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SEN06257-C6
Shop Manual
HYDRAULIC EXCAVATOR
PC300 -8M0 PC300LC-8M0 PC350 -8M0 PC350LC-8M0 SERIAL NUMBERS
PC300PC300LCPC350PC350-
C90001 C90001 C90415 C90415
and up
SEN06259-06
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
00 Index and foreword
1
100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
PC300, 300LC, 350, 350LC-8M0
00-100
1
SEN06259-06
100 Index Composition of shop manual
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN06257-C6
00 Index and foreword 100 Index 200 Foreword and general information
SEN06258-06 SEN06259-06 q SEN06260-01
01 Specification 100 Specification and technical data
SEN06261-01 SEN06262-01
10 Structure, function and maintenance standard 100 Engine and cooling system 200 Power train 300 Undercarriage and frame 401 Hydraulic system, Part 1 402 Hydraulic system, Part 2 403 Hydraulic system, Part 3 500 Work equipment 600 Electrical system
SEN06263-03 SEN06264-01 SEN06265-01 SEN06266-01 SEN06267-02 q SEN06268-01 SEN06269-02 SEN06270-01 SEN06271-01
20 Standard value table 100 Standard service value table
SEN06275-00 SEN06276-00
30 Testing and adjusting 101 Testing and adjusting, Part 1 102 Testing and adjusting, Part 2 103 Testing and adjusting, Part 3
SEN06277-02 SEN06278-02 q SEN06279-00 SEN06280-00
40 Troubleshooting 100 Failure code table and fuse locations 200 General Information on troubleshooting 301 Troubleshooting by failure code, Part 1 302 Troubleshooting by failure code, Part 2 303 Troubleshooting by failure code, Part 3 304 Troubleshooting by failure code, Part 4 305 Troubleshooting by failure code, Part 5 400 Troubleshooting of electrical system (E-mode)
SEN06353-00 SEN06354-00 SEN06355-00 SEN06356-00 SEN06357-00 SEN06358-00 SEN06359-00 SEN06360-00 SEN06361-00
00-100
2
PC300, 300LC, 350, 350LC-8M0
100 Index Composition of shop manual
500 Troubleshooting of hydraulic and mechanical system (H-mode) 600 Troubleshooting of engine (S-mode)
SEN06259-06
SEN06362-00 SEN06363-00
50 Disassembly and assembly 100 Related information on disassembly and assembly 200 Engine and cooling system 300 Power train system 400 Undercarriage and frame 500 Hydraulic system 600 Work equipment 700 Cab and its attachments 800 Electrical system
SEN06344-01 SEN06345-00 SEN06346-00 SEN06347-00 SEN06348-00 SEN06349-00 SEN06350-01 SEN06351-00 SEN06352-00
80 Appendix 100 Air conditioner
SEN06364-00 SEN06365-00
90 Diagrams and drawings 100 Hydraulic diagrams and drawings 200 Electrical diagrams and drawings
SEN06272-00 SEN06273-00 SEN06274-00
PC300, 300LC, 350, 350LC-8M0
00-100
3
SEN06259-06
Table of contents
100 Index Table of contents
1
00 Index and foreword 100 Index SEN06259-06 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 200 Foreword and general information SEN06260-01 Foreword, safety and general information ....................................................................................2 How to read the shop manual.......................................................................................................9 Explanation of terms for maintenance standard ......................................................................... 11 Handling equipment of fuel system devices ...............................................................................13 Handling of intake system parts..................................................................................................14 Handling of hydraulic equipment ................................................................................................15 Method of disconnecting and connectingof push-pull type coupler ............................................17 Handling of electrical equipment.................................................................................................20 How to read electric wire code....................................................................................................29 Precautions when performing operation .....................................................................................32 Practical use of KOMTRAX ........................................................................................................35 Standard tightening torque table .................................................................................................36 List of abbreviation......................................................................................................................40 Conversion table.........................................................................................................................45 01 Specification 100 Specification and technical data SEN06262-01 Specification dimension drawings.................................................................................................2 Specifications................................................................................................................................4 Weight table ................................................................................................................................10 Table of fuel, coolant and lubricants ...........................................................................................12 10 Structure, function and maintenance standard 100 Engine and cooling system SEN06264-01 Engine related parts......................................................................................................................2 Radiator, oil cooler and aftercooler ...............................................................................................3 200 Power train SEN06265-01 Power train....................................................................................................................................2 Swing circle...................................................................................................................................3 Swing machinery ..........................................................................................................................4 Final drive .....................................................................................................................................6 Sprocket........................................................................................................................................8 300 Undercarriage and frame SEN06266-01 Track frame and recoil spring .......................................................................................................2 Idler...............................................................................................................................................4 Carrier roller..................................................................................................................................6 Track roller ....................................................................................................................................7 Track shoe ....................................................................................................................................9 401 Hydraulic system, Part 1 SEN06267-02 Hydraulic equipment layout drawing.............................................................................................2 Hydraulic tank and filter ................................................................................................................4 Hydraulic pump.............................................................................................................................6 402 Hydraulic system, Part 2 SEN06268-01 Control valve.................................................................................................................................2 CLSS ..........................................................................................................................................14 Functions and operation by valve ...............................................................................................18 Attachment circuit selector valve ................................................................................................57 Hydraulic drift prevention valve...................................................................................................60
00-100
4
PC300, 300LC, 350, 350LC-8M0
100 Index Table of contents
SEN06259-06
403 Hydraulic system, Part 3 SEN06269-02 Valve control ................................................................................................................................. 2 PPC valve..................................................................................................................................... 4 Solenoid valve ............................................................................................................................ 24 PPC accumulator........................................................................................................................ 26 Anti-drop valve for boom ............................................................................................................ 28 Anti-drop valve for arm ............................................................................................................... 34 Center swivel joint ......................................................................................................................41 Travel motor................................................................................................................................43 Swing motor................................................................................................................................55 Work equipment cylinder ............................................................................................................ 63 500 Work equipment SEN06270-01 Work equipment ........................................................................................................................... 2 Dimensions of components .......................................................................................................... 4 600 Electrical system SEN06271-01 Engine control system .................................................................................................................. 2 Electronic control system............................................................................................................ 11 Machine monitor system.............................................................................................................36 Sensor ........................................................................................................................................ 56 KOMTRAX system ..................................................................................................................... 59 20 Standard value table 100 Standard service value table SEN06276-00 Standard value table for engine related parts ............................................................................... 2 Standard value table for chassis related parts.............................................................................. 3 30 Testing and adjusting 101 Testing and adjusting, Part 1 SEN06278-02 Tools for testing, adjusting and troubleshooting ........................................................................... 3 Sketches of special tools .............................................................................................................. 7 Testing engine speed.................................................................................................................... 8 Testing air boost pressure ............................................................................................................ 9 Testing exhaust gas color ........................................................................................................... 10 Adjusting valve clearance........................................................................................................... 12 Testing compression pressure.................................................................................................... 14 Testing blowby pressure .............................................................................................................18 Testing engine oil pressure.........................................................................................................19 Testing fuel pressure .................................................................................................................. 20 Handling during cylinder cutout operation .................................................................................. 25 Handling during no-injection cranking operation ........................................................................ 25 Testing fuel return rate and leakage ...........................................................................................26 Bleeding air from fuel circuit ....................................................................................................... 28 Checking fuel circuit for leakage................................................................................................. 29 Testing and adjusting air compressor belt tension......................................................................30 Replacing fan belt.......................................................................................................................31 Replacing alternator belt.............................................................................................................32 Testing clearance in swing circle bearings ................................................................................. 33 Testing and adjusting track tension ............................................................................................34 Testing and adjusting oil pressure in work equipment, swing and travel circuit.......................... 35 Testing control circuit oil pressure .............................................................................................. 39 Testing and adjusting pump PC control circuit oil pressure ........................................................ 40 Testing and adjusting pump LS control circuit oil pressure.........................................................43 Testing solenoid valve output pressure ......................................................................................48 Testing PPC valve output pressure ............................................................................................52 Adjusting play of work equipment and swing PPC valves .......................................................... 53 Inspecting locations of hydraulic drift of work equipment ........................................................... 54 Releasing remaining pressure from hydraulic system ................................................................56
PC300, 300LC, 350, 350LC-8M0
00-100
5
SEN06259-06
100 Index Table of contents
Testing oil leakage amount .........................................................................................................60 Bleeding air from various parts ...................................................................................................62 Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) .....................................................................................................................64 Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) .66 Replacing accumulator bladder on high pressure side for accumulator piping ..........................68 102 Testing and adjusting, Part 2 SEN06279-00 Special functions of machine monitor ...........................................................................................2 103 Testing and adjusting, Part 3 SEN06280-00 Handling voltage circuit of engine controller .................................................................................2 Preparation work for troubleshooting of electrical system ............................................................3 Procedure for testing diodes.........................................................................................................7 Pm clinic service ...........................................................................................................................8 40 Troubleshooting 100 Failure code table and fuse locations SEN06354-00 Failure codes table .......................................................................................................................2 Fuse locations.............................................................................................................................10 200 General Information on troubleshooting SEN06355-00 Symptom and troubleshooting numbers .......................................................................................2 Sequence of events in troubleshooting.........................................................................................4 Checks before troubleshooting .....................................................................................................6 Classification and procedures for troubleshooting........................................................................8 Symptom and troubleshooting numbers .....................................................................................10 Information in troubleshooting table............................................................................................12 Connector list and layout ............................................................................................................14 Connection table for connector pin numbers ..............................................................................24 T- branch box and T- branch adapter table.................................................................................60 Troubleshooting method for open circuit in wiring harness of pressure sensor system .............63 301 Troubleshooting by failure code, Part 1 SEN06356-00 Failure code [879AKA] A/C Inner Sensor Open Circuit ................................................................3 Failure code [879AKB] A/C Inner Sensor Short Circuit ................................................................3 Failure code [879BKA] A/C Outer Sensor Open Circuit ...............................................................3 Failure code [879BKB] A/C Outer Sensor Short Circuit................................................................3 Failure code [879CKA] Ventilating Sensor Open Circuit...............................................................3 Failure code [879CKB] Ventilating Sensor Short Circuit...............................................................4 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit....................................................4 Failure code [879EMC] Ventilation Damper Abnormality..............................................................4 Failure code [879FMC] Air Mix Damper Abnormality ...................................................................4 Failure code [879GKX] Refrigerant Abnormality...........................................................................4 Failure code [989L00] Engine Controller Lock Caution1 ..............................................................5 Failure code [989M00] Engine Controller Lock Caution2 .............................................................6 Failure code [989N00] Engine Controller Lock Caution3..............................................................7 Failure code [AA10NX] Air Cleaner Clogging ...............................................................................8 Failure code [AB00KE] Charge Voltage Low ..............................................................................10 Failure code [B@BAZG] Eng Oil Press Low...............................................................................12 Failure code [B@BAZK] Engine Oil Level Low...........................................................................13 Failure code [B@BCNS] Eng Water Overheat ...........................................................................14 Failure code [B@BCZK] Radiator Coolant Level Low ................................................................16 Failure code [B@HANS] Hyd Oil Overheat ................................................................................18 Failure code [CA111] ECM Critical Internal Failure.....................................................................19 Failure code [CA115] Eng Ne and Bkup Speed Sens Error........................................................19 Failure code [CA122] Chg Air Press Sensor High Error .............................................................20 Failure code [CA123] Chg Air Press Sensor Low Error..............................................................22 Failure code [CA131] Throttle Sensor High Error .......................................................................24 Failure code [CA132] Throttle Sensor Low Error........................................................................26 Failure code [CA144] Coolant Temp Sens High Error ................................................................28
00-100
6
PC300, 300LC, 350, 350LC-8M0
100 Index Table of contents
SEN06259-06
Failure code [CA145] Coolant Temp Sens Low Error................................................................. 30 Failure code [CA153] Chg Air Temp Sensor High Error .............................................................32 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................. 34 Failure code [CA155] Chg Air Temp High Speed Derate............................................................36 Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................. 38 Failure code [CA221] Ambient Press Sens High Error ...............................................................40 Failure code [CA222] Ambient Press Sens Low Error................................................................42 Failure code [CA227] Sens 2 Supply Volt High Error ................................................................. 44 Failure code [CA234] Eng Overspeed........................................................................................ 44 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................45 Failure code [CA271] IMV/PCV1 Short Error .............................................................................46 Failure code [CA272] IMV/PCV1 Open Error .............................................................................48 Failure code [CA281] Abnormal supply pump pressure balance ...............................................50 302 Troubleshooting by failure code, Part 2 SEN06357-00 Failure code [CA322] Inj #1(L#1) Open/Short Error ..................................................................... 4 Failure code [CA323] Inj #5(L#5) Open/Short Error ..................................................................... 6 Failure code [CA324] Inj #3(L#3) Open/Short Error ..................................................................... 8 Failure code [CA325] Inj #6(L#6) Open/Short Error ...................................................................10 Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................12 Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................14 Failure code [CA342] Calibration Code Incompatibility .............................................................. 16 Failure code [CA351] Injectors Drive Circuit Error......................................................................17 Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................. 18 Failure code [CA386] Sens Supply 1 Volt High Error ................................................................. 20 Failure code [CA428] Water in Fuel Sensor High Error.............................................................. 22 Failure code [CA429] Water in Fuel Sensor Low Error...............................................................24 Failure code [CA435] Eng Oil Press Sw Error............................................................................26 Failure code [CA441] Battery Voltage Low Error ........................................................................ 28 Failure code [CA442] Battery Voltage High Error ....................................................................... 30 Failure code [CA449] Rail Press Very High Error....................................................................... 31 Failure code [CA451] Rail Press Sensor High Error...................................................................32 Failure code [CA452] Rail Press Sensor Low Error ...................................................................34 Failure code [CA488] Chg Air Temp High Torque Derate........................................................... 36 Failure code [CA553] Rail Press High Error ............................................................................... 37 Failure code [CA559] Rail Press Low Error ................................................................................38 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................... 40 Failure code [CA731] Eng Bkup Speed Sens Phase Error.........................................................44 Failure code [CA757] All Continuous Data Lost Error ................................................................45 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................. 46 Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................49 Failure code [CA2186] Throt Sens Sup Volt Low Error .............................................................. 50 Failure code [CA2249] Rail Press Very Low Error......................................................................51 Failure code [CA2265] Fuel Feed Pump Open Error ................................................................. 52 Failure code [CA2266] Fuel Feed Pump Short Error.................................................................. 54 Failure code [CA2311] lMV Solenoid Error ................................................................................. 55 Failure code [CA2555] Grid Htr Relay Open Circuit Error .......................................................... 56 Failure code [CA2556] Grid Htr Relay Short Circuit Error .......................................................... 58 303 Troubleshooting by failure code, Part 3 SEN06358-00 Failure code [D110KB] Battery Relay Drive Short Circuit ............................................................. 4 Failure code [D19JKZ] Personal Code Relay Abnormality ........................................................... 6 Failure code [D811MC] KOMTRAX Error ..................................................................................... 8 Failure code [D862KA] GPS Antenna Open Circuit ..................................................................... 9 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .................................................................. 10 Failure code [DA22KK] Pump Solenoid Power Low Error.......................................................... 12 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................... 14 Failure code [DA26KP] 5V Sensor 2 Power Abnormality ........................................................... 16 Failure code [DA29KQ] Model Selection Abnormality ................................................................18 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................20 PC300, 300LC, 350, 350LC-8M0
00-100
7
SEN06259-06
100 Index Table of contents
Failure code [DAF0MB] Monitor ROM Abnormality ....................................................................23 Failure code [DAF0MC] Monitor Error ........................................................................................24 Failure code [DAF8KB] Camera Power Supply Short Circuit .....................................................26 Failure code [DAF9KQ] Model Selection Abnormality ................................................................28 Failure code [DAFGMC] GPS Module Error ...............................................................................29 Failure code [DAFQKR] CAN2 Discon .......................................................................................30 Failure code [DAZ9KQ] A/C Model Selection Abnormality .........................................................31 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................32 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................34 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................38 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit..................................................40 Failure code [DHPAMA] F Pump Press Sensor Abnormality......................................................42 Failure code [DHPBMA] R Pump Press Sensor Abnormality .....................................................44 304 Troubleshooting by failure code, Part 4 SEN06359-00 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality..............................................4 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ......................................6 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ........................................8 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality......................................10 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality..........................................12 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ..........................................14 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ........................................16 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality....................................18 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ......................................20 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality .....................................22 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality......................................24 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ......................................26 Failure code [DHX1MA] Overload Sensor Abnormality ..............................................................28 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ............................................30 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ............................................32 Failure code [DV20KB] Travel Alarm Short Circuit .....................................................................34 Failure code [DW43KA] Travel Speed Sol Open Circuit .............................................................36 Failure code [DW43KB] Travel Speed Sol Short Circuit .............................................................38 Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit ...................................................40 Failure code [DW45KB] Swing Brake Sol Short Circuit ..............................................................42 Failure code [DW91KA] Travel Neutral Sol Open Circuit............................................................44 Failure code [DW91KB] Travel Neutral Sol Short Circuit............................................................46 305 Troubleshooting by failure code, Part 5 SEN06360-00 Failure code [DWA2KA] Attachment Sol Open Circuit..................................................................2 Failure code [DWA2KB] Attachment Sol Short Circuit..................................................................4 Failure code [DWJ0KA] Merge-divider Sol. Open Circuit .............................................................6 Failure code [DWJ0KB] Merge-divider Sol. Short Circuit .............................................................8 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...........................................................10 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit............................................................12 Failure code [DWK2KA] Variable Back Press Sol Open Circuit .................................................14 Failure code [DWK2KB] Variable Back Press Sol Short Circuit..................................................16 Failure code [DXA8KA] PC-EPC Sol Open Circuit .....................................................................18 Failure code [DXA8KB] PC-EPC Sol Short Circuit .....................................................................20 Failure code [DXE0KA] LS-EPC Sol Open Circuit......................................................................22 Failure code [DXE0KB] LS-EPC Sol Short Circuit......................................................................24 Failure code [DXE4KA] Attachment Flow EPC Open Circuit......................................................26 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ......................................................28 Failure code [DY20KA] Wiper Working Abnormality...................................................................30 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................32 Failure code [DY2CKB] Washer Drive Short Circuit ...................................................................34 Failure code [DY2DKB] Wiper Drive (Fwd) Short .......................................................................36 Failure code [DY2EKB] Wiper Drive (Rev) Short........................................................................38 400 Troubleshooting of electrical system (E-mode) SEN06361-00 Fuse locations...............................................................................................................................4 00-100
8
PC300, 300LC, 350, 350LC-8M0
100 Index Table of contents
SEN06259-06
Information contained in troubleshooting table ............................................................................. 6 E-1 Engine does not start (Engine does not crank) ...................................................................... 8 E-2 Preheater does not operate ................................................................................................. 13 E-3 When starting switch is turned to ON position, machine monitor displays nothing .............. 17 E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up................................................................................................................................................20 E-5 Precaution monitor lights up while engine is running ........................................................... 21 E-6 Emergency stop monitor lights up while engine is running ..................................................23 E-7 Fuel level gauge does not indicate properly ........................................................................ 24 E-8 Engine coolant temperature gauge does not indicate properly............................................26 E-9 Hydraulic oil temperature gauge does not indicate properly ................................................27 E-10 Displays on machine monitor are different from those for actual machine ........................ 30 E-11 Some areas of machine monitor screen are not displayed ................................................31 E-12 Function switch does not operate ......................................................................................31 E-13 Automatic warm-up system does not operate (in cold season) .........................................32 E-14 Auto-decelerator does not operate properly ......................................................................33 E-15 Working mode does not change ........................................................................................ 34 E-16 Travel speed does not change........................................................................................... 35 E-17 Alarm buzzer cannot be canceled......................................................................................36 E-18 When starting switch is turned OFF, service meter is not displayed ..................................36 E-19 Service mode cannot be selected......................................................................................36 E-20 Any of work equipment, swing and travel do not operate or cannot be locked ..................37 E-21 Swing holding brake does not operate properly................................................................. 39 E-22 One-touch power maximizing function does not operate properly..................................... 42 E-23 Travel alarm does not sound or does not stop sounding ...................................................45 E-24 Horn does not sound or does not stop............................................................................... 46 E-25 Windshield wiper and window washer do not operate ....................................................... 48 E-26 Machine push-up function cannot be canceled.................................................................. 50 E-27 Machine push-up function does not operate......................................................................52 E-28 BOOM DOWN indicator is not displayed properly with monitoring function ......................53 E-29 ARM DUMP indicator is not displayed properly with monitoring function .......................... 53 E-30 ARM IN indicator is not displayed properly with monitoring function ................................. 53 E-31 BOOM RAISE indicator is not displayed properly with monitoring function ....................... 54 E-32 BUCKET CURL indicator is not displayed properly with monitoring function .................... 54 E-33 BUCKET DUMP indicator is not displayed properly with monitoring function.................... 54 E-34 SWING indicator is not displayed properly with monitoring function..................................55 E-35 TRAVEL indicator is not displayed properly with monitoring function ................................ 55 E-36 ATTACHMENT indicator is not displayed properly with monitoring function......................56 E-37 Attachment hydraulic circuit cannot be changed ...............................................................58 E-38 KOMTRAX system does not operate properly...................................................................59 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN06362-00 System chart for hydraulic and mechanical system ..................................................................... 4 Information contained in troubleshooting table ............................................................................. 6 H-1 All work equipment lack power, or travel and swing speeds are slow ................................... 8 H-2 Engine speed sharply drops or engine stalls ....................................................................... 10 H-3 No work equipment, swing or travel move........................................................................... 11 H-4 Abnormal noise is heard from around hydraulic pump ........................................................ 11 H-5 Auto-decelerator does not work........................................................................................... 12 H-6 Fine control mode does not function or responds slow ....................................................... 12 H-7 Boom moves slowly or lacks power..................................................................................... 13 H-8 Arm moves slowly or lacks power........................................................................................ 14 H-9 Bucket moves slowly or lacks power ...................................................................................15 H-10 Work equipment does not move in its single operation ..................................................... 15 H-11 Work equipment has a bit too fast hydraulic drift ...............................................................16 H-12 Work equipment has big time lag ......................................................................................18 H-13 Other work equipment moves when relieving single circuit ...............................................18 H-14 Power max. switch does not operate................................................................................. 19 H-15 In compound operation, work equipment with larger load moves slowly ........................... 19 PC300, 300LC, 350, 350LC-8M0
00-100
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SEN06259-06
100 Index Table of contents
H-16 In swing + boom RAISE operation, boom moves slowly....................................................20 H-17 In swing + travel operation, travel speed drops sharply.....................................................20 H-18 Machine swerves in travel..................................................................................................21 H-19 Machine travels slowly .......................................................................................................22 H-20 Machine cannot be easily steered or lacks power .............................................................23 H-21 Travel speed does not shift, or it is too slow or fast ...........................................................24 H-22 Track shoe does not turn (on one side only)......................................................................25 H-23 Machine does not swing ....................................................................................................26 H-24 Swing acceleration is poor, or swing speed is slow ...........................................................28 H-25 Excessive overrun when stopping swing ...........................................................................30 H-26 There is big shock when stopping swing ...........................................................................31 H-27 Large sound is made when upper structure stops swinging. .............................................31 H-28 Swing hydraulic drift is too big ...........................................................................................32 600 Troubleshooting of engine (S-mode) SEN06363-00 Method of using troubleshooting charts........................................................................................3 S-1 Starting performance is poor. .................................................................................................6 S-2 Engine does not start .............................................................................................................7 S-3 Engine does not pick up smoothly .......................................................................................10 S-4 Engine stops during operations............................................................................................ 11 S-5 Engine does not rotate smoothly..........................................................................................12 S-6 Engine lacks output (or lacks power) ...................................................................................13 S-7 Exhaust smoke is black (incomplete combustion) ...............................................................14 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................15 S-9 Oil becomes contaminated quickly.......................................................................................16 S-10 Fuel consumption is excessive ..........................................................................................17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ................................18 S-12 Oil pressure drops..............................................................................................................19 S-13 Oil level rises (water, fuel in oil)..........................................................................................20 S-14 Coolant temperature becomes too high (overheating).......................................................21 S-15 Abnormal noise is made.....................................................................................................22 S-16 Vibration is excessive.........................................................................................................23 50 Disassembly and assembly 100 Related information on disassembly and assembly SEN06345-00 How to read this manual...................................................................................................................2 Coating materials list ........................................................................................................................4 Special tools list................................................................................................................................8 Sketches of special tools................................................................................................................12 200 Engine and cooling system SEN06346-00 Removal and installation of supply pump assembly.........................................................................2 Removal and installation of engine front oil seal ..............................................................................6 Removal and installation of engine rear oil seal...............................................................................9 Removal and installation of cylinder head assembly......................................................................14 Removal and installation of radiator assembly...............................................................................28 Removal and installation of hydraulic oil cooler assembly .............................................................30 Removal and installation of aftercooler assembly ..........................................................................32 Removal and installation of engine and hydraulic pump assembly ................................................34 300 Power train system SEN06347-00 Removal and installation of travel motor and final drive assembly...................................................2 Disassembly and assembly of final drive assembly .........................................................................3 Removal and installation of swing motor and swing machinery assembly .....................................13 Disassembly and assembly of swing motor and swing machinery assembly ................................14 Removal and installation of swing circle assembly ........................................................................22 400 Undercarriage and frame SEN06348-00 Disassembly and assembly of carrier roller assembly .....................................................................2 Disassembly and assembly of track roller assembly........................................................................5 Removal and installation of idler and idler cushion assembly ..........................................................7
00-100
10
PC300, 300LC, 350, 350LC-8M0
100 Index Table of contents
SEN06259-06
Disassembly and assembly of idler assembly.................................................................................. 8 Disassembly and assembly of recoil spring assembly ................................................................... 11 Removal and installation of sprocket .............................................................................................13 Separation and connection of track assembly ............................................................................... 14 Removal and installation of revolving frame assembly .................................................................. 18 Removal and installation of counterweight assembly .................................................................... 20 500 Hydraulic system SEN06349-00 Removal and installation of center swivel joint assembly ................................................................ 2 Disassembly and assembly of center swivel joint assembly ............................................................ 4 Removal and installation of hydraulic tank assembly....................................................................... 5 Removal and installation of control valve assembly......................................................................... 7 Disassembly and assembly of control valve assembly .................................................................. 10 Removal and installation of hydraulic pump assembly .................................................................. 15 Removal and installation of hydraulic pump input shaft oil seal ..................................................... 18 Disassembly and assembly of work equipment PPC valve assembly ........................................... 19 Disassembly and assembly of travel PPC valve assembly ............................................................21 Disassembly and assembly of work equipment cylinder assembly................................................23 600 Work equipment SEN06350-01 Removal and installation of work equipment assembly ................................................................... 2 Removal and installation of anti-drop valve assembly for boom ...................................................... 5 Removal and installation of anti-drop valve assembly for arm ......................................................... 8 Disassembly and assembly of anti-drop valve assembly ...............................................................10 700 Cab and its attachments SEN06351-00 Removal and installation of operator's cab assembly ...................................................................... 2 Removal and installation of operator's cab glass (adhered window glass) ...................................... 5 Removal and installation of front window assembly....................................................................... 14 Removal and installation of floor frame assembly.......................................................................... 20 800 Electrical system SEN06352-00 Removal and installation of air conditioner unit assembly ............................................................... 2 Removal and installation of KOMTRAX terminal assembly ............................................................. 7 Removal and installation of machine monitor assembly .................................................................. 9 Removal and installation of pump controller assembly .................................................................. 11 Removal and installation of engine controller assembly ................................................................13 80 Appendix 100 Air conditioner SEN06365-00 Precautions for refrigerant................................................................................................................ 3 Air conditioner component ............................................................................................................... 4 Configuration and function of refrigeration cycle.............................................................................. 6 Outline of refrigeration cycle ............................................................................................................ 7 Air conditioner unit ........................................................................................................................... 9 Air conditioner controller ................................................................................................................15 Compressor.................................................................................................................................... 16 Condenser......................................................................................................................................17 Receiver drier................................................................................................................................. 18 Sensor............................................................................................................................................19 Procedure for testing and troubleshooting ..................................................................................... 20 Circuit diagram and arrangement of connector pins ......................................................................22 System diagram .............................................................................................................................24 Parts and connectors layout........................................................................................................... 26 Testing air leakage (duct) ............................................................................................................... 29 Testing with self-diagnosis function................................................................................................31 Testing vent (mode) changeover.................................................................................................... 33 Testing FRESH/RECIRC air changeover ....................................................................................... 34 Testing sunlight sensor...................................................................................................................35 Testing (dual) pressure switch for refrigerant .................................................................................36 Testing relays ................................................................................................................................. 37
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SEN06259-06
100 Index Table of contents
Troubleshooting chart 1..................................................................................................................38 Troubleshooting chart 2..................................................................................................................40 Information in troubleshooting table ...............................................................................................42 Failure code list related to air conditioner.......................................................................................43 Failure code [879AKA] A/C Inner sensor Open Circuit ..................................................................44 Failure code [879AKB] A/C Inner sensor Short Circuit...................................................................45 Failure code [879BKA] A/C Outer sensor Open Circuit..................................................................46 Failure code [879BKB] A/C Outer sensor Short Circuit..................................................................48 Failure code [879CKA] Ventilating sensor Open Circuit.................................................................50 Failure code [879CKB] Ventilating sensor Short Circuit .................................................................51 Failure code [879DKZ] Sunlight sensor Open or Short Circuit.......................................................52 Failure code [879EMC] Ventilating Damper Abnormality ...............................................................54 Failure code [879FMC] Air Mix Damper Abnormality .....................................................................55 Failure code [879GKX] Refrigerant Abnormality ............................................................................56 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate).......................................................................................................................................... 58 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................60 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)....................63 Troubleshooting for FRESH/RECIRC air changeover....................................................................65 Troubleshooting with gauge pressure ............................................................................................67 Connection of service tool ..............................................................................................................69 Precautions for disconnecting and connecting air conditioner piping.............................................71 Handling of compressor oil.............................................................................................................73 90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN06273-00 Symbols in hydraulic circuit diagram ................................................................................................2 Hydraulic circuit diagram ..................................................................................................................5 200 Electrical diagrams and drawings SEN06274-00 Symbols in electric circuit diagram ...................................................................................................2 Electrical circuit diagram ..................................................................................................................5
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100 Index Table of contents
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SEN06259-06
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06259-06
© 2019 KOMATSU All Rights Reserved Printed in Japan 03-19 (01)
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SEN06260-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
00 Index and foreword
1
200 Foreword and general information Foreword, safety and general information ...................................................................................................... 2 How to read the shop manual ......................................................................................................................... 9 Explanation of terms for maintenance standard ............................................................................................11 Handling equipment of fuel system devices.................................................................................................. 13 Handling of intake system parts .................................................................................................................... 14 Handling of hydraulic equipment................................................................................................................... 15 Method of disconnecting and connectingof push-pull type coupler .............................................................. 17 Handling of electrical equipment................................................................................................................... 20 How to read electric wire code...................................................................................................................... 29 Precautions when performing operation ....................................................................................................... 32 Practical use of KOMTRAX........................................................................................................................... 35 Standard tightening torque table ................................................................................................................... 36 List of abbreviation........................................................................................................................................ 40 Conversion table ........................................................................................................................................... 45
PC300, 300LC, 350, 350LC-8M0
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200 Foreword and general information Foreword, safety and general information
SEN06260-01
Foreword, safety and general information
1
Important safety notice q Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. q The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. General precautions k Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. q Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. q Locate a place in the repair workshop to keep the 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, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. q When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. q When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator's compartment. q Only qualified workers must perform the work and operation which require license or qualification. q Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
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q
q q
If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place. Safety points 1 Good arrangement 2 Correct work clothes 3 Observance of work standard 4 Practice of making and checking signals 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
Preparation q Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving. q Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.
