Professional Documents
Culture Documents
PC350lc PDF
PC350lc PDF
PC350LC -7E0
PC300,300LC- 50001-50216
PC300,300LC- 55001 and up
SERIAL NUMBERS
PC350,350LC- 30001-30093
PC350,350LC- 55001 and up
SEN03539-03
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03539-03 00 Index and foreword
01 Specification SEN03541-00
Specification and technical data SEN03542-00
40 Troubleshooting SEN03558-03
Failure code table and fuse locations SEN04148-02 q
General information on troubleshooting SEN03559-03 q
Troubleshooting by failure code (Display of code), Part 1 SEN03560-02 q
Troubleshooting by failure code (Display of code), Part 2 SEN03561-01
Troubleshooting by failure code (Display of code), Part 3 SEN03562-01
Troubleshooting of electrical system (E-mode) SEN03563-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03564-01
2 PC300, 350-7E0
00 Index and foreword SEN03539-03
PC300, 350-7E0 3
SEN03539-03 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN03539-03
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN03540-01
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data SEN03542-00
Specification dimension drawings............................................................................................ 2
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 10
Table of fuel, coolant and lubricants ........................................................................................ 12
4 PC300, 350-7E0
00 Index and foreword SEN03539-03
PPC accumulator..................................................................................................................... 21
Return oil filter ......................................................................................................................... 22
Center swivel joint ................................................................................................................... 23
Travel motor............................................................................................................................. 24
Swing motor............................................................................................................................. 36
Hydraulic cylinder .................................................................................................................... 45
Work equipment SEN03550-00
Work equipment ...................................................................................................................... 2
Dimensions of components ..................................................................................................... 4
Cab and its attachments SEN03551-00
Air conditioner piping ............................................................................................................... 2
Electrical system SEN03552-02
Engine control.......................................................................................................................... 2
Electronic control system......................................................................................................... 11
Monitor system ........................................................................................................................ 36
Sensor ..................................................................................................................................... 54
KOMTRAX system .................................................................................................................. 57
PC300, 350-7E0 5
SEN03539-03 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN04148-02
Failure codes table .................................................................................................................. 2
Before carrying out troubleshooting when failure code is displayed........................................ 6
General information on troubleshooting SEN03559-03
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Checks before troubleshooting ................................................................................................ 4
Classification and troubleshooting steps ................................................................................. 5
Information in troubleshooting table......................................................................................... 6
Connection table for connector pin numbers ........................................................................... 11
T- branch box and T- branch adapter table.............................................................................. 47
Troubleshooting by failure code (Display of code), Part 1 SEN03560-02
Failure code [AA10NX] Air cleaner Clogging........................................................................... 4
Failure code [AB00KE] Charge Voltage Low ........................................................................... 6
Failure code [B@BAZG] Eng Oil Press. Low........................................................................... 8
Failure code [B@BAZK] Eng Oil Level Low............................................................................. 10
Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 12
Failure code [B@BCZK] Eng Water Level Low ....................................................................... 14
Failure code [B@HANS] Hydr Oil Overheat ............................................................................ 16
Failure code [CA111] EMC Critical Internal Failure.................................................................. 18
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
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 Supply 2 Volt High Error .............................................................. 44
Failure code [CA234] Eng Overspeed ..................................................................................... 45
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 46
Failure code [CA271] IMV/PCV1 Short Error........................................................................... 47
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 48
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error ............................................................ 50
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error ............................................................ 52
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error ............................................................ 54
Failure code [CA325] Inj #6 (L/B#6) Open/Short Error ............................................................ 56
Failure code [CA331] Inj #2 (L/B#2) Open/Short Error ............................................................ 58
Failure code [CA332] Inj #4 (L/B#4) Open/Short Error ............................................................ 60
6 PC300, 350-7E0
00 Index and foreword SEN03539-03
PC300, 350-7E0 7
SEN03539-03 00 Index and foreword
8 PC300, 350-7E0
00 Index and foreword SEN03539-03
PC300, 350-7E0 9
SEN03539-03 00 Index and foreword
10 PC300, 350-7E0
00 Index and foreword SEN03539-03
PC300, 350-7E0 11
SEN03539-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
12
SEN03540-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
1
SEN03540-01 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2
00 Index and foreword SEN03540-01
3
SEN03540-01 00 Index and foreword
4
00 Index and foreword SEN03540-01
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
5
SEN03540-01 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6
00 Index and foreword SEN03540-01
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
7
SEN03540-01 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8
00 Index and foreword SEN03540-01
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
9
SEN03540-01 00 Index and foreword
10
00 Index and foreword SEN03540-01
11
SEN03540-01 00 Index and foreword
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12
00 Index and foreword SEN03540-01
13
SEN03540-01 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14
00 Index and foreword SEN03540-01
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
15
SEN03540-01 00 Index and foreword
16
00 Index and foreword SEN03540-01
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
17
SEN03540-01 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18
00 Index and foreword SEN03540-01
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
19
SEN03540-01 00 Index and foreword
20
00 Index and foreword SEN03540-01
q 114 engine
q 107 engine
21
SEN03540-01 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
00 Index and foreword SEN03540-01
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
23
SEN03540-01 00 Index and foreword
2. Dimensions
(Table 2)
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
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
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 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24
00 Index and foreword SEN03540-01
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
25
SEN03540-01 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26
00 Index and foreword SEN03540-01
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
27
SEN03540-01 00 Index and foreword
28
00 Index and foreword SEN03540-01
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 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 receiving container.
2. 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 portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
29
SEN03540-01 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30
00 Index and foreword SEN03540-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
31
SEN03540-01 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
00 Index and foreword SEN03540-01
33
SEN03540-01 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34
00 Index and foreword SEN03540-01
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
35
SEN03540-01 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36
00 Index and foreword SEN03540-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
37
SEN03540-01 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38
00 Index and foreword SEN03540-01
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
39
SEN03540-01 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–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
40
00 Index and foreword SEN03540-01
41
SEN03540-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN03542-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................. 10
Table of fuel, coolant and lubricants.............................................................................................................. 12
PC300, 350-7E0 1
SEN03542-00 01 Specification
2 PC300, 350-7E0
01 Specification SEN03542-00
1
1
Working ranges 1
PC300, 350-7E0 3
SEN03542-00 01 Specification
Specifications 1
PC300-7E0, PC300LC-7E0
mm 6,480 6,480
depth
Max. digging radius mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,210 10,210
Performance
4 PC300, 350-7E0
01 Specification SEN03542-00
Nm/rpm
Max. torque 1,108/1,450 {113/1,450}
{kgm/rpm}
High idle under no load rpm 2,050
Low idle under no load rpm 1,000
g/kWh
Min. fuel consumption ratio 205 {151}
{g/HPh}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 35 A
Battery 12 V, 126 Ah x 2
Radiator type Aluminum wave type, 4 rows
Carrier roller Two on one side
Undercarriage
PC300, 350-7E0 5
SEN03542-00 01 Specification
MPa
Set pressure 37.8 {380}
{kg/cm2}
Type
piston piston 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 Box-shaped, closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF40-1 (Air-cooling type)
*1: Cushion is provided on head side
*2: Cushion is provided on bottom side
6 PC300, 350-7E0
01 Specification SEN03542-00
PC350-7E0, PC350LC-7E0
mm 6,480 6,480
depth
Max. digging radius mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,210 10,210
Performance
PC300, 350-7E0 7
SEN03542-00 01 Specification
Nm/rpm
Max. torque 1,108/1,450 {113/1,450}
{kgm/rpm}
High idle under no load rpm 2,050
Low idle under no load rpm 1,000
g/kWh
Min. fuel consumption ratio 205 {151}
{g/HPh}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 35 A
Battery 12 V, 126 Ah x 2
Radiator type Aluminum wave type, 4 rows
Carrier roller Two on one side
Undercarriage
8 PC300, 350-7E0
01 Specification SEN03542-00
MPa
Set pressure 37.8 {380}
{kg/cm2}
Type
piston piston piston
Cylinder inner diameter mm 140 160 140
Piston rod diameter mm 100 110 110
Stroke mm 1,480 1,825 1,825
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 Box-shaped, closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler CF40-1 (Air-cooling type)
*1: Cushion is provided on head side
*2: Cushion is provided on bottom side
PC300, 350-7E0 9
SEN03542-00 01 Specification
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
PC300-7E0, PC300LC-7E0
Unit: kg
Machine model PC300-7E0 PC300LC-7E0
Serial number 50001 and up
Engine assembly 1,148 1,148
q Engine 865 865
q Damper 14.3 14.3
q Hydraulic pump 178 178
Radiator and oil cooler assembly 153 153
Hydraulic tank and filter assembly (Not including
176 176
hydraulic oil)
Fuel tank and filter assembly (Not including fuel) 238 238
Revolving frame 2,723 2,723
Cab 292 292
Operator seat 35 35
Counterweight 5,470 5,470
Swing machinery 442 442
Control valve 242 242
Swing motor 88 88
Travel motor 164 x 2 164 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,311 7,979
q Track frame 3,879 4,441
q Swing circle 487 487
q Idler 169 x 2 169 x 2
q Idler cushion 287.5 x 2 287.5 x 2
q Carrier roller 28 x 4 28 x 4
q Track roller 52.2 x 14 52.2 x 16
q Final drive (including travel motor) 583 x 2 583 x 2
Track shoe assembly
q Standard triple shoe (600 mm) 3,470 3,700
q Standard triple shoe (700 mm) 4,030 4,300
q Wide triple shoe (800 mm) 4,380 4,680
q Load liner (Rubber pad type) (600 mm) – –
Boom assembly 2,290 2,290
Arm assembly 1,105 1,105
Bucket assembly 1,015 1,015
Boom cylinder assembly 254 x 2 254 x 2
Arm cylinder assembly 382 382
Bucket cylinder assembly 228 228
Link (large) assembly 316 316
Link (small) assembly – –
Boom pin 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42
Arm pin 13 + 17 13 + 17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
10 PC300, 350-7E0
01 Specification SEN03542-00
PC350-7E0, PC350LC-7E0
Unit: kg
Machine model PC350-7E0 PC350LC-7E0
Serial number 30001 and up
Engine assembly 1,148 1,148
q Engine 865 865
q Damper 14.3 14.3
q Hydraulic pump 178 178
Radiator and oil cooler assembly 153 153
Hydraulic tank and filter assembly (Not including
176 176
hydraulic oil)
Fuel tank assembly (Not including fuel) 238 238
Revolving frame 2,828 2,828
Cab 287 287
Operator seat 35 35
Counterweight 6,370 6,370
Swing machinery 442 442
Control valve 242 242
Swing motor 88 88
Travel motor 164 x 2 164 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,538 8,183
q Track frame 4,074 4,602
q Swing circle 487 487
q Idler 169 x 2 169 x 2
q Idler cushion 287.5 x 2 287.5 x 2
q Carrier roller 28 x 4 28 x 4
q Track roller (double frame) 57.5 x 6 57.5 x 8
q Track roller (single frame) 52.2 x 8 52.2 x 8
q Final drive (including travel motor) 583 x 2 583 x 2
Track shoe assembly
q Standard triple shoe (600 mm) 3,670 3,920
q Standard triple shoe (700 mm) 4,030 4,300
q Wide triple shoe (800 mm) – –
q Load liner (Rubber pad type) (600 mm) – –
Boom assembly 2,450 2,450
Arm assembly 1,211 1,211
Bucket assembly 1,508 1,508
Boom cylinder assembly 254 x 2 254 x 2
Arm cylinder assembly 382 382
Bucket cylinder assembly 228 228
Link (large) assembly 316 316
Link (small) assembly – –
Boom pin 76 + 15x2 + 56 + 17 + 42 76 + 15x2 + 56 + 17 + 42
Arm pin 13 + 17 13 + 17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
PC300, 350-7E0 11
SEN03542-00 01 Specification
12 PC300, 350-7E0
01 Specification SEN03542-00
Unit: l
PC300/300LC-7E0, PC350/350LC-7E0
Reservoir
Specified (l) Refill (l)
Engine oil pan 38 35
Swing machinery case 16.5 16.5
Final drive case (each) 8.5 8.5
Damper case 1.3 1.3
Hydraulic system 365 188
Fuel tank 605 —
Cooling system 32 —
PC300, 350-7E0 13
SEN03542-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
14
SEN03544-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03544-00 10 Structure, function and maintenance standard
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03544-00
Specifications
Radiator: Aluminum wave type, 4th row
Oil cooler: CF40-1
PC300, 350-7E0 3
SEN03544-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
4
SEN03545-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03545-00 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 (HMF230ABE-5)
12. Swing circle
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03545-00
PC300, 350-7E0 3
SEN03545-00 10 Structure, function and maintenance standard
Final drive 1
Specifications
Reduction ratio: –((11+97)/11) x ((19+97)/19) = –58.943
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03545-00
Unit: mm
No. Check Item Criteria Remedy
Backlash between No. 1 sun gear Standard clearance Clearance limit
15 and No.1 planetary gear
0.12 – 0.44 0.9
Backlash between No. 1 planetary
16 gear and ring gear
0.18 – 0.62 1.2
PC300, 350-7E0 5
SEN03545-00 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip
336.5 324.5
Build-up welding
2 Thickness of tooth root 20 14
for rebuilding or
3 Width of tooth 87 84 replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth
4 Wear of tooth shape shape)
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03545-00
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.
PC300, 350-7E0 7
SEN03545-00 10 Structure, function and maintenance standard
Swing machinery 1
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03545-00
Specifications
Reduction ratio: ((19+68)/19) x ((24+68)/24) = 17.553
Unit: mm
No. Check Item Criteria Remedy
Backlash between swing motor Standard clearance Clearance limit
15 shaft and No. 1 sun gear
0.18 – 0.28 –
Backlash between No. 1 sun gear
16 and No.1 planetary gear
0.15 – 0.51 1.00
PC300, 350-7E0 9
SEN03545-00 10 Structure, function and maintenance standard
Swing circle 1
Specifications
Reduction ratio: –90/13 = –6.923
Amount of grease: 33 l (G2-LI)
Unit: mm
No. Check Item Criteria Remedy
Axial clearance of bearing (when Standard clearance Clearance limit
4 mounted on chassis) Replace
0.5 – 1.6 3.2
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03545-00
PC300, 350-7E0 11
SEN03545-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
12
SEN03546-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial No.
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03546-00 10 Structure, function and maintenance standard
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03546-00
Standard shoe
Models
PC300-7E0 PC350-7E0 PC300LC-7E0 PC350LC-7E0
Item
Shoe width (triple shoe) (mm) 600 600 700 600
Link pitch (mm) 216 216 216 216
No. of shoes (one side) 45 45 48 48
Unit: mm
No. Check Item Criteria Remedy
Standard size Tolerance Rapair limit
Track +2
Vertical width of idler 123 127
9 guide frame –1
Idler sup- Build-up welding
120 ±0.5 118 for rebuilding or
port
replace
Track +3
266 271
Horizontal width of idler frame –1
10 guide Idler sup-
261 — 259
port
Standard size Rapair limit
Free length x Installation Installation Installation
Free length
11 Recoil spring O.D. length load load Replace
208.7 kN 167.0 kN
811 x 261 655 —
{21,290 kg} {17,030 kg}
PC300, 350-7E0 3
SEN03546-00 10 Structure, function and maintenance standard
Idler 1
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03546-00
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of protrusion
635 —
2 Outside diameter of tread 590 578
Build-up welding for
3 Difference of tread 22.5 28.5 rebuilding or
4 Thickness of tread — — replace
PC300, 350-7E0 5
SEN03546-00 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of flange
179 —
2 Outside diameter of tread 152 138
3 Width of tread 50.3 —
4 Thickness of tread 32 25
5 Width of flange 19 —
Standard Tolerance Standard Clearance
Clearance between shaft and bush- size Shaft Hole clearance limit Replace
6 ing –0.250 +0.074 0.250 –
54 —
–0.280 +0.040 0.354
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
7 bushing +0.117 +0.030 0.057 –
61 —
+0.087 +0.040 0.117
Standard clearance Clearance limit
8 Axial clearance of roller
0.5 – 0.7 —
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03546-00
Track roller 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange
216 —
Outside diameter of inner flange
2 (Double flange)
210 —
PC300, 350-7E0 7
SEN03546-00 10 Structure, function and maintenance standard
Track shoe 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch
216.3 219.3 Reverse or
Standard size Reverse replace
2 Outside diameter of bushing
66.9 61.9
3 Thickness of bushing metal 10.8 5.8 Adjust or replace
Standard size Repair limit
4 Link height
116 107
Repair or replace
Thickness of link metal (bushing
5 press-fitting portion)
30.7 21.7
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03546-00
Unit: mm
No. Check Item Criteria Remedy
6 178.4
7 Shoe bolt pitch 140.4 Replace
8 76.2
Inside
9 width
102
Overall
10 Link width
47.8 Repair or replace
Tread
11 width
42.6
Tolerance
Standard size Standard clearance
Clearance between regular pin and Shaft Hole
23 bushing +0.235 +0.915
44.6 0.180 – 0.830 Adjust or replace
+0.085 +0.415
Tolerance Standard interfer-
Standard size
24 Interference between master pin Shaft Hole ence
(*) and link +0.03 –0.188
44.6 0.188 – 0.280
+0.03 –0.250
Tolerance
Standard size Standard clearance
25 Clearance between master pin and Shaft Hole
(*) bushing +0.050 +0.915
44.3 0.365 – 0.965
–0.050 +0.415
PC300, 350-7E0 9
SEN03546-00 10 Structure, function and maintenance standard
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Height 36 24
(*) 30 18
2 Thickness 11
32
3
(*) 29
Length of base
26
4
(*) 24 Build-up welding
24 for rebuilding or
5 replace
(*) 22
18
6 Length at tip
(*) 16
18
7
(*) 22
Standard size Repair limit
8 Thickness 47 35
(*) 41 29
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03546-00
PC300, 350-7E0 11
SEN03546-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
12
SEN03547-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03547-00 10 Structure, function and maintenance standard
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
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 3
SEN03547-00 10 Structure, function and maintenance standard
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 5
SEN03547-00 10 Structure, function and maintenance standard
Hydraulic pump 1
Type: HPV125+125
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
EPC valve and variable volume valve.
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, 350-7E0 7
SEN03547-00 10 Structure, function and maintenance standard
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
Function
q The pump converts the engine rotation trans-
mitted to the shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by q Piston (6) carries out relative movement in the
spline (14). axial direction inside each cylinder chamber of
q Shaft (1) is supported by front and rear bear- cylinder block (7).
ings (15). q Cylinder block (7) seals the pressurized oil to
q Tip of piston (6) is shaped as a concave ball valve plate (8) and carries out relative rotation.
and shoe (5) is caulked to it to form one unit. q This surface is designed so that the oil pres-
q Piston (6) and shoe (5) constitute the spherical sure balance is maintained at a suitable level.
bearing. q The oil inside each cylinder chamber of cylin-
q Rocker cam (4) has flat surface (A), and shoe der block (7) is suctioned and discharged
(5) is always pressed against this surface while through valve plate (8).
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 pres-
sure bearing when it slides.
PC300, 350-7E0 9
SEN03547-00 10 Structure, function and maintenance standard
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
th e axia l d ir ection of cylinde r bloc k ( 7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 11
SEN03547-00 10 Structure, function and maintenance standard
1. LS valve
12 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
Operation
q The LS valve is a 3-way selector valve, with q Spool (6) is pushed to the right, and port (C)
pressure (PLS) (LS pressure) from the outlet and port (D) will be connected.
port of the control valve brought to spring q Pump pressure (PP) is conducted to the larger
chamber (B), and main pump discharge pres- diameter end from the port (K).
sure (PP) brought to port (H) of sleeve (8). q The same pump pressure (PP) is conducted to
q Magnitude of the force resulting from this LS the smaller diameter end from the port (J).
pressure (PLS), force of spring (4) and the q According to the difference in the areas on
pump delivery pressure (self pressure) (PP) servo piston (12), the pressure moves in such
determine the position of spool (6). that the swash plate angle may be minimized.
q 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)
q Before the engine is started, servo piston (12) is
pushed to the right. (See the figure)
q 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 intercon-
nected to the drain circuit via the control valve
spool)
PC300, 350-7E0 13
SEN03547-00 10 Structure, function and maintenance standard
q When the difference between the main pump q If the output pressure of the EPC valve for the
pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is
words, LS differential pressure (EPLS) generated on piston (7).
becomes smaller (for example, when the area q If piston (7) is pushed to the right, setting force
of opening of the control valve becomes larger of spring (4) is weakened, changing the LS dif-
and pump pressure PP drops), spool (6) is ferential pressure (EPLS) [Difference between
pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D)
pressure (PLS) and the force of spring (4). and (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q 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.)
q 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 dis-
charge amount larger.
14 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 15
SEN03547-00 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the
the large diameter end of the piston as (A1), position of the balanced stop of this spool (6)
the area receiving the pressure at the small may be determined when (PP) – (PLS) = 2.45
diameter end as (A0), and the pressure flowing MPa {25 kg/cm2} on the front pump side and
into the large diameter end of the piston as (PP) – (PLS) = 2.55 MPa {26 kg/cm2} on the
(PEN). rear pump side at the median of the specified
q If the main pump pressure (PP) of the LS valve value.
and the combined force of spring (4) and LS q If (PSIG) [Output pressure of LS-EPC valve, 0
pressure (PLS) are balanced, and the relation- to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G),
ship is (A0) x (PP) = (A1) x (PEN), servo piston the position of the balanced stop is changed.
(12) will stop in that position. The front pump side will be moved in the range
q And the swash plate of the pump will be held in of (PP) –(PLS) = 2.45 to 0.98 MPa {25 to 0 kg/
an intermediate position. [Spool (6) will be cm2} and the rear pump will be moved in the
stopped at a position where the distance of the range of (PP) – (PLS) = 2.55 to 1.08 MPa {26
opening from port (D) to port (E) and the dis- to 11 kg/cm2} in proportion to (PSIG) pressure.
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
16 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
2. PC valve
Function
q When the pump discharge pressure (PP1) q If the engine speed goes below the specified
(self-pressure) and (PP2) (other pump pres- value because of increased load, the controller
sure) are high, the PC valve controls the pump sends a command current to PC-EPC valve
so that the volume of oil beyond the discharge solenoid in order to reduce the slope angle in
pressure-based specific flowrate may not be proportion to reduction in the engine speed.
conducted however you may increase the con-
trol valve stroke. Namely it is intended at con-
trolling 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 delivery.
q And if the pump delivery pressure goes low, it
increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (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 delivery to recover the speed.
PC300, 350-7E0 17
SEN03547-00 10 Structure, function and maintenance standard
Operation
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
18 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 19
SEN03547-00 10 Structure, function and maintenance standard
Action of spring
q Load of springs (4) and (6) on the PC valve is q When pump pressures (PP1) and (PP2) are
determined by the swash plate position. small, spool (3) will be positioned in the left
q As servo piston (9) moves to right, spring (6) is side.
retracted. q Port (C) and (D) are connected, and the pres-
q If the servo piston moves further, it will be con- sure entering the LS valve becomes drain
tacted again seat (5) and spring (6) will be pressure (PT).
fixed. q If port (E) and port (G) of the LS valve are con-
q After that, spring (4) alone will operate. nected, the pressure entering the large diame-
q The spring load is changed by servo piston (9) ter end of the piston from port (J) becomes
as it extends or compresses springs (4) and drain pressure (PT), and servo piston (9)
(6). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Accompanied with move of servo piston (9),
q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the
affected by the command current (X) to PC- spring force becomes weaker.
EPC valve solenoid. q As the spring force is weakened, spool (3)
q Port (C) of the PC valve is connected to port moves to the right, the connecting between
(E) of the LS valve. port (C) and port (D) is shut off and the pump
q Self pressure (PP1) enters port (B) and the discharge pressure ports (B) and (C) are con-
small diameter end of servo piston (9), and nected.
other pump pressure (PP2) enters port (A).
20 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 21
SEN03547-00 10 Structure, function and maintenance standard
(2) When load on actuator is large and pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) via LS valve. At the end this flow, level to make the pump delivery the minimum.
of this pressure becomes approximately half of q When servo piston (9) moves to the right,
the main pump pressure (PP2). 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 pis-
ton (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.
22 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
PC300, 350-7E0 23
SEN03547-00 10 Structure, function and maintenance standard
2) As the emergency pump drive switch is turned on due to failure on the pump controller
q If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the discharge amount
q In this case, the power is directly supplied from larger.
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure 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.
q 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.
24 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on In the same way as in above, the command drive switch is ON is situated further to the left
current (X) sent to PC-EPC valve solenoid (1) (B) than when the pump controller is normal
becomes constant. (A).
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q 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.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the figure correspond-
ing to the current sent to the PC-EPC valve
solenoid through the resistor.
PC300, 350-7E0 25
SEN03547-00 10 Structure, function and maintenance standard
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
26 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0 (coil is deener-
tion. gized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is deenergized.
sure in proportion to the size of the signal, and q Spool (5) is pushed to the left by spring (4).
outputs it to the LS (PC) valve. q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank via port (C) and port (T).
PC300, 350-7E0 27
SEN03547-00 10 Structure, function and maintenance standard
2) When signal current is very small (coil is 3) When signal current is maximum (coil is
energized) energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and LS
shut off from port (C). (PC) valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be balance
with pressure of port (C) + spring load of spring
(4).
q The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in propor-
tion to the size of the signal current.
28 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03547-00
Function
q The variable volume valve stabilizes the EPC
valve's output pressure.
Operation
q Output pressure from EPC valve is conducted
to port (C) and as the result propulsion force of
piston (3) is increased by the load of spring (4).
q Piston (3) is pushed to the left, and volume of
port (C) is increased.
q The propulsion force of piston (3) becomes
smaller than the load of spring (4).
q Piston (3) is pushed toward right, and volume
of port (C) is decreased.
PC300, 350-7E0 29
SEN03547-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
30
SEN03548-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03548-01 10 Structure, function and maintenance standard
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 con-
nected to each other inside the assembly, the
assembly is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in construc-
tion.
