... 20-708 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............................... 20-709 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected) ............................ 20-710 S-3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20-711 S-4 Engine stops during operations ........................................................................................................ 20-712 S-5 Engine does not rotate smoothly (Hunting) ...................................................................................... 20-713 S-6 Engine lacks output (or lacks power) ................................................................................................ 20-714 S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-715 S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-716 S-9 Oil becomes contaminated quickly ................................................................................................... 20-717 S-10 Fuel consumption is excessive ......................................................................................................... 20-718 S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-719 S-12 Oil pressure monitor lights up (Drop in oil pressure) ........................................................................ 20-720 S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-721 S-14 Water temperature becomes too high (Overheating)........................................................................ 20-722 S-15 Abnormal noise is made ................................................................................................................... 20-723 S-16 Vibration is excessive ....................................................................................................................... 20-724
PC300/350(LC)-7
20-701 (7)
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING 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 [A] + [B] in the chart on the right corresponds to the items where answers can be obtained from the user. The items in [B] 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 [C] in the chart on the right correspond to this. The serviceman narrows down the causes from information [A] that he has obtained from the user and the results of [C] 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].
Causes
[A]
Questions
(1) (2) (3)
(a) (b) (c) (d)
[C]
(e)
Check items
[B]
Troubleshooting
i
20-702 (7)
ii iii
PC300/350(LC)-7
METHOD OF USING TROUBLESHOOTING CHARTS
fuel
injec tion)
Causes
Seiz
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability are marked with w. Check each of the [Questions] and [Check items] in turn, and marked the Q or w 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. 1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with E to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. 2. Use the E 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.
ed t urbo char Clog ger, ged inter air c fere lean Wor nce er e n pis le men ton ring t Clog , cyli ged nde , seiz r ed f Imp uel in rope jectio r fue l inje n no Defe ction zzle ctive timin fuel g injec tion pum p (e xces sive
TROUBLESHOOTING
Confirm recent repair history Degree of use
PC300/350(LC)-7
Operatred for long period
20-703 (7)
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. S-7
Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black • Insufficient intake of air • Improper condition of fuel injection • Excessive injection of fuel
Seiz
Legend : 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) : Items to confirm the cause.
ed tu rboc Clog harg ged er, in air c terfe Wor lean re n pis er e to leme nce n Clog ring nt , ged cylin , s der eize Imp d fu rope el in r fue jec Defe l inje ctive ction tion noz zle fuel timin Imp injec g rope tion r va pum Crus lve c p (e lear hed xces ance , clo Lea sive gge kage dm fuel uffle injec of a Defe r ir tion) b etwe ctive e conta n tu Deff r boch ct of ectiv a valv e fu e, va rger and el in jecti lve s cylin on p eat der ump hea (rac d k, plu n ge r se ized )
Causes
Confirm recent repair history Degree of use
Operated for long period
Questions
Suddenly became black Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel has been used Noise of interference is heard from around turbocharger Dust indicator is red Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Match marks on fuel injection pump are out of alignment Seal on fuel injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and cylinder head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low Speed of some cylinders does not change when operating on reduced cylinders When check is made using delivery method, fuel injection timing is found to be incorrect Fuel injection pump test shows that fuel injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust gas color returns to normal
20-704 (7)
Replace
Repair
Replace
Adjust
Replace
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy or does not return
PC300/350(LC)-7
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
Three symptoms
Step 2 Add up the total of and marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: (2) Air leakage between turbocharger and cylinder head: (3) Clogged, seized fuel injection nozzle: (4) Defective contact of valve, valve seat: (5) Worn piston ring, cylinder: 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 . The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
PC300/350(LC)-7
20-705 (7)
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (Starting always takes time) 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, ASTM D975 No. 2 diesel fuel is used) a Battery charging rate
Causes
• •
100 %
90 %
80 %
75 %
70 %
20°C
1.28
1.26
1.24
1.23
1.22
0°C
1.29
1.27
1.25
1.24
1.23
–10°C
1.30
1.28
1.26
1.25
1.24
Wor n pis ton r Defe ing, cylin ctive der li cont Clog ner act o ged f valv air c e, va Clog lean lve s e ged r ele eat fuel men Clog filter t , stra ged feed iner Defe pum ctive p ga uze elec filter trica l inta ke a ir he ater
Charging rate Ambient temperature
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.
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse Starts when warm
Preheating monitor does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel has being used Air cleaner clogging monitor lights up Battery charging monitor lights up Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Engine does not pick up smoothly, and combustion is irregular
Check items
Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged Troubleshooting
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 Heater mount does not become warm Yes
Is voltage 26 30V between alternator terminal B and terminal E with engine at low idling?
No
Either specific gravity of electrolyte or voltage of battery is low 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 (check after removing fuel injection pump)
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
Use a test stand when adjusting.
20-706 (7)
PC300/350(LC)-7
PC300/350(LC)-7
Replace
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Replace
Replace Defe ctive regu Defe lator ctive alter Defe nato ctive r or de Defe terio ctive rated injec batte Defe tion ry tive nozz injec le Defe tion timin tive injec g Leak tion pum age, p c lo (rack ggin Clog , plu g, air ged nger air b in fu stuc reath Defe el pip k) ctive er ho ing feed le in Defe f p uel t ump ctive ank boos t com pens ator canc el
TROUBLESHOOTING S-1
Causes
20-707
(7)
TROUBLESHOOTING
S-2
S-2 Engine does not start (1) Engine does not turn General causes why engine does not turn Internal parts of engine seized a If internal parts of the engine are seized, carry out troubleshooting for S-4 "Engine stops during operations".
• •
Failure in hydraulic pump system Defective electrical system
Questions
Defe
•
ctive wirin Defe g of ctive star or d ting Defe eter circu iora ctive it t e s d ba tarti Brok ttery ng m en r otor ing g Defe ear ctive safe Defe ty re ctive lay batt Defe e ry re ctive lay batt Defe ery ctive term inal eng Defe conn ine s ctive ectio top sole star n ting noid swit ch
Causes
Confirm recent repair history Operated for long period Degree of use of machine Condition of horn when Horn sounds starting switch is turned ON Horn volume is low Speed of rotation is low When starting switch is turned to START, pinion moves out, but
Makes grating noise Soon disengages pinion again
20-708 (7)
Replace
Replace
Remedy
Replace
For the following conditions 1) - 4), turn the starting switch OFF, connect the cord, and carry out troubleshooting 1) When terminal B and terminal C of starting switch are connected, engine starts 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 connected, engine starts 4) There is no 24V between battery relay terminal b and terminal E When ring gear is inspected directly, tooth surface is found to be chipped When linkage of engine stop solenoid is disconnected, engine does not start
Replace
Troubleshooting
Specific gravity of electrolyte, voltage of battery is low
Replace
When battery is checked, battery electrolyte is found to be low
Replace
When starting switch is turned to ON, linkage does not move
Replace
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
When starting switch is turned to ON, there is no clicking sound
Replace
Check items
Makes rattling noise and does not turn When starting switch is turned to START, pinion does not move out
PC300/350(LC)-7
TROUBLESHOOTING
S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) General causes why engine turns but no exhaust smoke comes out • • •
Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)
Causes
Brok
en in jecti Defe on p ctive ump injec drive Seiz tion shaf ed, pum t, ke brok p (ra y en f Clog c k, plu eed ged p nge u f uel f mp r se Clog pisto ilter, ized ged n stra ) feed i n e Insu r pum fficie p s t nt fu rain Clog er el in ged tank , lea Clog king ged fuel air b pipin Defe reat g ctive her h e ole i ngin Imp n fu e sto rope el ta p so r fue nk leno l use i d d
a Standards for use of fuel
Questions
Confirm recent repair history Operated for long period Degree of use of machine Exhaust smoke suddenly stops coming out (when starting again) Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty There is leakage from fuel piping Mud is stuck to fuel tank cap Check items
When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pump piping sleeve nut is loosened When starting switch is turned to ON, linkage does not move Rust and water are found when fuel tank is drained
Troubleshooting
Inspect injection pump directly When control rack is pushed, it is found to be heavy, or does not return Inspect feed pump directly 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 When fuel cap is inspected directly, it is found to be clogged
PC300/350(LC)-7
Replace
Replace
Repair
Repair
Add
Clean
Clean
Replace
Replace
Remedy
Replace
When linkage of engine stop solenoid is disconnected, engine does not start
20-709 (7)
TROUBLESHOOTING
S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start
Defe
• • •
Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel
ctive , bro ken v Defe alve ctive syste injec Wor m (v tion alve, n pis pum rocke ton p (ra ring Clog r leve ck, p , cyl ged r, etc lu i n nge fuel der .) r Clog liner stuc filter ged k) , s t rain feed e Clog r pum ged p str air c aine Defe lean r ctive er e leme intak Defe n e air t ctive hea or d ter Lea eter kage iora , clo ted batt Clog ggin ery g, a ged i r in injec fuel Clog tion syst ged nozz em air b le, d Imp reat efec rope h tive e r ho r fue spra le in l use y fuel d tank cap
•
Causes
Confirm recent repair history
Questions
Degree of use of machine
Operated for long period
Suddenly failed to start When engine is cranked, abnormal noise is heard from around cylinder head Engine oil must be added more frequently Non-specified fuel is being used Replacement of filters has not been carried out according to Operation Manual Rust and water are found when fuel tank is drained Air cleaner clogging monitor lights up Preheating monitor does not light up Starting motor cranks engine slowly Mud is stuck to fuel tank cap
Check items
When fuel dial is placed at FULL position, it does not contact stopper When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping
Troubleshooting
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low When fuel filter is drained, no fuel comes out Remove head cover and check directly 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 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 When air cleaner element is inspected directly, it is found to be clogged Heater mount does not become warm Either specific gravity of electrolyte or voltage of battery is low When feed pump is operated, there is no response, or operation is too heavy Speed does not change when operation of certain cylinders is stopped
20-710 (7)
Replace
Clean
Clean
Correct
Replace
Correct
Clean
Clean
Clean
Replace
Replace
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
PC300/350(LC)-7
TROUBLESHOOTING
S-3
S-3 Engine does not pick up smoothly (Follow-up is poor) General causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injction Improper fuel used
Clog ged air c lean Clog er e ged leme f u e l Clog nt filter ged , str aine feed Clog r p u mp ged stra injec iner Seiz tion ed in nozz jectio le, d Wor efec n pu n pis tive mp plun spra ton Seiz ring ger y , cyl ed t inde urbo r line char Imp rope ger, r r va inter lve c Clog fere lear ged nce ance air b reat Clog her ged hole , lea in fu Defe king el ta ctive fuel nk c pipin cont ap act o g f val ve a nd v alve seat
• • • •
Causes
Questions
Confirm recent repair history Operated for long period Degree of use of machine 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 Engine pick-up suddenly became poor Rust and water are found when fuel tank is drained Air cleaner clogging monitor lights up Noise of interference is heard from around turbocharger Color of exhaust gas
Blue under light load Black
Check items
Clanging sound is heard from around cylinder head Mud is stuck to fuel tank cap 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 after starting engine, temperature of some cylinders is low
Troubleshooting
Blow-by gas is excessive When air cleaner element is inspected directly, it is found to be clogged 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 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 When valve clearance is checked directly, it is found to be outside standard value When fuel tank cap is inspected directly, it is found to be clogged
PC300/350(LC)-7
Replace
Correct
Clean
Adjust
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Clean
When feed pump is operated, operation is too light or too heavy
20-711 (7)
TROUBLESHOOTING
S-4
S-4 Engine stops during operations General causes why engine stops during operations • • •
Seized parts inside engine Insufficient supply of fuel Overheating a If there is overheating and the engine stops, carry out troubleshooting for overheating.
•
Failure in hydraulic pump a If the engine stops because of a failure in the hydraulic pump, carry out troubleshooting for H mode.
20-712 (7)
PC300/350(LC)-7
TROUBLESHOOTING
S-5
S-5 Engine does not rotate smoothly (Hunting) Gener al caus es why engine does not r otate smoothly
ctive ope Defe ratio ctive n of adju gove Defe stme rnor ctive nt o f go o pera Low v erno tion idlin r of co g sp Insu n e t r ed is ol ra fficie ck too nt fu low Clog el in ged tank feed Clog pum ged p str f uel f aine Clog i lter, r ged, stra air in i ner Clog c ir cuit ged, betw air in een Clog circu fuel ged it be tank air b twee and reat n feed feed her pum pum hole p p an in fu d no el ta zzle nk
Air in fuel system Defective governor mechanism Defective governor motor mechanism a If hunting stops when governor spring is disconnected, carry out troubleshooting for E mode.
Defe
• • •
Causes
Confirm recent repair history
Questions
Degree of use of machine
Operated for long period Occurs at a certain speed range
Condition of hunting
Occurs at low idling Occurs even when speed is raised Occurs on slopes
Replacement of filters has not been carried out according to Operation Manual Fuel tank is found to be empty Rust, water are found when fuel tank is drained Check items
Leakage from fuel piping When feed pump is operated, 1) No response, light, return is quick 2) No response, light, return is normal Engine speed sometimes rises too far Engine is sometimes difficult to stop Seal on injection pump has come off
Troubleshooting
When governor lever is moved it is found to be stiff When injection pump is tested, governor is found to be improperly adjusted When control rack is pushed, it is found to be heavy, or does not return When fuel tank cap is inspected directly, it is found to be clogged When feed pump strainer is inspected directly, it is found to be clogged
PC300/350(LC)-7
Clean
Correct
Correct
Clean
Clean
Add
Adjust
Adjust
Adjust
Remedy
Adjust
When fuel filter, strainer are inspected directly, they are found to be clogged
20-713 (7)
TROUBLESHOOTING
S-6
S-6 Engine lacks output (or lacks power) General causes why engine lacks output
Clog
•
ged air c lean ed t er e urbo leme char Wor nt ger, n pis inter ton ring fere Clog , nce cylin ged fuel der Clog filter ged , s train feed er Clog pum ged p str i n aine jecti Seiz r on n ed in ozzl jecti e, d Imp o n pu efec rope tive mp r va plun spra lve c Defe g y er lear ctive a n c c o e ntac Ben t of t go valv vern e an or s Clog d va prin ged g, d lve s , lea efec eat king Clog t i ve a f uel p ged djus air b iping t men Defe reat t her ctive hole boo in fu st co el ta mpe nk nsat or d iaph ragm
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 overtaking a If there is overheating and lack of output, carry out troubleshooting for overheating.
Seiz
• • • •
Causes
Confirm recent repair history Degree of use of machine
Questions
Power was lost
Operated for long period Suddenly Gradually
Engine oil must be added more frequently Replacement of filters has not been carried out according to Operation Manual Non-specified fuel is being used Air cleaner clogging monitor lights up Color of exhaust gas
Black Blue under light load
Noise of interference is heard from around turbocharger Blow-by gas is excessive Check items
Engine pickup is poor and combustion is irregular High idling speed under no load is normal, but speed suddenly drops when load is applied When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low There is hunting from engine (rotation is irregular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping When air cleaner element is inspected directly, it is found to be clogged When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
When compression pressure is measured, it is found to be low 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 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 valve clearance is checked directly, it is found to be outside standard value When fuel dial is placed at FULL position, lever does not contact stopper When feed pump is operated, operation is too light or too heavy
20-714 (7)
Replace
Clean
Correct
Adjust
Replace
Adjust
Replace
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
When fuel tank cap is inspected directly, it is found to be clogged
PC300/350(LC)-7
TROUBLESHOOTING
S-7
S-7 Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black
Seiz ed t urbo Clog char ger, ged air c inter Wor lean fere n pis nce er e leme ton ring Clog nt , cyl ged inde injec r Imp tion rope nozz r inje le, d Defe ction ctive timin efective injec g spra Imp tion y rope pum r va p l ve c Crus (exc lear essi hed ance ve in , clo gge Leak jecti dm on) age uffle of air r Defe betw ctive een turbo cont Defe char act o ctive ger a f val injec nd in ve a tion take nd v pum alve man p (ra ifold seat ck, p lung er s eize d)
• • •
Causes
Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Confirm recent repair history Degree of use of machine
Operated for long period
Questions
Suddenly became black Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel is being used Noise of interference is heard from around turbocharger Air cleaner clogging monitor lights up Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
When compression pressure is measured, it is found to be low Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal
PC300/350(LC)-7
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return
20-715 (7)
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue) a Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
• • •
Abnormal combustion of oil External leakage of oil Wear of lubrication system
Brok en p iston Wor ring n pis ton ring Clog , cyli ged nde brea r Lea ther kage or b reat from Lea her oil fi kage hose lter from or o Lea il co o i l pip kage oler ing from Lea oil d kage rain from plug Brok oil p en o an o il co r cyl Wor oler inde n se r he al at ad Wor turb ine e n se al at n d Wor blow n, b er e roke nd n re Dus ar s Turb t suc e a ocha l, se ked al su rger Wor in fr om n va r f a c intak e lve ( e sy stem stem , gu ide) , bro ken seal
General causes why oil consumption is excessive
Causes
Confirm recent repair history Degree of use of machine
Operated for long period
Oil consumption suddenly increased Questions
Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas
Excessive None
Area around engine is dirty with oil Check items
There is oil in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in damper chamber rises Clamps for intake system are loose
Troubleshooting
When compression pressure is measured, it is found to be low When breather element is 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 Inspect rear seal directly When intake manifold is removed, dust is found inside
20-716 (7)
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be dirty with oil
PC300/350(LC)-7
TROUBLESHOOTING
S-9
S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • • • • •
Entry of exhaust gas due to internal wear Clogging of lubrication passage Improper fuel Improper oil used Operation under excessive load
PC300/350(LC)-7
20-717 (7)
TROUBLESHOOTING
S-10
S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Leakage of fuel Improper condition of fuel injection Excessive injection of fuel
Defe ctive injec Defe tion pum ctive p (ex nozz Defe cess le h olde ive in ctive r spr jectio injec ay Defe t n) io n ctive pum p f u p e lung l inje Exte er ction rnal leak timin age g Leak from age fuel of fu pipin Defe el in g, fu side ctive el filt head oil se er Defe cove al in ctive r s id e fee adju stme d pu mp ( nt of pisto gove n) rnor sprin g
• • •
Causes
Questions
Confirm recent repair history Degree of use of machine Condition of fuel consumption
Operated for long period More than for other machines of same model Gradually increased Suddenly increased
Exhaust smoke color
Black White
Seal on injection pump has come off Check items
There is irregular combustion When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on injection pump is misaligned There is external leakage of fuel from engine Engine oil level rises and smells of diesel fuel Engine low idling and high idling speeds are high Injection pump measurement shows that injection amount is excessive Troubleshooting
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 check is made using delivery method, injection timing is found to be incorrect Remove head cover and inspect directly Remove feed pump and inspect directly
20-718 (7)
Adjust
Correct
Correct
Correct
Adjust
Replace
Replace
Remedy
Adjust
When engine speed is measured, low idling and high idling speeds are found to be high
PC300/350(LC)-7
TROUBLESHOOTING
S-11
S-11 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
Brok en o il co oler Brok core en c , Oylind ring Brok er h en h ead , he y d r ad g aulic Hole aske s ca oil c used t oole Inte r b y pit rnal ting crac ks in cylin der bloc k
• •
Causes
Questions
Confirm recent repair history Degree of use of machine Oil level
Operated for long period Suddenly increased Gradually increased
Engine oil level has risen, oil is cloudy white Excessive air bubbles inside radiator, spurts back Hydraulic oil is cloudy white When hydraulic oil is drained, water is found Pressure-tightness test of oil cooler shows there is leakage Pressure-tightness test of cylinder head shows there is leakage
PC300/350(LC)-7
Replace
Replace
Replace
Remedy
Replace
Remove oil pan and inspect directly Replace
Troubleshooting
Check items
Hard water is being used as cooling water
20-719 (7)
TROUBLESHOOTING
S-12
S-12 Oil pressure monitor lights up (Drop in oil pressure) General causes why oil pressure monitor lights up • • • •
Leakage, clogging, wear of lubricating system Defective oil pressure control Improper oil used (improper viscosity) Deterioration of oil due to overheating
a Standards for engine oil selection
20-720 (7)
PC300/350(LC)-7
TROUBLESHOOTING
S-13
S-13 Oil level rises (Water, fuel in oil) a If there is oil in the cooling water, carry out troubleshooting for "Oil is in cooling water".
