COMPONENT CODE IK1/

PARTS & SERVICE .mFNO.A950238

DATE
NEWS
Dec. 28,1995
Page 1 of 13

SUBJECT: FLUSHING PROCEDURE WHEN HYD. PUMP FAILED ON PC300,350,400,

450-6

PURPOSE: To introduce repair procedures when the hydraulic pump of PC300-6, PC350-6,
PC400-6 and PC450-6 hydraulic excavators has gone out of order.

APPLICATION: PC300-6, PC350-6, PC400-6, PC450-6 Hydraulic Excavators

DESCRIPTION:

1. Introduction
When the hydraulic pump of the hydraulic excavators PC3OO,PC350,PC400 and PC450-6 has
gone out of order by damages occurring in its internal parts, repair the trouble following the
procedures outlined in this SERVICE NEWS. (Such as replacement of the pump, filters and O-
rings and cleaning of the hydraulic oil tank, hoses, tubes and relief valves.)

2. Content of the modification

2.1 Replacing the hydraulic pump

2.2 Replacing the consumable parts and defective parts

(1) Line filter element ................................................... .2 pcs

(2) Motor drain filter ...................................................... 1 pc
Consumable parts
(3) Return filter element ................................................ 1 pc
(4) Hydraulic tank strainer and breather element.. ..... 1 pc each
(5) o-ring ......................................................................... As occasion demands
(6) Defective parts such as hoses and tubes ................. As occasion demands

2.3 Washing or cleaning the pipings and equipment

(1) Hydraulic oil tank - Hydraulic plump

(2) Hydraulic pump - Line filter Tubes and hoses
(3) Pump dram filter - Hydraulic oil tank
(4) Hydraulic oil tank
(5) Line filter case Equipment
(6) Return filter case

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2.3.1 Disassemble the hydraulic pipings before washing or cleaning respective filter cases, hoses,
tubes and the hydraulic oil tank and replacing consumable parts (such as filter elements
and O-rings).

(1) Whenever defects are found with hoses, tubes or with any other attachments, replace
them with new parts.

(2) Use light oil or kerosene as the washing agent.

(3) Wash or clean the pipings and equipment given in Item 2.3. (Fig. 1 thru Fig. 4)

(4) Replace the consumable parts given in Item 2.2. (Fig. 1 thru Fig. 4)

Circuit names being referred to in the above paragraphs (3) and (4) and whereabouts of
their indications are as follows:

Markings Hydraulic circuit names Fig. numbers

(a) Hydraulic pump Fig. 1

(b) Hydraulic tank Fig. 2

cc> Return filter line Fig. 2

(d) Hydraulic oil tank - Pump suction line Fig. 3

(e) Pump drain line Fig. 4

(0 Pump - Line-filter line Fig. 1

(5) Since dirt accumulates on the bottom surface of the hydraulic oil tank, wash the dirt away
thoroughly and carefully check if any dirt is not remaining there.

(6) Dirt adheres on bore surfaces of pipings. Therefore, strike the pipings lightly with a small
mallet to separate the dirt before washing them.

(7) Choose a clean site to wash these parts and wrap them after the washing has been fin-
ished using vinyl covers or the sort to protect them from penetration of foreign matters,
until they are re-assembled.

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2.4 Repair procedures

(1) Prepare the necessary hydraulic pump and consumable parts.

(2) Dram all the hydraulic oil content.

(3) Disassemble the hydraulic pipings before washing the filter case, hoses, tubes and hy-
draulic tank and replacing the consumable parts (such as filter elements and O-rings).

(4) Replace the hydraulic pump and re-assembly the hydraulic pipings and relevant equip-
ment.

(5) Replace the hydraulic oil return filter element with the exclusive flushing-element.

(6) Refill hydraulic oil and let the oil fill inside the pump structure.

(7) Air bleeding from inside the pump.

(8) Check if oil leaks are not occurring.

(9) Air bleeding from the structure of the travel motor.

