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HYDRAULIC
PC300 -8
EXCAVATOR
PC300LC -8
PC350 -8
PC350LC -8
PC300- 60001
PC300LC- 60001
SERIAL NUMBERS and up
PC350- 60001
PC350LC- 60001
SEN01985-07
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01985-07 00 Index and foreword
01 Specification SEN01987-01
Specification and technical data SEN01988-01
40 Troubleshooting SEN02001-04
Failure code table and fuse locations SEN02627-03 q
General Information on troubleshooting SEN02628-03
Troubleshooting by failure code (Display of code), Part 1 SEN02629-02
Troubleshooting by failure code (Display of code), Part 2 SEN02630-03 q
Troubleshooting by failure code (Display of code), Part 3 SEN02631-02
Troubleshooting of electrical system (E-mode) SEN02632-02
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02633-02
2 PC300, 350-8
00 Index and foreword SEN01985-07
PC300, 350-8 3
SEN01985-07 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN01985-07
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
01 Specification
Specification and technical data SEN01988-01
Specification dimension drawings ............................................................................................... 2
Dimensions.................................................................................................................................. 2
Working ranges ........................................................................................................................... 3
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 10
Table of fuel, coolant and lubricants ............................................................................................ 12
4 PC300, 350-8
00 Index and foreword SEN01985-07
PC300, 350-8 5
SEN01985-07 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN02627-03
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 5
General Information on troubleshooting SEN02628-03
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
Possible problems and troubleshooting No................................................................................. 8
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 SEN02629-02
Failure code [989L00] Engine Controller Lock Caution 1............................................................ 3
Failure code [989M00] Engine Controller Lock Caution 2........................................................... 3
Failure code [989N00] Engine Controller Lock Caution 3 ........................................................... 4
Failure code [AA10NX] Air cleaner Clogging .............................................................................. 6
Failure code [AB00KE] Charge Voltage Low............................................................................... 8
Failure code [B@BAZG] Eng Oil Press. Low .............................................................................. 10
Failure code [B@BAZK] Eng Oil Level Low ................................................................................ 12
Failure code [B@BCNS] Eng. Water Overheat........................................................................... 14
Failure code [B@BCZK] Eng Water Level Low........................................................................... 16
6 PC300, 350-8
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PC300, 350-8 7
SEN01985-07 00 Index and foreword
8 PC300, 350-8
00 Index and foreword SEN01985-07
PC300, 350-8 9
SEN01985-07 00 Index and foreword
10 PC300, 350-8
00 Index and foreword SEN01985-07
PC300, 350-8 11
SEN01985-07
2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (01)
12
SEN01986-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
PC300, 350-8 3
SEN01986-02 00 Index and foreword
4 PC300, 350-8
00 Index and foreword SEN01986-02
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.
PC300, 350-8 5
SEN01986-02 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: N D-OIL8,
VA L E O T H E R M A L S Y ST E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 PC300, 350-8
00 Index and foreword SEN01986-02
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.
PC300, 350-8 7
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
Example:
Standard size Tolerance
0.022
120
0.126
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
PC300, 350-8 9
SEN01986-02 00 Index and foreword
10 PC300, 350-8
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PC300, 350-8 11
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
PC300, 350-8 13
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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
PC300, 350-8 15
SEN01986-02 00 Index and foreword
16 PC300, 350-8
00 Index and foreword SEN01986-02
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
W hen 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.
PC300, 350-8 17
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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.
PC300, 350-8 19
SEN01986-02 00 Index and foreword
20 PC300, 350-8
00 Index and foreword SEN01986-02
q 114 engine
q 107 engine
PC300, 350-8 21
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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-
General wiring
wire for AV tor tric appliance
(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)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC300, 350-8 23
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
(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
PC300, 350-8 25
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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.
PC300, 350-8 27
SEN01986-02 00 Index and foreword
28 PC300, 350-8
00 Index and foreword SEN01986-02
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.
PC300, 350-8 29
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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)
PC300, 350-8 31
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
PC300, 350-8 33
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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 51 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
PC300, 350-8 35
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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
PC300, 350-8 37
SEN01986-02 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 PC300, 350-8
00 Index and foreword SEN01986-02
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
PC300, 350-8 39
SEN01986-02 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.
1C = 33.8F
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 PC300, 350-8
00 Index and foreword SEN01986-02
PC300, 350-8 41
SEN01986-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN01988-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
01 Specification 1
Specification and technical data
Specification dimension drawings................................................................................................................... 2
Specifications.................................................................................................................................................. 4
Weight table.................................................................................................................................................. 10
Table of fuel, coolant and lubricants ............................................................................................................. 12
PC300, 350-8 1
SEN01988-01 01 Specification
2 PC300, 350-8
01 Specification SEN01988-01
1
1
Working ranges 1
PC300, 350-8 3
SEN01988-01 01 Specification
Specifications 1
PC300-8, PC300LC-8
mm 6,400 6,400
depth
Max. digging radius mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,100 10,100
Performance
4 PC300, 350-8
01 Specification SEN01988-01
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, 60 A
Battery 12 V, 126 Ah x 2
Radiator type Aluminum wave type, 4 rows
Undercarriage
PC300, 350-8 5
SEN01988-01 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, 350-8
01 Specification SEN01988-01
PC350-8, PC350LC-8
mm 6,400 6,400
depth
Max. digging radius mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,100 10,100
Performance
PC300, 350-8 7
SEN01988-01 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, 60 A
Battery 12 V, 126 Ah x 2
Radiator type Aluminum wave type, 4 rows
Undercarriage
8 PC300, 350-8
01 Specification SEN01988-01
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, 350-8 9
SEN01988-01 01 Specification
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
PC300-8, PC300LC-8
Unit: kg
Machine model PC300-8 PC300LC-8
Serial number 60001 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 570 570
Operator seat 35 35
Counterweight 5,480 5,480
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, 350-8
01 Specification SEN01988-01
PC350-8, PC350LC-8
Unit: kg
Machine model PC350-8 PC350LC-8
Serial number 60001 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 570 570
Operator seat 35 35
Counterweight 6,380 6,380
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, 350-8 11
SEN01988-01 01 Specification
12 PC300, 350-8
01 Specification SEN01988-01
Unit: l
PC300/300LC-8, PC350/350LC-8
Reservoir
Specified (l) Refill (l)
Engine oil pan 40 35
Swing machinery case 16.5 16.5
Final drive case (each) 9 9
Damper case 1.3 1.3
Hydraulic system 365 188
Fuel tank 605
Cooling system 32
PC300, 350-8 13
SEN01988-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (01)
14
SEN01990-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01990-00 10 Structure, function and maintenance standard
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01990-00
Specifications
Radiator: Aluminum wave type, 4th row
Oil cooler: CF40-1
PC300, 350-8 3
SEN01990-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
4
SEN01991-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01991-00 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, 350-8
10 Structure, function and maintenance standard SEN01991-00
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
PC300, 350-8 3
SEN01991-00 10 Structure, function and maintenance standard
Swing machinery 1
4 PC300, 350-8
10 Structure, function and maintenance standard SEN01991-00
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, 350-8 5
SEN01991-00 10 Structure, function and maintenance standard
Final drive 1
Specifications
Reduction ratio: ((11+97)/11) x ((19+97)/19) = 58.943
6 PC300, 350-8
10 Structure, function and maintenance standard SEN01991-00
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, 350-8 7
SEN01991-00 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)
8 PC300, 350-8
10 Structure, function and maintenance standard SEN01991-00
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, 350-8 9
SEN01991-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
10
SEN01992-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01992-00 10 Structure, function and maintenance standard
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01992-00
Standard shoe
Models
PC300-8 PC350-8 PC300LC-8 PC350LC-8
Item
Shoe width (triple shoe) (mm) 600 600 600 600
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
PC300, 350-8 3
SEN01992-00 10 Structure, function and maintenance standard
Idler 1
4 PC300, 350-8
10 Structure, function and maintenance standard SEN01992-00
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, 350-8 5
SEN01992-00 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, 350-8
10 Structure, function and maintenance standard SEN01992-00
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, 350-8 7
SEN01992-00 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 Repair limit 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, 350-8
10 Structure, function and maintenance standard SEN01992-00
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, 350-8 9
SEN01992-00 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, 350-8
10 Structure, function and maintenance standard SEN01992-00
PC300, 350-8 11
SEN01992-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
12
SEN01993-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01993-00 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, 350-8
10 Structure, function and maintenance standard SEN01993-00
PC300, 350-8 3
SEN01993-00 10 Structure, function and maintenance standard
4 PC300, 350-8
10 Structure, function and maintenance standard SEN01993-00
PC300, 350-8 5
SEN01993-00 10 Structure, function and maintenance standard
Hydraulic pump 1
Type: HPV125+125
6 PC300, 350-8
10 Structure, function and maintenance standard SEN01993-00
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
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8 PC300, 350-8
10 Structure, function and maintenance standard SEN01993-00
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.
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SEN01993-00 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.
the ax ial di rec tio n of cy li nder b loc 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, 350-8
10 Structure, function and maintenance standard SEN01993-00
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SEN01993-00 10 Structure, function and maintenance standard
1. LS valve
12 PC300, 350-8
10 Structure, function and maintenance standard SEN01993-00
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)
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SEN01993-00 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.
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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.
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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.
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Operation
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
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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, 350-8
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(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.
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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, 350-8
10 Structure, function and maintenance standard SEN01993-00
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.
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3. LS(PC)-EPC Valve
C: To LS(PC) valve
P: From self pressure reducing valve
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
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10 Structure, function and maintenance standard SEN01993-00
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).
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SEN01993-00 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, 350-8
10 Structure, function and maintenance standard SEN01993-00
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, 350-8 29
SEN01993-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
30
SEN01994-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01994-00 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.
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10 Structure, function and maintenance standard SEN01994-00
General view
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SEN01994-00 10 Structure, function and maintenance standard
Sectional view
(1/5)
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Unit: mm
PC300, 350-8 5
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(2/5)
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Unit: mm
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(3/5)
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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
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(4/5)
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10 Structure, function and maintenance standard SEN01994-00
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
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(5/5)
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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
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SEN01994-00 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
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10 Structure, function and maintenance standard SEN01994-00
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.
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16 PC300, 350-8
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3. System diagram
PC300, 350-8 17
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18 PC300, 350-8
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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.
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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.
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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.
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SEN01994-00 10 Structure, function and maintenance standard
(If the load pressure is higher than other work equipment during a combined operation)
24 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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.
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SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 27
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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 bottom. 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, 350-8 29
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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 head via circuit (D).
q Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
PC300, 350-8 31
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 33
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 35
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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 [(d area x P2 pres-
q Valve (7) is pressed to the closing direction of sure) = force of spring (8) + ( 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 [(d area x P2 pres- reduces, reducing the engine horsepower loss.
sure) = force of spring (8) + ( 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, 350-8 37
SEN01994-00 10 Structure, function and maintenance standard
38 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 39
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 41
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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)[= (d1) area (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, 350-8 43
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 45
SEN01994-00 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)[= (d1) area (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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 47
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 49
SEN01994-00 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[ 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 (d2 pressure receiving force > d1 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 [d2 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 51
SEN01994-00 10 Structure, function and maintenance standard
52 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 53
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
PC300, 350-8 55
SEN01994-00 10 Structure, function and maintenance standard
56 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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 D1
A2: Area of D2
F: Force of spring
P: Pump discharge oil pressure
PC300, 350-8 57
SEN01994-00 10 Structure, function and maintenance standard
Unit: mm
58 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 59
SEN01994-00 10 Structure, function and maintenance standard
60 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
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, 350-8 61
SEN01994-00 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, 350-8
10 Structure, function and maintenance standard SEN01994-00
2. When pressurized oil flows from the main valve to the cylinder
PC300, 350-8 63
SEN01994-00 10 Structure, function and maintenance standard
3. When returning pressurized oil to the main valve from the work equipment cylinder
64 PC300, 350-8
10 Structure, function and maintenance standard SEN01994-00
PC300, 350-8 65
SEN01994-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
66
SEN01995-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01995-00 10 Structure, function and maintenance standard
Valve control 1
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 3
SEN01995-00 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve
4 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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
PC300, 350-8 5
SEN01995-00 10 Structure, function and maintenance standard
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.
6 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 7
SEN01995-00 10 Structure, function and maintenance standard
8 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 9
SEN01995-00 10 Structure, function and maintenance standard
10 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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
PC300, 350-8 11
SEN01995-00 10 Structure, function and maintenance standard
12 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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-
ti o n , t h e hi g h e r o ne o f t h e P P C o u tp u t
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).
PC300, 350-8 13
SEN01995-00 10 Structure, function and maintenance standard
Operation
1) When in neutral
14 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 15
SEN01995-00 10 Structure, function and maintenance standard
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.
16 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
4) When counter-rotated
a The illustration shows the circuit for travelling left reverse and right forward.
PC300, 350-8 17
SEN01995-00 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of Work equipment swing PPC valve.
18 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
PC300, 350-8 19
SEN01995-00 10 Structure, function and maintenance standard
1. EPC valve
Unit: mm
20 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (coil is de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
pump controller, it generates the EPC output the controller to coil (14), coil (14) is deener-
pressure in proportion to the size of the signal, gized.
and outputs it to the control valve. q Spool (11) is pushed to the right by spring (12).
q Port (P) closes and the pressurized oil from the
front pump does not flow to the control valve.
q The pressurized oil from the control valve is
drained to the tank via port (C) and port (T).
PC300, 350-8 21
SEN01995-00 10 Structure, function and maintenance standard
22 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 23
SEN01995-00 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of Work equipment swing PPC valve.
24 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Installation
Free length
9 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 x 15.3 28.4 spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 x 8.10 22.0
{1.70 kg}
{1.36 kg}
PC300, 350-8 25
SEN01995-00 10 Structure, function and maintenance standard
Solenoid valve 1
PPC lock, travel junction, merge-divider, travel speed, swing brake, machine push-up and 2-stage
relief solenoid valves
26 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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.
PC300, 350-8 27
SEN01995-00 10 Structure, function and maintenance standard
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
28 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
For breaker
PC300, 350-8 29
SEN01995-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 shaft
Replace
80
30 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
Travel motor 1
Type: HMV160ADT-2
PC300, 350-8 31
SEN01995-00 10 Structure, function and maintenance standard
32 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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}
PC300, 350-8 33
SEN01995-00 10 Structure, function and maintenance standard
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).
34 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 35
SEN01995-00 10 Structure, function and maintenance standard
36 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 37
SEN01995-00 10 Structure, function and maintenance standard
38 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 39
SEN01995-00 10 Structure, function and maintenance standard
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.
40 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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.
PC300, 350-8 41
SEN01995-00 10 Structure, function and maintenance standard
42 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
Swing motor 1
Type: KMF230ABE-5
PC300, 350-8 43
SEN01995-00 10 Structure, function and maintenance standard
44 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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}
PC300, 350-8 45
SEN01995-00 10 Structure, function and maintenance standard
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.
46 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 47
SEN01995-00
48
10 Structure, function and maintenance standard SEN01995-00
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)
PC300, 350-8 49
SEN01995-00 10 Structure, function and maintenance standard
50 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
PC300, 350-8 51
SEN01995-00 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
52 PC300, 350-8
10 Structure, function and maintenance standard SEN01995-00
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
PC300, 350-8 53
SEN01995-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
54
SEN01996-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01996-01 10 Structure, function and maintenance standard
Work equipment 1
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01996-01
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, 350-8 3
SEN01996-01 10 Structure, function and maintenance standard
Dimensions of components 1
1. Dimension of arm
4 PC300, 350-8
10 Structure, function and maintenance standard SEN01996-01
Unit: mm
PC300-8 PC350-8
No. Measuring position Standard Tolerance Standard Tolerance
size Shaft Hole size Shaft Hole
0.036 +0.1 0.036 +0.1
1 100 100
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
4 110 110
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 90 90
0.090 0 0.090 0
16 345.0 0.5 345.0 0.5
0.036 +0.054 0.036 +0.054
17 90 90
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, 350-8 5
SEN01996-01 10 Structure, function and maintenance standard
2. Dimension of bucket
6 PC300, 350-8
10 Structure, function and maintenance standard SEN01996-01
Unit: mm
PC300-8 PC350-8
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 9419' 9414'
4 513.6 513.6
5 1658 1666
6 193 208
7 50 42
+0.2 +0.2
8 90 90
+0.0 +0.0
+0.054 +0.054
9 120 120
+0.054 +0.054
+0.1 +0.1
10 125 125
+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 26 26
16 165 165
17 150 150
18 200 200
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, 350-8 7
SEN01996-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 06-07 (01)
8
SEN01997-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01997-00 10 Structure, function and maintenance standard
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01997-00
PC300, 350-8 3
SEN01997-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
4
SEN01998-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN01998-02 10 Structure, function and maintenance standard
Engine control 1
2 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 3
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
Engine controller
PC300, 350-8 5
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
PC300, 350-8 7
SEN01998-02 10 Structure, function and maintenance standard
Rotation sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
8 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
1. Connector
2. Tube
3. Sensor
4. O-ring
1. Connector
2. Bracket
3. Float
4. Switch
PC300, 350-8 9
SEN01998-02 10 Structure, function and maintenance standard
10 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Control function
1
Auto-deceleration function
8
Attachment flow control and circuit selector function
(if equipped)
Self-diagnosis function
PC300, 350-8 11
SEN01998-02 10 Structure, function and maintenance standard
12 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 13
SEN01998-02 10 Structure, function and maintenance standard
14 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 15
SEN01998-02 10 Structure, function and maintenance standard
B and L modes
16 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
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 (1) 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, 350-8 17
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 19
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 21
SEN01998-02 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 1,300 rpm), this function lowers the
engine speed to the deceleration operation
level (approximately 1,300 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 23
SEN01998-02 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 30C
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 100C
ant temperature: Engine speed: Keep as is. Under above condition, controller
Above 100C 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 102C
Engine speed: Keep as is.
ant temperature: Under above condition, controller
Monitor alarm lamp: Lights up.