• • •
Water in oil (milky white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component
Brok en o il co oler Defe core ctive , Onozz ring Brok le ho en c lder y l i nde s le Wor eve r he n, d ad, ama hea ged Defe d gask rear ctive et seal pum Lea surf p au kage ace x i l iary of fu equ Defe el fr ipme ctive om pipin nt se p a Defe rt in g ins al side ctive ide h i n t j ead h ectio erm Hole cove n pu osta s ma r t mp de b Crac y pit ks in ting side cylin der bloc k
General causes why oil level rises
Causes
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
There is oil in radiator cooling water Fuel must be added more frequently
Check items
Exhaust smoke is white When engine is first started, drops of water come from muffler Leave radiator cap open. When engine is run at idling, an abnormal number of bubbles appear, or water spurts back Oil level goes down in damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Water temperature is low Pressure-tightness test of oil cooler shows there is leakage
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage When compression pressure is measured, it is found to be low Inspect rear seal directly When pump auxiliary equipment is removed, seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly Defective contact with thermostat seal valve
PC300/350(LC)-7
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Remedy
Replace
Remove oil pan and check directly
20-721 (7)
TROUBLESHOOTING
S-14
S-14 Water temperature becomes too high (Overheating) 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 Rise in oil temperature in hydraulic pump system a Carry out troubleshooting for H mode.
Brok en w ater Clog pum ged p , cru shed Clog ged radia radi tor f ator Defe ins core ctive t herm Defe osta ctive t (do wate es n Lack r tem ot o of co p pen erat oling ) ure Fan w g belt aug ater e slipp Clog ing, ged worn , bro fan ken Defe pulle oil c ctive y o o p ler ress Brok ure en c valv ylind e Hole er h s ma ead , he d e b ad g Rise y pit aske ting in hy t drau lic p ump oil te mpe ratu re
• • • •
Causes
Confirm recent repair history
Questions
Degree of use of machine Condition of overheating Water temperature gauge
Operated for long period Suddenly overheated Always tends to overheat Rises quickly Does not go down from red range
Radiator water level monitor lights up Fan belt whines under sudden load Cloudy white oil is floating on cooling water Cooling water flows out from overflow hose
Check items
Excessive air bubbles inside radiator, water spurts back Engine oil level has risen, oil is cloudy white There is play when fan pulley is rotated Radiator shroud, inside of underguard are clogged with dirt or mud When light bulb is held behind radiator, no light passes through Water is leaking because of cracks in hose or loose clamps When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator tanks is excessive Temperature difference between top and bottom radiator tanks is slight When water filler port is inspected, core is found to be clogged When function test is carried out on thermostat, it does not open even at cracking temperature
Carry out troubleshooting for H mode.
Troubleshooting
Hydraulic oil temperature enters red range faster than engine water temperature
When water temperature is measured, it is found to be normal When oil cooler is inspected directly, it is found to be clogged When measurement is made with radiator cap tester, set pressure is found to be low When compression pressure is measured, it is found to be low
20-722 (7)
Replace
Replace
Replace
Replace
Correct
Add
Replace
Replace
Correct
Correct
Remedy
Replace
Remove oil pan and inspect directly
PC300/350(LC)-7
TROUBLESHOOTING
S-15
S-15 Abnormal noise is made a Judge if the noise is an internal noise or an external noise.
ssive wear Seiz of pis ed t ton r urbo ing, char Miss cylin ger, ing, der li inter seiz ner fere ed b Clog nce ushi ged n , g seiz Defe ed in ctive jecti injec on n Defe tion ozzl ctive pum e injec p (ra Defo t ck, p i o n pu rme lung d fa mp er s n, fa Defe (exc eize n be essi ctive d) v l t e a i n djus injec t e Brok r f eren tme t i en d o n nt o ) ce ynam f val ic va Imp ve c rope lve s lear ystem r ge ance ar tr Leak (valv ain b age e, ro of air ackl cker ash Defe b e tw lever ct ins een , etc turbo ide m .) ch a r uffle ger a r (div nd in iding ta ke boar d ou man t of p ifold ositio n)
Causes
General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion Air sucked in from intake system
Exce
• • •
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Condition of abnormal noise
Gradually occurred Suddenly occurred
Non-specified fuel is being used Engine oil must be added more frequently Color of exhaust gas
Blue under light load Black
Metal particles are found in oil filter Blow-by gas is excessive Noise of interference is heard from around turbocharger Check items
Engine pickup is poor and combustion is abnormal When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Seal on injection pump has come off Abnormal noise is loud when accelerating engine Clanging sound is heard from around cylinder head Leakage of air between turbocharger and cylinder head, loose clamp Vibrating noise is heard from around muffler When compression pressure is measured, it is found to be low When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
Remove gear cover and inspect directly 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 Injection pump test shows that injection amount is incorrect Fan is deformed, belt is loose When valve clearance is checked, it is found to be outside standard value Remove cylinder head cover and inspect directly
PC300/350(LC)-7
Replace
Replace
Replace
Correct
Replace
Correct
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
When muffler is removed, abnormal noise disappears
20-723 (7)
TROUBLESHOOTING
S-16
S-16 Vibration is excessive
General causes why vibration is excessive • • •
Defective parts (abnormal wear, breakage) Improper alignment Abnormal combustion
Causes Wor n co nne cting Wor n ca rod, mb main u Loo shin bea se e g ring ngin em Brok oun en p ting art i bolts nsid Cen , bro e da ter o ken mpe f en cush gine r Imp rope ion and r ge h ydra ar tr Defe ulic ain b ctive pum dyna ackl pm Defe mic v ash isali ctive alve gne syste d injec m (va tion lve, r pum ocke p (e r leve xces r, etc sive . stuc fuel k) injec tion)
a If there is abnormal noise together with the vibration, carry out troubleshooting also for "Abnormal noise is made".
Questions
Confirm recent repair history Degree of use of machine Condition of vibration
Operated for long period Suddenly increased Gradually increased
Non-specified oil is being used Metal particles are found in oil filter Metal particles are found when oil is drained
Check items
Oil pressure is low at low idling Vibration occurs at mid-range speed Vibration follows engine speed Exhaust smoke is black Seal on injection pump has come off Remove oil pan and inspect directly
Troubleshooting
Remove side cover and inspect directly Inspect directly for loose engine mounting bolts, broken cushion Inspect inside damper directly When face runout and radial runout are inspected, they are found to be incorrect Remove front cover and inspect directly Remove head cover and inspect directly
20-724 (7)
Adjust
Replace
Correct
Correct
Replace
Replace
Replace
Remedy
Replace
Injection pump test shows that injection amount is incorrect
PC300/350(LC)-7
30
DISASSEMBLY AND ASSEMBLY
12 HOW TO READ THIS MANUAL . . . . . . . . . . 30-3 Removal and Installation of Assemblies . . . . . . . . . . . . . . . . . . . . . . . 30-3 Disassembly and Assembly of Assemblies . . . . . . . . . . . . . . . . . . . . . . . 30-4 PRECAUTIONS WHEN PERFORMING OPERATION . . . . . . . . . . . . . . . . . . . . 30-5 SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . 30-6-1 SKETCHES OF SPECIAL TOOLS . . . . . . . . 30-6-5 STARTING MOTOR ASSEMBLY . . . . . . . . . 30-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 FUEL INJECTION PUMP ASSEMBLY . . . . . . 30-8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . 30-8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-10 ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . 30-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-12-1 ENGINE REAR SEAL . . . . . . . . . . . . . . . . . 30-12-2 Special Tools . . . . . . . . . . . . . . . . . . . . . 30-12-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-12-2 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-12-3 CYLINDER HEAD ASSEMBLY . . . . . . . . . . 30-15 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-18 RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . 30-21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-22 HYDRAULIC OIL COOLER ASSEMBLY . . . 30-23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-24 ENGINE AND HYDRAULIC PUMP ASSEMBLIES . . . . . . . . . . . . . . . . . . 30-25 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-28 FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . 30-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-29 DISASSEMBLY AND ASSEMBLY Special Tools . . . . . . . . . . . . . . . . . . . . 30-30 Disassembly . . . . . . . . . . . . . . . . . . . . 30-30 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-33 SWING MOTOR, SWING MACHINERY ASSEMBLY . . . . . . . . 30-40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-40 DISASSEMBLY AND ASSEMBLY Special Tools . . . . . . . . . . . . . . . . . . . . 30-41 PC300/350(LC)-7
Disassembly . . . . . . . . . . . . . . . . . . . . . 30-41 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-43 SWING MOTOR, SWING MACHINERY ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-48 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-48 Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-48 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-48-2 CARRIER ROLLER ASSEMBLY . . . . . . . . . . 30-49 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-49 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 TRACK ROLLER ASSEMBLY . . . . . . . . . . . . 30-50 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-51 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-51 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-51 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 RECOIL SPRING ASSEMBLY . . . . . . . . . . . . 30-54 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-54 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-54 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-55 SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-56 TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . 30-57 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-57 Expansion . . . . . . . . . . . . . . . . . . . . . . . . 30-57 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . 30-59 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-59 REVOLVING FRAME ASSEMBLY . . . . . . . . 30-60 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-62 CENTER SWIVEL JOINT ASSEMBLY . . . . . 30-63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-64 DISASSEMBLY AND ASSEMBLY Special Tools . . . . . . . . . . . . . . . . . . . . 30-65 Disassembly . . . . . . . . . . . . . . . . . . . . 30-65 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-65 HYDRAULIC TANK ASSEMBLY . . . . . . . . . 30-66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-67 CONTROL VALVE ASSEMBLY . . . . . . . . . . 30-68 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-70 DISASSEMBLY AND ASSEMBLY Special Tools . . . . . . . . . . . . . . . . . . . . 30-71 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-72
30-1 (8)
DISASSEMBLY AND ASSEMBLY 12 HYDRAULIC PUMP ASSEMBLY . . . . . . . . . 30-73 Special Tools. . . . . . . . . . . . . . . . . . . . . . 30-73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-73 Installation. . . . . . . . . . . . . . . . . . . . . . . . 30-75 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT . . . . . . . . . . . . . . . . . . 30-76 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-76 WORK EQUIPMENT PPC VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-77 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-77 TRAVEL PPC VALVE ASSEMBLY . . . . . . . . 30-78 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-78 HYDRAULIC CYLINDER ASSEMBLY . . . . . 30-79 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-79 Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-79 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-81 WORK EQUIPMENT ASSEMBLY . . . . . . . . 30-85 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-85 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-86 AIR CONDITIONER UNIT ASSEMBLY. . . . . 30-88 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-88 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-88 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-90 COUNTERWEIGHT ASSEMBLY . . . . . . . . . 30-91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-91 OPERATOR’S CAB ASSEMBLY . . . . . . . . . 30-92 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-93 OPERATOR’S CAB GLASS (STUCK GLASS) . . . . . . . . . . . . . . . . 30-97 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-99 FRONT WINDOW ASSEMBLY. . . . . . . . . . 30-107 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-107 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-109 MONITOR ASSEMBLY . . . . . . . . . . . . . . . 30-113 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-113 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-113 GOVERNOR PUMP CONTROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-114 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Installation . . . . . . . . . . . . . . . . . . . . . . . 30-114
30-2 (8)
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL REMOVAL AND INSTALLATION OF ASSEMBLIES SPECIAL TOOLS
INSTALLATION OF PARTS
•
•
•
Special tools that are deemed necessary for removal or installation of parts are listed. List of the special tools contains the following kind of information. 1) Necessity ■: Special tools which cannot be substituted, should always be used. ●: Special tools which are very useful if available, can be substituted with commercially available tools.
•
•
2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark ({) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools. ★ Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
Except where otherwise instructed, install parts is the reverse order of removal. Instructions and precautions for installing parts are shown with mark in the INSTALLATION Section, identifying which step the instructions are intended for. Marks shown in the INSTALLATION Section stand for the following.
★
This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark stands for a specific coating agent to be used. This mark indicates the specified torque. This mark indicates an amount of oil or water to be added.
SKETCHES OF SPECIAL TOOLS •
Various special tools are illustrated for the convenience of local manufacture.
REMOVAL OF PARTS •
•
The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the REMOVAL Section are explained and listed below.
★
This mark indicates safety-related precautions which must be followed when doing the work. This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts. This mark shows oil or water to be drained.
PC300/350(LC)-7
30-3 c
DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
12
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES SPECIAL TOOLS
ASSEMBLY
•
•
•
Special tools which are deemed necessary for disassembly and assembly are listed in this section. List of the special tools contains the following kind of information. 1) Necessity ■: Special tools which cannot be substituted, should always be used. ●: Special tools which are very useful if available, can be substituted with commercially available tools. 2) Distinction of new and existing special tools N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from already available tools for other models. Blank: Tools already available for other models, used without any modification. 3) Circle mark ({) in sketch column: A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
•
Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil or water to be added. Various symbols used in the ASSEMBLY Section are explained and listed below. This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. This mark stands for a specific coating agent to be used. This mark indicates the specified torque. This mark indicates an amount of oil or water to be added.
SKETCHES OF SPECIAL TOOLS 1) Various special tools are illustrated for the convenience of local manufacture.
4) Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx. DISASSEMBLY •
•
The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the DISASSEMBLY Section are explained and listed below. This mark indicates safety-related precautions which must be followed when doing the work. ★ This mark gives guidance or precautions when doing the procedure. This mark shows that there are instructions or precautions for installing parts. This mark shows oil or water to be drained.
30-4 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN PERFORMING OPERATION
12
PRECAUTIONS WHEN PERFORMING OPERATION Be sure to follow the general precautions given below when performing removal or installation (disassembly or assembly) of units.
1. Precautions when performing removal work • If the engine coolant water contains antifreeze, dispose of it properly. • After disconnecting hoses or tubes, cover them or install 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 during assembly. • To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wiring, hold onto the connectors when disconnecting them. • Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any mistakes when re-installing. • Count and check the number and thickness of the shims, and keep them in a safe place. • When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembly Install the following blind plugs into the piping after disconnecting it during disassembly operations. A. Face seal type hoses and tubes Nominal number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
B. Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used: Dimensions
Nominal number
Part Number
06
07049-00608
6
5
8
08
07049-00811
8
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
PC300/350(LC)-7
D
d
L
30-5 3
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN PERFORMING OPERATION
12 2. 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 pin or lock plate securely. • When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three 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-P). • After installing snap rings, check that the snap ring is installed securely in the ring groove. • When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it securely. • When using eye bolts, 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 the cylinders, pumps and other hydraulic equipment removed for repair, bleed the air as follows: 1.
Start the engine and run it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping the cylinders 100 mm from the end of their 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. ★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations • If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified level. Run the engine to circulate the coolant water through the system. Then check the coolant 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 for repair, 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 related parts.
30-6
2
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST ★ Tools with part number 79 Ttured).
-
cannot be supplied (they are items to be locally manufac-
★ Necessity:
■ ............ Cannot be substituted, must always be installed (used) ●............. Extremely useful if available or can be substituted with commercially available part ★ 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, can be used without any modification
Q'ty
■
1
Remover
■
1
Removal of fuel injection pump
3 795-931-1100
Seal puller
■
1
Removal of engine seal
1 795-799-1170
Puller
■
1
Removal and installation of nozzle holder assembly
2 790-331-1110
Wrench
■
1
Retightening of cylinder head bolt
796-460-1210
Oil stopper
●
1
796-770-1320
Adapter
●
1
796-627-1610
Wrench assembly
■
1
N
• 796-627-1620 • Wrench
1
N
• 796-427-1140 • Pin
3
• 01314-20612 • Screw
3
Part No.
1 795-799-1131 A 2 795-799-1390
Part name
Engine assembly B
Engine, hydraulic pump assembly
C
1
Final drive assembly
Nature of work, remarks
Oil stopper
Removal and installation of nut
796T-627-1630
Push tool
■
1
790-101-2510
Block
■
1
791-830-1320
Rod
■
2
01580-11613
Nut
■
2
790-101-2570
Washer
■
2
01643-31645
Washer
■
2
790-105-2100
Jack assembly
■
1
790-101-1102
Pump
■
1
3 791-580-1510
Installer
■
1
Installation of floating seal
4 790-331-1110
Wrench
■
1
Tightening of cover bolt
D 2
PC300/350(LC)-7
Sketch
Necessity
Gear
Symbol
Component
New/Remodel
★ Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS).
N
Installation of bearing
30-6-1 (8)
Q'ty
Push tool
●
1
Press-fitting of bearing
2 796T-626-1140
Push tool
■
1
Press-fitting of oil seal
3 790-201-2480
Push tool
■
1
Press-fitting of bearing
Push tool kit
■
1
Part No.
790-101-5401
E 4
• 790-101-5521 • Plate
1
• 790-101-5421 • Grip
1
• 01010-51240
1
F
Track roller assembly
G
Idler assembly
H
1 Recoil spring assembly
J
2
Track shoe assembly
■
1
791-601-1000
Installer
■
1
791-430-3230
Oil pump
■
1
796-670-1010
Installer
■
1
791-601-1000
Oil pump
■
1
796-570-1020
Installer
■
1
791-601-1000
Oil pump
■
1
791-685-8006
Compressor
■
1
791-635-3160
Extension
■
1
790-101-1600
Cylinder (686 kN {70 t} )
■
1
790-101-1102
Pump
■
1
790-201-1500
Push tool kit
■
1
• 790-201-1620 • Plate
1
• 790-101-5021 • Grip
1
• 01010-50816
• Bolt
791-630-3000
Remover & installer
■
1
Cylinder (980 kN {100 t} )
■
1
Pump
■
1
Wrench
■
1
Push-puller
■
1
1 790-101-1300
K
790-101-1102 2 790-331-1110 790-101-2501
Center swivel joint assembly
30-6-2 (8)
L
• Bolt Push tool
5 793T-815-1110 Carrier roller assembly
Part name
Sketch
Necessity
Swing motor, swing machinery assembly
1 796T-626-1110
Symbol
Component
SPECIAL TOOL LIST New/Remodel
DISASSEMBLY AND ASSEMBLY
Nature of work, remarks
Press-fitting of oil seal
Press-fitting of bearing Refilling oil
Refilling oil
Disassembly and assembly of recoil spring
Installation of dust seal
1
• 790-101-2510 • Block
1
• 790-101-2520 • Screw
1
• 791-112-1180 • Nut
1
• 790-101-2540 • Washer
1
• 790-101-2630 • Leg
2
• 790-101-2570 • Plate
4
• 790-101-2560 • Nut
2
• 790-101-2650 • Adapter
2
Extraction of master pin
Tightening of shoe bolt
Disassembly and assembly of center swivel joint assembly
PC300/350(LC)-7
796-946-1310
Guide
(For 723-46-40100, 723-46-40601) 796-946-1810 1
Guide
(For 723-46-43100, 723-46-43400) 796-946-2110
Guide
(For 723-46-44100) 796-946-2210
Guide
(For 723-46-45100) 796-946-1320
Guide
(For 723-46-40100, 723-46-40601) 796-946-1820
Guide
(For 723-46-43100, 723-46-43400) 2 Control valve assembly
M
796-946-2120
Guide
(For 723-46-44100) 796-946-2220
Guide
(For 723-46-45100) 796-946-1420
Guide
(For 723-46-42800) 796-946-1330
■
1
■
1
■
1
■
1
■
1
■
1
■
1
■
1
■
1
Sleeve Sleeve
796-946-2130
Sleeve
1
(For 723-46-44100) 796-946-2230
Sleeve Sleeve
(For 723-46-42800)
PC300/350(LC)-7
Replacement of pressure compensation valve seal
1
(For 723-46-45100) 796-946-1430
Replacement of pressure compensation valve seal
1
(For 723-46-43100, 723-46-43400) 3
Nature of work, remarks
1
(For 723-46-40100, 723-46-40601) 796-946-1830
Sketch
Part name
New/Remodel
Part No.
