Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Shop
Manual
PC350LC-8
PC350HD-8
HYDRAULIC EXCAVATOR
PC350LC-8 A10001
SERIAL NUMBERS and UP
PC350HD-8 A00001
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
00-2 b PC350LC/HD-8
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-2 1 PC350LC/HD-8
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
PC350LC/HD-8 00-2-3 1
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-4 1 PC350LC/HD-8
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
PC350LC/HD-8 00-2-5 1
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-6 1 PC350LC/HD-8
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
PC350LC/HD-8 00-2-7 1
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-8 1 PC350LC/HD-8
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
❍ 60-32 b ❍ 60-65 b
❍ 60-33 b ❍ 60-66 b
❍ 60-34 b ❍ 60-67 b
❍ 60-35 b ❍ 60-68 b
❍ 60-36 b ❍ 60-69 b
❍ 60-37 b ❍ 60-70 b
❍ 60-38 b ❍ 60-71 b
❍ 60-39 b ❍ 60-72 b
❍ 60-40 b ❍ 60-73 b
❍ 60-41 b ❍ 60-74 b
❍ 60-42 b ❍ 60-75 b
❍ 60-43 b ❍ 60-76 b
❍ 60-44 b ❍ 60-77 b
❍ 60-45 b ❍ 60-78 b
❍ 60-46 b ❍ 60-79 b
❍ 60-47 b ❍ 60-80 b
❍ 60-48 b ❍ 60-81 b
❍ 60-49 b ❍ 60-82 b
❍ 60-50 b ❍ 60-83 b
❍ 60-51 b ❍ 60-84 b
❍ 60-52 b ❍ 60-85 b
❍ 60-53 b ❍ 60-86 b
❍ 60-54 b
❍ 60-55 b ● 90-1 b
❍ 60-56 b ● 90-2 b
❍ 60-57 b ● 90-3 b
❍ 60-58 b ● 90-5 b
❍ 60-59 b ● 90-7 b
❍ 60-60 b ● 90-9 b
❍ 60-61 b ● 90-11 b
❍ 60-62 b ● 90-13 b
❍ 60-63 b ● 90-15 b
❍ 60-64 b
PC350LC/HD-8 00-2-9 1
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
00-2-10 1 PC350LC/HD-8
FOREWORD SAFETY
12
SAFETY 00
Safety Notice 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
General Precautions 00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work..
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the
control levers and hang warning signs on them.
PC350LC/HD-8 00-3
FOREWORD SAFETY
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with apropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-4 PC350LC/HD-8
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
AIR CONDITIONING
This section explains the air conditioning system. The structure, function, maintenance standard, testing, adjusting,
troubleshooting, servicing and some disassembly and assembly.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
PC350LC/HD-8 00-5 b
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
Volumes 00 Revisions 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Weight
Caution necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special
2. Following examples show how to read the page number: Tightening
attention for tightening torque
Example: torque
during assembly.
10-5
00-6 PC350LC/HD-8
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
Hoisting 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
PC350LC/HD-8 00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
Type 1 00
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
Connection 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8 PC350LC/HD-8
FOREWORD PUSH PULL COUPLER
Type 2 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
PC350LC/HD-8 00-9
FOREWORD PUSH PULL COUPLER
12
Type 3 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-10 PC350LC/HD-8
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
PC350LC/HD-8 00-11
FOREWORD COATING MATERIALS
prevent squeaking).
disulphide
lubricant
00-12 PC350LC/HD-8
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
mm mm N•m lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
mm mm N•m lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
PC350LC/HD-8 00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
Tightening Torque of Hose Nuts 00
00-14 PC350LC/HD-8
FOREWORD STANDARD TIGHTENING TORQUE
12
Table of Tightening Torques for O-ring Boss Piping Joints 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (N•m {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (N•m {lbf ft})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (N•m {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 {57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
10 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
12 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
14 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
PC350LC/HD-8 00-15
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
Classification by Thickness 00
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue & Yel-
Color — Black & Red
Blue Yellow Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 PC350LC/HD-8
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
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
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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
PC350LC/HD-8 00-17
FOREWORD CONVERSION TABLES
12
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
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 PC350LC/HD-8
FOREWORD CONVERSION TABLES
12
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
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
PC350LC/HD-8 00-19
FOREWORD CONVERSION TABLES
12
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 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 PC350LC/HD-8
FOREWORD CONVERSION TABLES
12
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
PC350LC/HD-8 00-21
FOREWORD CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°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 81 117.8
-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
00-22 PC350LC/HD-8
01 GENERAL
PC350LC/HD-8 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
Dimensions
Item Unit PC350LC-8 PC350HD-8
kg
Operating weight 32,930 (72,600) 36,836 (81,210)
(lb)
Bucket capacity m3 (cu.yd) 1.4 (1.8)
Name of engine KOMATSU SAA6D114E-3 diesel engine
Engine horsepower kW (HP) /rpm 184 (247) /1,900
A Overall length mm (ft in) 11,140 (36' 7“) 11,140 (36’7”)
F Radius of upper structure mm (ft in) 3,450 (11' 4“) 3,450 (11’4”)
H Tumbler center distance mm (ft in) 4,030 (13' 3“) 4,350 (14’3”)
Min. ground clearance mm (ft in) 498 (1' 8“) 550 (2’0”)
01-2 PC350LC/HD-8
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
Working Ranges
Working ranges Unit PC350LC-8 PC350HD-8
A Max. digging reach mm (ft in) 11,100 (36' 5“) 11,100 (36’4”)
B Max. digging depth mm (ft in) 7,380 (24' 3“) 7,277 (24’0”)
C Max. digging height mm (ft in) 10,100 (33' 2“) 10,313 (34’0”)
D Max. vertical wall depth mm (ft in) 6,400 (20' 12“) 6,377 (21’0”)
E Max. dumping height mm (ft in) 7,050 (23' 2“) 7,213 (23’6”)
F Min. dumping height mm (ft in) 2,640 (8' 8“) 2,743 (9’0”)
G Max. reach at ground level mm (ft in) 10,920 (35' 10“) 10,920 (35’8”)
PC350LC/HD-8 01-3
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Machine model PC350LC-8 PC350HD-8
01-4 PC350LC/HD-8
GENERAL SPECIFICATIONS
12
Machine model PC350LC-8 PC350HD-8
Model SAA6D114E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection, with
turbocharger and aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement L {cc} 8.27 {8,270}
brake): x 2 brake): x 2
Hydraulic system
PC350LC/HD-8 01-5
GENERAL SPECIFICATIONS
*1: Cushion is provided on head side
*2: Cushion is provided on bottom side
01-6 PC350LC/HD-8
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
WARNING! This weight table is for use when handling components or when transporting the
machine.
Unit: kg
• Carrier roller 28 x 4 32 x 4
PC350LC/HD-8 01-7
GENERAL WEIGHT TABLE
12
Unit: kg
Boom pin 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
01-8 PC350LC/HD-8
GENERAL FUEL, COOLANT, AND LUBRICANTS
12
FUEL, COOLANT, AND LUBRICANTS
Remark
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this
machine uses an electronically controlled high-pressure fuel injection device. This device requires high
precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop
markedly.
PC350LC/HD-8 01-9
GENERAL FUEL, COOLANT, AND LUBRICANTS
Note 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or higher
than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bush-
ings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)
1. Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2. For details of the ratio when diluting super coolant with water, Supercoolant AF-NAC may be supplied in premix. In this
case, always top off with premix solution. (never dilute with water)
3. To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.
01-10 PC350LC/HD-8
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Engine Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Radiator, Oil Cooler and Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Track Frame and Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Triple Grouser Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Hydraulic Equipment Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Hydraulic Tank and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Type: HPV125+125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
LS Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
PC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
LS(PC)-EPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Variable Volume Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
CLSS (Closed Center Load Sensing System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Valve Functions and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Hydraulic Circuit Diagram and the Name of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
LS Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
PC350LC/HD-8 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
Pressure Compensation Valve Inner Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
Boom Regeneration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
Arm Regeneration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
Merge-divider Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
LS Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
Self Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
Travel Junction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
Travel PPC Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
Boom Drift Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
Arm Drift Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
Quick Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
Lift Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
2-Stage Safety-suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
Variable Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
Attachment Circuit Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
Drift Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
Travel PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Service PPC Valve (with EPC Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
Service PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
PPC Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
Return Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
Center Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
Travel Motor - Type: HMV160ADT-2 - PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
Parking Brake - PC350LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
Travel Motor - Type: KMV200ADT-2 - PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
Parking Brake - PC350HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Reverse Prevention Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
Dimension Of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
Dimension Of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
Fuel Control Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
Boost Pressure And Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
WIF (Water-in-fuel Detection) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
Engine Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
10-2 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
Engine and Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Pump and Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
LS Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
Cut-off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
2-Stage Relief Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
Power Maximizing and Machine Push-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-226
Auto-deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-228
Auto-warm-up and Overheat Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
Attachment Flow Control and Circuit Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-236
System Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-237
PPC Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-237
Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-238
Pump Pressure Sensor (High Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-239
Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-240
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-243
Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-244
Monitor Control, Display Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-248
Monitor Items And Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-254
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-271
KOMTRAX Terminal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-273
KOMTRAX Communication Modem - TH300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-274
PC350LC/HD-8 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
ENGINE AND COOLING SYSTEM
10-4 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
Radiator, Oil Cooler and Aftercooler
Specifications
PC350LC/HD-8 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
Power Train
10-6 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
MEMORANDUM
PC350LC/HD-8 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Final Drive
PC350LC-8
3. No. 1 planetary gear (No. of teeth: 42) 8. Cover 13. Travel motor
Specifications
10-8 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Unit: mm
No. Check Item Criteria Remedy
Standard clearance Clearance limit
Backlash between No. 1 sun gear and No. 1 plane-
15 tary gear 0.12 - 0.44 0.9
16 Backlash between No. 1 planetary gear and ring
0.18 - 0.62 1.2
gear
17 Backlash between No. 2 planetary carrier and motor 0.06 - 0.25 -
18 Backlash between No. 2 sun gear and No.2
0.15 - 0.51 1.00 Replace
planetary gear
19 Backlash between No. 2 planetary gear and ring
0.19 - 0.66 1.3
gear
20 Backlash between No. 2 planetary carrier and No. 2
0.39 - 0.80 1.6
sun gear
21 Amount of wear on sprocket tooth Repair limit: 6
Build-up welding for
Standard size Repair limit rebuilding or replace
22 Width of sprocket tooth 87 84
Torque
N•m lbf ft
1st: 98 1st: 72.3
23 Bolt 2nd: 105 ±5° 2nd: 10 5±5°
24 Bolt 640 - 785 472 - 579
25 Bolt 49 - 74 36.1 - 54.6
26 Bolt 490 - 608 361 - 448
PC350LC/HD-8 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
PC350HD-8
4. No. 1 sun gear (No. of teeth: 10) 9. Ring gear (No. of teeth: 98)
Specifications
Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
Backlash between No. 1 sun gear and No. 1 planetary
14 gear 0.15 - 0.54 1.10
15 Backlash between No. 1 planetary gear and ring gear 0.18 - 0.66 1.30
16 Backlash between No. 2 planetary carrier and motor 0.06 - 0.24 -
Replace
Backlash between No. 2 sun gear and No. 2 planetary
17 gear 0.15 - 0.51 1.00
18 Backlash between No. 2 planetary gear and ring gear 0.17 - 0.60 1.20
Backlash between No. 2 planetary carrier and No. 2
19 sun gear 0.15 - 0.54 -
PC350LC/HD-8 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Sprocket
PC350LC-8
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip 336.5 324.5
2 Thickness of tooth root 20 14 Build-up welding for
rebuilding or replace
3 Width of tooth 87 84
Repair limit: 6 (measure with the full-size drawing of
4 Wear of tooth shape sprocket tooth shape)
10-12 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Full-size drawing of sprocket tooth shape.
★ 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.
PC350LC/HD-8 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
PC350HD-8
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip 355 343
2 Thickness of tooth root 20.8 14.8 Build-up welding for
rebuilding or replace
3 Width of tooth 90 87
4 Wear of tooth shape Repair limit: 6 (measure with the full-size drawing of
sprocket tooth shape)
10-14 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Full-size drawing of sprocket tooth shape.
★ 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.
PC350LC/HD-8 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Swing Machinery
10-16 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Specifications
18 Backlash between No. 1 planetary carrier and No. 0.40 - 0.75 1.20
2 sun gear
Replace
19 Backlash between No. 2 sun gear and No.2 0.16 - 0.55 1.00
planetary gear
20 Backlash between No. 2 planetary gear and ring 0.17 - 0.60 1.10
gear
PC350LC/HD-8 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Swing Circle
1. Swing circle inner race (No. of teeth: 90) a. Inner race soft zone "S" position
10-18 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Specifications
Unit: mm
No. Check Item Criteria Remedy
Standard clearance Clearance limit
Axial clearance of bearing (when Replace
4 mounted on chassis) 0.5 - 1.6 3.2
Torque
N•m lbf ft
5 Bolt 824 - 1030 608 - 759
PC350LC/HD-8 10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
UNDERCARRIAGE AND FRAME
Track Frame and Recoil Spring
PC350LC-8
10-20 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Standard shoe
Model
Item PC350LC-8
Shoe width (triple shoe) (mm) 600
Link pitch (mm) 216
No. of shoes (one side) 48
Unit: mm
Criteria Remedy
No Check Item
Standard size Tolerance Rapair limit
Track +2
123 127
Vertical width of idler frame -1
9 Build-up
guide Idler 120 ±0.5 118 welding for
support rebuilding or
Track +3 replace
266 271
Horizontal width of idler frame -1
10 guide
Idler 261 - 259
support
Standard size Rapair limit
Free length Installation Installation Installation
x Free length
length load load
11 Recoil spring O.D. Replace
208.7 kN 167.0 kN
811 x 261 655 {21,290 - {17,030 kg}
kg}
PC350LC/HD-8 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
10-22 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Standard shoe
Model
Item PC350HD-8
Shoe width 700
Link pitch (mm) 228
No. of shoes (one side) 49
Unit: mm
Criteria Remedy
No Check Item
Standard size Tolerance Rapair limit
Track +3
148 -
Vertical width of idler frame -1
9 guide Idler 145 ±0.5 - Rebuild or
support replace
Track +4
302 -
Horizontal width of idler frame -1
10 guide
Idler 297 - -
support
Standard size Rapair limit
Free length Installation Installation Installation
x Free length
length load load
11 Recoil spring O.D. Replace
239 kN
845 x 262 690 {24,375 - -
kg}
PC350LC/HD-8 10-23
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Idler
PC350LC-8
10-24 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
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 replace
4 Thickness of tread - -
5 Total width 190 -
6 Width of tread 44 50
PC350LC/HD-8 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
10-26 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of protruding
704 ---
2 Outside diameter of tread 660 648
Rebuild or
3 Depth of tread 22 28 replace
4 Thickness of tread 21 15
5 Total width 202 ---
6 Width of tread 48.5 54.5
Clearance between bushing and
7 support 0.46 - 0.86 ---
(Sum of clearance at both sides)
Tolerance Standard
Standard size
Shaft Hole clearance
8 Clearance between shaft and bushing
Replace
-0.120 +0.360
95 0.340-0.507 bushing
-0.207 +0.220
Tolerance Standard
Standard size
Shaft Hole interference
9 Interference between idler and bushing
+0.087 -0.027
102.6 0.010-0.149
+0.037 -0.062
Torque N•m Torque lbf ft
10 Bolt
130 - 180 96 - 132
PC350LC/HD-8 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Carrier Roller
PC350LC-8
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 -
10-28 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
Unit: mm
No Check item Criteria Remedy
Standard size Repair 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 ---
+0.117 +0.030
61 0.057 - 0.117 ---
7 Clearance between roller and bushing +0.087 0
Standard clearance Clearance limit
8 Axial clearance of roller 0.5 - 0.7 ---
PC350LC/HD-8 10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Track Roller
PC350LC-8
10-30 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Unit: mm
No Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange 216 -
Outside diameter of inner flange (Double
2 210 -
flange)
3 Outside diameter of tread 180 168
4 Thickness of tread 54 48
5 Overal width 250 - Build-up
Single welding for
49 rebuilding or
flange
6 Width of tread - replace
Double 47.7
flange
Single
flange
7 Width of flange 27 -
Double
flange
Width of inner frange
8 98 -
(Double frame)
Clearance between bushing and collar
9 0.44-0.97 -
(Sum of clearance at both sides)
PC350LC/HD-8 10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
10-32 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Unit: mm
No Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange 240 -
Outside diameter of inner flange (Double
2 237 -
flange)
3 Outside diameter of tread 200 188
4 Thickness of tread 56.2 50.2
5 Overal width 278 - Build-up
welding for
Single rebuilding or
54.6
flange replace
6 Width of tread -
Double 51.6
flange
Single 34.4 -
flange
7 Width of flange
Double 34.4 -
flange
8 Width of inner frange (Double frame) 23.0 -
9 Axial play 0.4-1.0 -
-0.250 +0.174
80 0.279-0.524 - Replace
10 Clearance between shaft and bushing -0.350 +0.029 bushing
Standard Tolerance Standard Interference
size Shaft Hole interference limit
Interference between roller and +0.087 +0.022
87.6 0.015-0.100 -
11 bushing +0.037 -0.013
Torque
N•m lbf ft
12 Bolt 10 - 20 7.3 - 14.0
PC350LC/HD-8 10-33
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Track Shoe
PC350LC-8
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch 216.3 219.3 Reverse or replace
2 Outside diameter of bushing 66.9 61.9
3 Thickness of bushing metal 10.8 5.8 Adjust or replace
4 Link height 116 107
Thickness of link metal Repair or replace
5 30.7 21.7
(bushing press-fitting portion)
10-34 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
Unit: mm
No Check Item Criteria Remedy
6 178.4
7 Shoe bolt pitch 140.4 Replace
8 76.2
Inside
9 102
width
Overall
10 Link 47.8 Repair or replace
width
Tread
11 42.6
width
12 Protrusion of pin 4.2
13 Protrusion of regular bushing 5.25
14 Overall length of pin 242
Adjust or replace
15 Overall length of bushing 148.4
Standard size Reverse
16 Thickness of spacer 10.8 5.8
17 Bushing 98 - 264.6 kN (10 - 27 ton)
Regular
18 Press-fitting force 147 - 362.6 kN (15 - 37 ton)
pin -
19 Master 98 - 215.6 kN (10 - 22 ton)
(*) pin
Torque (N•m {kgm}) Retightening angle (deg.)
a.Regu-
lar link 393±39
Triple grouser shoe 120±10
{40±4}
20 Shoe bolt Retighten
Retightening angle Lower limit torque
b.Master Torque (N•m {kgm}) (deg.) (N•m {kgm})
link
- - -
Tolerance Standard
Standard size
Shaft Hole interference
Interference between bushing +0.464 +0.074
66.5 0.350-0.464
21 and link +0.424 0
22
Interference between regular 44.6 +0.235 -0.188 0.273-0.485
pin and link +0.085 -0.250
Standard
23
Clearance between regular pin 44.6 +0.235 +0.915 clearance Adjust or replace
and bushing +0.085 +0.415
0.180-0.830
Standard
24 Interference between master pin +0.03 -0.188 interference
44.6
(*) and link 0 -0.250
0.188-0.280
Standard
25 Clearance between master pin +0.050 +0.915 clearance
44.3
(*) and bushing -0.050 +0.415
0.365-0.965
PC350LC/HD-8 10-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch 228.9 231.9 Reverse or replace
2 Outside diameter of bushing 71.5 66.5
3 Thickness of bushing metal 11.9 6.9 Adjust or replace
4 Link height 129 119
Thickness of link metal Repair or replace
5 34.5 24.5
(bushing press-fitting portion)
10-36 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Unit: mm
No Check Item Criteria Remedy
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
Inside
9 106
width
Overall
10 Link 51.6 Repair or replace
width
Tread
11 44.8
width
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer -
17 Bushing 118 - 304 kN (12 - 31 ton)
Regular
18 Press-fitting force 176 - 451 kN (18 - 46 ton)
pin -
19 Master 137 - 284 kN (14 - 29 ton)
(*) pin
Torque (N•m {kgm}) Retightening angle (deg.)
a.Regu-
lar link 393±39
Triple grouser shoe 120±10
{40±4}
20 Shoe bolt Retighten
Retightening angle Lower limit torque
b.Master Torque (N•m {kgm}) (deg.) (N•m {kgm})
link
- - -
Tolerance Standard
Standard size
Shaft Hole interference
Interference between bushing +0.494 +0.074
71 0.380-0.494
21 and link +0.454 0
22
Interference between regular 47 +0.235 -0.218 0.303-0.515
pin and link +0.085 -0.280
Standard
23
Clearance between regular pin 47 +0.235 +0.915 clearance Adjust or replace
and bushing +0.085 +0.415
0.180-0.830
Standard
24 Interference between master pin +0.03 -0.218 interference
47
(*) and link 0 -0.280
0.218-0.310
Standard
25 Clearance between master pin -0.2 +0.915 clearance
47
(*) and bushing -0.4 +0.415
0.615-1.315
PC350LC/HD-8 10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Triple Grouser Shoe
PC350LC-8
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
36 24
2 Thickness 11
3 32
Length at of base
4 26 Build-up welding for
5 24 rebuilding or replace
6 Length at tip 18
7 18
Standard size Repair limit
8 Thickness
47 35
10-38 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC350HD-8
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
37 22
2 Thickness 13
3 33
Length at of base
4 27 Build-up welding for
5 25.5 rebuilding or replace
PC350LC/HD-8 10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM
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
10-40 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PC350LC/HD-8 10-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Hydraulic Tank and Filter
Specifications
10-42 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Hydraulic Pump
Type: HPV125+125
10-44 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Outline
• 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
Torque
N•m lbf ft
8. Plug 19.6 - 37.4 14.4 - 20.2
9. Plug 98 - 123 72.2 - 90.7
10. Plug 11.8 - 14.7 8.7 - 10.8
11. Screw 6.9 - 9.8 5.0 - 7.2
12. Screw 11.8 - 14.7 8.7 - 10.8
13. Drain plug 58.8 - 78.4 43.3 - 57.8
14. LS valve 132 - 157 97.3 - 115.7
PC350LC/HD-8 10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Torque
N•m lbf ft
14. Plug 7.8 - 9.8 5.7 - 7.2
15. Plug 58.8 - 78.4 43.3 - 57.8
16. Bolt 246.3 - 308.7 181.6 - 227.6
17. Bolt 245 - 309 180.7 - 227.9
18. Valve 637 - 764.4 469.8 - 563.7
10-46 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• The pump converts the engine rotation transmitted to the shaft to oil pressure and delivers pressurized oil corresponding to
the load.