Above 102C 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 105C Under above condition, controller
Alarm buzzer: Sounds
is set to condition before opera-
tion of function. (Manual reset)
24 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Function
The swing lock and swing holding brake function
are provided as a swing control function.
PC300, 350-8 25
SEN01998-02 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 (1) 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 27
SEN01998-02 10 Structure, function and maintenance standard
28 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 29
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
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, 350-8 31
SEN01998-02 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, 350-8
10 Structure, function and maintenance standard SEN01998-02
4) Pump controller
PC300, 350-8 33
SEN01998-02 10 Structure, function and maintenance standard
CN-C01
CN-C01 Input/
Input/ Pin No. Signal name
Pin No. Signal name output
output 52 Service switch Input
1 PWR_IN_BATT Input 53 Boom raise pressure switch Input
2 GND_PWR Input 54 NC(*)
3 Washer motor output 55 Travel switch Input
4 PWR_IN_BATT Input 56 Wiper limit switch Input
5 GND_PWR Input 57 Window limit switch Input
6 NC(*) 58 Machin select 4 Input
7 NC(*) 59 NC(*)
8 NC(*) 60 Start switch Input
9 PWR_OUT_5V_0 output 61 NC(*)
10 NC(*) Input 62 NC(*) Input
11 NC(*) 63 NC(*)
12 NC(*) Input/
13 NC(*) 64 COMM_CAN_L_0
output
14 Boom lower switch Input 65 GND_SIG_A
15 Arm dump switch Input 66 NC(*)
16 Swing pressure switch Input 67 NC(*)
17 Arm curl pilot sensor Input 68 R pump pressure sensor Input
18 GND_SIG_A Input 69 NC(*)
19 Swing lock switch Input 70 NC(*)
20 NC(*) 71 NC(*) Input
21 Machin select 2 Input 72 NC(*)
22 NC(*) 73 Bucket curl pilot sensor Input
23 NC(*) 74 Overload pressure sensor
24 PWR_CTR_KEY Input 75 Wiper limit switch (P) Input
25 NC(*) 76 NC(*)
26 NC(*) 77 Machin select 3 Input
27 NC(*) 78 Overload caution enable switch
28 NC(*) 79 Start switch (ACC) Input
29 Hydraulicoil temperature Input 80 NC(*)
30 NC(*) 81 GND_SIG_D
31 NC(*) *: Never connect to NC or malfunctions or failures will
32 NC(*) occur.
33 NC(*)
34 Bucket dump pressure switch Input
35 NC(*)
36 Travel steering switch Input
37 GND_SIG_D
38 Swing prolix switch Input
39 Machin select 5 Input
40 Machin select 1 Input
41 Knob switch Input
42 NC(*)
43 PWR_CTR_KEY Input
44 GND_SIG_P Input
Input/
45 COMM_CAN_H_0
output
46 GND_SIG_A Input
47 GND_SIG_A
48 NC(*)
49 F pump pressure sensor Input
50 NC(*)
51 NC(*)
34 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
CN-C02
Input/
Pin No. Signal name
output
82 NC(*)
83 NC(*)
84 NC(*)
85 NC(*)
86 Att circuit change solenoid output
87 Travel speed solenoid output
88 NC(*) output
89 NC(*)
90 NC(*)
91 NC(*)
92 NC(*)
93 NC(*)
94 NC(*)
95 NC(*) output
96 PCQEPC (F) output
97 Att flux limit EPC output
98 NC(*)
99 NC(*)
100 NC(*)
101 Swing brake solenoid output
102 NC(*)
103 NC(*)
104 NC(*)
105 NC(*)
106 NC(*)
107 NC(*)
108 Battery relay output
109 2-stage relief solenoid output
110 Travel valve solenoid output
111 NC(*)
112 Merge-divider solenoid (Main) output
113 NC(*)
114 Wiper motor () output
115 GND_ACT Input
116 Solenoid power supply Input
117 GND_ACT Input
118 Solenoid power supply Input
119 Wiper motor (+) output
120 GND_ACT Input
121 Solenoid power supply Input
*: Never connect to NC or malfunctions or failures will
occur.
PC300, 350-8 35
SEN01998-02 10 Structure, function and maintenance standard
Monitor system 1
36 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Machine monitor 1
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, 350-8 37
SEN01998-02 10 Structure, function and maintenance standard
38 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
CN-CM05
Input/
Pin No. Signal name
output
Electric power supply for cam-
1 Output
era
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
Electric power supply GND for
5
camera
6 Camera signal GND1
7 Camera signal GND2
8 Camera signal GND3
PC300, 350-8 39
SEN01998-02 10 Structure, function and maintenance standard
40 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 41
SEN01998-02 10 Structure, function and maintenance standard
Engine coolant
temperature
Hydraulic oil See gauge display on next page.
temperature
Fuel level
42 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or vol-
Gauge Range Indicator Buzzer sound
ume
A1 105 Red Q
A2 102 Red
Engine coolant tem- A3 100 Off
perature
(C) A4 80 Off
A5 60 Off
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera- B3 100 Off
ture
(C) B4 85 Off
B5 40 Off
B6 20 White
C1 417 Off
C2 347.5 Off
C3 277.5 Off
Fuel level (l)
C4 199 Off
C5 100 Off
C6 62 Red
PC300, 350-8 43
SEN01998-02 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.
Lights up when
Battery charge q
abnormal.
Lights up when
Engine oil level q abnormal.
Lights up when
Air cleaner clogging q
abnormal.
44 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Display
Symbol Display item Display range Display method
category
Green:
Displays state of message
KOMTRAX There is unread message.
(for only machine equipped
message Blue:
with KOMTRAX).
There is unreturned message.
Air conditioner/
ON OFF Displays operating condition.
Heater
Monitor
Lo Mi Hi
Travel speed Displays set speed.
Displays time.
12-hour display
Clock Clock (Changes to service meter if
24-hour display F4 is depressed.)
PC300, 350-8 45
SEN01998-02 10 Structure, function and maintenance standard
Switches 1
46 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
Selects item on lower side (Selects top item after bottom
F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top
F4 Select item
item)/Holds monitoring.
Selects page on lower side (Selects top page after bottom
F1 Select item
page).
Selects page on upper side (Selects bottom page after top
F2 Select item
page).
PC300, 350-8 47
SEN01998-02 10 Structure, function and maintenance standard
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
Crawler symbol + Hi High speed
F5 : Starts up in E mode.
F6 : Starts up in B mode.
48 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 49
SEN01998-02 10 Structure, function and maintenance standard
50 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 51
SEN01998-02 10 Structure, function and maintenance standard
Maintenance function 1
q Pressing F5 on the normal screen switches to
the maintenance screen.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 500
F1 : Displays the next page.
04 Hydraulic filter 1000
Displays the top page when the last page is
05 Hydraulic tank breather 500
displayed.
06 Corrosion resistor 1000(*)
F2 : Displays the previous page.
07 Damper case oil 1000
Displays the last page when the top page is
displayed. 08 Final case oil 2000
F3 : Selects (highlights) an item one down. 09 Machinery case oil 1000
F4 : Selects (highlights) an item one up. 10 Hydraulic oil 5000
F5 : Returns to the normal screen. *: If equipped (To be determined)
F6 : Switches to the maintenance time reset screen.
No operation at least 30 sec. : Returns to the nor- q The content of the caution display differs
mal screen. according to the remaining time. The relation-
ship is as shown in the table below.
q If the remaining time on the maintenance table
screen is less than 30 hours, the relevant items Display Condition
are highlighted in yellow, and if 0 hours, they Remaining time for mainte-
are done in red. None nance for all items is more
q On the maintenance time reset screen, reset than 30 hours.
the remaining time for the selected item to There is one or more items
Notice display (black sym-
return to the default. with less than 30-hour
bol displayed on yellow
remaining time for mainte-
background)
nance.
There is one or more items
Warning display (white
with less than 0-hour
symbol displayed on red
remaining time for mainte-
background)
nance.
52 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 53
SEN01998-02 10 Structure, function and maintenance standard
Breaker/attachment setting
q For an attachment-equipped machine, this
menu allows you to adjust a flow rate in B
mode and ATT mode.
q For a machine with no attachment, this menu
does not appear.
54 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
1. Breaker setting selection screen. q On the flow rate level setting screen,
q On this screen, you can allocate one of change the set flow rate.
two set flow rates as a flow rate in breaker
mode.
q The B symbol is displayed before items
specified to breaker mode.
a The defaults of both flow rates are 230 l/
min.
PC300, 350-8 55
SEN01998-02 10 Structure, function and maintenance standard
F3 : Selects (highlights) an item one down. F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up. F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker/attachment setting F5 : Returns to the breaker setting menu
screen. screen.
F6 : Switches to the setting screen for the selected F6 : Switches to the flow rate level setting
(highlighted) item. screen for the selected (highlighted) item.
1. Attachment setting selection screen q On the flow rate level setting screen,
q On this screen, you can allocate one of change the set flow rate.
two set flow rates as a flow rate in attach-
ment mode.
q The ATT symbol is displayed before items
specified to attachment mode.
a The defaults of both flow rates are 530 l/
min.
56 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Message display
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message moni-
tor appears on the upper left of the normal
screen.
q The lighting green monitor indicates that there
are messages to be read.
q The lighting blue monitor appears when you
have not sent replies yet after opening mes-
sages which accept replies.
Screen adjustment
q Selecting the Screen adjustment from the user
q Press F6 to enter user mode and select Mes- menu and pressing F6 switches to the screen
sage display and you can view (open) the adjustment screen.
messages. q From this menu, you can adjust the brightness,
contrast, and luminance of the machine moni-
tor screen.
q When the light switch is in Night mode ON, the
night mode screen is adjustable.
q When the light switch is in Daytime mode ON
or OFF, the daytime mode screen is adjust-
able.
PC300, 350-8 57
SEN01998-02 10 Structure, function and maintenance standard
1) Time setting
F3 : Selects (highlights) an item one down. Set the clock time. If the time setting item
F4 : Selects (highlights) an item one up. is not highlighted, press F6 to highlight it.
F5 : Cancels changes you made before confirming
them with F6 to return to the menu screen. The time display part is highlighted.
F6 : Moves to the setup items of the selected (high- F3 : Advances the clock one hour.
lighted) item. F4 : Sets the clock back one hour.
F5 : Cancels changes you made before
q The adjustment methods for the camera confirming them with F6 to return to
screen and normal screen are the same. the user menu.
q The background when adjusting the camera F6 : Confirms the changes and moves to
screen is the No. 1 camera image. minute setting.
58 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language
to be displayed on the monitor. Available lan-
guages are as follows.
English, Japanese, Chinese, French, Spanish, F3 : Selects (highlights) an item one down.
Portuguese, Italian, German, Russian, Turkish, F4 : Selects (highlights) an item one up.
Indonesian, and Thai. F5 : Cancels the changes to return to the user menu.
F6 : Cancels the changes to return to the user menu.
PC300, 350-8 59
SEN01998-02 10 Structure, function and maintenance standard
60 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 61
SEN01998-02 10 Structure, function and maintenance standard
62 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
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
PC300, 350-8 63
SEN01998-02 10 Structure, function and maintenance standard
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Float 3. Cover
2. Connector 4. Variable resistor
64 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
PC300, 350-8 65
SEN01998-02 10 Structure, function and maintenance standard
KOMTRAX system 1
66 PC300, 350-8
10 Structure, function and maintenance standard SEN01998-02
KOMTRAX terminal
Model: TH300
q The KOMTRAX system uses satellite communication technology.
AMP-10P [CN-CK02]
Pin No. Signal name Input/output
B-1 Serial signal DCD Output
B-2 Serial signal RXD Output
B-3 Serial signal TXD Input
B-4 Serial signal DTR Input
B-5 Serial signal SGND
B-6 Serial signal DSR Output
B-7 NC (*)
B-8 NC (*)
B-9 NC (*)
B-10 NC (*)
*: Never connect to NC, or malfunctions or failures will
occur.
PC300, 350-8 67
SEN01998-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (01)
68
SEN02624-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02624-02 20 Standard value table
PC300, 300LC-8
Applicable model
PC350, 350LC-8
Engine SAA6D114E-3
Coolant temperature:
Engine speed Low idle rpm 1,000 25 1,000 25
operating range
Oil temperature Whole speed range (inside oil pan) C 80 110 120
2 PC300, 350-8
20 Standard value table SEN02624-02
PC300, 300LC-8
Applicable model
PC350, 350LC-8
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 point, see Control valve. mm 9.5 0.5 9.5 0.5
PC300, 350-8 3
SEN02624-02 20 Standard value table
PC300, 300LC-8
Applicable model
PC350, 350LC-8
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, 350-8
20 Standard value table SEN02624-02
PC300, 300LC-8
Applicable model
PC350, 350LC-8
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, 350-8 5
SEN02624-02 20 Standard value table
PC300, 300LC-8
Applicable model
PC350, 350LC-8
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, 350-8
20 Standard value table SEN02624-02
PC300, 300LC-8
Applicable model
PC350, 350LC-8
Cate- Standard value for Judgement
Item Measurement condition Unit
gory new machine criteria
Whole work Hydraulic oil temperature: Within
equipment operating range PC300: Max. 450 PC300: Max. 675
(Lowering dis- Flat and level ground PC350: Max. 550 PC350: Max. 825
tance of tooth Bucket load: 2,160 kg
tip)
Hydraulic drift of work equipment
Engine stopped
Boom cylinder Work equipment control lever in
(Retraction dis- NEUTRAL position PC300: Max. 25 PC300: Max. 38
tance of cylin- Fall amount for 15 minutes as PC350: Max. 30 PC350: Max. 45
der) measured every 5 minutes starting
immediately after initial setting
mm
Whole work equipment: Lowering
Arm cylinder distance of tooth tip
(Extraction dis- Boom cylinder: Retraction distance of PC300: Max. 135 PC300: Max. 203
tance of cylin- cylinder PC350: Max. 165 PC350: Max. 248
der) Arm cylinder: Extraction distance of
cylinder
Bucket cylinder Bucket cylinder: Retraction distance
(Retraction dis- of cylinder PC300: Max. 20 PC300: Max. 30
tance of cylin- For measuring posture, see Work PC350: Max. 25 PC350: Max. 38
der) equipment 1
Hydraulic oil temperature:
Work equipment
PC300, 350-8 7
SEN02624-02 20 Standard value table
PC300, 300LC-8
Applicable model
PC350, 350LC-8
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, 350-8
20 Standard value table SEN02624-02
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, 350-8 9
SEN02624-02 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, 350-8
20 Standard value table SEN02624-02
PC300, 350-8 11
SEN02624-02 20 Standard value table
12 PC300, 350-8
20 Standard value table SEN02624-02
PC300, 350-8 13
SEN02624-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
14
SEN02625-03
PC300, 350-8
SEN02625-03
HYDRAULIC EXCAVATOR
Shop Manual
PC300-8
PC300LC-8
PC350-8
PC350LC-8
Machine model Serial number
PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up
PC300, 350-8 1
SEN02625-03 30 Testing and adjusting
Testing and adjusting oil pressure in work equipment, swing and travel circuit.......................................... 35
Testing and adjusting control circuit oil pressure ........................................................................................ 39
Testing and adjusting pump PC control circuit oil pressure ........................................................................ 40
Testing and adjusting pump LS control circuit oil pressure......................................................................... 43
Testing solenoid valve output pressure....................................................................................................... 48
Testing PPC valve output pressure............................................................................................................. 52
Adjusting play of work equipment and swing PPC valves........................................................................... 53
Inspecting locations of hydraulic drift of work equipment............................................................................ 54
Releasing remaining pressure in hydraulic circuit....................................................................................... 56
Testing oil leakage amount ......................................................................................................................... 56
Bleeding air from various parts ................................................................................................................... 59
Diode inspection procedures....................................................................................................................... 61
2 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 3
SEN02625-03 30 Testing and adjusting
4 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 5
SEN02625-03 30 Testing and adjusting
6 PC300, 350-8
30 Testing and adjusting SEN02625-03
Socket
PC300, 350-8 7
SEN02625-03 30 Testing and adjusting
8 PC300, 350-8
30 Testing and adjusting SEN02625-03
Testing air boost pressure 5. Run the engine at middle or higher speed and
drain oil from the hose.
a When draining the oil, open the self seal of
a Air boost pressure measuring tools
the hose by insert approximately half of the
Symbol Part No. Part name
gauge and hose connection. Repeat opera-
A 1 799-201-2202 Boost gauge kit
tion until the oil is drained out.
a If Pm kit (A) is available, you may use the air
1. Open the engine hood. bleeding coupling (790-261-1130) in that kit.
a If oil is left in the hose, the gauge does not
2. Remove intake air pressure pickup plug (1) (R work. Accordingly, be sure to drain the oil.
1/8).