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200 Foreword and general information Foreword, safety and general information
q
q
When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work. Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing.
Precautions during work q For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to the OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first. q Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out. q When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit. q Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently. q Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, engine speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment. q The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
PC300, 300LC, 350, 350LC-8M0
SEN06260-01
q
q
q
q
q
q
q
q
q q
q
When removing the part which is under internal pressure or reaction force of the spring, always leave two bolts in diagonal positions. Loosen those two bolts gradually and alternately and release the pressure, then, remove the part. When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires. When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular. Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated. When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct. When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly. When aligning two holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole. When measuring hydraulic pressure, check that the measuring tools are correctly installed. Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track. If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well.
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200 Foreword and general information Foreword, safety and general information
SEN06260-01
Precautions for slinging work and making signals q Only one appointed worker must make signals and co-worker must communicate with each other frequently. The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. 1. Do not stand under the load. 2. Do not step on the load. q Check the slings before starting sling work. q Keep putting on the gloves during sling work. (Put on the leather gloves, if available.) q Measure the weight of the load by the eye and check its center of gravity. q Use the proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. q Do not sling a load with one wire rope only. If do so, the load may rotate or the sling gets loose and the sling may slip off. Install two or more wire ropes symmetrically. 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 slinging position on the load, which can result in a dangerous accident. q Hanging angle must be 60 degrees or smaller as a rule. q When hanging a heavy load (25kg or heavier), the hanging angle of the rope must be narrower than that of the hook. a When slinging a load with two ropes or more, the larger the hanging angle is, the larger the tension of each rope. The figure bellow shows the variation of allowable load in kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000kg} a load vertically, at various hanging angles. When the two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1000 kg} when the two ropes make a hanging angle of 120 degrees. If the two ropes sling a 19.6 kN {2000 kg} load at a hanging angle of 150 degrees, each rope is subjected to a force as large as 39.2 kN {4000 kg}.
q
q q
q q
q
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4
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc. Apply wire ropes to the middle portion of the hook. a Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle part.
Do not use twisted or kinked wire ropes. When slinging up a load, observe the following. 1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught. 2. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. 3. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. 4. Do not lift up the load at an angle. When lowering a load, pay attention to the following.
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Foreword, safety and general information
1.
2. 3.
When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. Check that the load is stable, and then remove the sling. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane k The hoist or crane must be used to sling the components weighing 25 kg or heavier. A part weighing 25 kg or heavier in “disassembly and assembly” section is indicated with the symbol of 4. q
q q q
q q q q q q q q
q
q
Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collisio n pr even tion d evice , an d en erg izing warning lamp, and check the following safety items. Observe the signals for sling work. Operate the hoist at a safe place. Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button. Do not sling a load at an angle. Do not move the crane while the slung load is swinging. Do not raise or lower a load while the crane is moving longitudinally or laterally. Do not drag a sling. When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. Consider the travel route in advance and lift up a load to a safe height. Place the control switch in a position where it will not be an obstacle to work and passage. After operating the hoist, do not swing the control switch. Remember the position of the main switch so that you can turn off the power immediately in an emergency. Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupter for electric shock prevention, check that the devices related to that switch are not in operating condition. If you find an obstacle around the hoist, stop the operation.
PC300, 300LC, 350, 350LC-8M0
SEN06260-01
q
After finishing the work, stop the hoist at the specified position and raise the hook to at least two meters above the floor. Do not leave the sling attached to the hook.
Selecting wire ropes q Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below Wire ropes (standard “Z” twist ropes without galvanizing) (JIS G3525, Type 6x37-A) Nominal diameter of rope mm 10 12 14 16 18 20 25 30 40 50 60
a
Allowable load kN 8.8 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6 221.6 318.3
ton 0.9 1.3 1.7 2.3 2.9 3.6 5.6 8.1 14.4 22.6 32.4
The allowable load is calculated as one sixth of the breaking load of the rope to be used (safety coefficient: 6).
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit Disconnection k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working cloth with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
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200 Foreword and general information Foreword, safety and general information
SEN06260-01
q
When loosening the nuts fixing air conditioner hoses and tubes, be sure to use two wrenches; use one wrench to fix and use the other one to loosen the nut.
Connection q When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and water into the hose. q Check that the O-rings are fitted to the joints when connecting the air conditioner piping. q Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. q When removing the O-rings, use a soft tool so that the piping is not damaged. q Check that the O-ring is not damaged or deteriorated. q Apply compressor oil for refrigerant (R134a) to the O-ring. a However, do not apply oil to the threaded portion of a bolt, nut or union. Manufacturer DENSO VALEO THERMAL SYSTEMS SANDEN q
a
For tightening torques, see “Others”, “Precautions for disconnection and connection of air conditioner piping”.
Part name
ND-OIL8 ZXL100PG (equivalent to PAG46) SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use two wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). Example of fitting of O-ring q An O-ring is fitted to every joint of the air conditioner piping.
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200 Foreword and general information Foreword, safety and general information
SEN06260-01
Fire prevention Action if fire occurs q Turn the starting switch to the OFF position to shutdown the engine. q Use the handrails and steps to get off the machine. q Do not jump off the machine. You may fall or suffer serious injury. q The fume generated by a fire contains harmful materials which have a bad influence on a human body when they are sucked. Don't breathe a fume. q After a fire, there may be harmful compounds left. If it touches your skin it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton-work-gloves, wear rubber gloves under them. Prevent fire q Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid.There is danger that they may catch fire. Always observe the following. q Do not smoke or use any flame near fuel or other flammable substances. q Shut down the engine before adding fuel. q Do not leave the machine when adding fuel or oil. q Tighten all the fuel and oil caps securely. q Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. q After adding fuel or oil, wipe up any spilled fuel or oil. q Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace. q When washing parts with oil, use a nonflammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire. q Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. q Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
PC300, 300LC, 350, 350LC-8M0
q
When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
q
Fire caused by accumulation or attachment of flammable material q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers. q To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
q
Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. q Keep all the electric wiring connections clean and securely tightened. q Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
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SEN06260-01
q
Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
q
Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. The exhaust gas discharged during the purification process (regeneration) can be higher temperature than that of existing models. Do not bring any flammable material close to the outlet of the exhaust pipe. q If there are thatched houses, dry leaves or pieces of paper around the job site, set the system to the “Regeneration Disable” before starting operation to prevent fire hazard of highly heated exhaust gas caused by KDPF regeneration. See the operation and maintenance manual for the setting procedure.
q
Explosion caused by lighting equipment q When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. q When taking the electrical power for the lighting equipment from the machine itself, follow the instructions in the operation and maintenance manual.
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200 Foreword and general information Foreword, safety and general information
Dispose of waste materials To prevent pollution, pay full attention to the way to dispose of waste materials. q Always put the oil and coolant drained from the machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. q Observe the related laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce poisonous gas harmful to human body when they are burned. q As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations.
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information How to read the shop manual
SEN06260-01
How to read the shop manual q q q
1
Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. Materials and specifications are subject to change without notice. The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual q This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use. 00. Index and foreword This section includes the index, foreword, safety and basic information.
q
01. Specification This section explains the specifications of the machine.
q
10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
q
20. Standard value table The standard values for a new machine and trouble shooting are described. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
q
30. Testing and adjusting This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
q
40. Troubleshooting This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
q
50. Disassembly and assembly This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
q
80. Appendix The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
q
90. Diagrams and drawings This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most upto-date information before you start any work. Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
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200 Foreword and general information How to read the shop manual
SEN06260-01
q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically. Symbol
Item
k
Safety
a
Caution
The special technical precautions or other precautions for preserving standards required when performing work are described.
4
Weight
3
The weight of part or component and the cautions required when selecting hoisting wire or when working posture is important are described.
Tightening torque
The tightening torques that require special attention during assembly work are described.
Coat
The places to be coated with adhesives, etc. during assembling are indicated.
2 5
Oil, coolant
6
Drain
Remarks The special safety precautions required for performing work are described.
The places to which oil is supplied and the quantity of the oil are indicated. The places from which oil is drained and quantity of the oil are indicated.
Unit q q
In this shop manual, the units are indicated with International System of units (SI). For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
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200 Foreword and general information Explanation of terms for maintenance standard
SEN06260-01
Explanation of terms for maintenance standard q
The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance q To be accurate, the finished dimension of a part is slightly different from one to another. q To specify the finished dimension of a part, a certain dimension is set for the part and an allowable difference from that dimension is indicated. q The above dimension set is called the “standard dimension” and the range of difference from the standard dimension is called the “tolerance”. q The standard dimension and tolerance are indicated by attaching the symbols of + or and a number on the right side of the standard dimension. Example: Standard dimension
q
q
The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/lower limit of tolerance).” Example: 120(-0.022/-0.126) Usually, the dimension of a hole and the dimension of a shaft to be inserted into the hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of dimension of rotating shaft and hole and their related drawing. Example: Standard dimension 60
q
When some parts are repaired, the value of performance/function is set to the standard value.
Tolerance –0.022 –0.126
120 q
1
Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
Standard clearance and standard value q The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q The values indicating performance and function of new products or equivalent are called the “standard value”, which is indicated by a range or a target value. PC300, 300LC, 350, 350LC-8M0
Standard interference When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the “interference”. q Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is the “standard interference”. q After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range. q
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SEN06260-01
200 Foreword and general information Explanation of terms for maintenance standard
Repair limit and allowable value or allowable dimension q The dimensions of parts change because of the wear or deformation while they are used. When the dimension changes exceeding certain value, the parts can not be used any longer. This value is called “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of the products lower while they are used. When the value of the performance and function lowers exceeding a certain limit and it influences the operation etc., this value is called the allowable value or allowable dimension. q A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgement must be made in consideration of the operating condition and customer’s requirement. Allowable clearance q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “allowable clearance”. q If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired. Allowable interference The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “allowable interference”. q The allowable interference shows the repair limit of the part of smaller tolerance. q The parts whose interferences are out of the allowable interference must be replaced or repaired. q
00-200
12
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling equipment of fuel system devices
SEN06260-01
Handling equipment of fuel system devices q
1
The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Use care for working environment q Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust. Sealing openings Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.
q
How to clean parts when dirt is stuck . q If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. q The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter element other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter element. q
PC300, 300LC, 350, 350LC-8M0
00-200
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SEN06260-01
Handling of intake system parts
200 Foreword and general information Handling of intake system parts
1
Be careful of working environment q Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust. Sealing openings Plug the pipes and the openings of the components which are removed, with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left open or plugged with rag since foreign material may enter.
q
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14
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling of hydraulic equipment
SEN06260-01
Handling of hydraulic equipment q
1
With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or w h en d i s a s s em b l i ng o r a s s e m bl i n g t h e hydraulic components.
Be careful of working environment q Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust. Disassembly and maintenance work in the field When disassembly or maintenance work of the hydraulic is performed in the field, there is danger of dust entering the components. It is also difficult to check the performance of the components after repairs, so it is desirable to use the component exchange service. The disassembly and assembly of the hydraulic components must be performed in the specially arranged dustproof workshop and the performance test of the components must be performed with the special testing equipment.
Preventing intrusion of foreign materials during refilling operations. q Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible to remove the dirt that is collected during storage. It is a surer means.
Sealing openings Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never leave the openings of the pipes and hoses without being covered or plugged with cloth as foreign material may enter them or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.
Replacing hydraulic oil while its temperature is high q When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil.
q
q
PC300, 300LC, 350, 350LC-8M0
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SEN06260-01
200 Foreword and general information Handling of hydraulic equipment
Flushing operations q After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them. Normally, flushing is performed twice. Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil.
Cleaning operations q After repairing the hydraulic equipment (pump, control valve, etc.) or when the machine is in operation, perform oil cleaning to remove the sludge or contaminant in the hydraulic oil circuit. The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device.
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PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Method of disconnecting and connectingof push-pull type
SEN06260-01
Method of disconnecting and connectingof push-pull type coupler k k
1
Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 Disconnection 1. Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a It can be pushed in by approximately 3.5mm. a Do not hold rubber cap portion (4). 2. While pushing hose joint (2) into adapter (3), push rubber cap (4) against adapter (3) until “click” is heard. (Fig. 2) 3. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.
PC300, 300LC, 350, 350LC-8M0
Connection 1. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3) aligning them with each other. (Fig. 4) a Do not hold rubber cap part (4). 2. After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition. (Fig.4) a When the hose fitting is pulled back, the rubber cap will move toward the hose, however, it is not a problem.
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SEN06260-01
200 Foreword and general information Method of disconnecting and connectingof push-pull type
Type 2 Disconnection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side. (Fig. 6) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8)
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Connection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side to connect it. (Fig. 9)
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Method of disconnecting and connectingof push-pull type
SEN06260-01
Type 3 Disconnection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male side. (Fig. 10) 2. While keeping the condition of Step 1, push cover (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 11) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12)
PC300, 300LC, 350, 350LC-8M0
Connection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (a) at the hexagonal portion on the male side to connect them. (Fig. 13)
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200 Foreword and general information Handling of electrical equipment
SEN06260-01
Handling of electrical equipment q
1
To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.
Precautions for handling electric equipment Handling wiring harnesses and connectors q Wiring harnesses consist of wires 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 wires. q 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 the wiring harnesses.
Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female connectors) q Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or b ecau se one or bot h of conn ecto rs a re deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately ten times.
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Defective crimping or soldering of connectors q The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joining area may become loose, which may result in a defective connection or breakage.
Disconnections in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, the crimping of the connector may separate, or the soldering may be damaged, or the wiring harness may be broken.
q
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling of electrical equipment
High-pressure water entering connector q 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. Accordingly, take care not to spray water over the connector. The connector is designed to prevent water from entering, but once water does enter, it is difficult to drain it. 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.
Entry of water, mud or dirt when disconnecting a connector q If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air.
PC300, 300LC, 350, 350LC-8M0
SEN06260-01
Oil, mud or dirt stuck to connector q If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the oil and water from the compressed air completely before cleaning the connector with the compressed air.
Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors 1. Hold the connectors when disconnecting. q Disconnect connectors by holding the connector bodies. For the connectors held by a screw, loosen the screw fully, then hold the male and female connectors with each hand respectively and pull them apart horizontally. For the connectors with lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull the connector with one hand.
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200 Foreword and general information Handling of electrical equipment
SEN06260-01 a
2.
When removing from clips q Both of the connector and clip have stoppers, which are engaged with each other when the connector is connected.
q
3.
If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the right and left, the housing may break.
Action to take after removing connectors q After removing the connector, cover it with the vinyl bag to prevent entry of dust, dirt,oil or water in the contact portion.
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Connecting connectors 1. Check the connector visually. q Check that there is no oil, dirt or water stick to the connector pins (joint portion). q Check that the connector pins are free from deformation, defective contact, corrosion, or damage. q Check that external surfaces of the connectors are free from damage or breakage. a If any oil, water or dirt is stuck to the connector, wipe it off with a dry cloth. If any water is inside the connector, warm the connector and the inside of the wiring harness with a dryer. But be careful not to make it too hot as it causes short circuit. a If there is any damage or breakage, replace the connector. 2. Fix the connector securely. q Align the connectors correctly, and fit them securely. For the connectors with the lock stopper, push in the connectors until “click” is heard.
3.
Correct the protrusion of the boot and misalignment of the wiring harness PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling of electrical equipment
q
For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the position, put it in its original position. a If the connector cannot be corrected easily, remove the clamp and adjust the position.
q
If the connector clamp is removed, be sure to return it to its original position. And check that it is securely installed.
Deutsch connector (DT8-pin, DT12-pin) Disconnection 1. While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
PC300, 300LC, 350, 350LC-8M0
SEN06260-01
Connection 1. Push in female connector (2) horizontally until the lock clicks. (Arrow: x) 2. Since locks (a) and (b) may not be set completely, push in female connector (2) with curving movement until the locks are set normally. (Arrow: x, y, and z) a Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
Drying wiring harness q If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing by using steam. If the wire harness must be washed in water, do not apply high pressure water or steam directly to 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. a If the connector is to be blown with dry compressed air, there is a risk that oil in the air may cause defective contact of the conditioner, remove oil and water in the air before starting air blow.
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SEN06260-01
2.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time to use hot air in order to prevent the connector or related parts from becoming too hot, as it causes deformation or damage to the connector.
3.
Perform a continuity test on the connector.After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them.
200 Foreword and general information Handling of electrical equipment
Handling of connectors used on engine Slide, lock type (Type 1) (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right. 2. While pressing lock (L2), pull out connector (1) toward you. a In the case that even if lock (L2) is pressed, connector (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
Connection 1. Insert the connector securely until a click is heard. Slide, lock type (Type 2) (FRAMATOME-24) Disconnection 1. Slide down lock (red) (L1).
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PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling of electrical equipment
2.
While pressing lock (L2), pull out connector (1).
SEN06260-01
Connection 1. Insert the connector securely until a click is heard. Push lock type (1) (BOSCH-3) Disconnection 1. While pressing lock (C), pull out connector (3) in the direction of the arrow. q 114 series
a
Lock (L2) is located in the back of connector (1).
q
107 series
a
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Connection 1. Insert the connector securely until a click is heard. Pull lock type (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
PC300, 300LC, 350, 350LC-8M0
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SEN06260-01
Connection 1. Insert the connector securely until a click is heard.
200 Foreword and general information Handling of electrical equipment
Example) Injection pressure control valve of supply pump: PCV (SUMITOMO-2)
Push lock type (2) (SUMITOMO-4) Disconnection 1. While pressing lock (C), pull out connector (4) in the direction of the arrow. Connection 1. Insert the connector securely until a click is heard.
Example) Speed sensor of supply pump: G (SUMITOMO-3) a Pull the connector straight up.
Push lock type (3) (AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc (AMP-3)
Connection 1. Insert the connector securely until a click is heard.
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PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Handling of electrical equipment
Turn-housing type (Round green connector) (CANNON-4) Disconnection 1. Turn housing (H1) in the direction of the arrow. a Unlock the connector by turning housing (H1). When the lock is release the housing is felt tight to turn. 2. Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
SEN06260-01
Handling controller q The electronic circuits for control including the microcomputers are assembled in the controller. These electronic circuits in the controller must be handled with care as they control the machine. q Do not place objects on top of the controller.
q q q
Connection 1. Insert the connector to the end while aligning its grove to the other. 2. Turn housing (H1) in the direction of the arrow until it “clicks”.
q
PC300, 300LC, 350, 350LC-8M0
Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts. During rainy weather, do not leave the controller in a place where it is exposed to rain. Do not place the controller on oil, water, or soil, or in a place that can be heated to a high temperature even for a short period of time. (Place it on a suitable dry stand.)
Precautions when performing arc welding When performing arc welding on the machine body, disconnect all the wiring harness connectors connected to the controller. Put the arc welding ground to the place close to the welding point.
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200 Foreword and general information Handling of electrical equipment
Precautions for troubleshooting electrical circuits q Be sure to turn the starting switch to the “OFF” position before disconnecting or connecting the connectors. q Before performing troubleshooting, check all the related connectors for loose connection. a Check the related connectors for their performance by disconnecting and connecting them several times. q Be sure to connect all the disconnected connectors before proceeding to the next step. a If the starting switch is turned to the “ON” position with the connectors disconnected, the failure which is not related to the part which is actually failed. q When performing the troubleshooting for the c i r c u i t ( m e a s u r e m e n t o f v o l ta g e , r e s i s tance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. a If there is any value change on the multimeter, there may be a defective contact in the circuit.
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PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information How to read electric wire code
SEN06260-01
How to read electric wire code
1
In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
q
AEX
0.85 L
Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.) Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates color of wire by color code. Color codes are shown in Table 3.
Type, symbol, and material AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating.
q
(Table 1) Type
Symbol
Conductor Material
Low-voltage wire for AV automobile Thin-cover low-voltage wire for AVS Soft polyvinyl chloride automobile Annealed (Type 1) copper for elecThin-cover tric applilow-voltage ance CAVS wire for automobile Type 2 Heat-resistant low-voltHeat-resistant crosslinked AEX age wire for polyethylene automobile
PC300, 300LC, 350, 350LC-8M0
Temperature range (°C) in use
Example of use For large current wiring (nominal No. 5 and above)
–30 to +60
General wiring (nominal No. 3 and lower)
For mid- to small-size excavators (nominal No. 1.25 and lower)
–50 to +110
(Safety factor: Wiring at high-temperature place
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200 Foreword and general information How to read electric wire code
SEN06260-01
Dimension (Table 2)
Coating D
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand CrossConductor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 sectional area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – AV Standard – – – – – – – 4.6 AEX
Standard
Coating D
Nominal No. Number of strands/Diameter of strand CrossConductor sectional area (mm2) d (approx.) AVS Standard AV Standard AEX
Standard
Coating D
Nominal No. Number of strands/Diameter of strand CrossConductor sectional area (mm2) d (approx.)
a
CAVS
Standard
2.0
2.2
2.7
3.0
3.1
50
–
60
3.8
85
4.6
8
15
20
30
40
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5
4.8 – 7.0
6.0 – 8.2
8.0 – 10.8
8.6 – 11.4
9.8 – 13.0
10.4 – 13.6
12.0 – 16.0
13.6 – 17.6
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
108/0.80 127/0.80 169/0.80 217/0.80
0.5f
0.5
0.75f
0.85
1.25f
1.25
–
7/round compression
–
11/round compression
–
16/round compression
–
0.56
–
0.88
–
1.29
–
0.9
–
1.1
–
1.4
–
1.6
–
1.8
–
2.1
“f” of nominal No. denotes flexible”.
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200 Foreword and general information How to read electric wire code
SEN06260-01
Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR a
Color of wire
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of two colors, the first color is the color of the background and the second color is the color of the marking. Examples) GW means that the background is “Green” and marking is “White”.
Types of circuits and color codes Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Appendix
AVS, AV, CAVS R B R RW Y G L Br Lg O Gr P Sb Dg Ch
PC300, 300LC, 350, 350LC-8M0
AEX
–
R B R D Y G L
–
–
WG
–
–
–
–
–
–
–
–
–
– –
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– –
Gr Br – –
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200 Foreword and general information Precautions when performing operation
SEN06260-01
Precautions when performing operation q
1
When performing “removal or installation” and “disassembly or assembly” of the components, observe the following general cautions.
Precautions for removal work q If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the sewage rashly. q After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering. q When draining oil, prepare a container with sufficient capacity. q Check the match marks which indicate the installing position, and put match marks on the places where they seem necessary before removal of the components to prevent any mistake when assembling. q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. q Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing. q Check the number and thickness of the shims, and keep them in a safe place. q When hoisting the components, prepare the slings with sufficient strength. q When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately. q Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal. a Precautions when handling piping during disassembly Use the plugs indicated below for the pipes disconnected at the disassembly. Face seal type hoses and tubes Nominal No. 02 03 04 05 06
Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628
Sleeve nut (elbow end) 02789-20210 02789-20315 02789-20422 02789-20522 02789-20628
Split flange type hoses and tubes Nominal No. 04 05
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Flange (hose end) 07379-00400 07379-00500
Sleeve head (tube end) 07378-10400 07378-10500
Split flange 07371-30400 07371-30500
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200 Foreword and general information Precautions when performing operation
SEN06260-01
If the part is not under hydraulic pressure, the following corks can be used. Nominal No.
Part Number
06 08 10 12 14 16 18 20 22 24 27
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734
D 6 8 10 12 14 16 18 20 22 24 27
Dimensions d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5
L 8 11 12 15 18 20 22 25 28 30 34
Precautions for installation work q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES). q Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are. q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts. q Bend the cotter pins and lock plates securely. q When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the threaded portion. q When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage. q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them. q Coat the rotating parts and sliding parts with engine oil. q Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P). q After installing the snap ring, check that the snap ring is settled in the ring groove completely. q When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then connect them securely. q Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook. q When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side. a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure. 1. Start and run the engine at low idle. 2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm before the stroke end four to five times. PC300, 300LC, 350, 350LC-8M0
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a
3. Operate the hydraulic cylinder three to four times to the end of its stroke. After the completion of repair and when operating the machine which is stored long term, perform the air bleeding with the same procedure as the one described above.