• It is possible to change the discharge amount by changing the swash plate angle.
Structure
PC350LC/HD-8 10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
• Cylinder block (7) rotates together with shaft (1), and shoe (5) slides
on flat surface (A).
• When this happens, rocker cam (4) moves along cylindrical surface
(B), so angle (a) between center line (X) of rocker cam (4) and the
axial direction of cylinder block (7) changes.
• (a) is named the swash plate angle.
• With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
• In this way, piston (6) slides on the inside of cylinder block (7), so a
difference between volumes (E) and (F) is created inside cylinder
block (7).
• A single piston (6) sucks and discharges the oil by the amount
(F) – (E).
• As cylinder block (7) rotates and the volume of chamber (E)
becomes smaller, the pressurized oil is discharged.
• On the other hand, the volume of chamber (F) grows larger and, in
this process, the oil is suctioned.
• As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) (swash plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7) becomes 0.
• Suction and discharge of pressurized oil is not carried out in this
state. Namely pumping action is not performed. (Actually, however,
the swash plate angle is not set to 0)
10-48 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Control of discharge amount
• If the swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and pump delivery (Q)
increases.
• Servo piston (12) is used for changing swash plate angle (a).
• Servo piston (12) carries out linear reciprocal movement according
to the signal pressure from the PC and LS valves.
• This linear movement is transmitted to rocker cam (4) via slider (13).
• Being supported by cradle (2) on the cylindrical surface, rocker cam
(4) slides on the surface while continuing revolving movement.
• Space of the pressure receiving area of servo piston (12) are not
identical on the left side and right side. Main pump discharge
pressure (self pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
• Output pressure (PEN) of the LS valve is brought to the chamber
receiving the pressure at the large diameter piston end.
• The relationship in the size of pressure (PP) at the small diameter
piston end and pressure (PEN) at the large diameter piston end, and
the ratio between the area receiving the pressure of the small
diameter piston and the large diameter piston controls the movement
of servo piston (12).
PC350LC/HD-8 10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS Valve
Function
Front Pump
• The LS (load sensing) valve detects the load and controls the
discharge amount.
• This valve controls main pump delivery (Q) according to
differential pressure (ΔPLS)[= PP ~ LS], called the LS differential
pressure (the difference between main pump pressure PP and
control valve outlet port pressure PLS).
• Main pump pressure (PP), pressure (PLS) (called the LS pressure)
coming from the control valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional solenoid valve enter
this valve.
Rear Pump
• The relationship between the LS differential pressure between the
main pump pressure (PP) and LS pressure (PLS) (ΔPLS) [= (PP) -
(PLS)] and the pump delivery (Q) changes as shown in the diagram
according to LS selector current (ISIG) of the LS-EPC valve.
• If (ISIG) changes from 0 to 1A, setting force the spring changes,
too. As the result, the specified median of the pump delivery
volume switching point changes as shown in the diagram. As for
the front pump side, it will change in the range of 0.98 to 2.45 MPa
{in the range of 10 to 25 kg/cm2} and as for the rear pump side, it
will change in the range of 1.08 to 2.55 MPa {in the range of 11 to
26 kg/cm2}.
10-50 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
• The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve
brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (self
pressure) (PP) determine the position of spool (6).
• However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for the LS valve
entering port (G) also changes the position of spool (6). (Setting force of the spring is changed)
• Before the engine is started, servo piston (12) is pushed to the right. (See the figure)
• If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/
cm2}. (It is interconnected to the drain circuit via the control valve spool)
• Spool (6) is pushed to the right, and port (C) and port (D) will
be connected.
• Pump pressure (PP) is conducted to the larger diameter end
from the port (K).
• The same pump pressure (PP) is conducted to the smaller
diameter end from the port (J).
• According to the difference in the areas on servo piston (12),
the pressure moves in such that the swash plate angle may be
minimized.
PC350LC/HD-8 10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Action for the direction of maximizing the pump delivery
• When the difference between the main pump pressure (PP) and LS pressure (PLS), in other words, LS differential
pressure (ΔPLS) becomes smaller (for example, when the area of opening of the control valve becomes larger and
pump pressure PP drops), spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of
spring (4).
• When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve.
• The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT).
(The operation of the PC valve is explained later.)
• The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP)
enters port (J) at the small diameter end, so servo piston (12) is pushed to the left side. Therefore, the swash plate is
moved in the direction to make the discharge amount larger.
• If the output pressure of the EPC valve for the LS valve enters port (G), rightward force is generated on piston (7).
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential pressure
(ΔPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected.
10-52 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. Action for the direction of minimizing the pump delivery
• When LS differential pressure (ΔPLS) becomes larger (for example, when the area of opening of the control valve
becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo
piston (12), pump pressure (PP) pushes spool (6) to the right.
• When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large
diameter end of the piston.
• Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in
area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the right. As the
result, servo piston (12) moves into the direction of reducing the swash plate angle.
• As LS selector pressure (PSIG) is input to port (G), setting force of spring (4) is reduced.
PC350LC/HD-8 10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
4. When servo piston is balanced
• Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the
pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as
(PEN).
• If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are
balanced, and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position.
• And the swash plate of the pump will be held in an intermediate position. [Spool (6) will be stopped at a position
where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the
same.]
• At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0): (A1) = 3: 5, so the
pressure applied across the piston when it is balanced becomes (PP): (PEN) approximately 5: 3.
• Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when
(PP) - (PLS) = 25 kg/cm2 (355.5 psi) on the front pump side and (PP) - (PLS) = 26 kg/cm2 (369.8 psi) on the rear
pump side at the median of the specified value.
• If (PSIG) [Output pressure of LS-EPC valve, 0 to 30 kg/cm2 (0 to 426.7 psi)] is input to port (G), the position of the
balanced stop is changed. The front pump side will be moved in the range of (PP) - (PLS) = 25 to 0 kg/cm2 (355.5
psi) and the rear pump will be moved in the range of (PP) - (PLS) = 26 to 11 kg/cm2 (369.8 to 156.4 psi) in proportion
to (PSIG) pressure.
10-54 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PC Valve
1. Plug
2. Servo piston assembly PA : Pump port
3. Pin PA2 : Pump pressure pilot port
4. Spool PDP : Drain port
5. Retainer PM : PC Mode selector pressure pilot port
6. Seat PPL : LS Control pressure output port
7. Cover
8. Wiring
Function
• When the pump discharge pressure (PP1) (self-pressure) and (PP2) (other pump pressure) are high, the PC valve controls
the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however
you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it
may not exceed the engine hose power.
• If the pump discharge pressure increases due to increased load during operation, this valve decreases the pump delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• In this case, relation between the mean discharge 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.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed.
• If the engine speed goes below the specified value because of
increased load, the controller sends a command current to PC-EPC
valve solenoid in order to reduce the slope angle in proportion to
reduction in the engine speed.
PC350LC/HD-8 10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
1. When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
• Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller.
• This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston (2).
• Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4) and
(6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure).
• The pressure [port (C) pressure] output from PC valve is changed depending on the above position.
• The size of command current (X) is determined by the nature of the operation (lever operation), the selected working
mode, and the set value and actual value of the engine speed.
★ Other pump's pressure denotes the pressure of the pump situated on the opposite side.
★ For the front pump pressure, the other pump's pressure is that of the rear pump.
★ And for the rear pump pressure, the other pump's pressure is that of the front pump.
10-56 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Action of spring
• Load of springs (4) and (6) on the PC valve is determined by the swash plate position.
• As servo piston (9) moves to right, spring (6) is retracted.
• If the servo piston moves further, it will make contact against seat (5) and spring (6) will be fixed.
• After that, spring (4) alone will operate.
• The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6).
• If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).
• Spring load of springs (4) and (6) is also affected by the command current (X) to PC-EPC valve solenoid.
• Port (C) of the PC valve is connected to port (E) of the LS valve.
• Self pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and other pump pressure (PP2) enters
port (A).
• When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the left side.
• Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
• If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port
(J) becomes drain pressure (PT), and servo piston (9) moves to the left side.
• The pump delivery will be set to the increasing trend.
• Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker.
• As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and
the pump discharge pressure ports (B) and (C) are connected.
• As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the
leftward move of servo piston (9) is stopped.
• Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the
pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the
pushing force of springs (4) and (6) are balanced.
PC350LC/HD-8 10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When load on actuator is large and pump discharge pressure is high
Outline
• When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right
becomes larger and spool (3) will be moved to the position shown in above figure.
• Part of the pressure to be conducted from port (C) to LS valve flows from port (B) to port (C) and (D) via LS valve. At the
end this flow, level of this pressure becomes approximately half of the main pump pressure (PP2).
Operation
• When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of
servo piston (9), stopping servo piston (9).
• If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to
port (C) and acts to make the pump delivery the minimum.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).
• When spool (3) moves to the left, the opening of port (C) and port (D) becomes larger.
• As a result, the pressure on port (C) (= J) is decreased and the rightward move servo piston (9) is stopped.
• 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.
10-58 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
• The relationship between the average pump pressure (PP1 + PP2)/2
and servo piston (9) in terms of their positions can be represented
by the broken line in the figure springs (4) and (6) form the double
springs.
• The relationship between the average pump pressure (PP1 + PP2)/2
and average pump delivery (Q) becomes as shown below.
PC350LC/HD-8 10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
As the emergency pump drive switch is turned on due to failure on the pump controller
3. As the emergency pump drive switch is turned on due to failure on the pump controller
• If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor
side.
• In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in
between to control the current flowing to PC-EPC valve solenoid (1).
• The current becomes constant, so the force pushing piston (2) is also constant.
• If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve
solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left.
• At this point, port (C) is connected to the drain pressure of port (D), and the large diameter end of the piston of servo
piston (9) also becomes the drain pressure (PT) through the LS valve.
• Since the pressure on the small diameter end of the piston large, servo piston (9) moves in the direction to make the
discharge amount larger.
10-60 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
When the main pump is under heavy load
• If the emergency pump drive switch is turned on In the same way as in above, the command current (X) sent to PC-EPC
valve solenoid (1) becomes constant.
• For this reason, the force of piston (2) pushing spool (3) is constant.
• If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the right than when the main pump load is
light, and is balanced at the position in the diagram above.
• In this case, the pressure from port (B) flows to port (C), so servo
piston (9) moves to the right (smaller pump delivery) and stops at a
position to the further to the right then when the load on the pump is
light.
• 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 corresponding to the current sent to the
PC-EPC valve solenoid through the resistor.
• The curve resulting when the emergency pump drive switch is ON
is situated further to the left (B) than when the pump controller is
normal (A).
PC350LC/HD-8 10-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS(PC)-EPC Valve
1. Connector
2. Coil
3. Body C: To LS (PC) valve
4. Spring P: From self pressure reducing valve
5. Spool T: To tank
6. Rod
7. Plunger
Torque
N•m lbf ft
8. Screw 0.1 - 0.3 0.07 - 0.22
9. Bolt 9.8 - 12.7 7.2 - 9.3
10-62 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
• When it receives signal current (i) from the controller, it generates
the EPC output pressure in proportion to the size of the signal, and
outputs it to the LS (PC) valve.
Operation
PC350LC/HD-8 10-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When signal current is very small (coil is energized)
• When a very small signal current flows to coil (2), coil (2) is
energized, and a propulsion force is generated on the right side
of plunger (7).
• Rod (6) pushes spool (5) to the right, and pressurized oil flows
from port (P) to port (C).
• Pressures on port (C) increases and the force to act on spool (5)
surface and the spring load on spring (4) become larger than
the propulsion force of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port
(C).
• Port (C) and port (T) are connected.
• Spool (5) moves up and down so that the propulsion force of
plunger (7) may be balance with pressure of port (C) + spring
load of spring (4).
• The circuit pressure between the EPC valve and the LS (PC)
valve is controlled in proportion to the size of the signal
current.
10-64 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Variable Volume Valve
1. Plug
C1: To PC valve
2. Block
P1: From self pressure reducing valve
3. Piston
T1: To tank
4. Spring
Torque
N•m lbf ft
5. Plug 44.1 - 53.9 32.5 - 39.7
Function
• The variable volume valve stabilizes the EPC valve's output
pressure.
Operation
• 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).
• Piston (3) is pushed to the left, and volume of port (C) is increased.
• The propulsion force of piston (3) becomes smaller than the load of
spring (4).
• Piston (3) is pushed toward right, and volume of port (C) is
decreased.
PC350LC/HD-8 10-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Control Valve
Outline
• 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 and boom drift preventive valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the
assembly, the assembly is compact and easy to maintain.
A1: To bucket cylinder bottom P-5: From service 2 and PPC valves
A2: To L.H. travel motor P-6: From service 2 and PPC valves
A3: To boom cylinder bottom PLS1: To front pump control
A4: To swing motor PLS2: To rear pump control
A5: To R.H. travel motor PP1: From front pump
A6: To arm cylinder head PP2: From rear pump
A-1: To boom cylinder bottom PP1S: Pressure sensor mounting port
A-2: To attachment 1 PP2S: Pressure sensor mounting port
A-3: To attachment 2 PPS1: To front pump control
B1: To bucket cylinder head PPS2: To rear pump control
B2: To L.H. travel motor PR: To solenoid valve, PPC valve, and EPC valve
B3: To boom cylinder head PS: From merge-divide solenoid valve
B4: To swing motor PST: From travel junction valve solenoid valve
B5: To R.H. travel motor PX1: From 2-stage relief solenoid valve
B6: To arm cylinder bottom PX2: From 2-stage relief solenoid valve
B-1: To arm cylinder bottom T: To tank
B-2: To attachment 1 T1: To tank
B-3: To attachment 2 TS: To tank
BP1: Boom raising PPC output pressure TSW: To swing motor S-port (suction side)
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve 1. 6-spool valve
P1: From bucket PPC and EPC valves 2. Cover A
P2: From bucket PPC and EPC valves 3. Cover B
P3: From L.H. travel PPC valve 4. Boom Hi and arm Hi valve
P4: From L.H. travel PPC valve 5. Service valve 1
P5: From boom PPC and EPC valves 6. Service valve 2
P6: From boom PPC and EPC valves 7. Merge-divider valve
P7: From swing PPC and EPC valves 8. Boom drift preventive valve
P8: From swing PPC and EPC valves 9. Quick return valve
P9: From R.H. travel PPC valve 10. Boom Hi valve check valve
P10: From R.H. travel PPC valve Torque
P11: From arm PPC and EPC valves N•m lbf ft
P12: From arm PPC and EPC valves 11. Bolt 156.9-176.5 115.7-130.1
P-3: From service 1 and PPC valves 12. Bolt 27.5-34.3 20.2-25.2
P-4: From service 1 and PPC valves 13. Bolt 58.8-73.6 43.3-54.2
10-66 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
General view
PC350LC/HD-8 10-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Sectional view (1/5)
10-68 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Pressure compensation valve (Arm out) 16. Pressure compensation valve (Arm in)
2. Pressure compensation valve (R.H. travel reverse) 17. Main relief valve
3. Pressure compensation valve (Left swing) 18. Unload valve
4. Pressure compensation valve (Boom raise) 19. Unload valve
5. Pressure compensation valve (L.H. travel reverse) 20. Main relief valve
6. Pressure compensation valve (Bucket dump) 21. Spool (Service 2)
7. Pressure compensation valve (Boom Hi raise) 22. Spool (Service 1)
8. Variable pressure compensation valve (Service 1) 23. Spool (Boom Hi)
9. Variable pressure compensation valve (Service 2) 24. Spool (Bucket)
10. Pressure compensation valve (Arm Hi in) 25. Spool (L.H. travel)
11. Pressure compensation valve (Bucket curl) 26. Spool (Boom)
12. Pressure compensation valve (L.H. travel forward) 27. Spool (Swing)
13. Pressure compensation valve (Boom lower) 28. Spool (R.H. travel)
14. Pressure compensation valve (Right swing) 29. Spool (Arm)
15. Pressure compensation valve (R.H. travel forward) 30. Spool (Arm Hi)
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
417 N 333 N
31 Spool return spring 54.2 x 34.8 51.2 {42.5 kg} - {34.0 kg} If damaged or
393 N 315 N deformed, replace
32 Spool return spring 54.5 x 34.8 51.2 - spring.
{40.1 kg} {32.1 kg}
421 N 336 N
33 Spool return spring 54.6 x 34.8 51.2 -
{42.9 kg} {34.3 kg}
251 N 201 N
34 Spool return spring 54.9 x 24.2 52.0 -
{25.6 kg} {20.5 kg}
Torque
N•m lbf ft
35 Valve 372.7 - 411.9 274.8 - 303.8
36 Plug 65.7 - 85.3 48.4 - 62.9
37 Plug 33.3 - 43.1 24.5 - 31.7
PC350LC/HD-8 10-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(2/5)
10-70 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed If damaged or
24 Suction valve spring Free length
Outside diameter length load load deformed,
46.8 x 7.5 40.6 5.5 N — 4.4 N replace spring.
25 Check valve spring 11.5 x 4.6 8.5 1.5 N — 1.2 N
Torque
N•m lbf ft
26. Plug 137.3 - 156.9 101.2 - 115.7
27. Plug 19.6 - 27.5 14.4 - 20.2
28. Valve 107.9 - 147.1 79.5 - 108.4
29. Plug 34.0 - 44.0 25.0 - 32.4
PC350LC/HD-8 10-71
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(3/5)
10-72 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load If damaged or
19.6 N 15.7 N deformed, replace
50.0 x 14.4 42.0 - spring.