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
General view
PC300, 350-7E0 3
SEN03548-01 10 Structure, function and maintenance standard
Sectional view
(1/5)
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Unit: mm
PC300, 350-7E0 5
SEN03548-01 10 Structure, function and maintenance standard
(2/5)
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Unit: mm
PC300, 350-7E0 7
SEN03548-01 10 Structure, function and maintenance standard
(3/5)
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Unload valve
2. Safety valve (Boom raise)
3. Main relief valve
4. Lift check 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)
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm
PC300, 350-7E0 9
SEN03548-01 10 Structure, function and maintenance standard
(4/5)
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divide valve (Main)
6. 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)
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
PC300, 350-7E0 11
SEN03548-01 10 Structure, function and maintenance standard
(5/5)
12 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
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
PC300, 350-7E0 13
SEN03548-01 10 Structure, function and maintenance standard
CLSS 1
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity pis-
tem, which has the following characteristics: ton pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
14 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Basic principle
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
(EPLS) (the difference between pump pres- (EPLS) is lower than the set pressure of the
sure PP and control valve outlet port LS pres- LS valve (when the actuator load pressure is
sure PLS) (load pressure of actuator) is high).
constant. q If it becomes higher than the set pressure
q [LS differential pressure (EPLS) = Pump dis- (when the actuator load pressure is low), the
charge pressure (PP) – LS pressure (PLS)] pump swash plate angle shifts toward the mini-
mum position.
PC300, 350-7E0 15
SEN03548-01 10 Structure, function and maintenance standard
16 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
3. System diagram
PC300, 350-7E0 17
SEN03548-01 10 Structure, function and maintenance standard
18 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
PC300, 350-7E0 19
SEN03548-01 10 Structure, function and maintenance standard
Unload valve
1. When the unload valve is actuating
Function Operation
q Drains an oil discharge for the portion of the q Pressure of pump circuit (3) is received by the
minimum pump swash plate angle while all end of valve (2).
control valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set pressure of LS circuit (1) is 0 MPa{0 kg/cm2}.
load of spring (5) inside the valve (this pres- q Pressurized oil of pump circuit (3) stops at
sure will be P1). valve (2), and the pressure rises as no relief is
q Since LS pressure is drained from the LS available.
bypass valve, LS pressure C tank pressure C 0 q When this pressure becomes larger than the
MPa{0 kg/cm2}. 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.
20 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
PC300, 350-7E0 21
SEN03548-01 10 Structure, function and maintenance standard
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (down-
stream pressure of the spool meter-in) of pres-
sure compensation valve (3) and leads to LS
shuttle valve (7) as the LS pressure.
q Connected to actuator port (B) via valve (4),
and makes LS pressure C actuator load pres-
sure.
q Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.
Operation
q 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.
22 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
LS bypass plug
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. 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 pres-
sure.
q Bypass flow from LS bypass plug (5) causes a
pressure loss to be generated 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, 350-7E0 23
SEN03548-01 10 Structure, function and maintenance standard
(If the load pressure is higher than other work equipment during a combined operation)
24 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
2. 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 meter-
in 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 according 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 pres-
sure 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, 350-7E0 25
SEN03548-01 10 Structure, function and maintenance standard
Function
q The state of division changes according to the
area ratio of pressure compensation portion
(A1) and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1 : the spool meter-in down-
stream 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.
26 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle
valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by port
(A) pressure and cuts off 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 sepa-
rated.
PC300, 350-7E0 27
SEN03548-01 10 Structure, function and maintenance standard
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensa-
tion valve without shuttle valve (3) is adopted.
28 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Hydraulic pump
2. Boom spool
3. Pressure compensation valve
4. Safety-suction valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q Provides the regeneration circuit from the cyl- q If the cylinder head pressure is lower than the
inder bottom to the cylinder head when the bottom pressure, pressurized oil (A) from the
boom is lowered and increases flow to the cyl- cylinder bottom flows to drain circuit (B) from
inder head. 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).
PC300, 350-7E0 29
SEN03548-01 10 Structure, function and maintenance standard
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
30 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Hydraulic pump
2. Arm spool
3. Pressure compensation valve
4. Safety-suction valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q During arm digging, regeneration circuit pro- q If the cylinder head pressure is lower than the
vided from the cylinder head to the bottom bottom pressure, pressurized oil (A) from the
increases the cylinder speed as the cylinder cylinder bottom flows to drain circuit (B) from
flow involves the pump delivery plus regener- the notch of arm spool (2).
ated flow. q On the other hand, remaining oil flows to
regeneration circuit (C), opens check valve (6)
and flows to the cylinder bottom via circuit (D).
q Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
PC300, 350-7E0 31
SEN03548-01 10 Structure, function and maintenance standard
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
32 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Merge-divider valve 1
1. When flows from the pumps merge [if pilot pressure (PS) is OFF]
Function Operation
q Merges pressurized oil (P1) and (P2) dis- q Since pilot pressure (PS) is OFF, output pres-
charged from the two pumps or divides (to sure from PPC valve is 0 kg/cm2.
respective control valve group). q Main spool (1) is pressed to the right by spring
q Merges and divides LS circuit pressure. (2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) dis-
charged from the two 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), and
ports (A) - (D) and ports (B) - (C) are intercon-
nected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and
(8) to all the pressure compensation valves.
PC300, 350-7E0 33
SEN03548-01 10 Structure, function and maintenance standard
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
q Pilot pressure (PS) turns ON, and output pres-
sure from the PPC valve shifts main spool (1)
to the left, and ports (E) and (F) are divided.
q Pressurized oil discharged from the two pumps
are sent to respective control valves.
34 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
LS select valve
Function Operation
q Prevents high LS pressure from the swinging 1. If pilot pressure (BP) is OFF
from entering the LS circuit of work valves q Since pilot pressure (BP) is OFF, piston (3) is
while the swinging and work equipment are in pressed to the left by spring (2).
combined operation. q When swing-operated, swing LS pressure (P1)
q Prevents high pressure generated during enters port (A) after passing swing spool (5).
swing drive and improves operability of work q Valve (1) is pressed to the left and ports (A)
equipment. and (B) are interconnected.
q Swing LS pressure (P1) flows to LS shuttle
valve (8).
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
PC300, 350-7E0 35
SEN03548-01 10 Structure, function and maintenance standard
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).
36 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
2. During neutral and when load pressure (P2) 3. When load pressure (P2) is high
is low q Load pressure (A2) increases with the opera-
a When load pressure (A2) is lower than self tion of digging, etc., and the pump discharge
pressure reducing valve output pressure (PR) increases accordingly.
q Pressure (P2) increases to [(φd area x P2 pres-
q Valve (7) is pressed to the closing direction of sure) = force of spring (8) + ( φ d area x PR
circuit between ports (P2) and (A2) by spring pressure)]., and valve (7) moves to the right to
(8) and under pressure (PR) (which is 0 MPa the stroke end.
{0 kg/cm2}). q As a result, opening between ports (P2) and
q When pressurized oil flows in from port (P2), a (A2) increases, and the pass resistance
balance is reached due to [(φd area x P2 pres- reduces, reducing the engine horsepower loss.
sure) = force of spring (8) + ( φ d area x PR q When pressure (PR) rises above the set pres-
pressure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure q Pressurized oil flows from port (PR) to orifice
(P2) at a constant level over pressure (PR). (a) in spool (14), then flows to seal drain port
q When pressure (PR) rises above the set pres- (TS) from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and
q Pressurized oil flows from port (PR) to orifice after orifice (a) in spool (14) and then spool
(a) in spool (14), then flows to seal drain port (14) moves to close the pass between ports
(TS) from poppet (11) opening. (P2) and (PR).
q Differential pressure is generated before and q Pressure (P2) is reduced by the opening at this
after orifice (a) in spool (14) and then spool time and adjusted to a constant pressure (the
(14) moves to close the pass between ports set pressure) and supplied as pressure (PR).
(P2) and (PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the
set pressure) and supplied as pressure (PR).
PC300, 350-7E0 37
SEN03548-01 10 Structure, function and maintenance standard
38 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Function Operation
q This valve connects the L.H. and R.H. travel q Pilot pressure from the travel junction solenoid
circuits via travel junction valve so that the valve contracts spring (1), and travel junction
hydraulic oil will be supplied evenly to both spool (2) moves to the left to the stroke end.
travel motors to improve machine's straight q Junction circuit between port (PTL) (L.H. travel
travel performance. circuit) and port (PTR) (R.H. travel circuit) is
q When the machine is steered, outside pilot closed.
pressure (PST) closes the travel junction valve
to improve steering performance.
PC300, 350-7E0 39
SEN03548-01 10 Structure, function and maintenance standard
Operation
q If pilot pressure (PST) from the solenoid valve q If the oil flow rates to the L.H. and R.H. travel
is 0, travel junction spool (2) is pressed by the motors become different from each other, the
force of spring (1) against the right side and oil flows through the route between port (PTL),
the pass between ports (PTL) and (PTR) is travel junction spool (2), and port (PTR) so that
open. the oil flow rates to both motors will be equal-
ized again.
40 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Function Operation
q Regulates flow to each cylinder by controlling q The oil in stroke regulation signal chamber (a)
the stroke of each spool of the boom, arm, and is drained through orifices (5) and (6) of pis-
bucket using the pilot pressure of travel PPC tons (3) and (4) in the travel spring case and
valve while climbing a steep grade, raising the the travel PPC valve.
boom, digging with arm, dumping, bucket-dig- q When operated for boom raising (or arm dig-
ging or operating dump. ging, dumping, bucket digging, dumping),
q When controlling the stroke of the boom, arm spool (1) moves to the left until it makes con-
and/or bucket, pilot pressure of travel PPC tact with the end face of spring casing (2) (st0).
valve passes through the circuit inside the con-
trol valves to actuate the system.
PC300, 350-7E0 41
SEN03548-01 10 Structure, function and maintenance standard
2. When traveling
Operation
q If the right travel lever is set in the reverse (or q Maximum stroke of the spool is limited to (st1)
forward) direction, pilot pressure from the PPC for the amount of movement (st2) of piston (8)
valve presses spool (7) to the left (or right). to the 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 operated for boom raising (or arm IN,
OUT, bucket CURL, DUMP), spool (1) moves
to the left.
42 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
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 the boom is raised, 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, 350-7E0 43
SEN03548-01 10 Structure, function and maintenance standard
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 Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
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.
44 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
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 pop-
pet is drained via orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in 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, 350-7E0 45
SEN03548-01 10 Structure, function and maintenance standard
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 the arm OUT is operated, 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 diam-
eter (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.
46 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Operation
q Moves the lever to neutral with the arm
dumped.
q Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
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, 350-7E0 47
SEN03548-01 10 Structure, function and maintenance standard
3. When arm IN
Operation
q When the arm IN is operated, pilot spool (2) is
pushed under the pilot pressure from the PPC
valve.
q Pressurized oil in chamber (b) inside the pop-
pet is drained via orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T), and
the pressurized oil 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.
48 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
q If abnormally high pressure is generated in the q If arm drift prevention valve (optional) is
boom cylinder bottom circuit, the pressurized installed to the arm cylinder head circuit, the
oil in port (B) pushes check valve (6) open, boom cylinder bottom circuit pressure force or
then safety valve (3) operates. arm cylinder head circuit pressure force,
whichever having higher pressurized oil,
pushes check valve (6) or (6A) open to actuate
safety valve (3).
PC300, 350-7E0 49
SEN03548-01 10 Structure, function and maintenance standard
Function
q When arm OUT, large volume of oil returns
from the cylinder bottom.
q Reduces this pressure loss.
Operation
q When the arm OUT is operated, pilot spool (1) increases by the sum of the pressure receiving
is pushed under the pilot pressure from the force of pressure receiving portion[φ d1 area
PPC valve. (S1)] on the chamber (b) side of valve (2) and
q Pressurized oil in chamber (b) inside the valve the spring force.
is drained via orifice (c). q Or (φd2 pressure receiving force > φd1 pres-
q Pressurized oil of the arm bottom side flows to sure receiving force + spring force)
orifice (a) o chamber (b) o orifice (c) o drain q Valve (2) is pressed to the left and pressurized
(T), and the pressure in chamber (b) lowers. oil is led from port (A) to (B).
q If the pressure of chamber (b) drops lower than q From port (B), pressurized oil is drained
that of port (A), pressure receiving force of the directly to the tank.
pressure receiving portion [φd2 area (S2) (seat
d i am e te r a r ea ) ] o n th e s i d e o f po r t ( A )
50 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
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, 350-7E0 51
SEN03548-01 10 Structure, function and maintenance standard
52 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Spring
2. Poppet
Function
q Set pressure of the relief valve is in two stages.
q When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes
higher.
Operation
q 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 com-
pletes the setting of the 2nd stage.
PC300, 350-7E0 53
SEN03548-01 10 Structure, function and maintenance standard
1. Spring
2. Piston
3. Spring
4. Holder
Function Operation
q Enables to provide the safety valve set pres- q The safety set pressure is determined by
sure in two stages, and make the low-pressure spring (1) installed load.
setting smaller.
q Enables to relieve a load without lever opera- 1. If pilot pressure is OFF (high-pressure set-
tion if high load is applied to the cylinder. ting)
q Improves work efficiency and reduces machine q Since pilot pressure (P) is OFF, piston (2) is
body vibration. pressed to the left by spring (3). [Spring (1)
installed load < spring (3) installed load]
q Spring (1) installed load becomes maximum
and the set pressure rises.
q Passage (B) is interconnected to the drain cir-
cuit via passage (C) and chamber (D).
54 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
PC300, 350-7E0 55
SEN03548-01 10 Structure, function and maintenance standard
56 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
Operation when jointly operated with a high- q If the difference between the pump discharge
load work equipment (such as the boom rais- pressure (P) and cylinder port pressure (B) is
ing) larger than the force of spring (5), poppet (4) is
pressed to the right.
q Both of the pump discharge pressure (P) and
q Pump discharge pressure (P) flows to orifice
LS pressures are determined by other equip-
(a) and chamber (g) and is interconnected to
ment's pressure, while cylinder port pressure
cylinder port via passages (b) and (c).
causes the attachment to operate.
q Differential pressure is generated between the
q If the difference between the pump discharge
upstream and downstream of orifice (a), which
pressure (P) and cylinder pressure is smaller
reduces the pressure force in chamber (g).
than the force of spring (5), the balance of
q Force that presses valve (1) to the left is
forces applying to valve (1) may be expressed
reduced.
with the following equation:
q A state is reached where the area ratio has
become smaller.
P x A1 = P x A2 + LS(A2 – 1) + F
q Valve (1) moves to the right, and the flow
increases from the pump to the cylinder.
A1: Area of φD1
A2: Area of φD2
F: Force of spring
P: Pump discharge oil pressure
PC300, 350-7E0 57
SEN03548-01 10 Structure, function and maintenance standard
Unit: mm
58 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
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 2. When breaker is installed
installed q Pilot pressure from the attachment circuit
q Spool (1) is pressed to the left by the force of selector solenoid valve contracts spring (2),
spring (2). and spool (1) moves to the right to the stroke
q Ports (ATT) and (V) are interconnected and end.
ports (ATT) and (T) are shut off. Attachment is q Ports (ATT) and (V) are shut off and ports
thus interconnected to the control valve. (ATT) and (T) are interconnected.
q Pressurized oil returning from the breaker
returns directly to the hydraulic tank via port (T)
without passing through the control valve.
PC300, 350-7E0 59
SEN03548-01 10 Structure, function and maintenance standard
60 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
1. Pilot spool
2. Spring (1st stage spool)
3. Spring (2nd stage spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed
Free length
7 Check valve spring Outside diameter length load load
12.7 N 10.2 N
20.8 x 12.2 13.5
{1.3 kg}
— {1.04 kg} If damaged or
58.8 N 47.1 N deformed, replace
8 Spool return spring 41.1 x 9.6 35.0
{6.0 kg}
— {4.8 kg} spring.
78.5 N 62.8 N
9 Spool return spring 41.9 x 25.8 41.0
{8.0 kg}
— {6.4 kg}
181 N 145 N
10 Spool return spring 44.6 x 25.6 41.0
{18.5 kg}
— {14.8 kg}
PC300, 350-7E0 61
SEN03548-01 10 Structure, function and maintenance standard
Function
q Prevents the pressurized oil from reversing
from the work equipment cylinder and the latter
from a sudden drop if the piping bur sts
between the control valve and the work equip-
ment cylinder.
Operation
1. When the work equipment lever is in neutral
62 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
2. When pressurized oil flows from the main valve to the cylinder
PC300, 350-7E0 63
SEN03548-01 10 Structure, function and maintenance standard
3. When returning pressurized oil to the main valve from the work equipment cylinder
64 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03548-01
PC300, 350-7E0 65
SEN03548-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
66
SEN03549-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03549-00 10 Structure, function and maintenance standard
Valve control 1
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PPC valve 1
Work equipment and swing PPC valve
PC300, 350-7E0 3
SEN03549-00 10 Structure, function and maintenance standard
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever connection)
Unit: mm
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Operation
1. When in neutral q The relationship of the position of spool (1) and
q Ports (A) and (B) of the control valve and ports body (10) [fine control hole (f) is in the middle
(P1) and (P2) of the PPC valve are connected between drain chamber (D) and pump pres-
to drain chamber (D) via fine control hole (f) in sure chamber (PP)] does not change until
spool (1). retainer (9) contacts spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
the stroke of the control lever.
q 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.
PC300, 350-7E0 5
SEN03549-00 10 Structure, function and maintenance standard
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 7
SEN03549-00 10 Structure, function and maintenance standard
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 9
SEN03549-00 10 Structure, function and maintenance standard
1. Plate
2. Body
3. Piston
4. Collar
5. Centering spring
6. Metering spring
7. Valve
8. Dumper
9. Steering signal spool
10. Steering signal spool spring
Unit: mm
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 11
SEN03549-00 10 Structure, function and maintenance standard
3) During fine control q Therefore, the pilot pressure oil from the self
(When control lever is returned) pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from
is pushed up by the force of centering spring port (P1) to push the control valve spool.
(3) and pressure at port (P1). q The oil returning from chamber (B) passes
q Because of this, fine control hole (f) is con- from port (P2) through fine control hole (f') and
nected to drain chamber (D), and the pressur- flows to drain chamber (D).
ized oil at port (P1) is released.
q If the pressure of port (P1) is lowered exces-
sively, spool (1) is pushed down by metering
spring (2).
q Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
tion, the higher one of the PPC output
pressures of both sides is output as the steer-
ing signal.
q Any signal is not output from port (P6) while
the machine is travelling straight (forward or
reverse) or in neutral.
4) At full stroke
q Accordingly, whether the machine is being
q Lever (5) pushes down piston (4), and retainer
steered is judged by the signal of port (P6).
(9) pushes down spool (1).
q Fine control hole (f) is shut off from drain
chamber (D), and is interconnected to pump
pressure chamber (PP).
12 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Operation
1) When in neutral
PC300, 350-7E0 13
SEN03549-00 10 Structure, function and maintenance standard
14 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
a The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.
q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering sig-
between both sides is higher than a certain nal.
level), the pilot pressure is output as the steer-
ing signal.
q The pressure in left spring chamber (k) of
steering signal spool (j) is (P2).
q The pressure in right spring chamber (l) is
(P4).
q When the pressure state reaches [(P4 - P2) x
(Spool section) > Spring set load], the spool is
switched to the direction of the arrow.
PC300, 350-7E0 15
SEN03549-00 10 Structure, function and maintenance standard
4) When counter-rotated
a The illustration shows the circuit for travelling left reverse and right forward.
16 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
a For the details of operation, see the paragraph of “Work equipment swing PPC valve.“
PC300, 350-7E0 17
SEN03549-00 10 Structure, function and maintenance standard
Unit: mm
18 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Solenoid valve 1
PPC lock, travel junction, merge-divider, travel speed, swing brake, machine push-up and 2-stage
relief solenoid valves
PC300, 350-7E0 19
SEN03549-00 10 Structure, function and maintenance standard
1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring
Operation
When solenoid is deenergized When solenoid is energized
q Since the signal current does not flow from the q The signal current flows from the controller to
controller, solenoid (3) is deenergized. For this solenoid (3), and the latter is energized.
reason, spool (4) is pushed to the left by spring Accordingly, spool (4) is pressed against to the
(6). By this operation, the pass from port (P) to right side. By this operation, the pressurized oil
port (A) is closed and the pressurized oil from from the main pump flows through port (P) and
the main pump does not flow into the actuator. spool (4) to port (A), then flows into the actua-
At this time, the oil from the actuator is drained tor. At the same time, port (T) closes and stops
through ports (A) and (T) into the tank. the oil from flowing to the tank.
20 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
PC300, 350-7E0 21
SEN03549-00 10 Structure, function and maintenance standard
For breaker
22 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 shaft Replace
80 — —
PC300, 350-7E0 23
SEN03549-00 10 Structure, function and maintenance standard
Travel motor 1
Type: HMV160ADT-3
24 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 25
SEN03549-00 10 Structure, function and maintenance standard
1. Output shaft
2. Motor case
3. Rocker cam
4. Piston
5. Cylinder block
6. Valve plate
7. End cover
8. Slow return valve
9. Brake spring
10. Brake piston
11. Plate
12. Disc
13. Regulator piston
14. Check valve
15. Counterbalance valve
16. Safety valve
17. Ball
18. Regulator valve
19. Spring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installed Installed
Free length
20 Spool return spring Outside diameter length load load
427 N 341 N
58.43 x 30.0 42.0 —
{43.5 kg} {34.8 kg} If damaged or
1.27 N 0.98 N deformed, replace
21 Check valve spring 33.0 x 13.8 23.0
{0.13 kg}
—
{0.10 kg} spring.
Regulator piston 221 N 177 N
22 spring 61.1 x 23.2 43.9
{22.5 kg}
—
{18.0 kg}
Regulator valve 98.1 N 78.5 N
23 spring 29.6 x 9.0 26.0
{10.0 kg}
—
{8.0 kg}
26 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is deenergized, the pilot q The combined force of the piston propulsion
pressurized oil from the self pressure reducing forces works as the moment of inclining rocker
valve does not flow to port (P). cam (3) toward the maximum swash plate
q Regulator valve (21) is pushed to the right by angle.
spring (22). q The pressurized oil at regulator piston (13)
q Pressurized oil being conducted from the con- passes through orifice (c) of regulator valve
trol valve to end cover (7) by pressing slow (21) and is drained to the motor case.
return valve (8) is shut off by regulator valve q Rocker cam (3) is inclined in the maximum
(21). swash plate angle direction. The motor capac-
q Fulcrum (a) of rocker cam (3) is eccentric to ity becomes maximum, turning on the low
the working point (b) of the combined force of speed travel.
the propulsion force of cylinder (5).
PC300, 350-7E0 27
SEN03549-00 10 Structure, function and maintenance standard
28 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 29
SEN03549-00 10 Structure, function and maintenance standard
30 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 31
SEN03549-00 10 Structure, function and maintenance standard
32 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
2. Safety valve
(bidirectional 2-stage set safety valve)
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 coun-
terbalance 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.
PC300, 350-7E0 33
SEN03549-00 10 Structure, function and maintenance standard
2) When pressure in chamber (MA) has Operation of mechanism for varying set pres-
become high (when rotating counterclock- sure
wise) 1) When starting travel (high-pressure setting)
q As long as the machine travel is stopped (or it q As the travel lever is operated, the pressurized
is travelling downhill), the check valve of coun- oil from the pump moves spool (19) toward
terbalance valve closes chamber (MA) of the right.
outlet port circuit. q Above opens the pilot circuit to the safety
q The motor tries to continue rotation resorting to valve, conducting the pressurized oil to cham-
inertial force, thus pressure on the outlet port ber (J) via chamber (G) and passage (H).
(MA) is increased. q Piston (3) is pushed rightward, 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.
34 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 35
SEN03549-00 10 Structure, function and maintenance standard
Swing motor 1
Type: KMF230ABE-5
36 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 37
SEN03549-00 10 Structure, function and maintenance standard
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Check valve spring
16. Shuttle valve
17. Shuttle valve spring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed
Free length
18 Check valve spring Outside diameter length load load If damaged or
6.96 N 5.59 N deformed, replace
66.5 x 25.6 45.0 — spring.