Precautions at the time of completing work Refilling of coolant, oil and grease q When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again. q When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again. q If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to “Testing and adjusting”. q Supply the specified amount of grease to the work equipment parts. Check of installed condition of cylinder heads and manifolds q Check the cylinder head and intake and exhaust manifold mountings for looseness. q If any bolt is loose, retighten it. a For the tightening torques, see the “Disassembly and assembly”. Check of engine piping for damage and looseness Intake and exhaust system Cooling system
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosely installed or damaged, retighten the bolts or repair the part. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage. If any part is loosely installed or damaged, retighten the bolts or repair the part. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. q Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts for looseness. If any part is loosely installed, retighten the bolts. q
Check of KDPF or muffler function q Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.If any unusual noise is heard, repair KDPF or muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
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Practical use of KOMTRAX
1
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX operator can refer this information in the office and provide various services to the customers. When KOMTRAX is installed on the machine, the machine information can be checked through the KOMTRAX system and the testing and troubleshooting can be performed efficiently. (KOMTRAX may not be installed on the machine in some countries or areas.) Merit of using KOMTRAX q The working place of the machine can be checked in the map on PC. q Operation information such as service meter reading, operating hours, fuel consumption, occurred caution and failure code can be checked. q The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil can be checked. q The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.) can be checked and the machine operating condition can be presumed with these information. q Various reports such as “Fuel saving operation support”, “Summary of operation”, etc. can be generated and utilized as an advice tool for the user and operator. How to use KOMTRAX practically With KOMTRAX, following support activities will be available. 1. Quick response to sudden request of repair 1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through KOMTRAX. 2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there. 2. Proactive maintenance 1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure code indicated by a red or yellow flag. 2) Check the condition of the machine with the customer and make a plan to visit. 3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3. Practice of periodic maintenance and periodic inspection service 1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for the consumable parts indicated by red flags are over. 2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer. 3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see “KOMTRAX basic operation manual”.
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Standard tightening torque table
1
Table of tightening torque for bolts and nuts Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below. 1. The following table applies to the bolts in Fig. A. Thread diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats (mm) 10 (10) 13 (12) 17 (14) 19 (17) 22 24 27 30 32 36 41 46 50 55 60
Tightening torque (Nm) 11.8 to 14.7 27 to 34 59 to 74 98 to 123 157 to 196 245 to 309 343 to 427 490 to 608 662 to 829 824 to 1,030 1,180 to 1,470 1,520 to 1,910 1,960 to 2,450 2,450 to 3,040 2,890 to 3,630
(kgm) 1.2 to 1.5 2.8 to 3.5 6.0 to 7.5 10.0 to 12.5 16 to 20 25 to 31.5 35 to 43.5 50 to 62 67.5 to 84.5 84 to 105 120 to 150 155 to 195 200 to 250 250 to 310 295 to 370
a
2.
Values with ( ) in the “Width across flats” column are for (*) marked bolt (flange bolt) shown in Fig. A. The following table applies to the bolts in Fig. B. Thread diameter (mm) 6 8 10 12
Fig. A
a
Width across flats (mm) 10 12 14 17
Tightening torque (Nm) 5.9 to 9.8 13.7 to 23.5 34.3 to 46.1 74.5 to 90.2
(kgm) 0.6 to 1.0 1.4 to 2.4 3.5 to 4.7 7.6 to 9.2
Fig. B
Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
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Table of tightening torque for split flanged bolts a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below. Thread diameter (mm) 10 12 16
Width across flats (mm) 14 17 22
Tightening torque (Nm) 59 to 74 98 to 123 235 to 285
(kgm) 6.0 to 7.5 10.0 to 12.5 23.5 to 29.5
Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below. Nominal No. 02 – 03,04 05,06 10,12 14
Thread diameter (mm) 14 18 20 24 33 42
Width across flats mm
Tightening torque (Nm {kgm}) Range Target 35 to 63 {3.5 to 6.5} 44 {4.5} 59 to 98 {6.0 to10.0} 78 {8.0} Varies depending 84 to 132 {8.5 to13.5} 103 {10.5} on type of connec128 to 186 {13.0 to19.0} 157 {16.0} tor. 363 to 480 {37.0 to 49.0} 422 {43.0} 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter Width across flats (mm) mm 8 14 10 17 12 19 14 22 16 24 18 27 20 30 24 32 30 32 33 – 36 36 42 – 52 –
PC300, 300LC, 350, 350LC-8M0
Tightening torque (Nm {kgm}) Range Target 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75} 9.81 to 12.74 {1.0 to 1.3} 11.27 {1.15} 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8} 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3} 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0} 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0} 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0} 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0} 93.1 to 122.5 { 9.5 to 12.5} 107.8 {11.0} 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0} 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5} 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5} 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
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Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table. a The table is applied to the threads coated with engine oil (wet threads) Nominal No. of hose
Width across flats (mm)
02
19 22 24 27 32 36 41 46 55
03 04 05 06 (10) (12) (14)
Tightening torque (Nm {kgm})
Taper seal
Range
Target
Thread size (mm)
34 to 54 { 3.5 to 5.5} 34 to 63 { 3.5 to 6.5} 54 to 93 { 5.5 to 9.5} 59 to 98 { 6.0 to 10.0} 84 to 132 { 8.5 to 13.5} 128 to 186 {13.0 to 19.0} 177 to 245 {18.0 to 25.0} 177 to 245 {18.0 to 25.0} 197 to 294 {20.0 to 30.0} 246 to 343 {25.0 to 35.0}
44 { 4.5} 44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
– 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread root threads per diameter inch, type of (reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torque for face seal joints a The tightening torque table below applies to the seal joint (sleeve nut type) a The table is applied to the threads coated with engine oil (wet threads). Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 {16} 22 {20}
19 22 24 {27} 30 {32} 36
Tightening torque (Nm {kgm}) Range
Target
14 to 16 {1.4 to 1.6} 24 to 27 {2.4 to 2.7} 43 to 47 {4.4 to 4.8} 60 to 68 {6.1 to 6.8} 90 to 95 {9.2 to 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread root Nominal No. – diameter threads per inch, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
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Tightening torque table for bolts and nuts on 102,107 and 114 series engines a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table. Thread diameter (mm) 6 8 10 12 14
Tightening torque (Nm) 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
(kgm) 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
Tightening torque table for I-joints on 102,107 and 114 series engines a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the torque shown in the following table. Thread size (mm) 6 8 10 12 14
Tightening torque (Nm) 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
(kgm) 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Tightening torque table for tapered screws on 102,107 and 114 series engines a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series engines to the torques shown in the following table. Material Thread diameter (inch) 1/16 1/8 1/4 3/8 1/2 3/4
PC300, 300LC, 350, 350LC-8M0
In cast iron or steel Tightening torque (Nm) (kgm) 15 ± 2 1.53 ± 0.20 20 ± 2 2.04 ± 0.20 25 ± 3 2.55 ± 0.31 35 ± 4 3.57 ± 0.41 55 ± 6 5.61 ± 0.61 75 ± 8 7.65 ± 0.82
In aluminum Tightening torque (Nm) (kgm) 5±1 0.51 ± 0.10 15 ± 2 1.53 ± 0.20 20 ± 2 2.04 ± 0.20 25 ± 3 2.55 ± 0.31 35 ± 4 3.57 ± 0.41 45 ± 5 4.59 ± 0.51
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200 Foreword and general information List of abbreviation
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List of abbreviation
1
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. Abbreviations that are used in general society may not be included. Special abbreviations which appear infrequently are noted in the text(marked wit a). This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
q
q q q
List of abbreviations used in the shop manual Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
Explanation
ABS
Anti-skid Brake System
Function with which when the tires skid (wheels Travel and brake (HD, stop rotating), the brakes are released, and when HM) the wheels start to rotate, the brakes are applied again.
AISS
Automatic Idling Setting System
Engine
Automatic setting function of idling speed
AJSS
Advanced Joystick Steering System
Steering (WA)
Function that a lever can perform the steering operations, shifting gear speed operation and changing direction operation instead of a steering wheel.
ARAC
Automatic Retarder Accelerator Control
Function that the retarder works automatically with Travel and brake (HD, a certain braking force when the accelerator pedal HM) is released while the machine travels downhill.
ARSC
Automatic Retarder Speed Control
ASR
Automatic Spin Regulator
ATT
Attachment
BCV
Brake cooling oil control valve Controller Area Network Crankcase Depression Regulator Closed-center Load Sensing System
CAN CDR
CLSS
Common Rail Injection
CRI
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Function that the retarder works automatically with a certain braking force so that the machine travels Travel and brake (HD, with the speed not exceeding the speed set by the HM) operator when the accelerator pedal is released while the machine travels downhill. Function with which, when the rear wheels spin on Travel and brake (HD, soft ground surfaces, this function automatically HM) uses the optimum braking force to drive both wheels. A device that can be fixed onto a machine in order Work equipment to enable it to do different jobs. Valve that bypasses part of the brake cooling oil to Brake (HD) reduce the load on the hydraulic pump when the retarder is not being used. Communication and One of communication standards that is used in electronic control the network on the machine Regulator valve that is installed to the KCCV Engine ventilator It is not used independently and described CDR valve. System that can simultaneously actuate multiple Oil pressure actuators regardless of the load (provides better combined operation comparing to OLSS). Function to maintain optimum fuel injection amount and fuel injection timing by using engine Engine controller to perform electronic control of supply pump, common rail, and injector.
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information List of abbreviation
Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
ECM
Electronic Control Electronic control Module system
ECMV
Electronic Control Transmission (D, HD, Modulation Valve WA, etc.)
ECSS
Electronically Controlled Suspension System
ECU
Electronic Control Electronic control Unit system
EGR
Exhaust Gas Recirculation
EMMS
EPC
FOPS F-N-R
Equipment Management Monitoring System Electromagnetic Proportional Control Falling Object Protective Structure Forward-NeutralReverse
Travel (WA)
Engine
Machine monitor
SEN06260-01
Explanation Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators . (Same as ECU) Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of machine during travel Electronic control device that uses the signals from the sensors on the machine to indicate the optimum actuation to the actuators. (Same as ECM) Function to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature and to control emission of NOx. System that allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor.
Oil pressure
Electromagnetic proportional control Mechanism that actuator works in proportion to current
Cab and canopy
Structure that protects operator's head from falling objects. (Structure to protect operator) Performance standardized in ISO 3449
Operation
Forward - NEUTRAL - REVERSE
GPS
Communication Global Positioning (KOMTRAX System §KOMTRAX Plus)
Global Positioning System Satellite positioning system that is used to determine the current location on the earth Steering function that uses a combination of hydraulic motor and bevel shaft to control Steering (D) difference in travel speed of right and left tracks to turn machine without using steering clutch. Hydraulic transmission system that uses a Transmission (D, WA) combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. Valve that adjusts fuel intake amount at inlet port Engine of pump in order to control fuel discharge amount of supply pump. Same meaning as IMV Valve adjusting fuel intake amount at inlet port of Engine pump in order to control fuel discharge amount of supply pump. Described IMV (IMA) This mechanism separates oil in blowby gas and Engine returns it to the intake side to afterburn it there. It primarily consists of filters.
HSS
Hydrostatic Steering System
HST
Hydro Static Transmission
IMA
Inlet Metering Actuator
IMV
Inlet Metering Valve
KCCV
Komatsu Closed Crankcase Ventilation
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Abbreviation
Full Spelling
Purpose of use (major applicable machine (*), or equipment/device)
Komatsu Catalyzed Soot Engine Filter Komatsu Diesel Engine Oxidation Catalyst
KCSF KDOC
KDPF
Komatsu Diesel Particulate Filter
KTCS
Komatsu Traction Travel and brake (HM Control System system)
LCD
Liquid Crystal Display
Machine monitor
LED
Light Emitting Diode
Electronic parts
LIN
Local Interconnect Communication and Network electronic control
LS
Load Sensing
Oil pressure
LVDS
Low Voltage Differential Signaling
Communication and electronic control
Engine
MAF
Mass Air Flow
Engine
MMS
Multimedia Messaging Service
Communication
NC
Normally Closed
Electric and hydraulic
NO
Normally Open
Electric and hydraulic
Open-center Load Oil pressure Sensing System Pressure Oil pressure Compensation
OLSS PC
PCCS
Palm command control system
PCV
Pre-stroke Control Engine Valve
PPC
Proportional Pressure Control
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Steering (D)
Oil pressure
Explanation This filter is used to capture soot in exhaust gas. It is built in to KDPF. The catalyst used for purifying exhaust gas. It is built in to KDPF. This component with built-in KDOC (catalyst) and KCSF purifies exhaust gas. Part building in (sootcapturing filter) It is installed in place of the currently used muffler. Function that recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road. Liquid Display Image display equipment such as the monitor which assembles in the liquid crystal element. Light Emitting Diode Semi-conductor element that emits light when the voltage is applied in the normal direction. One of communication standards that is used in the network on the machine Function that detects differential pressure of pump and controls discharge amount according to load. One of communication standards that is used in the network on the machine It means the intake air flow of the engine. It is not used independently but used together with the sensor. The mass air flow sensor may be called MAF sensor. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. A function used to correct oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Proportional pressure control Mechanism that actuator works in proportion to hydraulic pressure
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200 Foreword and general information List of abbreviation
Abbreviation PPM PTO PTP
ROPS
SI
SOL TWV
SEN06260-01
Purpose of use (major applicable machine (*), Explanation or equipment/device) Piston Pump and Oil pressure Piston pump and motor. Motor (D, PC, etc.) Power Take Off Power transmission Power take-off mechanism Power Tilt and Function that performs hydraulic control of the tilt Work equipment (D) power Pitch dozer and pitch of the bulldozer blade. Structure that protects operator fastening seat belt from being crushed when machine tips over Roll-Over Protective Cab and canopy (Structure to protect operator when machine tips Structure over) Performance standardized in ISO 3471 Abbreviation for “International system of units” International unit Unit Unit system that is employed worldwide, and “one system unit against one factor” Actuator that moves a part with a movable iron Solenoid Electric core in the coil (solenoid), which is moved by energizing the coil. Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of flow. Full Spelling
*1: Code for applicable machine family D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC S/T STRG SIG SOL STD
Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actuator No Connection Steering Signal Solenoid Standard
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Abbreviation OPT OP PRESS SPEC SW TEMP T/C T/M
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Actual word spelled out Option (if equipped) Pressure Specification Switch Temperature Torque Converter Transmission
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200 Foreword and general information Conversion table
SEN06260-01
Conversion table
1
Method of using the conversion table q The unit conversion table enables the simple conversion in the figures between the different units. For further details of the method of use of the conversion table, see the examples given below. Example: Method of using the conversion table to convert a unit from millimeters to inches Conversion of 55 mm into inches 1. Locate the number 50 in the vertical column at the left side, take this as (A), and 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 vertical line down from (B). 3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit from millimeters to inches. Therefore, 55 mm = 2.165 in. Conversion of 550 mm into inches 1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Then convert 55 mm to 2.165 in by the same procedure as above. 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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65 in.
Millimeters to inches
(A)
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
PC300, 300LC, 350, 350LC-8M0
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-200
45
200 Foreword and general information Conversion table
SEN06260-01
Millimeters to inches
0 10 20 30 40 50 60 70 80 90
0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929 2.244 2.283 2.323 2.638 2.677 2.717 3.032 3.071 3.110 3.425 3.465 3.504 3.819 3.858 3.898
2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83
3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03
4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24
5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44
6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64
7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85
6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361
1 l = 0.2642 U.S.Gal 7 8 9 1.849 2.113 2.378 4.491 4.755 5.019 7.133 7.397 7.661 9.774 10.039 10.303 12.416 12.680 12.944 15.058 15.322 15.586 17.700 17.964 18.228 20.341 20.605 20.870 22.983 23.247 23.511 25.625 25.889 26.153
Kilogram to pound
0 10 20 30 40 50 60 70 80 90
0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42
1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62
1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 130.07 149.91 152.12 171.96 174.17 194.01 196.21 216.05 218.26
l to U.S. Gallons
0 10 20 30 40 50 60 70 80 90
00-200
0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775
46
1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040
2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304
3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568
4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832
5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Conversion table
SEN06260-01
l to U.K. Gallons
0 10 20 30 40 50 60 70 80 90
0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797
1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017
2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237
3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457
4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677
5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897
6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117
1 l = 0.21997 U.K.Gal 7 8 9 1.540 1.760 1.980 3.740 3.950 4.179 5.939 6.159 6.379 8.139 8.359 8.579 10.339 10.559 10.778 12.528 12.758 12.978 14.738 14.958 15.178 16.938 17.158 17.378 19.137 19.357 19.577 21.337 21.557 21.777
1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5
2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7
3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0
4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2
5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4
6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7
7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9
kgm to ft.lb
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3
PC300, 300LC, 350, 350LC-8M0
1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 426.8 491.8 499.1 564.2 571.4 636.5 643.7 708.8 716.1 781.2 788.4 853.5 860.7 925.8 933.1 998.2 1005.4 1070.5 1077.7 1142.8 1150.0 1215.1 1222.4 1287.5 1294.7 1359.8 1367.0 1432.1 1439.4
00-200
47
200 Foreword and general information Conversion table
SEN06260-01
kg/cm2 to lb/in2
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
00-200
0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414
48
1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428
2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442
3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456
4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470
5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485
6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 825.0 839.2 953.0 967.2 981.4 1,095 1,109 1,124 1,237 1,252 1,266 1,380 1,394 1,408 1,522 1,536 1,550 1,664 1,678 1,693 1,806 1,821 1,835 1,949 1,963 1,977 2,091 2,105 2,119 2,233 2,247 2,262 2,375 2,389 2,404 2,518 2,532 2,546 2,660 2,674 2,688 2,802 2,816 2,830 2,944 2,958 2,973 3,086 3,101 3,115 3,229 3,243 3,257 3,371 3,385 3,399 3,513 3,527 3,542
PC300, 300LC, 350, 350LC-8M0
200 Foreword and general information Conversion table
SEN06260-01
Temperature Conversion of Fahrenheit to Celsius q A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures on the following table show the temperatures in both Fahrenheit and Celsius. q When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. q When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.
°C –40
°F
°C –11.7 –11.1
°F
°C
11 12
51.8 53.6
7.8 8.3
1°C = 33.8°F °F
°F
°C
46 47
114.8 116.6
27.2 27.8
81 82
177.8 179.6
–40.4 –37.2
–35
–40.0 –31.0
–34.4
–30
–22.0
–10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
–31.7
–25
–13.0
–10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
–28.9
–20
–4.0
–9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
–28.3
–19
–2.2
–8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
–27.8
–18
–0.4
–8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
–27.2
–17
1.4
–7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
–26.7
–16
3.2
–7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
–26.1
–15
5.0
–6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
–25.6
–14
6.8
–6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
–25.0
–13
8.6
–5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
–24.4
–12
10.4
–5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
–23.9
–11
12.2
–4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
–23.3
–10
14.0
–3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
–22.8
–9
15.8
–3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
–22.2
–8
17.6
–2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
–21.7
–7
19.4
–2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
–21.1
–6
21.2
–1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
–20.6
–5
23.0
–1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
–20.0
–4
24.8
–0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
–19.4
–3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
–18.9
–2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
–18.3
–1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
–17.8
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
–17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
–16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
–16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
–15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
–15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
–14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
–13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
–13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
–12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
–12.2
PC300, 300LC, 350, 350LC-8M0
00-200
49
SEN06260-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06260-01
© 2018 KOMATSU All Rights Reserved Printed in Japan 02-18 (01)
00-200
50
SEN06262-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
01 Specification
100 Specification and technical data
1
Specification dimension drawings................................................................................................................... 2 Specifications.................................................................................................................................................. 4 Weight table.................................................................................................................................................. 10 Table of fuel, coolant and lubricants ............................................................................................................. 12
PC300, 300LC, 350, 350LC-8M0
01-100
1
01 Specification Specification dimension drawings
SEN06262-01
Specification dimension drawings Dimensions
1
1
Item
Unit
PC300-8M0
PC300LC-8M0
PC350-8M0
PC350LC-8M0
A Overall length
mm
11,150
11,150
11,150
11,150
B Overall height
mm
3,250
3,250
3,250
3,250
C Overall width
mm
3,190
3,190
3,190
3,190
D Shoe width
mm
600
600
600
600
E Cab height
mm
3,110
3,110
3,110
3,110
F Tail swing radius
mm
3,450
3,450
3,450
3,450
G Overall track length
mm
4,625
4,955
4,625
4,955
Length of track on H ground
mm
3,700
4,030
3,700
4,030
J Min. ground clearance
mm
498
498
498
498
01-100
2
PC300, 300LC, 350, 350LC-8M0
01 Specification Specification dimension drawings
SEN06262-01
1 Working ranges
Item
1
Unit
PC300-8M0
PC300LC-8M0
PC350-8M0
PC350LC-8M0
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
10,100
10,100
10,100
10,100
D
Max. vertical wall digging depth
mm
6,400
6,400
6,400
6,400
E
Max. dumping height
mm
7,050
7,050
7,050
7,050
mm
2,640
2,640
2,640
2,640
mm
10,920
10,920
10,920
10,920
F Min. dumping height G
Max. reach at ground level
PC300, 300LC, 350, 350LC-8M0
01-100
3
01 Specification Specifications
SEN06262-01
Specifications
1
PC300-8M0, PC300LC-8M0 Machine model
PC300-8M0
Serial number Bucket capacity
Working range
Performance
Machine weight
C90001 and up m
3
1.4
1.4
kg
31,100
31,600
Max. digging depth
mm
7,380
7,380
Max. vertical wall digging depth
mm
6,400
6,400
Max. digging radius
mm
11,100
11,100
Max. reach at ground level
mm
10,920
10,920
Max. digging height
mm
10,100
10,100
Max. dumping height
mm
7,050
7,050
kN {kg}
211.8 {21,600} (226.5 {23,100})
211.8 {21,600} (226.5 {23,100})
min-1 {rpm}
9.5 {9.5]
9.5 {9.5}
Max. digging force (When one-touch power maximizing function is turned on) Swing speed Swing operation max. slope angle
deg.
21
21
Travel speed
km/h
Lo: 3.2 Mi: 4.5 Hi: 5.5
Lo: 3.2 Mi: 4.5 Hi: 5.5
Gradeability
deg.
35
35
kPa {kg/cm }
62.9 {0.64}
59.0 {0.60}
Overall length
mm
11,150
11,150
Overall width
mm
3,190
3,190
Overall crawler width
mm
3,190
3,190
Overall height (During transportation)
mm
3,250
3,250
Machine body overall height
mm
3,110
3,110
Ground clearance of upper structure bottom
mm
1,185
1,185
Min. ground clearance
mm
498
498
Tail swing radius
mm
3,450
3,450
Work equipment minimum swing radius
mm
4,435
4,435
Top height at minimum swing radius of work equipment
mm
8,520
8,520
Length of track on ground
mm
3,700
4,030
Track gauge
mm
2,590
2,590
Cab height
mm
3,110
3,110
Width of standard shoe
mm
600
600
Ground pressure
Dimensions
PC300LC-8M0
01-100
4
2
PC300, 300LC, 350, 350LC-8M0
01 Specification Specifications
SEN06262-01
1 Machine model
PC300-8M0
Serial number
C90001 and up
Model
SAA6D114E-3
Type
4-cycle, water-cooled in-line, direct injection with turbocharger and air-cooled aftercooler
Number of cylinders – bore x stroke
Performance
mm
6-114x135
l {cc}
8.27 {8,270}
Rated horsepower q SAE J1995 [gross] q ISO 14396 q ISO 9249/SAE J1349 [net]
kW {HP}/ min-1 {rpm}
194 {260}/1,950 {1,950} 187 {250}/1,950 {1,950} 194 {260}/1,950 {1,950}
Max. torque
Nm {kgm}/ min-1 {rpm}
1,109 {113.1}/1,450 {1,450}
Max. speed with no load
min-1 {rpm}
2,050 {2,050}
Piston displacement
Engine
PC300LC-8M0
Min. speed with no load Min. fuel consumption ratio
-1
min {rpm}
1,000 {1,000}
g/kWh {g/HPh}
205 {151}
Starting motor
24 V, 7.5 kW
Alternator Battery
24 V, 60 A 12 V, 126 Ah x 2
Undercarriage
Radiator model
CF90-4
Carrier roller
2 on one side
Track roller
7 on one side
8 on one side
Track shoe
Assembly-type triple grosser 45 on one side
Assembly-type triple grosser 48 on one side
PC300, 300LC, 350, 350LC-8M0
01-100
5
01 Specification Specifications
SEN06262-01
Machine model
PC300-8M0
Swing motor Travel motor Control valve Hydraulic pump Hydraulic cylinder
Hydraulic system
Serial number
C90001 and up
Type and numbers Delivery Set pressure
PC300LC-8M0
HPV125+125, Variable displacement piston type: 2 l/min
267.5 x 2
MPa {kg/cm2}
37.8 {380}
Type and numbers
6-spool + 1-spool type: 1
Operating method
Hydraulic
Type and numbers
HMV160ADT-2, piston type: 2 (with brake valve and parking brake)
Type and numbers
KMF160ABE-5, piston type: 1 (with safety valve, shaft brake and reverse prevention valve) KMF160AB-5, piston type: 1 (with safety valve and shaft brake)
Type
Boom (*1)
Arm (*1) (*2)
Bucket
Double acting piston
Double acting piston
Double acting piston
Cylinder inner diameter
mm
140
160
140
Piston rod diameter
mm
100
110
100
Stroke
mm
1,480
1,825
1,285
Max. pin-to-pin distance
mm
3,525
4,255
3,155
Min. pin-to-pin distance
mm
2,045
2,430
1,870
Hydraulic tank Hydraulic oil filter Hydraulic oil cooler
Box-shaped, closed type Tank return side CF91-1 (Air-cooling type)
*1: Cushion is provided on head side *2: Cushion is provided on bottom side
01-100
6
PC300, 300LC, 350, 350LC-8M0
01 Specification Specifications
SEN06262-01
PC350-8M0, PC350LC-8M0 Machine model
PC350-8M0
Serial number Bucket capacity
m
1.4
1.4
kg
32,600
33,660
mm
7,380
7,380
Max. vertical wall digging depth
mm
6,400
6,400
Max. digging radius
mm
11,100
11,100
Max. reach at ground level
mm
10,920
10,920
Max. digging height
mm
10,100
10,100
Max. dumping height
mm
7,050
7,050
Max. digging force (When power max. function is turned on)
kN {kg}
212.8 {21,700} (227.5 {23,200})
212.8 {21,700} (227.5 {23,200})
min-1{rpm}
9.5 {9.5}
9.5 {9.5}
Swing speed Swing operation max. slope angle
deg.
18
18
Travel speed
km/h
Lo: 3.2 Mi: 4.5 Hi: 5.5
Lo: 3.2 Mi: 4.5 Hi: 5.5
Gradeability
deg.