22 Spool return spring {2.0 kg} {1.6 kg}
5.9 N 4.71 N
23 Check valve spring 31.5 x 10.3 19.5 -
{0.6 kg} {0.48 kg}
Torque
N•m lbf ft
24 Valve 137 - 157 101.0 - 115.7
25 Valve/Plug 147.1 - 186.3 108.4 - 137.4
26 Valve 49 - 58.8 36.1 - 43.3
PC350LC/HD-8 10-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(4/5)
10-74 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Return spring L.H. travel valve
2. Merge-divide valve (for LS)
15. Merge-divider valve (travel junction valve)
3. Valve (Sequence valve)
16. Return spring
4. Spring (Sequence valve)
17. LS shuttle valve
5. Merge-divide valve (Main)
18. Pressure compensation valve (Forward)
6. Return spring
19. Spool
20. Suction valve (Forward)
21. Suction valve (Reverse)
22. Pressure compensation valve (Reverse)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
157 N 126 N
46.6 x 21.8 33.0 -
29 Spool return spring {16.0 kg} {12.8 kg}
250 N 200 N
30 Check valve spring 70.9 x 18.0 56.0 -
{25.5 kg} {20.4 kg}
178 N 142 N If damaged or
31 Spool return spring 64.5 x 32.3 63.0 -
{18.1 kg} {14.5 kg} deformed,
replace spring.
35.3 N 28.2 N
32 Check valve spring 33.0 x 12.0 26.0 -
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
33 Check valve spring 16.4 x 8.9 11.5 -
{1.4 kg} {1.12 kg}
Check valve spring 5.9 N 4.71 N
34 31.5 x 10.3 19.5 -
{0.6 kg} {0.48 kg}
Piston return spring 50.0 N 40.0 N
35 30.7 x 20.5 23.0 -
{5.1 kg} {4.08 kg}
PC350LC/HD-8 10-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(5/5)
10-76 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Service valve 1
8. LS shuttle valve
9. Pressure compensation valve
10. Spool
11. 2-stage safety-suction valve
12. Safety-suction valve
Torque
N•m lbf ft
20 End bolt 19.6 - 24.5 14.4 - 18.0
21 Plug 65.7 - 85.3 48.4 - 62.9
22 Plug 24.5 - 34.3 18.0 - 25.2
23 Valve 49 - 58.8 36.1 - 43.3
24 Valve 147.1 - 186.3 108.4 - 137.4
25 Valve 51.9 - 65.7 38.2 - 48.4
26 Valve 34.3 - 44.1 25.2 - 32.5
PC350LC/HD-8 10-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
CLSS (Closed Center Load Sensing System)
Outline of CLSS
Features
CLSS stands for Closed Center Load Sensing System, which has the following characteristics:
• Fine control not influenced by load.
• Controllability enabling digging even with fine control.
• Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
• Energy saving using variable pump control.
Configuration
• CLSS is configured with variable capacity piston pumps, control valves, and respective actuators.
• The hydraulic pump is configured with pump body, PC valve and LS valve.
10-78 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Basic principle
PC350LC/HD-8 10-79
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Pressure compensation control.
• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When two actuators are operated together, this valve acts to make pressure difference ΔP between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
• In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of
each valve.
10-80 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. System Diagram
★ The illustration shows the actuator (7) in the merge mode with stroke end at the time of relief.
PC350LC/HD-8 10-81
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Valve Functions and Operation
Hydraulic Circuit Diagram and the Name of Valves
10-82 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PC350LC/HD-8 10-83
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Unloader Valve
When Valve is Actuated
Function
• Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are in the holding.
• The pump pressure will correspond to inside the valve set a load of spring (5) (this pressure will be P1).
• Since LS pressure is drained from the LS bypass valve, LS pressure approximately tank pressure 0 kg/cm2 (0 psi).
Operation
10-84 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
• During operation (a work within a scope of discharge by a
minimum swash plate angle), the discharge pressure for the portion
of minimum pump swash plate angle is set to LS pressure + P1
pressure.
• LS control differential pressure (ΔPLS) of discharge for the
portion of minimum swash plate angle will be equal to P1 pressure.
• When the cylinder reaches the stroke end, the main relief valve
opens.
• The pump delivery (Q) is relieved to the tank.(See the system
diagram)
• The pump discharge pressure (PP) and LS pressure (PLS) become
approximately the same flow at the upstream and downstream of
the spool, and LS differential pressure (ΔPLS) becomes 0 kg/cm2.
• As LS differential pressure (ΔPLS) is lower than the LS set
pressure of LS valve, LS valve is actuated to maximize the pump
swash plate angle.
• Mechanically, operation of PC valve has priority over the LS valve.
• The pump is held at a minimum swash plate angle by the cut-off function of PC valve.
PC350LC/HD-8 10-85
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS Pressure
Function
• Introduces the upstream pressure (downstream pressure of the spool meter-in) of pressure compensation valve (3) and
leads to LS shuttle valve (7) as the LS pressure.
• Connected to actuator port (B) via valve (4), and makes LS pressure approximate actuator load pressure.
• Inlet pore (a) inside main spool (2) has a small diameter concurrently serving as a throttle.
Operation
• When main spool (2) is operated, the pump pressure enters port (c) via inlet port (a) and is led to the LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens.
10-86 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS bypass plug
Function
• Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Bypass flow from LS bypass valve (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).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
PC350LC/HD-8 10-87
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Pressure Compensation Valve
Function
• High stress may occur when valve (2) collides with valve chamber
seat portion (C) if a high peak pressure is generated in the actuator
circuit or repetitive peak pressure occurs continuously (example:
when using the breaker).
• To prevent this, a pressure compensation valve with integrated valve
(2) and piston (4) is used.
• With the present machine, this device is adopted for the bucket valve
(cylinder bottom) and the service valve.
• As principle, port (C) and spring chamber (E) are not interconnected
in an integrated pressure compensation valve.
• If high peak pressure is generated at port (C), valve (7) does not col-
lide with the valve chamber.
• With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is seated.
10-88 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
2. When compensated.
★ If the load pressure is lower than other work equipment during a combined operation.
Function
• 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.
• 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.
• Pump flow is divided according to the ratio of the meter-in opening area.
Operation
PC350LC/HD-8 10-89
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. Pressure compensation valve area ratio.
Function
• The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2). Area ratio =
(A2)/(A1)
• If area ratio = 1 : the spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure
will be divided according to the opening area ratio.
• 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.
• 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.
10-90 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Pressure Compensation Valve Inner Shuttle
1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B).
Function
• Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection between ports (A) and (C).
• Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) and valve (2)
will not be separated.
PC350LC/HD-8 10-91
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. In the case of travel.
Outline
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve without shuttle
valve (3) is adopted.
10-92 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Boom Regeneration Circuit
1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.).
Function
• Provides the regeneration circuit from the cylinder bottom to the cylinder head when the boom is lowered and increases
flow to the cylinder bottom.
Operation
• If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain
circuit (B) from the notch of boom spool (2).
• On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head
via circuit (D).
• Flow from regeneration circuit (C) and pump (1) merges in circuit (E).
PC350LC/HD-8 10-93
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.).
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
10-94 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Arm Regeneration Circuit
Function
• During arm digging, regeneration circuit provided from the cylinder head to the bottom increases the cylinder speed as the
cylinder flow involves the pump delivery plus regenerated flow.
Operation
• If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain
circuit (B) from the notch of arm spool (2).
• On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head
via circuit (D).
• Flow from regeneration circuit (C) and pump (1) merges in circuit (E).
PC350LC/HD-8 10-95
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. If the cylinder head pressure is lower than the bottom pressure.
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
10-96 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Merge-divider Valve
1. When flows from the pumps merge [if pilot pressure (PS) is OFF] .
Function
• Merges pressurized oil (P1) and (P2) discharged from the two pumps or divides (to respective control valve group).
• Merges and divides LS circuit pressure.
Operation
• Since pilot pressure (PS) is OFF, output pressure from PPC valve is 0 kg/cm2 (0 psi).
• Main spool (1) is pressed to the right by spring (2) and ports (E) and (F) are interconnected.
• Merges pressurized oil (P1) and (P2) discharged from the two pumps at ports (E) and (F) and sends to necessary control
valve.
• 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 interconnected.
• Forwards LS pressure led from respective control valve spools to LS circuits (5), (6), (7) and (8) to all the pressure
compensation valves.
PC350LC/HD-8 10-97
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
2. When flows from the pumps are divided [if pilot pressure (PS) is ON].
Operation
• Pilot pressure (PS) turns ON, and output pressure from the PPC valve shifts main spool (1) to the left, and ports (E) and
(F) are divided.
• Pressurized oil discharged from the two pumps are sent to respective control valves.
• LS spool (3) too shifts to the left under the output pressure from the PPC valve, interconnects ports (A) and (C) and
divides other ports.
• Forwards LS pressure led from each control valve spool to LS circuits (5), (6), (7) and (8) to respective control valves.
10-98 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS Select Valve
Function
• Prevents high LS pressure from the swing circuit from entering the
LS circuit of work valves while the swing and work equipment are in
combined operation.
• Prevents high pressure generated during swing operation and
improves operability of work equipment.
Operation
PC350LC/HD-8 10-99
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Self Pressure Reducing Valve
Function
Operation
• Valve (14) is pressed by spring (13) against the left side and port
(P2) is connected to (TS).
10-100 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12 • Valve (7) is pressed by spring (8) against the left side and port
(P2) is closed to (A2).
PC350LC/HD-8 10-101
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When load pressure (P2) is high.
• Load pressure (A2) increases with the operation of digging, etc.,
and the pump discharge increases accordingly.
• Pressure (P2) increases to [(φd area x P2 pressure) = force of
spring (8) + (φd area x PR pressure)]., and valve (7) moves to
the right to the stroke end.
• As a result, opening between ports (P2) and (A2) increases, and
the pass resistance reduces, reducing the engine horsepower
loss.
• When pressure (PR) rises above the set pressure, poppet (11)
opens.
• Pressurized oil flows from port (PR) to orifice (a) in spool (14),
then flows to seal drain port (TS) from poppet (11) opening.
• Differential pressure is generated before and after orifice (a) in
spool (14) and then spool (14) moves to close the pass between
ports (P2) and (PR).
• Pressure (P2) is reduced by the opening at this time and adjusted
to a constant pressure (the set pressure) and supplied as pressure
(PR).
10-102 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Travel Junction Valve
1. When pilot pressure is turned ON.
Function
• This valve connects the L.H. and R.H. travel circuits via travel junction valve so that the hydraulic oil will be supplied
evenly to both travel motors to improve machine's straight travel performance.
• When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to improve steering
performance.
Operation
• Pilot pressure from the travel junction solenoid valve contracts spring (1), and travel junction spool (2) moves to the left to
the stroke end.
• Junction circuit between port (PTL) (L.H. travel circuit) and port (PTR) (R.H. travel circuit) is closed.
PC350LC/HD-8 10-103
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
2. When pilot pressure is turned OFF.
Operation
• If pilot pressure (PST) from the solenoid valve is 0, travel junction spool (2) is pressed by the force of spring (1) against
the right side and the pass between ports (PTL) and (PTR) is open.
• If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the oil flows through the route
between port (PTL), travel junction spool (2), and port (PTR) so that the oil flow rates to both motors will be equalized
again.
10-104 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Travel PPC Shuttle Valve
1. When travel lever is in neutral.
Function
• Regulates flow to each cylinder by controlling the stroke of each spool of the boom, arm, and bucket using the pilot
pressure of travel PPC valve while climbing a steep grade, raising the boom, digging with arm, dumping, bucket-digging
or operating dump.
• When controlling the stroke of the boom, arm and/or bucket, pilot pressure of travel PPC valve passes through the circuit
inside the control valves to actuate the system.
Operation
• The oil in stroke regulation signal chamber (a) is drained through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case and the travel PPC valve.
• When operated for boom raising (or arm digging, dumping, bucket digging, dumping), spool (1) moves to the left until it
makes contact with the end face of spring casing (2) (st0).
PC350LC/HD-8 10-105
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When traveling.
Operation
• If the right travel lever is set in the reverse (or forward) direction, pilot pressure from the PPC valve presses spool (7) to
the left (or right).
• 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.
• 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.
• When operated for boom raising (or arm IN, OUT, bucket CURL, DUMP), spool (1) moves to the left.
• Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.
10-106 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Boom Drift Prevention Valve
Function
• 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
• When the boom is raised, pressurized oil from the control valve works on the ring-shaped area (S)[= φ(d1) area – φ(d2)
area] caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the left.
• Contracts spring (4) and poppet (5) moves to the left.
• 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.
PC350LC/HD-8 10-107
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When the boom is in neutral.
Operation
10-108 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When lowering boom.
Operation
• When the boom is lowered, pilot pressure from the PPC valve presses pilot spool (2).
• Pressurized oil in chamber (b) inside the poppet is drained via orifice (c).
• Pressurized oil of the boom bottom flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressurized oil in
chamber (b) lowers.
• As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens.
• Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
PC350LC/HD-8 10-109
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Arm Drift Prevention Valve
(if equipped)
Function
• 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
• When the arm OUT is operated, pressurized oil from the control valve works on the ring-shaped area
(S)[= φ(d1) area – φ(d2) area] caused by the difference between the outside diameter (d1) of poppet (5) and the seat
diameter (d2) to move it to the left.
• Contracts spring (4) and poppet (5) moves to the left.
• As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder
head.
10-110 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When the arm is in NEUTRAL.
Operation
PC350LC/HD-8 10-111
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When arm IN.
Operation
• When the arm IN is operated, pilot spool (2) is pushed under the pilot pressure from the PPC valve.
• Pressurized oil in chamber (b) inside the poppet is drained via orifice (c).
• Pressurized oil of the arm head flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressurized oil in
chamber (b) lowers.
• As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens.
• Pressurized oil from port (B) is led to port (A) and then flows to the control valve.
10-112 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
4. When abnormally high pressure is generated.
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes
check valve (6) open, then safety valve (3) operates.
• If arm drift prevention valve (optional) is installed to the arm cylinder head circuit, the boom cylinder bottom circuit
pressure force or arm cylinder head circuit pressure force, whichever having higher pressurized oil, pushes check
valve (6) or (6A) open to actuate safety valve (3).
PC350LC/HD-8 10-113
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Quick Return Valve
Function
• When arm OUT, large volume of oil returns from the cylinder bottom.
• Reduces this pressure loss.
Operation
• When the arm OUT is operated, pilot spool (1) is pushed under the pilot pressure from the PPC valve.
• Pressurized oil in chamber (b) inside the valve is drained via orifice (c).
• Pressurized oil of the arm bottom side flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressure in
chamber (b) lowers.
• If the pressure of chamber (b) drops lower than that of port (A), pressure receiving force of the pressure receiving portion
[φd2 area (S2) (seat diameter area)] on the side of port (A) increases by the sum of the pressure receiving force of pressure
receiving portion[φd1 area (S1)] on the chamber (b) side of valve (2) and the spring force.
• Or (φd2 pressure receiving force > φd1 pressure receiving force + spring force)
• Valve (2) is pressed to the left and pressurized oil is led from port (A) to (B).
• From port (B), pressurized oil is drained directly to the tank.
10-114 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When the arm is in NEUTRAL.
Operation
• Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/cm2 (0 psi).
• The pressurized oil that has flowed and been drained through orifice (a) in valve (2) is closed by pilot piston (1).
• The holding pressure on the arm bottom side works on the difference between areas (S2) and (S1) of valve (2) to the right.
• Valve (2) is closed by the total of this force and the force of spring (3), so ports (A) and (B) are shut off.
PC350LC/HD-8 10-115
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Lift Check Valve
Function
Operation
10-116 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Main Relief Valve
1. Spring 2. Poppet
Function
Operation
• The set pressure of relief valve is determined by spring (1) installed load. (1st stage)
• Respective setting is not required for both the 1st and 2nd stages. Setting the 1st stage completes the setting of the 2nd
stage.
PC350LC/HD-8 10-117
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2-Stage Safety-suction Valve
★ Installed to port (B) on the boom cylinder head side and port (B) of the service valve.
1. Spring 3. Spring
2. Piston 4. Holder
Function
• Enables to provide the safety valve set pressure in two stages, and make the low-pressure setting smaller.
• Enables to relieve a load without lever operation if high load is applied to the cylinder.
• Improves work efficiency and reduces machine body vibration.
Operation
10-118 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. If pilot pressure is ON (low-pressure setting).
• If the pilot pressure (P) is ON, the pilot pressure is led to
section (A) via passage (B).
• Piston (2) works on the pressure-receiving bore portion
[(d2) − (d1)] of section A.
• This pilot pressure contracts spring (3), and piston (2) moves to
the right until making contact with holder (4).
• Spring (1) stretches, installed load is reduced, and the set
pressure lowers.
• Pressurized oil proportionate to the piston stroke is drained via
passage (C) and chamber (D).
PC350LC/HD-8 10-119
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Variable Pressure Compensation Valve
(Installed to the service valve)
1. Valve 5. Spring
2. Spring 6. Screw
3. Sleeve 7. Locknut
4. Poppet 8. Cap
Function
• Regulates flow distribution to the service valve when the service valve (attachment) and the work equipment valve (boom
raising, etc.) are operated together. (Equivalent surface area ratio variable)
• Pressurized oil from the service valve spool is applied to the left side of valve (1) and is led to chamber (g) via orifice (a).
• LS pressure is led to chamber (e) via orifice (d).
• Pressurized oil of cylinder port is led to chamber (h) via passage (c) and orifice (f).
• The force of spring (2) acts on valve (1), and the force of spring (5) acts on poppet (4).
• The force of spring (5) can be adjusted with screw (6).
10-120 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
P x A1 = P x A2 + LS(A2 – 1) + F
PC350LC/HD-8 10-121
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Attachment Circuit Selector Valve
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
If damaged
Free length x Installed Installed Installed or
Free length
Outside diameter length load load deformed,
replace
834 N 667 N spring.
132 x 29 114.5 --
3 Spool return spring {85.0 kg} {68.0 kg}
Torque
N•m lbf ft
4 Bolt 59 - 74 43.5 - 54.5
10-122 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• When a breaker is installed, the return oil from the breaker does not
pass through the main valve, but returns directly to the hydraulic
tank.
• When other attachments (crusher, etc.) are installed, the attachment
and the main valve are interconnected.
Operation
PC350LC/HD-8 10-123
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Drift Prevention Valve
(For the boom and arm)
10-124 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Spring (1st stage spool) PCY:For pressure pickup port and equalizer circuit
6. Spring
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed Free length
Outside diameter length load load
12.7 N 10.2 N
20.8 x 12.2 13.5 -
7 Check valve spring {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 - spring.
{6.0 kg} {4.8 kg}
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}
Torque
N•m lbf ft
11 Screw 27 - 34 19.9 - 25.0
12 Plug 176.4 - 215.8 130.1 - 159.0
13 Valve 137 - 157 101.0 - 115.7
PC350LC/HD-8 10-125
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• Prevents the pressurized oil from reversing from the work equipment cylinder and the latter from a sudden drop if the
piping bursts between the control valve and the work equipment cylinder.
Operation
10-126 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When pressurized oil flows from the main valve to the cylinder..
When the piping is free of burst:
• Pressurized oil led to chamber (a) from the control valve
becomes higher than the combined force of pressure from work
equipment cylinder circuit chamber (b) and spring (6).
• Check valve (5) opens and chambers (a) and (b) are
interconnected.
• Pressurized oil flows from the control valve to the work
equipment cylinder.
PC350LC/HD-8 10-127
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When returning pressurized oil to the main valve from the work
equipment cylinder.
When the piping is free of burst:
• Holding pressure of the work equipment cylinder is led to
chamber (b) and check valve (5) closes.