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
19 Shuttle valve spring 24.5 x 11.6 14.5
{0.76 kg}
—
{0.61 kg}
38 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Operation Operation
q As the swing holding brake is deenergized, the q As the swing brake solenoid valve is ener-
pressurized oil from the self pressure reducing gized, the valve is switched.
valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake via port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
PC300, 350-7E0 39
SEN03549-00 10 Structure, function and maintenance standard
40 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 41
SEN03549-00 10 Structure, function and maintenance standard
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
42 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
PC300, 350-7E0 43
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44 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
PC300, 350-7E0 45
SEN03549-00 10 Structure, function and maintenance standard
Bucket cylinder
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Cylinder
size Shaft Hole clearance limit
-0.036 +0.035 0.041 –
Boom 100 0.412
Clearance between -0.090 +0.005 0.125
1 piston rod and bushing
Replace bushing
-0.036 +0.261 0.083 –
Arm 110 0.412
-0.090 +0.047 0.351
-0.030 +0.257 0.083 –
Bucket 100 0.447
-0.076 +0.047 0.347
-0.030 +0.190 0.100 –
Boom 100 —
-0.060 +0.070 0.250
Clearance between
-0.030 +0.190 0.105 –
2 piston rod support Arm 100
-0.076 +0.070 0.251
—
shaft and bushing
-0.030 +0.190 0.100 –
Bucket 90 —
-0.076 +0.070 0.246 Replace pin or
-0.030 +0.190 0.075 – bushing
Boom 90 —
-0.060 +0.070 0.225
Clearance between
-0.030 +0.190 0.105 –
3 cylinder bottom support Arm 100
-0.076 +0.070 0.251
—
shaft and bushing
-0.030 +0.190 0.100 –
Bucket 90 —
-0.060 +0.070 0.230
46 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03549-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
PC300, 350-7E0 47
SEN03549-00
48
SEN03550-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03550-00 10 Structure, function and maintenance standard
Work equipment 1
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03550-00
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between pin connecting size clearance limit
Shaft Hole
1 boom and revolving frame and
bushing –0.036 +0.157 0.115 –
110 1.0
–0.090 +0.079 0.247
Clearance between pin connecting –0.036 +0.179 0.117 –
2 boom and arm and bushing 110
–0.090 +0.081 0.269
1.0
PC300, 350-7E0 3
SEN03550-00 10 Structure, function and maintenance standard
Dimensions of components 1
1. Dimension of arm
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03550-00
Unit: mm
PC300-7E0 PC350-7E0
No. Measuring position Standard Tolerance Standard Tolerance
size Shaft Hole size Shaft Hole
–0.036 +0.1 –0.036 +0.1
1 – φ100 φ100
–0.071 0 –0.071 0
+1.5 +1.5
Arm side 119.3 119.3
2 0 0
Cylinder head side 116 ±1.2 116 ±1.2
+0.5 +0.5
Boom side 320 320
0 0
3
–0.3 –0.3
Arm side 316 316
–0.8 –0.8
–0.036 +0.1 –0.036 +0.1
4 – φ110 φ110
–0.090 +0.1 –0.090 +0.1
5 – 470.6 ±1 470.6 ±1
6 – 236.5 ±0.5 236.5 ±0.5
7 – 1022.4 ±1 1022.4 ±1
8 – 3178 ±3 3178 ±3
9 – 2975.6 ±1 2975.6 ±1
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 – 1670 –
–0.036 +0.2 –0.036 +0.2
15 – φ90 φ90
–0.090 0 –0.090 0
16 – 345.0 ±0.5 345.0 ±0.5
–0.036 +0.054 –0.036 +0.054
17 – φ90 φ90
–0.090 +0.054 –0.090 +0.054
0 0
Arm itself 330 330
18 –0.5 –0.5
When press fitting bushing 345 – 345 –
Min. 1870 – 1870 –
19
Max. 3155 – 3155 –
PC300, 350-7E0 5
SEN03550-00 10 Structure, function and maintenance standard
2. Dimension of bucket
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03550-00
Unit: mm
PC300-7E0 PC350-7E0
No. Measuring position Standard Standard
Tolerance Tolerance
size size
1 – 512.2 ±0.5 512.2 ±0.5
2 – 37.9 ±0.5 37.9 ±0.5
3 – 94°19' – 94°14' –
4 – 513.6 – 513.6 –
5 – 1658 – 1666 –
6 – 193 – 208 –
7 – 50° – 42° –
+0.2 +0.2
8 – φ90 φ90
+0.0 +0.0
+0.054 +0.054
9 – φ120 φ120
+0.054 +0.054
+0.1 +0.1
10 – φ125 φ125
+0.1 +0.1
+1 +1
11 – 346
0
346
0
12 – 68 – 68 –
13 – 138 – 138 –
+0.5 +0.5
14 – 525.5
–0.25
525.5
–0.25
15 – φ26 – φ26 –
16 – φ165 – φ165 –
17 – φ150 – φ150 –
18 – φ200 – φ200 –
19 – 145.8 – 137.9 –
20 – 138.2 – 140.4 –
21 – R115 – R115 –
22 – R100 – R100 –
+2 +2
23 – 382
0
382
0
24 – 60 – 60 –
25 – 56 – 56 –
PC300, 350-7E0 7
SEN03550-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
8
SEN03551-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03551-00 10 Structure, function and maintenance standard
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03551-00
PC300, 350-7E0 3
SEN03551-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
4
SEN03552-02
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03552-02 10 Structure, function and maintenance standard
Engine control 1
2 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Operation of system
Starting engine Stopping engine
q When the starting switch is turned to the q When detecting that the starting switch is set to
START position, the starting signal flows to the the “STOP” position, the engine controller cuts
starting motor. Then, the starting motor turns to the fuel injection to stop the engine.
start the engine.
PC300, 350-7E0 3
SEN03552-02 10 Structure, function and maintenance standard
Component
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. 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 resis-
tance 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.
4 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Engine controller
PC300, 350-7E0 5
SEN03552-02 10 Structure, function and maintenance standard
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
28 NC(*) – 13 NC(*) B
29 NC(*) – 14 NC(*) B
30 NC(*) – 15 NC(*) B
31 NC(*) D 16 NC(*) B
32 NC(*) C 17 NC(*) B
33 GND A 18 NC(*) B
34 NC(*) – 19 NC(*) B
35 NC(*) A 20 NC(*) E
36 NC(*) – 21 NC(*) A
37 NC(*) A 22 Fuel control dial (+5V) A
38 NC(*) C 23 Fuel control dial (–) C
39 Key switch (ACC) – 24 NC(*) B
40 Electrical intake air heater relay drive – 25 NC(*) B
41 NC(*) – 26 NC(*) B
42 Electrical intake air heater relay return C 27 NC(*) B
43 NC(*) – 28 NC(*) B
44 Boost pressure sensor B 29 NC(*) C
45 Injector #1 (+) D 30 NC(*) B
46 Injector #5 (+) D 31 NC(*) B
47 Sensor GND C 32 NC(*) C
48 Ne sensor (–) C 33 GND C
49 NC(*) – 34 NC(*) C
50 NC(*) – 35 NC(*) B
51 Injector #2 (–) C 36 NC(*) B
52 Injector #3 (–) C 37 NC(*) C
53 Injector #1 (–) C 38 NC(*) D
54 Injector #2 (+) D 39 Key switch (ACC) A
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC(*) D
57 Injector #6 (+) D 42 Electrical intake air heater relay return C
58 Injector #4 (–) C 43 NC(*) D
59 Injector #6 (–) C 44 NC(*) D
60 Injector #5 (–) C 45 NC(*) –
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) D
CN-CE02 49 PWM OUTPUT D
Input/ 50 NC(*) D
Pin No. Signal name
output *: Never connect to NC or malfunctions or failures will
1 NC(*) B occur.
2 NC(*) B
3 NC(*) B CN-CE03
4 NC(*) B Input/
Pin No. Signal name
5 NC(*) B output
6 NC(*) B 1 GND C
7 NC(*) B 2 NC(*) C
8 NC(*) B Electric power supply (+24V con-
3 A
9 Fuel control dial (+) B stantly)
10 NC(*) B 4 NC(*) A
11 NC(*) B *: Never connect to NC or malfunctions or failures will
12 NC(*) B occur.
*: Never connect to NC or malfunctions or failures will
occur.
6 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
PC300, 350-7E0 7
SEN03552-02 10 Structure, function and maintenance standard
Rotation sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
8 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
1. Connector
2. Tube
3. Sensor
4. O-ring
1. Connector
2. Bracket
3. Float
4. Switch
PC300, 350-7E0 9
SEN03552-02 10 Structure, function and maintenance standard
10 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Control function
1
Auto-deceleration function
8
Attachment flow control and circuit selector function
(if equipped)
Self-diagnosis function
PC300, 350-7E0 11
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12 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
PC300, 350-7E0 13
SEN03552-02 10 Structure, function and maintenance standard
14 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
PC300, 350-7E0 15
SEN03552-02 10 Structure, function and maintenance standard
B and L modes
16 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
2) Function to control pump during travel 3) Function to control when emergency pump
q Traveling the machine in E or B mode drive switch is turned on
leaves the working mode unchanged, but q Even if any abnormality occurs in the controller
raises the pump absorption torque and or sensor, setting emergency pump drive
engine speed (N) to values same as those switch (10) to the “ON” position activates the
in P mode. machine with an absorption torque approxi-
q If the machine travels in L mode, the work- mately equivalent to that in E mode.
ing mode and engine speed (N) do not In this case, a constant current flows from the
change, but the pump absorption torque is battery to the EPC valve for PC and therefore,
increased. the oil pressure is sensed by only the EPC
valve for PC.
PC300, 350-7E0 17
SEN03552-02 10 Structure, function and maintenance standard
Function
q The machine is matched to various types of
work properly with the 2-stage relief function to
increase the digging force, etc.
18 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
2) Cut-off function
q This function increases PC-EPC current
(J) to reduce the flow rate in the relief
state, improving fuel consumption.
PC300, 350-7E0 19
SEN03552-02 10 Structure, function and maintenance standard
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 oper-
ator to increase the boom pushing force by
operating the machine push-up switch.
20 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
PC300, 350-7E0 21
SEN03552-02 10 Structure, function and maintenance standard
4. 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 (approxi-
mately 1,400 rpm), this function lowers the
engine speed to the deceleration operation
level (approximately 1,400 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 opera-
tion level, the engine speed instantly rises to
the level set with the fuel control dial.
22 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
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 tem-
perature is too high during operation to protect
the engine from overheating.
PC300, 350-7E0 23
SEN03552-02 10 Structure, function and maintenance standard
1) Auto-warm-up function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised auto-
matically to warm up the engine.
⇓
Resetting condition (Any one) Reset
⇒
Coolant temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3
Manual
sec. or longer
⇒ ⇒
Hydraulic oil or cool- Work mode: P or E mode ture: Below 100°C
ant temperature: Engine speed: Keep as is. • Under above condition, controller
Above 100°C Lower pump discharge. is set to condition before opera-
tion of function. (Automatic reset)
⇒ ⇒
Work mode: P, E, B or L mode
Hydraulic oil or cool- ture: Below 102°C
Engine speed: Keep as is.
ant temperature: • Under above condition, controller
Monitor alarm lamp: Lights up.
Above 102°C is set to condition before opera-
Lower pump discharge.
tion of function. (Automatic reset)
⇒ ⇒
Work mode: Any mode
Hydraulic oil or cool- Fuel control dial: Return to low idle
Engine speed: Low idle
ant temperature: position once.
Monitor alarm lamp: Lights up
Above 105°C • Under above condition, controller
Alarm buzzer: Sounds
is set to condition before opera-
tion of function. (Manual reset)
24 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Function
The swing lock and swing holding brake function
are provided as a swing control function.
PC300, 350-7E0 25
SEN03552-02 10 Structure, function and maintenance standard
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function when
tion swing lock switch is turned on
q The swing lock function (manual) is used q If swing lock switch (4) is turned on, the
to lock machine from swinging at any posi- pump cut-off function is cancelled and the
tion. The swing holding brake function relief pressure rises from 34.8 MPa {355
(automatic) is used to prevent hydraulic kg/cm2} to 37.2 MPa {380 kg/cm2}. If the
drift after the machine stops swinging. work equipment is relieved under this con-
q Operation of swing lock switch and swing dition, the hydraulic oil temperature rises
lock/holding brake quickly and the warm-up time can be
shortened.
Lock Lock Func-
Operation
switch lamp tion
If swing lever is set in
neutral, swing brake
Swing operates in about 7 sec.
OFF OFF holding If swing lever is oper-
brake ated, brake is released
and machine can swing
freely.
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is
lock
operated, swing lock is
not reset and machine
does not swing.
Swing
holding ON OFF
brake (when controller has (when controller is nor-
release trouble) maly)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing lock
Swing holding
is turned is can- is turned
brake brake is
on. celed. on.
turned on.
26 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
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, 350-7E0 27
SEN03552-02 10 Structure, function and maintenance standard
28 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Function
q This function is available only with the attach-
ment specification.
q The function acts as follows according to the
flow command and working mode from the
monitor.
1) It throttles the attachment PPC pressure
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, 350-7E0 29
SEN03552-02 10 Structure, function and maintenance standard
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q The junction block has 6 PPC oil pressure
switches.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
30 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
1. Sensor
2. Connector
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed.
q The deformation in the diaphragm causes the
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage ampli-
fier).
PC300, 350-7E0 31
SEN03552-02 10 Structure, function and maintenance standard
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
32 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
4) Pump controller
PC300, 350-7E0 33
SEN03552-02 10 Structure, function and maintenance standard
CN-CP01 CN-CP02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
1 NC(*) Input 1 NC(*) output
2 R pump pressure sensor Input 2 Emergency swing parking switch Input
3 NC(*) Input 3 NC(*) Input
4 NC(*) – 4 232C_RXD Input
5 NC(*) Input 5 NC(*) Input
6 NC(*) Input 6 NC(*) Input
7 NC(*) Input 7 Machine select 4 (ATT) Input
8 F pump pressure sensor Input 8 Service circuit SOL signal output
9 NC(*) Input 9 NC(*) output
10 GND (SIG) – 10 NC(*) Input
11 Knob switch Input 11 NC(*) output
12 NC(*) Input 12 CAN_SH –
13 Bucket digging pressure sensor Input 13 Machine select 5 (ATT) Input
14 NC(*) Input 14 232C_TXD output
15 NC(*) Input 15 NC(*) Input
16 NC(*) output 16 Travel steering signal Input
17 Key switch (C-terminal) Input 17 Machine select 3 Input
18 NC(*) Input 18 NC(*) output
19 Arm digging pressure sensor Input 19 NC(*) output
20 NC(*) Input 20 NC(*) Input
21 NC(*) – Input/
21 NC(*)
22 POT-PWR output output
23 Key switch (ACC-terminal) Input Input/
22 CANO_L
24 NC(*) Input output
*: Never connect to NC or malfunctions or failures will Input/
23 NC(*)
occur. output
24 FWE_switch Input
25 NC(*) Input
26 NC(*) Input
27 Machine select 2 Input
28 NC(*) Input
29 NC(*) –
30 NC(*) Input
31 NC(*) –
Input/
32 CANO_H
output
Input/
33 NC(*)
output
34 GND (232C GND) –
35 Service pressure switch Input
36 NC(*) Input
37 Machine select 1 Input
38 Swing prorix switch Input
39 NC(*) –
40 NC(*) Input
*: Never connect to NC or malfunctions or failures will
occur.
34 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
CN-CP03
Input/
Pin No. Signal name
output
1 VB (Controller PWR) Input
2 VIS (Solenoid PWR) Input
3 SOL_COM (SOL. COM. GND) –
4 Battery relay drive signal output
5 NC(*) output
6 LS-EPC output
7 Travel junction solenoid output
8 NC(*) output
9 (Bucket digging pressure switch) Input
10 Boom rise pressure switch Input
11 VB (Controller PWR) Input
12 VIS (Solenoid PWR) Input
13 SOL_COM (SOL. COM. GND) –
14 KEY_SIG Input
15 NC(*) output
16 PC-EPC output
17 Merge divider solenoid output
18 NC(*) output
19 Bucket dump pressure switch Input
20 Boom down pressure switch Input
21 GND (Controller GND) –
22 NC(*) Input
23 SOL_COM (SOL. COM. GND) –
24 KEY_SIG Input
25 NC(*) output
26 ATT currented output
27 Travel speed solenoid output
28 2-stage relief solenoid output
29 Swing pressure switch Input
30 (Arm digging pressure switch) Input
31 GND (Controller GND) –
32 GND (Controller GND) –
33 GND (Controller GND) –
34 NC(*) –
35 NC(*) output
36 NC(*) output
37 Swing parking brake SOL output
38 NC(*) output
39 Travel pressure switch Input
40 Arm dump pressure switch Input
*: Never connect to NC or malfunctions or failures will
occur.
PC300, 350-7E0 35
SEN03552-02 10 Structure, function and maintenance standard
Monitor system 1
36 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC300, 350-7E0 37
SEN03552-02 10 Structure, function and maintenance standard
CN-1 CN-3
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
1 Key ON Input 1 NC (*) Input
2 Key ON Input 2 NC (*) Input
3 Window washer motor output output 3 NC (*) Input
4 Starting signal Input 4 NC (*) Input
5 Limit switch (W) Input 5 NC (*) Input
6 GND – 6 NC (*) Input
7 GND – 7 RS230C CTS Input
8 VB+ Input 8 RS230C RXD Input
9 Wiper motor (+) output Input/
9 RS230C RXD
10 Wiper motor (–) output output
11 Buzzer ON signal Input Input/
10 RS230C RXD
12 Limit switch (P) Input output
11 BOOTSW Input
12 NC (*) Input
CN-2
13 GND –
Input/
Pin No. Signal name 14 CAN (SHIELD) Input
output
15 CAN (+) Input
1 Engine coolant temperature Input
16 CAN (–) Input
2 Fuel level Input
*: Never connect to NC or malfunctions or failures will
3 Radiator coolant level Input
occur.
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC (*) Input
7 Engine oil pressure Input
8 Engine oil level Input
Input/
9 Network signal
output
Input/
10 Network signal
output
11 Charge amount Input
12 Hydraulic oil temperature (analog) Input
13 GND (for analog signal) –
14 Buzzer drive Input
15 Limit switch (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Light switch Input
20 Network GND –
*: Never connect to NC or malfunctions or failures will
occur.
38 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
1. Wiper monitor
2. Preheating monitor
3. Swing lock monitor
4. Engine coolant temperature monitor
5. Hydraulic oil temperature gauge
6. Engine coolant temperature gauge
7. Working mode monitor
8. Service monitor
9. Travel speed monitor
10. Fuel gauge
11. Fuel level monitor
12. Hydraulic oil temperature monitor
13. Power maximizing monitor
14. Auto-deceleration monitor
15. Engine oil pressure monitor
16. Charge level monitor
17. Radiator coolant level monitor
18. Engine oil level monitor
19. Air cleaner clogging monitor
20. Maintenance time warning monitor
PC300, 350-7E0 39
SEN03552-02 10 Structure, function and maintenance standard
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
40 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Temperature or
Gauge Range Indicator Buzzer sound
volume
A1 105 Red Q
A2 102 Red
Engine coolant tem- A3 100 Green
perature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil temper- B3 100 Green
ature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 417 Green
C2 347.5 Green
Fuel level C3 277.5 Green
(l) C4 139 Green
C5 100 Green
C6 62 Red
PC300, 350-7E0 41
SEN03552-02 10 Structure, function and maintenance standard
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
When abnormal,
Engine oil pressure ● — lights up and buzzer
sounds
Lights up when
Battery charge ● —
abnormal
When abnormal,
Radiator coolant Lights up when
● lights up and buzzer
level abnormal
sounds
Lights up when
Engine oil level ● —
abnormal
Lights up when
Air cleaner clogging ● —
abnormal
42 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Displays set
Working mode
mode
Monitor
Displays set
Travel speed
speed
Lights up when
Service meter
Service meter When service meter is working service meter is
indicator
working
PC300, 350-7E0 43
SEN03552-02 10 Structure, function and maintenance standard
Switches
44 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
Auto-deceleration switch
The auto-deceleration switch toggles the auto-
deceleration function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
PC300, 350-7E0 45
SEN03552-02 10 Structure, function and maintenance standard
Method of use
a Carry out the setting on the normal screen
P mode, E mode
1) Press select switch (1).
4) After completing the level selection, press
input confirmation switch (3). The selec-
tion flow level is confirmed and the screen
moves to the normal screen. When input
confirmation switch (3) is pressed, the
attachment flow is updated. The relation-
ship between the flow level and the flow is
shown in the table below.
Flow level Flow (l/min) Remarks
8 530 Default
7 430
6 370
5 300
4 230
2) When the screen changed as below,
select "01" by operating switch (2), and 3 165
press input confirmation switch (3). 2 100
1 30
a Flow level is not changed until the
input confirmation switch is pressed.
It is, therefore, possible not to change
the flow level by pressing return
switch (4) to return to the normal
screen.
46 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
7) Select one of the three flow levels by mov- Control switch Actuation
ing the cursor with operation switch (2) or Flow level bar graph
entering the relevant number (01, 02 or extends to the right
03) with the 10-key pad. Flow level bar graph
retracts to the left
PC300, 350-7E0 47
SEN03552-02 10 Structure, function and maintenance standard
11) Check the set value with the working 3) The setting value adjusting screen shown
mode monitor. The relationship between below is displayed. Operate operation
the display level and the set value is switch (2) to select the setting value.
shown in the table below. Relationship between fuel mileage and
work rate for each of the setting values is
Display level Set value (l/min.)
as follows.
8 250 or 260 E0: Initial Setting Value
7 230 or 240 (highest priority is placed on work
6 210 or 220 rate.)
E1: Economy Adjusting 1
5 190 or 200
(Priority is placed on work rate.)
4 170 or 180 E2: Economy Adjusting 2
3 150 or 160 (Priority is placed on fuel mileage.)
2 130 or 140 E3: Economy Adjusting 3
(highest priority is placed on fuel mile-
1 120
age.)
2. Adjusting E mode setting value
User can change a setting value on the E
mode to adjust engine power and enhance fuel
mileage on the E mode.
1) Press select switch (1).
48 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
PC300, 350-7E0 49
SEN03552-02 10 Structure, function and maintenance standard
50 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
01 Contrast
02 Brightness
PC300, 350-7E0 51
SEN03552-02 10 Structure, function and maintenance standard
52 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
User code display function q If there are more than one service or failure
q If there is any problem in operating the codes, they are displayed in turn every 2 sec-
machine, the user code is displayed on the onds.
monitor to advise the operator of the steps to q Any service codes/failure codes that are not
take. This code appears on the normal screen. related to the displayed user code is displayed
q On the normal screen, the user code is dis- with this function.
played on the portion for the hydraulic oil tem-
perature gauge in the center of the screen.
PC300, 350-7E0 53
SEN03552-02 10 Structure, function and maintenance standard
Sensor 1
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is
always connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Hydraulic oil Resis-
– –
temperature tance
Resis-
Coolant temperature – –
tance
Resis-
Fuel level – –
tance
OFF ON
Air cleaner clogging Contact
(Closed) (Open)
1. Connector
2. Bracket
3. Float
4. Switch
54 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Float 3. Cover
2. Connector 4. Variable resistor
PC300, 350-7E0 55
SEN03552-02 10 Structure, function and maintenance standard
56 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
KOMTRAX system 1
PC300, 350-7E0 57
SEN03552-02 10 Structure, function and maintenance standard
KOMTRAX terminal 1
Model: TC301
q The KOMTRAX system uses satellite communication technology.
Outline
q This terminal sends various machine informa- a When starting to use the KOMTRAX system or
tion based on the network signals and input changing the country where it is used, you are
signals in the machine, as well as GPS position required to notify the country where it will be
data, via wireless communication. used in advance.
This terminal can send information via commu- a When using the KOMTRAX system in Japan,
nication antenna. the terminal special to Japan must be
q This terminal cannot be used in the countries mounted.
or territories where it is not authorized by the
low.
58 PC300, 350-7E0
10 Structure, function and maintenance standard SEN03552-02
PC300, 350-7E0 59
SEN03552-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
60
SEN03554-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03554-01 20 Standard value table
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Engine SAA6D114E-3
• Coolant temperature:
Engine speed Low idle rpm 1,000 ± 25 1,000 ± 25
operating range
• Oil temperature:
Engine
Oil temperature • Whole speed range (inside oil pan) °C 80 – 110 120
2 PC300, 350-7E0
20 Standard value table SEN03554-01
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value Judgement
Item Measurement condition Unit
gory for new machine criteria
• Engine coolant temperature: Within
operating range
• Hydraulic oil temperature: Within
2 pumps at relief rpm 2,030 ± 100 2,030 ± 100
operating range
• Engine at high idle
• Arm IN relief condition
Engine speed
• Engine stopped
Bucket control valve • For measuring position, see Control mm 9.5 ± 0.5 9.5 ± 0.5
valve
Swing control valve
PC300, 350-7E0 3
SEN03554-01 20 Standard value table
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
• Hydraulic oil temperature: Within
operating range
Unload pres- • Engine at high idle MPa 3.9 ± 1.0 3.9 ± 1.0
sure • Working mode: P mode {kg/cm2} {40 ± 10} {40 ± 10}
• Hydraulic pump output pressure with all
control levers in NEUTRAL position
34.81(+1.47/–0.98) 33.34 – 37.23
{355(+15/–10)} {340 – 375}
Raise
*37.26(+1.47/–0.98) *35.80 – 39.23
{380(+15/–10)} {365 – 400}
Boom relief
Lower (at low 18.13 ± 0.98 16.66 – 19.6
pressure setting) {185 ± 10} {170 – 200}
Lower (at high 31.36 ± 1.47 29.4 – 33.32
pressure setting) MPa {320 ± 15} {300 – 340}
• Hydraulic oil temperature: Within {kg/cm2} 34.81(+1.47/–0.98) 33.34 – 37.23
Arm relief
operating range {355(+15/–10)} {340 – 375}
• Engine at high idle *37.26(+1.47/–0.98) *35.80 – 39.23
Bucket relief
Hydraulic pressure
4 PC300, 350-7E0
20 Standard value table SEN03554-01
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
• Hydraulic oil temperature: Within
operating range
• Engine running at high idle
Swing brake deg. PC300: Max. 110 PC300: Max. 140
• Working mode: P mode
angle (mm) PC350: Max. 120 PC350: Max. 150
• Swing circle misalignment amount when
stopping after one turn
• For measuring posture, see Swing 1
PC300, 350-7E0 5
SEN03554-01 20 Standard value table
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
• Hydraulic oil temperature: STD: 55.0 ± 11.0 STD: 42.0 – 70.0
Within operating range Lo
LC: 58.0 ± 11.5 LC: 45.0 – 74.5
• Engine at high idle
• Working mode: P mode
Travel speed STD: 39.0 ± 5.5 STD: 31.5 – 48.5
• Time required for track shoes Mi sec.
(without load) LC: 41.5 ± 6.0 LC: 34.0 – 51.5
to make 5 turns after making
one initial idle turn
• For measuring posture, see STD: 32.0 ± 2.0 STD: 28.0 – 39.0
Hi
Travel 1 LC: 34.0 ± 2.0 LC: 32.0 – 41.5
range
• Engine at high idle
• Working mode: P mode
Travel devia-
• Travel speed: Lo mm Max. 200 Max. 300
tion
• Solid and flat ground
• Swerving amount while traveling 20 m (X)
after initial 10 m trial run
• For measuring posture, see Travel 2 and 3
• Hydraulic oil temperature: Within operating
range
• Engine stopped
Hydraulic drift
• Parking machine on slope of 12° with mm 0 0
of travel
sprocket facing upslope
• Sliding distance for 5 minutes
• For measuring posture, see Travel 4
• Hydraulic oil temperature: Within operating
range
Leakage of • Engine at high idle
l/min Max. 15 Max. 30
travel motor • Traveling with sprocket locked
• Oil leakage amount for one minute with
traveling in relief condition
6 PC300, 350-7E0
20 Standard value table SEN03554-01
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
• Hydraulic oil temperature: Within
Whole work operating range PC300: Max. 450 PC300: Max. 675
equipment • Flat and level ground PC350: Max. 550 PC350: Max. 825
• Bucket load: 2,160 kg
Hydraulic drift of work equipment
• Engine stopped
• Work equipment control lever in
NEUTRAL position PC300: Max. 25 PC300: Max. 38
Boom cylinder • Fall amount for 15 minutes as
PC350: Max. 30 PC350: Max. 45
measured every 5 minutes starting
immediately after initial setting
mm
• Whole work equipment: Lowering
distance of tooth tip
• Boom cylinder: Retraction distance of PC300: Max. 135 PC300: Max. 203
Arm cylinder
cylinder PC350: Max. 165 PC350: Max. 248
• Arm cylinder: Extraction distance of
cylinder
• Bucket cylinder: Retraction distance
of cylinder PC300: Max. 20 PC300: Max. 30
Bucket cylinder
• For measuring posture, see Work PC350: Max. 25 PC350: Max. 38
equipment 1
• Hydraulic oil temperature:
Work equipment
PC300, 350-7E0 7
SEN03554-01 20 Standard value table
PC300, 300LC-7E0
Applicable model
PC350, 350LC-7E0
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
• Hydraulic oil temperature: Within
operating range
• Engine at low idle
• Working mode: P mode
Boom • Time required from raise stroke end sec. Max. 3.0 Max. 3.6
till bucket touches ground and
pushes up machine front
• For measuring posture, see Work
equipment 5
• Hydraulic oil temperature: Within
operating range
• Engine at low idle
• Working mode: P mode
Time lag
• Time required from dumping stroke PC300: Max. 3.0 PC300: Max. 3.6
Arm sec.
end till bucket stops momentarily PC350: Max. 4.0 PC350: Max. 4.6
after control lever is tilted to digging
Work equipment
8 PC300, 350-7E0
20 Standard value table SEN03554-01
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pres-
sure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to
the specified speed with the fuel control dial, take the pump discharge amount and the engine speed at
the point of measurement, and use them as a base for calculating the pump discharge amount at the
specified speed.