6. Measure the air boost pressure at high idle
under the following conditions.
q Working mode: P-mode
q Swing lock switch: ON (high pressure relief)
q Work equipment, swing and travel: Arm IN
relief position
PC300, 350-8 9
SEN02625-03 30 Testing and adjusting
10 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 11
SEN02625-03 30 Testing and adjusting
Adjusting valve clearance 4. Remove cap (6), set gear C1 and rotate the
crank shaft forward to set No.1 cylinder to the
compression top dead center.
a Valve clearance adjustment tools
Symbol Part No. Part name
1 795-799-1131 Gear
C Commercially
2 Clearance gauge
available
12 PC300, 350-8
30 Testing and adjusting SEN02625-03
6. Adjust the valve clearance in the following 4) Turn the crankshaft forward by 360 and
procedure. align the counter mark applied in step 5
a When No.1 cylinder is at the compression top above accurately to the pointer.
dead center, adjust the valve clearance indi- a This alignment moves the supply pump
cated with q mark in the valve arrangement gear stamp line (b) to the position of
drawing. 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 adjustment of q mark.
PC300, 350-8 13
SEN02625-03 30 Testing and adjusting
Testing compression pressure 5. Move fuel filter and corrosion resistor assembly
(8) to the control valve side along with the hose
being connected to it.
a Testing tools for compression pressure
Symbol Part number Part name
1 795-799-6700 Puller
2 795-502-1590 Compression gauge
D
3 795-790-6110 Adapter
4 6754-11-3130 Gasket
14 PC300, 350-8
30 Testing and adjusting SEN02625-03
9. Disconnect high-pressure fuel tube (16). 13. Remove retainer (19) and remove fuel inlet
connector (20).
PC300, 350-8 15
SEN02625-03 30 Testing and adjusting
16. Install gasket D4 to the tip of adapter D3 and 21. Select the no-injection cranking operation from
connect it to the injector mount. the machine monitor.
a See the section of "Special functions of ma-
chine monitor".
k Be sure to select the no-injection crank-
ing operation. Otherwise, the engine can
be started during the inspection, poten-
tially inducing risks to the inspecting per-
sonnel.
16 PC300, 350-8
30 Testing and adjusting SEN02625-03
6) Tighten the sleeve nut of high-pressure fuel a Tighten the injector terminal nut with the follow-
hose (16) sequentially in the order of head ing torque.
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, 350-8 17
SEN02625-03 30 Testing and adjusting
18 PC300, 350-8
30 Testing and adjusting SEN02625-03
Testing engine oil pressure 5. Run the engine at the rated output and low idle
and test the oil pressure.
a Measuring tools for engine oil pressure
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
6215-81-9710 O-ring
PC300, 350-8 19
SEN02625-03 30 Testing and adjusting
20 PC300, 350-8
30 Testing and adjusting SEN02625-03
3) Run the engine at high idle and measure the 3) Measure pressure in the fuel low-pressure
pressure in the fuel negative pressure circuit. circuit when the engine is cranked.
a If the pressure in the fuel negative pres- a If the pressure in the fuel low-pressure cir-
sure circuit is in the following range, it is cuit (at the fuel filter inlet side) is in the fol-
normal. lowing range, it is normal.
q Standard pressure value in the fuel nega- q Standard pressure values of the fuel
tive pressure circuit (supply pump) Max. low-pressure circuit (fuel filter inlet side)
33.9 kPa {Max. 254 mmHg} Min. 0.14 MPa {Min. 1.4 kg/cm2}
4) After finishing measurement, remove the k In order to protect the starting motor, it
measuring tools and return the removed is prohibited to continue cranking for
parts. more than 20 seconds.
q Fuel pressure pickup plug:
2022 Nm {2.02.2 kgm}
PC300, 350-8 21
SEN02625-03 30 Testing and adjusting
22 PC300, 350-8
30 Testing and adjusting SEN02625-03
3) Run the engine at high idle and measure 2) Connect M10 computer check fitting G4to
drop of the pressure of the fuel low-pressure gauge G3.
circuit.
q Pressure drop in the fuel low-pressure cir-
cuit =
Fuel filter inlet pressure Fuel pressure
outlet pressure
a If the pressure drop in the fuel low-pres-
sure 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 ex-
ceeded the standard value, clogging of
the fuel filter should be suspected.
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).
6. Testing fuel lift pump outlet pressure (supply a The fuel lift pump operates for 30 sec-
pump section) onds after the starting switch is turned ON
1) Remove fuel pressure pickup plug (2) of the and then stops. Measure the pressure
supply pump. while the pump is operating.
a If the fuel lift pump outlet pressure is in the
following standard range, it is normal.
q Standard fuel lift pump outlet pressure
(supply pump section):
Min. 34 kPa {0.35 kg/cm2}
a If the fuel lift pump outlet pressure is not
in the standard range, perform the follow-
ing checks.
q Check that fuel is in the fuel lift pump.
q If fuel is not in the fuel lift pump just af-
ter the fuel filter is replaced or a fuel
system part is removed and returned,
operate the fuel lift pump 3 4 times
with the starting switch to bleed air
from the fuel circuit and fill the pump
with fuel and then measure the outlet
pressure again.
PC300, 350-8 23
SEN02625-03 30 Testing and adjusting
24 PC300, 350-8
30 Testing and adjusting SEN02625-03
a Reduced cylinder mode operation means to run a The no injection cranking operation denotes to
the engine with the fuel injectors of 1 or more cyl- crank the engine from the starting motor after
inders disabled electrically to reduce the number setting all cylinders to no injection mode. Follow-
of effective cylinders. The purposes and effects ing describes the objective and effects of this op-
of this operation are as follows. eration.
1. This operation is used to find out a cylinder
which does not output power normally (or, When a machine or engine has been stored for
combustion in it is abnormal). a long period of time, implementing the no injec-
2. If the engine speed and output remain the same tion cranking operation before restarting the
as the normal operation (full-cylinder mode oper- engine lubricates the engine respective parts
ation) when a cylinder is set to noinjection in the and thus helps preventing seizure of the engine.
cylinder cut-out operation, existence of a failure a See the section of Special functions of machine
on the subject cylinder should be suspected. monitor when turning on the no injection crank-
Followings are the potential causes. ing operation.
Leakage from the cylinder head gasket
Defective injection from the injector
Failure on the piston, piston ring or cylinder
liner
Failure on the valve mechanism (valve oper-
ating system)
Failure in the electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a See the section of Special functions of ma-
chine monitor when turning on the cylinder
cut-out operation.
PC300, 350-8 25
SEN02625-03 30 Testing and adjusting
Testing fuel return rate and k If the engine cannot be started, you
leakage may measure the fuel return rate while
rotating the engine with the starting
motor. Do not rotate for more than 30
a Testing tools for leakage from pressure limiter seconds continuously, however, for
and return rate from injector protection of the starting motor.
Symbol Part No. Part name
1 795-790-4800 Hose KIT
2 795-790-6700 Adapter
H
Commercially
3 Measuring cylinder
available
26 PC300, 350-8
30 Testing and adjusting SEN02625-03
4) Run the engine at low idle and test the return 4) Run the engine at low idle and test the return
rate from the pressure limiter. rate from the injector.
a If the leakage from the pressure limiter is a If the return rate from the injector is in the
in the following range, it is normal. following range, it is normal.
At low idle Below 30 droppings/min. At low idle Max. 300 cc/45 sec.
At cranking Max. 100 cc/30 sec.
PC300, 350-8 27
SEN02625-03 30 Testing and adjusting
Bleeding air from fuel circuit 3. Fill up the fuel tank with fuel.
28 PC300, 350-8
30 Testing and adjusting SEN02625-03
Checking fuel circuit for leakage 8. Run the engine at high idle and load it.
a When checking while the components to be
checked are mounted on the machine, stall
k Very high pressure is generated in the high-
the torque converter or relieve the hydraulic
pressure circuit of the fuel system. If fuel
pump.
leaks while the engine is running, it is dan-
gerous since it can catch fire.
9. Inspect the fuel piping and devices for fuel
After testing the fuel system or removing its
leakage.
parts, test it for fuel leakage according to the
a Check mainly around the high-pressure cir-
following procedure.
cuit parts coated with the color checker for
a Clean and degrease the engine and the parts
fuel leakage.
around it in advance so that you can test it easily
a If any fuel leakage is detected, repair it and
for fuel leakage.
check again from step 1.
a If no fuel leakage is detected, check is com-
1. Spray color checker (developer) over the fuel
pleted.
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
PC300, 350-8 29
SEN02625-03 30 Testing and adjusting
Adjustment
a If the belt deflection amount is not proper, adjust
it in the following manner.
30 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 31
SEN02625-03 30 Testing and adjusting
32 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 33
SEN02625-03 30 Testing and adjusting
34 PC300, 350-8
30 Testing and adjusting SEN02625-03
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 capacity
travel circuit
60 MPa {600 kg/cm2}.
PC300, 350-8 35
SEN02625-03 30 Testing and adjusting
Pump Actuator Valve to be relieved a When the boom LOWER is selected, the
(Unload) F unload valve relief pressure is lower than the main re-
Service Safety valve lief pressure.
Boom Hi Arm Hi F main relief valve a When the boom LOWER is selected,
Front Bucket F main relief valve
turning off the machine push-up switch in-
pump L.H travel F main relief valve
RAISE: R main relief troduces the low-pressure relief pressure
Boom Lo valve and turning it on introduces the high-pres-
LOWER: Safety valve sure relief pressure.
Swing Swing motor safety valve
Rear R.H travel R main relief valve 5. Measurement of swing relief pressure
pump Arm Lo R main relief valve
1) Start the engine and move the swing lock
(Unload) R unload valve
switch to the ON position.
2) Measure hydraulic oil pressure when the
3. Measurement of unload pressure engine is running at high idle and the swing
1) Start the engine. circuit is relieved.
2) Measure hydraulic oil pressure, when the a Hydraulic oil pressure when the swing
engine is running at high idle and all the motor safety valve is relieved is dis-
control levers are moved to the NEUTRAL played.
position. a The relief pressure of the swing motor is
a Hydraulic oil pressure when the unload lower than the main relief pressure.
valve unloads is displayed.
6. Measurement of travel circuit relief pressure
4. Measurement of work equipment relief pres- 1) Start the engine, and lock the travel.
sure k Insert pin [2] between the sprocket and
1) Start the engine and move the cylinder to be the track frame to positively lock the
measured to its stroke end. travel circuit.
2) Measure hydraulic oil pressure when the
cylinder is relieved while the engine is
running at high idle.
a Except when the boom LOWER is select-
ed, the pressure at which the main relief
valve was relieved is displayed.
a Except when the boom LOWER is select-
ed, releasing the power max. switch intro-
duces the low-pressure relief pressure
and pushing this switch introduces the
high-pressure relief pressure.
a Except when the boom LOWER is select-
ed, keep the swing lock switch in the OFF
position during the inspection. If it is
moved to the ON position, hydraulic oil 2) Measure the pressure when the engine is set
pressure is turned to high relief pressure, to high idle and the travel circuit is relieved.
as the constant 2-stage relief valve is a Hydraulic oil pressure with the main relief
moved to the ON position. valve in relief condition is displayed. In
a When the boom LOWER is selected, the the travel circuit relief, the pressure is
pressure at which the safety valve was re- high pressure relief all the time.
lieved is displayed.
36 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 37
SEN02625-03 30 Testing and adjusting
3) Check the pressure again after the adjust- 4. Adjustment of swing relief pressure
ment, following the aforementioned steps for a If the swing relief pressure is not normal, ad-
measurement. just the swing motor safety valve (12) in the
a Connect the pilot hose when measuring following manner.
the oil pressure.
38 PC300, 350-8
30 Testing and adjusting SEN02625-03
Testing and adjusting control 3. Start the engine and keep it running until the
circuit oil pressure hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure testing and adjusting 4. Measure hydraulic oil pressure, when the engine
tools is running at high idle and all the control levers
are moved to the NEUTRAL position.
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 1.25 mm)
2
07002-11023 O-ring
Measurement
k Lower the work equipment to the ground
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the
oil filler cap gradually to release pressure in-
side the tank.
PC300, 350-8 39
SEN02625-03 30 Testing and adjusting
Measurement
a Measurement of the oil pressure in the pump PC
control circuit shall be conducted after making 2) Fit nipple L2 and connect it to oil pressure
sure that oil pressure of the work equipment, gauge [1] of hydraulic tester L1.
swing, and travel circuits as well as basic pres- a Use the oil pressure gauge with capacity
sure of the control circuit is normal. 60 MPa {600 kg/cm2}.
k Lower the work equipment to the ground
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the
oil filler cap gradually to release pressure in-
side the tank.
40 PC300, 350-8
30 Testing and adjusting SEN02625-03
3) Start the engine and keep it running until the 2. Measurement of PC-EPC valve output pres-
hydraulic oil temperature rises to the oper- sure
ating range. 1) Remove oil pressure measurement plug (5).
a The plug is installed in the front side of the
machine.
PC300, 350-8 41
SEN02625-03 30 Testing and adjusting
42 PC300, 350-8
30 Testing and adjusting SEN02625-03
Measurement
a Measurement of the oil pressure in the pump LS
control circuit shall be conducted after making
sure that oil pressure of the work equipment,
swing, and travel circuits as well as basic pres-
sure of the control circuit is normal.
k Lower the work equipment to the ground
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the
oil filler cap gradually to release pressure in-
side the tank.
PC300, 350-8 43
SEN02625-03 30 Testing and adjusting
44 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 45
SEN02625-03 30 Testing and adjusting
4) Increase the hydraulic oil temperature to the 3. Measurement of LS-EPC valve output pres-
operating range. sure
1) Remove oil pressure measurement plug (7).
a The plug is installed on the rear pump.
LS differential
Lever operation
pressure
Unload pressure 3) Start the engine and keep it running until the
When all levers are set
(See standard hydraulic oil temperature rises to the oper-
to neutral
value) ating range.
Maximum LS
Travel lever set at half
differential pres-
stroke
sure
46 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 47
SEN02625-03 30 Testing and adjusting
a Measure the solenoid valve output pressure af- 2. Fit adapter N2 or N3 and then connect hose
ter confirming that the control circuit source pres- currently disconnected.
sure is normal.
k Lower the work equipment to the ground 3. Fit nipple [1] of hydraulic tester N1 and then
and, after stopping the engine, release resid- connect it to oil pressure gauge [2].
ual pressure in the piping by operating the a Use the oil pressure gauge with capacity 6.0
control lever several times. Then loosen the MPa {60 kg/cm2}.
oil filler cap gradually to release pressure in-
side the tank.
a Hose (1) is installed in the back side of oper- 4. Start the engine and keep it running until the
ator's cab, and hoses (2) through (7) are in- hydraulic oil temperature rises to the operating
stalled at the center of revolving frame. range.