• Pilot pressure from the PPC valve is led to port (PI) and reaches
[Pilot Pressure > Force of Spring (3)] (area of d).
• Spool (1) moves to the right to the standby position. (1st stage
stroke)
• At this point, chambers (a) and (b) are not interconnected.
• Pilot pressure further rises, and reaches
[Pilot pressure > Force of spring (2)] (area of d).
• Spool (1) moves further to the right, and chambers (a) and (b)
are interconnected. (2nd stage stroke)
• Pressurized oil returns to the control valve from the work
equipment cylinder.
10-128 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Valve Control
PC350LC/HD-8 10-129
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PPC Valve
Work Equipment and Swing PPC VALVE
P: From self pressure reducing valve P3: L.H. PPC: Swing left/R.H. PPC: Bucket curl
P1: L.H. PPC: Arm out/R.H. PPC: Boom lower P4: L.H. PPC: Swing right/R.H. PPC: Bucket dump
P2: L.H. PPC: Arm in/R.H. PPC: Boom raise T: To tank
10-130 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
If damaged or
Centering spring 17.7 N 13.7 N
42.5 x 15.5 34.0 - deformed,
12 (for ports P3 and P4) {1.80 kg} {1.40 kg} replace
13 Centering spring 29.4 N 23.5 N spring.
44.5 x 15.5 34.0 -
(for ports P1 and P2) {3.0 kg} {2.40 kg}
14 Metering spring 16.7 N 13.7 N
26.5 x 8.15 24.9 -
{1.70 kg} {1.40 kg}
Torque
N•m lbf ft
15 Bolt 11.8 - 14.7 8.7 - 10.8
16 Nut 69 - 88 50.8 - 64.9
17 Nut 39 - 49 28.7 - 36.1
18 Plug 34 - 44 25.0 - 32.3
19 Plug 6 - 11 4.4 - 8.1
20 Plug 4-9 2.9 - 6.6
PC350LC/HD-8 10-131
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
1. When in neutral.
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) via fine
control hole (f) in spool (1).
10-132 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. During fine control.
★ (When control lever is returned)
• When disc (5) starts to be returned, spool (1) is pushed up by the
force of centering spring (3) and the pressure at port (P1).
• Because of this, fine control hole (f) is connected to drain
chamber (D), and the pressurized oil at port (P1) is released.
• If the pressure of port (P1) is lowered excessively, spool (1) is
pushed down by metering spring (2).
• Fine control hole (f) is shut off from drain chamber (D), and it is
almost simultaneously interconnected to pump pressure
chamber (PP).
• Pump pressure is supplied until the pressure at port (P1)
recovers to the level equivalent to the lever position.
• When the spool of the control valve returns, the oil in drain
chamber (D) flows in from fine control hole (f') in the valve on
the side that is not working. The oil passes through port (P2) and
enters chamber (B) to replenish the chamber with pressurized
oil.
4. At full stroke.
• Disc (5) pushes down piston (4), and retainer (9) pushes down
spool (1).
• Fine control hole (f) is shut off from drain chamber (D), and is
interconnected to pump pressure chamber (PP).
• Therefore, the pilot pressure oil from the self pressure reducing
valve passes through fine control hole (f) and flows to chamber
(A) from port (P1) to push the control valve spool.
• The oil returning from chamber (B) passes from port (P2)
through fine control hole (f') and flows to drain chamber (D).
PC350LC/HD-8 10-133
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
MEMORANDUM
10-134 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Travel PPC Valve
Torque
N•m lbf ft
PC350LC/HD-8 10-135
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
10-136 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
12
1. Plate 6. Metering spring
2. Body 7. Valve
3. Piston 8. Dumper
4. Collar 9. Steering signal spool
5. Centering spring 10. Steering signal spool spring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed
Free length
Outside diameter length load load
108 N 86.3 N If damaged or
47.6 x 15.5 32.5 —
11 Centering spring {11.0 kg} {8.8 kg} deformed,
16.7 N 13.7 N replace spring.
12 Metering spring 26.5 x 8.15 24.9 —
{1.7 kg} {1.4 kg}
8.8 N 7.1 N
13 Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}
Torque
N•m lbf ft
14 Bolt 25 - 31 18.4 - 22.8
15 Plug 34 - 44 25.0 - 32.4
16 Plug 24.5 - 34.3 18.0 - 25.2
17 Bolt 19.6 - 27.4 14.4 - 20.2
PC350LC/HD-8 10-137
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Pressure Reducing Valve
Operation
1. When in neutral.
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) via fine
control hole (f) in spool (1).
10-138 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. During fine control.
★ (When control lever is returned)
• When lever (5) starts to be returned, spool (1) is pushed up by
the force of centering spring (3) and pressure at port (P1).
• Because of this, fine control hole (f) is connected to drain
chamber (D), and the pressurized oil at port (P1) is released.
• If the pressure of port (P1) is lowered excessively, spool (1) is
pushed down by metering spring (2).
• Fine control hole (f) is shut off from drain chamber (D), and it is
almost simultaneously interconnected to pump pressure
chamber (PP).
• Pump pressure is supplied until the pressure at port (P1)
recovers to the level equivalent to the lever position.
• When the spool of the control valve returns, the oil in drain
chamber (D) flows in from fine control hole (f') in the valve on
the side that is not working. The oil passes through port (P2) and
enters chamber (B) to replenish the chamber with pressurized
oil.
4. At full stroke.
• Lever (5) pushes down piston (4), and retainer (9) pushes down
spool (1).
• Fine control hole (f) is shut off from drain chamber (D), and is
interconnected to pump pressure chamber (PP).
• Therefore, the pilot pressure oil from the self pressure reducing
valve passes through fine control hole (f) and flows to chamber
(A) from port (P1) to push the control valve spool.
• The oil returning from chamber (B) passes from port (P2)
through fine control hole (f') and flows to drain chamber (D).
PC350LC/HD-8 10-139
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation
1. When in NEUTRAl
• No output is made from respective output ports [from port (P1) to (P4)], travel signal [port (P5)] and steering signal
[port (P6)].
10-140 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. During straight travel.
• When operating L.H. motor forward [port (P2) output] and R.H. motor forward [port (P4) output], pressure of both
L.H. spring chamber (k) and R.H. spring chamber (l) rises high.
• Steering signal spool (j) remains at neutral position and does not output a steering signal to port (P6).
PC350LC/HD-8 10-141
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When steered or pivot-turned.
★ The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.
• If the operation quantities of both levers are different from each other as in the steering operation (if the difference of
the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal.
• The pressure in left spring chamber (k) of steering signal spool (j) is (P2).
• The pressure in right spring chamber (l) is (P4).
• When the pressure state reaches [(P4 - P2) x (Spool section) > Spring set load], the spool is switched to the direction
of the arrow.
• Port (P4) pressure of the L.H. or R.H. PPC valves, whichever having a higher output pressure, is output to port (P6)
as the steering signal.
10-142 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
4. When counter-rotated.
★ The illustration shows the circuit for traveling left reverse and right forward.
• When operating L.H. motor reverse [port (P1) output] and R.H. motor forward [port (P4) output], pressure of the
R.H. spring chamber (l) only rises high.
• Steering signal spool (j) strokes to the left to output the steering signal to port (P6).
PC350LC/HD-8 10-143
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Service PPC Valve (with EPC Valve)
★ For the details of operation, see the paragraph of "Work equipment swing PPC valve."
10-144 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Spool 5. Retainer
2. Piston 6. Block
3. Lever 7. Body
4. Plate 8. EPC valve
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free length Installation
Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 x 15.3 28.4 -
9 Centering spring {12.7 kg} {10.2 kg} spring.
16.7 N 13.3 N
10 Metering spring 22.7 x 8.10 22.0 -
{1.70 kg} {1.36 kg}
Torque
N•m lbf ft
11 Screw 9.8 - 12.7 7.2 - 9.3
12 Bolt 11.76 - 14.7 8.6 - 10.8
PC350LC/HD-8 10-145
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. EPC valve
10-146 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Body 6. Plunger
2. Plug 7. Connector
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Installation Installation Free Installation
Free length length load length load
If damaged or deformed,
3.1 N replace EPC valve
9.0 8.4 - -
8 Return spring {0.32 kg} assembly.
Torque
N•m lbf ft
9 Screw 0.98 - 1.96 0.72 - 1.44
10 Bolt 9.8 - 12.7 7.2 - 9.36
11 Plug 19.6 - 24.5 14.4 - 18.0
12 Plug 7.84 - 11.8 5.7 - 8.7
PC350LC/HD-8 10-147
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
• When it receives signal current (i) from the pump controller, it
generates the EPC output pressure in proportion to the size of the
signal, and outputs it to the control valve.
Operation
10-148 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When signal current is very small.
(coil is energized)
• When a very small signal current flows to coil (5), coil (5) is
energized, and a propulsion force is generated on the left side of
plunger (6).
• Push pin (4) pushes spool (2) to the left, and pressurized oil
flows from port (P) to port (C).
• Pressures on port (C) increases and the force to act on surface
(a) of spool (2) and the spring load on spring (3) become larger
than the propulsion force of plunger (6).
• Spool (2) is pushed to the right, port (P) is shut off from port (C)
and ports (C) and (T) are connected.
• Spool (2) moves up and down so that the propulsion force of
plunger (6) may be balance with pressure of port (C) + spring
load of spring (3).
• The circuit pressure between the EPC valve and the control
valve is controlled in proportion to the size of the signal current.
PC350LC/HD-8 10-149
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Service PPC Valve
★ For the details of operation, see the paragraph of "Work equipment swing PPC valve."
10-150 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Spool 4. Plate
2. Piston 5. Retainer
3. Lever 6. Body
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free Installation
Outside length load length load
diameter If damaged or deformed,
125 N 100 N replace spring
33.9 x 15.3 28.4 -
7 Centering spring {12.7 kg} {10.2 kg}
16.7 N 13.3 N
8 Metering spring 22.7 x 8.10 22.0 -
{1.70 kg} {1.36 kg}
Torque
N•m lbf ft
9 Bolt 11.76 - 14.7 8.6 - 10.8
PC350LC/HD-8 10-151
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Solenoid Valve
★ PPC lock, travel junction, merge-divider, travel speed, swing brake, machine push-up and 2-stage relief solenoid valves
10-152 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring
Operation
PC350LC/HD-8 10-153
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PPC Accumulator
Specifications
10-154 1 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Return Oil Filter
For Breaker
Specifications
PC350LC/HD-8 10-155
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Center Swivel Joint
1. Cover 4. O-ring
2. Body 5. Shaft
3. Slipper seal
A1: To L.H. travel motor port PB C2: From control valve port A5
A2: From control valve port A2 D1: To R.H. travel motor port PB
B1: To L.H. travel motor port PA D2: From control valve port B5
B2: From control valve port B2 E: To L.H. and R.H. travel motors port P
C1: To R.H. travel motor port PA T1: From L.H. and R.H. travel motors port T
T2: To tank
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 80 — —
10-156 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
MEMORANDUM
PC350LC/HD-8 10-157
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Travel Motor - Type: HMV160ADT-2 - PC350LC-8
10-158 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Specifications
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HMV160ADT-2
Theoretical displacement: . . . . . . . . . . . . . . . . . (Min.):103.5 cm3/rev
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Max.):160.8 cm3/rev
Rated pressure: . . . . . . . . . . . . . . . . . . . . . . 380.5 kg/cm2 (5,410 psi)
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Capacity min.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,638 rpm
(Capacity max.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,590 rpm
Brake release pressure: . . . . . . . . . . . . . . . . . 12.0 kg/cm2 (170.6 psi)
Travel speed selector pressure:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . (differential pressure): 7.95 kg/cm2 (113.12 psi)
Torque
N•m lbf ft
PC350LC/HD-8 10-159
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
10-160 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
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,
21 Check valve spring 33.0 x 13.8 23.0 — replace spring.
(0.13 kg) (0.10 kg)
221 N 177 N
22 Regulator piston spring 61.1 x 23.2 43.9 —
(22.5 kg) (18.0 kg)
98.1 N 78.5 N
23 Regulator valve spring 29.6 x 9.0 26.0 —
(10.0 kg) (8.0 kg)
Torque
N•m lbf ft
24 Plug 324 - 402 238.9 - 296.4
25 Plug 123 - 155 90.7 - 114.3
26 Plug 19.6 - 27.5 14.4 - 20.2
27 Valve 372 - 421 274.3 - 310.5
28 Plug 373 - 466 275.1 - 343.7
PC350LC/HD-8 10-161
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation of Motor
• As the solenoid valve is de energized, the pilot pressurized oil from the self pressure reducing valve does not flow to
port (P).
• Regulator valve (21) is pushed to the right by spring (22).
• Pressurized oil being conducted from the control valve to end cover (7) by pressing slow return valve (8) is shut off
by regulator valve (21).
• Fulcrum (a) of rocker cam (3) is eccentric to the working point (b) of the combined force of the propulsion force of
cylinder (5).
• The combined force of the piston propulsion forces works as the moment of inclining rocker cam (3) toward the
maximum swash plate angle.
• The pressurized oil at regulator piston (13) passes through orifice (c) of regulator valve (21) and is drained to the
motor case.
• Rocker cam (3) is inclined in the maximum swash plate angle direction. The motor capacity becomes maximum,
turning on the low speed travel.
10-162 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. At high peed (motor swash plate angle at minimum).
• As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P).
• Regulator valve (21) is pushed to the left.
• The pressurized oil from the control valve passes through passage (d) in regulator valve (21) and enters regulator
piston (13).
• Regulator piston (13) is pushed to the right.
• Rocker cam (3) is inclined in the minimum swash plate angle direction. The motor capacity becomes minimum,
turning on the high speed travel.
PC350LC/HD-8 10-163
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Parking Brake - PC350LC-8
• As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (17), opening the
parking brake circuit.
• The pressurized oil is conducted to chamber (a) of brake piston (10) and compresses spring (9), pushing piston (10)
toward right.
• Since the pushing force to plate (11) and disc (12) disappears, plate (11) is separated from disc (12) and the brake is
released.
10-164 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When travel is stopped.
• As the travel lever is placed in neutral, counterbalance valve spool (17) returns to the neutral position and closing the
parking brake circuit.
• The pressurized oil in chamber (a) of brake piston (10) passes through orifice (f) of brake piston (10) and is drained to
the motor case.
• Brake piston (10) is pushed to the right by spring (9).
• Plate (11) and disc (12) are pushed together, and the brake is applied.
• As brake piston (10) returns, flow of pressurized oil is reduced with slow return valve (8).
• The time delay will be set to activate the brake only after the machine has stopped.
PC350LC/HD-8 10-165
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
BRAKE VALVE OPERATION
Function
• When traveling downhill, the machine travel speed tends to get faster
than the motor (engine) speed because of the downward force
generated from its own weight.
• If the machine travels with the engine at low speed, the motor may
rotate without load, resulting in run away and inviting a very
dangerous situation.
• These valves are used to prevent above by controlling the machine to
travel according to the engine speed (pump delivery).
• Operating the travel lever conducts the pressurized oil from the
control valve to port (PA).
• The pressurized oil push-opens check valve (14A) and then flows to
motor outlet port (MB) via motor inlet port (MA).
• The motor outlet side is closed by check valve (14B) and spool (24),
so the pressure at the supply side rises.
• The pressurized oil on the supply side flows to chamber (S1) via
orifice (E1) and orifice (E2) of the spool (24).
• As the pressure in chamber (S1) goes above the spool selector
pressure, spool (24) is pushed toward right.
• Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.
10-166 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
• The pressurized oil on the supply side flows to chamber (S1) via
orifice (E1) and orifice (E2) of the spool (24).
• As the pressure in chamber (S1) goes above the spool selector
pressure, spool (24) is pushed toward right.
• Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.
PC350LC/HD-8 10-167
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Safety valve (bidirectional 2-stage set safety valve).
Function
• As long as the machine travel is stopped (or it is traveling downhill), the counterbalance valve closes the inlet and outlet
circuits of the motor.
• Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially
resulting in damages on the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port side of the motor in order to prevent damages to the
equipment.
Bidirectional action
10-168 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
B. When pressure in chamber (MA) has become high (when
rotating counterclockwise).
• As long as the machine travel is stopped (or it is traveling
downhill), the check valve of counterbalance valve closes
chamber (MA) of the outlet port circuit.
• The motor tries to continue rotation resorting to inertial
force, thus pressure on the outlet port (MA) is increased.
PC350LC/HD-8 10-169
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation of mechanism for varying set pressure
10-170 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-171
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Travel Motor - Type: KMV200ADT-2 - PC350HD-8
10-172 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PA: From control valve
PB: From control valve
PI: From travel speed solenoid valve
T: To tank
Specifications
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMV200ADT-2
Theoretical displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . (Min.): 130 cm3/rev (0.0343 gal/rev)
. . . . . . . . . . . . . . . . . . . . . . . . . . (Max.): 200 cm3/rev (0.0528 gal/rev)
Rated pressure: . . . . . . . . . . . . . . . . . . . . . 380 kg/cm2 (5404.8 psi)
Rated speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Capacity min.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 rpm
(Capacity max.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,550 rpm
Brake release pressure: . . . . . . . . . . . . . . . . . . 10 kg/cm2 (142.2 psi)
Travel speed selector pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . (differential pressure):8 kg/cm2 (113.7 psi)
Torque
N•m lbf ft
1 Bolt 490 - 608 361.4 - 448.4
2 Nut 294 - 343 216.8 - 252.9
PC350LC/HD-8 10-173
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
10-174 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Output shaft 11. Check valve spring
2. Motor case 12. Check valve
3. Piston 13. Counter balance valve spool
4. Cylinder block 14. Spool return spring
5. Valve plate 15. Safety valve
6. End cover 16. Regulator valve
7. Slow return valve 17. Spring
8. Regulator piston 18. Brake spring
9. Plate 19. Brake piston
10. Disk 20. Check valve
Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
427 N 341 N If damaged or
62.5 x 32.0 42.0 -
21 Spool return spring {43.5 kg} {34.8 kg} deformed, replace
spring.
3.04 N 2.45 N
22 Check valve spring 62.5 x 20.0 39.0 -
{0.31 kg} {0.25 kg}
PC350LC/HD-8 10-175
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation of motor
• As the solenoid valve is de-energized, the pilot pressurized oil from the self pressure reducing valve does not flow to
port (P).
• Regulator valve (16) is being pushed down by spring (17).
• Pressurized oil conducted to end cover (6) by pressing check valve (20) is then conducted to chamber (b) via
regulator valve (16).
• Force is generated on regulator piston (8) that works in downward direction.
• Valve plate (5) and cylinder block (4) move in the maximum tilt and roll angle direction, increasing the motor
capacity to the maximum and thus turning on the low speed travel.
10-176 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. At high speed (motor swash plate angle at minimum).
• As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P).
• Regulator valve (16) is pushed upward.
• Pressurized oil in chamber (b) is drained to the case and oil is conducted to chamber (a) through regulator valve (16).
• Force is generated on regulator piston (8) that works in upward direction.
• Valve plate (5) and cylinder block (4) move in the minimum tilt and rotation angle direction, decreasing the motor
capacity to the minimum and thus turning on the high speed travel.
PC350LC/HD-8 10-177
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Parking Brake - PC350HD-8
• As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (13), opening the
parking brake circuit.
• The pressurized oil is conducted to chamber (e) of brake piston (19) and compresses spring (18), pushing piston (19)
toward right.
• Since the pushing force to plate (9) and disc (10) disappears, plate (9) is separated from disc (10) and the brake is
released.
10-178 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When travel is stopped.
• As the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and closing the
parking brake circuit.
• Pressurized oil in chamber (e) of brake piston (19) keeps flowing through the orifice of slow return valve (7) until
counter balance valve spool (13) is returned to the neutral.
• As counter balance valve spool (13) is returned to the neutral, pressurized oil is drained to the case through orifice (f)
of brake piston (19).
• Brake piston (19) is pushed to the left by spring (18).