Q'ty
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
■
1
30-6-3 (8)
■
1
790-102-4300
Wrench assembly
■
1
790-102-4310
Pin
■
2
Expander
●
1
796-720-1680
Ring
●
1
07281-01589
Clamp
●
1
790-201-1702
Push tool kit
■
1
1 790-502-1003
2
3 790-720-1000 4
Hydraulic cylinder assembly
N 5
• 790-201-1851 • Push tool kit (for bucket, boom)
1
• 790-201-1861 • Push tool (for arm)
1
• 790-101-5021 • Grip
1
• 01010-50816
• Bolt
1
790-201-1500
Push tool kit
■
• 790-101-5021 • Grip 6 • 01010-50816
Work equipment assembly
Air conditioner assembly
Operator’s cab glass
30-6-4 (8)
P
Q
Y
Disassembly and assembly of hydraulic cylinder assembly Removal and installation of piston assembly
Installation of piston ring
Press-fitting of bushing
1
• Bolt
1 1
• 790-201-1670 • Plate (for arm)
1
Remover
Nature of work, remarks
1
• Plate • 790-201-1660 (for bucket, boom) 796-670-1100
Sketch
Cylinder repair stand
Part No.
New/Remodel
Part name
Q'ty
SPECIAL TOOL LIST
Necessity
Component
Symbol
DISASSEMBLY AND ASSEMBLY
■
Press-fitting of dust seal
1
• 796-670-1110 • Sleeve
1
• 796-670-1120 • Plate
1
• 796-670-1130 • Screw
1
• 791-775-1150 • Adapter
1
• 01643-33080 • Washer
1
• 01803-13034 • Nut
1
790-101-4000
Puller (490 kN {50 t} long)
■
1
790-101-1102
Pump (294 kN {30 t} )
■
1
799-703-1200
Service tool kit
■
1
799-703-1100
Vacuum pump (100V) ■
1
799-703-1111
Vacuum pump (220V) ■
1
799-703-1121
Vacuum pump (240V) ■
1
799-703-1401
Gas leak detector
■
1
1 793-498-1210
Lifter (Suction cup)
■
2
2 20Y-54-13180
Adapter
■
2
Removal of foot pin
Charging of air conditioner gas
Removal and installation of operator’s cab glass
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Push tool
E1 Push tool
PC300/350(LC)-7
30-6-5 (8)
DISASSEMBLY AND ASSEMBLY
Note:
SKETCHES OF SPECIAL TOOLS
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E2 Push tool
E5 Push tool
30-6-6 (8)
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
STARTING MOTOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY REMOVAL
k Disconnect the cable from the negative (–) terminal of the battery. 1.
Open up the engine hood.
2. Disconnect the two wires from the engine starting motor at: • Wire (1) and (2) from terminal B.
INSTALLATION •
Install in reverse order of removal. 3 Engine starting motor terminal B Securing nut: 19.6 – 25.5 Nm {2.0 – 2.6 kgm} 2 Both faces of engine starting motor gasket: Gasket sealant (LG-1)
3. Remove 3 mounting bolts (3) to detach engine starting motor assembly (4).
30-7 (8)
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 8. Disconnect engine stop motor rod (7).
A
Gear
■
1
2 795-799-1390
Remover
■
1
Part No.
Part name
Sketch
Qty
1 795-799-1131
Mark
Distinction
Necessity
SPECIAL TOOLS
9. Disconnect governor rod (8).
REMOVAL
k Disconnect the negative (–) terminal of the battery. 1.
Open up the engine hood.
2. Remove radiator fan guard (1). 3. Disconnect air compressor hose clamp (2). 4. Remove bracket (3).
10. Disconnect exhaust brake hose (9) and lubrication tube (10). 11. Disconnect tube (11) between the fuel filter and the fuel injection pump.
5. Remove two hose clamps (4). 6. Disconnect tube (5).
7.
Disconnect engine stop motor connector (6).
30-8 (8)
12. Disconnect fuel return hoses (12) and (13). ★ When disconnecting hoses, fuel flows out. Put a wooden plug in them to stop the spillage.
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
12 13. Disconnect M34 air compressor connector (14). 14. Loosen adjusting bolts (15), (16) and (17) to remove fan belt (18). 15. Remove bracket (19).
18. Turn cap (22) to remove it. ★ When removing the cap, use a filter wrench.
16. Disconnect 6 delivery tubes (20).
19. Remove nut (23) and washer (24) from the fuel injection pump. ★ Be careful, do not let the nut and washer fall inside the case. 17. Set the fuel injection timing to the top of the No. 1 cylinder according to the following procedure. 1) Using tool A1 (gear), rotate the engine. ★ Refer to the "Testing and adjusting fuel injection timing" section in this manual. ★ Set yellow mark "a" of the crank pulley to the top. 2) Push in timing pin (21) of the fuel injection pump drive gear. ★ If timing pin (21) cannot be pushed in, the piston of the No. 6 cylinder is at the top. In this case, rotate the engine further to set yellow mark "a" of the crank pulley to the top again.
30-9 (8)
DISASSEMBLY AND ASSEMBLY 12 20. Using tool A2, separate shaft and drive gear from the fuel injection pump.
FUEL INJECTION PUMP ASSEMBLY
INSTALLATION •
Install in reverse order of removal. 3 Joint bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm} ★ Refer to the "Inspection and adjustment of air compressor belt tension" section of the TESTING AND ADJUSTING chapter in this manual.
21. Remove 2 mounting brackets (25) at the lower part of the fuel injection pump.
3 Sleeve nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 Nut: 178 ± 13 Nm {18.2 ± 1.3 kgm} •
22. Remove 4 nuts (26) and remove fuel injection pump assembly (27).
30-10 (8)
Mount the fuel injection pump assembly in the following manner. 1) Check that the timing pin is properly adjusted to the fuel injection timing. ★ Refer to Item 10 in the preceding REMOVAL procedure. 2) Remove plug (28). Reverse fuel injection pump timing pin (29) and reinstall the plug. ★ Check that the cutout on the timing pin is engaged with protrusion "a" inside the pump. ★ Refer to the "Inspection and adjustment of fuel injection timing" section in the TESTING AND ADJUSTING chapter, in this manual.
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
12 3) Install the fuel injection pump assembly (27) and secure it with 4 nuts (26).
3 Securing nut: 44 ± 6 Nm {4.49 ± 0.61 kgm}
4) Install washer (24) and temporarily secure it with nut (23). ★ When installing the nut and washer, be careful not to let them fall into the case. k Tighten the nut temporarily to the following torque. Take care not to damage the timing pin. 3 Nut: 178 ± 13 Nm {18.2 ± 1.3 kgm}
5) Disengage the fuel injector pump timing pin (on the timing gear side) from protrusion "a", and return the pin to its original position. •
Air bleeding Bleed air from the fuel injection system.
30-11 (8)
DISASSEMBLY AND ASSEMBLY
ENGINE FRONT SEAL
12
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL REMOVAL 1.
Remove the radiator and hydraulic oil cooler assembly, refer to the "Removal of radiator and hydraulic oil cooler assembly" in this manual.
2. Remove radiator fan (1). 3. Loosen tension pulley (2) to remove fan belt (3). 4. Loosen tension pulley (4) to remove alternator belt (5). 5. Remove the 4 mounting bolts to detach damper (6).
6.
Remove the 4 mounting bolts to detach front pulley (7). ★ Make counter marks on front pulley (7) and front cover (since the stamping mark of 1-6 TOP is on front pulley (7)).
30-12 (8)
7.
Remove 5 mounting nuts to take off seal (8) from seal carrier (9).
DISASSEMBLY AND ASSEMBLY
ENGINE FRONT SEAL
12 INSTALLATION ★ The plastic part P in the engine front seal is provided as a pilot (guide) that is used in installing the crankshaft. So, do not remove it. 1.
Apply some amount of neutral detergent to the outer periphery of engine front seal.
5. Push pilot P against the crankshaft and push it together with seal carrier (9) into the crankshaft. 6. Remove pilot P. 7.
Tighten 5 seal carrier (9) mounting bolts using the sequence shown in the figure below. 3 Seal carrier mounting bolt: 9.8 ± 2 Nm {1 ± 0.2 kgm} ★ Check that the engine front seal has been mounted to the seal carrier to 0.5 – 1 mm.
2. Using a clean cloth, remove adherents from the crankshaft flange.
3. Apply the following to the mounting hole for the seal carrier.
2 Inside of seal carrier mounting hole: Apply a 1 – 2 mm diameter ThreeBond 1207D or its equivalent.
4. Install engine front seal (8) to seal carrier (9). ★ Mounting dimension: 0.5 – 1 mm
•
Carry out installation in the reverse order to removal.
[*1]
3 Fan mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
[*2] ★ Temporarily install the front pulley and apply the fan belt and then tighten them to the specified torque. 3 Front pulley mounting bolt: 200 ± 10 Nm {20.4 ± 1 kgm}
30-12-1 (8)
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
12
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 4. Remove the mounting bolt, set the guide bolt, and then lift off flywheel (4) to remove it. [*2]
A3
795-931-1100
Seal puller
■
1
Sketch
Part name
Distinction
Part No.
Qty
Mark
Necessity
SPECIAL TOOLS
4
5. Temporarily lift off flywheel housing (5), remove the mounting bolts, set the guide bolt, and then lift off the flywheel housing to remove it. [*3] 4
REMOVAL
k Disconnect the cable from the negative (–) terminal of the battery. Remove the hydraulic pump assembly, refer to the "Hydraulic pump assembly removal" section in this manual.
Flywheel housing (5): 70 kg
6. Remove rear cover (6). 7.
1.
Flywheel assembly: 45 kg
Remove rear seal (7) from rear cover (6). ★ Take care not to damage the seal attached to the flywheel housing and the surface of the seal in contact with the crankshaft.
2. Remove damper assembly (10).
3. Disconnect engine speed sensor connector (1) and loosen locknut (2) to disconnect engine speed sensor (3) from flywheel housing (5). [*1]
30-12-2 (8)
★ If you cannot easily remove engine rear seal (7) from the crankshaft, drill a hole in the right and left sides of engine rear seal, approximately 3 mm in diameter. Using seal puller A3, remove the seal through the pulling impact created by slide hammer (SH).
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
12 INSTALLATION 1.
Clean and degrease the surface of gasket between the rear cover and the cylinder block and let dry.
2. Clean and degrease the surface of seal lip (on the crankshaft periphery) and let dry.
5. Using alignment tool A provided with the engine rear seal, push rear seal (7) into rear cover (6) until the desired depth is reached. 6. Remove alignment tool A.
7. 3. Apply some amount of neutral detergent to the outer periphery of engine rear seal. ★ The plastic part P in the engine rear seal is provided as a pilot (guide) that is used in installing the crankshaft. So, do not remove it.
Push pilot P against the crankshaft and push it together with rear cover (6) into the crankshaft. ★ Remember to put gasket G between the cylinder block and the rear cover. ★ Use guide pin [2].
8. Remove pilot P.
4. Install engine rear seal (7) to rear cover (6).
30-12-3 (8)
DISASSEMBLY AND ASSEMBLY 12 9. Reinstall alignment tool A to check that rear seal (7) is fitted up to the desired depth. ★ The difference between the cylinder block bottom and rear cover (6) bottom must be within 0.00 ± 0.10 mm.
ENGINE REAR SEAL
[*1]
2 Thread of engine speed sensor: LG-6 ★ Installing the engine speed sensor: 1) Screw the sensor until it comes into contact with the gear. 2) Back off it 1 ± 1/6 turns and tighten the locknut. ★ Clearance between engine speed sensor and flywheel: 0.75 – 1 mm 3 Engine speed sensor locknut: 69 – 74 Nm {7 – 7.5 kgm}
[*2] ★ Tighten the mounting bolts sequence shown in the figure.
using
the
3 Flywheel mounting bolt: 137 ± 7 Nm {13.97 ± 0.71 kgm}
★ Do the above procedure without removing alignment tool A. 10. Remove guide pin [2] and tighten 8 rear cover mounting bolts using the sequence shown in the figure below. 3 Rear cover mounting bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm} ★ The projection of rear cover gasket G above the cylinder block bottom must be within 0.25 mm. (See mark a portion.)
★ There should not be more than 0.2 mm variation of flywheel to flywheel housing.
11. Remove alignment tool A. •
Carry out installation in the reverse order to removal.
30-12-4 (8)
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
12 [*3]
2 Apply a 1 – 3 mm diameter gasket sealant to the periphery of mounting bolt hole at the cylinder block: Gasket sealant (LG-6) ★ Tighten the mounting bolts using the sequence shown in the figure. 3 Flywheel housing mounting bolt: 77 ± 12 Nm {7.85 ± 1.22 kgm}
30-12-5 (8)
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
12
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL REMOVAL
INSTALLATION
1.
•
Remove the Hydraulic Pump Assembly, refer to the Hydraulic Pump Assembly Removal section in this manual.
2. Remove damper assembly (1).
Install in reverse order of removal.
Flywheel mounting bolt: 137 ± 7 Nm (13.97 ± 0.71 kgm) ★ Tighten the mounting bolts sequence illustrated below.
in
the
3. Remove flywheel assembly (2).
★ Install the oil seal in the following manner. 1) Fit pilot b to new oil seal (3). ★ Before installing the oil seal, clean the crankshaft sealing face and the seal lip face. Remove all oil and dry thoroughly to prevent oil leakage.
4. Remove seal (3). ★ Remove the seal, inflicting no damage to the crankshaft.
PC300/350(LC)-7
30-13 c
DISASSEMBLY AND ASSEMBLY
ENGINE REAR SEAL
2) Push the oil seal into the flywheel by inserting pilot b with oil seal (3) into the crankshaft. 3) Pull out pilot b. Push the oil seal into the front cover from the inside to the outside. 4) Install the oil seal on the flywheel housing to the proper depth. Use an alignment tool. ★ Tap the head, bottom, right and left sides of the alignment tool to make sure that the seal carrier is not twisted, when it is being pushed in.
30-14 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
12
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY SPECIAL TOOLS Mark B
Part No.
Part Necessity Qty Distinction* Sketch Name
1 795-799-1170 Puller
■
1
2 790-331-1110 Wrench
■
1
8. Remove bracket (9) and remove air compressor assembly (10). ★ Remove the air compressor assembly in one piece with the bracket and put them aside near the control valve upper cover.
*Distinction between new and existing part.
REMOVAL Disconnect the cable from the negative (-) terminal of the battery. 1.
Drain engine coolant. Engine coolant: Approx. 32 l
2. Open up the engine hood. 3. Remove bracket (1), and then detach clamp (2) and hose clamp (3). 4. Disconnect tube (4). ★ Remove the tube in one piece with the bracket.
9. Disconnect exhaust brake hose (11) and lubrication tube (12). ★ When disconnecting the exhaust brake hose, also separate the clamp mounting plate from the head cover. 10. Disconnect after-cooler hose (13). 11. Remove protective cover (14).
5. Disconnect air compressor wiring connector (5). 6. Remove radiator fan guard (6). 7. Loosen adjusting bolt (7) to remove belt (8).
PC300/350(LC)-7
30-15 c
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
12
12. Disconnect lubrication inlet hose (15) and lubrication outlet hose (16).
16. Disconnect air feeding hose (21). 17. Separate gauge (22) from mounting plate. 18. Disconnect fuel filter tubes (23) and (24). 19. Disconnect electrical intake air heater wiring harness (25). 20. Disconnect tube (26). 21. Remove blow-by hose mounting clamp to detach bracket (27). ★ Detach the bracket in one piece with the fuel filter.
13. Remove protective covers (17) and (18). 14. Remove muffler connector V clamp (19).
22. Remove head cover (28).
15. Lift off turbocharger and exhaust manifold assembly (20). ★ Note that two different length mounting bolts are used for the exhaust manifold. Be careful when installing them.
23. Disconnect fuel return tube (29). 24. Disconnect six delivery tubes (30).
30-16 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
27. Remove rocker arm assembly (33) to remove oil tube (34).
25. Remove cover (31). ★ Know that the delivery tubes, fuel tube fixing plate and the mounting bolts have different lengths. Be careful when installing them.
26. Remove six nozzle holder assemblies (32). ★ Use tool B1, when it is difficult to remove the nozzle holder assembly. ★ Take care so that no dust or foreign object enters through the base of the nozzle holder assembly.
PC300/350(LC)-7
28. Remove push rod (35).
29. Lift off cylinder head assembly (36) after removing the 26 mounting bolts. Cylinder head assembly: 65 kg
30-17 c
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
12 30. Remove cylinder head gasket (37).
Fuel tube joint bolt: 36 ± 5 Nm {3.67 ± 0.51 kgm}
INSTALLATION •
Install in reverse order of removal. Joint bolt : 24 ± 4 Nm {2.45 ± 0.41 kgm} ★ Refer to the Inspection and Adjustment of Air Compressor Belt Tension section in the TESTING AND ADJUSTING chapter in this manual.
Head cover mounting bolt: 23.5 ± 3.9 Nm {2.4 ± 0.4 kgm}
V clamp: 6.9 - 8.8 Nm {0.7- 0.9 kgm} Sleeve nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} ★ Tighten the bolts in the sequence indicated in the figure at right. Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
Exhaust manifold mounting bolt: 1st step: Tighten to 23.5 ± 4 Nm {2.4 ± 0.41 kgm} in the sequence of b through 1@. 2nd step: Tighten to 23.5 ± 4 Nm {2.4 ± 0.41 kgm} in the sequence of b through e. 3rd step: Tighten to 43.1 ± 6 Nm {4.4 ± 0.61 kgm} in the sequence of b through 1@ 4th step: Tighten to 43.1 ± 6 Nm {4.4 ± 0.61 kgm} in the sequence of b through e.
★ Coat the surface of the oil boot with oil when installing the nozzle holder assemblies. ★ Coat a shim at the tip of the nozzle holder assembly with a small amount of grease so that it will firmly stay on the tip. , •
30-18 c
, Mount the rocker arm assembly and the cylinder head assembly in the following manner.
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
12 ★ Check that there is no dust or foreign matter sticking to the cylinder head mounting face or inside the cylinders. 1) Set cylinder head gasket (37) on the cylinder block. ★ Check that the gasket is correctly aligned with the corresponding cylinder holes.
2) Lift the cylinder head assembly (36) and place it on the cylinder block.
4) Install oil tube (34) and rocker arm assembly (33). Tighten their mounting bolts by hand. ★ Make sure that the ball portion of the adjusting screw is properly seated in the push rod socket.
5) Tighten cylinder head mounting bolts in the sequence shown in the figure below. ★ Coat the threads and seat surface of the mounting bolts with engine oil (15W-40).
Cylinder head mounting bolts:
3) Install push rods (35).
PC300/350(LC)-7
1st step: Tighten to 70 ± 5 Nm {7.1 ± 0.51 kgm} in the sequence of b through 2^. ★ Check that each bolt is tightened to the torque specified above, following the same sequence. 2nd step: Tighten to 145 ± 10 Nm {14.8 ± 1.0 kgm} in the sequence of b, c, h, i, j, 1), 1%, 1^, 1&, 1*, 2#, 2$, 2%, and 2^. ★ Check that each bolt is tightened to the torque specified above, following the same sequence.
30-19 c
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
12 3rd step: i)
When using tool B2. For tightening, turn the bolts with an angle tightening wrench by 90 ± 5° in the sequence of b to 2^.
6) Tighten the rocker arm mounting bolts. Rocker arm assembly mounting bolt: 65 ± 5 Nm {6.6 ± 0.5 kgm}
ii) When not using tool B2. Tighten the bolts by turning them to 90 ± 5°. Put a punch mark on the bolt head after tightening the bolt to show the frequency of tightening. • Do not use a bolt with 5 punch marks. Replace it with a new one.
7) Adjust the valve clearance. ★ Refer to the Adjustment of Valve Clearance section in the TESTING AND ADJUSTING chapter in this manual.
• ★ Install the rocker arm assembly and tighten the bolts by hand. • Check that the adjusting screw ball is well seated in the push rod socket.
Refilling engine coolant Fill engine coolant through the water filler port up to the specified level. Start the engine to allow the coolant to circulate and release any air pockets. Check the water level again.
Engine coolant: Approx. 32 l
30-20 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
RADIATOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY REMOVAL 1.