48 PC300, 350-8
30 Testing and adjusting SEN02625-03
5. Run the engine at full throttle, then turn each a When each output pressure shows the fol-
solenoid valve ON or OFF by operating the lowing values, it is judged normal.
control levers and switches, and measure the
pressure. Solenoid valve Output pressure
a For conditions for turning each solenoid OFF (De-energized) 0 MPa {0 kg/cm2}
valve ON or OFF, refer to the ensuing Table ON (Energized) 3 MPa {30 kg/cm2}
for functioning conditions for each solenoid
valve.
a You can check operation of the solenoid 6. Remove the measurement tools after the
valves from the monitoring function of the measurement, and make sure that the machine
monitor panel (Special Function of Machine is back to normal condition.
Monitor).
Table for functioning conditions PPC lock solenoid valve
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, 350-8 49
SEN02625-03 30 Testing and adjusting
Func-
Functioning conditions
tion
When the travel steering signal is ON
When travel steering When F or R pump pressure is 34.3 MPa {350 ON
When the travel steering signal is independently oper-
OFF ated kg/cm2}
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
When signal of the travel is OFF OFF
When F or R pump pressure is 32.3 MPa {330
When the travel speed switch is
When signal of the 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, 350-8
30 Testing and adjusting SEN02625-03
Func-
Functioning conditions
tion
When B mode is turned on When the service signal is ON
When independent signal of the travel is ON
When F or R pump pressure is 19.6 MPa {200 ON
When any
mode other kg/cm2} or above
When signals than L mode When F or R pump pressure is 14.7 MPa {150
of the work OFF
When signal of the travel is is turned on kg/cm2} or lower
equipment
OFF When F or R pump pressure is 16.7 MPa {170
and swing are ON
ON kg/cm2} or above
L mode
When F or R pump pressure is 11.8 MPa {120
kg/cm2} or lower OFF
Any other condition than above
PC300, 350-8 51
SEN02625-03 30 Testing and adjusting
Testing PPC valve output pres- 2. Fit nipple [1] of the hydraulic tester P and then
sure connect it to oil pressure gauge [2].
a Use the oil pressure gauge with capacity 6.0
MPa {60 kg/cm2}.
a PPC valve output pressure measurement tools
52 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 53
SEN02625-03 30 Testing and adjusting
54 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 55
SEN02625-03 30 Testing and adjusting
56 PC300, 350-8
30 Testing and adjusting SEN02625-03
4) Continue this condition for 30 seconds, then 4. Measurement of oil leakage amount from
measure the oil leakage amount for 1 minute. swing motor
1) Disconnect drain hoses (4) and install the oil
stopper plug in the hoses.
2) Turn the swing lock switch to the ON position.
3) Run the engine at high idle, relieve the swing
circuit, and measure the oil leakage.
a Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
a After measuring 1 time, swing 180, and
then measure again.
PC300, 350-8 57
SEN02625-03 30 Testing and adjusting
58 PC300, 350-8
30 Testing and adjusting SEN02625-03
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 idle
oozes out through the air bleeder. for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeder (1). the engine running at low idle.
3 Air bleeder: a Stop the piston approximately 100 mm in
7.8 9.8 Nm {0.8 1.0 kgm} front of the stroke end so that it may not
a Precautions on starting engine: be relieved.
When starting the engine after above 3) While running the engine at high idle,
operations, be sure to run the engine at perform step 2).
low idle for 10 minutes. If the engine 4) Set the piston rod to the stroke end at low idle
coolant temperature is low and an auto- and allow it to relieve.
matic engine warming-up function is 5) For bleeding air from the arm cylinder and
relied on, use the fuel dial, when it bucket cylinder, follow the same steps
becomes necessary to cancel it. explained in Item 2) through 4) above.
a In case a cylinder is replaced with new
one, it is advised to bleed air from the new
one before mounting the work equipment.
It is especially so with the boom cylinder,
because its rod does not extend to the
stroke end of LOWER side, after the work
equipment is mounted.
PC300, 350-8 59
SEN02625-03 30 Testing and adjusting
60 PC300, 350-8
30 Testing and adjusting SEN02625-03
PC300, 350-8 61
SEN02625-03 30 Testing and adjusting
2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
62
SEN02626-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02626-02 30 Testing and adjusting
2 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 3
SEN02626-02 30 Testing and adjusting
Page Page
t Operator mode (Outline) Service mode
6p 20p
A Display of KOMATSU logo 6p Monitoring 21p
A Display of inputting password 7p Mechanical Systems 26p
Abnormality
A Display of check of breaker mode 7p Electrical Systems 27p
Record
A Display of check before starting 7p Air-conditioning System/Heater System 33p
A Display of warning after check before starting 8p Maintenance Record 34p
A Display of ending of maintenance interval 8p Maintenance Mode Change 35p
A Display of check of working mode and travel speed 8p Phone Number Entry 37p
A Display of ordinary screen 8p Key-on Mode 38p
A Display of end screen 9p Unit 39p
B Selection of auto-deceleration 9p With/Without Attachment 40p
O (Special operation)
C Display of user code and failure code 15p Display of service message 56p
O (Special operation)
Function of checking display of LCD
D 17p
(Liquid Crystal Display)
D Function of checking service meter 17p
Function of changing attachment/maintenance
D 18p
password
4 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 5
SEN02626-02 30 Testing and adjusting
6 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 7
SEN02626-02 30 Testing and adjusting
Display of warning after check before starting Display of check of working mode and travel
If any abnormality is detected by the check before speed
starting, the warning monitor is displayed on the If the check before starting is finished normally, the
screen. screen to check the working mode and travel speed
a The following figure shows that the engine oil is displayed for 2 seconds.
level monitor (a) is warning of low of engine oil a After display of check of the working mode and
level. travel speed is finished, the screen changes to
Display of ordinary screen.
8 PC300, 350-8
30 Testing and adjusting SEN02626-02
Selection of auto-deceleration
While the ordinary screen is displayed, if the auto-
deceleration switch is pressed, large auto-deceler-
ation monitor (a) is displayed for 2 seconds and the
setting of the auto-deceleration is changed. 2. Operate the function switches or working mode
a Each time the auto-deceleration switch is selector switch to select and confirm the work-
pressed, the auto-deceleration is turned ON ing mode which you will use.
and OFF alternately. Function switches
a If the auto-deceleration is turned ON, large q [F3]: Move to lower working mode
monitor (a) and auto-deceleration monitor (b) q [F4]: Move to upper working mode
are displayed simultaneously. q [F5]: Cancel selection and return to ordi-
a If the auto-deceleration is turned OFF, auto- nary screen
deceleration monitor (b) goes off. q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function
switches and working mode selector
switch for 5 seconds, the selection is con-
firmed and the screen changes to the ordi-
nary screen.
PC300, 350-8 9
SEN02626-02 30 Testing and adjusting
10 PC300, 350-8
30 Testing and adjusting SEN02626-02
a Heater specification
PC300, 350-8 11
SEN02626-02 30 Testing and adjusting
Operation to display camera mode (if camera is a When an error that there is a user code occurs
installed) in the camera mode, if you do not touch any
When a camera is installed, if [F3] is pressed, the control lever for 10 seconds, the screen
multi-display changes to the camera image (Set the changes to the ordinary screen and displays
connection of the camera in the service mode). the error information.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
12 PC300, 350-8
30 Testing and adjusting SEN02626-02
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
PC300, 350-8 13
SEN02626-02 30 Testing and adjusting
14 PC300, 350-8
30 Testing and adjusting SEN02626-02
Display of automatic judgment of breaker Display of user code and failure code
If the operator performs breaker work in an If an abnormality which displays a user code and a
improper working mode, the breaker automatic failure code occurs on the ordinary screen or cam-
judgment screen is displayed to urge the operator era mode screen, all the information of the abnor-
to select a proper working mode. mality is displayed.
a The breaker automatic judgment is displayed (a): User code (3 digits)
when the following condition is satisfied while (b): Failure code (5 or 6 digits)
the display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnor-
When the pump controller measures the rear mality (failure code) for which a user code is
pump pressure for a certain time, the obtained set occurs.
value is similar to the pulsation wave form of a The telephone mark and telephone No. are
breaker operation which is held in the control- displayed only when the telephone No. is reg-
ler in advance. istered in the service mode.
a The breaker automatic judgment function is set a If multiple abnormalities occur simultaneously,
to Not used (Not displayed) when delivered. all the codes are displayed repeatedly in order.
a If this screen is displayed, check the setting of a Since the information of the displayed failure
the working mode. If the breaker is being code is recorded in the abnormality record in
used, select the breaker mode [B]. the service mode, check the details in the ser-
a To return to the ordinary screen, press [F5]. vice mode.
PC300, 350-8 15
SEN02626-02 30 Testing and adjusting
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
16 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 17
SEN02626-02 30 Testing and adjusting
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
18 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 19
SEN02626-02 30 Testing and adjusting
20 PC300, 350-8
30 Testing and adjusting SEN02626-02
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select Monitoring on the service menu
screen.
PC300, 350-8 21
SEN02626-02 30 Testing and adjusting
22 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 23
SEN02626-02 30 Testing and adjusting
24 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 25
SEN02626-02 30 Testing and adjusting
26 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 27
SEN02626-02 30 Testing and adjusting
28 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 29
SEN02626-02 30 Testing and adjusting
30 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 31
SEN02626-02 30 Testing and adjusting
32 PC300, 350-8
30 Testing and adjusting SEN02626-02
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.
PC300, 350-8 33
SEN02626-02 30 Testing and adjusting
34 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 35
SEN02626-02 30 Testing and adjusting
36 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 37
SEN02626-02 30 Testing and adjusting
1. Selecting menu
Select Phone Number Entry on the Service
Menu screen.
38 PC300, 350-8
30 Testing and adjusting SEN02626-02
3. Selecting mode
After the Key-on Mode screen is displayed,
select the mode to be set with the function
switches.
q Power Mode: [P] is displayed when key is
ON
q Economy Mode: [E] is displayed when key
is ON
q Lifting Mode: [L] is displayed when key is
ON
q Breaker Mode: [B] is displayed when key
is ON
q Attachment Mode: [ATT] is displayed
when key is ON
PC300, 350-8 39
SEN02626-02 30 Testing and adjusting
1. Selecting menu
Select Default on the Service Menu screen.
3. Selecting unit
After the Unit screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to
Default screen
q [F6]: Confirm selection and return to
Default screen
40 PC300, 350-8
30 Testing and adjusting SEN02626-02
3. Selecting With/Without
After the With/Without Attachment screen is
displayed, select the setting with the function
switches.
q Without Attachment:
When attachment is not installed
q With Attachment:
When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen
PC300, 350-8 41
SEN02626-02 30 Testing and adjusting
42 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 43
SEN02626-02 30 Testing and adjusting
1. Selecting menu
Select Default on the Service Menu screen.
44 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 45
SEN02626-02 30 Testing and adjusting
46 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 47
SEN02626-02 30 Testing and adjusting
48 PC300, 350-8
30 Testing and adjusting SEN02626-02
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select Cylinder Cut-Out on the Service
Menu screen.
PC300, 350-8 49
SEN02626-02 30 Testing and adjusting
[Reference] No Injection
q If a normally operating cylinder is Cut-Out, If the engine is operated after long storage of the
the following phenomena occur. machine, it may be worn or damaged because of
1) Lowering of engine speed insufficient lubrication with oil. To prevent this, the
2) Increase of final injection rate com- function to lubricate the engine before starting it by
mand (quantity) cranking it without injecting fuel is installed.
q If the engine is running near the high idle, Set the no-injection cranking while the engine is
however, the engine speed may not lower stopped.
for the reason of engine control.
q In this case, lower the engine speed with 1. Selecting menu
the fuel control dial and judge by increase Select No Injection on the Service Menu
of the injection rate command. screen.
50 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 51
SEN02626-02 30 Testing and adjusting
2. Starting measurement
After the screen of Fuel Consumption is dis-
played, start measurement with the function
switches.
q [F1]: Start 4. Finishing measurement
q [F2]: Clear Press [F1], and measurement is finished and
q [F5]: Return to Service menu screen the data are displayed on the finishing date
a When the screen of Fuel consumption is and time side.
displayed, if a data is indicated, it is the
data of the previous measurement. This 5. Displaying fuel consumption
data is not an obstacle to new measure- If the measurement is finished, the hourly fuel
ment and can be reset by pressing [F2]. consumption calculated from the fuel con-
a If [F1] is pressed, the data is displayed on sumption calculated by the engine controller
the starting date and time side and mea- and the elapsed time are displayed.
surement starts.
52 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 53
SEN02626-02 30 Testing and adjusting
KOMTRAX Settings (GPS & Communication Status) 3. Contents of display of GPS & communication
The setting condition and operating condition of status
KOMTRAX can be checked with KOMTRAX Set- On the screen of GPS & Communication Sta-
tings. tus, the following items are displayed.
GPS & communication status is used to check the q Positioning: Positioning condition of GPS
condition of positioning and communication of the q Communication: Communication environ-
KOMTRAX terminal. ment of communication MODEM and con-
necting condition of communication
1. Selecting menu MODEM
Select KOMTRAX Settings on the Service q Number of message not yet sent: Number
Menu screen. of mails which are saved in machine mon-
itor and not transmitted yet
q [F5]: Return to KOMTRAX settings screen
54 PC300, 350-8
30 Testing and adjusting SEN02626-02
1. Selecting menu
Select KOMTRAX Settings on the Service
Menu screen.
PC300, 350-8 55
SEN02626-02 30 Testing and adjusting
56 PC300, 350-8
30 Testing and adjusting SEN02626-02
PC300, 350-8 57
SEN02626-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
58
SEN02663-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02663-02 30 Testing and adjusting
2 PC300, 350-8
30 Testing and adjusting SEN02663-02
1. Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the day-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the day-
light sensor.
2) Remove cover (2).
a The cover is fixed with clips. Remove 2. Engine controller
it by pull it up. a The engine controller is installed in the left
a While removing the cover, discon- side of the engine.
nect connector M04 of the cigarette 1) Open the engine hood.
lighter. 2) Insert or connect troubleshooting T-
adapter in or to connectors ENGINE,
CE02 and CE03 of engine controller (3).
a Connectors are fixed with screw.
Loosen the screws before discon-
necting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
PC300, 350-8 3
SEN02663-02 30 Testing and adjusting
4 PC300, 350-8
30 Testing and adjusting SEN02663-02
PC300, 350-8 5
SEN02663-02 30 Testing and adjusting
7. Supply pump IMV solenoid (FUEL REGU- 8. Common rail pressure sensor (FUEL RAIL
LATOR) PRESS)
Electric priming pump (FUEL LIFT PUMP) a Disconnection and connection of connector
Water-in-fuel sensor intermediate connec- The connector of the common rail pres-
tor (WIF) sure sensor has a special locking mecha-
a Disconnection and connection of con- nism. Disconnect it according to steps (a)
nector (b) and connect it according to steps (c)
The connector of the supply pump IMV (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) Lock.
(d) as shown below.
Disconnection: (a) Unlock (b) Discon-
nect connector.
Connection: (c) Connect connector (d)
Lock.
6 PC300, 350-8
30 Testing and adjusting SEN02663-02
PC300, 350-8 7
SEN02663-02 30 Testing and adjusting
Pm clinic service 1
Machine model Model number Service meter
T PC300-8
h
T PC350-8 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
8 PC300, 350-8
30 Testing and adjusting SEN02663-02
PC300, 350-8 9
SEN02663-02 30 Testing and adjusting
10 PC300, 350-8
30 Testing and adjusting SEN02663-02
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
Boom and arm top horizontal PC300-8 2.9 3.5 Max. 3.8
6 Bucket CURL
Arm cylinder retracted fully PC350-8 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, 350-8 11
SEN02663-02 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]
Good
Bad
No. Checked part cm2} cm2} cm2} cm2} cm2}
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}
12 PC300, 350-8
30 Testing and adjusting SEN02663-02
Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
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]
Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
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, 350-8 13
SEN02663-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
14
SEN02627-03
PC300-8
PC300LC-8
PC350-8
PC350LC-8
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 5
PC300, 350-8 1
SEN02627-03 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02627-03
PC300, 350-8 3
SEN02627-03 40 Troubleshooting
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine moni-
tor.