35
35
kPa{kg/cm }
65.9 {0.67}
62.9 {0.64}
Overall length
mm
11,150
11,150
Overall width
mm
3,190
3,190
Overall crawler width
mm
3,190
3,190
Overall height (During transportation)
mm
3,250
3,250
Machine body overall height
mm
3,110
3,110
Ground clearance of upper structure bottom
mm
1,185
1,185
Min. ground clearance
mm
498
498
Tail swing radius
mm
3,450
3,450
Work equipment minimum swing radius
mm
4,435
4,435
Top height at minimum swing radius of work equipment
mm
8,520
8,520
Ground pressure
Dimensions
C90145 and up 3
Max. digging depth Working range
Performance
Machine weight
PC350LC-8M0
2
Length of track on ground
mm
3,700
4,030
Track gauge
mm
2,590
2,590
Cab height
mm
3,110
3,110
Width of standard shoe
mm
600
600
PC300, 300LC, 350, 350LC-8M0
01-100
7
01 Specification Specifications
SEN06262-01
Machine model
PC350-8M0
Serial number
C90145 and up
Model
SAA6D114E-3
Type
4-cycle, water-cooled in-line, direct injection with turbocharger and air-cooled aftercooler
Number of cylinders – bore x stroke
mm
6-114x135
l {cc}
8.27 {8,270}
Rated horsepower q SAE J1995 [gross] q ISO 14396 q ISO 9249/SAE J1349 [net]
kW {HP}/ min-1 {rpm}
194 {260}/1,950 {1,950} 187 {250}/1,950 {1,950} 194 {260}/1,950 {1,950}
Max. torque
Nm {kgm}/ min-1 {rpm}
1,109 {113.1}/1,450 {1,450}
Max. speed with no load
min-1 {rpm}
2,050 {2,050}
Performance
Piston displacement
Engine
PC350LC-8M0
Min. speed with no load Min. fuel consumption ratio
-1
min {rpm}
1,000 {1,000}
g/kWh {g/HPh}
205 {151}
Starting motor
24 V, 7.5 kW
Alternator Battery
24 V, 60 A 12 V, 126 Ah x 2
Undercarriage
Radiator model
CF90-4
Carrier roller
2 on one side
Track roller
7 on one side
8 on one side
Track shoe
Assembly-type triple grosser 45 on one side
Assembly-type triple grosser 48 on one side
01-100
8
PC300, 300LC, 350, 350LC-8M0
01 Specification Specifications
SEN06262-01
Machine model
PC350-8M0
Swing motor Travel motor Control valve Hydraulic pump Hydraulic cylinder
Hydraulic system
Serial number
C90145 and up
Type and numbers Delivery Set pressure
PC350LC-8M0
HPV125+125, Variable displacement piston type: 2 l/min
267.5 x 2
MPa {kg/cm2}
37.8 {380}
Type and numbers
6-spool + 1-spool type 1
Operating method
Hydraulic
Type and numbers
HMV160ADT-2, piston type: 2 (with brake valve and parking brake)
Type and numbers
KMF160ABE-5, piston type: 1 (with safety valve, shaft brake and reverse prevention valve) KMF160AB-5, piston type: 1 (with safety valve and shaft brake)
Type
Boom (*1)
Arm (*1) (*2)
Bucket
Double acting piston
Double acting piston
Double acting piston
Cylinder inner diameter
mm
140
160
140
Piston rod diameter
mm
100
110
110
Stroke
mm
1,480
1,825
1,285
Max. pin-to-pin distance
mm
3,525
4,255
3,155
Min. pin-to-pin distance
mm
2,045
2,430
1,870
Hydraulic tank Hydraulic oil filter Hydraulic oil cooler
Box-shaped, closed type Tank return side CF91-1 (Air-cooling type)
*1: Cushion is provided on head side *2: Cushion is provided on bottom side
PC300, 300LC, 350, 350LC-8M0
01-100
9
01 Specification Weight table
SEN06262-01
Weight table k
1
This weight table is prepared for your reference when handling or transporting the components.
PC300-8M0, PC300LC-8M0 Machine model Serial number Engine assembly q Engine q Damper q Hydraulic pump Radiator and oil cooler assembly Hydraulic tank and filter assembly (Not including hydraulic oil) Fuel tank and filter assembly (Not including fuel) Revolving frame Cab Operator seat Counterweight Swing machinery Control valve Swing motor Travel motor Center swivel joint Track frame assembly q Track frame q Swing circle q Idler q Idler cushion q Carrier roller q Track roller q Final drive (including travel motor) Track shoe assembly q Standard triple shoe (600 mm) q Standard triple shoe (700 mm) q Wide triple shoe (800 mm) q Load liner (Rubber pad type) (600 mm) Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Link (large) assembly Link (small) assembly Boom pin Arm pin Bucket pin Link pin 01-100
10
Unit: kg PC300-8M0 PC300LC-8M0 C90001 and up 1,175 1,175 865 865 14.3 14.3 205 205 187 187 176
176
243 2,844 570 35 5,480 455 242 91 165 x 2 29.9 7,552 3,946 487 169 x 2 283 x 2 28 x 4 53 x 14 605 x 2
243 2,844 570 35 5,480 455 242 91 165 x 2 29.9 8,078 4,285 487 169 x 2 283 x 2 28 x 4 53 x 16 605 x 2
3,470 3,700 4,030 4,300 4,380 4,680 – – 2,392 2,392 1,135 1,135 1,015 1,015 262 x 2 262 x 2 390 390 235 235 316 316 – – 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42 13 + 20 13 + 20 30 x 2 30 x 2 27 x 2 27 x 2 PC300, 300LC, 350, 350LC-8M0
01 Specification Weight table
SEN06262-01
1 PC350-8M0, PC350LC-8M0 Machine model Serial number Engine assembly q Engine q Damper q Hydraulic pump Radiator and oil cooler assembly Hydraulic tank and filter assembly (Not including hydraulic oil) Fuel tank assembly (Not including fuel) Revolving frame Cab Operator seat Counterweight Swing machinery Control valve Swing motor Travel motor Center swivel joint Track frame assembly q Track frame q Swing circle q Idler q Idler cushion q Carrier roller q Track roller (double frame) q Track roller (single frame) q Final drive (including travel motor) Track shoe assembly q Standard triple shoe (600 mm) q Standard triple shoe (700 mm) q Wide triple shoe (800 mm) q Load liner (Rubber pad type) (600 mm) Boom assembly Arm assembly Bucket assembly Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Link (large) assembly Link (small) assembly Boom pin Arm pin Bucket pin Link pin PC300, 300LC, 350, 350LC-8M0
Unit: kg PC350-8M0 PC350LC-8M0 C90145 and up 1,175 1,175 865 865 14.3 14.3 205 205 187 187 176
176
238 2,950 570 35 6,380 455 242 91 165 x 2 29.9 7,579 3,946 487 169 x 2 283 x 2 28 x 4 57.5 x 6 53 x 8 605 x 2
238 2,950 570 35 6,380 455 242 91 165 x 2 29.9 8,114 4,285 487 169 x 2 283 x 2 28 x 4 57.5 x 8 53 x 8 605 x 2
3,670 3,920 4,030 4,300 – – – – 2,555 2,555 1,247 1,247 1,508 1,508 262 x 2 262 x 2 390 390 235 235 316 316 – – 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42 13 + 20 13 + 20 30 x 2 30 x 2 27 x 2 27 x 2 01-100
11
SEN06262-01
01 Specification Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants a
1
For details of the notes (Notes 1, Note 2...) in the table, see Operation and Maintenance Manual.
* ASTM: American Society of Testing and Material
01-100
12
PC300, 300LC, 350, 350LC-8M0
01 Specification Table of fuel, coolant and lubricants
SEN06262-01
Unit: l Applicable portion
PC300/300LC-8M0, PC350/350LC-8M0 Specified quantity (l)
Refill capacity (l)
Engine oil pan
39
37
Swing machinery case
16
16
Final drive case (each)
9
8
Damper case
1.3
1.3
Hydraulic system
365
188
Fuel tank
605
—
Cooling system
31
31
PC300, 300LC, 350, 350LC-8M0
01-100
13
SEN06262-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06262-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
01-100
14
SEN06264-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 100 Engine and cooling system
1
Engine related parts ....................................................................................................................................... 2 Radiator, oil cooler and aftercooler................................................................................................................. 3
PC300, 300LC, 350, 350LC-8M0
10-100
1
10 Structure, function and maintenance standard Engine related parts
SEN06264-01
Engine related parts
1. Drive plate 2. Torsion spring 3. Stopper pin 4. Friction plate 5. Damper assembly 6. Muffler 7. Rear engine mount 8. Front engine mount
10-100
2
1
Outline A wet type damper assembly is used. Oil capacity: 1.3 l
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Radiator, oil cooler and aftercooler
SEN06264-01
Radiator, oil cooler and aftercooler
1
1. Reservoir tank 2. Radiator 3. Radiator cap 4. Oil cooler 5. Guard
6. Aftercooler 7. Radiator inlet hose 8. Radiator outlet hose 9. Shroud
Specifications Radiator: CF90-4 Oil cooler: CF91-1
PC300, 300LC, 350, 350LC-8M0
10-100
3
SEN06264-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06264-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
10-100
4
SEN06265-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 200 Power train
1
Power train...................................................................................................................................................... 2 Swing circle..................................................................................................................................................... 3 Swing machinery............................................................................................................................................. 4 Final drive ....................................................................................................................................................... 6 Sprocket .......................................................................................................................................................... 8
PC300, 300LC, 350, 350LC-8M0
10-200
1
SEN06265-01
Power train
10 Structure, function and maintenance standard Power train
1
1. Idler 2. Center swivel joint 3. Control valve 4. Final drive 5. Travel motor (HMV160ADT-2) 6. Engine (SAA6D114E) 7. Hydraulic pump (HPV125+125) 8. Travel speed solenoid valve 9. Swing brake solenoid valve 10. Swing machinery 11. Swing motor (KMF160ABE-5 or KMF160AB-5) 12. Swing circle
10-200
2
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing circle
Swing circle
SEN06265-01
1
1. Swing circle inner race (No. of teeth: 90) 2. Ball 3. Swing circle outer race a. Inner race soft zone “S“ position b. Outer race soft zone “S“ position Specifications Reduction ratio: –90/13 = –6.923 Amount of grease bath: 33 l (G2-LI) Unit: mm No.
Check Item Axial clearance of bearing (when
4 mounted on chassis)
PC300, 300LC, 350, 350LC-8M0
Criteria
Remedy
Standard clearance
Clearance limit
0.5 to 1.6
3.2
Replace
10-200
3
10 Structure, function and maintenance standard Swing machinery
SEN06265-01
Swing machinery
10-200
4
1
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing machinery
1. Swing pinion (No. of teeth: 13) 2. Cover 3. Plate 4. No. 2 planetary carrier 5. Ring gear (No. of teeth: 68) 6. No.2 planetary gear (No. of teeth: 25) 7. No.2 sun gear (No. of teeth: 16)
SEN06265-01
8. No. 1 planetary carrier 9. No. 1 planetary gear (No. of teeth: 24) 10. Swing motor 11. Oil level gauge 12. No. 1 sun gear (No. of teeth: 19) 13. Case 14. Drain plug
Specifications Reduction ratio: ((19+68)/19) x ((16+68)/16) = 24.039 Unit: mm No.
Check Item Backlash between swing motor
15 shaft and No. 1 sun gear 16
Backlash between No. 1 sun gear and No.1 planetary gear Backlash between No. 1 planetary
17 gear and ring gear
Backlash between No. 1 planetary
18 carrier and No. 2 sun gear
Backlash between No. 2 sun gear
19 and No.2 planetary gear
Backlash between No. 2 planetary
20 gear and ring gear
Backlash between No. 2 planetary
21 carrier and swing pinion
Backlash between swing pinion and
22 swing circle
Clearance between plate and No. 2
23 planetary carrier
Wear of swing pinion surface con-
24 tacting with oil seal
PC300, 300LC, 350, 350LC-8M0
Criteria
Remedy
Standard clearance
Clearance limit
0.18 to 0.28
–
0.15 to 0.51
1.00
0.17 to 0.60
1.20
0.40 to 0.75
1.50
0.14 to 0.44
0.90
0.16 to 0.55
1.10
0.07 to 0.23
–
0 to 1.21
2.40
0.38 to 0.82
–
Standard dimension
Repair limit
0 140 -0.100
–
Replace
Reapply hard chrome plating or replace
10-200
5
10 Structure, function and maintenance standard Final drive
SEN06265-01
Final drive
1. Level plug 2. Drain plug 3. No.1 planetary gear (No. of teeth: 42) 4. No.1 sun gear (No. of teeth: 10) 5. No. 2 sun gear (No. of teeth: 19) 6. No.1 planetary carrier 7. No. 2 planetary carrier
1
8. Cover 9. Ring gear (No. of teeth: 95) 10. Hub 11. Sprocket 12. Floating seal 13. Travel motor 14. No. 2 planetary gear (No. of teeth: 37)
Specifications Reduction ratio: –((10+95)/10) x ((19+95)/19) +1= –62.000
10-200
6
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Final drive
SEN06265-01
1
Unit: mm No.
Check Item Backlash between No. 1 sun gear
15 and No.1 planetary gear 16
Backlash between No. 1 planetary gear and ring gear Backlash between No. 2 planetary
17 carrier and motor
Backlash between No. 2 sun gear
18 and No.2 planetary gear
Backlash between No. 2 planetary
19 gear and ring gear
Backlash between No. 2 planetary
20 carrier and No. 2 sun gear 21 Amount of wear on sprocket tooth 22 Width of sprocket tooth
PC300, 300LC, 350, 350LC-8M0
Criteria
Remedy
Standard clearance
Clearance limit
0.14 to 0.48
1.00
0.19 to 0.66
1.3
0.06 to 0.25
–
0.15 to 0.51
1.00
0.19 to 0.66
1.3
0.44 to 0.74
1.6
Replace
Repair limit: 6 Standard dimension
Repair limit
87
81
Build-up welding for rebuilding or replace
10-200
7
10 Structure, function and maintenance standard Sprocket
SEN06265-01
Sprocket
1
Unit: mm No.
Check Item
1 Wear of tooth tip 2 Thickness of tooth root 3 Width of tooth 4 Wear of tooth shape
10-200
8
Criteria
Remedy
Standard dimension
Repair limit
336.5
324.5
20
14
87
84
Build-up welding for rebuilding or replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth shape)
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Sprocket
SEN06265-01
Full-size drawing of sprocket tooth shape
a
The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy on an OHP sheet, and apply it to sprocket.
PC300, 300LC, 350, 350LC-8M0
10-200
9
SEN06265-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06265-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
10-200
10
SEN06266-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial No.
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 300 Undercarriage and frame
1
Track frame and recoil spring.......................................................................................................................... 2 Idler ................................................................................................................................................................. 4 Carrier roller .................................................................................................................................................... 6 Track roller ...................................................................................................................................................... 7 Track shoe ...................................................................................................................................................... 9
PC300, 300LC, 350, 350LC-8M0
10-300
1
10 Structure, function and maintenance standard Track frame and recoil spring
SEN06266-01
Track frame and recoil spring a
1
The following drawing indicates PC300-8M0.
1. Idler 2. Track frame 3. Carrier roller 4. Final drive 5. Track roller 6. Center guard 7. Front guard
10-300
2
q
q
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 (one side)
PC300-8M0, PC350-8M0
7
PC300LC-8M0, PC350LC-8M0
8
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Track frame and recoil spring
SEN06266-01
Standard shoe Models
PC300-8M0
PC350-8M0
PC300LC-8M0
PC350LC-8M0
Shoe width (triple shoe) (mm)
600
600
600
600
Link pitch (mm)
216
216
216
216
45
45
48
48
Item
No. of shoes (one side)
Unit: mm No.
Check Item
Vertical width of idler
8 guide
9
Horizontal width of idler guide
Criteria
Remedy
Standard dimension
Tolerance
Rapair limit
Track frame
123
+3 –1
127
Idler support
120
±0.5
118
Track frame
266
+4 –1
271
Idler support
261
—
259
Standard dimension
10 Recoil spring
Free length x O.D. 811.5 x 261
PC300, 300LC, 350, 350LC-8M0
Installation length
Installation load
655
208.7 kN {21,287 kg}
Build-up welding for rebuilding or replace
Rapair limit Free length
Installation load
—
167.0 kN {17,030 kg}
Replace
10-300
3
10 Structure, function and maintenance standard Idler
SEN06266-01
Idler
10-300
1
4
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Idler
SEN06266-01
Unit: mm No.
Check Item
Criteria
Remedy
Standard dimension
Rapair limit
635
—
2 Outside diameter of tread
590
578
3 Difference of tread
22.5
28.5
4 Thickness of tread
Measurement unable
—
190
—
1 Outside diameter of protrusion
5 Total width 6 Width of tread 7
Clearance between shaft and bushing
44 Standard dimension 80
Interference between idler and
8 bushing
Standard dimension 87.6
Build-up welding for rebuilding or replace
50 Tolerance
Shaft
Hole
Standard clearance
Clearance limit
–0.225 –0.325
+0.130 –0.024
0.201 to 0.455
—
Tolerance Shaft
Hole
+0.087 +0.037
–0.027 –0.079
0.064 to 0.166
Clearance between bushing and
Standard dimension
Clearance limit
(Sum of clearance at both sides)
0.68 to 1.22
—
9 support
PC300, 300LC, 350, 350LC-8M0
Replace bushing
Standard Interference interference limit —
—
10-300
5
10 Structure, function and maintenance standard Carrier roller
SEN06266-01
Carrier roller
1
Unit: mm No.
Check Item
1 Outside diameter of flange
Criteria Standard dimension
Remedy Rapair limit
179
—
2 Outside diameter of tread
152
138
3 Width of tread
48.2
—
4 Thickness of tread
32
25
5
Width of flange
19
—
6
Clearance between shaft and bushing
Standard dimension 54
7
Interference between roller and bushing
Standard dimension 61
8 Axial clearance of roller
10-300
6
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.250 –0.280
+0.100 –0.036
0.214 to 0.380
—
Tolerance Shaft
Hole
Standard interference
Interference limit
+0.117 +0.087
+0.030 +0.040
0.057 to 0.117
—
Standard clearance
Clearance limit
0.5 to 0.7
—
Replace
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Track roller
Track roller
SEN06266-01
1
Unit: mm No.
Check Item
1 Outside diameter of outer flange
Criteria Standard dimension
Remedy Rapair limit
216
—
2 Inside diametor of outer flange
210
—
3 Outside diameter of tread
180
168
54
48
250
—
4 Thickness of tread 5 Overal width 6 Width of tread
Single flange
49
Double flange
47.7
7 Width of flange
Single flange Double flange
Width of inner frange
8 (Double frame)
PC300, 300LC, 350, 350LC-8M0
Build-up welding for rebuilding or replace
—
27
—
98
—
10-300
7
10 Structure, function and maintenance standard Track roller
SEN06266-01
Unit: mm No.
9
10
Check Item
Criteria
Clearance between bushing and collar (Sum of clearance at both sides) Clearance between shaft and bushing
0.44 to 0.97 Standard dimension 65
11
Interference between roller and bushing
Standard dimension 72
10-300
8
Remedy —
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.250 –0.350
+0.186 –0.064
0.186 to 0.536
—
Tolerance Shaft
Hole
Standard interference
Interference limit
+0.108 +0.008
–0.006 –0.036
0.014 to 0.144
—
Replace bushing
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Track shoe
Track shoe
a
SEN06266-01
1
P portion shows the link of bushing press fitting end. Unit: mm
No.
Check Item
1 Link pitch 2 Outside diameter of bushing 3 Thickness of bushing metal 4 Link height Thickness of link metal (bushing
5 press-fitting portion) 6 7 Shoe bolt pitch 8
PC300, 300LC, 350, 350LC-8M0
Criteria
Remedy
Standard dimension
Repair limit
216.3
219.3
66.9
61.9
10.8
5.8
116
107
30.7
21.7
Reverse or replace Adjust or replace Repair or replace
178.4 140.4
Replace
76.2
10-300
9
10 Structure, function and maintenance standard Track shoe
SEN06266-01
Unit: mm No.
Check Item
Criteria Inside width
102
10 Link
Overall width
47.8
11
Tread width
42.6
9
12 13 14 15
Protrusion of pin
4.2
Protrusion of regular bushing
5.25
Overall length of pin
Press-fitting force
19 (*)
Standard dimension
Reverse
10.8
5.8
Bushing
98 to 264.6 kN {10 to 27 ton}
Regular pin
147 to 362.6 kN {15 to 37 ton}
Master pin
98 to 215.6 kN {10 to 22 ton}
a. Regular link
20 Shoe bolt b. Master link
Interference between bushing and
21 link
Interference between regular pin
22 and link 23
Adjust or replace
148.4
16 Thickness of spacer 18
Repair or replace
242
Overall length of bushing
17
Remedy
Clearance between regular pin and bushing
Tightening torque (Nm {kgm}) Triple grouser shoe Tightening torque (Nm {kgm})
Retightening angle (deg.)
393±39 {40±4}
120±10
Retightening angle (deg.)
— Standard dimension
—
Retighten
Lower limit torque (Nm {kgm})
—
—
Tolerance
Standard interference
Shaft
Hole
66.5
+0.464 +0.424
+0.074 +0.074
0.350 to 0.464
44.6
+0.235 +0.085
–0.188 –0.250
0.273 to 0.485
Standard dimension 44.6
24 Interference between master pin (*) and link
Standard dimension
25 Clearance between master pin and (*) bushing
Standard dimension
44.6
44.3
Tolerance Shaft
Hole
+0.235 +0.085
+0.915 +0.415
Tolerance Shaft
Hole
+0.03 +0.03
–0.188 –0.250
Tolerance Shaft
Hole
+0.050 –0.050
+0.915 +0.415
Standard clearance 0.180 to 0.830
Adjust or replace
Standard interference 0.188 to 0.280 Standard clearance 0.365 to 0.965
* Dry type track link
10-300
10
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Track shoe
SEN06266-01
Triple grouser shoe
Unit: mm No.
Check Item
1 Height
Criteria *1 *2
Standard dimension
Repair limit
30
18
36
24
2 Thickness
11 *1
3
29
*2
32
4
*1
24
*2
26
5
*1
22
*2
24
6 Length at tip
*1
16
*2
18
7
*1
22
Length of base
8 Thickness
Remedy
*2 *1 *2
Build-up welding for rebuilding or replace
18 Standard dimension
Repair limit
41
29
47
35
*1: PC300-8M0, PC300LC-8M0: 600 mm width shoe *2: PC350-8M0, PC350LC-8M0: 600 mm width shoe
PC300, 300LC, 350, 350LC-8M0
10-300
11
SEN06266-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06266-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
10-300
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SEN06267-02
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard
1
401 Hydraulic system, Part 1 Hydraulic equipment layout drawing ............................................................................................................... 2 Hydraulic tank and filter .................................................................................................................................. 4 Hydraulic pump ............................................................................................................................................... 6
PC300, 300LC, 350, 350LC-8M0
10-401
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SEN06267-02
Hydraulic equipment layout drawing
10-401
2
10 Structure, function and maintenance standard Hydraulic equipment layout drawing
1
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic equipment layout drawing
SEN06267-02
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. Work equipment lock lever (electric type) 14. Center swivel joint 15. R.H. PPC valve 16. Travel PPC valve 17. Attachment circuit selector valve 18. Hydraulic drift prevention 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
PC300, 300LC, 350, 350LC-8M0
10-401
3
10 Structure, function and maintenance standard Hydraulic tank and filter
SEN06267-02
Hydraulic tank and filter
1. Oil filler cap 2. Bypass valve 3. Strainer 4. Filter element 5. Sight gauge 6. Hydraulic tank 7. Additional breather 8. Breather
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1
Specifications Tank capacity: 275 l Amount of oil inside tank: 188 l Pressure valve (This valve is installed inside the cap.) Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Bypass valve set pressure: 250 ± 50 kPa {2.5 ± 0.5 kg/cm2} Additional breather Relief cracking pressure: 0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2} Suction cracking pressure: 2.0 ± 0.3 kPa {0.02 ± 0.003 kg/cm2} PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic tank and filter
SEN06267-02
Hydraulic tank oil filler cap
Hydraulic tank breather
Structure
Structure
1: Bottom plate 2: Gasket Function Prevention of pressure rise in hydraulic tank While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and the temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders. When the pressure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure in the tank and prevent pressure rise. (Set pressure of exhaust valve: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2} )
PC300, 300LC, 350, 350LC-8M0
1: Nut 2: Cover 3: Filter element 4: Case 5: Valve assembly 6: Body Function Prevention of negative pressure in hydraulic tank Since the hydraulic tank is pressurized and sealed, if the oil level in it decreases, negative pressure is generated in it. At this time, valve assembly (5) is opened by the differential pressure from the ambient pressure, and ambient pressure is transmitted into the tank to prevent generation of negative pressure in the tank (Set pressure of intake valve: Max. 0.002 MPa {0.02 kg/cm2})
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10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
Hydraulic pump
1
Type: HPV125+125
10-401
6
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
Outline q This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve and variable volume valve. BMP: Breather fitting port IM: PC mode selector current ISIG: LS set pressure selector current OCP: Oil level detection port PAF: Front pump delivery port PAR: Rear pump delivery port PBF: Front pump pressure input port PBR: Rear pump pressure input port PD1F: Case drain port PD1R: Air breeder PD2F: Drain plug PD2R: Drain plug PENF: Front control pressure detection port PENR: Rear control pressure detection port PEPC: EPC basic pressure port PEPB: EPC basic pressure detection port PFC: Front pump delivery pressure detection port PLSC: LS set selector 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 PM: PC mode selector pressure detection port PRC: Rear pump delivery pressure detection port PS: Pump suction port 1. Front pump 2. Rear pump 3. LS valve 4. PC valve 5. LS-EPC valve 6. PC-EPC valve 7. Variable volume valve
PC300, 300LC, 350, 350LC-8M0
10-401
7
SEN06267-02
1. Front shaft 2. Cradle 3. Front case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block
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10 Structure, function and maintenance standard Hydraulic pump
8. Valve plate 9. End cap 10. Rear shaft 11. Rear case 12. Servo piston 13. PC valve
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
Function q The pump converts the engine rotation transmitted to the shaft to oil pressure and discharges pressurized oil corresponding to the load. q It is possible to change the discharge amount by changing the swash plate angle.
Structure Cylinder block (7) is supported to shaft (1) by spline (14). q Shaft (1) is supported by front and rear bearings (15). q Tip of piston (6) is shaped as a concave ball and shoe (5) is caulked to it to form one unit. q Piston (6) and shoe (5) constitute the spherical bearing. q Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular movement. q Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it rocks. q
PC300, 300LC, 350, 350LC-8M0
q
q q q
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). Cylinder block (7) seals the pressurized 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 suctioned and discharged through valve plate (8).
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SEN06267-02
Operation of pump q Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). q When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and th e axia l d ir ection of cylinde r bloc k ( 7) changes. q (a) is named the swash plate angle.
q
q
q q
q
10 Structure, function and maintenance standard Hydraulic pump
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts 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). A single piston (6) sucks and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is suctioned.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
Control of discharge amount q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump discharge (Q) increases. q Servo piston (12) is used for changing swash plate angle (a). q Servo piston (12) carries out linear reciprocal movement corresponding to the signal pressure from the PC and LS valves. q This linear movement is transmitted to rocker cam (4) via slider (13). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the small diameter piston side. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston 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).
PC300, 300LC, 350, 350LC-8M0
10-401
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SEN06267-02
10 Structure, function and maintenance standard Hydraulic pump
1. LS valve
PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PPL: Control pressure input port PSIG: LS mode selector pilot port
1. Sleeve 2. Piston 3. Spool 4. Spring 5. Seat 6. Sleeve 7. Plug 8. Locknut
Function q The LS (load sensing) valve detects the load and controls the discharge amount. q This valve controls main pump discharge (Q) corresponding to differential pressure (PLS) [= PP – LS], called the LS differential pressure (the difference between main pump pressure PP and control valve outlet port pressure PLS). q 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. q The relationship between the LS differential pressure between the main pump pressure (PP) and LS pressure (PLS) (PLS) [= (PP) – (PLS)] and the pump discharge (Q) changes as shown in the diagram corresponding to LS selector current (ISIG) of the LS-EPC valve. q If (ISIG) changes from 0 to 1A, setting force the spring changes, too. As the result, the specified median of the pump discharge volume switching point changes as shown in the diagram. As for the front pump side, it will change in the range of 0.98 to 2.45 MPa {in the range of 10 to 25 kg/cm2] and as for the rear pump side, it will change in the range of 1.08 to 2.55 MPa {in the range of 11 to 26 kg/cm2}.