PC300, 350-7E0 9
SEN03554-01 20 Standard value table
For all models (Posture of machine for measuring performance and measurement procedure)
Swing 1: Swing brake angle, time taken to start Travel 2: Travel speed (actual run), travel deviation
swing, time taken to swing
10 PC300, 350-7E0
20 Standard value table SEN03554-01
PC300, 350-7E0 11
SEN03554-01 20 Standard value table
12 PC300, 350-7E0
20 Standard value table SEN03554-01
PC300, 350-7E0 13
SEN03554-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
14
SEN03556-02
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03556-02 30 Testing and adjusting
2 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
Measuring intake air –101 – 200 kPa
A 799-201-2202 Boost gauge kit 1
pressure (boost pressure) {–760 – 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1 Degree of contamination 0 to 70%
Measuring exhaust gas (with the standard color)
B Commercially
color 2 Smoke meter 1 (Degree of contamination x 1/10 C
available Bosch index)
1 795-799-1131 Gear 1
Adjusting valve clearance C Commercially
2 Clearance gauge 1
available
1 795-799-6700 Injector puller 1
Measuring compression 2 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
D
pressure 3 795-790-6110 Adapter 1
4 6754-11-3130 Gasket 1
Measuring blow-by 1 799-201-1504 Blow-by checker 1 0 – 5.0 kPa {0 – 500 mmH2O}
E
pressure 2 795-790-3300 Tool (Nozzle) 1
Pressure gauge: 2.5, 6.0, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
Measuring engine oil {600 kg/cm2}
F
pressure Pressure gauge: 1.0 MPa
2 799-401-2320 Oil pressure gauge 1
{10 kg/cm2}
6732-81-3170 Adapter 1 10 x 1.0 mm o R1/8
3
6215-81-9710 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa
790-261-1204 Digital hydraulic tester 1
{600 kg/cm2}
6732-81-3170 Adapter 1 10 x 1.0 mm o R1/8
2
Measuring fuel pressure G 6215-81-9710 O-ring 1
Pressure gauge: 1.0 MPa
3 799-401-2320 Gauge 1
{10 kg/cm2}
Male: 7/8-14UNF–
795-790-1500 1
Female: 7/8-14UNF
4 Fuel vacuum gauge
Male: 3/4-16UNF–
799-201-1201 1 Female: 3/4-16UNF
PC300, 350-7E0 3
SEN03556-02 30 Testing and adjusting
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
Pressure gauge: 2.5, 6.0, 40, 60
Testing and adjusting oil Oil pressure gauge kit
799-101-5002 1 MPa
pressure in work equip- (Analog)
1 {25, 60, 400, 600 kg/cm2}
ment, swing and travel cir-
cuits, basic pressure of L Oil pressure gauge kit Pressure gauge: 60 MPa
790-261-1204 1
control circuit and oil pres- (Digital) {600 kg/cm2}
sure of pump PC control cir- 799-101-5220 Nipple 1
cuit 2 10 x 1.25 mm
07002-11023 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
Oil pressure gauge kit
799-101-5002 1 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting oil Oil pressure gauge kit Pressure gauge: 60 MPa
790-261-1204 1
pressure of pump LS con- M (Digital) {600 kg/cm2}
trol circuit 799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Differential pressure
3 799-401-1340 1
gauge
Pressure gauge: 2.5, 6.0, 40, 60
Oil pressure gauge kit
799-101-5002 1 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm2}
Oil pressure gauge kit Pressure gauge: 60 MPa
790-261-1204 1
Measuring solenoid valve (Digital) {600 kg/cm2}
N
output pressure 799-401-3100 Nipple 1 02 size
2
02896-11008 O-ring 1
799-401-3200 Nipple 1 03 size
3
02896-11009 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
Oil pressure gauge kit
799-101-5002 1 MPa
(Analog)
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve out- Oil pressure gauge kit Pressure gauge: 60 MPa
P 790-261-1204 1
put pressure (Digital) {600 kg/cm2}
2 799-401-3100 Nipple 1 02 size
3 799-401-3200 Nipple 1 03 size
Testing oil leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP040 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-7310 T-adapter 1 AWP (12 poles)
Diagnosis sensor and 799-601-7070 T-adapter 1 AWP (14 poles)
R
harness 799-601-4101 T-adapter assembly 1 Connected with engine
799-799-5530 • T-adapter 1 Engine coolant temperature
799-601-4230 • T-adapter 1 Boost temperature/pressure sensor
799-601-4130 • T-adapter 1 Ne sensor, CAM sensor
799-601-4160 • T-adapter 1 Hydraulic pressure sensor
799-601-4211 • T-adapter 1 Controller (50 poles)
799-601-4220 • T-adapter 1 Controller (60 poles)
4 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-601-4140 • T-adapter 1 Atmospheric pressure sensor
Diagnosis sensor and 799-601-4340 • T-adapter 1 Pump actuator
R
harness 799-601-4260 • T-adapter 1 Controller (4 poles)
799-601-4190 • T-adapter 1 Common rail pressure sensor
799-601-2500
or
9-601-2700
or
799-601-2800
or T-adapter assembly 1
799-601-2900 or
799-601-7100
or
799-601-7400 or
799-601-8000
799-601-2600 • T-adapter box 1 For Econo
799-601-2740 • MIC adapter 1 For MIC-5P
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
For AMP3P (Excl. 799-601-9000,
799-601-9420 • Adapter for AMP 1
799-601-9200)
Troubleshooting for chassis 799-601-7000
S
sensors/wiring harnesses or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
For X1P (Excl. 790-601-7000,
799-601-7010 • Adapter for X 1
799-601-7100)
799-601-7020 • Adapter for X 1 For X2P
799-601-7030 • Adapter for X 1 For X3P
799-601-7040 • Adapter for X 1 For X4P
799-601-7050 • Adapter for SWP 1 For SW6P (Excl. 799-601-8000)
799-601-7060 • Adapter for SWP 1 For SW8P (Excl. 799-601-8000)
799-601-7070 • Adapter for SWP For SW14P (Excl. 799-601-8000)
For M1P (Excl. 799-601-7000,
799-601-7080 • Adapter for M 1
799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7110 • Adapter for M 1 For M3P
799-601-7120 • Adapter for M 1 For M4P
799-601-7130 • Adapter for M 1 For M6P
799-601-7140 • Adapter for S For S8P
799-601-7160 • Adapter for S For S12P
PC300, 350-7E0 5
SEN03556-02 30 Testing and adjusting
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-601-7170 • Adapter for S For S16P
799-601-7210 • Adapter for AMP040 1 For A16P
799-601-7220 • Adapter for AMP040 1 For A20P
799-601-7320 • Adapter for SWP 1 For SW16P
799-601-7340 • Adapter for M 1 For M8P
799-601-7360 • Adapter for relay 1 For Rel. – 5P
799-601-7370 • Adapter for relay 1 For Rel. – 6P
Troubleshooting for chassis 799-601-7500 T-adapter assembly 1
S
sensors/wiring harnesses
799-601-7520 • Adapter for 070 1 For 070-12P
799-601-9000
or T-adapter assembly 1
799-601-9200
799-601-9030 • Adapter for DT 1
799-601-9110 • Adapter for DT(GR) 1 For DT12GR
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
Water and oil temperature — 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
Operating effort and 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Commercially
Stroke and hydraulic drift — Ruler 1
available
Commercially
Work equipment speed — Stopwatch 1
available
Voltage and resistance Commercially
— Circuit tester 1
value available
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
— Socket 1
available Applicable engine serial No.:
Removal and installation of 26850001 - 26857026
engine coolant
temperature sensor 19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
— 795T-981-1010 Socket 1
Applicable engine serial No.:
26857027 and up
6 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Socket
PC300, 350-7E0 7
SEN03556-02 30 Testing and adjusting
8 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 9
SEN03556-02 30 Testing and adjusting
10 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 11
SEN03556-02 30 Testing and adjusting
12 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
6. Adjust the valve clearance in the following pro- 4) Turn the crankshaft forward by 360° and
cedure. align the counter mark applied in step 5
a When No.1 cylinder is at the compression above accurately to the pointer.
top dead center, adjust the valve clear- a This alignment moves the supply
ance indicated with q mark in the valve pump gear stamp line (b) to the posi-
arrangement drawing. tion of stamp line (c) situated directly
below.
5) Adjust the valve clearance indicated with
Q mark in the above valve arrangement
drawing.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
a The adjustment procedure is the
same as that employed for adjust-
ment of q mark.
PC300, 350-7E0 13
SEN03556-02 30 Testing and adjusting
14 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 15
SEN03556-02 30 Testing and adjusting
18. Connect gauge assembly D2 to adapter D3. 23. After finishing testing, remove the testing tools
a Apply a little amount of engine oil to the and return the removed parts.
connecting parts of the adapter and gauge a Install the injector and fuel high-pressure
so that air will not leak easily. tube according to the following procedure.
1) Mate the injector's projection (a) to notch
19. Install rocker arm assembly. (b) of the holder and then set them to the
3 Rocker arm assembly mounting bolt: cylinder head.
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm} a Set the injector with the above mating
position toward the fuel inlet connec-
20. Adjust the valve clearance. tor insertion side.
a For the adjustment, refer to the section,
“Adjusting valve clearance”.
16 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
5) Tighten retaining nut (19) of the fuel inlet a After installing the rocker arm assembly, adjust
connector. the valve clearance. For details, see “Adjusting
3 Retaining nut: valve clearance”.
40.2 ± 3.9 Nm {4.1 ± 0.4 kgm} 3 Rocker arm assembly mounting bolt:
Apply the caulking compound (e) 64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
(hatched section) to retainer (10) and a Install the injector wiring harness terminal (5) in
the cylinder head. a direction where it will not interfere with the
2 Caulking compound: rocker arm (6) which moves up and down.
GE TOSHIBA SILICON TOSSEAL 381
6) Tighten the sleeve nut of high-pressure a Tighten the injector terminal nut with the follow-
fuel hose (16) sequentially in the order of ing torque.
head side and common rail side. 3 Terminal nut:
3 Sleeve nut: 1.25 ± 0.25 Nm {0.13 ± 0.03 kgm}
37.3 ± 4 Nm {3.8 ± 0.4 kgm} a Tighten the head cover with the following
torque.
3 Head cover mounting nut:
11.8 ± 1.96 Nm {1.2 ± 0.2 kgm}
PC300, 350-7E0 17
SEN03556-02 30 Testing and adjusting
18 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 19
SEN03556-02 30 Testing and adjusting
20 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
2) Connect adapter G2 and fuel vacuum 2) Install adapter G2 and nipple [1] of
gauge G4. hydraulic tester G1and connect them to
gauge G3.
PC300, 350-7E0 21
SEN03556-02 30 Testing and adjusting
22 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
3) Run the engine at high idle and measure 2) Connect M10 computer check fitting G4 to
drop of the pressure of the fuel low-pres- gauge G3.
sure circuit.
q Pressure drop in the fuel low-pres-
sure circuit =
Fuel filter inlet pressure – Fuel pres-
sure outlet pressure
a If the pressure drop in the fuel low-
pressure circuit is in the following
range, it is normal.
q Standard pressure drop values for the
fuel low-pressure circuit:
Max. 0.14 MPa {Max. 1.4 kg/cm2}
a When the measured pressure drop
exceeded the standard value, clog-
ging of the fuel filter should be sus-
pected. 3) Turn the starting switch ON, operate fuel
lift pump (5), and measure the fuel lift
pump outlet pressure.
Reference: Fuel lift pump (5) is installed to
cooling plate (7) on the back side of
engine controller (6).
PC300, 350-7E0 23
SEN03556-02 30 Testing and adjusting
24 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 25
SEN03556-02 30 Testing and adjusting
At low idle Max. 300 cc/30 sec. 2) Tighten adapter H2 together with return
At cranking Max. 200 cc/30 sec. tube (2) and insert the tip to measuring
cylinder H3.
3) Connect block tool H1 to the return tube
joint connection of the cylinder block side
to prevent leakage of the fuel.
26 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
4) Run the engine at low idle and test the 4) Run the engine at low idle and test the
return rate from the pressure limiter. return rate from the injector.
a If the leakage from the pressure lim- a If the return rate from the injector is in
iter is in the following range, it is nor- the following range, it is normal.
mal.
At low idle Max. 300 cc/45 sec.
At low idle Below 30 droppings/min. At cranking Max. 100 cc/30 sec.
PC300, 350-7E0 27
SEN03556-02 30 Testing and adjusting
28 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 29
SEN03556-02 30 Testing and adjusting
Adjustment
a If the belt deflection amount is not proper,
adjust it in the following manner.
30 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 31
SEN03556-02 30 Testing and adjusting
32 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Measuring clearance in swing 2. Keep the work equipment in the max. reach
circle bearings 1 posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
a Swing circle bearing clearance measurement frame.
tool a The upper structure is lowered at the front
and raised at the rear at that time.
Mark Part No. Part Name
J Commercially available Dial gauge 3. Set dial gauge to the zero point.
PC300, 350-7E0 33
SEN03556-02 30 Testing and adjusting
34 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Testing and adjusting oil pressure 2) Fit nipple L2 and connect it to oil pressure
in work equipment, swing and gauge [1] of hydraulic tester L1.
a Use the oil pressure gauge with
travel circuit 1 capacity 60 MPa {600 kg/cm2}.
a Testing and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equip-
ment, swing and travel
PC300, 350-7E0 35
SEN03556-02 30 Testing and adjusting
36 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Adjustment
a Adjustment of the unload valve is not available. 3) Check the pressure again after the adjust-
ment, following the aforementioned steps
1. Adjustment of main relief pressure for measurement.
a When the relief pressure of the work a Connect the pilot hose when measur-
equipment circuit or travel circuit is abnor- ing the oil pressure.
mal, adjust main relief valves (3) and (4)
according to the following procedure. 2. Adjustment of boom LOWER relief pres-
q (3): For the front pump circuit sure (on the side where high pressure is
q (4): For the rear pump circuit set)
a As for the main relief valve, be sure to a When the high-pressure relief pressure for
adjust its low-pressure relief pressure the boom LOWER is not normal, adjust
alone (adjusting the low-pressure relief the high pressure side of the safety and
pressure automatically sets the high-pres- suction valve (7) for the boom LOWER in
sure relief pressure, too.). the following procedure.
a When the low-pressure relief pressure is a The the high-pressure relief pressure
turned on, the 2-stage relief valve is OFF mode denotes the state in which the
and thus the pilot pressure is not applica- machine push-up switch is turned on, dis-
ble to the switching port. abling to apply the pilot pressure to the
switching port.
PC300, 350-7E0 37
SEN03556-02 30 Testing and adjusting
38 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Testing and adjusting control 3. Start the engine and keep it running until the
circuit oil pressure 1 hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure testing and adjust-
ing tools 4. Measure hydraulic oil pressure, when the
engine is running at high idle and all the control
Symbol Part No. Part name levers are moved to the NEUTRAL position.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measurement
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres-
sure inside the tank.
1. Remove oil pressure measurement plug (1). 5. Remove the measurement tool after the mea-
surement, and make sure that the machine is
back to normal condition.
a It is not allowed to adjust the relief valve of
the control circuit source pressure.
PC300, 350-7E0 39
SEN03556-02 30 Testing and adjusting
Measurement
a Measurement of the oil pressure in the pump
PC control circuit shall be conducted after
making sure that oil pressure of the work
equipment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres-
sure inside the tank.
40 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 41
SEN03556-02 30 Testing and adjusting
42 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Measurement
a Measurement of the oil pressure in the pump
LS control circuit shall be conducted after mak-
ing sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres-
sure inside the tank.
1. Measurement of LS valve output pressure 2) Fit nipple M2 and connect it to oil pressure
(servo piston inlet pressure) gauge [1] of hydraulic tester L1.
a LS valve output pressure (servo piston a Use the oil pressure gauge with
inlet pressure) is measured along with that capacity 60 MPa {600 kg/cm2}.
of the pump discharge pressure and the
result of the two is compared to each
other.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
q (1): For the front pump discharge
pressure (situated in the rear side of
the machine)
q (2): For the rear pump discharge
pressure (situated in the front side of
the machine)
q (3): For the front pump LS valve out-
put pressure
q (4): For the rear pump LS valve out-
put pressure
PC300, 350-7E0 43
SEN03556-02 30 Testing and adjusting
Lever operating
condition Travel lever at
All levers
half stroke posi-
and pedals
tion (Travel with
Tested in neutral
no load)
oil pressure
3) Start the engine and push up the track Pump Set measured
shoe on the measurement side using work discharge pressure Almost the valve as 1
equipment. same pres-
LS valve output pres- sure Approx. 3/5 of
q When measuring the front circuit: sure above pressure
Left track shoe
q When measuring the rear circuit: 6) Remove the measurement tools after the
Right track shoe measurement, and make sure that the
k Provide a working area of suffi- machine is back to normal condition.
cient space, as the raised track
shoe will be idly rotated.
4) Increase the hydraulic oil temperature to
the operating range.
44 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 45
SEN03556-02 30 Testing and adjusting
4) Increase the hydraulic oil temperature to 3. Measurement of LS-EPC valve output pres-
the operating range. sure
1) Remove oil pressure measurement plug
(7).
a The plug is installed on the rear
pump.
46 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 47
SEN03556-02 30 Testing and adjusting
48 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Func-
Functioning conditions
tion
Lock OFF
Lock lever
Released ON
Opera-
Operating condition
tion
ON ON
Machine push-up switch
OFF OFF
Func-
Functioning conditions
tion
When all signals are turned
OFF
OFF
Signal of work equipment, swing and travel
When one of the signals is
ON
turned ON
PC300, 350-7E0 49
SEN03556-02 30 Testing and adjusting
Func-
Functioning conditions
tion
When the travel steering signal is ON
When travel steer- ON
When the travel steering signal is ing independently When F or R pump pressure is 34.3 MPa {350 kg/cm2}
OFF operated
Any other condition than above OFF
Func-
Functioning conditions
tion
When the overheat 2nd setting is ON
When the fuel dial is at 1,200 rpm or lower
When the travel speed switch is at Lo OFF
When signal of the travel is OFF
When the travel speed switch is
When signal of the When F or R pump pressure is 32.3 MPa {330 kg/cm2}
at Mi or Hi
travel is ON When F or R pump pressure is 18.6 MPa {190 kg/cm2}
ON
Any other condition than above
Opera-
Operating condition
tion
Overheat 1st setting is ON
OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L mode is selected
ON
Boom LOWER signal is ON
Signals other than swing independent signal are
P or E mode is selected Left knob switch is ON ON
Swing independent signal is ON
OFF
Other than above conditions
50 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Func-
Functioning conditions
tion
When B mode is turned on When the service signal is ON
When independent signal of the travel is ON
ON
When any When F or R pump pressure is 19.6 MPa
mode other {200 kg/cm2} or above
When sig- than L
nals of the mode is When F or R pump pressure is 14.7 MPa
OFF
work equip- turned on {150 kg/cm2} or lower
When signal of the travel is OFF
ment and
When F or R pump pressure is 16.7 MPa
swing are ON
{170 kg/cm2} or above
ON L mode
When F or R pump pressure is 11.8 MPa
{120 kg/cm2} or lower OFF
Any other condition than above
PC300, 350-7E0 51
SEN03556-02 30 Testing and adjusting
52 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
4. Measure the pressure when the engine is run- Adjusting play of work equipment
ning at high idle and the control lever of the cir- and swing PPC valves 1
cuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If the right and left work equipment levers have
a If PPC valve output pressure is at the level large play, adjust them according to the follow-
shown below, it is judged normal. ing procedure.
PC300, 350-7E0 53
SEN03556-02 30 Testing and adjusting
54 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 55
SEN03556-02 30 Testing and adjusting
56 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 57
SEN03556-02 30 Testing and adjusting
4. Measurement of oil leakage amount from 3) Disconnect drain hose (5) of the travel
swing motor motor and fit an oil stopper plug in the
1) Disconnect drain hoses (4) and install the hose end.
oil stopper plug in the hoses. 4) Run the engine at high idle, relieve the
2) Turn the swing lock switch to the ON posi- travel circuit, and measure the oil leakage.
tion. k Wrong operation of the lever can
3) Run the engine at high idle, relieve the cause an accident. Accordingly,
swing circuit, and measure the oil leakage. make signs and checks securely.
a Start measuring the oil leakage 30 a Start measuring the oil leakage 30
seconds after relieving is started and seconds after relieving is started and
measure for 1 minute. measure for 1 minute.
a After measurement 1 time, swinging a Measure several times, moving the
180°, and then measure again. motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
58 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Bleeding air from hydraulic pump 2. Bleeding air from hydraulic cylinder
1) Loosen air bleeder (1) and check that oil 1) Start the engine and keep running at low
oozes out through the air bleeder. idle for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times
bleeder (1). with the engine running at low idle.
3 Air bleeder: a Stop the piston approximately 100
7.8 – 9.8 Nm {0.8 – 1.0 kgm} mm in front of the stroke end so that it
a Precautions on starting engine: may not be relieved.
When starting the engine after above 3) While running the engine at high idle, per-
operations, be sure to run the engine form step 2).
at low idle for 10 minutes. If the 4) Set the piston rod to the stroke end at low
engine coolant temperature is low idle and allow it to relieve.
and an automatic engine warming-up 5) For bleeding air from the arm cylinder and
function is relied on, use the fuel dial, bucket cylinder, follow the same steps
when it becomes necessary to cancel explained in Item 2) through 4) above.
it. a In case a cylinder is replaced with
new one, it is advised to bleed air
from the new one before mounting
the work equipment. It is especially so
with the boom cylinder, because its
rod does not extend to the stroke end
of LOWER side, after the work equip-
ment is mounted.
PC300, 350-7E0 59
SEN03556-02 30 Testing and adjusting
60 PC300, 350-7E0
30 Testing and adjusting SEN03556-02
PC300, 350-7E0 61
SEN03556-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
62
SEN03557-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03557-01 30 Testing and adjusting
2 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically and others are displayed through the switch operations according to
the internal setting of the machine monitor.
q Ordinary functions: Operator menu
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
q Special functions: Service menu
The functions in this mode are not ordinarily displayed. Display and setting of these functions are avail-
able from the serviceman's operations of the special switches.
This mode is used for special setting, testing, adjusting or troubleshooting.
PC300, 350-7E0 3
SEN03557-01 30 Testing and adjusting
a This section introduces only the outline of the 3. Check before starting function
operator menu. For details on the contents and Check before starting screen is displayed for 2
operation steps of each menu, refer to the seconds succeeding to display of KOMATSU
operation and maintenance manual or the logo.
chapter of “Structure, function and mainte-
nance standard” in this shop manual.
4 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 5
SEN03557-01 30 Testing and adjusting
6 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 7
SEN03557-01 30 Testing and adjusting
15. Failure code display function a The telephone mark and telephone num-
Operating any switch while an action code is ber are displayed only when the telephone
on the screen, sequentially displays the phone number is registered to the machine moni-
mark (if registered), phone number (if regis- tor.
tered) and failure code. Registration, correction or deletion of a
q Switching operation: (3) (keep the switch telephone number is done from the ser-
depressed) vice menu.
a The screen display sequentially changes a For detailed information of failure codes,
as shown below as long as the switch is see the failure codes table.
being depressed.
8 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 9
SEN03557-01 30 Testing and adjusting
10 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 11
SEN03557-01 30 Testing and adjusting
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
a E of at beginning the action code indicates the following state.
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
12 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
1) Confirmation of display
Make sure that the conventional display is
turned on.
a Changing to Service Menu is usually avail-
able only from this conventional display.
PC300, 350-7E0 13
SEN03557-01 30 Testing and adjusting
14 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 15
SEN03557-01 30 Testing and adjusting
16 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 17
SEN03557-01 30 Testing and adjusting
18 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
Num
Sub menu of abnormality record
ber
00 Return (End of abnormality record)
01 Electrical systems
02 Mechanical systems
PC300, 350-7E0 19
SEN03557-01 30 Testing and adjusting
2) Information to be displayed
q Oil and filter names
q Replacement time elapsed up to
present
q Time elapsed on service meter up to
the last replacement
20 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 21
SEN03557-01 30 Testing and adjusting
1) Menu selection
Select “05 Phone Number Entry” menu
from the Service Menu initial screen and
then depress [3] switch.
22 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 23
SEN03557-01 30 Testing and adjusting
a If the engine is stopped from B-mode 6) Function for selecting distinction of “With/
on a machine equipped with the Without Service Cir”.
attachment, this mode will be invari- It is possible in this function to set a dis-
ably selected as the starter switch is tinction between with or without attach-
turned ON the next time independent ment.
of above setting. q With Service Circuit: When an attach-
ment is installed.
4) Language setting function q Without Service Circuit: When no
Service Menu allows switching the lan- attachment is installed.
guage between Japanese and English.