4 PC300, 350-8
40 Troubleshooting SEN02627-03
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Emergency switch, pump resistor, lamp switch, swing
1 10A
holding release switch
Pump controller (Solenoid power supply)
2 30A
Machine push-up switch
F04 PPC oil pressure lock solenoid valve
Switch power supply 3 10A
(65A) Starting motor cut-off relay
Cigarette lighter
4 10A Windshield washer motor, electrical intake air heater
relay
5 10A Horn relay, horn
6 10A Auto preheater
7 10A Rotary lamp (if equipped)
F04 8 20A Working lamp (boom), working lamp (rear)
Switch power supply
(65A) Radio, speaker
9 10A
Left knob switch (pump controller input)
10 20A (Spare)
11 20A Air conditioner unit
12 10A (Spare)
13 10A Headlamp
F04
Switch power supply 14 10A Optional power supply (1)
(65A)
Travel alarm, 12 V power supply, heated seat
15 20A (if equipped)
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant power sup- F05 Pump controller, starting switch
17 20A
ply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
PC300, 350-8 5
SEN02627-03 40 Troubleshooting
6 PC300, 350-8
40 Troubleshooting SEN02627-03
Troubles that occur when controller power supply of pump controller is defective
a The controller power supply (F01-17) 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 connectors CP01 and CP02 of the controller and connect a T-adapter to the wiring har-
ness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins CP02 (116), (118), (121) and each of pins CP01 (2), (5).
* Pins CP02 (116), (118), (121) are the power supply and pins CP01 (2), (5) are the chassis ground.
* If the voltage is 20 30 V, it is normal.
PC300, 350-8 7
SEN02627-03 40 Troubleshooting
8 PC300, 350-8
40 Troubleshooting SEN02627-03
PC300, 350-8 9
SEN02627-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (01)
10
SEN02628-03
PC300, 350-8
SEN02628-03
HYDRAULIC EXCAVATOR
Shop Manual
PC300-8
PC300LC-8
PC350-8
PC350LC-8
Machine model Serial number
PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up
40 Troubleshooting
General Information on troubleshooting
PC300, 350-8 1
SEN02628-03 40 Troubleshooting
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to 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 hurry 3) Make checks of other items.
to disassemble the components. 4) Other maintenance items can be checked
If components are disassembled immediately externally, so check any item that is consid-
after any failure occurs: ered to be necessary.
q Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or as
q It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. a When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out trouble-
shooting, it is necessary to carry out thorough 5. Troubleshooting
prior investigation and to carry out trouble- Use the results of the investigation and inspec-
shooting 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 as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were there 2] Start from the most likely points.
problems with the machine condition before 3] Investigate other related parts or informa-
this? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? When were these repairs carried Even if the failure is repaired, if the root cause of
out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred occur again.To prevent this, always investigate
before? why the problem occurred. Then, remove the
root cause.
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
2 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 3
SEN02628-03 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02628-03
Classification of troubleshooting
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 [ ] 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 abnormality
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, 350-8 5
SEN02628-03 40 Troubleshooting
<Contents of description>
q Standard value in normal state to judge possible causes
q Remarks on judgment
1
<Troubles in wiring harness>
q Disconnection
Connector is connected imperfectly or wiring harness is
broken.
q Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
Possible causes of trouble
and standard
(Given numbers are refer-
value in normal
ence numbers, which do not
state <Precautions for troubleshooting>
indicate priority)
(1) Method of indicating connector No. and handling of
Tadapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
q If connector No. has no marks of male and female
, disconnect connector and insert T-adapters in both
male side and female side.
q If connector No. has marks of male and female,
disconnect 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.
q Connect positive (+) lead to pin No. or wiring harness
entered on front side.
q Connect negative () lead to pin No. or harness entered
on rear side.
6 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 7
SEN02628-03 40 Troubleshooting
Troubleshooting
No. Phenomena supposed to show 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.
When abnormality record is checked, failure code is dis- According
2 to dis-
played in electrical system abnormality record
When abnormality record is checked, failure code is dis- played code
3
played in 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)
6 Engine does Engine rotates, but exhaust gas does not S-2 b)
notstart come out
Engine emits exhaust gas, but it does not
7 S-2 c)
start
Engine does not pick up smoothly (follow-up performance
8 S-3
is poor)
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
Oil is in coolant, coolant spurts back or coolant level goes
16 S-11
down
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant/fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noiseis 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 work E-4
Phenomena related to work equipment, swing, and travel
Speed or power of whole work equipment, swing, and
25 H-1 S-6
travel is low
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment,swing, and travel systems do not work E-5 H-3
28 Abnormal soundcomes out from around hydraulic pump H-4
29 Fine controlperformance 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 driftof work equipment is large H-11
35 Time lag of worke quipment is large H-12
When part of work equipment is relieved singly, other parts
36 H-13
of work equipment movee
8 PC300, 350-8
40 Troubleshooting SEN02628-03
Troubleshooting
No. Phenomena supposed to show troubles Display of
E-mode H-mode S-mode
code
37 The power maximizing function does not work. E-6, 1823 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part
38 H-15
loaded more is low
When machine swings and raises boom simultaneously,
39 H-16
boom rising speed is low
When machineswings and travels simultaneously, travel
40 H-17
speed lowers largely
Phenomena related to travel
41 Machine deviatesduring travel H-18
42 Travel speed is low E-25 H-19
43 Machine is notsteered well or steering power is low E-25, 26 H-20
Travel speed does not change or travel speed is low or
44 E-25 H-21
high
45 Travel systemdoes not move (only one side) H-22
Phenomena related to swing
46 Upper structure does not swing E-24 H-23
47 Swing accelerationor swing speed is low H-24
Upper structure overruns remarkably when it stops swing-
48 H-25
ing
49 Large shock is made when upper structure stops swinging H-26
50 Large sound is made when upper structure stops swinging H-27
51 Hydraulic drift of swing is large H-28
Phenomena related to machine monitor (Operator menu: ordinary screen)
52 Machine monitor does not display any items E-7
53 Machine monitordoes not display some items E-8
Contents of display by machine monitor are different from
54 E-9
applicable machine
Radiator coolant level monitor lights up in red during check
55 B@BCZK
before starting
Engine oil level monitor lights up in red during check
56 B@BAZK
before starting
Maintenance interval monitor lights up in red during check
57 See the Operation and Maintenance Manual.
before starting
Charge level monitor lights up in red while engine is run-
58 AB00KE
ning
59 Fuel level monitor lights up in red while engine is running E-10
Air cleaner clogging monitor lights up in red while engine is
60 AA10NX
running
Engine coolant temperature monitor lights up in red while
61 B@BCNS
engine is running
Hydraulic oil temperature monitor lights up in red while
62 B@HANS
engine is running
Engine coolant temperature gauge does not indicate nor-
63 E-11
mally
Hydraulic oil temperature gauge does not indicate nor-
64 E-12
mally
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
67 E-15
monitor switch section
68 Windshield wiper and window washer do not operate E-16
69 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
PC300, 350-8 9
SEN02628-03 40 Troubleshooting
Troubleshooting
No. Phenomena supposed to show troubles Display of
E-mode H-mode S-mode
code
Monitoring function does not display "Boom RAISE" nor-
70 E-18
mally
Monitoring function does not display "Boom LOWER" nor-
71 E-19
mally
72 Monitoring function does not display "Arm IN" normally E-20
73 Monitoring function does not display "Arm OUT" normally E-21
Monitoring function does not display "Bucket CURL" nor-
74 E-22
mally
Monitoring function does not display "Bucket DUMP" nor-
75 E-23
mally
76 Monitoring function does not display "Swing" normally E-24
77 Monitoring function does not display "Travel" normally E-25
Monitoring function does not display "Travel Steering" nor-
78 E-26
mally
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, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 11
SEN02628-03 40 Troubleshooting
12 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 13
SEN02628-03 40 Troubleshooting
14 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 15
SEN02628-03 40 Troubleshooting
16 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 17
SEN02628-03 40 Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 19
SEN02628-03 40 Troubleshooting
20 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 21
SEN02628-03 40 Troubleshooting
22 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 23
SEN02628-03 40 Troubleshooting
24 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 25
SEN02628-03 40 Troubleshooting
26 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 27
SEN02628-03 40 Troubleshooting
28 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 29
SEN02628-03 40 Troubleshooting
30 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 31
SEN02628-03 40 Troubleshooting
32 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 33
SEN02628-03 40 Troubleshooting
34 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 35
SEN02628-03 40 Troubleshooting
36 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 37
SEN02628-03 40 Troubleshooting
38 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 39
SEN02628-03 40 Troubleshooting
40 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 41
SEN02628-03 40 Troubleshooting
42 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 43
SEN02628-03 40 Troubleshooting
44 PC300, 350-8
40 Troubleshooting SEN02628-03
PC300, 350-8 45
SEN02628-03 40 Troubleshooting
46 PC300, 350-8
40 Troubleshooting SEN02628-03
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 number Part name
symbol
PC300, 350-8 47
SEN02628-03 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 number Part name
symbol
48 PC300, 350-8
40 Troubleshooting SEN02628-03
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 number Part name
symbol
PC300, 350-8 49
SEN02628-03 40 Troubleshooting
2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
50
SEN02629-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Failure code [989L00] Engine Controller Lock Caution 1 ............................................................................... 3
Failure code [989M00] Engine Controller Lock Caution 2 .............................................................................. 3
Failure code [989N00] Engine Controller Lock Caution 3............................................................................... 4
Failure code [AA10NX] Air cleaner Clogging .................................................................................................. 6
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 8
Failure code [B@BAZG] Eng Oil Press. Low................................................................................................ 10
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. 12
Failure code [B@BCNS] Eng. Water Overheat............................................................................................. 14
Failure code [B@BCZK] Eng Water Level Low............................................................................................. 16
Failure code [B@HANS] Hydr Oil Overheat ................................................................................................. 18
Failure code [CA111] EMC Critical Internal Failure....................................................................................... 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 19
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 20
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ 22
PC300, 350-8 1
SEN02629-02 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 3
SEN02629-02 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 5
SEN02629-02 40 Troubleshooting
6 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 7
SEN02629-02 40 Troubleshooting
8 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 9
SEN02629-02 40 Troubleshooting
10 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 11
SEN02629-02 40 Troubleshooting
12 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 13
SEN02629-02 40 Troubleshooting
14 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 15
SEN02629-02 40 Troubleshooting
16 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 17
SEN02629-02 40 Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02629-02
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, 350-8 19
SEN02629-02 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, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 21
SEN02629-02 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, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 23
SEN02629-02 40 Troubleshooting
24 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 25
SEN02629-02 40 Troubleshooting
26 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 27
SEN02629-02 40 Troubleshooting
28 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 29
SEN02629-02 40 Troubleshooting
30 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 31
SEN02629-02 40 Troubleshooting
32 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 33
SEN02629-02 40 Troubleshooting
34 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 35
SEN02629-02 40 Troubleshooting
Action code Failure code Charge air temperature high speed derate
Trouble
E11 CA155 (Engine controller system)
Contents of
Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble
Action of
Limits output and continues operation.
controller
Problem that
Engine output lowers.
appears on
Engine stops.
machine
Related infor- Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
mation Method of reproducing failure code: Start engine
36 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 37
SEN02629-02 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, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 39
SEN02629-02 40 Troubleshooting
40 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 41
SEN02629-02 40 Troubleshooting
42 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 43
SEN02629-02 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, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 45
SEN02629-02 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, 350-8
40 Troubleshooting SEN02629-02
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, 350-8 47
SEN02629-02 40 Troubleshooting
48 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 49
SEN02629-02 40 Troubleshooting
50 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 51
SEN02629-02 40 Troubleshooting
52 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 53
SEN02629-02 40 Troubleshooting
54 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 55
SEN02629-02 40 Troubleshooting
56 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 57
SEN02629-02 40 Troubleshooting
58 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 59
SEN02629-02 40 Troubleshooting
60 PC300, 350-8
40 Troubleshooting SEN02629-02
PC300, 350-8 61
SEN02629-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
62
SEN02630-03
PC300-8
PC300LC-8
PC350-8
PC350LC-8
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 [CA488] Chg Air Temp High Torque Derate ............................................................................. 28
Failure code [CA553] Rail Press High Error ................................................................................................. 28
PC300, 350-8 1
SEN02630-03 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 3
SEN02630-03 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 5
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 7
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 9
SEN02630-03 40 Troubleshooting
10 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 11
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 13
SEN02630-03 40 Troubleshooting
14 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 15
SEN02630-03 40 Troubleshooting
16 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 17
SEN02630-03 40 Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 19
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 21
SEN02630-03 40 Troubleshooting
Circuit diagram related to common rail pressure sensor and engine controller ground line
22 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 23
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 25
SEN02630-03 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, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 27
SEN02630-03 40 Troubleshooting
User code Failure code Charge air temperature high torque derate
Trouble
E11 CA488 (Engine controller system)
Contents of
Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit.
trouble
Action of
Limits output and continues operation.
controller
Problem that
appears on Engine output lowers.
machine
Related infor- Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
mation Method of reproducing failure code: Start engine.
Possible causes Ground terminal may be connected defectively. Check following ter-
and standard minals directly.
value in normal Defective connection of Ground terminal of machine (() terminal of battery)
2
state ground terminal Ground terminal of engine
Ground terminal of engine controller
Ground terminal of starting motor
Defective O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
28 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 29
SEN02630-03 40 Troubleshooting
30 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 31
SEN02630-03 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) (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
32 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 33
SEN02630-03 40 Troubleshooting
Action code Failure code Engine Bkup speed sensor phase error
Trouble
E15 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 Turns the centralized warning lamp and alarm buzzer ON.
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
34 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 35
SEN02630-03 40 Troubleshooting
36 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 37
SEN02630-03 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)
38 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 39
SEN02630-03 40 Troubleshooting
40 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 41
SEN02630-03 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
42 PC300, 350-8
40 Troubleshooting SEN02630-03
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, 350-8 43
SEN02630-03 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
44 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 45
SEN02630-03 40 Troubleshooting
46 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 47
SEN02630-03 40 Troubleshooting
48 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 49
SEN02630-03 40 Troubleshooting
50 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 51
SEN02630-03 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 4C.
52 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 53
SEN02630-03 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 4C.
54 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 55
SEN02630-03 40 Troubleshooting
56 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 57
SEN02630-03 40 Troubleshooting
58 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 59
SEN02630-03 40 Troubleshooting
Configuration drawing
60 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 61
SEN02630-03 40 Troubleshooting
62 PC300, 350-8
40 Troubleshooting SEN02630-03
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between CP01 (female) (34)
state P01 (female) (2), P01 (female) (1) J03 Resis-
Min. 1 Mz
ground (T08) tance
[Bucket DUMP PPC pressure switch system]
Wiring harness between CP01 (female) (53)
P03 (female) (2), P03 (female) (1) J03 Resis-
Min. 1 Mz
ground (T08) tance
[Boom RAISE PPC pressure switch system]
Ground fault in wiring har-
2 ness (Short circuit with GND Wiring harness between CP01 (female) (73)
circuit) P04 (female) (2), P04 (female) (1) J03 Resis-
Min. 1 Mz
ground (T08) tance
[Bucket CURL PPC pressure switch system]
Wiring harness between CP01 (female) (17)
P05 (female) (2), P05 (female) (1) J03 Resis-
Min. 1 Mz
ground (T08) tance
[Arm IN PPC pressure switch system]
Wiring harness between CP01 (female) (16)
P07 (female) (2), P07 (female) (1) J03 Resis-
Min. 1 Mz
ground (T08) tance
[Swig RIGHT PPC pressure switch system]
PC300, 350-8 63
SEN02630-03 40 Troubleshooting
64 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 65
SEN02630-03 40 Troubleshooting
66 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 67
SEN02630-03 40 Troubleshooting
68 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 69
SEN02630-03 40 Troubleshooting
70 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 71
SEN02630-03 40 Troubleshooting
72 PC300, 350-8
40 Troubleshooting SEN02630-03
PC300, 350-8 73
SEN02630-03
2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (01)
74
SEN02631-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Failure code [DAFRMC] CAN discon (Monitor detected)................................................................................ 4
Failure code [DGH2KB] Hydr Oil Sensor Short .............................................................................................. 6
Failure code [DHPAMA] F Pump Press Sensor Abnormality .......................................................................... 8
Failure code [DHPBMA] R Pump Press Sensor Abnormality ....................................................................... 10
Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality ........................................................................ 12
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.......................................................... 14
Failure code [DHX1MA] Overload Sensor Abnormality (Analog).................................................................. 16
Failure code [DW43KA] Travel Speed Sol. Open Circuit .............................................................................. 18
Failure code [DW43KB] Travel Speed Sol. Short Circuit .............................................................................. 20
Failure code [DW45KA] Swing Brake Sol. Open Circuit ............................................................................... 22
Failure code [DW45KB] Swing Brake Sol. Short Circuit ............................................................................... 26
Failure code [DW91KA] Travel Junction Sol. Open Circuit ........................................................................... 28
Failure code [DW91KB] Travel Junction Sol. Short Circuit ........................................................................... 30
Failure code [DWA2KA] Attachment Sol Open Circuit.................................................................................. 32
PC300, 350-8 1
SEN02631-02 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 3
SEN02631-02 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 5
SEN02631-02 40 Troubleshooting
6 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 7
SEN02631-02 40 Troubleshooting
Defective F pump pressure a If the power supply voltage is normal and the signal voltage is
2 sensor not normal, perform troubleshooting as follows.