Drain the engine coolant. Engine coolant:
8. Remove fan cover (7). ★ First remove the clamp for mounting the after-cooler hose which is tightened together and then remove the fan cover.
Approx. 32 l
2. Lift off engine hood (1) temporarily. ★ Be careful not to damage the rubber seal when lifting the engine hood. ★ Support the engine hood with an appropriate sling and lifting device.
9. Disconnect radiator hose (8).
3. Remove engine hood mounting bolt to remove pin (2). 4. Lift off engine hood (1).
10. Lift off radiator assembly, using two slings b.
5. Disconnect reservoir tank hose (3). ★ Disconnect the hose on the radiator side. 6. Disconnect radiator hose (4). 7.
Remove fan guards (5) and (6).
PC300/350(LC)-7
30-21 c
DISASSEMBLY AND ASSEMBLY
RADIATOR ASSEMBLY
12 11. Lift off radiator assembly (9) after removing mounting bolts. Radiator assembly: 45 kg
INSTALLATION • •
Install in reverse order of removal. Refilling engine coolant Refill engine coolant through the water filler port up to the specified level. Start the engine to allow the coolant to circulate and release any air pockets. Check the water level again. Engine coolant: Approx. 32 l
30-22 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL COOLER ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY REMOVAL 1.
Remove cover (1).
4. Remove engine hood mounting bolt and remove pin (4). 2. Remove plug (2) from the hydraulic oil drain hose to drain the hydraulic oil. ★ Unscrew the cap on the hydraulic tank before draining oil to release the remaining pressure inside the tank. Then drain oil through the cooler hose.
5. Lift off engine hood (3).
6. Remove cover (5).
3. Lift off engine hood (3) temporarily. ★ Be careful not to damage the rubber seal when lifting off the engine hood. ★ Support the engine hood with an appropriate sling and lifting device.
PC300/350(LC)-7
30-23 c
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL COOLER ASSEMBLY
12 7.
Remove hydraulic oil cooler drain hose (6).
INSTALLATION • •
Install in reverse order of removal. Refilling hydraulic oil (hydraulic tank) Refill hydraulic oil through oil filler port up to the specified level and circulate oil in the hydraulic system by starting the engine. Then check the oil level again.
8. Remove hydraulic oil cooler mounting bolts (7) and (8).
9. Lift off hydraulic oil cooler assembly (9), using two slings b.
30-24 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES ★ Support the engine hood with an appropriate sling and lifting device.
SPECIAL TOOLS Mark
Part No.
Part Necessity Qty Distinction* Sketch Name Oil Stopper
●
1
796-770-1320 Adapter
●
1
796-460-1210 C
*Distinction between new and existing part.
REMOVAL Lower the work equipment to the ground for safety and stop the engine. Disconnect the cable from the negative (-) terminal of the battery. To release the internal pressure, gradually loosen the oil filler cap on the hydraulic tank. ★ Attach an identification tag to each pipe. This will avoid a possible mistake when reinstalling. 1.
4. Remove engine hood mounting bolts and then remove pin (2). 5. Lift off engine hood (1).
Remove the hydraulic tank strainer and stop the flow of oil, using Tool C. ★ When not using tool C, remove the drain plug to drain oil from the hydraulic tank and piping. Hydraulic tank: Approx. 365 l
6. Disconnect air feeding hose (3). 7.
Remove bracket (4) and disconnect clamp (5) and hose clamp (6).
8. Disconnect tube (7). ★ Remove the tube in one piece with the bracket.
2. Drain engine coolant. Engine coolant: Approx. 32 l 3. Lift up engine hood (1). ★ Be careful not to damage the rubber seal when lifting off the engine hood. PC300/350(LC)-7
30-25 c
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12 9. Disconnect air compressor wiring connector (8).
14. Remove cover (17).
10. Remove fan guard (9). 11. Loosen adjusting bolt (10) to remove fan belt (11). 12. Remove bracket (12) with compressor assembly (13). ★ Remove the compressor assembly in one piece with the bracket and put them aside near the control valve upper cover. 15. Remove covers (18), (19) and (20).
13. Remove covers (14), (15) and (16). 16. Disconnect hydraulic pump wiring connectors at two places. • (21): V22 (PC-EPC solenoid valve) Color band: Red • (22): V21 (LS-EPC solenoid valve) Color band: White
30-26 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12 17. Disconnect eight hoses (23) through (30) and tube (31). • (23): Drain port hose • (24): Front load pressure input port hose • (25): Rear load pressure input port hose (Color band: Red) • (26): EPC source pressure port hose (Color band: Yellow) • (27): Rear pressure input port hose (Color band: Yellow) • (28): Front pressure input port hose • (29): Rear pump discharging port hose • (30): Front pump discharging port hose • (31): Pump suction port tube
19. Disconnect compressor hose clamp (35). 20. Disconnect fuel inlet hose (36), Fuel return hoses (37) and (38).
21. Disconnect radiator hose (39) and remove fan guard (40).
18. Disconnect wiring connectors (32), (33) and (34). • (32): E08 (Intermediate connector) • (33): E11 (Governor motor) • (34): E10 (Potentiometer)
PC300/350(LC)-7
22. Disconnect after-cooler hose (41) and radiator hose (42).
30-27 c
DISASSEMBLY AND ASSEMBLY
ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12 23. Disconnect engine starting motor wiring (43) and heater hose (44).
Engine and Hydraulic Pump Assembly: 1,200 kg
24. Disconnect two engine filter hoses (45). INSTALLATION •
Install in reverse order of removal. ★ Refer to the Inspection and Adjustment of Air Compressor Belt Tension section in the TESTING AND ADJUSTING chapter of this manual.
Engine mounting bolt: (Front) 384.9 ± 41.7 Nm {39.25 ± 4.25 kgm) (Rear) 926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
25. Disconnect engine grounding wiring (46). 26. Remove four front and rear engine mounting bolts (47).
•
Refilling engine coolant Refilling engine coolant Refill engine coolant through the water filler port up to the specified level. Engine coolant: Approx. 32 l
•
Refilling hydraulic oil (hydraulic tank) Refill hydraulic oil through oil filler port up to the specified level. Hydraulic tank: Approx. 365 l
27. Lift off engine and hydraulic pump assembly (48). ★ Lift off the assembly only after making sure that there is no wiring or piping which is left still connected.
30-28 c
★ Let the water circulate to release any air pockets by starting the engine. Check the water level again. ★ Circulate oil in the hydraulic system by starting the engine. Then check the oil level again. • Air bleeding Refer to the Air Bleeding of Various Part section in the INSPECTION AND MAINTENANCE chapter of this manual.
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY REMOVAL 1.
4. Remove the 21 mounting bolts from final drive assembly (6) and lift it off to remove.
Remove the sprocket, refer to the "Removal of sprocket" section in this manual.
k Lower the work equipment to the ground for safety. Stop the engine and loosen the oil filler cap on the hydraulic tank to release pressure inside.
★ Be careful. Do not damage the face of the fitting seal at the base of the hose. ★ When lifting off the final drive assembly, do not use a tapped hole for lifting the cover. 4
2. Remove cover (1).
3. Disconnect drain hose (2), travel speed shifting hose (3) and travel motor hoses (4) and (5).
Final drive assembly: 500 kg
INSTALLATION •
Install in reverse order of removal. 3 Final drive assembly mounting bolt: 490 – 608 Nm {50 – 62 kgm}
•
Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specified level, and let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
•
Air bleeding Refer to the "Air bleeding of various part" section in the TESTING AND ADJUSTING chapter of this manual.
30-29 (8)
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
796-627-1610 1 796-627-1620 796-427-1140
Wrench assembly
■
1
N N
• Wrench
1
• Pin
3
01314-20612
• Screw
3
796T-627-1630
Push tool
■
1
790-101-2510
Block
■
1
791-830-1320
Rod
■
2
01580-11613
Nut
■
2
790-101-2570
Washer
■
2
01643-31645
Washer
■
2
790-105-2100
Jack ass’y
■
1
790-101-1102
Pump
■
1
3 791-580-1510
Installer
■
1
4 790-331-1110
Wrench
■
1
D 2
N
Sketch
Part name
Distinction
Part No.
Qty
Mark
Necessity
SPECIAL TOOLS
Q
3. Spacer Remove spacer (2).
DISASSEMBLY 1. Draining Oil Remove drain plug and drain oil from final drive case. 6
Final drive case: Approx. 8.5 l
2. Cover
4. No. 1 carrier assembly 1) Remove No. 1 carrier assembly (3).
1) Remove mounting bolts, then use forcing screws [1] to disconnect cover (1).
2) Use eyebolts [2] to remove cover (1).
30-30 (8)
2) Disassemble No. 1 carrier assembly as follows. i) Push in pin (4) and pull out shaft (5) from carrier (6). ★ After removing the shaft (5), remove pin (4).
DISASSEMBLY AND ASSEMBLY
ii) Remove thrust washer (7), gear (8), bearing (9), and thrust washer (10).
5. No. 1 sun gear shaft Remove No. 1 sun gear shaft (11).
FINAL DRIVE ASSEMBLY
8. Ring gear Using eyebolts d, remove ring gear (14).
9. No. 2 carrier assembly 1) Remove No. 2 carrier assembly (15)
6. No. 2 sun gear Remove No. 2 sun gear (12).
7. Thrust washer Remove thrust washer (13).
PC300/350(LC)-7
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).
30-31 c
DISASSEMBLY AND ASSEMBLY
10. Nut 1) Remove lock plate (23).
2) Use tool D1 and remove nut (24).
11. Hub assembly
FINAL DRIVE ASSEMBLY
2) Disassemble hub assembly as follows. i) Remove floating seal (26).
ii) Remove bearings (27) and (28) from hub (29).
3) Remove floating seal (30) from travel motor (31).
1) Using eyebolts e, remove hub assembly (25) from travel motor.
30-32 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12 ASSEMBLY ★ Clean all parts and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.
3) Using tool D3, install floating seal (30) onto travel motor (31). ★ The procedure for installation is the same as in the previous Step 2).
1. Hub assembly 1) Assemble hub assembly as follows. Using push tool, press fit bearings (27) and (28) to hub (29).
4) Using eyebolts e, set hub assembly (25) onto the travel motor. Use the push tool and tap to press fit the bearing.
2) Using tool D3, install floating seal (26). ★ Remove all oil and grease from the Oring and O-ring contact surface. Dry the parts before installing the floating seal. ★ 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.
PC300/350(LC)-7
2. Nut 1) Install nut as follows. i) Using tool D2, push bearing inner race (27). ★ Pushing force: 12.7 - 16.7 kN {1.3 - 1.7 tons} ★ Rotate the hub 2 - 3 times before applying the pushing force to the bearing inner race.
30-33 c
DISASSEMBLY AND ASSEMBLY
ii) Measure dimension a in the condition in Step 1) above.
iii) Measure thickness b of the nut (24) as an individual part. iv) Calculate a - b = c. v) Tighten nut (24) with tool D1 until dimension c is obtained.
FINAL DRIVE ASSEMBLY
vii) Install lock plate (23).
★ Install the lock plate as shown in the diagram below. Thread of mounting bolt: Thread tightener (LT-2) ★ Do no coat the threaded portion of the nut with thread tightener (LT-2). Mounting bolt: 49 - 74 Nm {6 - 7.5 kgm}
vi) Using push-pull scale f, measure tangential force in the direction of rotation of the hub in relation to the motor case. ★ Tangential force: Max. 490 N {50 kg} ★ The tangential force is the maximum force when starting rotation.
30-34 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12 3. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. ★ Replace thrust washers (19), (22) and pin (16) with new ones. ★ There are remains of caulking when the pin is inserted at the end face of hole e at the side of the carrier. 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).
ii) Align the position of pin holes on the shaft and carrier, then tap with a plastic hammer to install shaft (17). ★ When installing the shaft, rotate the planetary gear. Be careful not to damage the thrust washer. iii) Insert pin (16). ★ Insert the pin in such a way that any of the three claws (f portions) on the periphery will not fall on the slender (g) portion of the carrier. Take note, however, that depending on the actual carriers, this slender portion is on the opposite side. Hence when inserting the pin, check them carefully to see on which side of the carrier a thin portion is, and insert the pin the way its claw does not come to the thin portion. If there is a groove, meanwhile, avoid it.
PC300/350(LC)-7
★ After inserting the pin, caulk the pin portion of the carrier. ★ After assembling the carrier assembly, check that gear (20) rotates smoothly.
2) Install No. 2 carrier assembly (15). ★ Align the three tips of the gear shafts of the carrier assembly (15) to enter the three hollows in the end face of the motor case, then install.
30-35 c
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12 4. Ring gear Install O-ring on hub end. Use eyebolts d to install ring gear (14). ★ 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.
7. No. 1 carrier assembly 1)
Assemble No. 1 carrier assembly as follows. ★ Replace thrust washers (7) and (10), and pin (4) with new ones. ★ There are remains of caulking when the pin is inserted at the end face of hole h at the side of the carrier. 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 (10), and set gear assembly in carrier (6).
5. Thrust washer Install thrust washer (13). 6. No. 2 sun gear Install No. 2 sun gear (12). ii) Align the position of pin holes on the shaft and carrier, then tap with a plastic hammer to install shaft (5). ★ When installing the shaft, rotate the planetary gear. Be careful not to damage the thrust washer.
30-36 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
12 iii) Insert pin (4). ★ Insert the pin in such a way that any of the three claws (f portions) on the periphery will not fall on the slender (g) portion of the carrier. Take note, however, that depending on the actual carriers, this slender portion is on the opposite side. Hence when inserting the pin, check them carefully to see on which side of the carrier a thin portion is, and insert the pin the way its claw does not come to the thin portion. If there is a groove, meanwhile, avoid it.
2) Install No. 1 carrier assembly (3).
8. No. 1 sun gear shaft Install No. 1 sun gear shaft (11).
★ After inserting the pin, caulk the pin portion of the carrier. ★ After assembling the carrier assembly, check that gear (8) rotates smoothly. 9. Spacer Install spacer (2). ★ Take measurement of dimension "i" after installing the spacer. If "i" dimension exceeds 15 mm, the spacer is not installed correctly. In that case, check it again and if necessary, try to install it correctly once more.
PC300/350(LC)-7
30-37 c
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
11. Refilling with oil ★ Tighten drain plug and add engine oil through oil filler. 5 Final drive case: Approx. 8.5 l ★ Do a final check of the oil level at the determined position after installing the final drive assembly to the chassis.
10. Cover Using eyebolts [2], lift and install cover (1), then tighten mounting bolts with angle tightening wrench D4. 2 Mounting surface of cover: Gasket sealant (LG-6)
3 Mounting bolt: Initial torque: 98.1 Nm {10 kgm} Additional tightening angle: Turn 100 – 110°
30-38 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
12
REMOVAL AND INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY REMOVAL
k Release the residual pressure in the hydraulic circuit. Refer to the "Releasing of residual pressure in hydraulic circuit" section in the TESTING AND ADJUSTING chapter of this manual. k Lower the work equipment to the ground for safety. After stopping the engine, loosen the oil filler cap on the fuel tank to release the residual pressure inside the tank and move the safety lock lever to the LOCK position. 1.
4. Lift and remove swing motor and swing machinery assembly (7). ★ When lifting the swing motor and swing machinery assembly for removal, do slowly so that the hoses and other parts will not be damaged. ★ Take good care, when lifting the assembly, until the spigot joint portion is pulled out. 4
Swing motor and swing machinery assembly: 450 kg
Disconnect 5 swing motor hoses (1) through (5). • (1): Between swing motor and control valve (MA port) • (2): Between swing motor and control valve (MB port) • (3): Suction hose (S port) • (4): Drain hose (T port) • (5): Swing brake releasing pilot hose (B port)
2. Disconnect arm cylinder hose (6). INSTALLATION •
Install in reverse order of removal. 3 Mounting bolt: 824 – 1,030 Nm {84 – 105 kgm}
•
Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again.
•
Air bleeding Refer to the "Air bleeding of various parts" section in the TESTING AND ADJUSTING chapter of this manual.
3. Detach the swing motor and swing machinery assembly, using forcing screw [1] after removing the mounting bolts.
30-40 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING MACHINERY ASSEMBLY PC300, 300LC-7 Serial No. 40001 – 40573 PC350, 350LC-7 Serial No. 20001 – 20337
E
Push tool
●
1
2 796T-626-1140
Push tool
■
1
Part No.
Part name
Sketch
Qty
1 796T-626-1110
Mark
Distinction
Necessity
SPECIAL TOOLS
Q
DISASSEMBLY 1. Draining oil Loosen the drain plug and drain oil from the swing machinery case. 6
4. No. 1 carrier assembly 1) Disassemble No. 1 carrier assembly (3).
Swing machinery case: Approx. 13.4 l
2. Swing motor assembly 1) Place swing motor and swing machinery assembly on block [1]. 2) Remove the 6 mounting bolts to disconnect swing motor assembly (1). 4
Swing motor assembly: 70 kg
2) Disassemble the No. 1 carrier assembly in the following manner. i)
Remove snap ring (4) first and then remove thrust washer (8), gear (6), bearing (7), thrust washer (8) and plate (9).
ii) Using the press, remove shaft (5). ★ Press fitting force for assembly (Reference value) 29.2 – 54 kN {2,980 – 5,510 kg} 3. No. 1 Sun gear 1) Remove No. 1 sun gear (2).
30-41 (8)
DISASSEMBLY AND ASSEMBLY
5. Ring gear Remove the mounting bolts and remove ring gear (10).
SWING MOTOR, SWING MACHINERY ASSEMBLY
7. Bolt Remove the holder mounting bolt (12). 8. No. 2 carrier assembly 1) Remove No. 2 carrier assembly (13).
6. No. 2 sun gear Remove No. 2 sun gear (11).
30-42 (8)
2) Disassemble the No. 2 carrier assembly by hand in the following manner. i) Push in pin (14) and knock out shaft (15) from carrier (16). ★ After removing the shaft, remove pin (14) . ii) Remove thrust washer (17), gear (18), bearing (19) and thrust washer (20). iii) Remove plate (21).
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
12 9. Shaft assembly 1) Place the shaft case assembly on a press, and push shaft assembly (22) out of shaft case assembly (23), using push tool [2].
ASSEMBLY ★ Clean all related parts and check that there is no dirt or damage on the surface. Coat sliding surfaces with engine oil and then assemble the parts. ★ Do not reuse the removed bearing and oil seal (since their durability cannot be assured). 1. Shaft and case assembly 1) Set plate (25) to shaft (26).
2) Disassemble the shaft assembly in the following manner. Remove bearing (24) and plate (25) from shaft (26), using push tool [3].
10. Bearing Remove bearing (27) and oil seal (28) from case (29), using a push tool.
2) Set bearing (24) to shaft (26). Using push tool [5], press fit the inner race of the bearing. ★ Use a new bearing. ★ Install the bearing with the sealed side down (on the gear side). ★ Press fitting force (Reference value): 35.3 – 102 kN {3,600 – 10,400 kg}
3) Fill the hatched area (Part "a") with grease (G2-LI). 2 Injected grease amount: Approx. 200 – 340 g
30-43 (8)
DISASSEMBLY AND ASSEMBLY
4) Set shaft assembly (22) on case assembly (23) and press fit it with push tools [6] and [7]. ★ Press fitting force: 0 – 28.4 kN {0 – 2,900 kg}
SWING MOTOR, SWING MACHINERY ASSEMBLY
3. Bearing 1) Using tool E1, press fit bearing (27). ★ Press the bearing inner race and outer race simultaneously. Do not press only the inner race. ★ After press fitting the bearing, check that the case rotates smoothly. ★ Press fitting force (Reference value): Inner race side: 16.7 – 47.1 kN {1,700 – 4,800 kg} Outer race side: 0 – 16.7 kN {0 – 1,700 kg}
5) Reverse the shaft and case assembly. 2. Oil seal 1) Set case assembly (23) on block [8] horizontally. 2) Set block [9] under the shaft so that the shaft will not lean. 3) Using tool E2 and push tool [10], press fit oil seal (28). ★ Use new oil seal (28). 2 Outside of oil seal: Gasket sealant (LG-6) ★ When press fitting the oil seal, take care that gasket sealant (LG-6) will not stick to the oil seal lip.