• Plate (9) and disc (10) are pushed together, and the brake is applied.
• As brake piston (19) returns, flow of pressurized oil is reduced with slow return valve (7).
• The time delay will be set to activate the brake only after the machine has stopped.
PC350LC/HD-8 10-179
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
BRAKE VALVE OPERATION
• When traveling downhill, the machine travel speed tends to get faster
than the motor (engine) speed because of the downward force
generated from its own weight.
• If the machine travels with the engine at low speed, the motor may
rotate without load, causing the machine to run away, resulting in a
very dangerous situation.
• These valves are used to prevent above by controlling the machine to
travel according to the engine speed (pump delivery).
• Operating the travel lever conducts the pressurized oil from the
control valve to port (PA).
• The pressurized oil push-opens check valve (12A) and then flows to
motor outlet port (MB) via motor inlet port (MA).
• The motor outlet side is closed by check valve (12B) and spool (13),
so the pressure at the supply side rises.
10-180 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
• The pressurized oil on the supply side flows to chamber (S1) via
orifice (E1) and orifice (E2) of the spool (13).
• As the pressure in chamber (S1) goes above the spool selector
pressure, spool (13) is pushed toward right.
• Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.
PC350LC/HD-8 10-181
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Safety Valve
★ (bidirectional 2-stage set safety valve)
Function
Bidirectional Action
10-182 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12 • As the pressure goes above the set pressure, [Difference in areas
of circles (D1) and (D3) x Pressure] compresses spring (2).
• Poppet (1) is moved leftward and the pressurized oil flows into
chamber (MB) of the opposite circuit.
PC350LC/HD-8 10-183
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When travel is stopped (low-pressure setting)
• When the travel lever is placed in neutral, the pressure in cham-
ber (PA) drops and spool (24) returns to the neutral
position.
• When spool (24) is in the process of returning to the neutral
position, the pressurized oil in chamber (J) flows to chamber
(PA) via passage (H) and chamber (G).
• Piston (3) moves to the left side, decreasing the set load.
• The safety valve is forced to the low pressure setting, thereby
attenuating the shocks when the speed is reduced.
10-184 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-185
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Swing Motor
Type: KMF230ABE-5
10-186 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Torque
N•m lbf ft
3 Bolt 27 - 34 20 - 25
4 Bolt 98.1 - 122.6 72 - 90
5 Valve 294 - 392 217 - 289
PC350LC/HD-8 10-187
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
10-188 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Brake spring 10. Cylinder block
2. Drive shaft 11. Valve plate
3. Spacer 12. Center shaft
4. Case 13. Center spring
5. Disc 14. Check valve
6. Plate 15. Check valve spring
7. Brake piston 16. Shuttle valve
8. Housing 17. Shuttle valve spring
9. Piston
Unit: mm
No Check item Criteria Remedy
Basic dimensions Repair limit
Free length x Installed Installed Free Installed
Outside length load length load
diameter If damaged or deformed,
6.96 N 5.59 N replace spring.
66.5 x 25.6 45.0 -
18 Check valve 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}
Torque
N•m lbf ft
20 Cap 294 - 392 217 - 289
21 Cap 490.5 - 608.2 362 - 449
22 Cap 98.1 - 122.6 72 - 90
23 Cap 176.5 - 215.8 130 - 160
PC350LC/HD-8 10-189
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Swing holding brake
10-190 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
RELIEF VALVE PORTION
Outline
• The relief valve portion consists of check valves (2) and (3), shuttle
valves (4) and (5), and relief valve (1).
Function
• When the machine is in the swing holding mode, control valve (6)
closes the motor outlet circuit, but the motor rotation is continued by
inertial force.
• The motor output, therefore, is abnormally increased, resulting in
damage to the motor.
• In order to prevent motor damage, the relief valve relieves the
abnormally high pressure to port (S) from the motor outlet side
(high-pressure side) of the motor.
Operation
PC350LC/HD-8 10-191
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Reverse Prevention Valve
10-192 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
PC350LC/HD-8 10-193
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function
• This valve reduces the swing back generation in the swing body by the inertia of the swing body, the backlash and rigidity
of the machinery system, and the compression of the hydraulic oil when the swing is stopped.
• The valve contributes in preventing collapsing of load when the swing is stopped and also contributes in reducing cycle
time (enhances the positioning performance, enabling you to proceed to the next work remove than ever).
Operation
10-194 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-195
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Hydraulic Cylinder
Boom Cylinder
Arm Cylinder
Bucket Cylinder
10-196 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Unit: mm
No Check item Criteria Remedy
PC350LC/HD-8 10-197
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT
Work Equipment
10-198 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Unit: mm
No Check item Criteria Remedy
PC350LC/HD-8 10-199
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Dimension Of Arm
10-200 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Unit: mm (in)
PC350LC/HD-8
Measuring
No. Tolerance
position Standard size
Shaft Hole
–0.036 (0.001) +0.1 (0.004)
1 – φ100 (3.94)
–0.071 (0.003) 0 (0)
0.59
Arm side 119.3 (4.69)
2 0 (0)
Cylinder head side 116 (4.56) ±1.2 (0.05)
+0.5 (0.02)
Boom side 320 (12.6)
0 (0)
3
–0.3 (0.012)
Arm side 316 (12.4)
–0.8 (0.031)
–0.036 (0.001) +1 (0.004)
4 – φ110 (4.33)
–0.090 (0.004) 0 (0)
5 – 470.6 (18.5) ±1 (0.04)
6 – 236.5 (9.31) ±0.5 (0.02)
7 – 1022.4 (40.25) ±1 (0.04)
8 – 3178 (125.1) ±3 (0.12)
9 – 2975.6 (117.1) ±1 (0.04)
10 – 472.5 (18.6) –
11 – 731.0 (28.78) ±0.2 (0.01)
12 – 728.0 (28.66) ±0.5 (0.02)
13 – 513.6 (20.2) –
14 – 1670 (65.74) –
–0.036 (0.001) +0.2 (0.01)
15 – φ90 (3.54)
–0.090 (0.004) 0 (0)
16 – 345.0 (13.58) ±0.5 (0.02)
–0.036 (0.001) +0.2 (0.01)
17 – φ90 (3.54)
–0.090 (0.004) 0 (0)
0 (0)
Arm itself 330 (12.99)
18 –0.5 (0.02)
When press fitting bushing 345 (13.58) –
Min. 1870 (73.62) –
19
Max. 3155 (124.2) –
PC350LC/HD-8 10-201
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Dimension Of Bucket
10-202 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Unit: mm
PC350LC/HD-8
No Measuring position
Standard size Tolerance
1 – 512.2 ±0.5
2 – 37.9 ±0.5
3 – 94°19' –
4 – 513.6 –
5 – 1658 –
6 – 193 –
7 – 50° –
+0.2
8 – ∅90
+0.1
+0.2
9 – ∅90
+0.1
+0.2
10 – ∅90
+0.0
+1
11 – 346
0
12 – 68 –
13 – 138 –
+0.5
14 – 525.5
–0.25
15 – ∅26 –
16 – ∅165 –
17 – ∅150 –
18 – ∅200 –
19 – 145.8 –
20 – 138.2 –
21 – R115 –
22 – R100 –
+2
23 – 382
0
24 – 60 –
25 – 56 –
PC350LC/HD-8 10-203
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD AIR CONDITIONER PIPING
12
AIR CONDITIONER PIPING
10-204 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
Engine Control
Outline
• The engine can be started and stopped with only starting switch (3).
PC350LC/HD-8 10-205
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Operation Of System
Starting Engine
Stopping Engine
10-206 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Fuel Control Dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
PC350LC/HD-8 10-207
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Engine Controller
• Meanings of signal classes in the terminal table shown below are as follows.
A: Power Supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
10-208 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
CN-CE01
Pin No. Signal name Input/output
1 Electric power supply for fuel feed pump D
2 Electric power supply for IMA D
3 Atmosphere sensor B
4 NC(*) –
5 NC(*) –
6 CAN(–) E
7 NC(*) –
8 CAN(+) E
9 NC(*) –
10 NC(*) –
*: Never connect to NC or malfunctions or failures will occur.
11 Fuel feed pump return C
12 NC(*) –
13 NC(*) B
14 WATER-IN-FUEL sensor B
15 Coolant temperature sensor B
16 5V electric power supply for sensor A
17 Oil pressure switch B
18 NC(*) –
19 NC(*) –
20 NC(*) –
21 NC(*) –
22 NC(*) D
23 Boost temperature sensor B
24 NC(*) –
25 Common rail pressure sensor B
26 Backup sensor B
27 NE sensor (+) B
*: Never connect to NC or malfunctions or failures will occur.
28 NC(*) –
29 NC(*) –
30 NC(*) –
31 NC(*) D
32 NC(*) C
33 GND A
34 NC(*) –
35 NC(*) A
36 NC(*) –
37 NC(*) A
38 NC(*) C
39 Key switch (ACC) –
40 Electrical intake air heater relay drive –
41 NC(*) –
42 Electrical intake air heater relay return C
43 NC(*) –
44 Boost pressure sensor B
45 Injector #1 (+) D
46 Injector #5 (+) D
PC350LC/HD-8 10-209
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
CN-CE01
Pin No. Signal name Input/output
47 Sensor GND C
48 Ne sensor (–) C
49 NC(*) –
50 NC(*) –
51 Injector #2 (–) C
52 Injector #3 (–) C
53 Injector #1 (–) C
54 Injector #2 (+) D
55 Injector #3 (+) D
56 Injector #4 (+) D
57 Injector #6 (+) D
58 Injector #4 (–) C
59 Injector #6 (–) C
60 Injector #5 (–) C
*: Never connect to NC or malfunctions or failures will occur.
CN-CE02
Pin No. Signal name Input/output
1 NC(*) B
2 NC(*) B
3 NC(*) B
4 NC(*) B
5 NC(*) B
6 NC(*) B
7 NC(*) B
8 NC(*) B
9 Fuel control dial (+) B
10 NC(*) B
11 NC(*) B
12 NC(*) B
13 NC(*) B
14 NC(*) B
15 NC(*) B
16 NC(*) B
17 NC(*) B
18 NC(*) B
19 NC(*) B
20 NC(*) E
21 NC(*) A
22 Fuel control dial (+5V) A
23 Fuel control dial (–) C
24 NC(*) B
25 NC(*) B
26 NC(*) B
27 NC(*) B
28 NC(*) B
29 NC(*) C
30 NC(*) B
31 NC(*) B
10-210 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
CN-CE02
Pin No. Signal name Input/output
32 NC(*) C
33 GND C
34 NC(*) C
35 NC(*) B
36 NC(*) B
37 NC(*) C
38 NC(*) D
39 Key switch (ACC) A
40 Electrical intake air heater relay drive D
41 NC(*) D
42 Electrical intake air heater relay return C
43 NC(*) D
44 NC(*) D
45 NC(*) –
46 CAN(+) E
47 CAN(–) E
48 NC(*) D
49 PWM OUTPUT D
50 NC(*) D
*: Never connect to NC or malfunctions or failures will occur.
CN-CE03
Pin No. Signal name Input/output
1 GND C
2 NC(*) C
3 Electric power supply (+24V constantly) A
4 NC(*) A
*: Never connect to NC or malfunctions or failures will occur.
PC350LC/HD-8 10-211
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Sensors
Coolant Temperature Sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
10-212 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
Engine Speed Sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
PC350LC/HD-8 10-213
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
WIF (Water-in-fuel Detection) Sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
1. Connector
2. Bracket
3. Float
4. Switch
10-214 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
ELECTRONIC CONTROL SYSTEM
Control Function
Auto-deceleration function
8
Attachment flow control and circuit selector function (if
equipped)
Self-diagnosis function
PC350LC/HD-8 10-215
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
System Diagram
10-216 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
PC350LC/HD-8 10-217
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Engine and Pump Control
10-218 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Function
• This function allows the operator to select proper engine torque and
pump absorption torque according to the type of work. Four modes
are provided: P, E, B and L. Using the work mode switch on the
monitor panel, the operator is required to select one of them.
• The pump controller detects the speed of the engine governor set
with the fuel control dial and the actual engine speed (N) and
controls them so that the pump will absorb all the torque at each
output point of the engine, according to the pump absorption torque
set in each mode.
PC350LC/HD-8 10-219
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Control method in each mode.
P and E modes
Matching point in P mode: Rated speed
• If the pump load increases and the pressure rises, engine speed
(N) lowers. At this time, the controller lowers the pump
discharge so that the engine speed will be near the maximum
output point.
If the pressure lowers, the controller increases pump discharge
(Q) so that the engine speed will be near the maximum output
point.
By repeating these operations, the controller constantly uses
the engine near the maximum output point.
10-220 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12 B and L modes
PC350LC/HD-8 10-221
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
2. Function to control pump during travel.
• Traveling the machine in E or B mode leaves the working
mode unchanged, but raises the pump absorption torque and
engine speed (N) to values same as those in P mode.
• If the machine travels in L mode, the working mode and engine
speed (N) do not change, but the pump absorption torque is
increased.
10-222 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
3. Function to control when emergency pump drive switch is turned
on.
• Even if any abnormality occurs in the controller or sensor,
setting emergency pump drive switch (1) to the “ON”
position activates the machine with an absorption torque
approximately equivalent to that in E mode.
• In this case, a constant current flows from the battery to the
EPC valve for PC and therefore, the oil pressure is sensed by
only the EPC valve for PC.
PC350LC/HD-8 10-223
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Pump and Valve Control
Function
The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
10-224 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
LS Control Function
• Depending on the operation condition of the actuator, this function
changes the pressure output from the LS-EPC valve to LS valve to
change the change point (LS set differential pressure (DLS)) of the
pump discharge in the LS valve.
• By this operation, the start-up time of the pump discharge is
optimized and the composite operation and fine control
performance is improved.
Cut-off Function
• This function increases PC-EPC current (J) to reduce the flow rate
in the relief state, improving fuel consumption.
PC350LC/HD-8 10-225
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Power Maximizing and Machine Push-up
Function
• The power maximizing function allows the operator to increase power for a certain time by operating the left knob switch.
• The machine push-up function allows the operator to increase the boom pushing force by operating the machine push-up
switch.
10-226 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Power maximizing function.
• This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock).
• If the left knob switch is pressed in P or E mode, the hydraulic force is increased about 7% to increase the digging
force. Each function is set automatically as shown below.
Function Setting
Engine and pump control Matching at rated ouptut point
355 kg/cm2
(5,049 psi)
2-stage relief function ↓
380 kg/cm2
(5,409 psi)
Software cut-off function Cancel
★ These settings are automatically reset after 8.5 seconds when the switch is pressed.
PC350LC/HD-8 10-227
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Auto-deceleration
Function
10-228 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-229
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Auto-warm-up and Overheat Prevention
Function
• 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.
• The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during
operation to protect the engine from overheating.
10-230 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Warm-up Function
• After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up
the engine.
⇓
Resetting condition (Any one) Reset
⇒
Coolant temperature: Above 30°C (86°F).
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.
Manual
or longer
• If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to protect the
engine from overheating.
• This function is turned on when the coolant temperature rises above 95°C (203°F).
⇒ ⇒
Hydraulic oil Work mode: Travel (203 °F)
temperature: Above Engine speed: Keep as is. • Under above condition, controller is
95°C (203 °F) Lower travel speed. set to condition before operation of
function. (Automatic reset)
⇒ ⇒
Hydraulic oil or Work mode: P or E mode Below 100°C (212 °F)
coolant temperature: Engine speed: Keep as is. • Under above condition, controller is
Above 100°C ((212 °F) Lower pump discharge. set to condition before operation of
function. (Automatic reset)
⇒ ⇒
Work mode: P, E, B or L mode
Hydraulic oil or Below 102°C (216 °F)
Engine speed: Keep as is.
coolant temperature: • Under above condition, controller is
Monitor alarm lamp: Lights up.
Above 102°C (216 °F) set to condition before operation of
Lower pump discharge.
function. (Automatic reset)
⇒ ⇒
Work mode: Any mode
Hydraulic oil or Fuel control dial: Return to low idle
Engine speed: Low idle
coolant temperature: position once.
Monitor alarm lamp: Lights up
Above 105°C (221 °F) • Under above condition, controller is
Alarm buzzer: Sounds
set to condition before operation of
function. (Manual reset)
PC350LC/HD-8 10-231
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Swing Control
Function
The swing lock and swing holding brake function are provided as a swing control function.
10-232 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Swing lock and swing holding brake function
• The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake
function (automatic) is used to prevent hydraulic drift after the machine stops swinging.
• Operation of swing lock switch and swing lock/holding brake
Lock
Lock switch Function Operation
lamp
Swing holding If swing lever is set in neutral, swing brake operates in about 7 sec.
OFF OFF
brake If swing lever is operated, brake is released and machine can swing freely.
Swing lock operates and machine is locked from swinging.
ON ON Swing lock
Even if swing lever is operated, swing lock is not reset and machine does not swing.
PC350LC/HD-8 10-233
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Travel Control
Function
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.
10-234 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Pump control function during travel.
• If the machine travels in a work mode other than P mode, the work mode and the engine speed are kept as they are
and the pump absorption torque is increased.
• For details, see “Engine and Pump Control” on page 10-218
Travel speed switch (PC350LC-8) Lo (Low speed) Mi (Mid. speed) Hi (High speed)
Pump capacity (%) 90 82 100
Motor capacity Max. Min Min.
Travel speed: km/h (mph) 3.2 (2.0) 4.5 (2.8) 5.5 (3.4)
Travel speed switch (PC350HD-8) Lo (Low speed) Mi (Mid. speed) Hi (High speed)
Pump capacity (%) 90 80 100
Motor capacity Max. Min Min.
Travel speed: km/h (mph) 2.5 (2.0) 4.0 (2.5) 4.9 (3.0)
PC350LC/HD-8 10-235 1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Attachment Flow Control and Circuit Selector
(if equipped)
Function
A. It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully.
B. In B mode and the other modes, it switches to attachment single acting (B) or double acting (other modes).
10-236 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
System Component Parts
PPC Oil Pressure Switch
1. Plug
2. Switch
3. Connector
Specifications
Function
PC350LC/HD-8 10-237
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Oil Pressure Sensor
1. Sensor
2. Connector
Function
• The pump pressure sensor is installed to the input circuit of the control valve.
• It converts the pump discharge pressure into a voltage and transmits it to the pump controller.
Operation
10-238 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Pump Pressure Sensor (High Pressure)
1. Sensor
2. Connector
Operation
PC350LC/HD-8 10-239
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
Pump Controller
10-240 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
CN-C01 CN-C01
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 PWR_IN_BATT Input 52 Service switch Input
2 GND_PWR Input 53 Boom raise pressure switch Input
3 Washer motor output 54 NC(*) -
4 PWR_IN_BATT Input 55 Travel switch Input
5 GND_PWR Input 56 Wiper limit switch Input
6 NC(*) - 57 Window limit switch Input
7 NC(*) - 58 Machin select 4 Input
8 NC(*) - 59 NC(*) -
9 PWR_OUT_5V_0 output 60 Start switch Input
10 NC(*) Input 61 NC(*) -
11 NC(*) - 62 NC(*) Input
12 NC(*) - 63 NC(*) ó
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
Overload caution enable
27 NC(*) - 78 switch -
PC350LC/HD-8 10-241
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
CN-C02
Pin No. Signal name Input/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 PCQñEPC (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 (ñ) 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.
10-242 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
MONITOR SYSTEM
• The monitor system notifies the operator of machine status. It monitors the condition of the machine with sensors installed
on various parts of the machine, processes and immediately displays the obtained information on the panel. The
information that appears on the panel is roughly divided as follows.
B. Machine status, including coolant temperature, hydraulic oil temperature and fuel level
• The machine monitor also has various mode selector switches and functions to operate the machine control system.