(Internal defect) 1) Turn starting switch to OFF position.
2) Replace connector P25 with connector P26 of R pump
pressure sensor.
3) Turn starting switch to ON position and display the electri-
cal failure history screen of the machine monitor.
4) If E mark is not lighted in failure code column, F pump
pressure sensor is defective.
Possible causes
a After the troubleshooting, restore the connector.
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CP01 (female) (9) Resis-
ness Max. 1 z
P25 (female) (3) tance
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (18) Resis-
defective contact in connec- Max. 1 z
tor) P25 (female) (1) tance
Wiring harness between CP01 (female) (49) Resis-
Max. 1 z
P25 (female) (2) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
4
(Short circuit with GND cir- Wiring harness between CP01 (female) (49) Resis-
cuit) Min. 1 Mz
P25 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (9)
5 Voltage Max. 1 V
24V circuit) in wiring harness P25 (female) (3) and chassis ground
Wiring harness between CP01 (female) (49)
Voltage Max. 1 V
P25 (female) (2) and chassis ground
8 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 9
SEN02631-02 40 Troubleshooting
Defective R pump pressure a If the power supply voltage is normal and the signal voltage is
2 sensor not normal, perform troubleshooting as follows.
(Internal defect) 1) Turn starting switch to OFF position.
2) Replace connector P26 with connector P25 of R pump
pressure sensor.
3) Turn starting switch to ON position and display the electri-
cal failure history screen of the machine monitor.
4) If E mark is not lighted in failure code column, R pump
pressure sensor is defective.
Possible causes
a After the troubleshooting, restore the connector.
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CP01 (female) (9) Resis-
ness Max. 1 z
P26 (female) (3) tance
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (18) Resis-
defective contact in connec- Max. 1 z
tor) P26 (female) (1) tance
Wiring harness between CP01 (female) (68) Resis-
Max. 1 z
P26 (female) (2) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
4
(Short circuit with GND cir- Wiring harness between CP01 (female) (68) Resis-
cuit) Min. 1 Mz
P26 (female) (2) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (9)
5 Voltage Max. 1 V
24V circuit) in wiring harness P26 (female) (3) and chassis ground
Wiring harness between CP01 (female) (68)
Voltage Max. 1 V
P26 (female) (2) and chassis ground
10 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 11
SEN02631-02 40 Troubleshooting
12 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 13
SEN02631-02 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, 350-8
40 Troubleshooting SEN02631-02
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC300, 350-8 15
SEN02631-02 40 Troubleshooting
16 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 17
SEN02631-02 40 Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 19
SEN02631-02 40 Troubleshooting
20 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 21
SEN02631-02 40 Troubleshooting
22 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 23
SEN02631-02 40 Troubleshooting
24 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 25
SEN02631-02 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).
26 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 27
SEN02631-02 40 Troubleshooting
28 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 29
SEN02631-02 40 Troubleshooting
30 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 31
SEN02631-02 40 Troubleshooting
32 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 33
SEN02631-02 40 Troubleshooting
34 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 35
SEN02631-02 40 Troubleshooting
36 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 37
SEN02631-02 40 Troubleshooting
38 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 39
SEN02631-02 40 Troubleshooting
40 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 41
SEN02631-02 40 Troubleshooting
42 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 43
SEN02631-02 40 Troubleshooting
44 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 45
SEN02631-02 40 Troubleshooting
46 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 47
SEN02631-02 40 Troubleshooting
48 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 49
SEN02631-02 40 Troubleshooting
50 PC300, 350-8
40 Troubleshooting SEN02631-02
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, 350-8 51
SEN02631-02 40 Troubleshooting
52 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 53
SEN02631-02 40 Troubleshooting
54 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 55
SEN02631-02 40 Troubleshooting
56 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 57
SEN02631-02 40 Troubleshooting
Action code Failure code Window washer drive system short circuit
Trouble
DY2CKB (Pump controller system)
Contents of When output to window washer drive system was turned OFF (ground circuit was disconnected),
trouble short circuit was detected in circuit.
Action of Turns output to washer motor OFF.
controller Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on Window washer does not operate.
machine
Related infor-
Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
mation
58 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 59
SEN02631-02 40 Troubleshooting
Action code Failure code Wiper motor drive forward system short circuit
Trouble
DY2DKB (Pump controller system)
Contents of
When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of Turns output to wiper motor drive forward side OFF.
controller Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on Windshield wiper does not operate.
machine
Related infor-
Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
mation
60 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 61
SEN02631-02 40 Troubleshooting
Action code Failure code Wiper motor drive reverse system short circuit
Trouble
DY2EKB (Pump controller system)
Contents of
When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of Turns output to wiper motor drive reverse side OFF.
controller Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on Windshield wiper does not operate.
machine
Related infor-
Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
mation
62 PC300, 350-8
40 Troubleshooting SEN02631-02
PC300, 350-8 63
SEN02631-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
64
SEN02632-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
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 ................................................................................................. 20
E-8 Machine monitor does not display some items ...................................................................................... 22
E-9 Contents of display by machine monitor are different from applicable machine .................................... 22
E-10 Fuel level monitor was lighted in red while engine running .................................................................. 23
E-11 Engine coolant temperature gauge does not indicate normally............................................................ 24
E-12 Hydraulic oil temperature gauge does not indicate normally................................................................ 26
PC300, 350-8 1
SEN02632-02 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 3
SEN02632-02 40 Troubleshooting
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Emergency switch, pump resistor, lamp switch, swing
1 10A
holding release switch
Pump controller (Solenoid power supply)
2 30A
Machine push-up switch
F04 PPC oil pressure lock solenoid valve
Switch power supply 3 10A
(65A) Starting motor cut-off relay
Cigarette lighter
4 10A Windshield washer motor, electrical intake air heator
relay
5 10A Horn relay, horn
6 10A Auto preheater
7 10A Rotary lamp (if equipped)
F04 8 20A Working lamp (boom), working lamp (rear)
Switch power supply
(65A) Radio, speaker
9 10A
Left knob switch (pump controller input)
10 20A (Spare)
11 20A Air conditioner unit
12 10A (Spare)
13 10A Headlamp
F04 14 10A Optional power supply (1)
Switch power supply
(65A)
Travel alarm, 12 V power supply, heated seat
(if equipped)
15 20A
Optional power supply (2), heated seat, air suspension
seat
Radio (backup power supply)
16 10A
Room lamp
Constant power sup- F05 Pump controller, starting switch
17 20A
ply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
4 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 5
SEN02632-02 40 Troubleshooting
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.
6 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 7
SEN02632-02 40 Troubleshooting
8 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 9
SEN02632-02 40 Troubleshooting
10 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 11
SEN02632-02 40 Troubleshooting
12 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 13
SEN02632-02 40 Troubleshooting
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 sec-
onds after to notify completion of preheating (It stops flashing about 10 seconds after).
Related infor- If engine coolant temperature is below 30C, automatic warm-up system operates and preheating
mation monitor lights up for up to 30 seconds.
Condition of starting switch (preheating) signal can be checked with the monitoring function.
(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 30C), pump controller drives the heater relay
mation for 100 sec. after engine start to automatically preheat.
14 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 15
SEN02632-02 40 Troubleshooting
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
16 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 17
SEN02632-02 40 Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 19
SEN02632-02 40 Troubleshooting
Trouble Machine monitor does not display at all when starting switch is turned ON.
Related infor-
mation
20 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 21
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
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)
PC300, 350-8 23
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 25
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
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, 350-8 27
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 29
SEN02632-02 40 Troubleshooting
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-21.
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
30 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 31
SEN02632-02 40 Troubleshooting
Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related Condition of wiper switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
Trouble (2) When wiper switch is operated, wiper does not operate.
Related Condition of window rear limit switch signal can be checked with monitoring function.
information (Code: 02204 Switch input 5)
32 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 33
SEN02632-02 40 Troubleshooting
Trouble (3) When window washer switch is operated, window washer does not operate.
Related Condition of window washer switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)
34 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 35
SEN02632-02 40 Troubleshooting
36 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 37
SEN02632-02 40 Troubleshooting
Trouble Boom RAISE operation is not displayed normally by machine monitoring function (Special functions).
Related infor-
Monitoring code: 01900 (Pressure Switch 1)
mation
38 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 39
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 41
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 43
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 45
SEN02632-02 40 Troubleshooting
Trouble Bucket CURL is not displayed normally by machine monitoring function (Special functions).
Related infor-
Monitoring code:01901 (Output Switch 2)
mation
46 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 47
SEN02632-02 40 Troubleshooting
Trouble Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions).
Related infor-
Monitoring code: 01900 (Output Switch 2)
mation
48 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 49
SEN02632-02 40 Troubleshooting
Trouble Swing is not displayed normally by machine monitoring function (Special function).
Related infor-
Monitoring code: 01900 (Output Switch 1)
mation
50 PC300, 350-8
40 Troubleshooting SEN02632-02
Circuit diagram related to right and left swing PPC oil pressure switches
PC300, 350-8 51
SEN02632-02 40 Troubleshooting
Trouble Travel is not displayed normally by machine monitoring function (Special functions).
Related infor-
Monitoring code: 01900 (Output Switch 1)
mation
52 PC300, 350-8
40 Troubleshooting SEN02632-02
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC300, 350-8 53
SEN02632-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 55
SEN02632-02 40 Troubleshooting
Trouble Service is not displayed normally by machine monitoring function (Special functions).
Related infor-
Monitoring code: 01901 (Output Switch 2)
mation
56 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 57
SEN02632-02 40 Troubleshooting
a Select Terminal Status from 12 Display of a Select GPS & Communication Status from
KOMTRAX setting in the service menu of the 12 Display of KOMTRAX setting in the ser-
machine monitor. vice menu of the machine monitor.
58 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 59
SEN02632-02 40 Troubleshooting
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 Resis-
Disconnection in wiring har- Max. 1 z
AC01 (male) (4) tance
ness
Wiring harness between M26 (male) (7) Resis-
3 (Disconnection in wiring or Max. 1 z
P17 (female) (1) tance
Possible causes defective contact in connec-
tor) Wiring harness between AC01 (male) (5) Resis-
and standard Max. 1 z
value in normal chassis ground tance
state Wiring harness between P17 (female) (2) Resis-
Max. 1 z
J04 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 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- AC01 (male) (4) and chassis ground tance
cuit)
Wiring harness between AC01 (male) (7) 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)
AC01 Voltage
Between (1) (3) 20 30 V
60 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 61
SEN02632-02 40 Troubleshooting
E-30 Travel alarm does not sound or does not stop sounding 1
62 PC300, 350-8
40 Troubleshooting SEN02632-02
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC300, 350-8 63
SEN02632-02 40 Troubleshooting
64 PC300, 350-8
40 Troubleshooting SEN02632-02
PC300, 350-8 65
SEN02632-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
66
SEN02633-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
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, 350-8 1
SEN02633-02 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 3
SEN02633-02 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02633-02
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, 350-8 5
SEN02633-02 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, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 7
SEN02633-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 9
SEN02633-02 40 Troubleshooting
10 PC300, 350-8
40 Troubleshooting SEN02633-02
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
PC300, 350-8 11
SEN02633-02 40 Troubleshooting
12 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 13
SEN02633-02 40 Troubleshooting
14 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 15
SEN02633-02 40 Troubleshooting
16 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 17
SEN02633-02 40 Troubleshooting
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
18 PC300, 350-8
40 Troubleshooting SEN02633-02
Failure phe-
In a compound operation, work equipment with larger load tends to move slowly.
nomenon
Relative infor-
mation
PC300, 350-8 19
SEN02633-02 40 Troubleshooting
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
20 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 21
SEN02633-02 40 Troubleshooting
22 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 23
SEN02633-02 40 Troubleshooting
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
24 PC300, 350-8
40 Troubleshooting SEN02633-02
H-22 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.
PC300, 350-8 25
SEN02633-02 40 Troubleshooting
26 PC300, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 27
SEN02633-02 40 Troubleshooting
28 PC300, 350-8
40 Troubleshooting SEN02633-02
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
PC300, 350-8 29
SEN02633-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 31
SEN02633-02 40 Troubleshooting
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, 350-8
40 Troubleshooting SEN02633-02
PC300, 350-8 33
SEN02633-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
34
SEN02634-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
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, 350-8 1
SEN02634-02 40 Troubleshooting
2 PC300, 350-8
40 Troubleshooting SEN02634-02
[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, 350-8 3
SEN02634-02 40 Troubleshooting
4 PC300, 350-8
40 Troubleshooting SEN02634-02
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, 350-8 5
SEN02634-02 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, 350-8
40 Troubleshooting SEN02634-02
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, 350-8 7
SEN02634-02 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
Clean
Remedy
Add
8 PC300, 350-8
40 Troubleshooting SEN02634-02
c) Exhaust smoke comes out but engine does not start Cause
(fuel is being injected)
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
Replace
Correct
Clean
Clean
Remedy
PC300, 350-8 9
SEN02634-02 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
Replace
Correct
Adjust
Clean
Clean
Remedy
10 PC300, 350-8
40 Troubleshooting SEN02634-02
Replace
Replace
Replace
Replace
Correct
Clean
Remedy
Add
PC300, 350-8 11
SEN02634-02 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, 350-8
40 Troubleshooting SEN02634-02
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
PC300, 350-8 13
SEN02634-02 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Remedy
14 PC300, 350-8
40 Troubleshooting SEN02634-02
Turbocharger
Abnormal consumption of oil
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC300, 350-8 15
SEN02634-02 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, 350-8
40 Troubleshooting SEN02634-02
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, 350-8 17
SEN02634-02 40 Troubleshooting
q
Troubleshooting
18 PC300, 350-8
40 Troubleshooting SEN02634-02
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, 350-8 19
SEN02634-02 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, 350-8
40 Troubleshooting SEN02634-02
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, 350-8 21
SEN02634-02 40 Troubleshooting
w Q
ders is low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
22 PC300, 350-8
40 Troubleshooting SEN02634-02
machine
Replace
Replace
Replace
Adjust
Remedy
PC300, 350-8 23
SEN02634-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
24
SEN02635-02
PC300, 350-8
SEN02635-02
HYDRAULIC EXCAVATOR
Shop Manual
PC300-8
PC300LC-8
PC350-8
PC350LC-8
Machine model Serial number
PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up
PC300, 350-8 1
SEN02635-02 50 Disassembly and assembly
2 PC300, 350-8
50 Disassembly and assembly SEN02635-02
PC300, 350-8 3
SEN02635-02 50 Disassembly and assembly
Catego
Komatsu code Part number Q'ty Container Main features and applications
ry
q Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions,and cork plugs from coming out.
q Used for plastic (except polyethylene,poly-
Polyethyl- propylene, tetrafluoroethylene and vinyl chlo-
20 g
LT-1B 790-129-9050 ene con- ride), rubber, metal, and non-metal parts
(2pcs.)
tainer which require immediate and strong adhe-
sion.
Polyethyl-
q Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
Adhesive:1
790-129-9060
kg q Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: tics.
and hardener)
500 g
Adhesive
Polyethyl-
LT-4 790-129-9040 250 g ene con- q Used to seal plugs.
tainer
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Quick-setting adhesive.
Polyethyl-
q Setting time: Within 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g ene con-
q Used mainly to stick metals, rubbers, plas-
tainer
tics, and woods.
q Quick-setting adhesive.
Polyethyl- q Quick-setting type. (max. strength is ob-
Aron-alpha 201 790-129-9130 2g ene con- tained after 30 minutes)
tainer q Used mainly to stick rubbers, plastics, and
metals.
Polyethyl- q Features: Resistance to heat and chemicals.
Loctite 648-50 79A-129-9110 50 cc ene con- q Used for fitted portions used at high temper-
tainer atures.
q Use to seal various threaded portions, pipe-
Polyethyl-
joints, and flanges.