Front pump
10-401
12
Rear pump
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
Operation
1) When the control valve is situated at neutral
q
q
q
q q
The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge pressure (self pressure) (PP) determine the position of spool (6). However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for the LS valve entering port (G) also changes the position of spool (6). (Setting force of the spring is changed) Before the engine is started, servo piston (12) is pushed to the right. (See the figure) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool)
PC300, 300LC, 350, 350LC-8M0
q q q q
Spool (6) is pushed to the right, and port (C) and port (D) will be connected. Pump pressure (PP) is conducted to the larger diameter end from the port (K). The same pump pressure (PP) is conducted to the smaller diameter end from the port (J). Corresponding to the difference in the areas on servo piston (12), the pressure moves in such that the swash plate angle may be minimized.
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SEN06267-02
10 Structure, function and maintenance standard Hydraulic pump
2) Action for the direction of maximizing the pump discharge
q
q
q
q
When the difference between the main pump pressure (PP) and LS pressure (PLS), in other w o r d s , L S d i ffe r e n t i a l p r e s s u re (P L S) becomes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) 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 left side. Therefore, the swash plate is moved in the direction to make the discharge amount larger.
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q
q
If the output pressure of the EPC valve for the LS valve enters port (G), rightward force is generated on piston (7). If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential pressure (PLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
3) Action for the direction of minimizing the pump discharge
q
q
q
q
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) because of the rightward move (it reduces discharge amount) of servo piston (12), pump pressure (PP) pushes spool (6) to the right. When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large diameter end of the piston. Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the right. As the result, servo piston (12) moves into the direction of reducing the swash plate angle. As LS selector pressure (PSIG) is input to port (G), setting force of spring (4) is reduced.
PC300, 300LC, 350, 350LC-8M0
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SEN06267-02
10 Structure, function and maintenance standard Hydraulic pump
4) When servo piston is balanced
q
q
q
q
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 spring (4) and LS pressure (PLS) are balanced, and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position. And the swash plate of the pump will be held in an intermediate position. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0) : (A1) = 3 : 5, so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 5 : 3
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q
q
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when (PP) – (PLS) = 2.45 MPa {25 kg/cm2} on the front pump side and (PP) – (PLS) = 2.55 MPa {26 kg/cm2} on the rear pump side at the median of the specified value. If (PSIG) [Output pressure of LS-EPC valve, 0 to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the position of the balanced stop is changed. The front pump side will be moved in the range of (PP) –(PLS) = 2.45 to 0.98 MPa {25 to 0 kg/ cm2} and the rear pump will be moved in the range of (PP) – (PLS) = 2.55 to 1.08 MPa {26 to 11 kg/cm2} in proportion to (PSIG) pressure.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
2. PC valve
PA: Pump port PA2: Pump pressure pilot port PDP: Drain port PM: Mode selector pressure pilot port PPL: Control pressure output port (to LS valve)
Function q When the pump discharge pressure (PP1) (self-pressure) and (PP2) (other pump pressure) are high, the PC valve controls the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it may not exceed the engine hose power. q If the pump discharge pressure increases due to increased load during operation, this valve decreases the pump discharge. q And if the pump discharge pressure goes low, it increases the pump discharge. q In this case, relation between the mean discharge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and the pump discharge (Q) will becomes as shown in the diagram if the relation is represented as the parameter the current value (X) to be given to PC-EPC valve solenoid. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load, the controller reduces the pump discharge to recover the speed.
PC300, 300LC, 350, 350LC-8M0
1. Plug 2. Servo piston assembly 3. Pin 4. Spool 5. Retainer 6. Seat 7. Cover 8. Wiring
q
If the engine speed goes below the specified value because of increased load, the controller sends a command current to PC-EPC valve solenoid in order to reduce the slope angle in proportion to reduction in the engine speed.
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10 Structure, function and maintenance standard Hydraulic pump
Operation
1) When pump controller is normal (1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2). q Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure). q The pressure [port (C) pressure] output from PC valve is changed depending on the above position. q The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
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a
Other pump's pressure denotes the pressure of the pump situated on the opposite side. For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump pressure, the other pump's pressure is that of the front pump.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
PC300, 300LC, 350, 350LC-8M0
SEN06267-02
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Action of spring q Load of springs (4) and (6) on the PC valve is determined by the swash plate position. q As servo piston (9) moves to right, spring (6) is retracted. q If the servo piston moves further, it contacts to seat (5), and spring (6) will be fixed. q After that, spring (4) alone operates. q The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6). q If the command current (X) to PC-EPC valve solenoid (1) changes, so the force pushing piston (2) also changes. q Spring load of springs (4) and (6) is also affected by the command current (X) to PCEPC valve solenoid. q Port (C) of the PC valve is connected to port (E) of the LS valve. q Self pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and other pump pressure (PP2) enters port (A).
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10 Structure, function and maintenance standard Hydraulic pump
q q
q
q q
q
When pump pressures (PP1) and (PP2) are small, spool (3) is positioned in the left side. 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, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the left side. The pump delivery is set to the increasing trend. Accompanied with move of servo piston (9), springs (4) and (6) are expanded and the spring force becomes weaker. As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
q
q
SEN06267-02
As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move of servo piston (9) is stopped. Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and (6) are balanced.
PC300, 300LC, 350, 350LC-8M0
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10 Structure, function and maintenance standard Hydraulic pump
(2) When load on actuator is large and pump discharge pressure is high
Outline When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right becomes larger and spool (3) will be moved to the position shown in above figure. q Part of the pressure to be conducted from port (C) to LS valve flows from port (B) to port (C) and (D) via LS valve. At the end this flow, level of this pressure becomes approximately half of the main pump pressure (PP2). q
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Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to port (C) and acts to make the pump delivery the minimum. q When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3). q When spool (3) moves to the left, the opening of port (C) and port (D) becomes larger. q As a result, the pressure on port (C) (= J) is decreased and the rightward move servo piston (9) is stopped. q The position in which servo piston (9) stops at this time is further to the right than the position when pump pressures (PP1) and (PP2) are low.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
q
q
q
q
SEN06267-02
The line is bent in the line graph which shows relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions since sprinngs (4) and (6) form the double springs. The relationship between the average pump pressure (PP1 + PP2)/2 and average pump discharge (Q) becomes as shown below.
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 (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. Namely, the force of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the pump discharge (Q) moves from (A) to (B) as the command current (X) is increased.
PC300, 300LC, 350, 350LC-8M0
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10 Structure, function and maintenance standard Hydraulic pump
2) When the emergency pump drive switch is turned on due to failure on the pump controller (1) When the main pump is under light load
q
q
q q
q
If there is a failure in the pump controller, the emergency pump drive switch is turned on, and is shifted to the resistor side. In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1). The current becomes constant, so the force pushing piston (2) is also constant. If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left. 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.
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q
Since the pressure on the small diameter end of the piston large, servo piston (9) moves in the direction to make the discharge amount larger.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
SEN06267-02
(2) When the main pump is under heavy load
q
q q
q
q
If the emergency pump drive switch is turned on in the same way as in above, the command current (X) sent to PC-EPC 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 right 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 (B) flows to port (C), so servo piston (9) moves to the right (smaller pump delivery) and stops at a position to the further to the right then when the load on the pump is light. Also when the emergency pump drive switch is turned on, the pump pressure (PP) and pump delivery (Q) have a relationship as shown with the curve in the figure corresponding to the current sent to the PC-EPC valve solenoid through the resistor.
PC300, 300LC, 350, 350LC-8M0
q
The curve resulting when the emergency pump drive switch is ON is situated further to the left (B) than when the pump controller is normal (A).
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3. LS(PC)-EPC Valve
C: To LS(PC) valve P: From self pressure reducing valve T: To tank 1. Connector 2. Coil 3. Body 4. Spring 5. Spool 6. Rod 7. Plunger
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q When it receives signal current (i) from the controller, it generates the EPC output pressure in proportion to the size of the signal, and outputs it to the LS (PC) valve.
SEN06267-02
Operation 1) q q q
q
PC300, 300LC, 350, 350LC-8M0
When signal current is 0 (coil is de-energized) When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the LS (PC) valve. The pressurized oil from the LS (PC) valve is drained to the tank via port (C) and port (T).
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2) q
q q
q q q
q
When signal current is very small (coil is energized) When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves up and down so that the propulsion force of plunger (7) may be balance with pressure of port (C) + spring load of spring (4). The circuit pressure between the EPC valve and the LS (PC) valve is controlled in proportion to the size of the signal current.
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10 Structure, function and maintenance standard Hydraulic pump
3) q q
q q
q
When signal current is maximum (coil is energized) As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward right side by rod (6). The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and LS (PC) valve to the maximum level. Since port (T) is closed, pressurized oil does not flow to the tank.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic pump
PC300, 300LC, 350, 350LC-8M0
SEN06267-02
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29
SEN06267-02
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06267-02
© 2019 KOMATSU All Rights Reserved Printed in Japan 03-19 (01)
10-401
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SEN06268-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 402 Hydraulic system, Part 2
1
Control valve................................................................................................................................................... 2 CLSS ............................................................................................................................................................ 14 Functions and operation by valve ................................................................................................................. 18 Attachment circuit selector valve .................................................................................................................. 57 Hydraulic drift prevention valve..................................................................................................................... 60
PC300, 300LC, 350, 350LC-8M0
10-402
1
SEN06268-01
10 Structure, function and maintenance standard Control valve
Control valve
1
Outline q The control valve consists of a 7-spool valve (6-spool valve + boom Hi, arm Hi valve) and a set of service valves. A merge-divider valve, a back pressure valve, a boom drift prevention valve are installed to it. q Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the assembly, the assembly is compact and easy to maintain. A1: To bucket cylinder bottom A2: To L.H. travel motor A3: To boom cylinder bottom A4: To swing motor A5: To R.H. travel motor A6: To arm cylinder head A-1: To boom cylinder bottom A-2: To Attachment 1 A-3: To Attachment 2 B1: To bucket cylinder head B2: To L.H. travel motor B3: To boom cylinder head B4: To swing motor B5: To R.H. travel motor B6: To arm cylinder bottom B-1: To arm cylinder bottom B-2: To Attachment 1 B-3: To Attachment 2 BP1: Boom raising PPC output pressure BP5: From 2-stage safety valve solenoid valve BP6: From attachment select solenoid valve CN: Variable back pressure selector solenoid controlle valve P1: From bucket PPC and EPC valves P2: From bucket PPC and EPC valves P3: From L.H. Travel PPC valve P4: From L.H. Travel PPC valve P5: From boom PPC and EPC valves P6: From boom PPC and EPC valves P7: From swing PPC and EPC valves P8: From swing PPC and EPC valves P9: From R.H. Travel PPC valve P10: From R.H. Travel PPC valve P11: From arm PPC and EPC valves P12: From arm PPC and EPC valves P-3: From Service 1 and PPC valves P-4: From Service 1 and PPC valves P-5: From Service 2 and PPC valves P-6: From Service 2 and PPC valves
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PLS1: To front pump control PLS2: To rear pump control PP1: From front pump PP2: From rear pump PP1S: Pressure sensor mounting port PP2S: Pressure sensor mounting port PPS1: To front pump control PPS2: To rear pump control PR: To solenoid valve, PPC valve, and EPC valve PS: From merge-divide solenoid valve PST: From travel junction valve solenoid valve PX1: From 2-stage relief solenoid valve PX2: From 2-stage relief solenoid valve T: To tank T1: To tank TS: To tank TSW: To swing motor S-port (suction side) 1. 6-spool valve 2. Cover A 3. Cover B 4. Boom Hi and arm Hi valve 5. Service valve 1 6. Service valve 2 7. Merge-divider valve 8. Boom drift prevention valve 9. Quick return valve 10. Boom Hi valve check valve
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
SEN06268-01
General view
PC300, 300LC, 350, 350LC-8M0
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3
SEN06268-01
10 Structure, function and maintenance standard Control valve
Sectional view (1/5)
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4
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
SEN06268-01
Pressure compensation valve (Arm OUT) Pressure compensation valve (R.H. travel REVERSE) Pressure compensation valve (Swing LEFT) Pressure compensation valve (Boom RAISE) Pressure compensation valve (L.H. travel REVERSE) Pressure compensation valve (Bucket DUMP) Pressure compensation valve (Boom Hi RAISE) Pressure compensation valve (Service 1) Pressure compensation valve (Service 2) Pressure compensation valve (Arm Hi IN) Pressure compensation valve (Bucket CURL) Pressure compensation valve (L.H. travel FORWARD) Pressure compensation valve (Boom LOWER) Pressure compensation valve (Swing RIGHT) Pressure compensation valve (R.H. travel FORWARD) Pressure compensation valve (Arm IN) Main relief valve Unload valve Main relief valve Spool (Service 2) Spool (Service 1) Spool (Boom HI) Spool (Bucket) Spool (L.H. travel) Spool (Boom) Spool (Swing) Spool (R.H. travel) Spool (Arm) Spool (Arm HI)
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
30 Spool return spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
54.2 x 34.8
51.2
417 N {42.5 kg}
—
333 N {34.0 kg}
—
315 N {32.1 kg}
31 Spool return spring
54.5 x 34.8
51.2
393 N {40.1 kg}
32 Spool return spring
54.6 x 34.8
51.2
421 N {42.9 kg}
—
336 N {34.3 kg}
33 Spool return spring
54.9 x 24.2
52.0
251 N {25.6 kg}
—
201 N {20.5 kg}
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
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5
SEN06268-01
10 Structure, function and maintenance standard Control valve
(2/5)
10-402
6
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
SEN06268-01
Suction valve (Arm OUT) Suction valve (R.H. travel REVERSE) Suction valve (Boom RAISE) Suction valve (L.H. travel REVERSE) Safety-suction valve (Service 1) Safety-suction valve (Service 2) 2-stage safety-suction valve (Service 1) Safety-suction valve (Arm Hi IN) Safety-suction valve (Bucket CURL) Suction valve (L.H. travel FORWARD) 2-stage safety-suction valve (Boom LOWER) Suction valve (R.H. travel FORWARD) Safety-suction valve (Arm IN) LS shuttle valve (Arm) LS shuttle valve (R.H. travel) LS select valve LS shuttle valve (Boom) LS shuttle valve (L.H. travel) LS shuttle valve (Bucket) LS shuttle valve (Service 1) LS shuttle valve (Service 2) LS check valve
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
23 Suction valve spring
Free length x Outside diameter
24 Check valve spring
PC300, 300LC, 350, 350LC-8M0
Repair limit
Installed length
Installed load
Free length
Installed load
40.6
5.5 N {0.56 kg}
—
4.4 N {0.45 kg}
46.8 x 7.5 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.
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7
SEN06268-01
10 Structure, function and maintenance standard Control valve
(3/5)
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8
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
1. 2. 3. 4.
SEN06268-01
Unload valve Safety valve (Boom RAISE) Main relief valve Variable back pressure valve
Arm valve 5. LS shuttle valve 6. Pressure compensation valve (IN) 7. Spool 8. Safety-suction valve (IN) 9. Regeneration circuit check valve 10. Safety-suction valve (OUT) 11. Pressure compensation valve (OUT) R.H. travel valve 12. LS shuttle valve 13. Pressure compensation valve (FORWARD) 14. Spool 15. Suction valve (FORWARD) 16. Suction valve (REVERSE) 17. Pressure compensation valve (REVERSE) Swing valve 18. LS select valve 19. Pressure compensation valve (R.H.) 20. Spool 21. Pressure compensation valve (L.H.)
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
22 Spool return spring
Free length x Outside diameter
23 Check valve spring
PC300, 300LC, 350, 350LC-8M0
Repair limit
Installed length
Installed load
Free length
Installed load
42.0
19.6 N {2.0 kg}
—
15.7 N {1.6 kg}
50.0 x 14.4 31.5 x 10.3
19.5
5.9 N {0.6 kg}
—
4.71 N {0.48 kg}
If damaged or deformed, replace spring.
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9
SEN06268-01
10 Structure, function and maintenance standard Control valve
(4/5)
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10
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
1. 2. 3. 4. 5. 6.
SEN06268-01
Return spring Merge-divide valve (for LS) Valve (Sequence valve) Spring (Sequence valve) Merge-divide valve (Main) Return spring
Boom valve 7. Drift prevention valve 8. LS shuttle valve 9. Pressure compensation valve (LOWER) 10. Spool 11. 2-stage safety-suction valve (LOWER) 12. Regeneration circuit check valve 13. Suction valve (RAISE) 14. Pressure compensation valve (RAISE) L.H. travel valve 15. Merge-divider valve (travel junction valve) 16. Return spring 17. LS shuttle valve 18. Pressure compensation valve (FORWARD) 19. Spool 20. Suction valve (FORWARD) 21. Suction valve (REVERSE) 22. Pressure compensation valve (REVERSE) Bucket valve 23. LS shuttle valve 24. Pressure compensation valve (CURL) 25. Spool 26. Safety-suction valve (CURL) 27. Safety-suction valve (DUMP) 28. Pressure compensation valve (DUMP) Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
46.6 x 21.8
33.0
157 N {16.0 kg}
—
126 N {12.8 kg}
30 Check valve spring
70.9 x 18.0
56.0
250 N {25.5 kg}
—
200 N {20.4 kg}
31 Spool return spring
64.5 x 32.3
63.0
178 N {18.1 kg}
—
142 N {14.5 kg}
32 Check valve spring
33.0 x 12.0
26.0
35.3 N {3.6 kg}
—
28.2 N {2.88 kg}
33 Check valve spring
16.4 x 8.9
11.5
13.7 N {1.4 kg}
—
11.0 N {1.12 kg}
34 Check valve spring
31.5 x 10.3
19.5
5.9 N {0.6 kg}
—
4.71 N {0.48 kg}
35 Piston return spring
30.7 x 20.5
23.0
50.0 N {5.1 kg}
—
40.0 N {4.08 kg}
29 Spool return spring
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
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11
SEN06268-01
10 Structure, function and maintenance standard Control valve
(5/5)
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12
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Control valve
SEN06268-01
Boom Hi and arm Hi valve 1. 2. 3. 4. 5. 6. 7.
Boom Hi check valve Quick return valve Pressure compensation valve (Arm Hi IN) Arm Hi spool Safety-suction valve (Arm Hi IN) Boom Hi spool Pressure compensation valve (Boom Hi RAISE)
Service valve 1 8. LS shuttle valve 9. Pressure compensation valve 10. Spool 11. 2-stage safety-suction valve 12. Safety-suction valve Service valve 2 13. LS shuttle valve 14. Pressure compensation valve 15. Spool 16. Safety-suction valve 17. Unload valve 18. Main relief valve 19. LS bypass plug 20. Slow return valve
PC300, 300LC, 350, 350LC-8M0
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13
10 Structure, function and maintenance standard CLSS
SEN06268-01
CLSS
1
Outline of CLSS
Features CLSS stands for Closed center Load Sensing System, which has the following characteristics. q q q
q
Fine control not influenced by load Controllability enabling digging even with fine control Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving by using variable pump control
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Configuration q CLSS is configured with variable capacity piston pumps, control valves, and respective actuators. q The hydraulic pump is configured with pump body, PC valve and LS valve.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard CLSS
SEN06268-01
Basic principle 1. q
q
Pump swash plate angle control The pump swash plate angle (pump discharge) is controlled so that LS differential pressure (ΔPLS) (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. [LS differential pressure (ΔPLS) = Pump discharge pressure (PP) – LS pressure (PLS)]
q
q
The pump swash plate angle shifts toward the maximum position if LS differential pressure (ΔPLS) is lower than the set pressure of the LS valve (when the actuator load pressure is high). If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate angle shifts toward the minimum position.
LS differential pressure (ΔPLS) and pump swash plate angle
a
PC300, 300LC, 350, 350LC-8M0
For details of functions, see the “Hydraulic pump” paragraph.
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SEN06268-01 2.
Pressure compensation control
q
A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When actuators are operated in combination, the pressure difference (ΔP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve.
q
q
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10 Structure, function and maintenance standard CLSS
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard CLSS 3.
System diagram
a
The illustration shows actuator (7) in the merge mode with stroke end at the time of relief.
PC300, 300LC, 350, 350LC-8M0
SEN06268-01
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Front pump Rear pump Main relief valve Unload valve Merge-divider valve Control valve Actuator Pump circuit LS circuit Tank circuit Valve Spring LS bypass valve LS valve PC valve
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Functions and operation by valve
1
Hydraulic circuit diagram and the name of valves
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18
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
Arm valve R.H. travel valve Swing valve Boom valve L.H. travel valve Bucket valve Boom Hi valve Arm Hi valve Service valve 1 Service valve 2 Spool (arm) Spool (R.H. travel) Spool (swing) Spool (boom) Spool (L.H. travel) Spool (bucket) Spool (boom Hi) Spool (arm Hi) Spool (service 1) Spool (service 2) Pressure compensation valve Pressure compensation valve Suction valve Check valve (for boom regeneration circuit) Check valve (for arm regeneration circuit) LS shuttle valve LS select valve Merge-divider valve Arm quick return valve Self pressure reducing valve Travel junction valve Variable back pressure valve Boom drift prevention valve Boom Hi check valve Main relief valve (bucket side) Set pressure: 36.1 ± 0.25 MPa {367.5 ± 2.5 kg/cm2} (112 l/min)
SEN06268-01
36. Main relief valve (arm side) Set pressure: 36.1 ± 0.25 MPa {367.5 ± 2.5 kg/cm2} (112 l/min) When digging force is increased: 38.2.1 ± 0.25 MPa {389.5.5 ± 2.5 kg/cm2} (110 l/min) 37. Unload valve (bucket side) Cracking pressure: 3.1 ± 0.5 MPa {32 ± 5 kg/cm2} 38. Unload valve (arm side) Cracking pressure: 3.1 ± 0.5 MPa {32 ± 5 kg/cm2} 39. Safety-suction valve (service 1) Set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2} 40. Safety-suction valve (dump, digging or arm Hi) Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2} 41. 2-stage safety-suction valve (service 1) Set pressure: 1 stage: 20.1 ± 0.5 MPa {205 ± 5 kg/cm2} 2 stage: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2} 42. 2-stage safety-suction valve (dump or digging) Set pressure: 1 stage: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2} 2 stage: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2} 43. Safety valve Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
When digging force is increased: 38.2 ± 0.25 MPa {389.5.5 ± 2.5 kg/cm2} (110 l/min)
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Unload valve 1.
When the unload valve is actuating
1. 2. 3.
LS circuit Valve Pump circuit
Function q Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are in the holding. q The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1). q Since LS pressure is drained from the LS bypass valve, LS pressure C tank pressure C 0 MPa{0 kg/cm2}.
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4. 5.
Tank circuit Spring
Operation q Pressure of pump circuit (3) is received by the end of valve (2). q Since the control valve is in neutral position, pressure of LS circuit (1) is 0 MPa{0 kg/cm2}. q Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available. q When this pressure becomes larger than the force of spring (5), valve (2) moves to the left. q Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (4). q The pressurized oil of LS circuit (1) passes from orifice (a) via port (c) and is drained to the tank circuit (4). q When actuated, LS pressure C tank pressure. q Since the pump discharge pressure - LS circuit pressure during unloading is larger than the pump LS control pressure, the signal is output to minimize the pump swash plate angle.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
2. q
q
During operation (a work within a scope of discharge by a minimum swash plate angle), the discharge pressure for the portion of minimum pump swash plate angle is set to LS pressure + P1 pressure. LS control differential pressure (ΔPLS) of discharge for the portion of minimum swash plate angle will be equal to P1 pressure.
q q q
q
q q
PC300, 300LC, 350, 350LC-8M0
Operation of relief valve When the cylinder reaches the stroke end, the main relief valve opens. The pump delivery (Q) is relieved to the tank.(See the system diagram) The pump discharge pressure (PP) and LS pressure (PLS) become approximately the same as each has not flow at the upstream and downstream of the spool, and LS differential pressure (ΔPLS) becomes 0 kg/cm2. As LS differential pressure (ΔPLS) is lower than the LS set pressure of LS valve, LS valve is actuated to maximize the pump swash plate angle. Mechanically, operation of PC valve is given priority over that of LS valve. The pump is held at a minimum swash plate angle by the cut-off function of PC valve.
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Introduction of LS pressure
1. 2. 3. 4. 5. 6. 7.
Hydraulic pump Main spool Pressure compensation valve Valve Check valve LS circuit LS shuttle valve
Function q Introduces the upstream pressure (downstream pressure of the spool meter-in) of pressure compensation valve (3) and leads to LS shuttle valve (7) as the LS pressure. q Connected to actuator port (B) via valve (4), and makes LS pressure C actuator load pressure. q The diameter of inlet pore (a) inside main spool (2) is small and it serves as a throttle concurrently. Operation When main spool (2) is operated, the pump pressure enters port (c) via inlet pore (a) and is led to the LS circuit. q When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens. q
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22
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
LS bypass plug
1. 2. 3. 4. 5. 6.
Hydraulic pump Main spool Pressure compensation valve LS shuttle valve LS bypass plug LS circuit
Function q Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b). q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure. q Bypass flow from LS bypass plug (5) causes a pressure loss due to the circuit resistance between throttle (c) of main spool (2) and LS shuttle valve (4). q Effective LS differential pressure drops to improve a dynamic stability of the actuator.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Pressure compensation valve 1.
During independent operation and under maximum load pressure
(If the load pressure is higher than other work equipment during a combined operation)
1. 2. 3.
Hydraulic pump Valve Shuttle valve
Function q Pressure compensation valve works as the load check valve. q If the pump pressure (LS pressure) is lower than the load at port (c), shuttle valve (3) in pressure compensation valve piston (4) interconnects spring chamber (E) and port (C). q The force of spring (5) operates piston (4) and valve (2) to the closing direction.
4. 5. 6.
Piston Spring LS shuttle valve
q
As principle, port (C) and spring chamber (E) are not interconnected in an integrated pressure compensation valve. If high peak pressure is generated at port (C), valve (7) does not collide with the valve chamber. With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is seated.
q
q
Integrated pressure compensation valve High stress may occur when valve (2) collides with valve chamber seat portion (C) if a high peak pressure is generated in the actuator circuit or repetitive peak pressure occurs continuously (example: when using the breaker). q To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used. q With the present machine, this device is adopted for the bucket valve (cylinder bottom) and the service valve. q
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 2.
SEN06268-01
When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function q The pressure compensation valve closes under LS pressure of port (D), and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment. q Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meterin differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure] becomes equivalent to all the spools in operation. q Pump flow is divided corresponding to the ratio of the meter-in opening area. Operation q Spring chamber (E) is interconnected to port (D). q Piston (4) and valve (2) operate in the closing direction (to the right) under the LS circuit pressure from other work equipment of port (F). q Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with LS pressure.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01 3.
10 Structure, function and maintenance standard Functions and operation by valve
Pressure compensation valve area ratio
Function q The state of division changes corresponding to the area ratio of pressure compensation portion (A1) and (A2). Area ratio = (A2)/(A1) q If area ratio = 1 : the spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure will be divided according to the opening area ratio. q If area ratio = 1 or over : the spool meter-in downstream pressure will be greater than the maximum load pressure, and the pressure will be divided smaller than the opening area ratio. q If area ratio = 1 or under : the spool meter-in downstream pressure will be smaller than the maximum load pressure, and the pressure will be divided greater than the opening area ratio.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Shuttle valve in pressure compensation valve 1.
If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1. 2. 3.
Hydraulic pump Valve Pressure compensation valve inner shuttle valve Piston
4.
Function q Shuttle valve (3) is pushed to the right by port (A) pressure and shut off interconnection between ports (A) and (C). q Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) and valve (2) will not be separated.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
When traveling
Outline q Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve without shuttle valve (3) is adopted.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Boom regeneration circuit 1.
If the cylinder head pressure is lower than the bottom pressure (hydraulic drift, etc.)