2 Oil seal lip: Grease (G2-LI) ★ Check the press fitting finish point in advance and make a mark on it (since you cannot see if the oil seal has been inserted to the end). ★ Outside diameter of push tool E2: 174 – 174.5 mm
30-44 (8)
4. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. ★ There is caulking mark h made when the pin was inserted around the side hole of carrier (16) (See v)) and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i)
Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit top and bottom thrust washers (17) and (20), and then set the gear assembly to carrier (16).
DISASSEMBLY AND ASSEMBLY
iii) Aligning the pin holes of shaft (15) and carrier (16), lightly hit the shaft with a plastic hammer to install. ★ When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iv) Insert pin (14). ★ When inserting the pin, do not set the 3 claws (parts "a") on the periphery to the thin part of the carrier (part "b"). The thin part may be on the opposite side, however. Check the thin part and avoid setting the claws to it.
SWING MOTOR, SWING MACHINERY ASSEMBLY
5. Bolt 1) Tighten bolt (12).
2 Threads of mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 343 – 427 Nm {34 – 43.5 kgm} 2) Install the O-ring to the case.
v) After inserting the pin, caulk 2 parts "h" around the pin hole of the carrier. ★ Check that all the gears turn smoothly.
6. No. 2 sun gear Install No. 2 sun gear (11).
2) Install No. 2 carrier assembly (13).
30-45 (8)
DISASSEMBLY AND ASSEMBLY
7. Ring gear Using eyebolts (M10 x 1.5), install ring gear (10). ★ Degrease the mating surfaces of ring gear (10) and case (29). ★ Do not stick gasket sealant to the mating surfaces of ring gear (10) and case (29). ★ When installing the ring gear, match counter mark (part "d") to the projection (part "c") of the case flange. ★ Install the washer. 3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
SWING MOTOR, SWING MACHINERY ASSEMBLY
8. No. 1 carrier assembly 1) Assemble the No. 1 carrier assembly according to the following procedure. i)
Press fit shaft (5) to the carrier in the direction of the arrow until the snap ring groove is seen. ★ Press fitting force (Reference value): 29.2 – 54 kN {2,980 – 5,510 kg}
ii) Install snap ring (4), and then push it back until it is fitted to face "P" of the carrier. Take care not to push it back too much.
iii) Install plate (9). iv) Install thrust washer (8), bearing (7), gear (6), and thrust washer (8). v) Install snap ring (4) to shaft (5).
30-46 (8)
DISASSEMBLY AND ASSEMBLY
2) Install No. 1 carrier assembly (3).
SWING MOTOR, SWING MACHINERY ASSEMBLY
10. Swing motor assembly Fit the O-ring to ring gear (10) and install swing motor assembly (1). ★ Degrease the mating surfaces of swing motor assembly (1) and ring gear (10). ★ Do not stick gasket sealant to the mating surfaces of swing motor assembly (1) and ring gear (10). ★ Set motor port (part "f") and projection (part "c") of the case as shown in the figure. 4
Swing motor assembly: 70 kg
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm} 9. No. 1 sun gear assembly Install No. 1 sun gear (2). ★ Take care not to install the No. 1 sun gear upside down. ★ Install the No. 1 sun gear with the tooth side (part "e") down.
★ "P": Press fitting plate
•
Refilling with oil Tighten the drain plug and add engine oil through the oil filler to the specified level. 5
Swing machinery case: Approx. 13.4 l
30-47 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING MACHINERY ASSEMBLY PC300, 300LC-7 Serial No. 40574 and up PC350, 350LC-7 Serial No. 20338 and up
Qty
Push tool
●
1
Q
2 796T-626-1140
Push tool
■
1
Q
Part No.
Part name
Sketch
Necessity
1 796T-626-1110
Mark
E
Distinction
SPECIAL TOOLS
DISASSEMBLY 1. Draining oil Loosen the drain plug and drain oil from the swing machinery case. 6
4. No. 1 carrier assembly 1) Disassemble No. 1 carrier assembly (3).
Swing machinery case: Approx. 13.4 l
2. Swing motor assembly 1) Place swing motor and swing machinery assembly on block [1]. 2) Remove the 6 mounting bolts to disconnect swing motor assembly (1). 4
Swing motor assembly: 70 kg 2) Disassemble the No. 1 carrier assembly in the following manner. i)
Remove snap ring (4) first and then remove thrust washer (8), gear (6), bearing (7), thrust washer (8) and plate (9).
ii) Using the press, remove shaft (5). ★ Press fitting force for assembly (Reference value) 29.2 – 54 kN {2,980 – 5,510 kg} 3. No. 1 Sun gear 1) Remove No. 1 sun gear (2).
30-48 (8)
DISASSEMBLY AND ASSEMBLY
5. Ring gear Remove the mounting bolts and remove ring gear (10).
SWING MOTOR, SWING MACHINERY ASSEMBLY
2) Disassemble the No. 2 carrier assembly by hand in the following manner. i) Push in pin (14) and knock out shaft (15) from carrier (16). ★ After removing the shaft, remove pin (14) . ii) Remove thrust washer (17), gear (18), bearing (19) and thrust washer (20). iii) Remove plate (21).
6. No. 2 sun gear Remove No. 2 sun gear (11).
9. Shaft assembly 1) Remove mounting bolts (23). 2) Set shaft and case assembly to press, then using push tool [2], remove shaft assembly (24) from case assembly (25).
7. Bolt Remove the holder mounting bolt (12). 8. No. 2 carrier assembly 1) Remove No. 2 carrier assembly (13).
30-48-1 (8)
DISASSEMBLY AND ASSEMBLY
3) Disassemble shaft assembly as follows. i) Using push tool [3], remove cover assembly (26) and bearing (27) from shaft (28). ii) Remove oil seal (29) from cover (30).
SWING MOTOR, SWING MACHINERY ASSEMBLY
ASSEMBLY a Clean all parts and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. a Do not reuse the removed bearing and oil seal since their durability cannot be assured. Prepare new ones. 1. Bearing Using push tool E3, [4], press fit bearing (27) to case (32). a Use new bearing (27). a Press fitting force (Reference value): 0 – 26.4 kN {0 – 2,690 kg}
10. Bearing Using push tool, remove bearing (31) from case (32).
2. Cover assembly 1) Using push tool E4, press fit oil seal (29) to cover (30). a Use new oil seal (29). a When not using push tool E4, use another push tool to push the outside frame of the oil seal evenly. a Take care that oil seal (29) will not lean. 2 Outside circumference of oil seal: Gasket sealant (LG-6) a Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting.
30-48-2 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
12 2) Fit cover assembly (26) to case (32), and tighten mounting bolts (23). a Match the oil passage of cover assembly (26) to drilled hole A of case (32). 2 Cover mounting surface : Gasket sealant (LG-6) a Take care that LG-6 will not stick to drilled hole A. 3 Mounting bolt : 98 – 123 Nm {10 – 12.5 kgm}
3) Press-fit bearing (31), using push tool E1, [6]. ★ Use new bearing (31). ★ When press-fitting the bearing, press both inner and outer races of the bearing at the same time. Avoid pressing the inner race only. ★ After the bearing is press-fitted, check that the case will turn freely.
2 Lip of oil seal : Grease (G2-LI)
3. Case assembly 1) Reverse case assembly (25) and set it to shaft (28). a Take extreme care not to damage the oil seal. 2) Using push tool E5, [5], [7], press fit the bearing inner race. a Using push tool E5, [5], hit shaft lightly with a plastic hammer so that it will not come off, and then press fit it with the press. a Press fitting force (Reference value): 39 – 110 kN {3,980 – 11,260 kg} a Set push tool [7] so that case assembly (25) will not slant largely. a Hit the flange of case assembly (25) lightly and frequently to correct its slant.
★ Hit the flange of case assembly (25) frequently and lightly to correct the lean of case assembly (25). In particular, adjust the flange so that oil seal mating face B of the shaft will be at the center of oil seal (29).
4) Using push tool E1, [6], press fit bearing (31). ★ Use a new bearing. ★ Press the bearing inner race and outer race simultaneously. Do not press only the inner race. ★ After press fitting the bearing, check that the case rotates smoothly. ★ Press fitting force (Reference value): Inner race side: 15.3 – 43.2 kN {1,560 – 4,410 kg} Outer race side: 0 – 16.2 kN {0 – 1,650 kg}
30-48-3 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
v) After inserting the pin, caulk 2 parts "h" around the pin hole of the carrier. ★ Check that all the gears turn smoothly.
4. No. 2 carrier assembly 1) Assemble the No. 2 carrier assembly according to the following procedure. ★ There is caulking mark "h" made when the pin was inserted around the side hole of carrier (16) (See v)) and the inside wall of the hole is swelled at that mark. Flatten the swelled part in advance. i)
Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit top and bottom thrust washers (17) and (20), and then set the gear assembly to carrier (16).
2) Install No. 2 carrier assembly (13). 5. Bolt 1) Tighten bolt (12).
2 Threads of mounting bolt: Adhesive (LT-2) 3 Mounting bolt : 343 – 427 Nm {34 – 43.5 kgm}
2) Install the O-ring to the case assembly.
iii) Aligning the pin holes of shaft (15) and carrier (16), lightly hit the shaft with a plastic hammer to install. ★ When installing the shaft, revolve the planetary gear and take care not to damage the thrust washers. iv) Insert pin (14). ★ When inserting the pin, do not set the 3 claws (parts "a") on the periphery to the thin part of the carrier (part "b"). ★ The thin part may be on the opposite side, however. Check the thin part and avoid setting the claws to it.
30-48-4 (8)
DISASSEMBLY AND ASSEMBLY
SWING MOTOR, SWING MACHINERY ASSEMBLY
6. No. 2 sun gear Install No. 2 sun gear (11).
8. No. 1 carrier 7. Ring gear Using eyebolts (M10 x 1.5), install ring gear (10). ★ Degrease the mating surfaces of ring gear (10) and case (32). ★ Do not stick gasket sealant to the mating surfaces of ring gear (10) and case (32). ★ When installing the ring gear, match counter mark (part "d") to the projection (part "c") of the case flange. ★ Install the washer. 3 Mounting bolt : 245 – 309 Nm {25 – 31.5 kgm}
1) Assemble the No. 1 carrier assembly according to the following procedure. i)
Press fit shaft (5) to the carrier in the direction of the arrow until the snap ring groove is seen. ★ Press fitting force (Reference value): 29.2 – 54 kN {2,980 – 5,510 kg}
ii) Install snap ring (4), and then push it back until it is fitted to face "P" of the carrier. Take care not to push it back too much.
30-48-5 (8)
DISASSEMBLY AND ASSEMBLY
iii) Install plate (9).
SWING MOTOR, SWING MACHINERY ASSEMBLY
★ "P": Press fitting plate
iv) Install thrust washer (8), bearing (7), gear (6), and thrust washer (8). v) Install snap ring (4) to shaft (5).
2) Install No. 1 carrier assembly (3).
10. Swing motor assembly Fit the O-ring to ring gear (10) and install swing motor assembly (1). ★ Degrease the mating surfaces of swing motor assembly (1) and ring gear (10). ★ Do not stick gasket sealant to the mating surfaces of swing motor assembly (1) and ring gear (10). ★ Set motor port (part "f") and projection (part "c") of the case as shown in the figure. 4 Swing motor assembly: 70 kg 3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
9. No. 1 sun gear assembly Install No. 1 sun gear (2). ★ Take care not to install the No. 1 sun gear upside down. ★ Install the No. 1 sun gear with the tooth side (part "e") down.
30-48-6 (8)
DISASSEMBLY AND ASSEMBLY
•
SWING MOTOR, SWING MACHINERY ASSEMBLY
Refilling with oil Tighten the drain plug and add engine oil through the oil filler to the specified level. 5
Swing machinery case: Approx. 13.4 l
30-48-7 (8)
DISASSEMBLY AND ASSEMBLY
CARRIER ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY ★ This section deals only with precautions to be followed when reassembling the carrier roller assembly.
F
Installer
■
1
791-430-3230
Oil pump
■
1
Part name
Sketch
791-601-1000
Part No.
Distinction
Qty
Mark
Necessity
SPECIAL TOOLS
•
Carrier roller ★ Check the amount of air leakage from the seal with tool F by applying the standard pressure to the oil filler port. ★ Check that the gauge needle does not go down, when the below standard pressure is applied for 10 seconds. Standard pressure: 0.1 MPa {1 kg/cm²}
ASSEMBLY •
Floating seal ★ Before installing a floating seal, completely degrease both contact surfaces of the O-ring and the floating seal (hatched area in the illustration). Furthermore, take care so that no dust or dirt sticks to the contact surface of the floating seal. ★ Be sure to use the installer to insert the floating seal. ★ After inserting the floating seal, check that the inclination of the seal is less than 1 mm and that protrusion "a" of the seal remains within the range of 5 – 7 mm.
★ Fill the carrier roller assembly with oil, using tool F, and screw in the plug.
5
Carrier roller: 145 – 155 cc (EO30-CD)
30-49 (8)
DISASSEMBLY AND ASSEMBLY
TRACK ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
796-670-1010
Installer
■
1
791-601-1000
Oil Pump
■
1
Mark
Part No.
G
Part name
Sketch
• Distinction*
SPECIAL TOOLS
Qty
•
Necessity
★ This chapter deals only with precautions to be followed when reassembling the Track Roller Assembly.
*Distinction between new and existing part.
Track roller cover mounting bolt.
3 Track roller cover mounting bolt: 44.12 – 53.93 Nm {4.5 – 5.5 kgm} Track roller ★ Using tool G, apply the specified air pressure to the oil filler port to check air leakage from the seal. ★ Keep applying the following specified air pressure for 10 seconds to check that the gauge needle does not go down. Specified air pressure: 0.1 MPa {1 kg/cm²}
ASSEMBLY •
Floating seal ★ Before installing a floating seal, completely degrease both contact surfaces of the O-ring and the floating seal (hatched area in the illustration). Furthermore, take care so that no dust or dirt sticks to the contact surface of the floating seal. ★ After inserting the floating seal, check that inclination of the seal is less than 1 mm and that protrusion "a" of the seal remains within the range of 7 – 11 mm.
★ Fill the track roller assembly with hydraulic oil. Use tool G and screw in the plug. 5
Track roller: 250 – 280 cc (EO30-CD)
3 Plug: 10 – 20 Nm {1 – 2 kgm}
30-50 (8)
DISASSEMBLY AND ASSEMBLY
IDLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY SPECIAL TOOLS Mark H
Part No.
Part Name
Necessity Qty Distinction* Sketch
796-570-1020 Installer
■
1
791-601-1000 Oil pump
■
1
*Distinction between new and existing part.
DISASSEMBLY
3. Detach idler (4) from shaft (5) and support assembly (7). ★ The idler contains 230 ± 10 cc of oil. Drain the oil at this stage of disassembly. Take care and spread a cloth on the floor to prevent smearing the floor with flushing oil. 4. Remove floating seal (6) on the opposite side of idler (4), shaft (5) and support assembly (7).
5. Remove dowel pin (8) to detach support (7) from shaft (5). 6. Remove bushings (9) and (10) from idler (4).
1.
Remove dowel pin (1) and then support (2).
2. Remove floating seal (3) from support (2) and idler (4).
PC300/350(LC)-7
30-51 c
DISASSEMBLY AND ASSEMBLY
IDLER ASSEMBLY
12 ASSEMBLY 1.
Press fit bushing (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5) with dowel pin (8).
★ Before installing the floating seal, completely degrease both contact surfaces of the O-ring and the floating seal (hatched area in the illustration). Furthermore, take care so that no dust or dirt sticks to the contact surface of the floating seal. ★ After inserting the floating seal, check that inclination of the seal is less than 1 mm and that protrusion a of the seal remains within the range of 5 - 7 mm.
★ Install the shaft with UP mark facing upward.
3. Using tool H, install floating seal (6) to idler (4), shaft (5) and support (7) assembly. 4. Assemble shaft (5) and support (7) assembly to idler (4).
30-52 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
IDLER ASSEMBLY
12 5. Using tool H, install floating seal (3) to idler (4) and support (2).
6. Install O-ring, then install support (2) with dowel pin (1). ★ After inserting the pin, caulk the support pin. 7.
Add oil and tighten plug. Oil: Approx. 230 ± 10 cc (EO 30-CD)
Plug: 130 - 180 Nm {13 - 18 kgm}
★ 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.
PC300/350(LC)-7
30-53 c
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 1.
SPECIAL TOOLS Mark
1
J
2
Part No.
Part Name
Necessity Qty Distinction* Sketch
791-685-8006 Compressor
■
1
791-635-3160 Extension
■
1
■
1
790-101-1102 Pump
■
1
790-201-1500 Push tool kit
■
790-101-1600
Cylinder 686 kN {70 T}
• 790-201-1620 • Plate
Remove piston assembly (2) from recoil spring assembly (1).
1 1
• 790-101-5021 • Grip
1
• 01010-50816 • Bolt
1
*Distinction between new and existing part.
2. Disassembly of recoil spring assembly 1) Set tool J1 to recoil spring assembly (1). The recoil spring is under large installed load, so be very sure to set the tool properly. Failure to do this is dangerous. ★ Installed load of spring: 208.6 kN {21,280 kg}
DISASSEMBLY
2) Apply hydraulic pressure slowly to compress the spring. Remove lock plate (3). Then remove nut (4). ★ Compress the spring to a point where the nut becomes loose. ★ Release the hydraulic pressure slowly to decompress the spring. ★ Free length of spring: 814 mm 3) Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from spring (5). 3. Dissassembly of piston assembly 1) Remove lock plate (11) from piston (10), then remove valve (12). 2) Remove snap ring (13), then remove Upacking (14) and ring (15).
30-54 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING ASSEMBLY
12 ASSEMBLY
2. Assembly of recoil spring assembly 1) Using tool J2, install dust seal (9) to cylinder (7).
2) Assemble cylinder (7) collar (8), and yoke (6) to spring (5), and place in tool J1. Sliding portion of cylinder: Grease (G2-L1)
1. Assembly of piston assembly 1) Assemble ring (15) and U-packing (14) to piston (10) and secure with snap ring (13). 2) Tighten valve (12) temporarily, and secure with lock plate (11).
PC300/350(LC)-7
30-55 c
DISASSEMBLY AND ASSEMBLY
SPROCKET
12
REMOVAL AND INSTALLATION OF SPROCKET 3) Apply hydraulic pressure slowly to compress the spring and tighten nut (4) so that the installed length of the spring is dimension a, then secure it with lock plate (3). ★ Installed length a of spring: 655 mm
4) Remove recoil spring assembly (1) from tool J1. 3. Assemble piston assembly (2) to recoil spring assembly (1).
REMOVAL 1. Remove track shoe assembly. For details, see TRACK SHOE ASSEMBLY, REMOVAL. 2. Swing work equipment 90°, push up chassis with work equipment and place block b between track frame and track shoe.
3. Remove mounting bolts and lift off sprocket (1). Sprocket: 65 kg
Sliding portion of wear ring: Grease (G2-L1) ★ Install the piston assembly so the valve installing position is on the outside. ★ Fill the inside of the cylinder with 180 cc of grease (G2-L1), then bleed the air and check that grease comes out of the grease hole.
INSTALLATION •
Install in reverse order of removal.
Thread of sprocket mounting bolt: Gasket sealant (LG-6) Sprocket mounting bolt: 640 - 785 Nm {65 - 80 kgm}
30-56 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
TRACK SHOE ASSEMBLY
12
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 3. Disassemble track shoe (3) above master pin (2).
791-630-3000 K
1 790-101-1300 790-101-1102 2 790-331-1110
1
Cylinder ■ (980 kN {100 t} )
1
Remover & installer
Pump
■
1
Wrench
■
1
Sketch
■
Part name
Distinction
Part No.
Qty
Mark
Necessity
SPECIAL TOOLS
EXPANSION 1. Set master pin at the position for expanding. ★ Start the engine and bring the master pin in front of the idler. ★ Put block [1] under the track shoe in front of the idler.
4. Using tool K1, pull out master pin (2).
2. Lower the work equipment, then loosen lubricator (1), and relieve track tension.
k The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.