24 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
Adjust- Adjust-
Torque adjust- Torque adjust-
ment ment
ment value ment value
value value
220 +4.0 kgm 225 –1.0 kgm
221 +3.0 kgm 226 –2.0 kgm
222 +2.0 kgm 227 –3.0 kgm
2) Sub menu selection 223 +1.0 kgm 228 –4.0 kgm
Select the sub menu on which setting
224 0.0 kgm
change is to be done and then press [3]
switch.
4) ATT flow rate adjustment function at com-
pound operation
In the compound operation of attach-
ments, you can adjust the flow rate alloca-
tion of the pump within the range shown in
the table below.
Num
Adjustment of sub menu
ber
00 Return (Ends the adjustment)
01 Pump absorption torque
Adjustment of flow to attachment in com-
02
pound operation
Adjust-
3) Function for Pump Absorption Torque ment Flow rate allocation to ATT
adjustment value
The pump absorption torque can be 370 0.5 times
adjusted within the range shown in the
371 0.7 times
table below.
372 1.0 times
373 0.4 times
PC300, 350-7E0 25
SEN03557-01 30 Testing and adjusting
1) Selecting menu
Select “08 Cylinder cut out” menu from the
service menu initial screen and press [3]
switch.
26 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
4) Engine speed holding function [Reference]: Using the holding function effectively
Pressing [E] switch while the engine The engine speed being displayed on the screen
operation on cylinder cut out screen is through the holding function remains on it until the
turned on holds the engine speed and its holding is cancelled. In other words, enabling or
speed is newly displayed in the lower disabling of the cylinder cut out mode does not
space. affect the display.
Pressing [ R ] switch during holding can- Thus, when identifying a failed cylinder quicker, fol-
cels the holding function and deletes the lowing operation is effective.
display in the lower space.
a If the holding function is used, the (1) Run the engine from the normal operation
held speed is displayed in the lower mode (no cylinder cut out) and then hold the
space along with ( ) and the upper speed of that time.
space continuously displays the cur- (2) Specify the cylinder to be diagnosed as the cut
rent speed. out.
a The holding function is usable inde- (3) Run the engine under the same condition as
pendent of the currently set mode – that for (1). Then compare the engine speed at
the cylinder cut out or not. that time and the held speed being displayed
to diagnose the cylinder.
(4) Reset a cut out cylinder independent of the
fluctuations in the engine speed.
(5) Repeat above steps (2) to (4) and then com-
pare the results against that obtained from
other cylinders.
a If the diagnosis identified a cylinder on which
there was no decrease in the engine speed or
the decrease was small, it can be safely
judged that there must be some abnormalities
in its combustion.
PC300, 350-7E0 27
SEN03557-01 30 Testing and adjusting
1) Selecting menu
Select “09 No Injection Cranking” from the
service menu initial screen and press [3]
switch.
4) Select “No Injection” and press [3] switch.
“Under Preparation” will be displayed on
the screen.
a The letters “Under Preparation” are
displayed in red.
28 PC300, 350-7E0
30 Testing and adjusting SEN03557-01
PC300, 350-7E0 29
SEN03557-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
30
SEN04147-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN04147-01 30 Testing and adjusting
2 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
PC300, 350-7E0 3
SEN04147-01 30 Testing and adjusting
4 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
PC300, 350-7E0 5
SEN04147-01 30 Testing and adjusting
The KOMTRAX system indicates the information in the system and contents of processing with the LED dis-
play unit at the top of the KOMTRAX terminal. Accordingly, if the system seems to have a trouble, carry out
the following checks.
q Check of antennas
q Check of terminal LEDs
Before using the KOMTRAX system, you must complete application for start of use and inspection of the
machine for starting use.
Check of antennas
a Before checking the indication of the LED unit, check that the communication antenna and GPS
antenna are free from abnormality.
q The communication antenna must not be off the position and must not be broken.
q The communication antenna cable must not be disconnected and must be connected to the KOMTRAX
terminal normally.
q The GPS antenna must not be off the position and must not be broken.
q The GPS antenna cable must not be disconnected and must be connected to the KOMTRAX terminal
normally.
6 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
PC300, 350-7E0 7
SEN04147-01 30 Testing and adjusting
8 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
3. Pump controller
a The engine throttle and pump controller
are installed in the cover situated in the
2) Remove the 3 mounting screws to discon- rear side of the operator seat.
nect machine monitor (2) from the mount. 1) Remove cover (5).
a Use care so that the screws may not
fall into the console.
3) Insert or connect troubleshooting T-
adapter in or to connectors P01, P02, and
P70 of machine monitor.
PC300, 350-7E0 9
SEN04147-01 30 Testing and adjusting
10 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
6. Boost pressure and temperature sensor 7. Supply pump IMV solenoid (FUEL REGU-
(BOOST PRESS & IMT) LATOR)
a Disconnection and connection of con- Electric priming pump (FUEL LIFT PUMP)
nector Water-in-fuel sensor intermediate connec-
The connector of the boost pressure and tor (WIF)
temperature sensor has a special locking a Disconnection and connection of con-
mechanism. Disconnect it according to nector
steps (a) – (b) and connect it according to The connector of the supply pump IMV
steps (c) – (d) as shown below. solenoid has a special locking mecha-
Disconnection: (a) Unlock – (b) Discon- nism. Disconnect it according to steps (a)
nect connector. – (b) and connect it according to steps (c)
Connection: (c) Connect connector – (d) – (d) as shown below.
Lock. Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
PC300, 350-7E0 11
SEN04147-01 30 Testing and adjusting
12 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
PC300, 350-7E0 13
SEN04147-01 30 Testing and adjusting
Pm clinic service 1
Machine model Model number Service meter
T PC300-7E0
h
T PC350-7E0 T LC
User name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Engine oil T Damper case oil T Machinery case oil
T Hydraulic oil T Final drive case oil T( )
Ambient temperature Altitude
°C m
Operator's opinion
Max. range of engine coolant temperature Max. range of hydraulic oil temperature gauge
gauge
14 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
PC300, 350-7E0 15
SEN04147-01 30 Testing and adjusting
16 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
1. Engine
Checking condition
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
1 Engine speed rpm 2,000 – 2,100 2,000 – 2,100
All levers in
Engine oil MAX MPa 0.34 – 0.59 0.21
2 neutral
pressure {kg/cm2} {3.5 – 6.0} {2.1}
OFF
3 Engine speed rpm 975 – 1,025 975 – 1,025
All levers in
Engine oil MIN OFF MPa Min. 0.15 0.08
4 neutral
pressure P {kg/cm2} {Min. 1.5} {0.8}
5 Engine speed rpm 1,830 – 2,030 1,830 – 2,030
Blow-by ON Arm IN relief kPa Max. 1.57 Max. 2.55
6
pressure MAX {mmH2O} {Max. 160} {Max. 260}
Engine oil All levers in
7 ON OFF rpm 1,300 – 1,500 —
pressure neutral
Good
Service limit
Bad
No. Check item Fuel Work- Unit value for sured
control ing Checking posture, etc. value
new machine value
dial mode
No load, work equipment PC300-7E0 3.3 – 4.1 Max. 4.5
1 Boom RAISE
extended fully PC350-7E0 3.4 – 4.2 Max. 4.6
PC300-7E0 2.6 – 3.2 Max. 3.5
2 Arm IN P
PC350-7E0 2.9 – 3.5 Max. 3.7
PC300-7E0 3.4 – 4.2 Max. 4.5
3
PC350-7E0 3.4 – 4.2 Max. 4.5
Boom top horizontal
PC300-7E0 3.6 – 4.6 Max. 4.9
4 Arm OUT E
PC350-7E0 3.5 – 4.5 Max. 4.8
PC300-7E0 4.4 – 5.4 Max. 5.7
5 L
MAX PC350-7E0 sec 4.4 – 5.4 Max. 5.7
Boom and arm top horizontal PC300-7E0 2.9 – 3.5 Max. 3.8
6 Bucket CURL
Arm cylinder retracted fully PC350-7E0 2.9 – 3.5 Max. 3.8
7 Swing (5 turns) Work equipment extended fully 28.7 – 34.5 Max. 38
STD 44.0 – 66.0 42.0 – 70.0
LO
P LC 46.5 – 69.5 45.0 – 74.5
STD 33.5 – 44.5 31.5 – 48.5
8 Travel (5 turns) One side of track pushed up MI
LC 35.5 – 47.5 34.0 – 51.5
STD 30.0 – 34.0 28.0 – 39.0
HI
LC 32.0 – 36.0 32.0 – 41.5
PC300, 350-7E0 17
SEN04147-01 30 Testing and adjusting
Good
value for Service limit
Bad
No. Check item Fuel Work- Unit sured
control ing Checking posture, etc. new value
value
dial mode machine
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D D D D
4 Unload valve All levers in neutral —
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.03 – 3.43 {31 – 35} 2.84 – 3.43 {29 – 35}
B (Work equipment relief pressure,
33.83 – 36.28 {345 – 370} 33.34 – 36.77 {340 – 375}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.28 – 38.73 {370 – 395} 35.8 – 39.23 {365 – 400}
high)
{kg/cm2}
D (Unload pressure) 2.9 – 4.9 {30 – 50} 2.9 – 4.9 {30 – 50}
E (LS differential pressure) 2.35 – 2.55 {24 – 26} 2.35 – 2.55 {24 – 26}
F (Swing relief pressure) 28.42 – 32.85 {285 – 335} 28.42 – 32.85 {285 – 335}
G (Travel relief pressure) 36.29 – 40.21 {370 – 410} 35.8 – 40.7 {365 – 415}
18 PC300, 350-7E0
30 Testing and adjusting SEN04147-01
Good
Bad
No. Check item
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value
Checked oil pressure Unit Standard value for new machine Service limit value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Checking condition
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve J4 J4
L — — —
OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
Travel lever oper- — — — —
10 LS-EPC valve P
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated
Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output pressure 1) Approx. 1.1 {Approx. 11}
J2 (PC-EPC valve output pressure 2) Approx. 0.3 {Approx. 3}
Standard value
PC300, 350-7E0 19
SEN04147-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
20
SEN04148-02
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Before carrying out troubleshooting when failure code is displayed ............................................................... 6
PC300, 350-7E0 1
SEN04148-02 40 Troubleshooting
2 PC300, 350-7E0
40 Troubleshooting SEN04148-02
PC300, 350-7E0 3
SEN04148-02 40 Troubleshooting
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine moni-
tor.
4 PC300, 350-7E0
40 Troubleshooting SEN04148-02
PC300, 350-7E0 5
SEN04148-02 40 Troubleshooting
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
F04 3 20A Machine monitor
Switch power supply
(65A) Wiper drive
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Rotary lamp (If equipped)
F04 8 10A Relay for lamp
Switch power supply
(65A) Radio, speaker
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
F04
Switch power supply 13 20A Lamp, lamp relay drive
(65A)
14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
F05 Starting switch
Constant power supply 17 10A
(30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
6 PC300, 350-7E0
40 Troubleshooting SEN04148-02
PC300, 350-7E0 7
SEN04148-02 40 Troubleshooting
Troubles that occur when controller power supply of pump controller is defective
a The controller power supply (F01-1) of the pump controller drives the controller system. Accordingly, if it
is turned off, the controller cannot control the system and the troubles shown below occur simulta-
neously (The following is an example of the troubles).
q The working mode cannot be changed.
q The auto-decelerator does not work or is not reset.
q The travel speed does not change.
q The power maximizing function does not work.
q The swing holding brake cannot be reset automatically.
q The machine deviates during travel.
Troubles that occur when solenoid power supply of pump controller is defective
a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids
and relays. Accordingly, if the solenoid power supply is turned off, when the controller outputs the power
to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of
the following failure codes are displayed simultaneously.
q [DW43KA], [DW43KB]: Travel speed solenoid system
q [DW45KA], [DW45KB]: Swing holding brake solenoid system
q [DW91KA], [DW91KB]: Travel junction solenoid system
q [DWA2KA], [DWA2KB]: Service solenoid system
q [DWK0KA], [DWK0KB]: 2-stage relief solenoid system
q [DXA0KA], [DXA0KB]: PC-EPC (F) solenoid system
q [DXE0KA], [DXE0KB]: LS-EPC solenoid system
q [DXE4KA], [DXE4KB]: Service current EPC system (if attachment is installed)
q [DWJ0KA], [DWJ0KB]: Merge-divider main solenoid system
a If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
1) Disconnect connector CP03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2), and (12) and each of pins (27), (32), and (33).
* Pins (2) and (12) are the power supply and pins (27), (32), and (33) are the chassis ground.
* If the voltage is 20 – 30 V, it is normal.
8 PC300, 350-7E0
40 Troubleshooting SEN04148-02
PC300, 350-7E0 9
SEN04148-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
10
SEN03559-03
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and troubleshooting steps......................................................................................................... 5
Information in troubleshooting table................................................................................................................ 6
Connection table for connector pin numbers .................................................................................................11
T- branch box and T- branch adapter table ................................................................................................... 47
PC300, 350-7E0 1
SEN03559-03 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting Use the results of the investigation and inspec-
in accordance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were 2] Start from the most likely points.
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before Even if the failure is repaired, if the root cause
the failure? When were these repairs car- of the failure is not repaired, the same failure
ried out? will occur again.To prevent this, always investi-
6) Has the same kind of failure occurred gate why the problem occurred. Then, remove
before? the root cause.
2 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 3
SEN03559-03 40 Troubleshooting
4 PC300, 350-7E0
40 Troubleshooting SEN03559-03
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting steps
If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by
performing the following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [3] switch at panel switch section to display
failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality
record function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code
is recorded in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnor-
mality record, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting corresponding to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
PC300, 350-7E0 5
SEN03559-03 40 Troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
6 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 7
SEN03559-03 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to action code/failure code
1 An action code is displayed on machine monitor.
According
When abnormality record is checked, failure code is displayed in
2 to
electrical system abnormality record
displayed
When abnormality record is checked, failure code is displayed in code
3
mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 a)
Engine does
6 Engine rotates, but exhaust gas does not come out S-2 b)
not start
7 Engine emits exhaust gas, but it does not start S-2 c)
8 Engine does not pick up smoothly (follow-up performance is poor) S-3
9 Engine stops during operations H-2 S-4
10 Engine rotation is unstable (it hunts). S-5
11 Engine lacks output or power H-1 S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant or fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Auto-decelerator does not operate E-2 H-5
23 Automatic warm-up system does not operate E-3
24 Preheater does not operate E-4
Phenomena related to work equipment, swing, and travel
25 Speed or power of whole work equipment, travel, and swing is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment, swing, and travel mechanism do not move E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
Phenomena related to work equipment
30 Speed or power of boom is low E-18,19 H-7
31 Speed or power of arm is low E-20,21 H-8
32 Speed or power of bucket is low E-22,23 H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work
36 H-13
equipment move
8 PC300, 350-7E0
40 Troubleshooting SEN03559-03
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
37 Power maximizing function does not work. E-6, 18 - 23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part loaded
38 H-16
more is low
When machine swings and raises boom simultaneously, boom rising
39 H-17
speed is low
When machine swings and travels simultaneously, travel speed
40 H-18
lowers largely
Phenomena related to travel
41 Machine deviates during travel H-19
42 Travel speed is low E-25 H-20
43 Machine is not steered well or steering power is low E-25,26 H-21
44 Travel speed does not change or travel speed is low or high E-25 H-22
45 Travel system does not move (only one side) H-23
Phenomena related to swing
46 Upper structure does not swing E-24 H-24
47 Swing acceleration or swing speed is low H-25
48 Upper structure overruns remarkably when it stops swinging H-26
49 Large shock is made when upper structure stops swinging H-27
50 Large sound is made when upper structure stops swinging H-28
51 Hydraulic drift of swing is large H-29
Phenomena related to machine monitor (Operator menu: ordinary screen)
52 Machine monitor does not display any items E-7
53 Machine monitor does not display some items E-8
Contents of display by machine monitor are different from applicable
54 E-9
machine
Radiator coolant level monitor lights up in red during check before
55 B@BCZK
starting
56 Engine oil level monitor lights up in red during check before starting B@BAZK
Maintenance interval monitor lights up in red during check before See the Operation and Maintenance
57
starting Manual.
58 Charge level monitor lights up in red while engine is running AB00KE
59 Fuel level monitor lights up in red while engine is running E-10
60 Air cleaner clogging monitor lights up in red while engine is running AA10NX
Engine coolant temperature monitor lights up in red while engine is
61 B@BCNS
running
Hydraulic oil temperature monitor lights up in red while engine is
62 B@HANS
running
63 Engine coolant temperature gauge does not indicate normally E-11
64 Hydraulic oil temperature gauge does not indicate normally E-12
65 Fuel level gauge does not indicate normally E-13
66 Swing lock monitor does not indicate normally E-14
Machine monitor display anything even when operated on monitor
67 E-15
switch section
68 Windshield wiper and window washer do not operate E-16
69 Machine push-up function does not work normally E-17 H-15
PC300, 350-7E0 9
SEN03559-03 40 Troubleshooting
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to machine monitor (Service menu: special functions screen)
70 Monitoring function does not display “Boom RAISE“ normally E-18
71 Monitoring function does not display “Boom LOWER“ normally E-19
72 Monitoring function does not display “Arm IN“ normally E-20
73 Monitoring function does not display “Arm OUT“ normally E-21
74 Monitoring function does not display “Bucket CURL“ normally E-22
75 Monitoring function does not display “Bucket DUMP“ normally E-23
76 Monitoring function does not display “Swing“ normally E-24
77 Monitoring function does not display “Travel“ normally E-25
78 Monitoring function does not display “Travel Steering“ normally E-26
79 Monitoring function does not display “Service“ normally E-27
Phenomena related to KOMTRAX
80 KOMTRAX system does not operate normally E-28
Other phenomena
81 Air conditioner does not operate E-29
82 Travel alarm does not sound or does not stop sounding E-30
83 Horn does not sound E-31
10 PC300, 350-7E0
40 Troubleshooting SEN03559-03
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC300, 350-7E0 11
SEN03559-03 40 Troubleshooting
12 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 13
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14 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 15
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40 Troubleshooting SEN03559-03
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18 PC300, 350-7E0
40 Troubleshooting SEN03559-03
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40 Troubleshooting SEN03559-03
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40 Troubleshooting SEN03559-03
PC300, 350-7E0 25
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26 PC300, 350-7E0
40 Troubleshooting SEN03559-03
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40 Troubleshooting SEN03559-03
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40 Troubleshooting SEN03559-03
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32 PC300, 350-7E0
40 Troubleshooting SEN03559-03
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40 Troubleshooting SEN03559-03
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36 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 37
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38 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 39
SEN03559-03 40 Troubleshooting
40 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 41
SEN03559-03 40 Troubleshooting
42 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 43
SEN03559-03 40 Troubleshooting
44 PC300, 350-7E0
40 Troubleshooting SEN03559-03
PC300, 350-7E0 45
SEN03559-03 40 Troubleshooting
46 PC300, 350-7E0
40 Troubleshooting SEN03559-03
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
PC300, 350-7E0 47
SEN03559-03 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
48 PC300, 350-7E0
40 Troubleshooting SEN03559-03
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
PC300, 350-7E0 49
SEN03559-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
50
SEN03560-02
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Failure code [AA10NX] Air cleaner Clogging .................................................................................................. 4
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 6
Failure code [B@BAZG] Eng Oil Press. Low.................................................................................................. 8
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. 10
Failure code [B@BCNS] Eng. Water Overheat............................................................................................. 12
Failure code [B@BCZK] Eng Water Level Low............................................................................................. 14
Failure code [B@HANS] Hydr Oil Overheat ................................................................................................. 16
Failure code [CA111] EMC Critical Internal Failure....................................................................................... 18
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
PC300, 350-7E0 1
SEN03560-02 40 Troubleshooting
2 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 3
SEN03560-02 40 Troubleshooting
4 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 5
SEN03560-02 40 Troubleshooting
6 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 7
SEN03560-02 40 Troubleshooting
8 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 9
SEN03560-02 40 Troubleshooting
10 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 11
SEN03560-02 40 Troubleshooting
12 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 13
SEN03560-02 40 Troubleshooting
14 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 15
SEN03560-02 40 Troubleshooting
16 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 17
SEN03560-02 40 Troubleshooting
18 PC300, 350-7E0
40 Troubleshooting SEN03560-02
Action code Failure code Engine Ne and Bkup speed sensor error
Trouble
E10 CA115 (Engine controller system)
Contents of
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
trouble
Action of con-
troller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related infor-
• Method of reproducing failure code: Start engine
mation
PC300, 350-7E0 19
SEN03560-02 40 Troubleshooting
Action code Failure code Charge air pressure sensor high error
Trouble
E11 CA122 (Engine controller system)
Contents of
• Pressure signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of con-
• Fixes charge pressure value and continues operation.
troller
Problem that
appears on • Engine output lowers.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
20 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 21
SEN03560-02 40 Troubleshooting
Action code Failure code Charge air pressure sensor low error
Trouble
E11 CA123 (Engine controller system)
Contents of
• Pressure signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of con-
• Fixes charge pressure value and continues operation.
troller
Problem that
appears on • Engine output lowers.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
22 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 23
SEN03560-02 40 Troubleshooting
24 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 25
SEN03560-02 40 Troubleshooting
26 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 27
SEN03560-02 40 Troubleshooting
28 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 29
SEN03560-02 40 Troubleshooting
30 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 31
SEN03560-02 40 Troubleshooting
Action code Failure code Charge air temperature sensor high error
Trouble
E15 CA153 (Engine controller system)
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of con-
• Fixes charge temperature value and continues operation.
troller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
32 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 33
SEN03560-02 40 Troubleshooting
Action code Failure code Charge air temperature sensor low error
Trouble
E15 CA154 (Engine controller system)
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of con-
• Fixes charge temperature value and continues operation.
troller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
34 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 35
SEN03560-02 40 Troubleshooting
36 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 37
SEN03560-02 40 Troubleshooting
Action code Failure code Sensor power supply 2 voltage low error
Trouble
E15 CA187 (Engine controller system)
Contents of
• Low voltage was detected in sensor power supply 2 circuit.
trouble
Action of con- • Fixes charge pressure and charge temperature values and continues operation.
troller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
38 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 39
SEN03560-02 40 Troubleshooting
40 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 41
SEN03560-02 40 Troubleshooting
42 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 43
SEN03560-02 40 Troubleshooting
Action code Failure code Sensor power supply 2 voltage high error
Trouble
E15 CA227 (Engine controller system)
Contents of
• High voltage was detected in sensor power supply 2 circuit.
trouble
Action of con- • Fixes charge pressure and charge temperature values and continues operation.
troller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
44 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 45
SEN03560-02 40 Troubleshooting
Action code Failure code Ne speed sensor supply power voltage error
Trouble
E15 CA238 (Engine controller system)
Contents of
• Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble
Action of con-
• Controls the engine with signal from engine Bkup speed sensor.
troller
Problem that
• Engine does not start easily.
appears on
• Engine hunts.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
46 PC300, 350-7E0
40 Troubleshooting SEN03560-02
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard Short circuit in wiring har- ing without turning starting switch ON.
value in normal 3 ness Between CE01 (female) (2) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
nectors disconnected)
Connecting parts between supply pump actuator – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (2) – chassis ground Min. 100 kz
PC300, 350-7E0 47
SEN03560-02 40 Troubleshooting
48 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 49
SEN03560-02 40 Troubleshooting
50 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 51
SEN03560-02 40 Troubleshooting
52 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 53
SEN03560-02 40 Troubleshooting
54 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 55
SEN03560-02 40 Troubleshooting
56 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 57
SEN03560-02 40 Troubleshooting
58 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 59
SEN03560-02 40 Troubleshooting
60 PC300, 350-7E0
40 Troubleshooting SEN03560-02
PC300, 350-7E0 61
SEN03560-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
62
SEN03561-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
Failure code [CA342] Calibration Code Incompatibility................................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 8
Failure code [CA428] Water in Fuel Sensor High Error ................................................................................ 10
Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 12
Failure code [CA435] Eng. Oil Press Sw Error ............................................................................................. 14
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 16
Failure code [CA442] Battery Voltage High Error ......................................................................................... 18
Failure code [CA449] Rail Press Very High Error ......................................................................................... 20
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 24
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 26
Failure code [CA553] Rail Press High Error ................................................................................................. 28
Failure code [CA559] Rail Press Low Error .................................................................................................. 29
PC300, 350-7E0 1
SEN03561-01 40 Troubleshooting
2 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 3
SEN03561-01 40 Troubleshooting
4 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 5
SEN03561-01 40 Troubleshooting
Action code Failure code Sensor power supply 1 voltage low error
Trouble
E15 CA352 (Engine controller system)
Contents of
• Low voltage was detected in sensor power supply 1 circuit.
trouble
Action of con-
• Fixes ambient pressure value and continues operation.
troller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
6 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 7
SEN03561-01 40 Troubleshooting
Action code Failure code Sensor power supply 1 voltage high error
Trouble
E15 CA386 (Engine controller system)
Contents of
• High voltage was detected in sensor power supply 1 circuit.
trouble
Action of con-
• Fixes ambient pressure value and continues operation.
troller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
8 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 9
SEN03561-01 40 Troubleshooting
10 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 11
SEN03561-01 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard Short circuit in wiring har- ing without turning starting switch ON.
value in normal 3 ness Between CE01 (female) (14) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
nectors disconnected)
Connecting parts between water-in-fuel sensor – engine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
5 Defective engine controller CE01 (female) Resistance
Between (14) – (47) 10 – 100 kz
Between (14) – chassis ground Min. 100 kz
12 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 13
SEN03561-01 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness (With another wiring Wiring harness among all pins between
state harness) Resis- Min.
CE01 (female) (17) – CE01 (female) (With all
tance 100 kz
connectors of wiring harness disconnected)
Connecting parts among engine oil pressure switch, engine wiring
harness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
4 • Loose connector, broken lock, broken seal
connector
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (17) – body Max. 10 z
14 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 15
SEN03561-01 40 Troubleshooting
16 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 17
SEN03561-01 40 Troubleshooting
18 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 19
SEN03561-01 40 Troubleshooting
Action code Failure code Common rail pressure very high error
Trouble
E11 CA449 (Engine controller system)
Contents of
• There is high pressure error (2) in common rail circuit.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that
appears on • Engine output lowers.
machine
Related infor-
• Method of reproducing failure code: Start engine.
mation
20 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 21
SEN03561-01 40 Troubleshooting
Circuit diagram related to common rail pressure sensor and engine controller ground line
22 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 23
SEN03561-01 40 Troubleshooting
Action code Failure code Common rail pressure sensor high error
Trouble
E11 CA451 (Engine controller system)
Contents of
• There is high voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
24 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 25
SEN03561-01 40 Troubleshooting
Action code Failure code Common rail pressure sensor low error
Trouble
E11 CA452 (Engine controller system)
Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
26 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 27
SEN03561-01 40 Troubleshooting
28 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 29
SEN03561-01 40 Troubleshooting
Note 1: Check the following items for defect in low pressure circuit parts.