1. 2. 3. 4. 5. 6. 7.
Hydraulic pump Boom spool Pressure compensation valve Safety-suction valve Suction valve Check valve LS shuttle valve
Function q Provides the regeneration circuit from the cylinder bottom to the cylinder head when the boom is lowered and increases flow to the cylinder bottom.
PC300, 300LC, 350, 350LC-8M0
Operation q If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of boom spool (2). q On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head via circuit (D). q Flow from regeneration circuit (C) and pump (1) merges in circuit (E).
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
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30
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Arm regeneration circuit 1.
If the cylinder head pressure is higher than the bottom pressure
1. 2. 3. 4. 5. 6. 7.
Hydraulic pump Arm spool Pressure compensation valve Safety-suction valve Suction valve Check valve LS shuttle valve
Function q When moving arm to IN position, regeneration circuit provided from the cylinder head to the bottom increases the cylinder speed as the cylinder flow involves the pump delivery plus regenerated flow.
PC300, 300LC, 350, 350LC-8M0
Operation q If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain circuit (B) from the notch of arm spool (2). q On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head via circuit (D). q Flow from regeneration circuit (C) and pump (1) merges in circuit (E).
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
If the cylinder head pressure is lower than the bottom pressure
Function q Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
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32
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Merge-divider valve 1.
When flows from the pumps merge [if pilot pressure (PS) is OFF]
1. 2. 3. 4.
Main spool Spring LS spool Spring
Function q Merges pressurized oil (P1) and (P2) discharged from the 2 pumps or divides (to respective control valve group). q Merges and divides LS circuit pressure.
PC300, 300LC, 350, 350LC-8M0
5. 6. 7. 8.
LS circuit (bucket side) LS circuit (bucket side) LS circuit (arm side) LS circuit (arm side)
Operation q Since pilot pressure (PS) is OFF, output pressure from PPC valve is 0 kg/cm2. q Main spool (1) is pressed to the right by spring (2) and ports (E) and (F) are interconnected. q Merges pressurized oil (P1) and (P2) discharged from the 2 pumps at ports (E) and (F) and sends to necessary control valve. q Since pilot pressure (PS) is OFF for LS spool (3), it is pressed to the right by spring (4), then ports (A) and (D), ports (B) and (C) are interconnected respectively. q Forwards LS pressure led from respective control valve spools to LS circuits (5), (6), (7) and (8) to all the pressure compensation valves.
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation q Pilot pressure (PS) turns ON, and output pressure from the PPC valve shifts main spool (1) to the left, and ports (E) and (F) are divided. q Pressurized oil discharged from the 2 pumps are sent to respective control valves. P1 pressure: To bucket, L.H. travel, and boom P2 pressure: To swing, R.H. travel, and arm q
q
LS spool (3) too shifts to the left under the output pressure from the PPC valve, interconnects ports (A) and (C) and divides other ports. Forwards LS pressure led from each control valve spool to LS circuits (5), (6), (7) and (8) to respective control valves.
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34
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
LS select valve Function q This valve prevents high LS pressure from the swinging from entering the LS circuit of work valves while the swinging and work equipment are in combined operation. q This valve prevents high pressure generated during swing drive and improves operability of work equipment.
Operation 1. If pilot pressure (BP) is OFF q Since pilot pressure (BP) is OFF, piston (3) is pressed to the left by spring (2). q When swing-operated, swing LS pressure (P1) enters port (A) after passing swing spool (5). q Valve (1) is pressed to the left and ports (A) and (B) are interconnected. q Swing LS pressure (P1) flows to LS shuttle valve (8).
2. q
q q q
a
The illustration shows the state of simultaneous operation of swinging and R.H. travel. [(BP) pressure ON]
1. 2. 3. 4. 5. 6. 7. 8. 9.
Valve Spring Piston Piston Swing spool L.H. travel spool Arm spool LS shuttle valve LS circuit
PC300, 300LC, 350, 350LC-8M0
If pilot pressure (BP) is ON If pilot pressure (BP) is ON, BP pressure contracts spring (2), and piston (3) shifts to the right. Valve (1) is pressed to the right and interconnection between ports (A) and (B) is closed. Swing LS pressure (P1) stops flowing to LS shuttle valve (8). If swing LS pressure (P1) rises, other LS circuits are not affected.
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35
SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Self pressure reducing valve Function q Reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves, EPC valves, etc. Operation 1. While engine is stopped q Poppet (11) is pressed by spring (12) against the seat and port (PR) is not connected to (TS). q Valve (14) is pressed by spring (13) against the left side and port (P2) is connected to (TS). q Valve (7) is pressed by spring (8) against the left side and port (P2) is closed to (A2).
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36
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 2. a
During neutral and when load pressure (P2) is low When load pressure (A2) is lower than self pressure reducing valve output pressure (PR)
SEN06268-01 3. q
q q
q
q q q
q
q
Valve (7) is pressed to the closing direction of circuit between ports (P2) and (A2) by spring (8) and under pressure (PR) (which is 0 MPa {0 kg/cm2}). When pressurized oil flows in from port (P2), a balance is reached due to [(φd area x P2 pressure) = force of spring (8) + ( φ d area x PR pressure)]. Adjusts valve (7) opening to keep pressure (P2) at a constant level over pressure (PR). When pressure (PR) rises above the set pressure, poppet (11) opens. Pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from poppet (11) opening. Differential pressure is generated before and after orifice (a) in spool (14) and then spool (14) moves to close the pass between ports (P2) and (PR). Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR).
PC300, 300LC, 350, 350LC-8M0
q
q q
q
q
When load pressure (P2) is high Load pressure (A2) increases with the operation of digging, etc., and the pump discharge increases accordingly. Pressure (P2) increases to [(φd area x P2 pressure) = force of spring (8) + ( φ d area x PR pressure)]., and valve (7) moves to the right to the stroke end. As a result, opening between ports (P2) and (A2) increases, and the pass resistance reduces, reducing the engine horsepower loss. When pressure (PR) rises above the set pressure, poppet (11) opens. Pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from poppet (11) opening. Differential pressure is generated before and after orifice (a) in spool (14) and then spool (14) moves to close the pass between ports (P2) and (PR). Pressure (P2) is reduced by the opening at this time and adjusted to a constant pressure (the set pressure) and supplied as pressure (PR).
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SEN06268-01 4. q
q q
10 Structure, function and maintenance standard Functions and operation by valve
When abnormally high pressure is generated If pressure (PR) of self pressure reducing valve becomes abnormally high, ball (16) contracts spring (15) and becomes separated from the seat. Allows the pressurized oil to (TS) from port (PR) and lowers pressure (PR). Protects PPC valve, solenoid valve and other devices from abnormal pressure.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Travel junction valve 1.
When pilot pressure is turned ON
Function q This valve connects the L.H. and R.H. travel circuits via travel junction valve so that the hydraulic oil will be supplied evenly to both travel motors to improve machine's straight travel performance. q When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to improve steering performance. PC300, 300LC, 350, 350LC-8M0
Operation q Pilot pressure from the travel junction solenoid valve contracts spring (1), and travel junction spool (2) moves to the left to the stroke end. q Junction circuit between port (PTL) (L.H. travel circuit) and port (PTR) (R.H. travel circuit) is closed.
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
When pilot pressure is turned OFF
Operation q If pilot pressure (PST) from the solenoid valve is 0, travel junction spool (2) is pressed by the force of spring (1) against the right side and the pass between ports (PTL) and (PTR) is open.
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40
q
If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the oil flows through the route between port (PTL), travel junction spool (2), and port (PTR) so that the oil flow rates to both motors will be equalized again.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Travel PPC shuttle valve 1.
When travel lever is in neutral
Function q Regulates flow to each cylinder by controlling the stroke of each spool of the boom, arm, and bucket using the pilot pressure of travel PPC valve while climbing a steep grade, operating the boom RAISE, arm IN, arm OUT, bucket CURL, bucket DUMP. q When controlling the stroke of the boom, arm and/or bucket, pilot pressure of travel PPC valve passes through the circuit inside the control valves to actuate the system.
PC300, 300LC, 350, 350LC-8M0
Operation q The oil in stroke regulation signal chamber (a) is drained through orifices (5) and (6) of pistons (3) and (4) in the travel spring case and the travel PPC valve. q When operating boom RAISE, (or arm IN, arm OUT, bucket CURL, bucket DUMP), spool (1) moves to the left until it makes contact with the end face of spring casing (2) (st0).
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
When traveling
Operation q If the right travel lever is set in the reverse (or forward) direction, pilot pressure from the PPC valve presses spool (7) to the left (or right). q Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber (a) and the drain circuit of the travel PPC valve. q At this time, the right travel reverse (or forward) lever is set, PPC pressure is applied through orifice (6) of piston (4) to the left end of piston (8) to push piston (8) to the right. q When operating boom RAISE, (or arm IN, arm OUT, bucket CURL, bucket DUMP), spool (1) moves to the left.
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q
Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
Boom drift prevention valve 1.
When raising boom
Function q This valve prevents the oil in the boom cylinder bottom from leaking through spool (1) and the boom from lowering under its weight while the boom lever is not operated. Operation q When moving arm to OUT position, pressurized oil from the control valve works on the ring-shaped area (S)[= φ(d1) area – φ(d2) area] caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the left. q Contracts spring (4) and poppet (5) moves to the left. q As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the bottom end of the boom cylinder.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01 2.
10 Structure, function and maintenance standard Functions and operation by valve
When the boom is in neutral
Operation q Moves the lever to neutral with the boom raised. q Pressurized oil flown inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2). q The holding pressure of boom cylinder bottom works on the ring-shaped area (S) caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right. q The sum of this force and the force of spring (4) closes poppet (5). q Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 3.
SEN06268-01
When lowering boom
Operation q When the boom is lowered, pilot pressure from the PPC valve presses pilot spool (2). q Pressurized oil in chamber (b) inside the poppet is drained via orifice (c). q Pressurized oil of the boom bottom flows to orifice (a) o chamber (b) o orifice (c) o drain (T), and the pressurized oil in chamber (b) lowers. q As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens. q Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Arm drift prevention valve (if equipped) 1.
When arm OUT
Function q This valve prevents the oil in the arm head from leaking through spool (1) and the boom from lowering under its weight while the arm lever is not operated. Operation q When moving arm to OUT position, pressurized oil from the control valve works on the ring-shaped area (S)[= φ(d1) area – φ(d2) area] caused by the difference between the outside diameter (d1) of poppet (5) and the seat diameter (d2) to move it to the left. q Contracts spring (4) and poppet (5) moves to the left. q As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder head.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 2.
SEN06268-01
When the arm is in neutral
Operation q Moves the lever to neutral with the arm at OUT position. q Pressurized oil flown inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2). q The holding pressure of arm cylinder head works on ring-shaped area (S) caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right. q The sum of this force and the force of spring (4) closes poppet (5). q Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01 3.
10 Structure, function and maintenance standard Functions and operation by valve
When arm IN
Operation q When moving arm to IN position, pilot spool (2) is pushed under the pilot pressure from the PPC valve. q Pressurized oil in chamber (b) inside the poppet is drained via orifice (c). q Pressurized oil of the arm head flows to orifice (a) o chamber (b) o orifice (c) o drain (T), and the pressurized oil in chamber (b) lowers. q As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens. q Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 4.
When abnormally high pressure is generated
q
If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes check valve (6) open, then safety valve (3) operates.
PC300, 300LC, 350, 350LC-8M0
SEN06268-01
q
If arm drift prevention valve (optional) is installed to the arm cylinder head circuit, the boom cylinder bottom circuit pressure force or arm cylinder head circuit pressure force, whichever having higher pressurized oil, pushes check valve (6) or (6A) open to actuate safety valve (3).
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Quick return valve 1.
When arm OUT
Function q When moving arm to OUT position, large volume of oil returns from the cylinder bottom. q Reduces this pressure loss. Operation q When moving arm to OUT position, pilot spool (1) is pushed under the pilot pressure from the PPC valve. q Pressurized oil in chamber (b) inside the valve is drained via orifice (c). q Pressurized oil of the arm bottom side flows to orifice (a) o chamber (b) o orifice (c) o drain (T), and the pressure in chamber (b) lowers. q If the pressure of chamber (b) drops lower than that of port (A), pressure receiving force of the pressure receiving portion [φd2 area (S2) (seat d ia m e t e r a r e a ) ] o n t h e s i d e o f p o r t ( A )
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q q q
increases by the sum of the pressure receiving force of pressure receiving portion[φd1 area (S1)] on the chamber (b) side of valve (2) and the spring force. Or (φd2 pressure receiving force > φd1 pressure receiving force + spring force) Valve (2) is pressed to the left and pressurized oil is led from port (A) to (B). From port (B), pressurized oil is drained directly to the tank.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve 2.
SEN06268-01
When the arm is in neutral
Operation q Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/cm2. q The pressurized oil that has flowed and been drained through orifice (a) in valve (2) is closed by pilot piston (1). q The holding pressure on the arm bottom side works on the difference between areas (S2) and (S1) of valve (2) to the right. q Valve (2) is closed by the total of this force and the force of spring (3), so ports (A) and (B) are shut off.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Variable back pressure valve
Function q This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in each actuator circuit (motors, cylinders, etc). q In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation other than the travel and swing is performed. Operation When engine is stopped q Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1). q No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and valve (6) is pressed to the right by the reaction force of spring (5). q Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
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When engin is running (during swing or travel operation) q The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid valve (3). q Since drive signal (IS3) of variable back pressure solenoid valve (3) is OFF, pressurized oil (PR) is flown to spring chamber (C) of variable back pressure valve (4). q Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6) (surface of φd), and it pushes valve (6) to the right as a combined force with the reaction force of spring (5). q Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of φd1) to push valve (6) to the left. q Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA=(Area of surface φd) x Pressure (PR) + Reaction force of spring (5) / Area of surface φd1. q Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words, the set pressure of variable back pressure valve (4) is adjusted.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
When engin is running (during swing or travel operation) q The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve (3). q Since drive signal (IS3) of variable back pressure solenoid valve (3) is ON, pressurized oil (PR) from self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained through variable back pressure solenoid valve (3). q Only the reaction force of spring (5) pushes valve (6) to the right. q Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of φd1) to push valve (6) to the left. q Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA=Reaction force of spring (5) / Area of surface φd1. q Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words, the set pressure of variable back pressure valve (4) is adjusted.
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01
10 Structure, function and maintenance standard Functions and operation by valve
Main relief valve
1. 2.
Spring Poppet
Function q Set pressure of the relief valve is in 2 stages. q When power is needed, pilot pressure (P) is turned ON and the set pressure becomes higher. Operation The set pressure of relief valve is determined by spring (1) installed load. (1st stage) q Respective setting is not required for both the 1st and 2nd stages. Setting the 1st stage completes the setting of the 2nd stage. q
1.
If pilot pressure (P) is OFF: Low-pressure setting Set pressure is determined by spring (1) installed load.
2.
If pilot pressure (P) is ON: High-pressure setting Spring (1) installed load is added with pilot pressure (P) applied to the area of poppet diameter (d1), raising the set pressure to higher level.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Functions and operation by valve
SEN06268-01
2-stage safety-suction valve
[Installed to port (B) on the boom cylinder head side and port (B) of the service valve]
1. 2. 3. 4.
Spring Piston Spring Holder
Function q Enables to provide the safety valve set pressure in 2 stages, and make the low-pressure setting smaller. q Enables to relieve a load without lever operation if high load is applied to the cylinder. q Improves work efficiency and reduces machine body vibration.
Operation q The safety set pressure is determined by spring (1) installed load. 1. q
q q
PC300, 300LC, 350, 350LC-8M0
If pilot pressure is OFF (high-pressure setting) Since pilot pressure (P) is OFF, piston (2) is pressed to the left by spring (3). [Spring (1) installed load < spring (3) installed load] Spring (1) installed load becomes maximum and the set pressure rises. Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
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SEN06268-01 2. q q q
q q
10 Structure, function and maintenance standard Functions and operation by valve
If pilot pressure is ON (low-pressure setting) If the pilot pressure (P) is ON, the pilot pressure is led to section (A) via passage (B). Piston (2) works on the pressure-receiving bore portion [(d2) – (d1)] of section A. This pilot pressure contracts spring (3), and piston (2) moves to the right until making contact with holder (4). Spring (1) stretches, installed load is reduced, and the set pressure lowers. Pressurized oil proportionate to the piston stroke is drained via passage (C) and chamber (D).
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Attachment circuit selector valve
SEN06268-01
Attachment circuit selector valve
ACC: ATT: P1: T: TS: V:
To accumulator To attachment From attachment selector solenoid valve To hydraulic oil tank To hydraulic oil tank To control valve
1
1. 2.
Spool Spring
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
3
Spool return spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
132 x 29
114.5
834 N {85.0 kg}
—
667 N {68.0 kg}
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
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SEN06268-01
10 Structure, function and maintenance standard Attachment circuit selector valve
Function q 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. q When other attachments (crusher, etc.) are installed, the attachment and the main valve are interconnected. Operation 1. When attachment other than breaker is installed q Spool (1) is pressed to the left by the force of spring (2). q Ports (ATT) and (V) are interconnected and ports (ATT) and (T) are shut off. Attachment is thus interconnected to the control valve.
2. q
q q
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When breaker is installed Pilot pressure from the attachment circuit selector solenoid valve contracts spring (2), and spool (1) moves to the right to the stroke end. Ports (ATT) and (V) are shut off and ports (ATT) and (T) are interconnected. Pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without passing through the control valve.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Attachment circuit selector valve
PC300, 300LC, 350, 350LC-8M0
SEN06268-01
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SEN06268-01
10 Structure, function and maintenance standard Hydraulic drift prevention valve
Hydraulic drift prevention valve 1 (For the boom and arm)
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic drift prevention valve CY: PCY: PI: T: V: 1. 2. 3. 4. 5. 6.
SEN06268-01
To work equipment cylinder For pressure pickup port and equalizer circuit From PPC valve To tank From control valve
Pilot spool Spring (1st stage spool) Spring (2nd stage spool) Safety valve Check valve Spring
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
7 Check valve spring
Repair limit
Free length x Outside diameter
Installed length
Installed load
Free length
Installed load
20.8 x 12.2
13.5
12.7 N {1.3 kg}
—
10.2 N {1.04 kg}
—
47.1 N {4.8 kg}
8 Spool return spring
41.1 x 9.6
35.0
58.8 N {6.0 kg}
9 Spool return spring
41.9 x 25.8
41.0
78.5 N {8.0 kg}
—
62.8 N {6.4 kg}
10 Spool return spring
44.6 x 25.6
41.0
181 N {18.5 kg}
—
145 N {14.8 kg}
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
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SEN06268-01
10 Structure, function and maintenance standard Hydraulic drift prevention valve
Function q This valve prevents the pressurized oil from reversing from the work equipment cylinder and the latter from a sudden drop if the piping bursts between the control valve and the work equipment cylinder. Operation 1. When the work equipment lever is in neutral When the piping is free of burst q Check valve (5) is closed under the holding pressure of the cylinder led from port (CY) to chamber (b). q Pilot pressure led to port (PI) from the PPC valve when in neutral is 0 MPa {0 kg/cm2}. q Spool (1) is pressed to the left by the force of springs (2) and (3) q Chambers (a) and (b) are shut off. q No pressurized oil flows between the control valve and the work equipment cylinder. q Accordingly, the work equipment is held in position. q If the work equipment cylinder has abnormally high pressure, safety valve (4) is actuated by the holding pressure of the work equipment cylinder. q Chambers (b) of L.H. and R.H. hydraulic drift prevention valve for the boom are interconnected by port (PCY). q Chambers (b) will have the same pressure if the L.H. and R.H. hydraulic drift prevention valves have a difference in leakage.
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If the piping is bursted q If piping (A) bursts between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off same as when the piping has no burst. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic drift prevention valve 2.
SEN06268-01
When pressurized oil flows from the main valve to the cylinder
When the piping is free of burst q Pressurized oil led to chamber (a) from the control valve becomes higher than the combined force of pressure from work equipment cylinder circuit chamber (b) and spring (6). q Check valve (5) opens and chambers (a) and (b) are interconnected. q Pressurized oil flows from the control valve to the work equipment cylinder. If the piping is bursted If piping (A) bursts between the control valve and the work equipment cylinder, pressurized oil in chamber (a) flows outside from the bursted portion. q Pressure force in chamber (a) drops. q Pressure force in chamber (a) drops lower than the combined pressure force of chamber (b) and spring (6). q Check valve (5) closes and chambers (a) and (b) are shuft off. q Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment. q
PC300, 300LC, 350, 350LC-8M0
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SEN06268-01 3.
10 Structure, function and maintenance standard Hydraulic drift prevention valve
When returning pressurized oil to the main valve from the work equipment cylinder
When the piping is free of burst q Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5) closes. q Pilot pressure from the PPC valve is led to port (PI) and reaches [Pilot Pressure > Force of Spring (3)] (area of d). q Spool (1) moves to the right to the standby position. (1st stage stroke) q At this point, chambers (a) and (b) are not interconnected. q Pilot pressure further rises, and reaches [Pilot pressure > Force of spring (2)] (area of d). q Spool (1) moves further to the right, and chambers (a) and (b) are interconnected. (2nd stage stroke) q Pressurized oil returns to the control valve from the work equipment cylinder.
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If the piping is bursted q If piping (A) bursts between the control valve and the work equipment cylinder. q Pressurized oil in chamber (a) flows out to the bursted portion but resupplied from chamber (b). q Since pressurized oil flows via opening (c) of spool (1), a sudden drop of the cylinder is prevented.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Hydraulic drift prevention valve
PC300, 300LC, 350, 350LC-8M0
SEN06268-01
10-402
65
SEN06268-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06268-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
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SEN06269-02
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard
1
403 Hydraulic system, Part 3 Valve control................................................................................................................................................... 2 PPC valve ...................................................................................................................................................... 4 Solenoid valve.............................................................................................................................................. 24 PPC accumulator ......................................................................................................................................... 26 Anti-drop valve for boom .............................................................................................................................. 28 Anti-drop valve for arm................................................................................................................................. 34 Center swivel joint ........................................................................................................................................ 41 Travel motor ................................................................................................................................................. 43 Swing motor ................................................................................................................................................. 55 Work equipment cylinder.............................................................................................................................. 63
PC300, 300LC, 350, 350LC-8M0
10-403
1
SEN06269-02
Valve control
10-403
2
10 Structure, function and maintenance standard Valve control
1
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Valve control
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H travel lever R.H. PPC valve R.H. work equipment control lever Solenoid block Accumulator Control valve Hydraulic pump Junction box L.H. work equipment control lever L.H. PPC valve
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
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. Swing (RIGHT) K. Swing (LEFT) L. Neutral M. Travel (REVERSE) N. Travel (FORWARD)
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3
SEN06269-02
10 Structure, function and maintenance standard PPC valve
PPC valve
1
PPC: Abbreviation for Proportional Pressure Control
Work equipment and swing PPC valve 1
P: P1: P2: P3: P4: T:
From self pressure reducing valve L.H. PPC valve: Arm OUT port/R.H. PPC valve: Boom LOWER port L.H. PPC valve: Arm IN port/R.H. PPC valve: Boom RAISE port L.H. PPC valve: Swing LEFT port/R.H. PPC valve: Bucket CURL port L.H. PPC valve: Swing RIGHT port/R.H. PPC valve: Bucket DUMP port To hydraulic tank
10-403
4
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
10-403
5
10 Structure, function and maintenance standard PPC valve
SEN06269-02
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Piston Disc Nut (for lever connection) Joint Plate Retainer Body Filter Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
10
Centering spring (for ports P3 and P4)
Free length x Outside diameter
Repair limit
Installed length
Load at installed length
Free length
Load at installed length
42.5 x 15.5
34.0
17.7 N {1.80 kg}
—
14.1 N {1.44 kg}
11
Centering spring (for ports P1 and P2)
44.5 x 15.5
34.0
29.4 N {3.0 kg}
—
23.5 N {2.40 kg}
12
Metering spring
26.5 x 8.15
24.9
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
10-403
6
If damaged or deformed, replace spring.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
Operation
SEN06269-02
q
1. When in neutral q
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).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, 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.
2. During fine control (Neutral o fine control) q
q
q
q
q
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). 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). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
PC300, 300LC, 350, 350LC-8M0
10-403
7
SEN06269-02
3. During fine control (When control lever is returned) q
q
q
q
q
q
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). 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 of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the 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 replenish the chamber with pressurized oil.
10-403
8
10 Structure, function and maintenance standard PPC valve
4. At full stroke q q
q
q
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 interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push 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).
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
Travel PPC valve
P P1 P2 P3 P4 T
SEN06269-02
1
: From self-pressure reducing valve : To control valve (L.H. travel REVERSE port) : To control valve (L.H. travel FORWARD port) : To control valve (R.H. travel REVERSE port) : To control valve (R.H. travel FORWARD port) : To hydraulic tank
PC300, 300LC, 350, 350LC-8M0
10-403
9
SEN06269-02
1. 2. 3. 4. 5. 6.
10 Structure, function and maintenance standard PPC valve
Plate Case Piston Seal Spool Damper
10-403
10
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
SEN06269-02
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
7
8
Centering spring
Metering spring
PC300, 300LC, 350, 350LC-8M0
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
48.6 x 15.5
32.5
108 N {11.0 kg}
—
86.3 N {8.8 kg}
26.5 x 8.15
24.9
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
If damaged or deformed, replace spring.
10-403
11
SEN06269-02
1. Pressure reducing valve function
10 Structure, function and maintenance standard PPC valve
q
Operation 1) When in neutral q 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).
q q q
The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) contracts in proportion to the stroke of the control lever. Pressure at port (P1) also rises in proportion to the stroke of the control lever. In this way, 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.
2) During fine control (Neutral o fine control) q When piston (4) is pushed by lever (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. q When fine control hole (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). q Pilot pressurized oil of the control pump is led to port (A) from port (P1) through fine control hole (f). q 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). q As a result, spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1). 10-403
12
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
3) During fine control (When control lever is returned) q
q
q
q
q
q
When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and 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 of port (P1) is lowered excessively, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. When the spool of the control valve returns, the 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 replenish the chamber with pressurized oil.
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
4) At full stroke q q
q
q
Lever (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 interconnected to pump pressure chamber (PP). Therefore, the pilot pressure oil from the self pressure reducing valve passes through fine control hole (f) and flows to chamber (A) from port (P1) to push 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).
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13
10 Structure, function and maintenance standard PPC valve
SEN06269-02
Service PPC valve (with EPC valve)
a
1
For the details of operation, see the paragraph of “Work equipment swing PPC valve.”
10-403
14
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
P: P1: P2: T:
From self pressure reducing valve To service valve To service valve To hydraulic tank
1. 2. 3. 4. 5. 6. 7.
Spool Piston Lever Plate Retainer Body EPC valve
SEN06269-02
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
8
9
Centering spring
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
33.9 x 15.3
28.4
125 N {12.7 kg}
—
100 N {10.2 kg}
22.7 x 8.10
22.0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
Metering spring
PC300, 300LC, 350, 350LC-8M0
Free length
Load at installed length
If damaged or deformed, replace spring.
10-403
15
10 Structure, function and maintenance standard PPC valve
SEN06269-02
1. EPC valve
C: P: T:
To control valve From self pressure reducing valve To hydraulic tank
1.
Body
2. 3. 4. 5. 6.
Spool Push pin Coil Plunger Connector Unit: mm
No.
Check item
Criteria
Remedy
Standard dimension
7
Return spring
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16
Repair limit
Free length
Installed length
Load at installed length
Free length
Load at installed length
9.5
8.4
3.1 N {0.32 kg}
—
2.5 N {0.26 kg}
If damaged or deformed, replace PPC valve assembly.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
SEN06269-02
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q 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 control valve.