PC350LC/HD-8 10-243
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Machine Monitor
Outline
• The machine monitor has the functions to display various items and the functions to select modes and electric parts.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
• The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-244 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Input and output signals
CN-CM01 CN-CM03
Pin No. Signal name Input/output Pin No. Signal name Input/output
Battery power (+24V con- RS232C CD for communica-tion
1 Input 1 Input
stantly) terminal
Battery power (+24V con- RS232C RXD for communication
2 stantly) Input 2 terminal Input
PC350LC/HD-8 10-245
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
CN-CM05
Pin No. Signal name Input/output
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera -
6 Camera signal GND1 -
7 Camera signal GND2 -
8 Camera signal GND3 -
10-246 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
MEMORANDUM
PC350LC/HD-8 10-247
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Monitor Control, Display Portion
10-248 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
1. Hydraulic oil temperature monitor
2. Hydraulic oil temperature gauge
3. Engine coolant temperature monitor
4. Engine coolant temperature gauge
5. KOMTRAX message monitor
6. Air conditioner monitor
7. Wiper monitor
8. Swing lock monitor
9. Engine pre-heating monitor/power maximizing monitor
10. Time/service meter
11. Auto-deceleration monitor
12. Working mode monitor
13. Travel speed monitor
14. ECO indicator
15. Fuel gauge
16. Fuel level monitor
17. Maintenance interval monitor
18. Engine oil pressure monitor
19. Charge level monitor
20. Radiator coolant level monitor
21. Engine oil level monitor
22. Air cleaner clogging monitor
23. Water separator monitor
PC350LC/HD-8 10-249
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Monitor Items And Display
Engine coolant
temperature
Hydraulic oil See gauge display on next page.
temperature
Fuel level
10-250 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to
disconnection of CAN.
PC350LC/HD-8 10-251
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
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.
Symbols appear in the order in which they occur from the upper left. When symbols are displayed, if the hydraulic oil
temperature is high or low, only its symbol is displayed.
10-252 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
PC350LC/HD-8 10-253
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
Switches
3. Guidance icon 6. Travel speed selector switch 9. Air conditioner control switch
Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer sounds.
Depending on the alarm buzzer type, it does not stop even if you press the buzzer cancel switch.
Auto-deceleration switch
The auto-deceleration switch toggles the auto-deceleration function on and off. When the working mode is switched, it is
automatically set to ON. When it is set to ON, the auto-deceleration monitor appears.
★ The auto-deceleration function does not work in L mode.
Guidance icon and function switch
The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it.
Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below.
10-254 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
PC350LC/HD-8 10-255
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Working mode selector switch
About B mode
Each time you press the travel speed selector switch, the travel speed
setting switches as shown below.
Lo ➡ Mi ➡ Hi ➡ Lo ….
The travel speed setting is confirmable on the travel speed monitor.
The relationship between the speed setting and the monitor display is
shown in the table below.
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
Crawler symbol + Hi High speed
While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
10-256 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Wiper switch
Each time you press the wiper switch, the wiper settings switch as follows.
OFF ➡ INT ➡ ON ➡ OFF ➡ ….
The wiper operation setting is confirmable on the wiper monitor.
The relationship between the wiper setting and the monitor display is shown in the table below.
Display Setting Wiper actuation status
None OFF Stowing stopped or now stowing
Wiper symbol + INT INT Intermittent actuation
Wiper symbol + ON ON Continuous actuation
To operate the air conditioner, use the air conditioner control switches.
9a: Specifies airflow
9b: Specifies temperature
9c: AUTO
9d: A/C
9e: Switches among air blowing modes
9f: Switches between inside air and outside air
9g: OFF
9a to 9c: Enables entered information simultaneously with switching to the
air conditioner control screen below.
9d to 9f: Switches to the air conditioner control screen below. Another
pressing switches among modes.
9g: Turns OFF the air conditioner function without switching to the air
conditioner screen.
PC350LC/HD-8 10-257
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
Camera screen display function
10-258 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
F6, or no operation for 5 sec.: Returns to the camera screen.
• Even when the camera screen is displayed, the working mode
selector switch, travel speed selector switch, auto-deceleration
switch, buzzer cancel switch, wiper switch, and window washer
switch are enabled.
• Changing the working mode or travel speed returns to the normal
screen.
• If an abnormality corresponding to an alarm item with the camera
screen displayed, the alarm monitor appears on the upper left of the
screen. If it appears, return to the normal screen with F5 to check the
alarm display.
• If an abnormality corresponding to an error item with the camera
screen displayed, the error monitor appears on the upper left of the
screen. If it appears, you must move the machine to safe posture
immediately and make inspections.
• If you do not operate the lever at least 10 sec. after the error monitor
starts to blink, the screen switches to the normal screen.
PC350LC/HD-8 10-259
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Maintenance function
10-260 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
The table shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the
machine is operated.
Replacement interval
No. Item (Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor 1000(*)
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
*: If equipped (To be determined)
• The content of the caution display differs according to the remaining time. The relationship is as shown in the table below.
Display Condition
Remaining time for maintenance for all items is more than 30
None hours.
Notice display (black symbol displayed on yellow There is one or more items with less than 30-hour remaining
background) time for maintenance.
Warning display (white symbol displayed on red background) There is one or more items with less than 0-hour remaining time
for maintenance.
PC350LC/HD-8 10-261
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
User mode
10-262 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
1. Breaker setting selection screen.
• On this screen, you can allocate one of two set flow rates as a
flow rate in breaker mode.
• The B symbol is displayed before items specified to breaker
mode.
★ The defaults of both flow rates are 230 l/min (60.7 gal/min).
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker setting menu screen.
F6: Specifies the selected (highlighted) item as a flow rate in breaker
mode.
PC350LC/HD-8 10-263
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Changing attachment mode setting
10-264 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Message display
• Press F6 to enter user mode and select “Message display” and you
can view (open) the messages.
F6: Returns to the user mode screen.
• Selecting the Screen adjustment from the user menu and pressing F6
switches to the screen adjustment screen.
• From this menu, you can adjust the brightness, contrast, and
luminance of the machine monitor screen.
• When the light switch is in Night mode ON, the night mode screen is
adjustable.
• When the light switch is in Daytime mode ON or OFF, the daytime
mode screen is adjustable.
F2: Returns all adjusted values to the defaults.
F3: Decreases the value indicated by the indicator one graduation
left.
F4: Increases the value indicated by the indicator one graduation right.
F5: Cancels changes you made before confirming them with F6 to return to the menu screen.
F6: Confirms the changes and moves to the next item.
PC350LC/HD-8 10-265
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
• For a camera-equipped machine, the brightness, contrast, and
illuminance of the camera screen are also adjustable.
• For a camera-equipped machine, selecting Screen adjustment from
the user menu switches to the screen for selecting a screen you want
to adjust.
• Selecting the Clock adjustment from the user menu and pressing F6
switches to the clock adjustment screen.
• On this screen, you can change the setting of the time displayed on
the normal screen.
1. Time setting
Set the clock time. If the time setting item is not highlighted, press
F6 to highlight it.
• Selecting the Language from the user menu screen and pressing F6
switches to the language setting screen.
• From this menu, you can change the language to be displayed on the
monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish, Portuguese, Italian,
German, Russian, Turkish, Indonesian, and Thai.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels the changes to return to the user menu.
F6: Cancels the changes to return to the user menu.
• Selecting the Economy mode adjustment from the user menu and
pressing F6 switches to the Economy mode setting screen.
• From this menu, you can adjust engine output to improve fuel
consumption in E mode.
• The fuel consumption level is specified to one of four levels from E0
to E3. The larger the value, the better the fuel consumption, but the
smaller the work rate.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels the changes to return to the user menu.
F6: Cancels the changes to return to the user menu.
PC350LC/HD-8 10-267
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Idle stop guidance function
10-268 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Service meter check function
PC350LC/HD-8 10-269
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
User code/failure code display function
• If multiple user codes or failure codes are issued, they are displayed
alternately every 2 sec.
• If the telephone number has been set in the service menu, the screen
shows the telephone symbol and telephone number simultaneously
with the user code/failure code. For information on how to input and
set the telephone number, see “MACHINE MONITOR - SPECIAL
FUNCTIONS” on page 30-66.
10-270 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
12
Sensors
• The signals from the sensors are input to the monitor panel directly.
• Either side of a sensor of contact type is always connected to the chassis ground.
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC350LC/HD-8 10-271 1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
Fuel level sensor
1. Float 3. Cover
10-272 1 PC350LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD KOMTRAX Terminal System
12
KOMTRAX Terminal System
• The KOMTRAX terminal system consists of a KOMTRAX communication modem, communication antenna, machine
monitor, and GPS antenna.
• This system transmits various kinds of machine information wirelessly. Persons who operate the KOMTRAX can refer to
the information at office to provide various kinds of services for customers.
• Information transmittable from the KOMTRAX terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
★ To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
PC350LC/HD-8 10-273 1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD KOMTRAX Terminal System
12
KOMTRAX Communication Modem - TH300
• This terminal sends various machine information based on the network signals and input signals obtained through the
machine monitor, as well as GPS position data, via wireless communication. This terminal can send information via
communication antenna.
• Conditions of this terminal can be checked with the "KOMTRAX Settings" in the service mode of the machine monitor.
• This terminal cannot be used in the countries or territories where it is not authorized by the law.
★ When starting to use the KOMTRAX system or changing the country where it is used, you are required to notify the
country where it will be used in advance.
Input and output signals
Connector A Connector B
Pin No. Signal name Input/output Pin No. Signal name Input/output
A-1 Electric power supply Input B-1 Serial signal DCD Output
A-2 NC(*) - B-2 Serial signal RXD Output
A-3 NC(*) - B-3 Serial signal TXD Input
Electric power supply
A-4 Output B-4 Serial signal DTR Input
switching
A-5 NC(*) - B-5 Serial signal SGND Input
A-6 NC(*) - B-6 Serial signal DSR Output
A-7 GND Input B-7 NC(*) -
A-8 GND Input B-8 NC(*) -
A-9 NC(*) - B-9 NC(*) -
A-10 NC(*) - B-10 NC(*) -
A-11 NC(*) - *: Never connect to NC or malfunctions or failures will occur.
A-12 NC(*) -
A-13 NC(*) -
A-14 NC(*) -
*: Never connect to NC or malfunctions or failures
will occur.
10-274 1 PC350LC/HD-8
20 STANDARD VALUE TABLES
★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3. These standard values are not the standards used in dealing with claims.
.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
PC350LC/HD-8 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
STANDARD VALUE TABLES
Engine Related
Applicable model PC350LC/HD-8
Engine SAA6D114E-3
Standard value
Service limit
Item Measurement condition Unit table for new
value
machine
High idling at operating temp. 2,050 ±50 2,050 ±50
Engine speed Low idling at operating temp. rpm 1,000 ±25 1,000 ±25
Rated speed at operating temp. 1,950 1,950
• Coolant at operating 147 - 187 120
Inlet of aftercooler
Intake air pressure temperature kPa {1,100 - 1,400} {900}
(boost pressure) • Arm IN relief +Power Max. {mmHg} 135 - 175 100
Outlet of aftercooler
{1,010 - 1,310} {750}
At sudden acceleration Max. 25 Max. 35
Exhaust gas color %
At high idling Max. 1.0 Max. 2.0
0.0152 -
Valve clearance Intake valve 0.305
mm 0.559
(Normal temperature)
Exhaust valve 0.559 0.381 - 0.813
kg/cm 2
Μιν. 26.5 21.4
• Oil temperature: 40 - 60º C (104 - 140°F) (psi) 304.3
Compression pressure
• Engine speed : Min. 170 rpm Μιν. 376.9
rpm 250 - 280 250 - 280
• (Coolant temperature: operating range) kPa Max. 1.57 2.25
Blow-by pressure
• Arm IN relief + power max. {mmH2O} {Max. 160} {260}
Oil pressure: (Coolant temperature: operating range)
3.5 - 6.0 2.1
(SAE0W-30E0S) At high idling
(50 - 85) (30)
(SAE5W-40E0S) kg/cm2
(SAE10W-30HD) At low idling (psi)
Min. 1.5 0.8
(SAE15W40HD)
(Min. 21) (11)
(SAE30HD)
80 - 120 (176 -
Oil temperature Whole speed range (inside oil pan) °C (°F) 120 (248)
248)
• Between fan pulley and alternator pulley
Auto-ten-
Fan belt tension • Deflection when pressed with finger force of approx. mm Auto-tensioner
sioner
98 N (22 lbf)
• Between fan pully and compressor pully
Air conditioner
• Deflection when pressed with finger force of mm 6-9 6-9
compressor belt tension
approximately 58.8 N (129.6 lbf)
20-2 1 PC350LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Chassis Related
Applicable model PC350LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value
• Engine coolant temperature:
Within operation range
• Hydraulic oil temperature: Within
2 pumps at relief 2,030 ±100 2,030 ±100
operation range
• Engine at high idling
• Arm in relief condition
• Engine coolant temperature:
Engine speed
mm
• Max. reading up to stroke end
(in) 85 ±10 85 ±10
Swing control lever (excepting lever play in
(3.3 ±0.4) (3.3 ±0.4)
NEUTRAL position)
115 ±12 115 ± 2
Travel control lever
(5 ±0.5) (5 ±0.5)
Max. 10 Max. 15
Play of control lever
(Max. 0.4) (Max. 1.0)
15.7 ±3.9 Max. 24.5
Boom control lever
(56 ±18) (Max. 88)
15.7 ±3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within (56 ±18) (Max. 88)
of control levers
Operating force
PC350LC/HD-8 20-3
STANDARD VALUE TABLES STANDARD VALUE TABLES
315+15
-25 285 - 335
Swing
+213 (4,054 - 4,764)
(4,480 -356 )
380+3
-1 365 - 415
Travel
(5,405+43 (5,192 - 5,903)
-14 )
• Hydraulic oil temperature: Within operation range
Control circuit • Engine running at high idling 33 ±2 29 - 35
source pressure • Self-reducing pressure valve output pressure with all (469 ±28) (412 - 498)
control levers in NEUTRAL position
• Hydraulic oil temperature: Within When all control
operation range levers in 40 ±10 40 ±10
• Engine at high idling NEUTRAL (569 ±142) (569 ±142)
LS differential • Working mode: P mode position
pressure • Traveling speed: Hi When traveling
• Hydraulic oil pump pressure - LS at half stroke 25 ±1 25 ±1
pressure (356 ±14) (356 ±14)
(without load)
• Hydraulic oil temperature: Within operation range 30+5.5 30+5.5
PPC valve output -1.5 -1.5
• Engine at high idling
pressure (427+78 (427+78
• Control lever at full stroke -21 ) -21 )
Swing
20-4 1 PC350LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value
Hydraulic drift of mm 0 0
swing • Hydraulic oil temperature: Within operation range (in) (0) (0)
• Engine stopped
• Keeping upper structure transverse on slope of 15
degrees
• Notching a mating mark on inner and outer races of
swing circle
• Mating mark misalignment amount during 5 minutes
• Hydraulic oil temperature: Within operation range
Leakage from swing • Engine running at high idling l/mim Max. 5.5 Max. 11
motor • Swing lock switch: ON (g/min) (Max. 1.5) (Max. 3.0)
• Leakage amount for one minute during swing relief
PC350LC/HD-8 20-5
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value
Travel speed
(idle travel) LC: 41.5 ±6.0 LC: 34.0 - 51.5
• Hydraulic oil temperature: Within Mi
HD: 50.3 ±7.3 HD: 43 - 57.6
operation range
• Engine running at high idling
• Working mode: P mode
• Time required for track shoes to LC: 34.0 ±2.0 LC: 32.0 - 41.5
make 5 turns after making one Hi
HD: 41 ±2.4 HD: 38.6 - 43.4
initial idle turn
sec.
Travel speed
(actual speed) • Hydraulic oil temperature: Within LC: 16.7 ±2.2 LC: 14.4 - 21.0
Mi
operation range HD: 18 ±2.4 HD: 15.6 - 20.4
• Engine running at high idling
Travel
20-6 PC350LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value
mm 0 0
Hydraulic drift of travel
• Hydraulic oil temperature: Within (in) (0) (0)
operation range
Travel
• Engine stopped
• Parking machine on slope of 12
degrees with sprocket facing up the
slope
• Sliding distance for 5 minutes
• Hydraulic oil temperature: Within
LC: Max. 15 LC: Max. 30
operation range
(Max.4.0) (Max. 8.0)
• Engine at high idling l/min
Leakage of travel motor
• Traveling with sprocket locked (g/min)
HD: Max. 20 HD: Max. 40
• Oil leakage amount for one minute
(Max.5.3) (Max.11.0)
with traveling in relief condition
Whole work equipment (tooth tip Max. 450 Max. 675
fall amount) (Max. 18) (Max. 27)
Boom cylinder (cylinder retraction Max. 25 Max. 38
amount) (Max. 1.0) (Max. 1.5)
Hydraulic drift of work equipment
PC350LC/HD-8 20-7
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value
RAISE
3.8 ±0.4 Max. 4.5
Boom
• Hydraulic oil temperature: Within operation
range
LOWER
• Engine running at high idling
• Working mode: P mode 2.8 +0.4 Max. 3.0
-0.1
• Time required from raise stroke end till bucket
touches ground
IN
3.8 ±0.4 Max. 4.5
Work equipment speed
Arm
sec.