1) Fuel level
2) Clogging in fuel tank breather
3) Stick of check valve inside engine controller cooling plate
4) Leakage or clogging of low-pressure fuel piping
5) Clogging in fuel pre-filter
6) Clogging in fuel main filter
7) Replace fuel filter if cause of failure is not detected with checking clogging.
30 PC300, 350-7E0
40 Troubleshooting SEN03561-01
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
6
(Short circuit with GND cir- Wiring harness between CE01 (female) (27) Resis- Min.
cuit) – C15 (female) (3) and chassis ground tance 100 kz
a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with and carry out troubleshooting.
7 5V/24V circuit) in wiring har-
ness Wiring harness between CE01 (female) (27)
Voltage Max. 1 V
– C15 (female) (3) and chassis ground
PC300, 350-7E0 31
SEN03561-01 40 Troubleshooting
32 PC300, 350-7E0
40 Troubleshooting SEN03561-01
Action code Failure code Engine Bkup speed sensor phase error
Trouble
E11 CA731 (Engine controller system)
Contents of
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of con-
• Controls the engine with signal from engine Ne speed sensor.
troller
Problem that • Engine does not start at all or does not start easily.
appears on • Idle speed is unstable.
machine • Exhaust gas becomes black.
Related infor-
• Method of reproducing failure code: Start engine.
mation
PC300, 350-7E0 33
SEN03561-01 40 Troubleshooting
34 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 35
SEN03561-01 40 Troubleshooting
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
6
(Short circuit with GND cir- Wiring harness between CE01 (female) (26) Resis- Min.
cuit) – C13 (female) (3) and chassis ground tance 100 kz
a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with and carry out troubleshooting.
7 5V/24V circuit) in wiring har-
ness Wiring harness between CE01 (female) (26)
Voltage Max. 1 V
– C13 (female) (3) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between CE01 (female) (26)
Short circuit in wiring har- Resis- Min.
– C13 (female) (3) and between CE01
8 ness tance 100 kz
(female) (37) – C13 (female) (1)
(with another wiring harness)
Wiring harness between CE01 (female) (26)
Resis- Min.
– C13 (female) (3) and between CE01
tance 100 kz
(female) (47) – C13 (female) (2)
36 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 37
SEN03561-01 40 Troubleshooting
38 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 39
SEN03561-01 40 Troubleshooting
Action code Failure code Throttle sensor supply voltage high error
Trouble
E14 CA2185 (Engine controller system)
Contents of
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of con- before detection of trouble and continues operation.
troller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
40 PC300, 350-7E0
40 Troubleshooting SEN03561-01
Action code Failure code Throttle sensor supply voltage low error
Trouble
E14 CA2186 (Engine controller system)
Contents of
• Low voltage was detected in throttle sensor power supply circuit.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of con- before detection of trouble and continues operation.
troller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related infor-
• Method of reproducing failure code: Turn starting switch ON.
mation
PC300, 350-7E0 41
SEN03561-01 40 Troubleshooting
Action code Failure code Common rail pressure very low error
Trouble
E11 CA2249 (Engine controller system)
Contents of
• There is low pressure error (2) in common rail circuit.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that • Engine does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
Related infor-
• Method of reproducing failure code: Start engine.
mation
42 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 43
SEN03561-01 40 Troubleshooting
44 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 45
SEN03561-01 40 Troubleshooting
46 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 47
SEN03561-01 40 Troubleshooting
48 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 49
SEN03561-01 40 Troubleshooting
Action code Failure code Grid heater relay volt low error
Trouble
E15 CA2555 (Engine controller system)
Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of con-
• None in particular.
troller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.
50 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 51
SEN03561-01 40 Troubleshooting
Action code Failure code Grid heater relay volt high error
Trouble
E15 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of con-
• None in particular.
troller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related infor- • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.
52 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 53
SEN03561-01 40 Troubleshooting
54 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 55
SEN03561-01 40 Troubleshooting
56 PC300, 350-7E0
40 Troubleshooting SEN03561-01
Circuit diagram related to service return relay and solenoid of pump controller
PC300, 350-7E0 57
SEN03561-01 40 Troubleshooting
58 PC300, 350-7E0
40 Troubleshooting SEN03561-01
Circuit diagram related to service return relay and solenoid of pump controller
PC300, 350-7E0 59
SEN03561-01 40 Troubleshooting
60 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 61
SEN03561-01 40 Troubleshooting
62 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 63
SEN03561-01 40 Troubleshooting
64 PC300, 350-7E0
40 Troubleshooting SEN03561-01
PC300, 350-7E0 65
SEN03561-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
66
SEN03562-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................................... 4
Failure code [DHPAMA] F Pump Press Sensor Abnormality .......................................................................... 6
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit ................................................................................... 8
Failure code [DHPBMA] R Pump Press Sensor Abnormality ....................................................................... 10
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality .............................................................. 12
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.......................................................... 14
Failure code [DW43KA] Travel Speed Sol. Open Circuit .............................................................................. 16
Failure code [DW43KB] Travel Speed Sol. Short Circuit .............................................................................. 18
Failure code [DW45KA] Swing Brake Sol. Open Circuit ............................................................................... 20
Failure code [DW45KB] Swing Brake Sol. Short Circuit ............................................................................... 24
Failure code [DW91KA] Travel Junction Sol. Open Circuit ........................................................................... 26
Failure code [DW91KB] Travel Junction Sol. Short Circuit ........................................................................... 28
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit ............................................................................. 30
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit.............................................................................. 32
PC300, 350-7E0 1
SEN03562-01 40 Troubleshooting
2 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 3
SEN03562-01 40 Troubleshooting
4 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 5
SEN03562-01 40 Troubleshooting
6 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 7
SEN03562-01 40 Troubleshooting
User code Failure code Hydraulic oil temperature sensor short circuit
Trouble
— DGH2KB (Pump controller system)
Contents of
• Ground fault was detected in hydraulic oil temperature sensor circuit.
trouble
Action of • Fixes hydraulic oil temperature value at 40°C and continues operation.
controller • If cause of failure disappears, system resets itself.
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from
appears on
top of white range (bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04402 Hydraulic oil temperature sensor voltage)
mation
• Method of reproducing failure code: Start engine.
8 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 9
SEN03562-01 40 Troubleshooting
10 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 11
SEN03562-01 40 Troubleshooting
12 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 13
SEN03562-01 40 Troubleshooting
Action code Failure code Bucket CURL PPC press sensor abnormality
Trouble
— DHS4MA (Pump controller system)
Contents of
• Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
troller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
Related infor- will be broken. Accordingly, take extreme care when checking.
mation • Input from bucket curl PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC pressure)
14 PC300, 350-7E0
40 Troubleshooting SEN03562-01
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC300, 350-7E0 15
SEN03562-01 40 Troubleshooting
16 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 17
SEN03562-01 40 Troubleshooting
18 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 19
SEN03562-01 40 Troubleshooting
20 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 21
SEN03562-01 40 Troubleshooting
22 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 23
SEN03562-01 40 Troubleshooting
Action code Failure code Swing holding brake solenoid short circuit
Trouble
E03 DW45KB (Pump controller system)
Contents of
• Abnormal current flowed at output to swing holding brake solenoid circuit.
trouble
Action of con- • Turns output to swing holding brake solenoid circuit OFF.
troller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring func-
tion. (Code 02300: Solenoid 1)
Related infor-
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
mation
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
24 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 25
SEN03562-01 40 Troubleshooting
26 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 27
SEN03562-01 40 Troubleshooting
28 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 29
SEN03562-01 40 Troubleshooting
30 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 31
SEN03562-01 40 Troubleshooting
32 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 33
SEN03562-01 40 Troubleshooting
34 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 35
SEN03562-01 40 Troubleshooting
36 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 37
SEN03562-01 40 Troubleshooting
38 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 39
SEN03562-01 40 Troubleshooting
40 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 41
SEN03562-01 40 Troubleshooting
42 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 43
SEN03562-01 40 Troubleshooting
44 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 45
SEN03562-01 40 Troubleshooting
46 PC300, 350-7E0
40 Troubleshooting SEN03562-01
Action code Failure code Service current EPC solenoid short circuit
Trouble
— DXE4KB (Pump controller system)
Contents of
• Abnormal current flowed to service current EPC solenoid circuit.
trouble
Action of con- • Sets output to service current EPC solenoid circuit to 0.
troller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related infor-
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
mation
(Code 01700: Service solenoid current)
PC300, 350-7E0 47
SEN03562-01 40 Troubleshooting
48 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 49
SEN03562-01 40 Troubleshooting
50 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 51
SEN03562-01 40 Troubleshooting
Action code Failure code Window washer drive system short circuit
Trouble
— DY2CKB (Machine monitor system)
Contents of • When washer drive circuit was connected to GND (when output was turned ON), abnormal current
trouble flowed.
Action of
machine • Turns output to washer motor circuit OFF.
monitor
Problem that
appears on • Window washer operation stops.
machine
Related infor-
mation
52 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 53
SEN03562-01 40 Troubleshooting
Action code Failure code Wiper motor drive forward system short circuit
Trouble
— DY2DKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive forward circuit.
trouble
Action of
machine • Turns output to wiper motor drive forward circuit OFF.
monitor
Problem that
appears on • Window washer operation stops.
machine
Related infor-
mation
54 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 55
SEN03562-01 40 Troubleshooting
Action code Failure code Wiper motor drive reverse system short circuit
Trouble
— DY2EKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive reverse circuit.
trouble
Action of
machine • Turns output to wiper motor drive reverse circuit OFF.
monitor
Problem that
appears on • Window washer operation stops.
machine
Related infor-
mation
56 PC300, 350-7E0
40 Troubleshooting SEN03562-01
PC300, 350-7E0 57
SEN03562-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
58
SEN03563-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 4
Information contained in troubleshooting table ............................................................................................... 6
E-1 Engine does not start ............................................................................................................................... 7
E-2 Auto-decelerator does not operate......................................................................................................... 10
E-3 Automatic warming-up system does not operate ................................................................................... 12
E-4 Preheater does not operate.................................................................................................................... 14
E-5 All work equipment, swing, and travel mechanism do not move ............................................................ 16
E-6 Power maximizing function does not operate......................................................................................... 18
E-7 Machine monitor does not display at all ................................................................................................. 19
E-8 Machine monitor does not display some items ...................................................................................... 21
E-9 Contents of display by machine monitor are different from applicable machine .................................... 21
E-10 Fuel level monitor was lighted in red while engine running .................................................................. 22
E-11 Engine coolant temperature gauge does not indicate normally............................................................ 24
E-12 Hydraulic oil temperature gauge does not indicate normally................................................................ 26
PC300, 350-7E0 1
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2 PC300, 350-7E0
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PC300, 350-7E0 3
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Type of power
Fusible link Fuse No. Fuse capacity Destination of power
supply
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
Switch power F04 3 20A Machine monitor
supply (65A) Wiper motor
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Rotary lamp (If equipped)
Switch power F04 8 10A Relay for lamp
supply (65A) Radio, speaker
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
Switch power F04
13 20A Lamp, lamp relay drive
supply (65A)
14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant F05 Starting switch
17 10A
power supply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
4 PC300, 350-7E0
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PC300, 350-7E0 5
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Failure phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
<Contents of description>
• Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
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8 PC300, 350-7E0
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PC300, 350-7E0 9
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10 PC300, 350-7E0
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PC300, 350-7E0 11
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12 PC300, 350-7E0
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PC300, 350-7E0 13
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Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Related infor- Input of preheating signal (ON/OFF) can be checked with monitoring function.
mation (Code 04500: Monitor Input 1)
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related infor- • During low temperature (coolant temperature below 30°C), pump controller drives the heater relay
mation for 100 sec. after engine start to automatically preheat.
14 PC300, 350-7E0
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E-5 All work equipment, swing, and travel mechanism do not move 1
Trouble • All travel, swing, and work equipment mechanism do not move.
Related infor-
—
mation
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Trouble • Machine monitor does not display at all when starting switch is turned ON
Related infor-
—
mation
20 PC300, 350-7E0
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PC300, 350-7E0 21
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Trouble • Machine monitor does not display some items when starting switch is turned ON
Related infor-
—
mation
Trouble • Contents of display by machine monitor are different from applicable machine.
Related infor-
—
mation
22 PC300, 350-7E0
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E-10 Fuel level monitor was lighted in red while engine running 1
Trouble • Fuel level monitor was lighted in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related infor-
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
mation
(Code 04200: Fuel level sensor voltage)
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• While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
• While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring
Related infor- function. (Code: 04105: Engine coolant temperature)
mation • Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated
(if yes, diagnose that failure first.)
24 PC300, 350-7E0
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PC300, 350-7E0 25
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• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related infor- • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
mation tion. (Code 04402: Hydraulic oil temperature)
26 PC300, 350-7E0
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• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F)
Related infor- • Input signal (voltage) from the fuel level sensor can be checked with monitoring function. (Code
mation 04200: Fuel level sensor voltage)
PC300, 350-7E0 27
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• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned OFF, swing lock monitor lights up.
Related infor- • Input from swing lock switch (ON/OFF) can be checked with monitoring function.
mation (Code 04502: Monitor Input 3)
28 PC300, 350-7E0
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Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related infor-
—
mation
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related infor-
a If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
mation
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related infor-
a If travel speed selection fails, proceed with troubleshooting No. H-22.
mation
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related infor-
a If wiper fails to operate, proceed with troubleshooting No. E-16.
mation
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Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
Related infor- • Input from window limit switch (ON/OFF) can be checked with monitoring function.
mation (Code 049: Monitor Input 3)
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Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related infor-
mation
34 PC300, 350-7E0
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PC300, 350-7E0 35
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36 PC300, 350-7E0
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PC300, 350-7E0 37
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Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Pressure Switch 1)
mation
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• Boom LOWER operation is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation
40 PC300, 350-7E0
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Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation
42 PC300, 350-7E0
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PC300, 350-7E0 43
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Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation
44 PC300, 350-7E0
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PC300, 350-7E0 45
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Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code:01901 (Output Switch 2)
mation
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PC300, 350-7E0 47
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Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01901 (Output Switch 2)
mation
48 PC300, 350-7E0
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Trouble • Swing is not displayed normally by machine monitoring function (Special function)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation
50 PC300, 350-7E0
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Circuit diagram related to right and left swing PPC oil pressure switches
PC300, 350-7E0 51
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Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation
52 PC300, 350-7E0
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Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC300, 350-7E0 53
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• Travel differential pressure is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left
Related infor-
travel PPC circuits (during steering).
mation
• Monitoring code: 01901 (Output Switch 2)
54 PC300, 350-7E0
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Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01901 (Output Switch 2)
mation
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1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
G01 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37), (38) ply
a Turn starting switch ON and carry out troubleshooting.
2 Defective GPS LED (2) Normal state
LED-A2 Lighted up
a Start engine and carry out troubleshooting.
LED (6) Normal state
LED-C1 Lighted up
a Prepare with starting switch OFF, then start engine and carry
Defective starting switch
out troubleshooting.
3 ACC signal and alternator R
Possible causes signal G01 Signal Voltage
and standard Between (36) –
value in normal Starting switch ACC 20 – 30 V
(37), (38)
state
Between (28) –
Alternator R 20 – 30 V
(37), (38)
a Turn starting switch ON and carry out troubleshooting.
LED (8) Normal state
LED-C3 Lighted up
a Prepare with starting switch OFF, then turn starting switch ON
Defective S-NET connection
4 and carry out troubleshooting.
and starting switch C signal
G01 Signal Voltage
Between (10) – (9) S-NET 6–9V
Between (27) –
Starting switch C Max. 1 V
(37), (38)
a Turn starting switch ON and carry out troubleshooting.
LED (9) Normal state
LED-C4 Lighted up
5 State of CAN connection a Prepare with starting switch OFF and carry out troubleshoot-
ing.
G01 Signal Resistance
Between (7) – (8) CAN 40 – 80 z
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LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
PC300, 350-7E0 59
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Defective A/C Hi/Lo pressure a Prepare with starting switch OFF, then carry out troubleshoot-
switch ing without turning starting switch ON.
2
(Internal disconnection or P17 (male) Resistance
defective contact) Between (1) – (2) Max. 1 z
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between F01-11 outlet – M26 Resis-
Disconnection in wiring har- Max. 1 z
(male) (5) tance
ness
Wiring harness between M26 (male) (12) – Resis-
3 (Disconnection in wiring or Max. 1 z
P17 (female) (1) tance
Possible causes defective contact in connec-
tor) Wiring harness between M26 (male) (8) – Resis-
and standard Max. 1 z
value in normal chassis ground tance
state Wiring harness between P17 (female) (2) – Resis-
Max. 1 z
J04 – A07 – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between F01-11 outlet – M26 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- (male) (5) and chassis ground tance
cuit)
Wiring harness between M26 (male) (12) – Resis-
Min. 1 Mz
P17 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (5) – (8) 20 – 30 V
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PC300, 350-7E0 61
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E-30 Travel alarm does not sound or does not stop sounding 1
62 PC300, 350-7E0
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Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC300, 350-7E0 63
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64 PC300, 350-7E0
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PC300, 350-7E0 65
SEN03563-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
66
SEN03564-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
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
PC300, 350-7E0 1
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2 PC300, 350-7E0
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PC300, 350-7E0 3
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4 PC300, 350-7E0
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a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical system.
PC300, 350-7E0 5
SEN03564-01 40 Troubleshooting
Failure phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
2
Presumed Cause for presumed failure
cause and stan- [Contents]
(The attached No. is for fil-
dard value in • The standard values in normalcy by which to judge “Good”
3 ing and reference purpose
normalcy or “No Good” about presumed causes.
only. It does not stand for
• References for making judgement of “good” or “No Good”
any priority.)
4
6 PC300, 350-7E0
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PC300, 350-7E0 7
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H-1 All work equipment lack power, or travel and swing speeds are
slow 1
Trouble • Speed or power of whole work equipment, travel, and swing is low
Related infor-
• Set the working mode in P-mode before start.
mation
8 PC300, 350-7E0
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PC300, 350-7E0 9
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10 PC300, 350-7E0
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Trouble • All work equipment, swing, and travel mechanism do not move.
Related infor-
• Set the working mode in P-mode before start.
mation
Failure phe-
• An abnormal noise is heard from around hydraulic pump.
nomenon
Relative infor-
mation
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12 PC300, 350-7E0
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16 PC300, 350-7E0
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Trouble • When part of work equipment is relieved singly, other parts of work equipment move
Related infor-
• Set the working mode in P-mode before start.
mation
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PC300, 350-7E0 19
SEN03564-01 40 Troubleshooting
Failure phe-
• In a compound operation, work equipment with larger load tends to move slowly.
nomenon
Relative infor-
—
mation
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related infor-
• If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
mation
Failure phe-
• In a compound operation of swing + travel, the travel speed drops sharply.
nomenon
Relative infor-
• If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
mation
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Trouble • Travel speed does not change or travel speed is low or high
Related infor-
• Set the working mode in P-mode before start.
mation
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H-23 Track shoe does not turn (on one side only) 1
Possible causes Defective seal of travel motor Check valve of travel motor may have defective seal. Check it
3
and standard (check valve) directly.
value in normal a Prepare with engine stopped, then run engine at high idle and
state carry out troubleshooting.
Lowering of travel motor out-
4
put Travel lever Leakage from travel motor
Travel relief Max. 30 l/min
Final drive may have internal defect. Check it directly.
5 Defective final drive a It may be checked by abnormal sound, abnormal heating,
metal chips in drain oil, etc.
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Trouble (2) • Swing acceleration or swing speed is low in only one direction.
Related infor-
• Set the working mode in P-mode before start.
mation
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Trouble (1) • Upper structure overruns remarkably when it stops swinging in both directions.
Related infor-
• Set the working mode in P-mode before start.
mation
Trouble (2) • Upper structure overruns remarkably when it stops swinging in only one direction.
Related infor-
• Set the working mode in P-mode before start.
mation
30 PC300, 350-7E0
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Trouble (1) • Hydraulic drift of swing is large (when swing holding brake is applied).
Related infor- • When swing emergency reset switch is turned OFF (normal position), swing holding brake operates
mation and upper structure is fixed with disc brake.
Trouble (2) • Hydraulic drift of swing is large (when swing holding brake is released).
Related infor- • When swing emergency reset switch is turned ON (in an emergency), swing holding brake is
mation released and upper structure is secured by only hydraulic pressure.
32 PC300, 350-7E0
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PC300, 350-7E0 33
SEN03564-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
34
SEN03565-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 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 (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
PC300, 350-7E0 1
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2 PC300, 350-7E0
40 Troubleshooting SEN03565-01
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They corresponds to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes”, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
PC300, 350-7E0 3
SEN03565-01 40 Troubleshooting
4 PC300, 350-7E0
40 Troubleshooting SEN03565-01
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
PC300, 350-7E0 5
SEN03565-01 40 Troubleshooting
Defective injector
crankshaft revolves 2 turns at maximum. This phenomenon
does not indicate a trouble, however.
ing motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low q q
Inspect fuel filter, strainer directly q
Carry out troubleshooting for “Rail Press (Very) Low Error.” See *1 for failure code. q
Troubleshooting
Carry out troubleshooting for “Power Lift Pump Error.” See *2 for failure code. q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
6 PC300, 350-7E0
40 Troubleshooting SEN03565-01
When safety switch terminal and terminal B of starting motor are con-
q
nected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
—
Remedy
PC300, 350-7E0 7
SEN03565-01 40 Troubleshooting
Carry out troubleshooting for “Rail Press (Very) Low Error.” See *1 for failure code.
Carry out troubleshooting for “IMV/PCV1 Short (Open) Error.” See *2 for failure
q
code.
Carry out troubleshooting for “Power Lift Pump Error.” See *3 for failure code. q
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode. q
If pressure limiter return pipe is disconnected, fuel flows out q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Add
8 PC300, 350-7E0
40 Troubleshooting SEN03565-01
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w Q
cranked with starting out
motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
PC300, 350-7E0 9
SEN03565-01 40 Troubleshooting
gas Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
10 PC300, 350-7E0
40 Troubleshooting SEN03565-01
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Add
PC300, 350-7E0 11
SEN03565-01 40 Troubleshooting
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Carry out troubleshooting for “Eng Ne Speed Sensor Error.” See *1 for failure code. q
Carry out troubleshooting for “Eng Bkup Speed Sensor Error.” See *2 for failure code. q
Replace
Replace
Replace
Replace
Replace
Clean
Remedy
Add
12 PC300, 350-7E0
40 Troubleshooting SEN03565-01
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
PC300, 350-7E0 13
SEN03565-01 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
14 PC300, 350-7E0
40 Troubleshooting SEN03565-01
Turbocharger
• Abnormal consumption of oil
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC300, 350-7E0 15
SEN03565-01 40 Troubleshooting
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
16 PC300, 350-7E0
40 Troubleshooting SEN03565-01
Carry out troubleshooting for “Rail Press (Very) Low Error.” See *1 for failure code. q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
If spill tube from injector is disconnected, much fuel spills q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error.” See *2 for failure code. q
Check with monitoring function of the machine monitor. q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC300, 350-7E0 17
SEN03565-01 40 Troubleshooting
q
Troubleshooting
18 PC300, 350-7E0
40 Troubleshooting SEN03565-01
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Man-
ual w
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
—
Remedy
Add
PC300, 350-7E0 19
SEN03565-01 40 Troubleshooting
Degree of use of
Operated for long period E E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
Check items
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or w Q
coolant spurts back
Exhaust smoke is white Q
Oil level in clutch or damper chamber of applicable machine is low w
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20 PC300, 350-7E0
40 Troubleshooting SEN03565-01
machine
Condition of Sudden overheated Q w Q
overheating Always tends to overheat Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Hydraulic oil temperature gauge indicates red range faster than engine coolant tem-
perature gauge does (if they are installed) w
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
PC300, 350-7E0 21
SEN03565-01 40 Troubleshooting
w Q
ders is low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
22 PC300, 350-7E0
40 Troubleshooting SEN03565-01
machine
Replace
Replace
Replace
Adjust
Remedy
PC300, 350-7E0 23
SEN03565-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
24
SEN03567-03
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03567-03 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
PC300, 350-7E0 3
SEN03567-03 50 Disassembly and assembly
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instanetaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instanetaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
4 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
Bellows-type
num disul- SYG2-400M 400 g × 10 q Do not use this grease for rolling bearings like
container
fide grease SYG2-400M-A 400 g × 20 swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg q Use this grease for work equipment pins only
Can
(G2-M) when installing them, but do not use it after-
ward.
Grease
SYG2-400T-A
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT 16 kg grease.
*: For cold Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB 16 kg
Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
PC300, 350-7E0 5
SEN03567-03 50 Disassembly and assembly
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Feature: Urea (organic system) grease with heat
Grease
22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL3
manufacture)
81
6 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
PC300, 350-7E0 7
SEN03567-03 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
8 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
796-946-1310 Guide
t 1
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
t 1
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
t 1
(For 723-46-44100)
796-946-2210 Guide
t 1
(For 723-46-45100)
796-946-1320 Guide
t 1
(For 723-46-40100, 723-46-40601)
796-946-1820 Guide
t 1
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2 t 1
Control valve (For 723-46-44100) Replacement of pressure com-
assembly 796-946-2220 Guide pensation valve seal
t 1
M (For 723-46-45100)
796-946-1420 Guide
t 1
(For 723-46-42800)
796-946-1330 Sleeve
t 1
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
t 1
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve
3 t 1
(For 723-46-44100)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42800)
4 796T-416-1010 Push tool t 1 N Q
Travel PPC valve Press fitting of bushing
5 796T-416-1030 Push tool t 1 N Q
assembly
6 796T-416-1020 Push tool t 1 N Q Installation of pin
PC300, 350-7E0 9
SEN03567-03 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
10 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
D2 push tool
E1 push tool
PC300, 350-7E0 11
SEN03567-03 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E5 push tool
12 PC300, 350-7E0
50 Disassembly and assembly SEN03567-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
PC300, 350-7E0 13
SEN03567-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
14
SEN03568-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03568-01 50 Disassembly and assembly
Removal and installation of fuel 7. Remove air conditioner compressor (10) and
supply pump assembly 1 bracket together and move them to a place
where they will not be obstacle to the work.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
A 1 795-799-1390 Remover q 1
Removal
1. Open the engine hood. 8. Remove No. 1 injector high-pressure pipe (11).
[*3]
2. Remove clamps (1) and (2), U-bolt (3), and air 9. Remove bracket (12).
intake tube (4). [*1]
10. Remove overflow tube (13).
3. Remove air intake connector (5).
11. Remove supply pump outlet high-pressure
4. Remove belt cover (6) and fan guard (7). pipe (14). [*3]
2 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
16. Remove front gear cover cap (20). 20. Remove 4 nuts (24).
[*1]
a Tighten the hose clamps before and after the
air intake tube to the following torque.