LG-5 790-129-9080 1 kg ene con-
q Used to seal tapered plugs, elbows, and nip-
tainer
ples of hydraulic piping.
q Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube q Used to seal flange surfaces and threaded
portions.
q Use to seal oil pan, final drive case, etc.
Gasket sealant
4 PC300, 350-8
50 Disassembly and assembly SEN02635-02
Catego
Komatsu code Part number Q'ty Container Main features and applications
ry
LG-10 q Used as lubricant/sealant when the radiator
Gasket sealant
q Spray type
q Thin molybdenum disulphide films are made
on metal surfaces to prevent the metals from
09995-00250 190 g Can
scuffing each other.
q Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
q Feature: Seizure and scuffing prevention
compound
revention
LC-G
Can q Used for the mounting bolt in the high tem-
NEVER-SEEZ
perature area of the exhaust manifold and
the turbocharger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI q Feature: Lithium grease with extreme pres-
G0-LI SYGA-160CNLI Various Various sure lubrication performance.
*: For cold district SYG0-400LI-A q General purpose type.
(*)
SYG0-160CNLI
(*)
q Used for parts under heavy load.
Bel- Caution:
Molybdenum dis- SYG2-400M 400 g 10 lows-type q Do not apply grease to rolling bearings
ulfide grease SYG2-400M-A 400 g 20 container like swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg q The grease should be applied to work
Can equipment pins at their assembly only,
not applied for greasing afterwards.
Grease
SYG2-400T-A
Hyper White q Seizure resistance, heat resistance and wa-
SYG2-16CNT Bel-
Grease ter resistance higher than molybdenum disul-
SYG0-400T-A 400 g lows-type
G2-T, fide grease.
(*) 16 kg container
G0-T (*) q Not conspicuous on machine since color is
SYG0-16CNT Can
*: For cold district white.
(*)
Biogrease SYG2-400B
G2-B SYGA-16CNB Bel-
q Since this grease is decomposed by natural
G2-BT (*) SYG2-400BT 400 g lows-type
bacteria in short period, it has less effects on
*: For use at high (*) 16 kg container
microorganisms, animals, and plants.
temperature and SYGA-16CNBT Can
under high load (*)
q Feature: Silicone grease with wide using
temperature range, high resistance to ther-
G2-S mal-oxidative degradation and performance
200 g Tube
ThreeBond 1855 to prevent deterioration of rubber and plastic
parts.
q Use for oil seals of the transmission, etc.
PC300, 350-8 5
SEN02635-02 50 Disassembly and assembly
Catego
Komatsu code Part number Q'ty Container Main features and applications
ry
q Feature: Urea (organic system) grease with
heat resistance and long life can be packed
into the confined space and left intact until
Grease
G2-U-S
427-12-11871 2 kg Can next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damp-
er.
Caution: Do not mix with lithium grease.
q Used as primer for cab side.
SUNSTAR PAINT Glass con-
20 ml (Using limit: 4 months after date of
PRIMER580 tainer
manufacture)
SUPER 417-926-3910
SUNSTAR q Used as primer for glass side.
Glass con-
GLASS PRIMER 20 ml (Using limit: 4 months after date of
22M-54-27230 20 ml
PRIMER435-95 tainer (Using limit: 4 months after date of
manufacture)
q Used as primer for black ceramic-coat-
SUNSTAR ed surface on glass side and for hard
GLASS PRIMER 22M-54-27240 150 ml Can polycarbonate-coated surface.
435-41 (Using limit: 4 months after date of
manufacture)
q Used as primer for sash (Almite).
SUNSTAR SASH Glass con-
22M-54-27250 20 ml (Using limit: 4 months after date of
PRIMERGP-402 tainer
manufacture)
q S is used for high-temperature sea-
SUNSTAR PEN-
Polyethyl- son and W for low-temperature sea-
GUINE SEAL580
417-926-3910 320 ml ene con- son as adhesive for glass.
SUPER S" or
tainer (Using limit: 4 months after date of
W"
Adhesive
manufacture)
Polyethyl- q Used as adhesive for glass.
Sika Japan, Sikaf-
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of
Adhesive for cab glass
lex 256HV
tainer manufacture)
SUNSTAR PEN- Ecocart q Used as adhesive for glass.
GUINE SUPER 22M-54-27210 320 ml (Special (Using limit: 6 months after date of
560 container) manufacture)
SUNSTAR PEN- Polyethyl- q Used to seal joints of glass parts.
GUINE SEAL No. 417-926-3920 320 ml ene con- (Using limit: 4 months after date of
Caulking material
6 PC300, 350-8
50 Disassembly and assembly SEN02635-02
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity:
t............Cannot be substituted, must always be installed (used)
q............Extremely useful if available or can be substituted with commercially available part
a New/Remodel:
N............Tools with new part numbers, newly developed for this model
R............Tools with upgraded part numbers, remodeled from items already available for other models
Blank:............Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketch-
es of special tools).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
PC300, 350-8 7
SEN02635-02 50 Disassembly and assembly
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
791-685-8006 Compressor t 1
791-635-3160 Extension t 1 Disassembly and assembly
1
790-101-1600 Cylinder (686 kN {70 t}) t 1 of recoil spring assembly
Recoil spring assem- 790-101-1102 Pump t 1
J
bly 790-201-1500 Plate tool kit t 1
790-201-1620 q Plate 1
2 Installation of dust seal
790-101-5021 q Grip 1
01010-50816 q Bolt 1
791-630-3000 Remover & installer t 1
Track shoe assembly K 790-101-1300 Cylinder (980 kN {100 t}) t 1 Pulling out master pin
790-101-1102 Pump t 1
790-101-5201 Push puller t 1
790-101-2510 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1 Disassembly and assembly
Center swivel joint
L 790-101-2540 q Washer 1 of center swivel joint assem-
assembly
790-101-2630 q Leg 2 bly
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2
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 assem- (For 723-46-44100) Replacement of pressure
bly 796-946-2220 Guide compensation valve seal
t 1
M (For 723-46-45100)
796-946-1420 Guide
t 1
(For 723-46-42800)
796-946-1330 Sleeve
t
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
t
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve
t
3 (For 723-46-44100)
796-946-2230 Sleeve
t
(For 723-46-45100)
796-946-1430 Sleeve
t
(For 723-46-42800)
4 796T-416-1010 Push tool t 1 N Q Press fitting of bushing
Travel PPC valve 5 796T-416-1030 Push tool t 1 N Q Press fitting of bushing
6 796T-416-1020 Push tool t 1 N Q Press fitting of pin
8 PC300, 350-8
50 Disassembly and assembly SEN02635-02
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
PC300, 350-8 9
SEN02635-02 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 push tool
E1 push tool
10 PC300, 350-8
50 Disassembly and assembly SEN02635-02
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E5push tool
PC300, 350-8 11
SEN02635-02 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
12 PC300, 350-8
50 Disassembly and assembly SEN02635-02
PC300, 350-8 13
SEN02635-02 50 Disassembly and assembly
2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
14
SEN02636-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02636-01 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
Qty
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, 350-8
50 Disassembly and assembly SEN02636-01
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, 350-8 3
SEN02636-01 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, 350-8
50 Disassembly and assembly SEN02636-01
Necessity
Symbol
Sketch
Qty
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, 350-8 5
SEN02636-01 50 Disassembly and assembly
6 PC300, 350-8
50 Disassembly and assembly SEN02636-01
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, 350-8 7
SEN02636-01 50 Disassembly and assembly
3. Install the sling to flywheel (2) and lift off the fly-
wheel.
4 Flywheel: 40 kg
8 PC300, 350-8
50 Disassembly and assembly SEN02636-01
a While lightly hitting the top, bottom, right, of housing: Gasket sealant (LG-7)
and left of aligning tool [1] to check that
the seal carrier does not slant, push in the 4. Install guide pin [2] to the cylinder block and
rear seal until the outside of aligning tool then install gasket (10) and rear seal and hous-
[1] touches the housing. ing assembly (7).
a Do not remove the pilot tool from the rear a Cut bottom (A) of gasket (10) at the end of
seal. the seal housing (at both right and left
sides).
PC300, 350-8 9
SEN02636-01 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, 350-8
50 Disassembly and assembly SEN02636-01
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, 350-8 11
SEN02636-01 50 Disassembly and assembly
[*1]
2 Damper assembly mounting bolt:
Adhesive (LT-2)
2 Spline of damper:
Molybdenum disulfide grease (LM-G)
12 PC300, 350-8
50 Disassembly and assembly SEN02636-01
Necessity
Symbol
Sketch
Qty
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, 350-8 13
SEN02636-01 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 for the pur-
pose of replacement.
16. Remove bracket (27). 21. Remove clamps (37) and (38).
14 PC300, 350-8
50 Disassembly and assembly SEN02636-01
24. Remove clamp (46). [*7] 33. Remove 12 mounting bolts (60) and turbo-
charger and exhaust manifold assembly (61).
25. Remove U-clamp (47) and U-bolts (48) and [*13]
(49). [*8] 4 Turbocharger and exhaust manifold
assembly: 35 kg
26. Remove muffler (50) and joint (51). [*9]
PC300, 350-8 15
SEN02636-01 50 Disassembly and assembly
36. Disconnect hoses (64) and (65) and remove 39. 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.
16 PC300, 350-8
50 Disassembly and assembly SEN02636-01
5) Remove bolt (74) and holder (75). 41. Remove 7 mounting bolts (78) and rocker
housing assembly (79). [*18]
PC300, 350-8 17
SEN02636-01 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
copper washer (36d) and coat the adapter
with gear oil #90 and tighten it.
2 Threaded part of adapter:
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, 350-8
50 Disassembly and assembly SEN02636-01
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, 350-8 19
SEN02636-01 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, 350-8
50 Disassembly and assembly SEN02636-01
[*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, 350-8 21
SEN02636-01 50 Disassembly and assembly
22 PC300, 350-8
50 Disassembly and assembly SEN02636-01
[*16] [*17]
a Install the injector wiring harness terminal (5) in a Check that the push rod end is in the tappet.
a direction where it will not interfere with the 2 Push rod: Engine oil (EO15W-40)
rocker arm (6) which moves up and down.
[*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}
[*19]
a Install the cylinder head assembly according to
the following procedure.
1) Measure stem length (a) of each cylinder
head mounting bolt and check that it is
shorter than the using limit.
q Using limit length of bolt: 162.6 mm
a If a bolt is longer than the using
limit, do not reuse it but replace
a Take care that wiring harness (73) will not be
pressed strongly against the inside wall of the it.
housing, will not come off guide (e), or will not
be bent sharply.
a Setting positions of wiring harnesses
Color of cable Cylinder No.
a Yellow Right side
1, 3, 5
b Orange Left side
c Red Right side
2, 4, 6
d Brown Left side
3 Mounting nut:
1.25 0.25 Nm {0.10 0.03 kgm}
PC300, 350-8 23
SEN02636-01 50 Disassembly and assembly
2) Check that there is no dirt and foreign 4) Tighten the mounting bolts at least 2 3
matter on the cylinder head mounting sur- turns with the fingers.
face and in the cylinders and then set cyl- 2 Threads and head seat of each
inder head gasket (87). bolt: Engine oil (EO15W-40)
a Check that the gasket is set to the 5) Tighten the bolts in the order of the num-
holes of the cylinder block. bers shown in the figure.
1st time: 150 9.8 Nm {15.3 1.0 kgm}
2nd time: Return all bolts 360
3rd time: 115 4.9 Nm {11.7 0.5 kgm}
4th time: Check tightening torque of
115 4.9 Nm {11.7 0.5 kgm}
5th time: 120 5 (Tighten with tool B3)
24 PC300, 350-8
50 Disassembly and assembly SEN02636-01
PC300, 350-8 25
SEN02636-01 50 Disassembly and assembly
Installation
[*1]
a Apply ThreeBond 4324 or equivalent to the
adapters of hoses (4), (7), (8), and (9).
26 PC300, 350-8
50 Disassembly and assembly SEN02636-01
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
the battery.
3. Open the cover at the front of the hydraulic oil 10. Remove seal (7).
cooler.
PC300, 350-8 27
SEN02636-01 50 Disassembly and assembly
28 PC300, 350-8
50 Disassembly and assembly SEN02636-01
Installation
PC300, 350-8 29
SEN02636-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Qty
N/R
Part number Part name
Removal
30 PC300, 350-8
50 Disassembly and assembly SEN02636-01
12. Disconnect fuel hoses (16) and (17). 18. Disconnect heater hoses (28) and (29).
PC300, 350-8 31
SEN02636-01 50 Disassembly and assembly
32 PC300, 350-8
50 Disassembly and assembly SEN02636-01
[*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}.
PC300, 350-8 33
SEN02636-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
34
SEN02637-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
Necessity
Symbol
Sketch
Qty
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: Approx. 9 l
2. Cover
1) Remove the mounting bolts.
Then, using forcing screws [1], separate
cover (1) from the case.
PC300, 350-8 3
SEN02637-01 50 Disassembly and assembly
7. Thrust washer
Remove thrust washer (13).
4 PC300, 350-8
50 Disassembly and assembly SEN02637-01
2) Use tool D1 to remove nut (24). 2] Remove bearings (27) and (28) from
hub (29).
PC300, 350-8 5
SEN02637-01 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 race 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, 350-8
50 Disassembly and assembly SEN02637-01
PC300, 350-8 7
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
PC300, 350-8 9
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
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, 350-8 11
SEN02637-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Qty
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, 350-8
50 Disassembly and assembly SEN02637-01
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, 350-8 13
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
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, 350-8 15
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
PC300, 350-8 17
SEN02637-01 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, 350-8
50 Disassembly and assembly SEN02637-01
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, 350-8 19
SEN02637-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
20
SEN02638-02
PC300, 350-8
SEN02638-02
HYDRAULIC EXCAVATOR
Shop Manual
PC300-8
PC300LC-8
PC350-8
PC350LC-8
Machine model Serial number
PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up
PC300, 350-8 1
SEN02638-02 50 Disassembly and assembly
Disassembly and assembly of a After inserting the floating seal with tool F1,
carrier roller check that its slant is less than 1 mm and its pro-
jection (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.
Assembly
a Assemble according to the following figure.
a Only the precautions for assembly are described
below. q Carrier roller
a Check the amount of air leakage from the seal
with tool F2 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}
q Floating seal
a Before installing floating seals (7) and (8), com-
pletely 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 float-
ing seal.
2 PC300, 350-8
50 Disassembly and assembly SEN02638-02
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.
q Floating seal
a Before installing floating seals (5) and (6), com-
pletely 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 float-
ing seal.
a After inserting the floating seal with tool G1,
check that its slant is less than 1 mm and its pro-
jection (a) is 5 7 mm.
PC300, 350-8 3
SEN02638-02 50 Disassembly and assembly
Disassembly and assembly of 4. Remove floating seal (6) on the opposite side
idler assembly 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, 350-8
50 Disassembly and assembly SEN02638-02
PC300, 350-8 5
SEN02638-02 50 Disassembly and assembly
5. Using tool H1, install floating seal (3) to idler (4), 7. Using tool H2, fill the idler assembly with oil and
shaft (2) and support (7) assembly. tighten the plug.
5 Idler: Approximately 230 10 cc (EO30)
3 Plug: 130180 Nm {1318 kgm}
6 PC300, 350-8
50 Disassembly and assembly SEN02638-02
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring 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 danger-
791-685-8006 Compressor t 1 ous.
791-635-3160 Extension t 1 a Installed load of spring:
1 Cylinder 208,741 N {21,287 kg}
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 q Plate 1
2
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Disassembly
PC300, 350-8 7
SEN02638-02 50 Disassembly and assembly
8 PC300, 350-8
50 Disassembly and assembly SEN02638-02
Removal
1. Expand the track shoe assembly referencing
Expansion and installation of track shoe
assembly.
Installation
q Installation is done in the reverse order of remov-
al.
[*1]
2 Threads of sprocket mounting bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
640 785 Nm {65 80 kgm}
PC300, 350-8 9
SEN02638-02 50 Disassembly and assembly
Expansion and installation of 3. Remove track shoe (3) on master pin (2). [*2]
track shoe assembly
Special tools
Necessity
Symbol
Sketch
Q'ty
N/R
Part number Part name
10 PC300, 350-8
50 Disassembly and assembly SEN02638-02
[*1]
a Refer to the Checking and adjusting track shoe
tension section in the Testing and adjusting
chapter of this manual.