• Hydraulic oil temperature: Within operation
range
OUT
• Engine running at high idling 2.9 ±0.3 Max. 3.5
• Working mode: P mode
Work equipment
Bucket
• Hydraulic oil temperature: Within operation
range
DUMP
20-8 PC350LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value
Hydraulic pump
See next page l/min. See next page
delivery
PC350LC/HD-8 20-9
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC350LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value
Performance of hydraulic pump
20-10 1 PC350LC/HD-8
30 TESTING AND ADJUSTING
PC350LC/HD-8 30-1 B
TESTING AND ADJUSTING TABLE OF CONTENTS
Display of Warning After Check Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
Display of Ending of Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Display of Check of Working Mode and Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Display of Ordinary Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Display of End Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Selection of Auto-deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Selection of Working Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
Selection of Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Operation to Stop Alarm Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Operation of Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Operation of Window Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Operation of Air Conditioner/heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Operation to Display Camera Mode (if CameraiIs Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
Operation to Display Clock and Service Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
Check of Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
Setting and Display of User Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
KOMTRAX Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Display of Energy-saving Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Display of Caution Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Display of Automatic Judgment of Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
Display of User Code and Failure Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
Function of Checking Display of LCD (Liquid Crystal Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
Function of Checking Service Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
Function of Changing Attachment/Maintenance Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Abnormality Record (Mechanical Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Abnormality Record (Electrical Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Abnormality Record (Air-conditioning System/Heater System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Maintenance Mode Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
Phone Number Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Default (Key-ON Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Default (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Default (With/Without Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
Default (Attachment/Maintenance Password) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
Default (Camera) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
Default (ECO Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112
Default (Breaker Detect) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Adjustment (Pump Absorption Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Adjustment (Low Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
Adjustment (Attachment Flow Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
Cylinder Cut-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
No Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-119
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
KOMTRAX Settings (Terminal Status) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-122
KOMTRAX Settings (GPS & Communication Status) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-123
KOMTRAX Setting (Modem S/N: TH300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-124
Display of KOMTRAX Service Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125
Long Distance Transport Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-126
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . 30-129
PROCEDURE FOR TESTING DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134
PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
30-2 B PC350LC/HD-8
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS‘
12
CHASSIS SERVICE TOOLS‘
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Intake air pressure 1 799-201-2202 Boost gauge kit 1 -101 - 200 kPa
A
(boost pressure) 2 799-401-2220 Hose 1 {-760 - 1,500 mmHg}
1 799-201-9001 Handy smoke checker 1 Degree of contamination 0 to 70%
(with the standard color)
Checking exhaust gas color B Commercially
2 Smoke meter 1 (Degree of contamination x 1/10
available approximate Bosch index)
1 795-799-1131 Gear 1
Adjusting valve clearance C Commercially
2 Clearance gauge 1
available
1 795-799-6700 Puller 1
4 6754-11-3130 Gasket 1
0 - 5.0 kPa
1 799-201-1504 Blow-by checker 1
Testing blow-by pressure E {0 - 500mm H2O}
2 795-790-3300 Tool (nozzle) 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 25, 60, 400, 600 kg/cm2
1 (356, 853, 5689, 8534 psi)
Pressure gauge:
799-261-1204 Digital hydraulic tester 1
600 kg/cm2 (8534 psi)
Testing engine oil pressure F
Pressure gauge:
2 799-401-2320 Gauge 1
1.0 MPa {10 kg/cm2}
6732-81-3170 Adapter 1 Size: 10 x 1.0 mm
3
6215-81-9710 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 25, 60, 400, 600 kg/cm2
1 (356, 853, 5689, 8534 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
600 kg/cm2 (8534 psi)
6732-81-3170 Adapter 1 Size: 10 x 1.0 mm
Testing fuel pressure G 2
6215-81-9710 O-ring 1
Pressure gauge:
3 799-401-2320 Gauge 1
10 kg/cm2 (142 psi)
795-790-1500 1 Male: 7/8 - 14UNF
Female: 7/8 - 14UNF
4 Fuel vacuum gauge
799-201-1201 1 Male: 3/4 - 16UNF
Female: 3/4 - 16UNF
1 795-790-4800 Hose kit 1
Testing fuel return rate 2 795-790-6700 Adapter 1
H
and leakage
Commercially
3 Measuring cylinder 1
available
Testing swing circle Commercially
J Dial gauge 1
bearing clearance available
PC350LC/HD-8 30-3 B
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS‘
12
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
Pressure gauge:
799-101-5002 Hydraulic tester 1 25, 60, 400, 600 kg/cm2
Oil pressure in work 1 (356, 853, 5689, 8534 psi)
equipment, swing and travel
circuits, basic pressure of L Pressure gauge:
790-261-1204 Digital hydraulic tester 1
control circuit and oil pressure 600 kg/cm2 (8534 psi)
of pump PC control circuit
799-101-5220 Nipple 1 Size: 10 x 1.0 mm
2
07002-11023 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 25, 60, 400, 600 kg/cm2
1 (356, 853, 5689, 8534 psi)
Pressure gauge:
799-261-1204 Digital hydraulic tester 1
Oil pressure of pump LS M 600 kg/cm2 (8534 psi)
control circuit
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Differential pressure
3 799-401-1340 1
gauge
Pressure gauge:
799-101-5002 Hydraulic tester 25, 60, 400, 600 kg/cm2
1 (356, 853, 5689, 8534 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
Testing solenoid valve output 600 kg/cm2 (8534 psi)
N
pressure 799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
799-401-3200 Adapter 1 Size: 03
3
02896-11009 O-ring 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 25, 60, 400, 600 kg/cm2
PPC valve output pressure P (356, 853, 5689, 8534 psi)
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
600 kg/cm2 (8534 psi)
Oil leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 • T-adapter 1 Ne sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
799-601-4211 • T-adapter 1 Engine controller
Troubleshooting for engine R 799-601-4220 • T-adapter 1 Engine controller
controller/sensors/actuators
799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-4260 • T-adapter 1 Engine controller
799-601-9420 • T-adapter 1 For injector
799-601-9430 • Socket 1 For supply pump PCV
30-4 B PC350LC/HD-8
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS‘
12
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 • T-adapter box 1 For Econo
799-601-2740 • MIC adapter 1 For MIC-5P
799-601-4100
or
799-601-4200
or T-adapter assembly 1
799-601-9000
or
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
Troubleshooting for chassis or
S 799-601-8000
sensors/wiring harnesses
799-601-7010 • Adapter for X 1
799-601-7020 • Adapter for X 1 For X2P
799-601-7040 • Adapter for X 1 For X4P
For SW6P (Does not include
799-601-7050 • Adapter for SWP 1 799-601-8000)
For SW8P (Does not include
799-601-7060 • Adapter for SWP 1 799-601-8000)
For SW14P (Does not include
799-601-7070 • Adapter for SWP 1 799-601-8000)
For M1P (Does not include
799-601-7080 • Adapter for M 1 799-601-7000 and 799-601-
7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7110 • Adapter for M 1 For M3P
799-601-7120 • Adapter for M 1 For M4P
799-601-7130 • Adapter for M 1 For M6P
799-601-7140 • Adapter for S 1 For S8P
799-601-7160 • Adapter for S 1 For S12P
799-601-7170 • Adapter for S 1 For S16P
799-601-7210 • Adapter for AMP040 1 For A16P
799-601-7220 • Adapter for AMP040 1 For A20P
799-601-7320 • Adapter for SWP 1 For SW16P
PC350LC/HD-8 30-5 B
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS‘
12
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
799-601-7340 • Adapter for M 1 For M8P
799-601-7360 • Adapter for relay 1 For REL-5P
799-601-7370 • Adapter for relay 1 For REL-6P
799-601-7500 • T-adapter assembly 1
799-601-7520 • Adapter for 070 1 For 070-12P
Troubleshooting for chassis 799-601-9000
S
sensors/wiring harnesses or T-adapter assembly 1
799-601-9200
799-601-9030 • Adapter for DT 1
799-601-9110 • Adapter for DT(GR) 1 For DT12PGR
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
Water and oil temperature - 799-101-1502 Digital thermometer 1 -99.9 - 1,299°C
30-6 B PC350LC/HD-8
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS‘
12
Sketches of special tools
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
PC350LC/HD-8 30-7 B
TESTING AND ADJUSTING ENGINE
12
ENGINE
Engine Speed
★ Measure the engine speed with the monitoring function of the machine monitor.
★ Measure the engine speed under the following condition.
Engine coolant temperature: . . . . . . . . . . . . . . Within operating range
Hydraulic oil temperature: . . . . . . . . . . . . . . . . Within operating range
1. Preparation work.
Operate the machine monitor so that the engine speed can be monitored.
★ For the operating method of the machine monitor, see “Special functions of machine monitor”.
★ Monitoring code: 01002 Engine speed.
5. Measuring the engine speed when 2-pumps relief and power maximizing (near rated speed).
A. Start the engine and move the arm cylinder to the IN stroke end.
B. Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P).
C. While operating the left work equipment control lever to relieve the arm at the IN stroke end and depressing the
power maximizing switch, measure the engine speed.
★ The power maximizing function is reset automatically in about 8.5 seconds even if the switch is being depressed.
Thus measurement of the engine speed must be completed within that period.
30-8 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
3. Install nipple [1] of boost gauge kit A and connect them to gauge [3].
4. Start the engine and keep it running until temperature of the engine
coolant and hydraulic oil rise to the operating range.
5. Run the engine at middle or higher speed and drain oil from the hose.
★ When draining the oil, open the self seal of the hose by insert
approximately half of the gauge and hose connection. Repeat
operation until the oil is drained out.
★ If Pm kit (A) is available, you may use the air bleeding coupling
(790-261-1130) in that kit.
★ If oil is left in the hose, the gauge does not work. Accordingly,
be sure to drain the oil.
6. Measure the air boost pressure at high idle under the following
conditions.
• Working mode: P-mode
• Swing lock switch: ON (high pressure relief)
• Work equipment, swing and travel: Arm IN relief position
PC350LC/HD-8 30-9 B
TESTING AND ADJUSTING ENGINE
12
Exhaust Gas Color
★ Exhaust gas color measurement tools.
WARNING! Be careful not to touch any hot part when removing or installing the measuring
instruments.
★ If an air source and an electric power source are not available in the field, use handy smoke checker B1. When recording
official data, use smoke meter B2.
30-10 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
B. Connect the probe hose, receptacle of the accelerator switch and
air hose to smoke meter B2.
★ Limit the supplied air pressure to 15 kg/cm2 (213 psi).
C. Connect the power cable to an AC receptacle.
★ Confirm that the smoke meter power switch is in the OFF
position, before connecting the power cable to an outlet.
D. Loosen the cap nut of the suction pump and fit in the filter paper.
★ Fit in the filter paper securely so that the exhaust gas may
not leak.
E. Turn on the power switch of smoke meter B2.
F. Start the engine and keep it running until the engine coolant
temperature rises to the operating range.
G. Accelerate the engine suddenly or run it at high idle and then depress the accelerator pedal of smoke meter B2 to
collect the exhaust gas into the filter paper.
H. Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets) in the filtering paper holder, and
read the indicated value.
I. Remove the measurement tools after the measurement, and make sure that the machine is back to normal condition.
PC350LC/HD-8 30-11 B
TESTING AND ADJUSTING ENGINE
12
Valve Clearance
★ Valve clearance adjustment tools.
2. Disconnect blow-by tube (2) and breather tube (3) and remove
cylinder head cover (4).
4. Remove cap (6), set gear C1 and rotate the crank shaft forward to set
No.1 cylinder to the compression top dead center.
★ Aligning TDC stamp line (a) of gear cover (7) and supply pump
gear stamp line (b), set No.1 cylinder to the compression top
dead center.
30-12 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
5. After setting No.1 cylinder to the compression top dead center, apply
counter mark C to the damper and then install pointer [1] of the
magnet base.
PC350LC/HD-8 30-13 B
TESTING AND ADJUSTING ENGINE
Compression Pressure
★ Testing tools for compression pressure.
Symbol Part No. Part name
1 795-799-6700 Puller
2 795-502-1590 Compression gauge
D
3 795-790-6110 Adapter
4 6754-11-3130 Gasket
3. Disconnect harness (2) and remove bracket (3) and air heater (4).
5. Move fuel filter and corrosion resistor assembly (8) to the control
valve side along with the hose being connected to it.
30-14 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
7. Disconnect air intake connector (10) and wiring harness connectors
(11) and (12).
10. Loosen injector terminal nuts (17) and remove the terminal from the
injector.
11. Move the cylinder to be tested to the compression top dead center.
★ For the adjustment, refer to the section, “Adjusting valve
clearance”.
13. Remove retainer (19) and remove fuel inlet connector (20).
PC350LC/HD-8 30-15 B
TESTING AND ADJUSTING ENGINE
21. Select the no-injection cranking operation from the machine monitor.
★ See the section of “Special functions of machine monitor”.
22. Rotate the engine by cranking the starting motor and measure the
compression pressure.
★ Read the pressure gauge pointer when it is stabilized.
30-16 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
23. After finishing testing, remove the testing tools and return the
removed parts.
★ Install the injector and fuel high-pressure tube according to the
following procedure.
A. Mate the injector's projection (a) to notch (b) of the holder and
then set them to the cylinder head.
★ Set the injector with the above mating position toward the
fuel inlet connector insertion side.
PC350LC/HD-8 30-17 B
TESTING AND ADJUSTING ENGINE
F. Tighten the sleeve nut of high-pressure fuel hose (16)
sequentially in the order of head side and common rail side.
Terminal nut:
1.25 ±0.25 N•m (0.92 ±0.18 lbf ft)
30-18 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
Blow-by Pressure
★ Blow-by pressure measurement tools.
Symbol Part No. Part name
1 799-201-1504 Blow-by checker
E
2 795-790-3300 Tool (Nozzle)
2. Install tool E2 to blow-by hose (1) and connect gauge [1] of blow-by
checker E1.
3. Start the engine and keep it running until temperature of the engine
coolant and hydraulic oil rise to the operating range.
4. Measure the blow-by pressure at high idle and under the following
conditions.
• Working mode: P-mode
• Swing lock switch: ON (high pressure relief)
• Work equipment: Arm IN relief position
★ Read off the blow-by pressure value, when the needle of the
gauge steadies itself.
PC350LC/HD-8 30-19 B
TESTING AND ADJUSTING ENGINE
12
Engine Oil Pressure
★ Measuring tools for engine oil pressure.
5. Run the engine at the rated output and low idle and test the oil
pressure.
6. After finishing testing, remove the measuring tools and return the
removed parts.
30-20 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
Fuel Pressure
PC350LC/HD-8 30-21 B
TESTING AND ADJUSTING ENGINE
12
2. Measuring pressure in the fuel negative pressure circuit (supply
pump).
A. Remove fuel pressure pickup plug (2) of the supply pump.
C. Run the engine at high idle and measure the pressure in the fuel
negative pressure circuit.
★ If the pressure in the fuel negative pressure circuit is in the
following range, it is normal.
• Standard pressure value in the fuel negative pressure circuit
(supply pump) Max. 33.9 kPa {Max. 254 mmHg}
D. After finishing measurement, remove the measuring tools and
return the removed parts.
30-22 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
C. Measure pressure in the fuel low-pressure circuit when the
engine is cranked.
★ If the pressure in the fuel low-pressure circuit (at the fuel
filter inlet side) is in the following range, it is normal.
• Standard pressure values of the fuel low-pressure circuit
(fuel filter inlet side) Min. 1.4 kg/ cm2 (Min. 19.9 psi)
PC350LC/HD-8 30-23 B
TESTING AND ADJUSTING ENGINE
C. Run the engine at high idle and measure the pressure of the fuel
low-pressure circuit.
★ If the pressure in the fuel low-pressure circuit (at the fuel
filter outlet side) is in the following range, it is normal.
• Standard pressure values of the fuel low-pressure circuit
(fuel filter outlet side) Min. 4.9 kg/cm2 (Min. 69.9 psi)
D. After finishing measurement, remove the measuring tools and
return the removed parts.
C. Run the engine at high idle and measure drop of the pressure of
the fuel low-pressure circuit.
• Pressure drop in the fuel low-pressure circuit = Fuel filter
inlet pressure – Fuel pressure outlet pressure
★ If the pressure drop in the fuel low pressure circuit is in the
following range, it is normal.
• Standard pressure drop values for the fuel low-pressure
circuit: Max. 1.4 kg/cm2 (Max. 19.9 psi)
★ When the measured pressure drop exceeded the standard
value, clogging of the fuel filter should be suspected.
D. After finishing measurement, remove the measuring tools and
return the removed parts.
30-24 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
6. Testing fuel lift pump outlet pressure (supply pump section).
A. Remove fuel pressure pickup plug (2) of the supply pump.
C. 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).
★ The fuel lift pump operates for 30 seconds after the starting
switch is turned ON and then stops. Measure the pressure
while the pump is operating.
★ If the fuel lift pump outlet pressure is in the following
standard range, it is normal.
Standard fuel lift pump outlet pressure (supply pump section):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Min. 0.35 kg/cm2 (4.97 psi)
PC350LC/HD-8 30-25 B
TESTING AND ADJUSTING ENGINE
12
Handling During Cylinder Cut-out Operation
★ Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled
electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows.
1. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal).
2. If the engine speed and output remain the same as the normal operation (full-cylinder mode operation) when a cylinder is
set to no injection in the cylinder cut-out operation, existence of a failure on the subject cylinder should be suspected.
Followings are the potential causes.
• 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 operating system).
• Failure in the electrical system.
3. Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform
the reduced cylinder mode operation easily with switches to find out a defective cylinder.
★ See the section of “Special functions of machine monitor” when turning on the cylinder cut-out operation.
30-26 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
Fuel Return Rate And Leakage
★ Testing tools for leakage from pressure limiter and return rate from injector.
Symbol Part No. Part name
1 795-790-4800 Hose KIT
2 795-790-6700 Adapter
H
Commercially
3 Measuring cylinder
available
WARNING! Park the machine on level ground and lower the work equipment to the ground.
B. Connect testing tool H1 to the supply pump side, and insert its
tip into measuring cylinder H3.
C. Connect blocking tool H2 to the fuel return connector side to
prevent leakage of the fuel.
D. Install the aftercooler hose, run the engine at low idle and then
measure the return rate from the supply pump.
★ If the return rate from the supply pump is in the following
range, it is normal.
At low idle Max. 300 cc/30 sec.
At cranking Max. 200 cc/30 sec.
WARNING! If the engine cannot be started, you may measure the fuel return rate while rotating the
engine with the starting motor. Do not rotate for more than 30 seconds continuously,
however, for protection of the starting motor.
E. After finishing testing, remove the testing tools and return the removed parts.
PC350LC/HD-8 30-27 B
TESTING AND ADJUSTING ENGINE
12
2. Testing leakage from pressure limiter.
★ If failure code [CA449] is displayed, carry out troubleshooting
for it first.
A. Disconnect joint bolt (3) of return tube (2) of the pressure
limiter.
E. After finishing testing, remove the testing tools and return the
removed parts.
D. Run the engine at low idle and test the return rate from the
injector.
★ If the return rate from the injector is in the following range,
it is normal.
At low idle Max. 300 cc/45 sec.
At cranking Max. 100 cc/30 sec.
30-28 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
E. After finishing testing, remove the testing tools and return the removed parts.
PC350LC/HD-8 30-29 B
TESTING AND ADJUSTING ENGINE
12
Bleeding Air From Fuel Circuit
★ If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit using the electric priming
pump according to the following procedure.
2. Remove fuel pre-filter (on the machine) and fill it with fuel.
★ Fill the fuel filter with clean fuel and take care that dirt will not
enter it.
★ Check that the cap is fitted to part (a) (central hole) of the fuel
pre-filter, and then add fuel through part (b) (holes around the
central hole).
★ After filling the fuel pre-filter with fuel, remove the cap from
part (a).
★ If clean fuel is not available, do not remove the fuel pre-filter
but fill it with the fuel by operating priming pump.
★ Do not add fuel to fuel main filter (1) from outside.
4. Keep the starting switch at the ON position for 30 seconds and keep it at the OFF position for 10 seconds.
30-30 B PC350LC/HD-8
TESTING AND ADJUSTING ENGINE
12
Fuel Circuit For Leakage
WARNING! Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire. After testing the
fuel system or removing its parts, test it for fuel leakage according to the following
procedure.
★ Clean and degrease the engine and the parts around it in advance so that you can test it easily for fuel leakage.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure
piping.
2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
PC350LC/HD-8 30-31 B
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION
12
AIR COMPRESSOR BELT TENSION
Inspection
Test belt deflection amount (a) when depressing the mid point between
the fan pulley and the compressor pulley with your finger.
Belt depressing force: . . . . . . . . . . . .98 N {10 kg} or equivalent
Adjustment
1. Loosen mounting bolt (2) and fixing bolt (3) of compressor bracket
(1).
2. Slide compressor bracket (1) using the bar, adjust the belt tension
and then tighten fixing bolt (3).
30-32 B PC350LC/HD-8
TESTING AND ADJUSTING FAN BELT
12
FAN BELT
★ The auto-tensioner is provided for the fan belt. Thus, testing and adjusting of the belt is usually not necessary.
★ Disconnect air conditioner compressor belt before replacing the fan belt.
WARNING! Park the machine on level ground and lower the work equipment to the ground.
1. Open engine hood and remove fan belt cover (1) and fan guard (2).
2. Insert a wrench (a) to the portion (A) (width across flats T 12.7 mm)
of the tensioner assembly (3), and rotate it opposite to the winding-
up direction to decrease the fan belt (4) tension.
WARNING! After removing the fan belt (4), return the tensioner assembly (3) slowly with care.
WARNING! Be careful not to get your fingers caught between the pulley and fan belt (4) during work.
PC350LC/HD-8 30-33 B
TESTING AND ADJUSTING ALTERNATOR BELT
12
ALTERNATOR BELT
★ The auto-tensioner is provided for the alternator belt. Thus, testing and adjustment of the belt is usually not necessary.
★ Disconnect air conditioner compressor belt before replacing the alternator belt.
1. Open engine hood and remove fan belt cover (1) and fan guard (2).
2. Insert a wrench (a) to the portion (B) (width across flats T 12.7 mm)
of the tensioner assembly (5), and rotate opposite to the winding-up
direction to decrease the alternator belt (6) tension.
WARNING! After removing the alternator belt (1), return the tensioner assembly (5) slowly with care.
WARNING! Be careful not to get your fingers caught between the pulley and alternator belt (6) during
work.
30-34 B PC350LC/HD-8
TESTING AND ADJUSTING SWING CIRCLE BEARINGS
12
SWING CIRCLE BEARINGS
★ Follow the steps explained below when measuring clearance in the swing circle bearing on the actual machine.