3 Hose clamp: 9.8 ± 0.5 Nm {1 ± 0.05 kgm}
[*2]
a Adjust the belt tension. For details, see Test-
ing and adjusting, "Testing and adjusting air
conditioner compressor belt".
[*3]
k Don't correct high-pressure tube by bend-
ing it for re-use.
k
19. Install tool A1 with bolts [1] (M8 x 1.25).
Always use genuine clamp for fixing high-
pressure pipe. Strictly observe the tighten-
ing torque requirements.
k Keep the harness assembly and other har-
nesses 10 mm and above away from the
high-pressure tube.
a Before installing the high-pressure pipe, check
it for the following defects. If there are any of
these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting part
(Part (a): Part of 2 mm from the end) for visible
lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part at 2
mm from the end) for stepped-type wear
(fatigue) which your nail can feel.
PC300, 350-7E0 3
SEN03568-01 50 Disassembly and assembly
[*4]
a Clean the inside of the hose connector and
insert the connector securely.
[*5]
a Install the fuel supply pump assembly accord-
ing to the following procedure.
1) Push in supply pump drive shaft (26),
matching its pin to key way (n) of supply
pump drive gear (21), and tighten nut (22)
and washer (23) temporarily.
4 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name form the work.
A 2 795-799-8120 Installer q 1
Removal
3. Loosen tensioner (2) to remove fan belt (3). 5. Remove pulley (6).
[*1]
a Insert a wrench to the portion (A) (width
across flats T 12.7 mm) of the tensioner
assembly (2), and rotate it to the winding-
up direction (a).
k Make sure that the wrench is secured
at the portion (A) before rotating it.
(The spring of the tensioner assembly
(2) is strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
extremely dangerous.)
k After removing the fan belt (3), return
the tensioner assembly (2) slowly with
care.
k Be careful not to get your fingers
6. Remove vibration damper (7). [*3]
caught between the pulley and fan belt
(3) during work.
PC300, 350-7E0 5
SEN03568-01 50 Disassembly and assembly
6 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
5. Install front seal and carrier assembly (8) to 2. Loosen tensioner (2) and install fan belt (3).
front cover (9). a Following the same procedure for installa-
1) Apply gasket sealant to the mounting face tion of alternator belt (5), insert the wrench
of the carrier. to the portion (A) of tensioner assembly
2 Mounting face of carrier: (2), and rotate it to the winding-up direc-
Gasket sealant (LG-7) tion (a).
2) Apply the pilot tool of the front seal to the k As described in step 1, carefully per-
crankshaft and push in the whole carrier. form the work.
3) Remove the pilot tool.
4) Tighten the mounting nuts in the order of
the numbers shown in the figure.
3 Mounting nut:
9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
[*3]
a Tighten the vibration damper to the following
torque.
3 Mounting bolt:
200 ± 10 Nm {20 ± 1.0 kgm}
6. Carry out the following installation in the
reverse order to removal.
[*1] [*2]
q Install alternator belt (5) and fan belt (3) as fol-
lows.
1. Loosen tensioner assembly (4) and install
alternator belt (5).
a Insert a wrench to the portion (B) (width
across flats T 12.7 mm) of the tensioner
assembly (4), and rotate it to the winding-
up direction (a).
k Make sure that the wrench is secured
at the portion (A) before rotating it.
(The spring of the tensioner assembly
(4) is strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
extremely dangerous.)
k After installing the fan belt (5), return
the tensioner assembly (4) slowly with
care.
k Be careful not to get your fingers
caught between the pulley and fan belt
(5) during work.
PC300, 350-7E0 7
SEN03568-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Removal
1. Remove the hydraulic pump assembly refer- 5. Temporarily sling engine assembly, and remove
ring to the section "Removal and installation of engine rear side mount bracket.
hydraulic pump assembly". 6. Remove 12 mounting bolts (4) and lift off fly-
wheel housing (5).
2. Remove damper assembly (1). [*1]
8 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
8. Remove rear seal (8) from seal housing (9). 2. Check the ends and seal inserting parts of the
crankshaft for burrs and rust and clean them
thoroughly.
PC300, 350-7E0 9
SEN03568-01 50 Disassembly and assembly
7. Tighten the mounting bolts according to the fol- 2) Tighten the mounting bolts in the order of
lowing procedure. the numbers shown in the figure.
1) Tighten the 4 oil pan mounting bolts (indi- 3 Mounting bolt:
cated by the arrows) temporarily. 77 ± 12 Nm {7.9 ± 1.2 kgm}
2) Tighten the seal housing mounting bolts in
the order of the numbers shown in the fig-
ure.
3 Mounting bolt:
12.7 ± 2.0 Nm {1.3 ± 0.2 kgm}
3) Tighten the 4 oil pan mounting bolts (indi-
cated by the arrows) to the following
torque.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
10 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
q Measuring facial runout 3) Using plate [103], fit the flywheel in fly-
1] Similarly to measurement of the radial wheel housing.
runout, set the probe of the dial 4) Using torque wrench [102], tighten the
gauge perpendicular to the end face mounting bolts in the order of the numbers
of the flywheel housing. shown in the figure.
a When measuring, bring the 3 Mounting bolt:
crankshaft to the front or rear 137 ± 7 Nm {14.0 ± 0.7 kgm}
side so that an error will not be
caused by the end play.
2] Set the dial gauge reading to "0",
rotate the crankshaft by 1 turn, and
measure the difference between the
lowest and highest values indicated
by the dial gauge.
PC300, 350-7E0 11
SEN03568-01 50 Disassembly and assembly
[*1]
2 Damper assembly mounting bolt:
Adhesive (LT-2)
2 Spline of damper:
Molybdenum disulfide grease (LM-G)
12 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
1 795-799-8150 Remover q 1
B 2 795-799-6700 Puller t 1
3 760-331-1110 Wrench q 1
Removal
PC300, 350-7E0 13
SEN03568-01 50 Disassembly and assembly
14. Remove air intake connector (22) and air 19. Disconnect drain tube (35).
heater together.
20. Remove common rail (36). [*5]
a Never remove fuel pressure sensor (36a)
and relief valve (36b) unless the purpose
of replacement.
16. Remove bracket (27). 21. Remove clamps (37) and (38).
14 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
25. Remove clamp (46). [*7] 34. Remove 12 mounting bolts (60) and turbo-
charger and exhaust manifold assembly (61).
26. Remove U-clamp (47) and U-bolts (48) and [*13]
(49). [*8] 4 Turbocharger and exhaust manifold
assembly: 35 kg
27. Remove muffler (50) and joint (51). [*9]
PC300, 350-7E0 15
SEN03568-01 50 Disassembly and assembly
37. Disconnect hoses (64) and (65) and remove 40. Remove the fuel injector assembly according
cylinder head cover (66). to the following procedure. [*15]
1) Clean the inlet connector carefully so that
mud, etc. sticking around it will not enter
its hole.
2) Remove retainer (70).
3) Tighten tool B1 into inlet connector (71)
and remove the inlet connector.
a Record the position of each crosshead 4) Loosen the upper nut and disconnect
and the positions of holes (a) and (b) for injector wiring harness (73). [*16]
the valve.
16 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
5) Remove bolt (74) and holder (75). 42. Remove 7 mounting bolts (78) and rocker
housing assembly (79). [*18]
PC300, 350-7E0 17
SEN03568-01 50 Disassembly and assembly
Installation
[*1]
a Tighten the hose clamps before and after the
air intake tube to the following torque.
3 Hose clamp:
9.8 ± 0.5 Nm {1 ± 0.05 kgm}
[*2]
a Adjust the belt tension. For details, see Test-
ing and adjusting, "Testing and adjusting air
conditioner compressor belt." 5) Connect the engine wiring harness. At this
time, take care not to connect the wiring
[*3] harness in reverse.
a Clean the inside of the hose connector and 6) Start the engine and check that fuel does
insert the connector securely. not leak.
For the testing procedure, see Testing and
[*4] adjusting, “Testing fuel system for leak-
a Tighten bracket (16) to the following torque. age”.
3 Mounting bolt: a Replace relief valve (36b), if necessary,
43 ± 6 Nm {4.4 ± 0.6 kgm} according to the following procedure.
[*5] 1) Before removing the relief valve (36b),
a Do not remove fuel pressure sensor (36a) from remove mud etc. from around it thoroughly
common rail (36) for a purpose other than and clean it.
replacement. 2) Remove the relief valve (36b).
a Once the fuel pressure sensor is removed from 3) If the leakage from the relief valve
the common rail, be sure to replace it. exceeds the specified value, do not reuse
a Replace fuel pressure sensor (36a), if neces- it.
sary, according to the following procedure. 4) Check that high-pressure seal surfaces
1) Before removing the fuel pressure sensor, (a) of the relief valve and rail are free from
remove mud etc. from around it thoroughly damage.
and clean it. 5) Check that the adapter (36c) is free from
2) Remove the fuel pressure sensor. flaw.
3) Check the fuel pressure sensor connector 6) Install the relief valve.
for crack, breakage, damage of the seal, 2 Threaded part of relief valve:
foreign matter on the pin and corrosion, Gear oil (#90)
bend and breakage of the pin. 3 Relief valve:
4) Install a new fuel pressure sensor. 100 ± 4 Nm {10.2 ± 0.4 kgm}
2 Threaded part of fuel pressure Excessive tightening can cause leak-
sensor: Gear oil (#90) age. Take care not to tighten too
3 Fuel pressure sensor: strongly.
70 ± 5 Nm {7.1 ± 0.5 kgm} 7) If adapter (36c) was removed, use a new
2 Threaded part of adapter: copper washer (36d) and coat the adapter
Gear oil (#90) with gear oil #90 and tighten it.
3 Adapter: 2 Threaded part of adapter:
37 ± 4 Nm {3.8 ± 0.4 kgm} Gear oil (#90)
3 Adapter:
37 ± 4 Nm {3.8 ± 0.4 kgm}
8) Start the engine and check that there is no
leakage.
For the testing procedure, see Testing and
adjusting, “Testing fuel system for leak-
age”.
18 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
k Don't correct high-pressure tube by bend- 43.1 ± 4.0 Nm {4.4 ± 0.4 kgm}
ing it for re-use. 8) Tighten clamp (82) permanently.
k Always use genuine clamp for fixing high-
pressure pipe. Strictly observe the tighten-
ing torque requirements.
k Keep the harness assembly and other har-
nesses 10 mm and above away from the
high-pressure tube.
a Before installing the high-pressure pipe, check
it for the following defects. If there are any of
these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting part
(Part (a): Part of 2 mm from the end) for visible
lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part at 2
mm from the end) for stepped-type wear [*6]
(fatigue) which your nail can feel. a When installing the No. 1 – No. 6 injector high-
pressure pipes and supply pump outlet high-
pressure pipe, set the slits of the bellows at
both ends of them in the following directions.
q No. 1 – No. 6 injector high-pressure pipes
(injector side): Down
(Common rail side): Out
q Supply pump outlet high-pressure pipe
(supply pump side and
common rail side): Out
[*7]
a Tighten the clamp to the following torque.
3
1st time: 39.2 – 49 Nm {4 – 5 kgm}
a Install the common rail and high-pressure pipe 2nd time: 68.6 – 122.5 Nm {7 – 12.5 kgm}
according to the following procedure.
1) Tighten the mounting bolts of common rail [*8]
(36) temporarily (with the fingers) a Tighten the U-clamp and U-bolt to the following
2) Tighten drain tube (35) temporarily. torque.
3) Install supply pump outlet high-pressure 3
PC300, 350-7E0 19
SEN03568-01 50 Disassembly and assembly
[*9] [*13]
a Tighten the clamp of the turbocharger connect- a Tighten the exhaust manifold mounting bolts
ing part of the joint to the following torque. according to the following procedure.
3 Clamp: 6.9 – 8.8 Nm {0.7 – 0.9 kgm} 3
1st time: Tighten all the bolts to 23.5 ± 4 Nm
[*10] {2.4 ± 0.41 kgm} in the order of the
a Tighten the clamp to the following torque. numbers shown in the figure.
3 Clamp: 7 ± 1.1 Nm {0.7 ± 0.1 kgm} 2nd time: Tighten only bolts 1 – 4 in the figure
to 23.5 ± 4 Nm {2.4 ± 0.41 kgm}.
[*11] 3rd time: Tighten all the bolts to 43.1 ± 6 Nm
a Tighten the clamp according to the following {4.4 ± 0.61 kgm} in the order of the
procedure. numbers shown in the figure.
1) Set punch mark (a) as shown in the figure 4th time: Tighten only bolts 1 – 4 in the figure
and set bridge (83) under band (84). to 43.1 ± 6 Nm {4.4 ± 0.61 kgm}.
2) Tighten the bolt so that dimension (b) will
be 8 – 10 mm.
3) Tighten the bolt to 16 – 17 Nm {1.6 – 1.7
kgm}.
[*14]
a When installing the crosshead and rocker arm
assembly, observe the following precautions.
a Install the crosshead so that parts (a) and (b)
[*12] on its back side will be at the positions
a Tighten the lubrication hose and lubrication checked when removed.
tube to the following torque. When installing a new crosshead, you do not
3 Lubrication hose flare nut: need to take care of the positions of parts (a)
19.6 – 28.4 Nm {2.0 – 2.9 kgm} and (b).
Lubrication tube mounting bolt:
7 ± 1.1 Nm {0.7 ± 0.1 kgm}
20 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
[*15]
a Install the fuel injector assembly according to
the following procedure.
a Check that the injector sleeve is free from flaw
and dirt.
1) Fit the gasket and O-ring to the injector.
2) Apply engine oil (EO15W-40) to the O-ring
of the injector and cylinder head side.
3) While matching projection (a) of injector 5) Apply engine oil (EO15W-40) to the O-ring
(76) to notch (b) of the holder, insert injec- of inlet connector (71) and cylinder head
tor (76) in the cylinder head. side.
a Direct fuel inlet hole (c) of the injector a When replacing the injector, replace the
toward the air intake manifold. inlet connector, too.
a Check the inlet connector for the following
items. If it is defective, replace it.
a] If there are burrs or deformation at
the inlet or outlet of the connector, do
not use the inlet connector.
b] If the edge filter is clogged or dirty or
there is sediment in it, do not use the
inlet connector.
c] If the O-ring is broken or deteriorated,
do not use the inlet connector.
d] If the sealing surface of the outlet side
is worn, in contact unevenly or has a
trace of leakage, do not use the inlet
connector.
If high-pressure fuel leaks, the seat
surface is eroded and has fine
streaks or flaws. If there are such
streaks or flaws, replace the connec-
tor and injector.
PC300, 350-7E0 21
SEN03568-01 50 Disassembly and assembly
22 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
[*16]
a Install the injector wiring harness terminal (5) in
a direction where it will not interfere with the
rocker arm (6) which moves up and down.
[*17]
a Check that the push rod end is in the tappet.
2 Push rod: Engine oil (EO15W-40)
[*18]
a Tighten the rocker housing mounting bolts in
the order of the numbers shown in the figure.
3 Mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Mounting nut:
1.25 ± 0.25 Nm {0.10 ± 0.03 kgm}
PC300, 350-7E0 23
SEN03568-01 50 Disassembly and assembly
24 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
PC300, 350-7E0 25
SEN03568-01 50 Disassembly and assembly
26 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
Installation
[*1]
a Apply ThreeBond 4324 or equivalent to the
adapters of hoses (4), (7), (8), and (9).
PC300, 350-7E0 27
SEN03568-01 50 Disassembly and assembly
Removal and installation of 8. Remove drain plug (5) from the bottom of the
hydraulic oil cooler assembly 1 hydraulic oil cooler to drain the oil from the pip-
ing.
Removal
9. Disconnect tube (6).
k Lower the work equipment to the ground
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure.
k Disconnect the negative (–) terminal from
battery.
3. Open the cover at the front of the hydraulic oil 10. Remove seal (7).
cooler.
28 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
PC300, 350-7E0 29
SEN03568-01 50 Disassembly and assembly
Installation
30 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Removal
PC300, 350-7E0 31
SEN03568-01 50 Disassembly and assembly
12. Disconnect fuel hoses (16) and (17). 18. Disconnect heater hoses (28) and (29).
32 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
PC300, 350-7E0 33
SEN03568-01 50 Disassembly and assembly
[*2] [*6]
a Apply ThreeBond 4324 or equivalent to the
adapter of the hose.
[*3]
a Adjust the belt tension. For details, see Test-
ing and adjusting, “Testing and adjusting air
conditioner compressor belt”.
[*4]
a Tighten the clamp to the following torque.
3 Clamp: 7 ± 1.1 Nm {0.7 ± 0.1 kgm}
[*5]
a Tighten the clamp according to the following
procedure.
1) Set bridge (83) under band (84).
2) Tighten the bolt so that dimension (a) will
be 8 – 10 mm.
3) Tighten the bolt to 16 – 17 Nm {1.6 – 1.7
kgm}.
34 PC300, 350-7E0
50 Disassembly and assembly SEN03568-01
PC300, 350-7E0 35
SEN03568-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
36
SEN03569-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03569-01 50 Disassembly and assembly
Installation
q Installation is done in the reverse order of
removal.
[*1]
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
2 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Disassembly
1. Oil draining
Remove drain plug and drain oil from final 4. No.1 carrier assembly
drive case. 1) Remove No.1 carrier assembly (3).
6 Final drive case: 9 l
2. Cover
1) Remove the mounting bolts.
Then, using forcing screws [1], separate
cover (1) from the case.
PC300, 350-7E0 3
SEN03569-01 50 Disassembly and assembly
7. Thrust washer
Remove thrust washer (13).
4 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
2) Use tool D1 to remove nut (24). 2] Remove bearings (27) and (28) from
hub (29).
PC300, 350-7E0 5
SEN03569-01 50 Disassembly and assembly
1. Hub assembly
1) Using the push tool, press-fit bearings (27)
and (28) to hub (29).
2. Nut
1) Install nut as follows.
1] Use tool D2 to press the inner lace of
bearing (27).
a Pressing force
12.7 – 16.7 kN {1.3 – 1.7 ton}
a Rotate the hub 2 – 3 turns before
pressing the bearing inner race.
6 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
PC300, 350-7E0 7
SEN03569-01 50 Disassembly and assembly
2] Align the position of pin holes on the 2) Install No.2 carrier assembly (15).
shaft and carrier, then tap with a plas- a Align the position so that the 3 tips of
tic hammer to install shaft (17). the gear shafts of carrier assembly
a Install the shaft, rotating the plan- (15) enter the 3 hollows in the end
etary gear. Take care so that face of the motor case, then install.
thrust washer is not damaged.
3] Insert pin (16).
a When inserting the pin, take care
that the 3 claws (parts (f)) on the
periphery of the pin will not be
placed on the thin parts of the
carrier (parts (g)).
Since the thin parts may be on
the opposite side, confirm them
on each carrier.
If there is a groove, avoid placing
the claws on that groove.
4. Ring gear
Fit the O-ring to the hub. Using eyebolts [3],
sling ring gear (14) and install it to the hub,
matching their bolt holes to each other.
a Remove all grease and oil from the mating
surface of the ring gear and hub.
a Do not put any gasket sealant on the mat-
ing surface of the ring gear and hub under
any circumstances.
8 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
PC300, 350-7E0 9
SEN03569-01 50 Disassembly and assembly
9. Spacer
Install spacer (2).
a After installing spacer (2), measure dis- 2)Tighten the mounting bolts according to
tance (i) from the top of planetary gear (8) the following procedure.
to the top of ring gear (14) and check the 3 Mounting bolt:
assembly condition. 1st step : 98 Nm {10 kgm}
a If dimension (i) is less than 1.3 mm or the 2nd step: Using tool D4, retighten each
top of planetary gear (8) is projected from mounting bolt by 100 – 110°.
the top of ring gear (14), they are not a If tool D4 is not available, make a
assembled correctly. In this case, check match mark on the cover and the bolt
again. with paint and then tighten the bolt by
100 – 110°.
10 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
Installation
q Installation is done in the reverse order of
removal.
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, "Bleeding air from vari-
ous parts".
PC300, 350-7E0 11
SEN03569-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Disassembly
1. Oil drain
Loosen the drain plug and drain oil from the
swing machinery case.
6 Swing machinery: 13.4 l
12 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
8. Shaft assembly
1) Remove 12 mounting bolts (23).
2) Set the shaft and case assembly on the
press and then, using push tool [2],
remove shaft assembly (24) from case
assembly (25).
PC300, 350-7E0 13
SEN03569-01 50 Disassembly and assembly
9. Bearing
Using push tool, take bearing (31) out of case (32).
2. Cover assembly
1) Using push tool E4, press fit oil seal (29)
to cover (30).
a Use a new oil seal.
a When not using push tool E4, use
another push tool to push the frame
around the oil seal evenly.
a Take care that oil seal (29) will not
slant.
2 Periphery of oil seal:
Gasket sealant (LG-6)
a Take care that the gasket sealant
(LG-6) will not stick to the oil seal lip
and shaft.
14 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
2) Install cover assembly (26) to case (32) 3) Using push tool E1 [6], press fit bearing
and tighten mounting bolts (23). (31).
a Match the oil passage of cover a Use a new bearing.
assembly (26) to hole (A) of case (32). a Press the bearing inner race and
2 Cover fitting face: outer race simultaneously. Do not
Gasket sealant (LG-6) press only the inner race.
a Take care that the gasket sealant will a After press fitting the bearing, check
not stick to hole (A). that the case rotates smoothly.
3 Mounting bolt: a Press fitting force (Reference value):
59 – 74 Nm {6.0 – 7.5 kgm} Inner race side:
2 Oil seal lip: Grease (G2-LI) 15.3 – 43.2 kN {1,560 – 4,410 kg}
Outer race side:
0 – 16.2 kN {0 – 1,650 kg}
3. Case assembly
1) Reverse case assembly (25) and set it to
shaft (28). 4. No.2 carrier assembly
a Take care extremely not to damage 1) Assemble No. 2 carrier assembly as fol-
the oil seal. lows.
2) Using push tool E5 [5] and guide [7], press a There are traces of expansion on the
fit the bearing inner race. end surface of carrier side hole (h)
a First, using push tool E5 [5], hit the which were originally caused when
bearing inner race with a hammer so the pin was inserted. Make such the
that the shaft will not fall, and then set end surfaces are smooth enough
it to the press to press fit. before reassembly.
a Press fitting force (Reference value): 1] Assemble plate (21) to carrier (16).
39 – 110 kN {3,980 – 11,260 kg} 2] Assemble bearing (19) to gear (18), fit
a Use guide [7] to prevent case assem- top and bottom thrust washers (17)
bly (25) from slanting. and (20) and then set the gear
a Hit the flange of case assembly (25) assembly on carrier (16).
frequently and lightly to correct the
lean of case assembly (25). In partic-
ular, adjust the flange so that oil seal
mating face (B) of the shaft will be at
the center oil seal (29).
PC300, 350-7E0 15
SEN03569-01 50 Disassembly and assembly
3] Match the pin hole of shaft (15) to that 5. Set No. 2 carrier assembly (13) and tighten
of the carrier and install the shaft by mounting bolt (12).
hitting it lightly with a plastic hammer, 2 Thread of mounting bolt:
etc. Adhesive (LT-2)
a While rotating the planetary gear, 3 Mounting bolt:
install the shaft and take care not 343 – 427 Nm {34 – 43.5 kgm}
to damage the thrust washer.
4] Insert pin (14).
a When inserting the pin, take care
so that any of the 3 pawls on the
circumference (Portion a) may
not touch the thin-walled portion
on the carrier (Portion b). Take
care, however, that the thin-
walled portion can be on the
opposite side of the carrier,
depending on actual individual
items. Pay attention so that a pin
pawl will not come to the slender
side of the carrier any way.
5] After inserting the pin, caulk 2 places
6. No.2 sun gear
(h) around the pin.
Install No. 2 sun gear (11).
6] Check that all the gears rotate
smoothly.
16 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
PC300, 350-7E0 17
SEN03569-01 50 Disassembly and assembly
9. No.1 sun gear assembly 3) Install ring gear (10) and swing motor
Assemble No. 1 sun gear (2). assembly (1) to the following positions.
18 PC300, 350-7E0
50 Disassembly and assembly SEN03569-01
Installation
q Installation is done in the reverse order of
removal.
[*1]
2 Threads of swing circle mounting bolt:
Adhesive (LT-2)
3 Swing circle mounting bolt:
926.7 ± 103 Nm {94.5 ± 10.5 kgm}
a Set the soft zone S mark on the inside ring of
the inner race facing the right side as shown in
the diagram. Then install to the track frame.
2 Volume charged to grease bath:
Grease (G2-LI) 33 l
PC300, 350-7E0 19
SEN03569-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
20
SEN03570-03
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03570-03 50 Disassembly and assembly
Disassembly and assembly of a After inserting the floating seal with tool F1,
carrier roller 1 check that its slant is less than 1 mm and its
projection (a) is 5 – 7 mm.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
1 791-430-3230 Installer t 1
F
2 791-601-1000 Oil pump assembly t 1
Disassembly
a Disassemble according to the following figure.
q Carrier roller
Assembly
a Check the amount of air leakage from the seal
a Assemble according to the following figure.
with tool F2 by applying the standard pressure
a Only the precautions for assembly are
to the oil filler port.
described below.
a Check that the gauge needle does not go
down, when the following standard pressure is
applied for 10 seconds.