[*2]
2 Mounting bolt: Seizure prevention agent
(Maruzen Morimax No.2 or equivalent)
3 Mounting bolt: 393 39 Nm {40 4 kgm}
[*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
PC300, 350-8 11
SEN02638-02 50 Disassembly and assembly
Removal and installation of 5. Remove plate (3) and pin (4), and then lift boom
revolving frame assembly cylinder assembly (2) to remove.
a Remove the boom cylinder assembly on the
opposite side in the same manner.
Removal 4 Boom cylinder assembly: 260 kg
k Extend the arm and bucket fully, lower the
work equipment to the ground and then
move the work equipment lock lever to the
LOCK position.
k Disconnect the negative terminal () from the
battery.
12 PC300, 350-8
50 Disassembly and assembly SEN02638-02
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 as
a When other parts can interfere with the lifting well as right and left balance of the revolving
hook in removal of the revolving frame, such frame assembly, with only 2 mounting bolts
parts must be removed beforehand. being left in the front and rear side of the as-
sembly. After the adjustment, remove the re-
maining two bolts.
k When removing the revolving frame as-
sembly, 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.
PC300, 350-8 13
SEN02638-02 50 Disassembly and assembly
Special tools
Necessity
Symbol
Sketch
Q'ty
N/R
Part number Part name
Commercially
Impact wrench q 1
available
Z Socket wrench
Commercially
(Width across flats : q 1
available
46 mm)
14 PC300, 350-8
50 Disassembly and assembly SEN02638-02
[*2]
a Installing and adjusting counterweight
1) Adjust the level difference from the exterior
part (vertical clearance) with the shim
between the counterweight and revolving
frame.
q Set shim thickness: 1.0 mm, 2.0 mm
2) Install counterweight in such a way that
clearance between the door and counter-
weight as well as clearance between the
revolving frame and counterweight become
10 5 mm.
3) The difference in level in left to right direction
between the exterior of door (D) and counter-
weight (C)
(a): 10 4 mm
The difference in level in left to right direction
between revolving frame(R) and counter-
weight (C)
(b): 5 mm or less
The difference in level in up and down direc-
tion between exterior upper cover (UC) and
counterweight (C)
(c): 0 5 mm
are the respective limits for the mounting
adjustment.
a Rear view (Enlarged view for right hand
side of the machine)
PC300, 350-8 15
SEN02638-02 50 Disassembly and assembly
2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
16
SEN02639-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02639-02 50 Disassembly and assembly
2 PC300, 350-8
50 Disassembly and assembly SEN02639-02
[*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, 350-8 3
SEN02639-02 50 Disassembly and assembly
Necessity
(3) from swivel shaft (5).
Symbol
Sketch
Qty
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, 350-8
50 Disassembly and assembly SEN02639-02
PC300, 350-8 5
SEN02639-02 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, 350-8
50 Disassembly and assembly SEN02639-02
PC300, 350-8 7
SEN02639-02 50 Disassembly and assembly
6. Disconnect 8 hoses and 8 tubes on the control 8. Disconnect 2 hoses and 8 tubes on the control
valve. valve.
q (9): TSW port hose (Swing motor S port) q (19): Bucket dump
q (10): T1 port hose (connected to the tank) (Hose band: Yellow -Blue)
q (11): From the top: q (20): PST port hose (Hose band: Brown)
A1 port tube (boom Hi bottom side)
A1 port tube (bucket bottom side), 9. Disconnect drain hoses (21).
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)
q (12): From the top: B1 port tube (arm Hi
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, 350-8
50 Disassembly and assembly SEN02639-02
PC300, 350-8 9
SEN02639-02 50 Disassembly and assembly
10 PC300, 350-8
50 Disassembly and assembly SEN02639-02
Removal and installation of 3. Open cover (1) and remove covers (2) (4).
hydraulic pump assembly 1
Special tools
Necessity
Symbol
Sketch
Qty
N/R
Part number Part name
Removal
k Disconnect the negative () terminal from
the battery. 4. Remove cover (5).
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.
PC300, 350-8 11
SEN02639-02 50 Disassembly and assembly
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).
12 PC300, 350-8
50 Disassembly and assembly SEN02639-02
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].
PC300, 350-8 13
SEN02639-02 50 Disassembly and assembly
14 PC300, 350-8
50 Disassembly and assembly SEN02639-02
PC300, 350-8 15
SEN02639-02 50 Disassembly and assembly
Necessity
16 PC300, 350-8
50 Disassembly and assembly SEN02639-02
PC300, 350-8 17
SEN02639-02 50 Disassembly and assembly
18 PC300, 350-8
50 Disassembly and assembly SEN02639-02
Necessity
Symbol
Sketch
Qty
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.
PC300, 350-8 19
SEN02639-02 50 Disassembly and assembly
20 PC300, 350-8
50 Disassembly and assembly SEN02639-02
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 60C) before
installing it.
PC300, 350-8 21
SEN02639-02 50 Disassembly and assembly
22 PC300, 350-8
50 Disassembly and assembly SEN02639-02
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.
PC300, 350-8 23
SEN02639-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 12-09 (01)
24
SEN02640-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02640-00 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
Qty
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, 350-8
50 Disassembly and assembly SEN02640-00
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, 350-8 3
SEN02640-00 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, 350-8
50 Disassembly and assembly SEN02640-00
PC300, 350-8 5
SEN02640-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 08-07 (01)
6
SEN02641-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02641-01 50 Disassembly and assembly
2 PC300, 350-8
50 Disassembly and assembly SEN02641-01
15. Remove duct (20). 23. Remove ducts (32) and (33).
16. Disconnect connector (21). a Cut tie-wrap.
17. Remove plates (22) and (23) from the operator 24. Disconnect wiper motor connector M05(34).
cab. 25. Remove harness (35) and antenna (36) from
the cab wall.
a Cut 2 points of tie-wrap.
PC300, 350-8 3
SEN02641-01 50 Disassembly and assembly
31. Detach harness clamp (41) from the right back 35. Lift off and remove operator's cab assembly
side of cab. (47).
4 Operator's cab assembly: 470 kg
[*1]
3 Mounting bolt of lock plate (43):
98 123 Nm {10 12.5 kgm}
[*2]
3 Bolt (44):
245 309 Nm {25 31.5 kgm}
4 PC300, 350-8
50 Disassembly and assembly SEN02641-01
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 5 panes (1) to (4) (2) : Left side rear window glass
and (18) are stuck. (3) : Door lower window glass
a In this section, the procedure for replacing the (4) : Front window glass
stuck glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Dam rubber
replace only the front window glass while the (17) : Center trim seal
front window assembly is installed to the opera- (18) : Rear glass
tor's cab.)
a For the procedure for replacing the front win-
dow assembly, see Removal and installation of
front window assembly.
PC300, 350-8 5
SEN02641-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Part number Part name metal sheets (glass sticking surfaces) of the
Qty
N/R
operator's cab.
2 793-498-1210 Lifter (Suction cup) t 2 a Remove the adhesive and dam rubber to
X a degree that they will not affect adhesion
3 20Y-54-13180 Stopper rubber t 2
of the new adhesive. Take care not to
scratch the painted surfaces.
(If the painted surfaces are scratched,
Removal adhesion will be lowered.)
a Remove the window glass to be replaced
according to the following procedure. 2. Remove oil, dust, and dirt, etc. form the stick-
1. Using seal cutter [1], cut the adhesive between ing surfaces of cab (8) and window glass (9)
broken window glass (7) and operator's cab with white gasoline.
(metal sheet)(8). a If the sticking surfaces are not cleaned
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 lease 5 minutes to dry.
6 PC300, 350-8
50 Disassembly and assembly SEN02641-01
PC300, 350-8 7
SEN02641-01 50 Disassembly and assembly
a Never apply the wrong primer. 4. Stick dam rubber (both-sided adhesive
If the glass primer, etc. is applied by mistake, tape)(6) along the inside edge of the glass
wipe it off with white gasoline. sticking section.
a Do not remove the release tape of dam
4) Apply the glass primer to the sticking sur- rubber on the glass sticking side before
faces of window glass (9). sticking the glass.
2 Glass primer: a When sticking the dam rubber, do not
Sunstar primer for glass 580 touch the cleaned surface to the utmost.
super or equivalent a Care should be taken not to float the dam
a Do not apply the primer more than 2 rubber of each sticking corner.
times.
(If it is applied more than 2 times, its
performance will be lowered.)
8 PC300, 350-8
50 Disassembly and assembly SEN02641-01
a Stick dam rubber (6a) additionally to 3) Stick dam rubber (6) for door lower win-
right side window glass (1). dow glass (3) to the position as shown in
q Positions to stick additional dam rub- the figure.
ber to the right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
PC300, 350-8 9
SEN02641-01 50 Disassembly and assembly
10 PC300, 350-8
50 Disassembly and assembly SEN02641-01
PC300, 350-8 11
SEN02641-01 50 Disassembly and assembly
a Since the window glass cannot be Sunstar primer for glass 580
removed and stuck again, stick it with super or equivalent
utmost caution. 2 Adhesive:
a Stick the glass within 5 minutes after SUNSTAR penguine seal 580
applying the adhesive. super S or W or equivalent
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber
closely.
a Press the corners of the window glass
firmly.
12 PC300, 350-8
50 Disassembly and assembly SEN02641-01
PC300, 350-8 13
SEN02641-01 50 Disassembly and assembly
14 PC300, 350-8
50 Disassembly and assembly SEN02641-01
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
PC300, 350-8 15
SEN02641-01 50 Disassembly and assembly
16 PC300, 350-8
50 Disassembly and assembly SEN02641-01
PC300, 350-8 17
SEN02641-01 50 Disassembly and assembly
18 PC300, 350-8
50 Disassembly and assembly SEN02641-01
8. Adjust the Open position of the front window 4) Loosen locknut (20) of right and left side of
assembly lock. rubber stoppers (18), and then pull back
1) After adjusting the Close position of the both rubber stoppers (18) so that they
front window assembly lock in steps 6 and won't contact with the fr ont window
7, raise the front window assembly to the assembly when it is in Open position.
ceiling.
2) Set the front window assembly locks at
the both sides of rear of the operator's cab
to the Open position, and then check the
following items.
q Check the working condition of right
a nd left l ock s ( 16) and ( 17) ( as
explained above).
q Front window assembly must be in
contact with the right and left rubber
stoppers (18) and furthermore, must
be pushing them backward for 1.5
3.0 mm.
q The front window assembly must be
pushing the limit switch backward for 5) Loosen both sides of locknuts (22), and
4 7 mm. adjust the position of striker bolt (21).
a The position of limit switch (19) can- a Striker bolt (21): M10
n ot be ad ju st ed. The re for e , th e Inner diameter of plate (23): 14.5
Open position of the front window mm
assembly is decided within the range
where this switch works.
a Limit switch (19) is used to prevent
the windshield wiper from moving
when turning the wiper switch on by
m i s ta k e w h e n t h e f r o n t w i n d o w
assembly is in Open position. If the
wiper operates when there is no glass
in the front, the wiper falls down
inside the cab and causes trouble.
To check whether limit switch (19) is
working, turn the key switch on and
see that, even if the wiper switch is
turned on, the wiper does not operate
when the front window assembly is in 1] Front window assembly (10) must be
Open position. pushing the limit switch backward for
4 7 mm (at Open position).
2] Working condition of lock (17).
PC300, 350-8 19
SEN02641-01 50 Disassembly and assembly
6) Adjustment of right and left rubber stop- 4] Tighten locknuts (20) of the both
pers (18). sides of rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in Open position) into
contact with right and left rubber stop-
pers (18).
20 PC300, 350-8
50 Disassembly and assembly SEN02641-01
[*2]
3 Left lower pin:
27 34 Nm {2.75 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC300, 350-8 21
SEN02641-01 50 Disassembly and assembly
22 PC300, 350-8
50 Disassembly and assembly SEN02641-01
PC300, 350-8 23
SEN02641-01 50 Disassembly and assembly
29. Disconnect the clamp of wiring harness (35). 34. Pull out PPC hose assembly (41) of the work
30. Move plates (36) and (37) together with wiring equipment.
harness (35) to the boom side.
24 PC300, 350-8
50 Disassembly and assembly SEN02641-01
Installation
q Installation is done in the reverse order of
removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexel:
ZXL100PG (PAG 46 or equivalent)).
3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
PC300, 350-8 25
SEN02641-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
26
SEN02642-01
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02642-01 50 Disassembly and assembly
Removal and installation of air 7. Pull down opening and closing lever (8) of the
conditioner unit assembly outside air filter cover.
8. Remove outside air filter (9).
Removal
k Disconnect the negative () terminal from
battery.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose
when the coolant temperature in the radia-
tor is high, you may be scalded. In this
case, wait until the coolant temperature
lowers and then disconnect the heater
hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 9. Remove rear covers (10) to (13).
a Never release the refrigerant (R134a) to the
atmosphere.
2 PC300, 350-8
50 Disassembly and assembly SEN02642-01
15. Remove ducts (20) and (21). 20. Disconnect connectors N10 (27) and AC01
a Cut tie-wrap. (28).
21. Disconnect connectors ECU10 and ECU11
( 2 9 ) f r o m t h e a ir c o n d i t i o n e r c o n t r o l l e r
(ACCONT).
PC300, 350-8 3
SEN02642-01 50 Disassembly and assembly
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexel:
24. Remove mounting bolt (33) and disconnect air ZXL100PG (PAG 46 or equivalent)).
conditioner tube (34). [*1] 3 Mounting bolt: 8 12 Nm {0.8 1.2 kgm}
25. Disconnect heater hose (35).
a Check the connecting point. q Filling air conditioner circuit with refriger-
ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 1000 50 g
4 PC300, 350-8
50 Disassembly and assembly SEN02642-01
Installation
q Installation is done in the reverse order of
removal.
PC300, 350-8 5
SEN02642-01 50 Disassembly and assembly
6 PC300, 350-8
50 Disassembly and assembly SEN02642-01
Installation
[*1], [*2]
1) Temporarily install monitor assembly (6) with 4
mounting bolts, and then install cover (5).
2) With cover (5) installed, tighten the mounting
bolts of monitor assembly.
PC300, 350-8 7
SEN02642-01 50 Disassembly and assembly
Installation
q Installation is done in the reverse order of re-
moval.
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2. Disconnect relay R08 (4) from the clip.
2) Move lever (3) up.
3. Disconnect bracket (5) and put it to the right
side.
4. Disconnect wiring connectors C01 (6) and C02
(7) as follows.
q Tilt lock (L12) inside while pressing lock
(L1).
a Bar (B) comes out and the lock is re-
leased.
5. Remove the 4 mounting bolts and pump con-
troller assembly (8).
8 PC300, 350-8
50 Disassembly and assembly SEN02642-01
a Connector without connector cover 3) Set claw (C) to the connector and place
(1) connector cover (1).
a Take care that wiring harness (5) will
not be caught.
PC300, 350-8 9
SEN02642-01 50 Disassembly and assembly
Removal
k Disconnect the negative () terminal from
the battery.
Installation
q Carry out installation in the reverse order to
removal.
10 PC300, 350-8
50 Disassembly and assembly SEN02642-01
PC300, 350-8 11
SEN02642-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
12
SEN02004-00
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02004-00 90 Diagrams and drawings
2 PC300, 350-8
Hydraulic circuit diagram
Hydraulic circuit diagram PC300, 300LC-8, PC350, 350LC-8 1 PC300, 300LC-8, PC350, 350LC-8
SEN02004-00
PC300, 350-8 3
90 Diagrams and drawings SEN02004-00
PC300, 350-8 5
SEN02004-00
2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
6
SEN02005-02
PC300-8
PC300LC-8
PC350-8
PC350LC-8
PC300, 350-8 1
SEN02005-02 90 Diagrams and drawings
2 PC300, 350-8
Electrical circuit diagram (1/5)
Electrical circuit diagram (1/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300, 350-8 3
Electrical circuit diagram (2/5)
Electrical circuit diagram (2/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300, 350-8 5
Electrical circuit diagram (3/5)
Electrical circuit diagram (3/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300, 350-8 7
Electrical circuit diagram (4/5)
Electrical circuit diagram (4/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300, 350-8 9
Electrical circuit diagram (5/5)
Electrical circuit diagram (5/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300, 350-8 11
Connector list and sterogram
Connector list and sterogram PC300, 300LC-8, PC350, 350LC-8 PC300, 300LC-8, PC350, 350LC-8
SEN02005-02
PC300,350-8
13
90 Diagrams and drawings SEN02005-02
PC300, 350-8 15
SEN02005-02
2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
16