5. Travel machine backward to expand track shoe.
30-57 (8)
DISASSEMBLY AND ASSEMBLY 12 ASSEMBLY •
Assemble in reverse order of expansion. ★ Refer to the "Inspection and adjustment of track shoe tension" section in the TESTING AND ADJUSTING chapter of this manual. ★ Using tool K2, tighten the bolt by angle tightening method.
2 Mounting bolt: Anti-seizure compound (equivalent to "Maruzen molymax No. 2")
3 Mounting bolt: 1st time: 393 ± 39 Nm {40 ± 4 kgm} 2nd time: 120 ± 10° (Angle tightening) ★ Press-fit the master pin with a proper tool until dimension "a", master pin protrusion amount, is obtained. Master pin protrusion amount "a": 4.2 ± 2 mm
30-58 (8)
TRACK SHOE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
SWING CIRCLE ASSEMBLY
12
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY REMOVAL
INSTALLATION
1.
•
Remove revolving frame assembly. Refer to the Removal and Installation of Revolving Frame Assembly section in this manual.
2. Sling swing circle assembly (1) at three points. Remove the mounting bolts and lift off the swing circle assembly.
Swing circle assembly: 500 kg
Install in reverse order of removal.
Thread of swing circle mounting bolt: Thread tightener (LT-2) Swing circle mounting bolt: 926.7 ± 103 Nm (94.5 ± 10.5 kgm) ★ Install the inner race to the track frame with the S mark of its inner soft zone spot facing the right side of machine as shown in the figure below. Grease bath fill: Grease (G2-L1) 33 l
PC300/350(LC)-7
30-59 c
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME ASSEMBLY
12
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY REMOVAL Extend the arm and bucket fully, then lower the work equipment to the ground and move the safety lock lever to the LOCK position. 1.
Remove the work equipment assembly, refer to the Removal of Work Equipment Assembly section in this manual.
2. Remove the counter weight assembly, refer to the Removal of Counterweight Assembly section in this manual. 3. Disconnect four boom cylinder hoses (1). ★ Plug the hose to stop oil flow-out.
6. Support the engine hood (5) with an appropriate sling and lifting device. ★ Remove any parts which may interfere with a sling, when removing the revolving frame.
4. Sling boom cylinder assembly (2). 7.
Remove engine hood mounting bolts to pull out pin (6).
8. Lift and remove engine hood (5).
5. Remove plate (3) and pin (4). Lift and remove the boom cylinder assembly (2). ★ Remove the boom cylinder assembly on the opposite side in the same manner. Boom cylinder assembly: 280 kg
30-60 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME ASSEMBLY
12 9. Remove plates (7) and (8). 10. Remove U bolt (9) and plate (10) to disconnect after-cooler tube (11). ★ If any other parts may interfere with the slings, remove them before lifting the assembly.
13. Sling revolving frame assembly (20) then remove 40 mounting bolts and lift off revolving frame assembly. ★ Use two lever blocks. ★ Leave the two mounting bolts at the front and rear and adjust the center of gravity with the lever blocks while lifting off. Remove the mounting bolts afterwards.. 11. Disconnect seven hoses (12) through (18). • (12): Center swivel joint (D port) Swing motor (T port) • (13): Center swivel joint (D port) Hydraulic tank • (14): Center swivel joint (E port) Solenoid valve • (15): Center swivel joint (B port) Left travel control lever (B2 port) • (16): Center swivel joint (D port) Right travel control lever (B5 port) • (17): Center swivel joint (A port) Left travel control lever (A2 port) • (18): Center swivel joint (C port) Right travel control lever (A5 port)
When removing the revolving frame assembly, take care so that it will not bump the center swivel joint assembly Revolving frame assembly: 7,800 kg
12. Pull out pin (19) on the side of center swivel joint and detach turning stopper plate from center swivel joint.
PC300/350(LC)-7
30-61 c
DISASSEMBLY AND ASSEMBLY
REVOLVING FRAME ASSEMBLY
12 INSTALLATION •
Install in reverse order of removal.
Swivel circle mating surface: Gasket sealant (LG-4) Threads of revolving frame mounting bolt: Adhesive compound (LT-2) Revolving frame mounting bolt: 926.7 ± 103 Nm (94.5 ± 10.5 kgm) •
•
Refilling hydraulic oil Refill hydraulic oil through the oil filler port to the specified level, and let the oil circulate in the hydraulic system by starting the engine. Then check the level again. Air bleeding Bleed air from the travel motor, refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.
30-62 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
12
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY REMOVAL Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, release of remaining pressure in hydraulic circuit. ★ Mark all the piping with tags to prevent mistakes in the mounting position when installing. 1. • • • • • • • •
Disconnect eight hoses (1) through (8) between travel motor and center swivel joint. (1): Center swivel joint (T port) Left travel motor (T port) (2): Center swivel joint (T port) Right travel motor (T port) (3): Center swivel joint (B port) Left travel motor (PA port) (4): Center swivel joint (D port) Right travel motor (PB port) (5): Center swivel joint (A port) Left travel motor (PB port) (6): Center swivel joint (C port) Right travel motor (PA port) (7): Center swivel joint (E port) Left travel motor (P port) (8): Center swivel joint (E port) Right travel motor (P port)
PC300/350(LC)-7
2. Disconnect seven hoses (9) through (15). • (9): Center swivel joint (D port) Swing motor (T port) • (10): Center swivel joint (D port) Hydraulic tank • (11): Center swivel joint (E port) Solenoid valve • (12): Center swivel joint (B port) Left travel control lever (B2 port) • (13): Center swivel joint (D port) Right travel control lever (B5 port) • (14): Center swivel joint (A port) - | Left travel control lever (A2 port) • (15): Center swivel joint (C port) Right travel control lever (A5 port) 3. Pull out pin (16) on the side of center swivel joint and remove the jam plate from the center swivel joint.
30-63 c
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
12 4. Remove four mounting bolts (17).
INSTALLATION •
Install in reverse order of removal. Install the center swivel joint facing in the direction shown in the diagram. (The diagram shows the machine as seen from above)
5. Remove center swivel joint assembly (18).
Center swivel joint assembly: 40 kg •
•
30-64 c
Refilling with oil (hydraulic tank) ★ Add oil through the oil filter 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. For details see TESTING AND ADJUSTING, Air Bleeding of Various Parts.
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 3. Using tool L. pull out swivel rotor (4) and ring (3) from swivel shaft (5).
SPECIAL TOOLS Mark
Part No.
Part Name Necessity Qty Distinction* Sketch
790-101-2501 Push puller
L
●
1
• 790-101-2510 • Block
1
• 790-101-2520 • Screw
1
• 791-112-1180 • Nut
1
• 790-101-2540 • Washer
1
• 790-101-2630 • Leg
2
• 790-101-2570 • Plate
4
• 790-101-2560 • Nut
2
• 790-101-2650 • Adapter
2
4. Remove seal (6) from swivel shaft (5). 5. Remove O-ring (7) and slipper seal (8) from swivel rotor (4).
*Distinction between new and existing part.
DISASSEMBLY
ASSEMBLY 1.
Assemble slipper seal (8) and O-ring (7) to swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5). 3. 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-L1) ★ When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring. 4. Install ring (3) and secure with snap ring (2). 5. Install O-ring and cover (1).
1.
Remove cover (1).
Mounting bolt: 31.4 ± 2.9 Nm {3.2 ± 0.3 kgm)
2. Remove snap ring (2).
PC300/350(LC)-7
30-65 c
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY REMOVAL 1.
Remove covers (1) and (2).
7.
Disconnect drain hoses (9), (10) and (11).
8. Detach clamps (12) at four points. 2. Drain oil from hydraulic tank. Hydraulic tank: Approx. 365 l 3. Open up engine hood. 4. Remove upper cover (3).
9. Disconnect suction tube (13) after removing four mounting bolts.
5. Disconnect drain hoses (4) and (5). 6. Detach clamp (6) and then disconnect control valve return hose (7) and oil cooler return hose (8).
30-66 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK ASSEMBLY
12 10. Lift hydraulic tank assembly temporarily to remove six mounting bolts (14).
11. Lift off and remove hydraulic tank assembly (15). Hydraulic tank assembly: 200 kg
INSTALLATION • •
Install in reverse order of removal. Refilling with oil (hydraulic tank) ★ Add oil through the oil filler to the specified level. Start and run the engine to circulate the oil through the system. Then check the oil level again. Hydraulic tank: Approx. 365 l
•
Air Bleeding ★ Bleed the air. For details. see TESTING AND ADJUSTING. Air Bleeding of Various Parts.
PC300/350(LC)-7
30-67 c
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY REMOVAL Lower the work equipment to the ground completely and stop the engine. Then loosen the cap on the hydraulic tank slowly to release the remaining pressure inside the tank, and put the safety lock lever to the LOCK position.
4. Disconnect four boom hoses (5). 5. Remove boom tube mounting clamps (6) and (7).
★ Attach a tag to each pipe to avoid making an error when installing them again later. 1.
Open up engine hood (1).
2. Remove control valve upper cover (2).
6. Remove plate (8).
3. Remove partition covers (3) and (4) between engine and control valves.
7.
30-68 c
Disconnect eight control valve hoses and eight tubes. • (9): TSW port hose (Swing motor S port) • (10): T1 port hose (to hydraulic tank) • (11): In the sequence of top to bottom A-1 port tube (Boom Hi bottom side) A1 port tube (Bucket bottom side) A2 port hose (Swivel joint A port) A3 port tube (Boom bottom side) A4 port hose (Swing motor MB port) A5 port hose (Swivel joint C port) A6 port tube (Arm head side)
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
12 •
(12): In the sequence of top to bottom B-1 port hose (Arm Hi bottom side) B1 port hose (Bucket head side) B2 port hose (Swivel joint B port) B3 port tube (Boom head side) B4 port hose (Swing motor MA port) B5 port hose (Swivel joint D port) B6 port tube (Arm bottom side)
8. Disconnect six PPC hoses on the right side. • (13): Bucket DUMP (Hose band: Black) • (14): Left FORWARD (Hose band: Red) • (15): Boom LOWER (Hose band: Brown) • (16): Right SWING • (17): Right FORWARD (Hose band: Green) • (18): Arm DIGGING (Hose band: Green)
PC300/350(LC)-7
9. Disconnect two hoses between control valves and solenoid. • (19): PS port hose (Hose band: Yellow - blue) • (20): PST port hose (Hose band: Brown) 10. Disconnect drain hose (21).
11. Disconnect seven PPC hoses and five control valve hoses on the left side. • (22): PLS2 port hose (Hose band: Red) • (23): PLS1 port hose • (24): PX1 port hose (Hose band: Green) • (25): In the sequence of top to bottom, Bucket DIGGING (Hose band: White) Left REVERSE Boom RAISE (Hose band: Green) SWING LS divider valve BP5 port hose (to solenoid) Left SWING (Hose band: Red) Right REVERSE (Hose band: Blue) Arm DUMP (Hose band: Yellow) • (26): PX2 port hose
30-69 c
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
12 12. Disconnect 7 hoses and wiring connectors at two points. • (27): PPS1 port hose (Front pump) • (28): PPS2 port hose (Rear pump) • (29): PR port hose (Solenoid) • (30): PR port hose (Pump) • (31): PP1 port hose (Front pump) • (32): PP2 port hose (Rear pump) • (33): T port hose (Oil cooler) • (34): A51 (Front pump pressure sensor)
INSTALLATION • •
•
(35): A52 (Rear pump pressure sensor) •
Install in reverse order of removal. 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 from the circuit between the valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Air Bleeding of Various Parts.
13. Lift and remove control valve assembly (36) after removing three mounting bolts. Control valve assembly: 250 kg
30-70 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY ★ This chapter deals only with precautions to be followed when disassembling and reassembling the control valve assembly.
796-946-1310
Guide
(For 723-46-40100, 723-46-40601) 796-946-1810 1
Guide
(For 723-46-43100, 723-46-43400) 796-946-2110
Guide
(For 723-46-44100) 796-946-2210
Guide
(For 723-46-45100) 796-946-1320
Guide
(For 723-46-40100, 723-46-40601) 796-946-1820
Guide
(For 723-46-43100, 723-46-43400) 2 M
796-946-2120
Guide
(For 723-46-44100) 796-946-2220
Guide
(For 723-46-45100) 796-946-1420
Guide
(For 723-46-42800) 796-946-1330
■
1
■
1
■
1
■
1
■
1
■
1
■
1
■
1
■
1
3. Install O-ring (6) onto piston (2).
1
4. Place tool M1 onto piston (2) and push it in slowly by hand so that seal (5) spreads out evenly. ★ The seal may be also installed by pushing it down to the flat surface of the tool and then pushing it in with the tool fitted to the piston.
Sleeve
(For 723-46-40100, 723-46-40601) 796-946-1830
Sleeve
1
(For 723-46-43100, 723-46-43400) 3
796-946-2130
Sleeve
1
(For 723-46-44100) 796-946-2230
Sleeve
796-946-1430
Sleeve
1.
Remove piston (2), plug (3), and string (4) from pressure compensation valve (1).
2. Remove seal (5) and O-ring (6) from piston (2).
★ There are many types of the pistons. ★ Clean the pressure compensation valve thoroughly. Install the seal using a tool, as indicated in the diagram.
1
(For 723-46-45100) (For 723-46-42800)
Sketch
Part name
Qty
Part No.
Necessity
Mark
Distinction
SPECIAL TOOLS
Procedures for replacing pressure compensation valve seal ★ Since there are many types of the pressure compensation valves, make a mark on each valve to indicate from where it was removed.
■
1
30-71 (8)
DISASSEMBLY AND ASSEMBLY 12 5. Likewise, set tool M2 to piston (2) in the same direction and push it slowly by hand so that the other seal (6) may be spread out evenly. ★ The seal may be also fitted by pushing it down to the flat surface of the tool and then pushing it in with the tool fitted to the piston.
6. Keep compensation tool M3 fitted to piston (2) for about one minute so that seals (5) and (6) will become well adapted. ★ Check that there is no protrusion or cut on the seal.
7.
Assemble the piston in the sleeve. ★ If it is difficult to install the sleeve, do not attempt to push it in forcibly, but try it again after repeating the same process in Step 6. above and confirming the seals are well adapted.
8. Fit plug (3) and spring (4) to piston (2) and assemble pressure compensation valve (1). ★ After the installation, push the piston by hand and check that the piston reacts only with spring force.
30-72 (8)
CONTROL VALVE ASSEMBLY
ASSEMBLY • Coat the sliding surface with engine oil and then reassemble the control valve assembly. • When installing spools (7) and (10) in the valve chamber, direct drilled holes (8) and (11) toward cylinder ports (9) and (12). ★ Install the other spools shown in sections H – H, K – K, L – L and M – M similarly.
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
•
•
Control valve top and bottom covers
2 Mating faces of control valve top and bottom covers: SEALEND 242 or equivalent ★ Use 2 washers (W2) each for only 2 places of the control valve top cover. Tighten the mounting bolts of the control valve top and bottom covers in the following order: (A o D o C o B) 3 Mounting bolt of control valve top and bottom covers: 156.9 – 176.5 Nm {16 – 18 kgm}
•
Install filters (13) to the bottom of PLS1 port and PLS2 port as shown (Take care of the caulked parts (*).)
30-72-1 (8)
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE ASSEMBLY
•
•
•
•
•
•
30-72-2 (8)
Merge-divider valve
2 Mating face of merge-divider valve: SEALEND 242 or equivalent Tighten the mounting bolts of the mergedivider valve similarly to those of the control valve covers.
3 Mounting bolt of merge-divider valve: 156.9 – 176.5 Nm {16 – 18 kgm} Tighten the mounting bolts of the boom Hi check valve, quick return valve, lock valve, and arm plate similarly to those of the control valve covers.
3 Mounting bolt of boom Hi check valve, quick return valve, lock valve, and arm plate: 58.8 – 73.6 Nm {6 – 7.5 kgm} After assembling, fit the cap so that oil and cleaning liquid will not enter the engine through the ø12 hole. Pressure compensation valve ★ Install each pressure compensation valve, paying attention to the counter mark that was put when removing it. Main relief valve assembly After building the main relief valve assembly in the control valves, refer to the Inspection And Adjustment of Hydraulic Oil Pressure In Hydraulic Circuit For "Work equipment, swing and travel" section in the TESTING AND ADJUSTING chapter, in this manual.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 3. Remove covers (1), (2) and (3).
SPECIAL TOOLS Mark
Part No.
Part Name Necessity Qty Distinction* Sketch
796-460-1210 Oil stopper
■
1
796-770-1320 Adapter
■
1
C
*Distinction between new and existing part.
REMOVAL Disconnect the negative (-) terminal of the battery before starting with the work. Lower the work equipment to the ground and stop the engine. Then loosen the oil filler cap on the hydraulic tank slowly to release pressure inside the tank.
4. Remove cover (4).
★ Attach identification tags to all piping to avoid mistakes when installing. 1.
Remove hydraulic tank strainer and stop oil flow-out using tool C. ★ If tool C is not used, remove the drain plug and drain oil from the hydraulic tank and piping. Hydraulic tank: Approx. 365 l
5. Remove covers (5), (6) and (7).
2. Drain oil from the damper case. Damper case: Approx. 13.5 l
PC300/350(LC)-7
30-73 c
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
12 6. Disconnect pump wiring connectors at two points. • (8): V22 (PC-EPC solenoid valve) Color band: Red • (9): V21 (LS-EPC solenoid valve) Color band: White
8. Disconnect muffler drain tube (21).
9. Disconnect clamps (22) at two points. 10. Remove muffler clamp (23) and two U bolts (24) to detach muffler (25). 7.
Disconnect ten hoses and one tube. • (10): Rear pump discharging port hose • (11): Front pump discharging port hose • (12): Drain port hose • (13): Front load pressure input port hose • (14): Rear load pressure input port hose Color band: Red • (15): EPC source pressure port hose Color band: Yellow • (16): Rear pressure port hose Color band: Yellow • (17): Front pressure input port hose • (18): Rear pump discharging port hose • (19): Front pump discharging port hose • (20): Pump suction port tube
11. Remove muffler bracket (26).
12. Lift and remove hydraulic pump assembly (27). Hydraulic pump assembly: 220 kg
30-74 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
12 INSTALLATION •
Install in reverse order of removal.
Hydraulic pump involute spline: Anti-friction compound (LM-G) Hydraulic pump case mating surface: Gasket sealant (LG-6) •
Refilling hydraulic oil (Damper case) Refill hydraulic oil through the oil filler port to the specified level. Damper hydraulic oil : Approx. 13.5 l
•
Refilling hydraulic oil (hydraulic tank) Refill hydraulic oil through the oil filler port to the specified level, and let the oil circulate in the hydraulic system by starting the engine. Then check the oil level again. Hydraulic tank : Approx. 365 l
•
Bleeding air ★ Bleed the air. For details. see TESTING AND ADJUSTING. Air Bleeding of Various Parts.
PC300/350(LC)-7
30-75 c
DISASSEMBLY AND ASSEMBLY
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT REMOVAL
INSTALLATION
1.
•
Remove the hydraulic pump assembly. Refer to the Removing Hydraulic Pump Assembly section.
2. Remove snap ring (1) and then remove spacer (2). 3. Pry off oil seal (3) with a screwdriver. ★ When attempting to pry off the seal, do not damage the shaft.
30-76 c
Install in reverse order of removal.
Oil seal lip portion: Grease (G2-LI) Oil seal outer circumference: Grease (G2-LI) ★ Coat the oil seal outer circumference thinly with grease. ★ Press-fit oil seal (3), using tool b.
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY PC300, 300LC-7 Serial No. 40001 – 40314 PC350, 350LC-7 Serial No. 20001 – 20221 ★ This section deals only with precautions to be followed when reassembling the PPC valve assembly for work equipment.
★ When assembling piston (8), coat the piston outer periphery and body hole inner periphery with grease. 3 Plate (5) mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2 Joint (4) sliding surface: Grease 2 – 4 cc (G2-LI)
2 Body female screw portion: Adhesive compound (LT-2) ★ Coat the female screw portion A of body with Loctite at 2 spots as shown in the diagram below. Each spot is to be coated with a drop (approx. 0.02 g).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm} ★ Strictly follow the specified torque for the joint.