PC300, 300LC, 350, 350LC-8M0
10-403
17
SEN06269-02
10 Structure, function and maintenance standard PPC valve
Operation 1) When signal current is 0 (coil is de-energized) When there is no signal current flowing from the controller to coil (4), coil (4) is de-energized. q Spool (2) is pushed to the left by spring (3). q Port (C) closes and the pressurized oil from the front pump does not flow to the control valve. q The pressurized oil from the control valve is drained to the tank through port (C) and port (T). q
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18
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
SEN06269-02
2) When signal current is very small (coil is energized) q When a very small signal current flows to coil (4), coil (4) is energized, and a propulsion force is generated on the right side of plunger (5). q Push pin (6) pushes spool (2) to the right, and pressurized oil flows from port (P) to port (C). q Pressures on port (C) increases and the force to act on surface (a) of spool (2) and the spring load on spring (3) become larger than the propulsion force of plunger (5). q Spool (2) is pushed to the left, port (P) is shut off from port (C) and ports (C) and (T) are connected. q Spool (2) moves so that the propulsion force of plunger (5) may be balance with pressure of port (C) + spring load of spring (3). q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current.
PC300, 300LC, 350, 350LC-8M0
10-403
19
SEN06269-02
10 Structure, function and maintenance standard PPC valve
3) When signal current is maximum (coil is energized) As the signal current flows to coil (4), coil (4) is energized. q The signal current is at maximum at this time, so the propulsion force of plunger (5) is also at its maximum. q Spool (2) is pushed to the left by push pin (6). q The maximum volume of pressurized oil is conducted from port (P) to port (C), increasing the circuit pressure across EPC valve and the control valve to the maximum level. q Since port (T) is closed, pressurized oil does not flow to the hydraulic tank. q
10-403
20
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
10-403
21
10 Structure, function and maintenance standard PPC valve
SEN06269-02
Service PPC valve
a
1
For the details of operation, see the paragraph of “Work equipment and swing PPC valve“.
10-403
22
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC valve
P: P1: P2: T:
From self pressure reducing valve To service valve To service valve To hydraulic tank
1. 2. 3. 4. 5. 6.
Spool Piston Lever Plate Retainer Body
SEN06269-02
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
7
8
Centering spring
Repair limit
Free length x Outside diameter
Installed length
Load at installed length
Free length
Load at installed length
33.9 x 15.3
28.4
125 N {12.7 kg}
—
100 N {10.2 kg}
22.7 x 8.10
22.0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
Metering spring
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
10-403
23
10 Structure, function and maintenance standard Solenoid valve
SEN06269-02
Solenoid valve
1
PPC lock, travel junction, merge-divider, travel speed, swing brake, machine push-up and 2-stage relief solenoid valves
T: A1: A2: A3: A4: A5: A6:
To tank To PPC valve To main valve (Travel junction valve) To main valve (Merge-divider valve) To both travel motors To swing motor To main valve (2-stage safety valve at boom cylinder head) A8: To main valve (2-stage relief valve) P1: From main pump ACC: To accumulator
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24
1. 2. 3. 4. 5. 6. 7.
PPC lock solenoid valve Travel junction solenoid valve Merge-divider solenoid valve Travel speed solenoid valve Swing brake solenoid valve Machine push-up solenoid valve 2-stage relief solenoid valve
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Solenoid valve
1. 2. 3.
Connector Moving core Coil
Operation When solenoid is de-energized q Since the signal current does not flow from the controller, solenoid (3) is de-energized. For this reason, spool (4) is pushed to the left by spring (6). By this operation, the pass from port (P) to port (A) is closed and the pressurized oil from the main pump does not flow into the actuator. At this time, the oil from the actuator is drained through ports (A) and (T) into the tank.
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
4. 5. 6.
Spool Block Spring
When solenoid is energized q The signal current flows from the controller to solenoid (3), and the latter is energized. Accordingly, spool (4) is pushed to the right side. By this operation, the pressurized oil from the main pump flows through port (P) and spool (4) to port (A), then flows into the actuator. At the same time, port (T) closes and stops the oil from flowing to the tank.
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25
SEN06269-02
10 Structure, function and maintenance standard PPC accumulator
PPC accumulator
1 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Specifications Gas capacity: 300 cc (for PPC)
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26
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard PPC accumulator
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
10-403
27
SEN06269-02
Anti-drop valve for boom
10 Structure, function and maintenance standard Anti-drop valve for boom
1
(Machine with anti-drop valve for boom)
Structure General view
10-403
28
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for boom
SEN06269-02
CY: To work equipment cylinder PCY: For pressure pickup and equalize circuit PI: From PPC valve T: To hydraulic tank V: From control valve 1: Pilot spool 2: Spring (1st level of spool) 3: Spring (2nd level of spool) 4: Safety valve 5: Check valve 6: Spring (check valve)
Function This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks.
PC300, 300LC, 350, 350LC-8M0
10-403
29
SEN06269-02
10-403
30
10 Structure, function and maintenance standard Anti-drop valve for boom
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for boom
SEN06269-02
Unit: mm No.
Check item
Criteria Standard size
1
Check valve spring
Remedy Repair limit
Free length Installation x Outside length diameter
Load at installed height
Free length
Load at installed height
20.8 × 12.2
13.5
12.74 N {1.3 kg}
—
10.2 N {1.0 kg}
2
Spool return spring
41.1 × 9.6
35.0
58.8 N {6.0 kg}
—
47.0 N {4.8 kg}
3
Spool return spring
41.85 × 25.8
41.0
78.4 N {8.0 kg}
—
62.7 N {6.4 kg}
PC300, 300LC, 350, 350LC-8M0
Replace (Replace spring if damaged or deformed as well)
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SEN06269-02
Operation When work equipment is in NEUTRAL When there is no damage in the piping 1. Holding pressure of the work equipment cylinder is led from port (CY) to chamber (b), and it closes check valve (5). 2. The pilot pressure which is led from PPC valve to port (PI) is 0 MPa{0 kg/cm 2 } when work equipment is in NEUTRAL. 3. Spool (1) is pressed to the left by the force of springs (2) and (3). 4. Chamber (a) and chamber (b) are disconnected. 5. The pressurized oil does not flow from control valve to work equipment cylinder. The work equipment cylinder is held. 6. When the pressure inside the work equipment cylinder is abnormally high, holding pressure of the work equipment cylinder operates safety valve (4). 7. Chambers (b) of anti-drop valves on the right and left are interconnected at port (PCY). 8. The pressures of chambers (b) are the same even when there is a difference of leakage amount between the anti-drop valves on the right and left. When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, chamber (a) and chamber (b) are disconnected. 2. The pressure of the work equipment is held to prevent the work equipment from sudden lowering.
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10 Structure, function and maintenance standard Anti-drop valve for boom
When the pressurized oil flows from the control valve to the work equipment cylinder When there is no damage in the piping 1. The pressurized oil which is led from the control valve to chamber (a) becomes higher than the combined force of the pressure of chamber (b) of work equipment cylinder circuit and spring (6). 2. Check valve (5) opens, and chamber (a) and chamber (b) are connected. 3. The pressurized oil flows from the control valve to the work equipment cylinder. When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part to the outside. 2. The pressure of chamber (a) drops. The pressure of chamber (a) becomes lower than the combined force of the pressure of chamber (b) and spring (6). 3. Check valve (5) closes, and chamber (a) and chamber (b) are disconnected. 4. The pressure of the work equipment is held to prevent the work equipment from sudden lowering.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for boom
SEN06269-02
When the pressurized oil returns from the work equipment cylinder to the control valve When there is no damage in the piping 1. Holding pressure of the work equipment cylinder is led to chamber (b), and it closes check valve (5). 2. The pilot pressure is led from PPC valve to port (PI). The pilot pressure is larger than the force of spring (2) (area of circle "d"). 3. Spool (1) moves rightward to the standby position. (The first stroke) 4. Chamber (a) and chamber (b) are not interconnected. 5. The pilot pressure rises further. The pilot pressure is larger than the force of spring (2) (area of circle "d"). 6. Spool (1) moves rightward further, and chamber (a) and chamber (b) are interconnected. (The second stroke) 7. The pressurized oil returns from the work equipment cylinder to the control valve. When there is a damage in the piping 1. When the piping (A) gets damaged in the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part. 2. The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equipment from sudden lowering.
PC300, 300LC, 350, 350LC-8M0
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33
SEN06269-02
Anti-drop valve for arm
10 Structure, function and maintenance standard Anti-drop valve for arm
1
(Machine with anti-drop valve for arm)
Structure General view
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34
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for arm
SEN06269-02
CY: To work equipment cylinder PCY: For pressure pickup and equalize circuit PI: From PPC valve T: To hydraulic tank V: From control valve 1: Pilot spool 2: Spring (1st level of spool) 3: Spring (2nd level of spool) 4: Safety valve 5: Check valve 6: Spring (check valve)
Function This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil from the work equipment when the piping between the control valve and the work equipment cylinder breaks.
PC300, 300LC, 350, 350LC-8M0
10-403
35
SEN06269-02
10-403
36
10 Structure, function and maintenance standard Anti-drop valve for arm
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for arm
SEN06269-02
Unit: mm No.
Check item
Criteria Standard size
1
Check valve spring
Remedy Repair limit
Free length Installation x Outside length diameter
Load at installed height
Free length
Load at installed height
20.8 × 12.2
13.5
12.74 N {1.3 kg}
—
10.2 N {1.0 kg}
2
Spool return spring
41.1 × 9.6
35.0
58.8 N {6.0 kg}
—
47.0 N {4.8 kg}
3
Spool return spring
41.85 × 25.8
41.0
78.4 N {8.0 kg}
—
62.7 N {6.4 kg}
PC300, 300LC, 350, 350LC-8M0
Replace (Replace spring if damaged or deformed as well)
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37
SEN06269-02
Operation When work equipment is in NEUTRAL When there is no damage in the piping 1. Holding pressure of the work equipment cylinder is led from port (CY) to chamber (b), and it closes check valve (5). 2. The pilot pressure which is led from PPC valve to port (PI) is 0 MPa{0 kg/cm 2 } when work equipment is in NEUTRAL. 3. Spool (1) is pressed to the left by the force of springs (2) and (3). 4. Chamber (a) and chamber (b) are disconnected. 5. The pressurized oil does not flow from control valve to work equipment cylinder. The work equipment cylinder is held. 6. When the pressure inside the work equipment cylinder is abnormally high, holding pressure of the work equipment cylinder operates safety valve (4). When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, chamber (a) and chamber (b) are disconnected. 2. The pressure of the work equipment is held to prevent the work equipment from sudden lowering.
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10 Structure, function and maintenance standard Anti-drop valve for arm
When the pressurized oil flows from the control valve to the work equipment cylinder When there is no damage in the piping 1. The pressurized oil which is led from the control valve to chamber (a) becomes higher than the combined force of the pressure of chamber (b) of work equipment cylinder circuit and spring (6). 2. Check valve (5) opens, and chamber (a) and chamber (b) are connected. 3. The pressurized oil flows from the control valve to the work equipment cylinder. When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part to the outside. 2. The pressure of chamber (a) drops. The pressure of chamber (a) becomes lower than the combined force of the pressure of chamber (b) and spring (6). 3. Check valve (5) closes, and chamber (a) and chamber (b) are disconnected. 4. The pressure of the work equipment is held to prevent the work equipment from sudden lowering.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Anti-drop valve for arm
SEN06269-02
When the pressurized oil returns from the work equipment cylinder to the control valve When there is no damage in the piping 1. Holding pressure of the work equipment cylinder is led to chamber (b), and it closes check valve (5). 2. The pilot pressure is led from PPC valve to port (PI). The pilot pressure is larger than the force of spring (2) (area of circle "d"). 3. Spool (1) moves rightward to the standby position. (The first stroke) 4. Chamber (a) and chamber (b) are not interconnected. 5. The pilot pressure rises further. The pilot pressure is larger than the force of spring (2) (area of circle "d"). 6. Spool (1) moves rightward further, and chamber (a) and chamber (b) are interconnected. (The second stroke) 7. The pressurized oil returns from the work equipment cylinder to the control valve. When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part to the outside, but it is supplied from chamber (b). 2. The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equipment from sudden lowering.
PC300, 300LC, 350, 350LC-8M0
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SEN06269-02
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10 Structure, function and maintenance standard Anti-drop valve for arm
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Center swivel joint
Center swivel joint
1. 2. 3. 4. 5.
SEN06269-02
1
Cover Body Slipper seal O-ring Shaft
A1: A2: B1: B2: C1: C2: D1: D2: E: T1: T2:
From control valve port A2 To L.H. travel motor REVERSE port PB From control valve port B2 To L.H. travel motor FORWARD port PA From control valve port A5 To R.H. travel motor REVERSE port PA From control valve port B5 To R.H. travel motor FORWARD port PB To L.H. and R.H. travel motors port P From L.H. and R.H. travel motors port T To tank Unit: mm
No.
6
Check item Clearance between rotor and shaft
PC300, 300LC, 350, 350LC-8M0
Criteria
Remedy
Standard dimension
Standard clearance
Clearance limit
80
0.056 to 0.105
0.111
Replace
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SEN06269-02
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10 Structure, function and maintenance standard Center swivel joint
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
Travel motor
SEN06269-02
1
Type: HMV160ADT-2
MA: MA pressure detection port MB: MB pressure detection port P: From travel speed solenoid valve PA: From control valve PB: From control valve T: To tank
PC300, 300LC, 350, 350LC-8M0
Specifications Type :HMV160ADT-2 Theoretical displacement (Min.) :106.7 cm3/rev (Max.) :165.9 cm3/rev Rated pressure : 37.3 MPa {380 kg/cm2} Rated speed (Capacity min.) :2,460 rpm (Capacity max.) :1,580 rpm Brake release pressure :1.18 MPa {12 kg/cm2} Travel speed selector pressure (differential pressure) :0.78 MPa {8 kg/cm2}
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SEN06269-02
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10 Structure, function and maintenance standard Travel motor
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
SEN06269-02
Output shaft Motor case Rocker cam Piston Cylinder block Valve plate End cover Slow return valve Brake spring Brake piston Plate Disc Regulator piston Check valve Counterbalance valve spool Safety valve Ball Regulator valve High pressure shuttle valve
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
20
Spool return spring
Repair limit
Free length x Outside diameter
Installation length
Installed load
Free length
Installed load
58.43 x 30.0
42.2
416.5 N {43 kg}
—
337 N {34.4 kg}
—
0.98 N {0.10 kg}
21
Check valve spring
33.0 x 13.8
23.0
1.27 N {0.13 kg}
22
Regulator piston spring
75.6 x 23.6
58.7
323 N {32.9 kg}
—
258 N {26.3 kg}
23
Regulator valve spring
29.6 x 9.0
26.0
98.1 N {10.0 kg}
—
78.5 N {8.0 kg}
PC300, 300LC, 350, 350LC-8M0
If damaged or deformed, replace spring.
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SEN06269-02
10 Structure, function and maintenance standard Travel motor
Operation of motor 1) At slow speed (motor swash plate angle at maximum)
q
q q
q
As the solenoid valve is de-energized, the pilot pressurized oil from the self pressure reducing valve does not flow to port (P). Regulator valve (18) is pushed to the right by spring (23). Pressurized oil being conducted from the control valve to end cover (7) by pressing highpressure shuttle valve (19) is shut off by regulator valve (18). Fulcrum (a) of rocker cam (3) is eccentric to the working point (b) of the combined force of the propulsion force of cylinder (5).
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q
q
q
The combined force of the piston propulsion forces works as the moment of inclining rocker cam (3) toward the maximum swash plate angle. The pressurized oil at regulator piston (13) passes through orifice (c) of regulator valve (18) and is drained to the motor case. Rocker cam (3) is inclined in the maximum swash plate angle direction. The motor capacity becomes maximum, turning on the low speed travel.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
2)
At high peed (motor swash plate angle at minimum)
q
As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P). Regulator valve (18) is pushed to the left. The pressurized oil from the control valve passes through passage (d) in regulator valve (18) and enters regulator piston (13). Regulator piston (13) is pushed to the right. Rocker cam (3) is inclined in the minimum swash plate angle direction. The motor capacity becomes minimum, turning on the high speed travel.
q q
q q
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
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SEN06269-02
10 Structure, function and maintenance standard Travel motor
Operation of parking brake 1) When starting travel
q
q
q
As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (15), opening the parking brake circuit. The pressurized oil is conducted to chamber (a) of brake piston (10) and compresses brake spring (9), pushing brake piston (10) toward right. Since the pushing force to plate (11) and disc (12) disappears, plate (11) is separated from disc (12) and the brake is released.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
2)
When travel is stopped
q
As the travel lever is placed in neutral, counterbalance valve spool (15) returns to the neutral position and closing the parking brake circuit. The pressurized oil in chamber (a) of brake piston (10) passes through orifice (f) of brake piston (10) and is drained to the motor case. Brake piston (10) is pushed to the left by brake spring (9). Plate (11) and disc (12) are pushed together, and the brake is applied. As brake piston (10) returns, flow of pressurized oil is reduced with slow return valve (8). The time delay will be set to activate the brake only after the machine has stopped.
q
q q q q
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
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SEN06269-02
Brake valve q The brake valve consists of check valves (14), counterbalance valve spool (15) and safety valve (16). q Functions and operations of respective components shall conform to the following. 1.
Counterbalance valve and check valve
10 Structure, function and maintenance standard Travel motor
Operation when pressurized oil is supplied q Operating the travel lever conducts the pressurized oil from the control valve to port (PA). q The pressurized oil push-opens check valve (14A) and then flows to motor outlet port (MB) via motor inlet port (MA). q The motor outlet side is closed by check valve (14B) and counterbalance valve spool (15), so the pressure at the supply side rises.
Function When traveling downhill, the machine travel speed tends to get faster than the motor (engine) speed because of the downward force generated from its own weight. q If the machine travels with the engine at low speed, the motor may rotate without load, causing the machine to run out of control, resulting in a very dangerous situation. q These valves are used to prevent above by controlling the machine to travel according to the engine speed (pump discharge). q
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
q
q
q
The pressurized oil on the supply side flows to chamber (S1) via orifice (E1) and orifice (E2) of the counterbalance valve spool (15). As the pressure in chamber (S1) goes above the counterbalance valve spool selector pressure, counterbalance valve spool (15) is pushed to the right side. Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the motor rotating.
PC300, 300LC, 350, 350LC-8M0
SEN06269-02
Operation of brake during travelling downhill q If indication of the machine runaway is sensed while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. q Pressure in chamber (S1) is released via orifices (E1) and (E2). q As the pressure in chamber (S1) goes below the spool selector pressure, counterbalance valve spool (15) is returned to the left by spring (21) and outlet port (MB) is throttled. q The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from running out of control. q The spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. q Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery.
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SEN06269-02
2.
10 Structure, function and maintenance standard Travel motor
Safety valve (bidirectional 2-stage set safety valve)
Function q As long as the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. q Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. q The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment.
q
q
As the pressure goes above the set pressure, [Difference in areas of circles (D1) and (D2) x Pressure] compresses spring (2). Poppet (1) is moved leftward and the pressurized oil flows into chamber (MA) of the opposite circuit.
Bidirectional action 1) When pressure in chamber (MB) has become high (when rotating clockwise) q As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance valve closes chamber (MB) of the outlet port circuit. q The motor tries to continue rotation resorting to inertial force, thus pressure on the outlet port (MB) is increased.
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Travel motor
2)
q
q
q
q
When pressure in chamber (MA) has become high (when rotating counterclockwise) As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance valve closes chamber (MA) of the outlet port circuit. The motor tries to continue rotation resorting to inertial force, thus pressure on the outlet port (MA) is increased.
SEN06269-02
Operation of mechanism for varying set pressure 1) When starting travel (high-pressure setting) q As the travel lever is operated, the pressurized oil from the pump moves counterbalance valve spool (15) toward right. q Above opens the pilot circuit to the safety valve, conducting the pressurized oil to chamber (J) via chamber (G) and passage (H). q Piston (3) is pushed to the right side, spring (2) is compressed and the set load is increased. q High pressure is turned on the safety valve, providing a large tractional force to the valve.
As the pressure goes above the set pressure, [Difference in areas of circles (D1) and (D3) x Pressure] compresses spring (2). Poppet (1) is moved leftward and the pressurized oil flows into chamber (MB) of the opposite circuit.
PC300, 300LC, 350, 350LC-8M0
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SEN06269-02
2) q
q
q q
10 Structure, function and maintenance standard Travel motor
When travel is stopped (low-pressure setting) When the travel lever is placed in neutral, the pressure in chamber (PA) drops and counterbalance valve spool (15) returns to the neutral position. When counterbalance valve spool (15) is in the process of returning to the neutral position, the pressurized oil in chamber (J) flows to chamber (PA) via passage (H) and chamber (G). Piston (3) moves to the left side, decreasing the set load. The safety valve is caused to the low pressure setting, thereby attenuating the shocks when the speed is reduced.
Set pressure of safety valve High pressure setting: 40.2 MPa {410 kg/cm2} (at start of travel and during travel) Low pressure setting: 27.5 MPa {280 kg/cm2} (during stop)
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PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing motor
SEN06269-02
Swing motor
1
Type: KMF160
B: From swing holding brake solenoid MA: From control valve MB: From control valve S: From control valve T: To tank 1. 2.
Reverse prevention valve Safety valve
PC300, 300LC, 350, 350LC-8M0
Specifications Type Theoretical displacement Safety valve set pressure Rated speed Brake release pressure
: KMF160 : 167.5 cm3/rev : 27.9 MPa {285 kg/cm2} : 1,570 rpm : 1.4 MPa {14 kg/cm2}
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SEN06269-02
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10 Structure, function and maintenance standard Swing motor
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing motor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
SEN06269-02
Brake spring Drive shaft Spacer Case Disc Plate Brake piston Housing Piston Cylinder block Valve plate Center shaft Center spring Check valve Check valve spring Shuttle valve Shuttle valve spring
Unit: mm No.
Check item
Criteria
Remedy
Standard dimension
18
19
Check valve spring
Free length x Outside diameter
Shuttle valve spring
PC300, 300LC, 350, 350LC-8M0
Repair limit
Installed length
Installed load
52.7 x 22.4 24.5 x 11.6
Free length
Installed load
36.9
4.9 N {0.5 kg}
—
3.92 N {0.4 kg}
14.0
7.7 N {0.79 kg}
—
6.16 N {0.63 kg}
If damaged or deformed, replace spring.
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SEN06269-02
Swing holding brake 1. When solenoid valve is de-energized Operation q As the swing holding brake is de-energized, the pressurized oil from the self pressure reducing valve is shut off. q Port (B) is connected to tank circuit. q Brake piston (7) is pushed down by brake spring (1). q Disc (5) and plate (6) are pushed together, and the brake is applied.
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10 Structure, function and maintenance standard Swing motor
2.
When solenoid valve is energized
Operation q As the swing brake solenoid valve is energized, the valve is switched. q The pressurized oil from the self pressure reducing valve is conducted brake chamber (a) via port (B). q After entering chamber (a), the pressurized oil compresses brake spring (1) and pushes brake piston (7) up. q Disc (5) is separated from plate (6), releasing the brake.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing motor
Relief valve portion
SEN06269-02
2. q
Outline q The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1). Function q When the machine is in the swing holding mode, control valve (6) closes the motor outlet circuit, but the motor rotation is continued by inertial force. q The motor output, therefore, is abnormally increased, resulting in damaging the motor. q In order to prevent the motor damages, the relief valve relieves the abnormally high pressure to port (S) from the motor outlet side (high-pressure side) of the motor. Operation 1. When starting swing q When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port (MA) via control valve (6). q The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate. q The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns to the tank.
PC300, 300LC, 350, 350LC-8M0
q
q q q
q q
q
When swing is stopped When the swing control lever is returned to neutral, the supply of pressurized oil from the pump to port (MA) is stopped. The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (6). Thus, pressure on port (MB) increases. Rotation resistance is generated on the motor and hence the brake starts working. Shuttle valve (4) is pressed as pressure on port (MB) goes above port (MA). The pressure on chamber (C) is increased to the se t pr es sur e of r el ief va lv e ( 1) an d becomes the same as that of port (MB). A high braking torque works on the motor, thereby stopping the motor. When relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are fed to port (MA) via check valve (3). This prevents cavitation on port (MA).
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SEN06269-02
10 Structure, function and maintenance standard Swing motor
Reverse prevention valve
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60
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Swing motor
SEN06269-02
MA: From control valve MB: From control valve T1: To tank T2: To tank 1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
Explanatory drawing of effects
PC300, 300LC, 350, 350LC-8M0
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SEN06269-02
Function q 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. q The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, enabling you to proceed to the next work quicker than ever). Operation 1. When port (MB) brake pressure is generated q Pressure (MB) is conducted to chamber (d) via notch (g). q The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves spool (5) to the left side. q Port (MB)o chamber (e) is interconnected. q Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is kept in. Thus the braking force is ensured.
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10 Structure, function and maintenance standard Swing motor
2. q
q q
q q
When motor is stopped temporarily The motor rotation is reversed by the closing pressure generated at port (MB). (1st time: reverse rotation) Reversing pressure is generated on port (MA). Pressure (MA) is conducted to chamber (a). The pressure compresses spring (3) by use of the difference in areas of circles (D3 > D4) of spool (2) and moves spool (2) to the right side. Port (MA) o chamber (b) is interconnected. Then ports (b) and (f) are interconnected through the drilled hole (h) on spool (5). This interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Work equipment cylinder
Work equipment cylinder
SEN06269-02
1
Boom cylinder
Unit: mm No.
1
Item Clearance between piston rod and bushing
Criteria Standard dimension
Tolerance
Remedy Standard clearance
Allowable limit
Shaft
Hole
100
-0.036 -0.090
+0.257 +0.047
0.083 to 0.347
0.447
-0.036 -0.071
+0.457 +0.370
0.406 to 0.528
1.0
-0.036 -0.090
+0.161 +0.074
0.110 to 0.251
2
Clearance between piston rod support shaft and bushing
100
3
Clearance between cylinder bottom support shaft and bushing
90
4
Tightening torque of cylinder head bolt
373 ± 54 Nm {38.0 ± 5.5 kgm}
5
Tightening torque of cylinder piston
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
6
Tightening torque of cylinder piston lock screw
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
PC300, 300LC, 350, 350LC-8M0
Replace bushing
Replace pin and bushing 1.0
Retighten
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10 Structure, function and maintenance standard Work equipment cylinder
SEN06269-02
Arm cylinder
Unit: mm No.
1
Item Clearance between piston rod and bushing
Criteria Standard dimension
Tolerance
Remedy Standard clearance
Allowable limit
Shaft
Hole
110
-0.036 -0.090
+0.261 +0.047
0.083 to 0.351
0.451
-0.036 -0.090
+0.457 +0.370
0.406 to 0.547
1.0
-0.036 -0.090
+0.457 +0.370
0.406 to 0.547
2
Clearance between piston rod support shaft and bushing
100
3
Clearance between cylinder bottom support shaft and bushing
100
4
Tightening torque of cylinder head bolt
530 ± 78.5 Nm {54.0 ± 8.0 kgm}
5
Tightening torque of cylinder piston
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
6
Tightening torque of cylinder piston lock screw
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
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Replace bushing
Replace pin and bushing 1.0
Retighten
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Work equipment cylinder
SEN06269-02
Bucket cylinder
Unit: mm No.