Standard pressure: 0.1 MPa {1 kg/cm2}
q Floating seal
a Before installing floating seals (7) and (8),
completely degrease both contact surfaces of
the O-ring and the floating seal (hatched area
in the illustration). Furthermore, take care so
that no dust will stick to the contact surface of
the floating seal.
2 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
Disassembly and assembly of a After inserting the floating seal with tool F1,
track roller assembly 1 check that its slant is less than 1 mm and its
projection (a) is 5 – 7 mm.
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
1 796-670-1010 Installer t 1
G
2 791-601-1000 Oil pump assembly t 1
Disassembly
a Disassemble according to the following figure.
Assembly
a Assemble according to the following figure.
a Only the precautions for assembly are q Mounting roller cover mounting bolt
described below. 3 Track roller cover mounting bolt:
44.12 – 53.93 Nm {4.5 – 5.5 kgm}
q Track roller
a Check the amount of air leakage from the seal
with tool G2 by applying the standard pressure
to the oil filler port.
a Check that the gauge needle does not go
down, when the following standard pressure is
applied for 10 seconds.
Standard pressure: 0.1 MPa {1 kg/cm2}
PC300, 350-7E0 3
SEN03570-03 50 Disassembly and assembly
Disassembly and assembly of 4. Remove floating seal (6) on the opposite side
idler assembly 1 from idler (4), shaft (5) and support assembly
(7).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
1 796-570-1020 Installer t 1
H
2 791-601-1000 Oil pump assembly t 1
Disassembly
4 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
PC300, 350-7E0 5
SEN03570-03 50 Disassembly and assembly
5. Using tool H1, install floating seal (3) to idler 6. Install O-ring, then install support (2) using
(4), shaft (2) and support (7) assembly. dowel pin (1).
a Caulk the pin of the support after insertion.
6 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring 1 assembly (1).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name load, so be very sure to set the tool
properly. Failure to do this is dan-
gerous.
791-685-8006 Compressor t 1
a Installed load of spring:
791-635-3160 Extension t 1 208.74 kN {21,287 kg}
1 Cylinder
790-101-1600 t 1
(686 kN {70 t})
J 790-101-1102 Pump t 1
790-201-1500 Push tool kit t 1
790-201-1620 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly
PC300, 350-7E0 7
SEN03570-03 50 Disassembly and assembly
8 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
Installation
q Installation is done in the reverse order of
removal.
[*1]
2 Threads of sprocket mounting bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
640 – 785 Nm {65 – 80 kgm}
PC300, 350-7E0 9
SEN03570-03 50 Disassembly and assembly
Expansion and installation of 4. Use tool K and remove nut (2). [*3]
track shoe assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Remover and
791-630-3000 t 1
installer
K Cylinder
790-101-1300 t 1
(980 kN {100 t})
790-101-1102 Pump t 1
[*3]
a Press-fit the master pin, using tool K in such that
the master pin protrusion becomes (a).
Master pin protrusion amount (a): 4.2 ± 2 mm
10 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
Removal and installation of 5. Remove plate (3) and pin (4), and then lift
revolving frame assembly 1 boom cylinder assembly (2) to remove.
a Remove the boom cylinder assembly on
Removal the opposite side in the same manner.
k Extend the arm and bucket fully, lower the 4 Boom cylinder assembly: 260 kg
work equipment to the ground and then
move the work equipment lock lever to the
LOCK position.
k Disconnect the negative (–) terminal from
battery.
3. Disconnect 4 boom cylinder hoses (1). 6. Sling engine hood (5) temporarily.
a Plug the hose to stop oil flow-out. a When slinging the engine hood, take care
not to damage the rubber seal.
PC300, 350-7E0 11
SEN03570-03 50 Disassembly and assembly
9. Remove plates (7) and (8). 13. Remove 40 mounting bolts and then lift off
revolving frame assembly (20). [*1]
10. Remove aftercooler tube (9). a Using the lever block, adjust fore and aft
a When other parts can interfere with the lift- as well as right and left balance of the
ing hook in removal of the revolving frame, revolving frame assembly, with only 2
such parts must be removed beforehand. mounting bolts being left in the front and
rear side of the assembly. After the adjust-
ment, remove the remaining two bolts.
k When removing the revolving frame
assembly, take care so that it does not
hit the swivel joint assembly.
4 Revolving frame assembly: 6,000 kg
q Air bleeding
Bleed air from the travel motor referencing the
“Bleeding air from various parts” section in the
Testing and adjusting chapter of this manual.
12 PC300, 350-7E0
50 Disassembly and assembly SEN03570-03
Necessity
Symbol
Sketch
Adhesive compound (LT-2)
Q’ty
N/R
Part number Part name
[*2]
Commercially
Impact wrench q 1
a Installing and adjusting counterweight
available 1) Adjust the level difference from the exte-
Z Socket wrench rior part (vertical clearance) with the shim
Commercially
(Width across flats q 1
available
: 46 mm) between the counterweight and revolving
frame.
a Use the impact wrench and socket wrench cor- q Set shim thickness: 1.0 mm, 2.0 mm
responding to the specified torque for mount- Maximum shim adjustment clearance:
ing bolts. 2.0 mm
2) Install counterweight in such a way that
Removal clearance between the door and counter-
k Disconnect the negative (–) terminal from weight as well as clearance between the
battery. r e v o l v i n g fr a m e a n d c o u n t e r w e i g h t
become 10 ± 5 mm.
1. Install eyebolt [1] to counterweight assembly 3) The difference in level in left to right direc-
(1), and sling. tion between the exterior of door (D) and
counterweight (C)
2. Remove 4 mounting bolts (2). [*1] (a): 10 ± 4 mm
a Record the locations where the shims The difference in level in left to right direc-
were used. tion between revolving frame(R) and
counterweight (C)
3. Lift off counterweight (1) horizontally using wire (b): 5 mm or less
or chain block. [*2] The difference in level in up and down
a Be careful not to bump it against the direction between exterior upper cover
engine or radiator or cooler assembly. (UC) and counterweight (C)
4
(c): 0 ± 5 mm
Counterweight assembly: 5,500 kg
are the respective limits for the mounting
adjustment.
a Rear view (Enlarged drawing for right
hand side)
Installation
q Install in reverse order of removal. a Precaution when installing the mounting bolts.
a Precautions in tightening mounting bolts Tight the mounting bolts by using the hand
Temporarily tighten the mounting bolts with the wrench until counterweight mating surface
handwrench, etc right before the counter- contacts the counter part.
weight seats to the frame. Then, tight the mounting bolts to the specified
Then, tighten the mounting bolts to the speci- torque by using large impact wrench or large
fied torque with impact wrench, etc. wrench.
PC300, 350-7E0 13
SEN03570-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09 (01)
14
SEN03571-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03571-01 50 Disassembly and assembly
2 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
[*1]
a Install the center swivel joint assembly
(18) with ports (B) and (D) directed to the
front of the machine (in the direction of the
arrow).
(Part (19) in the following figure is the
sprocket.)
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air from vari-
ous parts”.
PC300, 350-7E0 3
SEN03571-01 50 Disassembly and assembly
Necessity
(3) from swivel shaft (5).
Symbol
Sketch
Q’ty
N/R
Part number Part name
4. Remove dust seal (6) from cover (7).
790-101-2501 Push puller t 1
5. Remove O-ring (8) and slipper seal (9) from
790-101-2510 Block 1 swivel rotor (4).
790-101-2520 Screw 1
791-112-1180 Nut 1
L 790-101-2540 Washer 1
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2650 Adapter 2
Disassembly
Assembly
1. Assemble slipper seal (9) and O-ring (8) to
swivel rotor (4).
4 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 5
SEN03571-01 50 Disassembly and assembly
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air from vari-
10. Lift and remove hydraulic oil tank assembly ous parts”.
(15).
4 Hydraulic oil tank assembly: 200 kg
6 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
2. Remove partition covers (3) and (4) provided 6. Disconnect 8 hoses and 8 tubes on the control
between the engine and control valve. valve.
q (9): TSW port hose (Swing motor S port)
q (10): T1 port hose (connected to the tank)
q (11): From the top:
A1 port tube (boom Hi bottom side)
A1 port tube (bucket bottom side),
A2 port hose (swivel joint A port)
A3 port tube (boom bottom side),
A4 port hose (swing motor MB port)
A5 port hose (swivel joint C port),
A6 port tube (arm head side)
PC300, 350-7E0 7
SEN03571-01 50 Disassembly and assembly
q (12): From the top: B1 port tube (arm Hi 9. Disconnect drain hoses (21).
bottom side)
A1 port tube (bucket head side)
A2 port hose (swivel joint B port)
B3 port tube (boom head side)
B4 port hose (swing motor MA port)
B5 port hose (swivel joint D port)
B6 port tube (arm bottom side)
8 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 9
SEN03571-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
piston.
Q’ty
N/R
Part number Part name
796-946-1310 Guide
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1810 Guide
t 1
(For 723-46-43100 and 723-46-43400)
1
796-946-2110 Guide
t 1
(For 723-46-44100)
796-946-2210 Guide
t 1
(For 723-46-45100)
796-946-1320 Guide
t 1
(For 723-46-40100 and 723-46-43601)
796-946-1820 Guide
t 1 4. Likewise, set tool M2 to piston (1) in the same
(For 723-46-43100 and 723-46-43400)
direction and push it slowly by hand so that
796-946-2120 Guide
2 t 1 another seal (3) may be spread out evenly.
M
(For 723-46-44100) a The seal may be also fitted by pushing it
796-946-2220 Guide down to the flat surface of the tool and
t 1
(For 723-46-45100) then pushing it in with the tool fitted to the
796-946-1420 Guide piston.
t 1
(For 723-46-42800)
796-946-1330 Sleeve
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
796-946-2130 Sleeve
3 t 1
(For 723-46-44100)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42800)
10 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
5. Set correction tool M3 to piston (1) for about q The filter installed on the valve assembly
one minute in order to make seals (2) and (3) should be assembled in the direction shown in
securely adhered to the piston. the following figure.
a Check that there is no protrusion or cut on
the seal.
PC300, 350-7E0 11
SEN03571-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Removal
k Disconnect the cable from the negative (–)
terminal of the battery. 4. Remove cover (4).
k Lower the work equipment to the ground
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
a Attach an identification tag to each piping to
avoid a mistake in the position of installation
later.
12 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
6. Disconnect the pump wiring connectors at the 9. Disconnect wiring clamp (22) at two locations.
following two locations.
q (8): V19 (LS-EPC solenoid valve) 10. Remove muffler clamp (23) and two U-bolts
q (9): V11 (PC-EPC solenoid valve) (24) to remove muffler (25).
PC300, 350-7E0 13
SEN03571-01 50 Disassembly and assembly
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see
Testing and adjusting, “Bleeding air from vari-
ous parts”.
Installation
q Installation is done in the reverse order of
removal.
[*1]
2 Oil seal lip portion and outer circumference:
Grease (G2-LI)
a Coat the oil seal outer circumference thinly
with grease.
a Press-fit oil seal (3), using tool [1].
14 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 15
SEN03571-01 50 Disassembly and assembly
16 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
Necessity
PC300, 350-7E0 17
SEN03571-01 50 Disassembly and assembly
18 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 19
SEN03571-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Disassembly
1. Piston rod assembly
1) Remove piping from the cylinder assem-
bly.
2) Remove the mounting bolts and then dis-
connect head assembly (1). a If the caulking of screw (3) is too strong and it
3) Pull out piston rod assembly (2). cannot be removed, tighten the screw fully,
a Place a container under the cylinder then fit a tap to the thread and remove the
to catch the oil. screw.
20 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 21
SEN03571-01 50 Disassembly and assembly
Assembly
a Be careful not to damage the packing, dust
seal and O-ring.
a Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
a Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) before
installing it.
22 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 23
SEN03571-01 50 Disassembly and assembly
2] Machine one of the holes used to 7) Assemble piston rod assembly (2).
install screw (3). a Set the ring end gap (C) horizontally
a Using a drill, level off V-groove (sideways), and then insert it aligning
between piston (4) and rod (3). the axial center of cylinder tube.
a Machining of the cylinder with bottom a After inserting, make sure that the
cushion (arm cylinder) must not be ring is not broken and is present in its
done at the cushion plug position. place. Then push in the assembly
q Screw machining dimension (mm) fully.
Prepared Depth of
Tapping
hole drilling prepared Tap used
depth
diameter hole
10.3 27 12 x 1.75 20
Cylinder
Tightening torque
name
373 ± 54 Nm
Bucket
{38.0 ± 5.5 kgm}
4] Tighten screw (3).
3
Arm 490 ± 49 Nm {50.0 ± 5.0 kg}
Screw:
Boom 373 ± 54 Nm {38.0 ± 5.5 kgm}
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk thread at 4 places using a
punch.
9) Install piping.
24 PC300, 350-7E0
50 Disassembly and assembly SEN03571-01
PC300, 350-7E0 25
SEN03571-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
26
SEN03572-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03572-00 50 Disassembly and assembly
Removal and installation of work 4. Start the engine and then retract the piston rod.
equipment assembly 1 a Fasten the piston rod with wire and place
it on the stand so that it may not slip out,
Special tools or place a support to prevent the cylinder
from hanging toward the bottom.
a In the latter case, remove the bottom side
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name grease nipple.
a Remove the boom cylinder on the other
side in the same manner.
796-670-1100 Remover t 1
a When the work equipment assembly is
796-670-1110 • Sleeve 1 lifted up, if the sling touches the working
796-670-1120 • Plate 1 lamp, remove the working lamp.
796-670-1130 • Screw 1
5. Disconnect intermediate connector A42 (6) for
791-775-1150 • Adapter 1
P the working lamp.
01643-33080 • Washer 1
01803-13034 • Nut 1 6. Disconnect 3 arm cylinder hoses (7) and 2
Puller bucket cylinder hoses (8).
790-101-4000 t 1 a Apply the oil restraining plug and then fix
(490 kN {50 t} long)
Pump the hoses to the valve side by use of ropes.
790-101-1102 t 1
(294 kN {30 t})
Removal
k Extend the arm and bucket fully. Lower the
work equipment to the ground and set the work
equipment lock lever to the lock position.
k Release the residual pressure. For details,
see Testing and adjusting, “Releasing
residual pressure from hydraulic circuit”.
2. Sling boom cylinder assembly (2), and remove 7. Lift the work equipment, and then remove plate
lock bolt and nut (3). [*1] (9).
3. Remove plate (4), then remove head pin (5).[*2] 8. Using tool P, remove foot pin (10) [*3]
a Check the number as well as locations of a Check the number as well as locations of
the shims used. the shims used.
2 PC300, 350-7E0
50 Disassembly and assembly SEN03572-00
Installation
q Installation is done in the reverse order of
removal.
[*1]
a When tightening the locknut, make sure that
0.5 – 1.5 mm clearance (a) is maintained
between the plate and nut after the tightening.
[*2]
2 Inside surface of bushing when assembling pin:
Antifriction agent (LM-P)
2 Feed grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers into the pin hole.
a Adjust the clearance (b) between cylinder rod
(12) and plate (4) to 1.5mm or less using
shims.
Thickness of standard shim: 1.0 and 2.0 mm
PC300, 350-7E0 3
SEN03572-00 50 Disassembly and assembly
[*3]
2 Inside surface of bushing when assembling pin:
Antifriction agent (LM-P)
2 Feed grease after assembling pin:
Grease (LM-G)
a Adjust the clearance (c) between the foot's end
face of boom (13) and bracket (14) to 1 mm or
less by use of shims.
Thickness of standard shim:
2.0, 2.5, 3.0 and 3.5 mm
q Air bleeding
Bleed the air from the circuit between the valve
and the hydraulic cylinder. For details, see Test-
ing and adjusting, “Bleeding air from various
parts”.
4 PC300, 350-7E0
50 Disassembly and assembly SEN03572-00
PC300, 350-7E0 5
SEN03572-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
6
SEN03573-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03573-01 50 Disassembly and assembly
Removal and installation of 4. Remove clip (10) and disconnect cab wiring
operator's cab assembly 1 connectors M45 (11), H08 (12), and H09 (13).
3. Remove plate (8), duct (9) and the element. 8. Remove controller sub-plate (21) and incline it
a Remove the duct lock clip. against the air conditioner.
2 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
10. Move right console (24) into the cab. 15. Disconnect radio antenna (31).
11. Remove monitor panel undercover (25). 16. Remove clip (32) and take wiring harness (33)
out of grommet (34).
PC300, 350-7E0 3
SEN03573-01 50 Disassembly and assembly
20. Using lever block [1], lift off operator's cab Installation
assembly (39). q Carry out installation in the reverse order to
4 Operator's cab assembly: 300 kg removal.
4 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 4 panes (1) – (4) (2) : Left side rear window glass
are stuck. (3) : Door lower window glass
In this section, the procedure for replacing the (4) : Front window glass
stuck glass is explained. (5) : Front window assembly
When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Both-sided adhesive tape
replace only the front window glass while the (16): Center trim seal
front window assembly is installed to the oper-
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see “Removal and installation
of front window assembly”.
PC300, 350-7E0 5
SEN03573-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
ing adhesive and both-sided adhesive tape
Q’ty
N/R
Part number Part name from the metal sheets (glass sticking surfaces)
of the operator's cab.
Lifter a Remove the adhesive and both-sided
1 793-498-1210 t 2
Y (Suction cup) adhesive tape to a degree that they will
2 20Y-54-13180 Adapter t 2 not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
Removal f a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e
scratched, adhesion will be lowered.)
a Remove the window glass to be replaced
according to the following procedure.
2. Remove oil, dust, dirt, etc. from the sticking
surfaces of cab and window glass with white
1. Using seal cutter [1], cut the adhesive between
gasoline.
broken window glass (7) and operator's cab
a If the sticking surfaces are not cleaned
(metal sheet) (8).
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
6 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
PC300, 350-7E0 7
SEN03573-01 50 Disassembly and assembly
a Parts to be coated with primer: Apply a When sticking both-sided adhesive tape
the primer to the sticking surfaces of (6) around a frame, do not lap its finishing
window glass (9) and all over dimen- end over the starting end but make clear-
sion (d) which will be on both-sided ance (e) of about 5 mm between them.
adhesive tape (6) and operator's cab 1) Stick both-sided adhesive tape (6) for right
(8). side window glass (1) as shown in the fig-
a Do not apply the primer to the ure.
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply wrong primer. If the
glass primer is applied by mistake,
wipe it off with white gasoline.
8 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
2) Stick both-sided adhesive tape (6) for left 4) Stick both-sided adhesive tape (6) for front
side rear window glass (2) as shown in the window glass (4) as shown in the figure.
figure.
PC300, 350-7E0 9
SEN03573-01 50 Disassembly and assembly
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
10 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
3) Set adhesive cartridge (12) to caulking a Apply adhesive (15) additionally for
gun [7]. additional both-sided adhesive tape
a An electric caulking gun is more effi- (6a) of the right side window glass
cient. and additional both-sided adhesive
tape (6b) of door lower window glass.
PC300, 350-7E0 11
SEN03573-01 50 Disassembly and assembly
12 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
PC300, 350-7E0 13
SEN03573-01 50 Disassembly and assembly
Removal and installation of front 7. Remove rollers (8) and (9) under the both
window assembly 1 sides of the front window.
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
14 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
8. Remove left lower pin (10). [*3] 10. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) a Do not let the front window assembly
at the end of pull-up assist cable (11) touch the monitor.
comes off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator's
cab. Accordingly, take care when
removing left lower pin (10) to discon-
nect pull-up assist cable (11).
PC300, 350-7E0 15
SEN03573-01 50 Disassembly and assembly
Installation
[*1] [*2]
q Adjust opening and closing of the front window
assembly according to the following proce-
dure.
16 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
3. Raise the front window assembly and fix it with 5. Install left corner blocks (1) and (2) and secure
the rear locks (on both sides). left corner bracket (6) with left striker bolt (4).
a Check that the locks in the rear of the a Tighten the striker bolt securely after
operator's cab are applied securely. adjusting it in step 6.
a Install the left corner blocks so that there
4. Install right corner block (3) and fix right corner will be no level difference at 2 part (d).
block bracket (7) with right striker bolt (5). a Secure roller clearance (e).
a Tighten the striker bolt securely after
adjusting it in step 6.
a Install the right corner block so that there
will be no level difference at part (a).
a Install the right corner block so that level
difference (b) between the rail and right
corner block (3) will be 0 – 1.0 mm. Check
that the right corner block is not projected
from the rail at the rolling surface of the
roller.
a Secure roller clearance (c) at part P.
PC300, 350-7E0 17
SEN03573-01 50 Disassembly and assembly
6. Adjust the striker bolts according to the follow- 2) Open and close the front window assem-
ing procedure (Adjust the "CLOSE" positions bly and check the working condition of
of the front window assembly locks). both locks (20) and (21).
1) Tighten left striker bolt (4) and right striker i) If both locks do not work normally,
bolt (5) at roughly right positions so that move the striker bolts toward the rear
front window glass (18) will be fitted to of the cab and tighten them again.
cab-side trim seal (19). ii) After moving the striker bolts, check
the fitness of the front window glass
and cab-side trim seal which was
checked in step 6.
iii) Repeat the work in i) and ii) until the
fitness of the front window and the
working condition of both locks (20)
and (21) are acceptable, and then
tighten the striker bolts.
18 PC300, 350-7E0
50 Disassembly and assembly SEN03573-01
8. Adjust the "opening" lock of the front window 9. Adjust the front window stoppers.
assembly. 1) After adjusting "closing" lock of the front
1) After adjusting the "closing" lock of the window assembly in step 9, check the
front window in step 6, raise the front win- contact of both front window stoppers
dow assembly to the ceiling. (23).
2) Set the right and left front window assem- 2) If both stoppers (23) do not contact nor-
bly locks at the rear of the operator's cab mally, adjust and fix them at places where
to the "OPEN" positions, and then check they contact normally.
the following items.
q Check that right and left locks (20)
and (21) are closed normally.
q Check that right and left locks (20)
and (21) are inserted in parallel in
right and left striker plates (22).
q Check that right and left rubber stop-
pers (24) are in contact with the front
window assembly and their deflec-
tion allowance is 1.5 – 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera-
tor's cab.
10. Check the latching effort of the front window
assembly.
1) After finishing steps 6 – 9, check that
latching efforts of both locks (20) and (21)
are even.
a Check the latching efforts on both
"closing" side (in the front of the oper-
ator's cab) and "opening" side (in the
rear of the operator's cab).
[*3]
3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC300, 350-7E0 19
SEN03573-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
20
SEN03574-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
Machine model Serial number
PC300-7E0 50001 – 50216
55001 and up
PC300LC-7E0 50001 – 50216
55001 and up
PC350-7E0 30001 – 30093
55001 and up
PC350LC-7E0 30001 – 30093
55001 and up
PC300, 350-7E0 1
SEN03574-01 50 Disassembly and assembly
Removal and installation of 4. Remove duct (5), cover (6), and plate (7).
assembly 1
5. Remove plate (8) and duct (9).
a Remove the duct lock clip.
Removal
k Disconnect the negative (–) terminal from 6. Remove ducts (10) and (11).
battery.
k Drain the coolant or disconnect the heater
hose when the coolant temperature in the
radiator is high, you may be scalded. In this
case, wait until the coolant temperature
lowers and then disconnect the heater
hose.
1. Swing the upper structure by 90°.
2 PC300, 350-7E0
50 Disassembly and assembly SEN03574-01
[*1]
a Apply compressor oil (ND-OIL8) to the threads
of the refrigerant pipe joints and tighten each
nut with double spanner.
12. Remove mounting bolt (24) and connector
(25). [*1] 3 Hose clamp (M6 bolt):
8 – 12 Nm {0.8 – 1.2 kgm}
13. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1] 3 Hose screw of M16 x 1.5:
a Put tags to the disconnected hoses and 12 – 15 Nm {1.2 – 1.5 kgm}
tubes to prevent a mistake when re-con-
necting them. 3 Hose screw of M22 x 1.5:
20 – 25 Nm {2.0 – 2.5 kgm}
PC300, 350-7E0 3
SEN03574-01 50 Disassembly and assembly
1. Remove cover (1) and then disconnect the wir- 1. Remove covers (1), (2) and (3).
ing connector P15 for air conditioner sunlight
sensor (2).
a Lift the cover up to remove it.
Installation
q Installation is done in the reverse order of
removal.
Installation
q Installation is done in the reverse order of
removal.
4 PC300, 350-7E0
50 Disassembly and assembly SEN03574-01
Installation
q Carry out installation in the reverse order to
Installation removal.
q Carry out installation in the reverse order to
removal.
PC300, 350-7E0 5
SEN03574-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
6
SEN03577-00
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03577-00 90 Diagrams and drawings
2 PC300, 350-7E0
Hydraulic circuit diagram
Hydraulic circuit diagram PC300, 300LC-7E0, PC350, 350LC-7E0 1 PC300, 300LC-7E0, PC350, 350LC-7E0
SEN03577-00
PC300, 350-7E0 3
90 Diagrams and drawings SEN03577-00
PC300, 350-7E0 5
SEN03577-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
6
SEN03576-01
PC300-7E0
PC300LC-7E0
PC350-7E0
PC350LC-7E0
PC300, 350-7E0 1
SEN03576-01 90 Diagrams and drawings
2 PC300, 350-7E0
Electrical circuit diagram (1/4)
Electrical circuit diagram (1/4) PC300, 300LC-7E0, PC350, 350LC-7E0
SEN03576-01
PC300, 350-7E0 3
Electrical circuit diagram (2/4)
Electrical circuit diagram (2/4) PC300, 300LC-7E0, PC350, 350LC-7E0
SEN03576-01
PC300, 350-7E0 5
Electrical circuit diagram (3/4)
Electrical circuit diagram (3/4) PC300, 300LC-7E0, PC350, 350LC-7E0
SEN03576-01
PC300, 350-7E0 7
Electrical circuit diagram (4/4)
Electrical circuit diagram (4/4) PC300, 300LC-7E0, PC350, 350LC-7E0
SEN03576-01
PC300, 350-7E0 9
Connector list and stereogram
Connector list and stereogram PC300, 300LC-7E0, PC350, 350LC-7E0 PC300, 300LC-7E0, PC350, 350LC-7E0
PC300, 350-7E0 13
SEN03576-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
14