(10) Air bleeding from the structure of the swing motor.

(11) Air bleeding from inside the work equipment cylinders.

(12) Perform flushing of the hydraulic oil circuits.

(13) Check the hydraulic circuits.

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(a) Hydraulic pump

(f) Pump - Line-filter line Markings: 0 .... Disassemble to parts

and washed.
Wash or replace the parts so marked below. IJ .... Parts to be replaced.

Hydraulicpump

Fig. 1

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(b) Hydraulic oil tank

(c) Return filter line Markings: 0 .... Disassemble to parts

and washed.
Wash the hoses, valves and blocks or replace the 0 .... Parts to be replaced.
parts for the hydraulic oil tank and return filter line
according to the markings given below.

Revolving frame &I~,,

Fig. 2

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(d) Hydraulic oil tank - Pump suction line

Wash the tubes and replace the parts of the hydrau-

lic oil tank - pump suction line according to the Markings: 0 .... Disassemble to parts
makings given below. and washed.
0 .... Parts to be replaced.

Suctionline

Fig. 3

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(e) Pump drain line

Wash the hoses and elbow and replace the parts of

the pump drain line according to the markings given Markings: 0 .... Disassemble to parts
below. and washed.
0 .... Parts to be replaced.

Hydraulic pump

Hydraulic tank -+-

Fig. 4

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@ Short-circuiting pipes

@ Necessary parts for flushing

Necessa
Part names Part numbers nu,.

Exclusive flushing element 1 209-60-31130 [

Standard element 07063-01210

Pilot filter 704-28-0275 , Necessary
Parts
Small-sized strainer 206-60-41221

Pipe shorting flange 07377-01018

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3. Flushing procedures

Regarding procedures marked (*), when the pump is deeply damaged and substantial debris are
found in the line filter and the return filter, execute flushing after short-circuiting the circuits.
i However, when debris are not found, procedures marked (*) may be omitted. I

(1) Preparations for flushing

1. Install the exclusive flushing element.
2. Renew the pilot filter and the small-sized strainer.
(*I 3. Short the cylinder circuit. See pages lo/13 thru W13 regarding
(“14. Short the swing and travel motor circuits. 1 the short-circuiting procedures.
5. Refill the hydraulic oil upto the prescribed level.
6. Air bleeding from inside the main pump.
(Refer to pages 1203 thru 13/13 regarding the air bleeding procedures.)

(2) Flushing of the cylinder, swing motor and travel motor circuits.
1. Run-the engine at Low-Idling for 30 minutes.
(During this low-idling period, do not move the control levers in the operator’s cab.)
2. Run the engine at the medium speed for 30 minutes.
(During this medium speed running period, do not move the control levers in the operator’s
cab.)
When the oil temperature is found too low, prolong the duration of the above proce-
dures 1 and 2 to bring up the oil temperature to 20°C. (The oil temperature should
( more preferably be at 50” to SOW 1
3. Make the following operations running the engine at full speed:
1) Operation patterns
(Boom up) + (Boom down) + (Arm digging) + (Arm dumping) + (Bucket digging) +
(Bucket dump&g) + (Right-wise swing) + (Left-wise swing) + (Left-wise travel) +
(Right-wise travel)
2) Duration of the operations - Hold the control lever at each operation for 2 minutes.
3) Number of times of the operations - Repeat the above patterns for 5 times of more.

(*) (3) 1. Restore the cylinder circuit and swing motor circuit back to the normal circuitry.
(Leave the travel motor circuit as shorted.)
2. Refill the hydraulic oil upto the prescribed level.
3. Air bleeding from inside the main pump, cylinder and swing motor.
(Refer to pages 12/13 thru 13/13 regarding the air bleeding procedures.)