1
Item Clearance between piston rod and bushing
Criteria Standard dimension
Tolerance
Remedy Standard clearance
Allowable limit
Shaft
Hole
100
-0.036 -0.090
+0.257 +0.047
0.083 to 0.347
0.447
-0.036 -0.090
+0.457 +0.370
0.406 to 0.547
1.0
-0.036 -0.090
+0.457 +0.370
0.406 to 0.547
2
Clearance between piston rod support shaft and bushing
90
3
Clearance between cylinder bottom support shaft and bushing
90
4
Tightening torque of cylinder head bolt
373 ± 54 Nm {38.0 ± 5.5 kgm}
5
Tightening torque of cylinder piston
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
6
Tightening torque of cylinder piston lock screw
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
PC300, 300LC, 350, 350LC-8M0
Replace bushing
Replace pin and bushing 1.0
Retighten
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SEN06269-02
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06269-02
© 2016 KOMATSU All Rights Reserved Printed in Japan 01-17 (01)
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SEN06270-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 500 Work equipment
1
Work equipment............................................................................................................................................. 2 Dimensions of components............................................................................................................................ 4
PC300, 300LC, 350, 350LC-8M0
10-500
1
10 Structure, function and maintenance standard Work equipment
SEN06270-01
Work equipment
10-500
2
1
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Work equipment
SEN06270-01
Unit: mm No.
Check item Clearance between pin connecting
1 boom and revolving frame and bushing
Clearance between pin connecting
2 boom and arm and bushing
Clearance between pin connecting
3 arm and link and bushing
Clearance between pin connecting
4 arm and bucket and bushing
Clearance between pin connecting
5 link and bucket and bushing
Clearance between pin connecting
6 links and bushing 7 Bucket clearance
PC300, 300LC, 350, 350LC-8M0
Criteria Standard dimension
Tolerance
Remedy
Shaft
Hole
Standard clearance
110
–0.036 –0.090
+0.157 +0.079
0.115 to 0.247
1.0
110
–0.036 –0.090
+0.179 +0.081
0.117 to 0.269
1.0
90
–0.036 –0.090
+0.165 +0.072
0.108 to 0.255
1.0
90
–0.036 –0.090
+0.145 +0.083
0.119 to 0.235
1.0
90
–0.036 –0.090
+0.165 +0.072
0.108 to 0.255
1.0
90
–0.036 –0.090
+0.163 +0.069
0.105 to 0.253
1.0
0.5 to 1.0
Clearance limit
Replace
Adjust shims
10-500
3
SEN06270-01
Dimensions of components 1.
10 Structure, function and maintenance standard Dimensions of components
1
Dimension of arm
10-500
4
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Dimensions of components
SEN06270-01
Unit: mm PC300-8M0, PC300LC-8M0 No.
Measuring position
1 2
–
Standard dimension
φ100
Tolerance Shaft
Hole
–0.036 –0.071
+0.1 0
PC350-8M0, PC350LC-8M0 Standard dimension
φ100
Tolerance Shaft
Hole
–0.036 –0.071
+0.1 0
119.3
+1.5 0
119.3
+1.5 0
Cylinder head side
116
±1.2
116
±1.2
Boom side
320
+0.5 0
320
+0.5 0
Arm side
316
–0.3 –0.8
316
–0.3 –0.8
Arm side
3 –0.036 –0.090
+0.1 +0.1
–0.036 –0.090
+0.1 +0.1
4
–
φ110
5
–
470.6
±1
470.6
±1
6
–
236.5
±0.5
236.5
±0.5
7
–
1022.4
±1
1022.4
±1
8
–
3178
±3
3178
±3
9
–
2975.6
±1
2975.6
±1
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
–
1670
15
–
φ90
16
–
345.0
17
–
φ90
18 19
– –0.036 –0.090
1670 +0.2 0
±0.5 –0.036 –0.090
φ110
φ90
– –0.036 –0.090
345.0 +0.054 +0.054
φ90
+0.2 0 ±0.5
–0.036 –0.090
+0.054 +0.054
Arm itself
330
0 –0.5
330
0 –0.5
When press fitting bushing
345
–
345
–
Min.
1870
–
1870
–
Max.
3155
–
3155
–
PC300, 300LC, 350, 350LC-8M0
10-500
5
SEN06270-01 2.
10 Structure, function and maintenance standard Dimensions of components
Dimension of bucket
10-500
6
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Dimensions of components
SEN06270-01
Unit: mm PC300-8M0, PC300LC-8M0 No.
1 2 3 4 5 6 7
PC350-8M0, PC350LC-8M0
Measuring position
Standard dimension
Tolerance
Standard dimension
Tolerance
–
512.2
±0.5
512.2
±0.5
–
37.9
±0.5
37.9
±0.5
–
94°19'
–
94°14'
–
–
513.6
–
513.6
–
–
1658
–
1666
–
–
193
–
208
–
–
50°
–
42°
–
φ90
+0.2 +0.0
8
–
φ90
+0.2 +0.0
9
–
φ120
+0.054 +0.054
φ120
+0.054 +0.054
10
–
φ125
+0.1 +0.1
φ125
+0.1 +0.1
11
–
346
+1 0
346
+1 0
–
68
–
68
–
–
138
–
138
–
525.5
+0.5 –0.25
525.5
+0.5 –0.25
12 13 14 15 16 17 18 19 20 21 22 23 24 25
– –
φ26
–
φ26
–
–
φ165
–
φ165
–
–
φ150
–
φ150
–
–
φ200
–
φ200
–
–
145.8
–
137.9
–
–
138.2
–
140.4
–
–
R115
–
R115
–
–
R100
–
R100
–
–
382
+2 0
382
+2 0
–
60
–
60
–
–
56
–
56
–
PC300, 300LC, 350, 350LC-8M0
10-500
7
SEN06270-01
PC300-8M0, PC300LC-8M0, PC350-8M0, PC350LC-8M0 HYDRAULIC EXCAVATOR Form No. SEN06270-01
© 2013 KOMATSU All Rights Reserved Printed in Japan 02-13 (01)
10-500
8
SEN06271-01
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0 Machine model
Serial number
PC300-8M0 PC300LC-8M0 PC350-8M0 PC350LC-8M0
C90001 and up C90001 and up C90145 and up C90145 and up
10 Structure, function and maintenance standard 600 Electrical system
1
Engine control system .................................................................................................................................... 2 Electronic control system ..............................................................................................................................11 Machine monitor system .............................................................................................................................. 36 Sensor .......................................................................................................................................................... 56 KOMTRAX system ....................................................................................................................................... 59
PC300, 300LC, 350, 350LC-8M0
10-600
1
10 Structure, function and maintenance standard Engine control system
SEN06271-01
Engine control system
1. 2. 3. 4. 5. 6. 7.
Battery relay Battery Starting switch Fuel control dial Starting motor Engine throttle controller Pump controller
10-600
2
1
Outline q The engine can be started and stopped with only starting switch (3).
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Engine control system
Operation of system
Starting engine q When the starting switch is turned to START position, the starting signal flows to the starting motor. Then, the starting motor turns to start the engine.
SEN06271-01
Stopping engine q When detecting that the starting switch is set to “STOP” position, the engine controller cuts the fuel injection to stop the engine.
When it happens, the engine controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control q The fuel control dial sends a signal voltage corresponding to the rotation angle to the engine controller. q The pump controller receives the fuel dial position information from the engine controller through the network. q The pump controller calculates the engine speed in accordance with the working mode, the decelerate, and the like, and sends an instruction to the engine controller. q The engine controller determines the fuel injection quantity based on the instruction received from the pump controller.
PC300, 300LC, 350, 350LC-8M0
10-600
3
SEN06271-01
10 Structure, function and maintenance standard Engine control system
Component Fuel control dial
1. 2. 3.
Knob Dial Spring
4. 5. 6.
Ball Potentiometer Connector
Function q A potentiometer is installed under the knob. As the knob is turned, the potentiometer shaft is turned. q As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes and a throttle signal is sent to the engine controller. q The hatched area in the graph shown at right is the abnormality detection area. The engine speed is set to low idle in the abnormality detection area.
10-600
4
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Engine control system
SEN06271-01
Engine controller
q
Meanings of signal classes in the terminal table shown below are as follows. A: Power Supply B: Input C: Ground/Shield/Return D: Output E: Communication
CN-CE01 Input/ output 1 Electric power supply for fuel feed pump A 2 Electric power supply for IMA A 3 Atmosphere sensor B 4 NC(*) – 5 NC(*) – 6 CAN(–) E 7 NC(*) – 8 CAN(+) E 9 NC(*) – 10 NC(*) – *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
PC300, 300LC, 350, 350LC-8M0
CN-CE01 Input/ output 11 Fuel feed pump return C 12 NC(*) – 13 NC(*) – 14 WATER-IN-FUEL sensor B 15 Coolant temperature sensor B 16 5V electric power supply for sensor A 17 Oil pressure switch B 18 NC(*) – 19 NC(*) – 20 NC(*) – 21 NC(*) – 22 NC(*) – 23 Boost temperature sensor B 24 NC(*) – 25 Common rail pressure sensor B 26 Buckup sensor B 27 Ne sensor (+) B *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
10-600
5
10 Structure, function and maintenance standard Engine control system
SEN06271-01 CN-CE01
CN-CE02
Input/ output 28 NC(*) – 29 NC(*) – 30 NC(*) – 31 NC(*) – 32 IMA return C 33 5V electric power supply for sensor A 34 NC(*) – 35 NC(*) – 36 NC(*) – 37 5V electric power supply for sensor A 38 GND – 39 NC(*) – 40 NC(*) – 41 NC(*) – 42 NC(*) – 43 NC(*) – 44 Boost pressure sensor B 45 Injector #1 (+) D 46 Injector #5 (+) D 47 Sensor GND – 48 Ne sensor (–) C 49 NC(*) – 50 NC(*) – 51 Injector #2 (–) C 52 Injector #3 (–) C 53 Injector #1 (–) C 54 Injector #2 (+) D 55 Injector #3 (+) D 56 Injector #4 (+) D 57 Injector #6 (+) D 58 Injector #4 (–) C 59 Injector #6 (–) C 60 Injector #5 (–) C *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
CN-CE02 Input/ output 1 NC(*) – 2 NC(*) – 3 NC(*) – 4 NC(*) – 5 NC(*) – 6 NC(*) – 7 NC(*) – 8 NC(*) – 9 Fuel control dial (+) B 10 NC(*) – 11 NC(*) – 12 NC(*) – *: Never connect to NC or malfunctions or failures will occur. Pin No.
10-600
Signal name
6
Input/ output 13 NC(*) – 14 NC(*) – 15 NC(*) – 16 NC(*) – 17 NC(*) – 18 NC(*) – 19 NC(*) – 20 NC(*) – 21 NC(*) – 22 Fuel control dial (+5V) A 23 Fuel control dial (–) C 24 NC(*) – 25 NC(*) – 26 NC(*) – 27 NC(*) – 28 NC(*) – 29 NC(*) – 30 NC(*) – 31 NC(*) – 32 NC(*) – 33 GND – 34 NC(*) – 35 NC(*) – 36 NC(*) – 37 NC(*) – 38 NC(*) – 39 Key switch (ACC) A 40 Electrical intake air heater relay drive D 41 NC(*) – 42 Electrical intake air heater relay return C 43 NC(*) – 44 NC(*) – 45 NC(*) – 46 CAN(+) E 47 CAN(–) E 48 NC(*) – 49 PWM OUTPUT D 50 NC(*) – *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
CN-CE03 Pin No. 1 2
Signal name
Input/ output – –
GND NC(*) Electric power supply (+24V con3 A stantly) 4 NC(*) – *: Never connect to NC or malfunctions or failures will occur.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Engine control system
SEN06271-01
Coolant temperature sensor
1. 2. 3.
Connector Sensor O-ring
Oil pressure switch
1. 2. 3.
Connector Sensor O-ring
PC300, 300LC, 350, 350LC-8M0
10-600
7
SEN06271-01
10 Structure, function and maintenance standard Engine control system
Rotation sensor
1. 2. 3.
Connector Sensor O-ring
Boost pressure and temperature sensor
1. 2. 3.
Connector Sensor O-ring
10-600
8
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Engine control system
SEN06271-01
WIF (water-in-fuel detection) sensor
1. 2. 3. 4.
Connector Tube Sensor O-ring
Engine oil level sensor
1. 2. 3. 4.
Connector Bracket Float Switch
PC300, 300LC, 350, 350LC-8M0
10-600
9
SEN06271-01
10-600
10
10 Structure, function and maintenance standard Engine control system
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system
Electronic control system
SEN06271-01
1
Control function 1 Pump & engine combined control function 2 Pump and valve control function 3 Power maximizing function Machine push-up function 4 Auto-deceleration function 5 Auto-warm-up and overheat prevention function Electronic control system 6 Swing control function 7 Travel control function 8 Attachment flow control and circuit selector function (if equipped)
Self-diagnosis function a
For the self-diagnosis function, see “Troubleshooting“.
PC300, 300LC, 350, 350LC-8M0
10-600
11
SEN06271-01
10 Structure, function and maintenance standard Electronic control system
Machine control system diagram
10-600
12
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system
PC300, 300LC, 350, 350LC-8M0
SEN06271-01
10-600
13
SEN06271-01 1.
10 Structure, function and maintenance standard Electronic control system
Pump & engine combined control function
10-600
14
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system Function q This function allows the operator to select proper engine torque and pump absorption torque according to the type of work. 4 modes are provided: P, E, B and L. Using the work mode switch on the monitor panel, the operator is required to select one of them. q The pump controller detects the speed of the engine governor set with the fuel control dial and the actual engine speed (N) 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.
SEN06271-01 1)
Control method in each mode P and E modes q Matching point in P mode: Rated speed
q
q
PC300, 300LC, 350, 350LC-8M0
Mode
Matching point
P
186.8 kW/1,950 rpm {250 HP/1,950 rpm}
E
147.1 kW/1,950 rpm {197 HP/1,950 rpm}
In P mode and E mode, engine speed is controlled so that it is always kept to be around the matching point already set in each mode. If the pump load increases and the pump discharge pressure rises, engine speed (N) starts lowering. At this time, the controller lowers the pump discharge (Q) so that it becomes around the matching point. If the pump load decreases and the pump discharge pressure (P) lowers, the controller rises the pump discharge (Q) so that the engine speed (N) becomes around the matching point.
10-600
15
10 Structure, function and maintenance standard Electronic control system
SEN06271-01
B and L modes Mode Partial output point Mode B L q
q
q
10-600
B mode 74%
L mode 60%
Matching point 136.1 kW/1,780 rpm {182 HP/1,780 rpm} 110.3 kW/1,470 rpm {148 HP/1,470 rpm}
In B or L mode, the controller controls the pump discharge (Q) to ensure consistency of engine output (PW). The controller controls the pump absorption torque to lower engine speed (N) while maintaining constant engine torque (T) along the equal engine horsepower curve. The controller controls the pump discharge (Q) to maintain constant engine torque (T) along the equal engine horsepower curve.
16
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 2)
Function to control pump during travel q Traveling the machine in E or B mode leaves the working mode unchanged, but raises the pump absorption torque and engine speed (N) to values same as those in P mode. q If the machine travels in L mode, the working mode and engine speed (N) do not change, but the pump absorption torque is increased.
PC300, 300LC, 350, 350LC-8M0
SEN06271-01 3) q
Function to control when emergency pump drive switch is turned on Even if any abnormality occurs in the controller or sensor, setting emergency pump drive switch (1) to ON position activates the machine with an absorption torque approximately equivalent to that in E mode. In this case, a constant current flows from the battery to the EPC valve for PC and therefore, the oil pressure is sensed by only the EPC valve for PC.
10-600
17
SEN06271-01 2.
10 Structure, function and maintenance standard Electronic control system
Pump and valve control function
Function q The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
10-600
18
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 1)
2)
LS control function q Depending on the operation condition of the actuator, this function changes the pressure output from the LS-EPC valve to LS valve to change the change point (LS set differential pressure (DLS)) of the pump discharge in the LS valve. q By this operation, the start-up time of the pump discharge is optimized and the combined operations and fine control performance is improved.
SEN06271-01 3)
2-stage relief function q The relief pressure in the normal work is 34.8 MPa {355 kg/cm 2 }. If the 2-stage relief function is turned on, however, the relief pressure rises to approximately 37.2 MPa {380 kg/cm2}. By this operation, the hydraulic force is increased further.
Operating condition for turning on 2-stage relief function • During travel • When swing lock switch is turned to ON position • When boom is lowered • When power maximizing function is turned on • When L mode is operated
Relief pressure 34.8 MPa {355 kg/cm2} O 37.2 MPa {380 kg/cm2}
Cut-off function This function increases PC-EPC current (J) to reduce the flow rate in the relief state, improving fuel consumption.
q
Operating condition for turning on cut-off function When the average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm2} with the power maximizing function off. The cut-off function does not work, however, while the machine is travelling in P mode, swing lock switch is in ON position.
PC300, 300LC, 350, 350LC-8M0
10-600
19
SEN06271-01 3.
10 Structure, function and maintenance standard Electronic control system
Power maximizing and machine push-up function
Function q The power maximizing function allows the operator to increase power for a certain time by operating the left knob switch. q The machine push-up function allows the operator to increase the boom pushing force by operating the machine push-up switch.
10-600
20
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 1)
Power maximizing function q This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock). q If the left knob switch is pressed in P or E mode, the hydraulic force is increased approximately 7% to increase the digging force. Each function is set automatically as shown below.
Function Engine and pump control
2-stage relief function
Software cut-off function q
Setting Matching at rated horsepower point 34.8 MPa {355 kg/cm2} O 37.2 MPa {380 kg/cm2} Cancel
SEN06271-01 2)
Machine push-up function q The machine push-up function allows the operator to increase the boom pushing force that is required for ditching or mass excavation in hard ground by operating machine push-up switch (1). Switch
OFF
ON
2-stage safety valve function Setting of safety valve at boom cylinder head 14.7 MPa {150 kg/cm2} Setting of safety valve at boom cylinder head 28.4 MPa {290 kg/cm2}
These settings are automatically reset after 8.5 seconds when the switch is pressed.
PC300, 300LC, 350, 350LC-8M0
10-600
21
SEN06271-01 4.
10 Structure, function and maintenance standard Electronic control system
Auto-deceleration function
Function q The auto-deceleration function automatically reduces the engine speed to its medium speed range when the all control levers are set in NEUTRAL while waiting for a dump truck or work to reduce the fuel consumption and noise. q If any lever is operated, the engine speed instantly returns to the speed set with the fuel control dial. Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec. during operation at a engine speed above a decelerator operation level (approximately 1,000 rpm), this function lowers the engine speed to the deceleration operation level (approximately 1,000 rpm) and keeps it until you operate any lever. When any control lever is operated q If you operate any control lever while the engine speed is kept at the deceleration operation level, the engine speed instantly rises to the level set with the fuel control dial.
10-600
22
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 5.
SEN06271-01
Auto-warm-up and overheat prevention function
Function q The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts. q The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during operation to protect the engine from overheating.
PC300, 300LC, 350, 350LC-8M0
10-600
23
10 Structure, function and maintenance standard Electronic control system
SEN06271-01 1)
Auto-warm-up function q After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All)
Coolant temperature: Below 30°C. Engine speed: Max. 1,250 rpm
⇒
Operated Engine speed: Max. 1,250 rpm
⇓ Auto Manual 2)
Resetting condition (Any one) Coolant temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes Fuel control dial: Kept at 70% of full level for 3 sec. or longer
⇒
Reset Engine speed: Any level
Overheat prevention function q If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to protect the engine from overheating. q This function operates when the coolant temperature is 100°C or hydraulic temperature is 95°C.
Operating condition Hydraulic oil temperature: Above 95°C
Operation/Remedy
⇒
Operating condition Hydraulic oil or coolant temperature: Above 100°C
⇒
10-600
24
Work mode: P mode Engine speed: Keep as is. Lower pump discharge.
⇒
Resetting condition Hydraulic oil or coolant temperature: Below 100°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
⇒
Resetting condition Hydraulic oil or coolant temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
⇒
Resetting condition Hydraulic oil or coolant 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
⇒
Operating condition
Hydraulic oil or coolant temperature: Above 105°C
⇒
Operation/Remedy
Operating condition Hydraulic oil or coolant temperature: Above 102°C
Work mode: Travel Engine speed: Keep as is. Lower travel speed.
Resetting condition
Work mode: P, E or L mode Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge. Operation/Remedy
⇒
Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Hydraulic oil temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 6.
SEN06271-01
Swing control function
Function The swing lock and swing holding brake function are provided as a swing control function.
PC300, 300LC, 350, 350LC-8M0
10-600
25
10 Structure, function and maintenance standard Electronic control system
SEN06271-01 1)
Swing lock and swing holding brake function q 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. q Operation of swing lock switch and swing lock/holding brake
Lock switch
Lock lamp
Function
OFF
OFF
Swing holding brake
ON
ON
Swing lock
Operation If swing lever is set in neutral, swing brake operates in approximately 7 sec. If swing lever is operated, brake is released and machine can swing freely. 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.
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 (1). q 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. q If the swing lock is reset, only the hydraulic brake is applied by the safety valve. Note that if swinging is stopped on a slope, the upper structure may swing by its gravity. q
Swing holding brake release switch
ON (when controller has trouble)
Swing lock switch Swing brake
10-600
ON
OFF
Quick hydraulic oil warm-up function when swing lock switch is turned on q If swing lock switch (2) is turned on, the pump cut-off 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.
OFF (when controller is normaly) ON
Swing lock Swing lock Swing lock is turned is canis turned on. celed. on.
26
2)
OFF Swing holding brake is turned on.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 7.
SEN06271-01
Travel control function
Function q The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or allowing operator to change travel speed automatically or manually.
PC300, 300LC, 350, 350LC-8M0
10-600
27
SEN06271-01 1)
Pump control function during travel q If the machine travels in a work mode other than P mode, the work mode and the engine speed are kept as they are and the pump absorption torque is increased. q For details, see "Pump & engine combined control function".
10 Structure, function and maintenance standard Electronic control system 2)
Travel speed change function 1] Manual change with travel speed switch If one of Lo, Mi and Hi is selected with the travel speed switch, the pump controller controls the pump capacity and motor capacity at each gear speed as shown below to change the travel speed.
Travel speed switch
Lo (Low speed)
Mi (Medium speed)
Hi (High speed)
Pump capacity (%)
90
82
100
Max.
Min.
Min.
3.2
4.5
5.5
Motor capacity Travel speed (km/h)
10-600
28
2]
Automatic change by engine speed If the fuel control dial is used to set the engine speed to less than 1,200 rpm, the travel speed changes to Lo when the machine is travelling in Mi or Hi, and the travel speed will not change to Mi or Hi.
3]
Automatic change by pump discharge pressure When traveling with the travel speed switch set to Hi or Mi, if the load increases, such as when travelling uphill, and the travel pressure goes above 32.3 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.) If the load decreases, such as when travelling on level ground or travelling 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.
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 8.
SEN06271-01
Attachment flow control and circuit selector function (if equipped)
Function q This function is available only with the attachment specification. q The function acts as follows according to the flow command and working mode from the monitor. 1) It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully. 2) In B mode and the other modes, it switches to attachment single acting (B) or double acting (other modes).
PC300, 300LC, 350, 350LC-8M0
10-600
29
SEN06271-01 9. 1)
System component parts PPC oil pressure switch
1. 2. 3.
Plug Switch Connector
10 Structure, function and maintenance standard Electronic control system
Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) pressure: 0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2} Function q This switch is installed to the Attachment PPC valve (1 piece). q This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.
10-600
30
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 2)
Oil pressure sensor
1. 2.
Sensor Connector
Function q The sensor is installed to the travel PPC valve (4 pieces). q It converts the pump discharge pressure into a voltage and transmits it to the pump controller.
SEN06271-01
q
The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below.
q
The amplifier magnifies output voltage (E) and transmits it to the pump controller.
Operation The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part, the diaphragm is deformed. q The deformation in the diaphragm causes the resistance of the gauge to change. This causes a change in the output voltage, which is transmitted to the amplifier (voltage amplifier). q
PC300, 300LC, 350, 350LC-8M0
10-600
31
SEN06271-01 3)
Pump pressure sensor (high pressure)
1. 2.
Sensor Connector
10 Structure, function and maintenance standard Electronic control system
Operation q The relationship between the pressure applied to sensors (P) and output voltage (E) is shown in the figure below.
10-600
32
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system 4)
SEN06271-01
Pump controller
PC300, 300LC, 350, 350LC-8M0
10-600
33
10 Structure, function and maintenance standard Electronic control system
SEN06271-01
AMP-81P [CN-CP01]
AMP-81P [CN-CP01] Pin No.
Signal name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
PWR_IN_BATT GND_PWR Washer motor PWR_IN_BATT GND_PWR NC(*) NC(*) 5V potentiometer power supply 5V potentiometer power supply NC(*) NC(*) NC(*) NC(*) Boom LOWER pressure sensor Arm OUT pressure sensor Swing pressure sensor R.H. Arm IN pressure sensor GND_SIG_A Swing lock switch NC(*) Machin select 2 NC(*) NC(*) Key switch (ACC) NC(*) NC(*) NC(*) NC(*) Hydraulic–oil temperature NC(*) NC(*) NC(*) NC(*) Bucket DUMP pressure sensor Travel pressure sensor (near left) Travel pressure sensor (near right) GND_SIG_D Swing prolix switch Machin select 5 Machin select 1 Knob switch NC(*) Key switch (ACC) NC(*)
45
COMM_CAN_H_0
46 47 48 49 50 51
Analog signal GND NC(*) NC(*) F pump pressure sensor NC(*) NC(*)
10-600
34
Input/ Output Input Input Output Input Input — — Output Output — — — — Input Input Input Input — Input — Input — — Input — — — — Input — — — — Input Input Input — Input Input Input Input — Input — Input/ Output — — — Input — —
Input/ Output 52 NC(*) — 53 Boom RAISE pressure sensor Input 54 Travel pressure sensor (near left) Input 55 Travel pressure sensor (near right) Input 56 Wiper limit switch (W) Input 57 Window limit switch Input 58 Machin select 4 Input 59 NC(*) — 60 Key switch (C) Input 61 NC(*) — 62 External starting signal Input 63 NC(*) — Input/ 64 COMM_CAN_L_0 Output 65 NC(*) — 66 NC(*) — 67 NC(*) — 68 R pump pressure sensor Input 69 NC(*) — 70 NC(*) — 71 NC(*) Input 72 Swing pressure switch (right) Input 73 Bucket CURL pressure sensor Input 74 NC(*) — 75 Wiper contacts (P) Input 76 Swing pressure switch Input 77 Machin select 3 Input 78 NC(*) — 79 Key switch (ACC) Input 80 NC(*) — 81 NC(*) — *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
PC300, 300LC, 350, 350LC-8M0
10 Structure, function and maintenance standard Electronic control system
SEN06271-01
AMP-40P [CN-CP02] Input/ Output 82 NC(*) — 83 NC(*) — 84 NC(*) — 85 Variable back pressure solenoid valve Output 86 Att circuit change solenoid valve Output 87 Travel speed solenoid valve Output 88 LS-EPC Output 89 NC(*) — 90 NC(*) — 91 NC(*) — 92 NC(*) — 93 NC(*) — 94 NC(*) — 95 NC(*) — 96 PC-EPC Output 97 Att flux limit EPC Output 98 NC(*) — 99 NC(*) — 100 NC(*) — 101 Swing brake solenoid valve Output 102 NC(*) — 103 NC(*) — 104 NC(*) — 105 NC(*) — 106 NC(*) — 107 Travel alarm Output 108 Battery relay Output 109 2-stage relief solenoid valve Output 110 Travel valve solenoid valve Output 111 NC(*) — 112 Merge-divider solenoid valve (Main) Output 113 NC(*) — 114 Wiper motor (–) Output 115 GND_ACT Input 116 Solenoid power supply Input 117 GND_ACT Input 118 Solenoid power supply Input 119 Wiper motor (+) Output 120 GND_ACT Input 121 Solenoid power supply Input *: Never connect to NC or malfunctions or failures will occur. Pin No.
Signal name
PC300, 300LC, 350, 350LC-8M0
10-600
35
SEN06271-01
Machine monitor system
1. 2. 3. 4. 5. 6. 7. 8. 9.
Machine monitor Battery Pump controller Engine controller