2 Contact surfaces of piston (8) and disc (2): Grease 0.3 – 0.8 cc (G2-LI)
ASSEMBLY ★ Install spring (11 ) so that the end surface of smaller end coil diameter (inner diameter) will face the shim (12) side. ★ Springs (10 ) in use differ in the number of turns according to hydraulic ports as classified in the table below. Hence, take care when installing one. Port location
Spring free length
P1, P2
44.4 mm
P3, P4
42.4 mm
3 Nut (1): 98 – 127 Nm {10 – 13 kgm} ★ After assembling the disc, refer to the "Adjustment of work equipment and swing PPC valve" section of the TESTING AND ADJUSTING chapter of this manual.
★ The location of each port is stamped in the lower part of the valve body. 2 Piston (8): Grease (G2-LI)
30-77 (8)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY PC300, 300LC-7 Serial No. 40315 and up PC350, 350LC-7 Serial No. 20222 and up ★ This section deals only with precautions to be followed when reassembling the PPC valve assembly for work equipment.
★ When assembling piston (8), coat the piston outer periphery and body hole inner periphery with grease. 3 Plate (5) mounting bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Joint (4) sliding surface: Grease 2 – 4 cc (G2-LI)
2 Body female screw portion: Adhesive compound (LT-2) ★ Coat the female screw body with Loctite at 2 spots as shown in the diagram below. Each spot is to be coated with a drop (approx. 0.02 g). 3 Joint (4): 39 – 49 Nm {4 – 5 kgm} ★ Strictly follow the specified torque for the joint.
2 Contact surfaces of piston (8) and disc (2): Grease 0.3 – 0.8 cc (G2-LI)
ASSEMBLY ★ Install spring (11) so that the end surface of smaller end coil diameter (inner diameter) will face the shim (12) side. ★ Springs (10) in use differ in the number of turns according to hydraulic ports as classified in the table below. Hence, take care when installing one. Port location
Spring free length
P1, P2
44.4 mm
P3, P4
42.4 mm
★ The location of each port is stamped in the lower part of the valve body. 2 Piston (8): Grease (G2-LI)
30-77-1 (8)
3 Nut (1): 69 – 88 Nm {7 – 9 kgm} ★ After assembling the disc, refer to the "Adjustment of work equipment and swing PPC valve" section of the TESTING AND ADJUSTING chapter of this manual.
DISASSEMBLY AND ASSEMBLY
TRAVEL PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ★ This chapter deals only with precautions to be followed when reassembling. ASSEMBLY ★ When assembling, clean and inspect the paets closely and take care fully so that dirt, rush, flaw, etc. will not cause a trouble. 1.
When installing piston (1), apply grease (G2LI) to its outside and the inside of the body hole.
2. Install spring (2) with its small diameter side on the shim (3) side. • Diameter of spring (Inside diameter) Small diameter side: 4.9 mm Large diameter side: 5.55 mm 3. Do not drive in bushing (4) by hitting it directly with a hammer. 4. Do not drive in pin (5) by hitting it directly with a hammer. 5. Apply grease (G2-LI) to the rocking part of shaft (6) and the contact surfaces of lever (7) and piston (1) and the contrast surfaces of plate (8) and pin of lever (9). 2 Quantity of grease (G2-LI) Rocking part of shaft (6): 4 – 8 cc/periphery Connecting part of lever (7) and piston (1): 0.3 – 0.8 cc/part Connecting part of plate (8) and lever (9): 0.3 – 0.8 cc/part
6. Install washer (10) 1.6 mm thick first. If the difference between both sides at the stroke end of the lever exceeds 0.7°, change the washer thickness to reduce the difference to below 0.7°. (If the washer thickness is reduced by 0.3 mm, the stroke end angle is increased by 0.39°.) • Thickness of washer: 1.0, 1.3, 1.6 mm
30-78 (8)
7.
Tighten each part to the following torque. • Plug (11): 6 – 11 Nm {0.6 – 1.1 kgm} • Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm} (Apply LOCTITE #262.) • Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm} • Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm} • Bolt (15): 25 – 31 Nm {2.5 – 3.2 kgm} • Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm}
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
1
2 3 4
Cylinder repair stand
■
1
790-102-4300
Wrench Assembly
■
1
790-102-4310
Pin
■
2
790-720-1000
Expander
●
1
796-720-1680
Link
●
1
07281-01589
Clamp
●
1
790-201-1702
Push tool kit
■
1
• 790-201-1851
• Push tool (for bucket and boom)
1
• 790-201-1861
• Push tool (for arm)
1
• 790-101-5021
• Grip
1
• 01010-50816
• Bolt
1
N 5
790-201-1500 • 790-101-5021 • 01010-50816
Push tool kit
■
4) Disassemble piston rod assembly as follows. i) Set piston rod assembly (2) in tool N1.
1
• Grip
1
• Bolt
1
790-201-1660
• Plate (for boom and bucket)
1
790-201-1670
• Plate (for arm)
1
6
Sketch
790-502-1003
Part No.
Distinction
Part name
Qty
Mark
Necessity
SPECIAL TOOLS
DISASSEMBLY 1. Piston rod assembly 1) Remove piping from cylinder assembly.
ii) Remove stopper screw (3) of piston assembly. ★ Common screw size for boom, arm, and bucket cylinder: M12 x Pitch 1.75.
2) Remove mounting bolts and disconnect head assembly (1). 3) Pull out piston rod assembly (2). ★ Place a container under the cylinder to catch the oil.
30-79 (8)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12 ★ If the caulking of screw (3) is too strong and it cannot be removed, tighten the screw fully, then fit a tap to the thread and remove the screw.
iii) Using tool N2, remove piston assembly (4). • When not using tool N2, use the drill holes (DH) (∅ 10, 4 places) and loosen the piston assembly.
vii) Remove cap (8), and pull 12 balls (9), then remove plunger (10). • Arm cylinder only ★ Since cap (8) is made of nylon, tighten a screw into it and pull it out with pliers.
2. Disassembly of piston assembly 1) Remove rings (11). 2) Remove wear rings (12). iv) Remove plunger (5). • Boom and arm cylinder only v) Remove collar (6). • Boom and arm cylinder only vi) Remove head assembly (7).
30-80 (8)
3) Remove piston ring (13). 4) Remove O-ring and backup ring (14).
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12 3. Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (16), then remove dust seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).
2. Assembly of piston assembly 1) Using tool N3, expand piston ring (13). ★ Set the piston ring on tool N3, and turn the handle 8 – 10 times to expand the ring. 2) Set tool N4 in position, and compress piston ring (13). ASSEMBLY ★ Be careful not to damage the packing, dust seals, and O-rings. ★ Clean each part, then cover the piping ports and pin-inserting hole to prevent dust from entering them. ★ Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before installing it. 1. Assembly of head assembly 1) Using tool N5, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool N6, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).
30-81 (8)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12 3) Install backup ring and O-ring (14).
2) Assemble head assembly (7).
4) Assemble wear ring (12).
3) Fit O-ring and backup ring to collar (6), then assemble. • Boom and arm cylinder only
5) Assemble ring (11). ★ Be careful not to open the end gap of the ring too wide. 2 Ring grove: Grease (G2-LI)
3. Piston rod assembly 1) Set piston rod assembly (2) to tool N1.
30-82 (8)
4) Assemble plunger (5). • Boom and arm cylinder only
5) Set cushion plunger (10) to piston rod, then assemble 12 balls (9) and secure with cap (8). ★ Check that there is a small amount of play at the tip of the plunger. • Arm cylinder only
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12 6) Assemble piston assembly (4) as follows. • When using piston rod assembly (2) and piston assembly (4) again: ★ Wash thoroughly and remove all metal particles and dirt. i) Screw in piston assembly (4), then use tool Q2 to tighten piston assembly (4) so the position of the screw thread H hole matches. ★ Remove all burrs and flashes with a file.
•
When using a new part for either or both of piston rod assembly (2) and piston assembly (4). ★ For the rod with bottom cushion, mark the cap (8) position on the end of the rod. (See step 5).) • Arm cylinder only i)
Screw in until piston assembly (4) contacts end face of rod, then use tool to tighten.
3 Piston assembly: 294 ± 29.4 Nm {30 ± 3.0 kgm} ★ After tightening the piston, check that there is play in plunger (5). • Boom, arm cylinder only
ii) Tighten screw (3).
2 Screw thread: Loctite No. 262 3 Screw: 58.9 – 73.6 Nm {6 – 7.5 kgm} iii) Punch threads [1] at 4 points for caulking.
ii) Machine one of the holes used to install screw (3). ★ Align a drill horizontal with the Vgroove of the thread of piston rod assembly (2) and piston assembly (4), then carry out machining. ★ For the cylinder with bottom cushion (arm cylinder), avoid cap (8) machining holes position when machining. (See step 5).) • Screw machining dimension (mm) Drill diameter
Bottom hole depth
Tap used
Tap depth
10.3
27
12 x 1.75
20
30-83 (8)
DISASSEMBLY AND ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
12 iii) After machining, wash thoroughly to remove all metal particles and dust.
7) Assemble piston rod assembly (2). ★ Set the end gap of the ring horizontally (at the side position), align axial center of cylinder tube, then insert. ★ After inserting, check that the ring is not broken and has not come out, then push in fully.
iv) Tighten screw (3).
3 Screw: 58.9 – 73.6 Nm {6 – 7 kgm}
v) Caulk thread at 4 places with punch. 8) Tighten head assembly (1) with mounting bolts. 3 Mounting bolt: Cylinder
Tightening torque
Bucket
373 ± 54 Nm {38.0 ± 5.5 kgm}
Arm
490 ± 49 Nm {50.0 ± 5.0 kgm}
Boom
373 ± 54 Nm {38.0 ± 5.5 kgm}
9) Install piping.
30-84 (8)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT ASSEMBLY
12
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY SPECIAL TOOLS Mark
Part No. 796-670-1100
P
Part Name
Necessity Qty
Remover
■
1
• 796-670-1110 • Sleeve
1
• 796-670-1120 • Plate
1
• 796-670-1130 • Screw
1
• 791-775-1150 • Adapter
1
• 01643-33080 • Washer
1
• 01803-13034 • Nut
1
Puller 790-101-4000 (490 kN {50T}long) 790-101-1102
Pump (294 kN {30T})
DistincSketch tion*
■
1
■
1
4. Start the engine and retract the piston rod. ★ Fasten the piston rod with wire so that it will not slip out. Lower the cylinder onto a stand or place a support under the bottom of the cylinder to support it. In the latter case, remove the grease fitting on the bottom side first. ★ Remove the boom cylinder on the other side in the same manner. ★ Remove the working lamp on the work equipment if slings will hit the lamp when lifting the work equipment off. 5. Disconnect A42 intermediate connector (6) from working lamp.
*Distinction between new and existing part.
REMOVAL Extend the arm and bucket fully. Lower the work equipment to the ground and set the safety lock lever to the lock position.
6. Disconnect three arm cylinder hoses (7) and two bucket cylinder hoses (8). ★ Plug them to stop oil spillage and fasten the hoses with a rope on the valve side.
Release the residual pressure in the hydraulic circuit. Refer to the Release of Remaining Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this manual. 1.
Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and remove lock bolt (3). 3. Remove plate (4), then remove head pin (5). 7. ★ There are shims installed, so check the number and thickness, and keep them in a safe place.
PC300/350(LC)-7
Lift off work equipment assembly, remove plate (9) and then pin (10) at the foot.
30-85 c
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT ASSEMBLY
12 INSTALLATION •
Install in reverse order of removal.
•
When removing them, first remove plate (9) and then remove pin (10) at the foot, using Tool P. ★ Shims are installed, so do not forget to check their number and each location of installation.
★ When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.
8. Lift off work equipment assembly (11) and disassemble it.
Inside surface of bushing when assembling pin: Anti-friction compound (LM-P)
Work equipment assembly: 5,800 kg
Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole, never insert your fingers into the pin hole. ★ Adjust the shim thickness so that clearance b between cylinder rod (12) and plate (4) is below 1.5 mm. ★ Standard shim thickness: 1.0 mm and 2.0 mm.
30-86 c
PC300/350(LC)-7
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT ASSEMBLY
12 2 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole, never insert your fingers into the pin hole. ★ Adjust clearance "c" between the foot end surface of boom (13) and bracket (14) with shims so that it will be less than 1 mm. Thickness of standard shims: 2.0, 2.5 and 3.5 mm
•
•
Bleeding air ★ Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Air Bleeding of Various Parts. 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.
30-87 (8)
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT ASSEMBLY
12
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
3. Pull down outside air filter cover openingclosing lever (2).
Qty
799-703-1200
Service tool kit
■
1
799-703-1100
Vacuum Pump (100 V)
■
1
Q
799-703-1111
Vacuum Pump (220 V)
■
1
799-703-1121
Vacuum Pump (240 V)
■
1
799-703-1401
Gas leak detector
■
1
Sketch
Part name
Mark
Distinction
Part No.
Necessity
SPECIAL TOOLS
4. Remove outside air filter (3).
REMOVAL
k First, disconnect the cable from the negative (–) terminal of the battery. k Collect the air conditioner refrigerant. 1.
Drain coolant. 6
Coolant: Approx. 22.8 l
2. Remove floor mat (1).
30-88 (8)
5. Remove monitor panel lower covers (4) and (5). ★ When removing cover (4), first remove the M19 wiring for cigarette lighter.
DISASSEMBLY AND ASSEMBLY 12 6. Remove duct (6) on the right side.
7.
Remove rear covers (7), (8) and (9).
WORK EQUIPMENT ASSEMBLY
11. Remove cover (15).
12. Disconnect cab intermediate connectors (18) at the following 2 points. • H09: Upper side • H08: Lower side 13. Disconnect radio antenna (19). 14. Remove plate (20) and then remove cover (21).
8. Remove rear duct (10). 9. Remove plate (11) and then remove duct (12). 10. Remove plate (13) and right duct (14).
15. Remove duct (22). 16. Disconnect connectors at the following 7 points. • (23): D01 (Assembled-type diode connector) • (24): D02 (Assembled-type diode connector) • (25): C09 (Model selection switch connector) • (26): Air conditioner unit connector From top to bottom, M26, M27, M28 and M33 option power source connector
30-89 (8)
DISASSEMBLY AND ASSEMBLY 12 17. Remove the mounting clamp and disconnect air conditioner wiring connector (27). 18. Remove the 4 mounting bolts and remove governor pump control assembly (28). ★ Put the governor pump control assembly aside. 19. Remove cover (29).
WORK EQUIPMENT ASSEMBLY
INSTALLATION • Install in reverse order of removal. ★ Install hoses in the air conditioner circuit with care so that dirt, dust, water, etc. may not enter them. ★ Install air conditioner hoses only after checking that an O-ring is in place at the connecting part. ★ Check that there is no damage on O-rings, or that they have not deteriorated. ★ When connecting the refrigerant piping, coat the O-ring with compressor oil for R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG (PAG 46 or equivalent)) and tighten the nuts with 2 spanners. 3 Hose clamp screw: 8.83 – 14.7 Nm {0.9 – 1.5 kgm} 3 Hose screw M16 x 1.5: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 3 Hose screw M24 x 1.5: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
20. Disconnect air conditioner hoses (30) and (31) as well as air conditioner tubes (32) and (33). • 21. Remove the 8 mounting bolts and remove air conditioner unit assembly (34). ★ When removing the air conditioner unit assembly, do not forget to disconnect the 2 air conditioner hoses connected to the bottom.
30-90 (8)
Filling air conditioner gas Fill the air conditioner circuit with air conditioner gas (R134a), using tool Q.
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT ASSEMBLY
12
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 6. Remove ducts (10) and (11).
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
Q
799-703-1200
Service tool kit
■
1
799-703-1100
Vacuum pump (100V)
■
1
799-703-1111
Vacuum pump (220V)
■
1
799-703-1121
Vacuum pump (240V)
■
1
799-703-1401
Gas leak detector
■
1
REMOVAL
Sketch
Part name
Distinction
Part No.
Qty
Mark
Necessity
SPECIAL TOOLS
k Disconnect the cable from the negative (–) terminal of the battery. k Collect the air conditioner refrigerant. 1.
7.
Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20 (16), and K19 (17).
8. Remove and sling controller (18). 9. Remove plate (19). 10. Disconnect air conditioner unit connectors M27 (20) and M33 (21).
Swing the upper structure by 90°.
2. Open the engine hood. 3. Remove rear covers (1), (2), (3), and (4).
11. Remove the air conditioner unit undercover. ★ Part A
4. Remove duct (5), cover (6), and plate (7). 5. Remove plate (8) and duct (9). ★ Remove the duct lock clip.
30-90-1 (8)
DISASSEMBLY AND ASSEMBLY 12 12. Remove mounting bolt (24) and connector (25). 13. Disconnect heater hoses (22) and (23) and air conditioner tube (26). ★ Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
AIR CONDITIONER UNIT ASSEMBLY
INSTALLATION • Carry out installation in the reverse order to removal. ★ When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them. ★ When connecting each air conditioner hose, check that the O-ring is fitted to the joint. ★ Check that each O-ring is free from flaw and deterioration.
★ When connecting the refrigerant piping, coat the O-ring with compressor oil for R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100 PG (PAG 46 or equivalent)) and tighten the nuts with 2 spanners. 3 Hose clamp (M6 bolt): 7.84 – 11.8 Nm {0.8 – 1.2 kgm}
3 Hose screw of M16 x 1.5: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Hose screw of M22 x 1.5: 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
14. Remove the 7 mounting bolts and air conditioner unit assembly (27).
3 Hose screw of M24 x 1.5: 29.4 – 34.3 Nm {3.0 – 3.5 kgm} •
30-90-2 (8)
Charging air conditioner with refrigerant gas Using tool Q, charge the air conditioner circuit with refrigerant (R134a) from the compressor. ★ Quantity of refrigerant: 950 ± 50 g
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT ASSEMBLY
12
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY REMOVAL
INSTALLATION
1.
•
Attach eyebolts [1] to counterweight assembly (1), and sling.
2. Remove 4 mounting bolts (2) ★ Take note of where shims were inserted. 3. Lift off counterweight (1) horizontally with wire or chain block. ★ Be careful not to hit the engine, radiator or cooler. 4
Counterweight assembly: 5,500 kg
Install in reverse order of removal. 2 Thread of counterweight mounting bolt: Thread tightener (LT-2)
3 Counterweight mounting bolt: 1,814.1 ± 98.1 Nm {185 ± 10 kgm} ★ Installing and adjusting counterweight 1) Adjust clearance on the upper and lower sides with shims. 2) Install counterweight in such a way that clearance between the door and counterweight as well as clearance between the revolving frame and counterweight become 10 ± 5 mm.
30-91 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB ASSEMBLY
12
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
3. Remove rear covers (4), (5) and (6).
REMOVAL
k First, disconnect the cable from the negative (–) terminal of the battery. 1.
Remove floor mat (1).
4. Disconnect cab wiring intermediate connectors H10 (7), H11 (8) and H12 (9). 5. Remove duct (10) on the right side and rear duct (11). 6. Remove left plates (12) and (13). 2. Remove covers (2) and (3) under the monitor panel. ★ When removing cover (2), first disconnect the CN-M19 wiring for cigarette lighter.
7.
30-92 (8)
Pull down outside air filter cover openingclosing lever (14).
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB ASSEMBLY
12 8. Remove outside air filter (15).
9. Remove duct (16).
15. Remove step plate (24).
10. Remove cover (17).
16. Remove 5 mounting bolts (25) and 4 mounting nuts (26). ★ Check the bolt length beforehand.
11. Disconnect cab wiring intermediate connectors (20) at the following 2 points. • H09: Upper side • H08: Lower side
17. Lift and remove operator's cab assembly (27). 4
Operator's cab assembly: 290 kg
12. Disconnect radio antenna (21).
13. Remove duct (22) on the right side.
INSTALLATION
14. Remove window washer hose (23).
•
Install in reverse order of removal.
30-93 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB ASSEMBLY
12
REMOVAL AND INSTALLATION OF OPERATOR’S CAB PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up REMOVAL
k Disconnect the cable from the negative (–) terminal of the battery. 1.