(*>(4) Flushing of the center swivel

Run the engine at full speed and operate the LH and RH travel control levers simultaneously
to repeat:
Four times cycles of (Forward travel) + (Swing by 90’)
Four times cycles of (Backward travel) + (Swing by 90’).
[Hold the travel lever for 2 minutes each.]
The 90” swing as above should be made in the same direction, either left-wise or right-wise.
Note) The purpose of making the 90 x swing as above is to remove dirt accumulated inside
the center swivel from all the length of the oil grooves on the rotor side and shaft side.

(*>(5) 1. Restore the travel circuit back to the normal circuitry.

2. Replace the exclusive flushing element with a new exclusive flushing element.
3. Air bleeding from the travel motor structure.

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(6) Flushing through actual operations

Perform actual operations for 10 to 20 hours carrying the exclusive flushing element.
When the oil temperature is found too low, make a warming-up.

(7) Replace the element with the standard element. The small-sized strainer should be r-e-used
after washing.
Renew the pilot filter.
Reuse the in-line filter element after washing.

(8) Refill the hydraulic oil upto the specified level.

(9) Air bleeding from inside the main pump.

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fl
Swing circuit Mrk

Travel motor

Ravel &&it

I” I, ~~nnmetrical between
&vL~ and.RBsides.
/ I

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Bleeding air

Order for operations and procedure for bleeding air

Air bleedingitem Air bleedingprocedure

1 2 3 4 5 6
Bleeding Ble;z air Bleeding_
air Bleedingair
airfrom start fromswing fromtravel op~~a~ons
Natureof work engine cylinder motor motor
P-P
l Changehydraulicoil O’+ 0 + 0 + 0 + 0 + 0
l Cleanstrainer (Note)! (Note)1

l Replacereturnfilter element 0 > 0

I I
Replace,repairpump ) 0
0 -+ 0 + 0
l

l Remove suctionpiping
I I I
I
l Replace, repaircontrolvalve o.lto’ 1 0
I
Replacecylinder ) 0
0 1,O
l

l Removecylinderpiping
Replaceswingmotor I
l

0 -0-o
l Remove swing motor piping
Replace travel motor, swivel
0 )
l

l Remove travel motor, swivel piping I I I OTC

Note:Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.

1. Bleeding air from pump

1) Loosen air bleed plug (l), and check that
oil oozes out from the plug.
2) When oil oozes out, tighten plug (1).
m Air bleed plug: 8.8 & 1.0 Nm
(0.9 F 0.1 kgm)
* If no oil oozes out from the air bleed plug:
3) Leave plug (1) loosened and remove.drain
hose (2) and elbow (3).
4) Pour in oil through the elbow mount hole
until oil oozes out from plug (1).
5) Fit elbow (3) and install drain hose (2).
6) Tighten air bleed plug (1).
QTJ Air bleed plug: 8.8 f 1.0 Nm
(0.9 + 0.1 kgm)
Precautions when starting the engine.
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
If the coolant temperature is low and auto-
matic warming-up is carried out, cancel it
by using the fuel control dial after starting
the engine.

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2. Bleeding air from hydraulic cylinders Boom cvlinder

2) Start the engine and run at idling for
approx. 5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
* Operate the piston rod to approx. 100
mm before the end of its stroke. Do not
relieve the circuit under any circum-
stances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod. Be
particularly careful not to operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cylinder.

3. Bleeding air from swing motor

1) Inside motor case
Run the engine at low idling for 5 minutes.
* This operation will bleed the air inside
the motor case automatically
2) Inside brake case
Ir Normally, the air inside the brake case
is bled automatically, but ifit feels that
the brake is dragging when operating
the swing, bleed the air as follows.
Loosen the mouthpiece of brake hose (l),
start the engine, and operate the swing pro-
lix switch ON-OFF repeatedly. When oil
oozes out, tighten the mouthpiece.

4. Bleeding air from travel motor

1) Run the engine at low idling, loosen air
bleed plug (11, and check that oil oozes out
from the plug.
2) When oil oozes out, tighten air bleed plug
( 1) again.
w Air bleed plug: 8.8 + 1.0 Nm
(0.9 f 0.1 kgm)

BlPOO181

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