4. Remove clip (10) and disconnect cab wiring connectors M45 (11), H08 (12), and H09 (13). 5. Remove air conditioner connector plate (14).
Remove rear covers (1), (2), (3), and (4).
6. Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18). 7. 2. Remove duct (5), cover (6), and plate (7). 3. Remove plate (8), duct (9) and the element. ★ Remove the duct lock clip.
Disconnect upper and lower duct joints (19) and (20).
8. Remove controller sub-plate (21) and incline it against the air conditioner.
9. Remove cover (22) and floor mat (23).
30-94 (8)
DISASSEMBLY AND ASSEMBLY 12 10. Move right console (24) into the cab.
OPERATOR’S CAB ASSEMBLY
17. Take grommet (35) out of the right front of the cab.
11. Remove monitor panel undercover (25). 18. Disconnect the windshield washer hose from (36). 19. Remove 4 mounting bolts (37) and 5 mounting bolts (38). ★ Check the types of the bolts. ★ In the initial period, 7 mounting bolts (38) are used.
12. Disconnect cab wiring connector W04 (26) (Wiper motor). 13. Remove ducts (27) and (28). ★ Both (27) and (28) are 2 in number. ★ Cut the tie-wrap on the monitor wiring harness. 14. Remove cover (29) and monitor assembly (30).
20. Using lever block [1], lift off operator's cab assembly (39). 4
Operator's cab assembly: 300 kg
15. Disconnect radio antenna (31). 16. Remove clip (32) and take wiring harness (33) out of grommet (34).
30-95 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB ASSEMBLY
12 REFERENCE
INSTALLATION
When starting the engine while the operator's cab is removed (for transportation, etc.), use the following brackets.
•
1) Bracket (41) for controller (40) Part No.: 208-53-13920
2) Bracket (42) for monitor panel assembly (30) Part No.: 208-53-13910
30-96 (8)
Carry out installation in the reverse order to removal.
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
★ Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) – (4) are stuck. In this section, the procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the operator's cab.) For the procedure for replacing the front window assembly, see REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.
(1) : (2) : (3) : (4) : (5) :
Right side window glass Left side rear window glass Door lower window glass Front window glass Front window assembly (Front window glass + Front frame) (6) : Both-sided adhesive tape (16): Center trim seal
30-97 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 (The figure shows the operator's cab of a wheel loader.)
Y
■
2
2 20Y-54-13180
Adapter
■
2
Sketch
Lifter (Suction cup)
Part No.
New/Remodel
Q'ty
1 793-498-1210
Symbol
Part name
Necessity
SPECIAL TOOLS
REMOVAL ★ Remove the window glass to be replaced according to the following procedure. 1.
Using seal cutter [1], cut the adhesive between broken window glass (7) and operator's cab (metal sheet) (8).
★ If the window glass is broken finely, it may be removed with knife [4] and a screwdriver. ★ Widening the cut with a screwdriver, cut the adhesive and both-sided adhesive tape with knife [4]. (The figure shows the operator's cab of a wheel loader.)
★ If a seal cutter is not available, make holes on the adhesive and both-sided adhesive tape with a drill and pass a fine wire (piano wire, etc.) [2] through the holes. Grip the both ends of the wire with priors [3], etc. (or hold them by winding them onto something) and move the wire to the right and left to cut the adhesive and both-sided adhesive tape. Since the wire may be broken by the frictional heat, apply lubricant to it.
30-98 (8)
2. Remove the window glass.
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 INSTALLATION 1.
Using a knife and scraper [5], remove the remaining adhesive and both-sided adhesive tape from the metal sheets (glass sticking surfaces) of the operator's cab. ★ Remove the adhesive and both-sided adhesive tape to a degree that they will not affect adhesion of the new adhesive. Take care not to scratch the painted surfaces. (If the painted surfaces are scratched, adhesion will be lowered.) (The figure shows the operator's cab of a wheel loader.)
3. Apply primer (10). ★ The using limit of primer (10) is 4 months after the date of manufacture. Do not use primer (10) after this limit. ★ Use the primer within 2 hours after unpacking it. ★ Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time. (Discard the primer 24 hours after it is packed.) 1) Stir the primers for paint and glass sufficiently before using them. ★ If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stirring it. (If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.) 2) When reusing primer brush (11), wash it in white gasoline. ★ After washing the brush, check it again for dirt and foreign matter. ★ Prepare respective brushes for the paint primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and window glass (9) with white gasoline. ★ If the sticking surfaces are not cleaned well, the glass may not be stuck perfectly. ★ Clean the all black part on the back side of the window glass. ★ After cleaning the sticking surfaces, leave them for at least 5 minutes to dry. (The figure shows the operator's cab of a wheel loader.)
30-99 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 3) Evenly apply paint primer to the surfaces to stick both-sided adhesive tapes and the surfaces out of those surfaces on operator's cab (8) which will be coated with the adhesive. 2 Paint primer: SUNSTAR PAINT PRIMER 580 SUPER or equivalent ★ Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer: Apply the primer all over dimension "a". • Dimension "a" to apply primer: 25 mm
★ Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline. 4) Evenly apply glass primer to the sticking surfaces of window glass (9).
2 Glass primer: SUNSTAR GLASS PRIMER 580 SUPER or equivalent ★ Do not apply the primer more than 2 times. (If it is applied more than 2 times, its performance will be lowered.)
★ In addition to the above parts, apply the primer to right side window glass (1) and door lower window glass (3). • Range to apply primer additionally for right side window glass (1): "b" • Range to apply primer additionally for door lower window glass (3): "c" ★ After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry.
30-100 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 ★ Parts to be coated with primer: Apply the primer to the sticking surfaces of window glass (9) and all over dimension "d" which will be on both-sided adhesive tape (6) and operator's cab (8). ★ Do not apply the primer to the boarder about 5 mm wide between the black part and transparent part of the glass. ★ After applying the primer, leave it for at least 5 minutes (within 8 hours) to dry. ★ Never apply wrong primer. If the glass primer is applied by mistake, wipe it off with white gasoline.
★ When sticking both-sided adhesive tape (6) around a frame, do not lap its finishing end over the starting end but make clearance "e" of about 5 mm between them. 1) Stick both-sided adhesive tape (6) for right side window glass (1) as shown in the figure.
★ Stick both-sided adhesive tape (6a) additionally for right side window glass (1). • Positions to stick additional both-sided adhesive tape for right side window glass: f : 50 mm g : 90 mm h : 250 mm 4. Stick both-sided adhesive tape (6) along the inside edge of the glass sticking section. ★ Do not remove the release tape of the both-sided adhesive tape on the glass sticking side before sticking the glass. ★ When sticking the both-sided adhesive tape, do not touch the cleaned surface as long as possible. ★ Take that the both-sided adhesive tape will not float at each corner of the window frame.
30-101 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 2) Stick both-sided adhesive tape (6) for left side rear window glass (2) as shown in the figure.
4) Stick both-sided adhesive tape (6) for front window glass (4) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the figure.
★ Stick both-sided adhesive tape (6c) of the lower side of the front window glass along the outside edge of the lower line, differently from other bothsided adhesive tapes (6). (If it is stuck along the inside, it will be seen through the transparent part of the glass.)
★ Stick both-sided adhesive tape (6b) additionally for door lower window glass (3). ★ Positions to stick additional bothsided adhesive tape for door lower window glass: j : 110 mm k : 90 mm m : 200 mm
5. Position the new window glass. 1) Check the clearance between the window glass and the operator's cab on the right, left, upper, and lower sides, and then adjust it evenly. 2) Stick tapes [6] between window glass (9) and operator's cab (8) and draw positioning line "n". ★ Stick tapes [6] to the right, left, and lower parts of the right side window glass, left side rear window glass, and door lower window glass for accurate positioning. 3) Cut the tape between window glass (9) and operator's cab (8) with a knife, and then remove the window glass.
30-102 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 ★ Do not remove the tapes left on the window glass and operator's cab before installing the window glass.
6. Apply adhesive. ★ Use either of the 2 types of the adhesive.
2 Adhesive (Summer): SUNSTAR PENGUINE SEAL 580 SUPER "S"
★
★ ★ ★
2 Adhesive (Winter): SUNSTAR PENGUINE SEAL 580 SUPER "W" The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit. Keep the adhesive in a dark place where the temperature is below 25°C. Never heat the adhesive higher than 30°C. When reusing the adhesive, remove the all hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
★ When positioning front window glass (4), set its horizontal position to the frame width and set its vertical position so that height difference "p" between it and the frame top will be 3 mm.
2) Cut the tip of the adhesive nozzle (14) so that dimensions "q" and "r" will be as follows. • Dimension "q": 10 mm • Dimension "r": 15 mm
30-103 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 3) Set adhesive cartridge (12) to caulking gun [7]. ★ An electric caulking gun is more efficient.
★ Apply adhesive (15) additionally for additional both-sided adhesive tape (6a) of the right side window glass and additional both-sided adhesive tape (6b) of door lower window glass. 4) Remove the release tape of the both-sided adhesive tape on the glass side. 5) Apply adhesive (15) to the outside of both-sided adhesive tape (6) of the operator's cab.
★ Apply adhesive (15) to dimensions "s" and "t" of both-sided adhesive tape (6) of operator's cab (8). • Dimension "s": 10 mm • Dimension "t": 15 mm ★ Apply adhesive (15) higher than bothsided adhesive tape (6). ★ Apply the adhesive evenly.
30-104 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 7.
Install the window glass. 1) Install window glass (9), matching it to the lines of the positioning tapes drawn in step 5. ★ Since the window glass cannot be removed and stuck again, stick it very carefully. ★ Stick the glass within 5 minutes after applying the adhesive. 2) After sticking window glass (9), press all around it until it is stuck to the both-sided adhesive tape. ★ Press the corners of the window glass firmly.
★ After installing front window glass (4), fill the clearances between it and center trim seal (16) with caulking material in range "s" to dimensions "t" and "u". After applying the primer to glass (4) of section A – A, apply adhesive as caulking material. • Caulking dimension "t": 2 mm • Caulking dimension "u": 5 mm ★ When caulking, mask the glass side and form the adhesive with a rubber spatula as shown in the figure. ★ Wipe off projected adhesive. 2 Glass primer:
SUNSTAR GLASS PRIMER 580 SUPER
2 Adhesive: SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"
★ You can perform this work efficiently by pulling window glass (9) from inside of the operator's cab with suction cup Y1.
30-105 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 8. Fix the window glass. 1) After installing right window glass (1) to the operator's cab, insert stopper rubbers Y2 to 2 places "v" at the bottom of the glass to fix the glass.
9. After installing the window glass, remove the primer and adhesive from the operator's cab and window glass. ★ Using white gasoline, wipe off the adhesive before it is dried up. ★ When cleaning the glass, do not give an impact to it. 10. Protect the stuck window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours (at temperature of 20°C and humidity of 60%). 2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in total, before operating the machine actually.
2) Using styrene foam blocks [9] and rubber bands [10], fix the window glass and bothsided adhesive tape to fit them completely.
30-106 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY k Lower the work equipment to the ground and stop the engine. ★ To replace the front window glass, the front window assembly must be removed from the operator's cab. The procedure for removing and installing the front window assembly (front frame and front window glass) is explained below. REMOVAL 1.
5. Release the rear locks. 6. Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold them. 7.
Remove rollers (8) and (9) under the both sides of the front window.
Raise the front window assembly to the ceiling and fix it with the rear locks (on both sides).
2. Remove left corner blocks (1) and (2) and right corner block (3). [*1] 3. Remove left striker bolt (4), right striker bolt (5), left corner block bracket (6), and right corner block bracket (7). [*2] 4. Install left striker bolt (4) to the operator's cab again and tighten it lightly. ★ This bolt will be used to hang the pull-up assist cable in step 8.
8. Remove left lower pin (10). [*3] ★ If left lower pin (10) is removed, plate (12) at the end of pull-up assist cable (11) comes off. ★ Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied to the rear of the operator's cab. Accordingly, take care when removing left lower pin (10) to disconnect pull-up assist cable (11).
30-107 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12
11. Twist front window assembly (13) to the right and left to remove both upper rollers (14) and (15) from the rails, and then remove front window assembly (13).
9. Put out the bottom of front window assembly (13) through the rail opening portion and lower it gradually.
10. Lower front window assembly (13) completely. ★ Do not let the front window assembly touch the monitor.
30-108 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 INSTALLATION •
Carry out installation in the reverse order to removal.
[*1] [*2] • Adjust opening and closing of the front window assembly according to the following procedure. 1.
Open and close the front window to check that it does not interfere with the rails and the rollers are not hitch.
4. Install right corner block (3) and fix right corner block bracket (7) with right striker bolt (5). ★ Tighten the striker bolt securely after adjusting it in step 6. ★ Install the right corner block so that there will be no level difference at part "a". ★ Install the right corner block so that level difference "b" between the rail and right corner block (3) will be 0 – 1.0 mm. Check that the right corner block is not projected from the rail at the rolling surface of the roller. ★ Secure roller clearance "c" at part P.
2. If there is any problem in opening or closing of the front window, loosen the mounting bolts of roller adjustment brackets (16) and (17) and adjust the condition of the front window, and then tighten the mounting bolts again. 3 Mounting bolt: 9.8 Nm {1.0 kgm}
3. Raise the front window assembly and fix it with the rear locks (on both sides). ★ Check that the locks in the rear of the operator's cab are applied securely.
30-109 (8)
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 5. Install left corner blocks (1) and (2) and secure left corner bracket (6) with left striker bolt (4). ★ Tighten the striker bolt securely after adjusting it in step 6. ★ Install the left corner blocks so that there will be no level difference at 2 part "d". ★ Secure roller clearance "e".
30-110 (8)
6. Adjust the striker bolts according to the following procedure (Adjust the "CLOSE" positions of the front window assembly locks). 1) Tighten left striker bolt (4) and right striker bolt (5) at roughly right positions so that front window glass (18) will be fitted to cab-side trim seal (19).
DISASSEMBLY AND ASSEMBLY
OPERATOR’S CAB GLASS (STUCK GLASS)
12 2) Open and close the front window assembly and check the working condition of both locks (20) and (21). i)
If both locks do not work normally, move the striker bolts toward the rear of the cab and tighten them again.
3) After checking the above items, if necessary, adjust them by moving right and left striker plates (22) at the rear of the operator's cab.
ii) After moving the striker bolts, check the fitness of the front window glass and cab-side trim seal which was checked in step 1). iii) Repeat the work in i) and ii) until the fitness of the front window and the working condition of both locks (20) and (21) are acceptable, and then tighten the striker bolts.
7.
After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak into the cab.
9. Adjust the front window stoppers.
8. Adjust the "opening" lock of the front window assembly.
1) After adjusting "opening" lock of the front window assembly in step 8, check the contact of both front window stoppers (23).
1) After adjusting the "closing" lock of the front window in steps 6 and 7, raise the front window assembly to the ceiling.
2) If both stoppers (23) do not contact normally, adjust and fix them at places where they contact normally.
2) Set the right and left front window assembly locks at the rear of the operator's cab to the "OPEN" positions, and then check the following items. • heck that right and left locks (20) and (21) are closed normally. • Check that right and left locks (20) and (21) are inserted in parallel in right and left striker plates (22). • Check that right and left rubber stoppers (24) are in contact with the front window assembly and their deflection allowance is 1.5 – 3.0 mm.
30-111 (8)
DISASSEMBLY AND ASSEMBLY 12 10. Check the latching effort of the front window assembly. 1) After finishing steps 6 – 9, check that latching efforts of both locks (20) and (21) are even. ★ Check the latching efforts on both "closing" side (in the front of the operator's cab) and "opening" side (in the rear of the operator's cab).
[*3]
3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm} 2 Mounting bolt: Adhesive (LT-2)
30-112 (8)
OPERATOR’S CAB GLASS (STUCK GLASS)
DISASSEMBLY AND ASSEMBLY
MONITOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY REMOVAL
k First, disconnect the cable from the negative (–) terminal of the battery. 1.
Remove cover (1) and then disconnect the wiring connector P15 for air conditioner sunlight sensor (2). ★ Lift the cover up to remove it.
2. Remove the three mounting screws and remove monitor assembly (3). ★ Disconnect monitor panel wiring connectors P01, P02 and P03 at the three points, and then remove the monitor assembly.
INSTALLATION •
Install in reverse order of removal.
30-113 (8)
DISASSEMBLY AND ASSEMBLY
GOVERNOR, PUMP CONTROLLER ASSEMBLY
12
REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY PC300, 300LC-7 Serial No. 40001 – 45000 PC350, 350LC-7 Serial No. 20001 – 25000
PC300, 300LC-7 Serial No. 45001 and up PC350, 350LC-7 Serial No. 25001 and up
REMOVAL
REMOVAL
1.
1.
k First, disconnect the cable from the negative (–) terminal of the battery. Remove cover (1).
k First, disconnect the cable from the negative (–) terminal of the battery. Remove covers (1), (2) and (3).
2. Disconnect governor, pump controller wiring connectors C01 (2), C02 (3) and C03 (4).
2. Disconnect governor, pump controller wiring connectors C01 (4), C02 (5) and C03 (6).
3. Remove the four mounting bolts and remove governor, pump controller assembly (5).
3. Remove the four mounting bolts and remove governor, pump controller assembly (7).
INSTALLATION
INSTALLATION
•
•
Install in reverse order of removal.
30-114 (8)
Install in reverse order of removal.
90
OTHERS Hydraulic Circuit Diagram . . . . . . . . . . 90-3 PC300-7,PC300LC-7: Serial No. 40001–45000 PC350-7,PC350LC-7: Serial No. 20001–25000 Electrical Circuit Diagram (1/4) . . . . . 90-5 Electrical Circuit Diagram (2/4) . . . . . 90-7 Electrical Circuit Diagram (3/4) . . . . . 90-9 Electrical Circuit Diagram (4/4) . . . . 90-11 PC300-7,PC300LC-7: Serial No. 45001 and up PC350-7,PC350LC-7: Serial No. 25001 and up Electrical Circuit Diagram (1/4) . . . . 90-13 Electrical Circuit Diagram (2/4) . . . . 90-15 Electrical Circuit Diagram (3/4) . . . . 90-17 Electrical Circuit Diagram (4/4) . . . . 90-19
PC300-7
90-1 (6)
OTHERS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
PC300-7
90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4) PC300-7, PC300LC-7: Serial No. 40001 – 45000 PC350-7, PC350LC-7: Serial No. 20001 – 25000 FOR MULTI MONITOR
PC300-7
90-5 (6)
ELECTRICAL CIRCUIT DIAGRAM (2/4) PC300-7, PC300LC-7: Serial No. 40001 – 45000 PC350-7, PC350LC-7: Serial No. 20001 – 25000 FOR MULTI MONITOR
PC300-7
90-7 (6)
ELECTRICAL CIRCUIT DIAGRAM (3/4) PC300-7, PC300LC-7: Serial No. 40001 – 45000 PC350-7, PC350LC-7: Serial No. 20001 – 25000 FOR MULTI MONITOR
PC300-7
90-9 (6)
ELECTRICAL CIRCUIT DIAGRAM (4/4) PC300-7, PC300LC-7: Serial No. 40001 – 45000 PC350-7, PC350LC-7: Serial No. 20001 – 25000 FOR MULTI MONITOR
PC300-7
90-11 (6)
ELECTRICAL CIRCUIT DIAGRAM (1/4) PC300-7, PC300LC-7: Serial No. 45001 and up PC350-7, PC350LC-7: Serial No. 25001 and up
PC300-7
90-13 (6)
ELECTRICAL CIRCUIT DIAGRAM (2/4) PC300-7, PC300LC-7: Serial No. 45001 and up PC350-7, PC350LC-7: Serial No. 25001 and up
PC300-7
90-15 (6)
ELECTRICAL CIRCUIT DIAGRAM (3/4) PC300-7, PC300LC-7: Serial No. 45001 and up PC350-7, PC350LC-7: Serial No. 25001 and up
PC300-7
90-17 (6)
ELECTRICAL CIRCUIT DIAGRAM (4/4) PC300-7, PC300LC-7: Serial No. 45001 and up PC350-7, PC350LC-7: Serial No. 25001 and up
PC300-7
90-19 (6)