Mark Part No. Part Name
J Commercially available Dial gauge
WARNING! Be careful not to put a hand or foot under the undercarriage, while taking measurement.
1. Fasten dial gauge J to swing circle outer race (1) or inner race (2),
and contact the probe against the end surface of inner race (2) or
outer race (1) on the opposite side.
★ Set dial gauge J at the machine front or rear side.
2. Keep the work equipment in the max. reach posture and keep the
height of the bucket teeth tip level with the lower height of the
revolving frame.
★ The upper structure is lowered at the front and raised at the rear
at that time.
4. Hold the arm nearly perpendicular to the ground, and lower the
boom until the track shoes are lifted at the machine front.
★ The upper structure is raised at the front and lowered at the rear
at that time.
6. Return the machine to the posture in Item 2 above, and confirm dial
gauge J reading returns to zero.
★ If zero value is not indicated, repeat the steps in Items 3 through
5.
PC350LC/HD-8 30-35 B
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
INSPECTION
1. Travel the machine forward by the length of track on ground with the
engine at low idle and then stop the machine slowly.
2. Place straight bar [1] on the track shoe between the idler and the 1st
carrier roller.
★ L beam is recommended for bar [1] because of its
deflection-free nature.
3. Measure maximum clearance (a) between bar [1] and the track shoe.
Standard clearance (a): . . . . . . . . . . . . 10 - 30 mm (0.4 - 1.2 in)
ADJUSTMENT
30-36 B PC350LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT
12
OIL PRESSURE IN WORK EQUIPMENT
★ Checkup of the oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) is also available
from the monitoring function of the machine monitor (Special functions of machine monitor).
Measurement
1. Preparation work.
PC350LC/HD-8 30-37 B
TESTING AND ADJUSTING OIL PRESSURE IN TRAVEL CIRCUIT
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
30-38 B PC350LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN TRAVEL CIRCUIT
12
5. Measuring Swing Relief Pressure
A. Start the engine and move the swing lock switch to the ON position.
B. Measure hydraulic oil pressure when the engine is running at high idle and the swing circuit is relieved.
★ Hydraulic oil pressure when the swing motor safety valve is relieved is displayed.
★ The relief pressure of the swing motor is lower than the main relief pressure.
B. Measure the pressure when the engine is set to high idle and the
travel circuit is relieved.
★ Hydraulic oil pressure with the main relief valve in relief
condition is displayed. In the travel circuit relief, the
pressure is high pressure relief all the time.
ADJUSTING
C. Check the pressure again after the adjustment, following the last
steps for measurement.
★ Connect the pilot hose when measuring the oil pressure.
PC350LC/HD-8 30-39 B
TESTING AND ADJUSTING OIL PRESSURE IN TRAVEL CIRCUIT
12
2. Adjusting Boom LOWER Relief Pressure (on the side where high
pressure is set)
★ When the high-pressure relief pressure for the boom
LOWER is not normal, adjust the high pressure side of the
safety and suction valve (7) for the boom LOWER in the
following procedure.
★ The the high-pressure relief pressure mode denotes the state
in which the machine push-up switch is turned on, disabling
to apply the pilot pressure to the switching port.
3. Adjusting Boom LOWER Relief Pressure (on the side where low
pressure is set)
★ When low-pressure relief pressure of the boom LOWER is not
normal or when adjustment is made of the high pressure setting
side, adjust the low pressure side of the safety and suction valve
for the boom LOWER in the following procedure.
★ The low-pressure relief pressure mode denotes the state in
which the machine push-up switch is turned off, disabling to
apply the pilot pressure to the switching port.
A. Disconnect the pilot hose.
B. Loosen locknut (10) and turn holder (11) to adjust the relief
pressure.
★ Turning the holder clockwise increases the pressure. Turning it counterclockwise decreases the pressure.
Pressure adjustable from a single turn of the holder:. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 222 kg/cm2 (3,157 psi)
C. Check the pressure again after the adjustment, following the aforementioned steps for measurement.
★ Connect the pilot hose when measuring the oil pressure.
30-40 B PC350LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN TRAVEL CIRCUIT
12
4. Adjusting Swing Relief Pressure.
★ If the swing relief pressure is not normal, adjust the swing motor
safety valve (12) in the following manner.
A. Loosen locknut (13) and turn adjustment screw (14) to adjust the
relief pressure.
★ Turning the holder clockwise increases the pressure.
Turning it counterclockwise decreases the pressure.
Quantity of adjustment per turn of adjusting screw: . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .Approximately 47.9 kg/cm2 (681 psi)
PC350LC/HD-8 30-41 B
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
12
CONTROL CIRCUIT OIL PRESSURE
★ Control circuit oil pressure testing and adjusting tools.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
MEASURING
3. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
5. Remove the measurement tool after the measurement, and make sure
that the machine is back to normal condition.
★ It is not allowed to adjust the relief valve of the control circuit
source pressure.
30-42 B PC350LC/HD-8
TESTING AND ADJUSTING PUMP PC OIL PRESSURE
12
PUMP PC OIL PRESSURE
★ Pump PC control circuit oil pressure testing and adjusting tools.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
MEASURING
PC350LC/HD-8 30-43 B
TESTING AND ADJUSTING PUMP PC OIL PRESSURE
12
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the pump discharge pressure and PC valve output pres-
sure (pressure at servo piston inlet) at the same time after setting
following conditions with the engine running at high idle.
Working mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-mode
Swing lock switch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . ON (Turning 2-stage relief ON induces high-pressure relief)
Work equipment, swing and travel: . . . . . . . . . . . . Arm IN relief
★ Judgement method: When the ratio between the pump
discharge pressure and PC valve output pressure (servo
piston output pressure) reaches the following values, both
pressures are judged normal.
★ If there is any abnormality with PC valve or servo piston, the PC valve output pressure (servo piston output
pressure) becomes identical with the pump discharge pressure or comes to around of 0 pressure.
30-44 B PC350LC/HD-8
TESTING AND ADJUSTING PUMP PC OIL PRESSURE
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the hydraulic oil pressure with all the control levers
kept in the NEUTRAL position and the engine running at high
idle and at low idle.
ADJUSTING
1. Loosen locknut (8) and turn holder (9) to adjust the pump
absorption torque.
★ Turning the holder clockwise increases the pump absorption
torque. Turning the holder counterclockwise decreases the pump
absorption torque.
★ Following indicates the range of adjustment available from the
adjusting screw.
Counterclockwise: . . . . . . . . . . . . . . . . . . . . . . . . . Within 1 turn
Clockwise: . . . . . . . . . . . . . . . . . . . Within 1/2 turn (Within 180°)
2. After the adjustment, make sure that the PC valve output pressure (servo piston inlet pressure) is normal using the mea-
surement steps explained earlier.
PC350LC/HD-8 30-45 B
TESTING AND ADJUSTING PUMP LS OIL PRESSURE
12
PUMP LS OIL PRESSURE
30-46 B PC350LC/HD-8
TESTING AND ADJUSTING PUMP LS OIL PRESSURE
12
C. Start the engine and lift the track shoe on the side to be
measured using work equipment.
• When measuring the front circuit: Left track shoe
• When measuring the rear circuit: Right track shoe
F. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.
PC350LC/HD-8 30-47 B
TESTING AND ADJUSTING PUMP LS OIL PRESSURE
12
B. Install nipple M2 and connect it to oil pressure gauge on
differential pressure gauge M3 of hydraulic tester M1.
WARNING! Provide a working area of sufficient space, as the raised track shoe will be idly rotated.
F. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.
30-48 B PC350LC/HD-8
TESTING AND ADJUSTING PUMP LS OIL PRESSURE
12
3. Measurement of LS-EPC valve output pressure
A. Remove oil pressure measurement plug (7).
★ The plug is installed on the rear pump.
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the oil pressure when the engine is running at high idle
and the travel speed switch and travel control lever are operated.
★ If LS-EPC valve output pressure changes to the following
values, the pressure is normal.
Travel
Travel control lever Oil pressure
speed
Lo Neutral Approximately 14 kg/cm2 (199 psi)
Fine operation
Hi 0 kg/cm2 (0 psi)
(Remark)
Remark
Operate the travel control lever slightly to the extent that the PPC oil pressure switch is turned ON
(Stop the operation short of starting the machine).
E. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.
PC350LC/HD-8 30-49 B
TESTING AND ADJUSTING PUMP LS OIL PRESSURE
12
ADJUSTING
1. Loosen locknut (10) and turn holder (11) to adjust the differential
pressure.
★ Adjustment screw
• Turned to the right, the differential pressure is increased.
• Turned to the left, the differential pressure is decreased.
★ Quantity of adjustment per turn of adjusting screw:
Quantity of pressure adjustment (LS differential pressure) 13.3
kg/cm2 (189 psi)
2. After the adjustment, confirm that LS differential pressure is normal, following the steps for measurement explained
earlier.
30-50 B PC350LC/HD-8
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
SOLENOID VALVE OUTPUT PRESSURE
★ Solenoid valve output pressure measurement tools.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
799-401-3100 Nipple (02 size)
N 2
02896-11008 O-ring
799-401-3200 Nipple (03 size)
3
02896-11009 O-ring
★ Measure the solenoid valve output pressure after confirming that the
control circuit source pressure is normal.
★ Hose (1) is installed in the back side of operator's cab, and hoses
(2) through (7) are installed at the center of revolving frame.
4. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
PC350LC/HD-8 30-51 B
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
5. Run the engine at full throttle, then turn each solenoid valve ON or OFF by operating the control levers and switches, and
measure the pressure.
★ For conditions for turning each solenoid valve ON or OFF, refer to the ensuing table for functioning conditions for
each solenoid valve.
★ You can check operation of the solenoid valves from the monitoring function of the monitor panel (Special Function
of Machine Monitor).
★ When each output pressure shows the following values, it is judged normal.
6. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.
30-52 B PC350LC/HD-8
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
Table for functioning conditions - Travel speed shifting solenoid valve
PC350LC/HD-8 30-53 B
TESTING AND ADJUSTING PPC VALVE OUTPUT PRESSURE
12
PPC VALVE OUTPUT PRESSURE
★ PPC valve output pressure measurement tools.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
P 1
790-261-1204 Digital hydraulic tester
★ (1) through (8) are installed in the PPC relay block, and (9) and
(10) are installed in the back side of operator cab.
2. Install nipple [1] of the hydraulic tester P and then connect it to oil
pressure gauge.
★ Use the oil pressure gauge with capacity 60 kg/cm2 (853 psi).
3. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
4. Measure the pressure when the engine is running at high idle and the
control lever of the circuit to be measured is kept in the
NEUTRAL position and at the full stroke.
★ If PPC valve output pressure is at the level shown below, it is
judged normal.
5. Remove the measurement tool after the measurement, and make sure
that the machine is back to normal condition.
30-54 B PC350LC/HD-8
TESTING AND ADJUSTING WORK EQUIPMENT VALVE ADJUSTMENT
12
WORK EQUIPMENT VALVE ADJUSTMENT
3. Loosen locknut (2) and screw in disc (3) until it contacts the heads of
4 pistons (4).
★ Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten locknut (2) to the specified
tightening torque.
PC350LC/HD-8 30-55 B
TESTING AND ADJUSTING HYDRAULIC DRIFT IN WORK EQUIPMENT
12
HYDRAULIC DRIFT IN WORK EQUIPMENT
★ If hydraulic drift occurred on the work equipment (cylinder), check to see if the cause is on the cylinder packing side or
control valve side according to the following procedure.
2. When inspecting the boom cylinder, shift the boom control lever to
RAISE side and when inspecting the bucket cylinder, shift the
bucket control lever to CURL side.
If, as the result, drifting speed increases, failure on the cylinder
packing should be suspected.
If the speed remains unchanged, failure on the control valve should
be suspected.
★ Operate the control lever with the engine ignition switch in the
ON position.
★ If pressure in the accumulator has dropped, run the engine for approximately 10 seconds to charge the accumulator
again.
Arm Cylinder
1. Operate the arm cylinder to move the arm to the position 100 mm
before the digging stroke end, and stop the engine.
Remark
When the cause of the hydraulic drift is in the defective packing, the following explains why such occurred.
A. If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom
end leaks to the head end. However, the volume at the head end is small than the volume at the bottom end by the
volume of the rod end, so the internal pressure at the head end increases because of the oil flowing in from the bottom
end.
B. If the internal pressure of the head end increases, the pressure at the bottom end also rises in proportion to this and
balanced at certain level (this level depends on the volume of leakage). As the pressure is balanced, the drifting speed
is decreased.
C. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain
circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the
downward movement becomes faster.
30-56 B PC350LC/HD-8
TESTING AND ADJUSTING HYDRAULIC DRIFT IN WORK EQUIPMENT
12
Boom Lock Valve
1. Set the work equipment at the maximum reach and the boom top
horizontal. Then stop the engine.
2. Disconnect drain hose (1) of the control valve, and install an oil
stopper plug in the hose.
Oil stopper plug: . . . . . . . . . . . . . . . . . . . . . . . . . . .07376-70210
★ Leave the control valve end open.
★ If oil leaks out the opened port accompanying hydraulic drift of the work equipment, failure on the boom lock valve
should be suspected (loose contact).
PPC Valve
Measure the amount of hydraulic drift of the work equipment when the accumulator is charged with pressure and the lock
lever is put to the LOCK and FREE positions.
★ Operate the control lever with the engine ignition switch in the ON position.
★ If pressure in the accumulator has dropped, run the engine for approximately ten seconds to charge the accumulator again.
★ If the lock and free position cause any difference in the hydraulic drift volume, the PPC valve is defective (internal
failure).
PC350LC/HD-8 30-57 B
TESTING AND ADJUSTING RELEASING HYDRAULIC PRESSURE
12
RELEASING HYDRAULIC PRESSURE
WARNING! When disconnecting the piping routed from the hydraulic cylinder and the hydraulic motor
to the control valve, release the residual pressure in the circuit according to the following
procedure.
★ The swing motor circuit and travel motor circuit are free from residual pressure. However, since these circuits are affected
by the pressure inside the hydraulic tank, the operation up to opening of the hydraulic tank cap must be implemented.
1. Stop the engine and then gradually loosen the oil filler cap of the hydraulic tank to release the pressure in the tank.
2. Turn the engine ignition switch to the ON position and operate the control levers several times.
★ Power must be conducted to PPC lock valve, thus the ignition switch must be set to ON position prior to the lever
operation.
★ When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed.
3. Start the engine, run at low idle for approximately 10 seconds to accumulate pressure in the accumulator, then stop the
engine.
1. Start the engine and keep it running until the hydraulic oil tempera-
ture rises to the operating range. Then extend the boom cylinder to
the stroke end.
2. Disconnect hose (1) on the cylinder head end and block the hose end
with a plate.
3. Run the engine at high idle and relieve the boom circuit by raising the boom.
4. Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.
5. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.
30-58 B PC350LC/HD-8
TESTING AND ADJUSTING RELEASING HYDRAULIC PRESSURE
12
Measuring Oil Leakage Amount From Arm Cylinder
1. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the arm
cylinder to the IN stroke end.
WARNING! Release the pressure remaining in the piping referring to “Releasing pressure in hydraulic
circuit”.
2. Disconnect hose (2) on the cylinder head end and block the hose end
with a plate.
3. Run the engine at high idle and relieve the arm circuit by moving the
arm IN.
4. Continue this condition for 30 seconds, then measure the oil leakage
amount for one minute.
5. Remove the measurement tool after the measurement, and make sure
that the machine is back to normal condition.
1. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the bucket
cylinder to the CURL stroke end.
WARNING! Release the pressure remaining in the piping referring to “Releasing pressure in
hydraulic circuit”.
2. Disconnect hose (3) on the cylinder head end and block the hose end
with a plate.
3. Run the engine at high idle and relieve the bucket circuit by moving
the bucket CURL.
4. Continue this condition for 30 seconds, then measure the oil leakage
amount for one minute.
PC350LC/HD-8 30-59 B
TESTING AND ADJUSTING RELEASING HYDRAULIC PRESSURE
12
Measuring Oil Leakage Amount From Swing Motor
1. Disconnect drain hoses (4) and install the oil stopper plug in the
hoses.
3. Run the engine at high idle, relieve the swing circuit, and measure
the oil leakage.
★ Start measuring the oil leakage 30 seconds after relieving is
started and measure for 1 minute.
★ After measuring 1 time, swing 180°, and then measure again.
4. After the measurement, make sure that the machine is back to nor-
mal condition.
Measuring Oil Leakage Amount From Travel Motor
3. Disconnect drain hose (5) of the travel motor and fit an oil stopper
plug in the hose end.
4. Run the engine at high idle, relieve the travel circuit, and measure
the oil leakage.
5. After the measurement, make sure that the machine is back to normal condition.
30-60 B PC350LC/HD-8
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
BLEEDING AIR FROM VARIOUS SYSTEMS
Air bleeding Air bleeding procedures
items
1 2 3 4 5 6
Hydraulic Starting Swing Travel
Cylinder Operation
Contents of work pump engine motor motor
● ●
• Replacement of hydraulic motor
● ● ● (see (see ●
• Cleaning of strainer
Remark) Remark
• Replacement of return filter element ● ➞ ➞ ➞ ●
• Replacement and repair of hydraulic pump
● ● ● ➞ ➞ ●
• Removal of suction piping
• Replacement and repair of control valve ● ● ➞ ➞ ●
• Replacement of cylinder
● ● ➞ ➞ ●
• Removal of cylinder piping
• Replacement of swing motor
● ➞ ● ➞ ●
• Replacement of swing motor piping
• Replacement of travel motor and swivel
● ➞ ➞ ● ●
• Removal of travel motor and swivel piping
Remark
Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Loosen air bleeder (1) and check that oil oozes out through the air
bleeder.
PC350LC/HD-8 30-61 B
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
Bleeding Air From Hydraulic Cylinder
1. Start the engine and keep running at low idle for 5 minutes.
2. Raise and lower the boom four to five times with the engine running at low idle.
★ Stop the piston approximately 100 mm (4 in) in front of the stroke end so that it may not be relieved.
4. Set the piston rod to the stroke end at low idle and allow it to relieve.
5. For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in Item 2 through 4 above.
★ 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.
Bleeding Air From Swing Motor
2. Loosen air bleeder (2) and confirm that oil seeps out from the plug.
30-62 B PC350LC/HD-8
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
Bleeding Air From Travel Motor - PC350HD-8
4. After making sure that the oil from bleeder (4) is free from mixed air,
tighten the bleeder.
5. Using the work equipment, lift the track shoe of one side.
6. Gradually run the lifted track shoe at idle for approximately two
minutes.
★ Repeat the same for the opposite side track shoe.
PC350LC/HD-8 30-63 B
TESTING AND ADJUSTING DIODE INSPECTION PROCEDURES
12
DIODE INSPECTION PROCEDURES
★ Check an assembled-type diode (8 pins) and independent diode (2
pins) in the following manner.
★ The conduction direction of an assembled-type diode is as shown in
the diagram below.
★ The conduction direction of an independent diode is shown on the
diode surface.
1. Switch the testing mode to diode range and confirm the indicated
value.
★ Voltage of the battery inside is displayed with conventional
circuit testers.
2. Put the red probe (+) of the test lead to the anode (P) of and the black
probe (-) to the cathode (N) of diode, and confirm the
indicated value.
★ When the diode range is set, the testing method is the same as that done by use of the digital type circuit tester.
2. Apply the leads of the tester as explained below and check the
movement of the pointer.
A. Put the red probe (+) of the test lead to the anode (P) and the black probe (-) to the cathode (N) of diode.
30-64 B PC350LC/HD-8
TESTING AND ADJUSTING DIODE INSPECTION PROCEDURES
B. Put the red probe (+) of the test lead to the cathode (N) and the black probe (-) to the anode (N) of diode.
3. Determine if a specific diode is good or no good by the way the pointer swings.
• With the connection A above, the pointer is not moved. It swings, however, when the connection B is employed.
However, magnitude of the pointer's move (indicating the resistance value) varies depending on the given tester
model and the measurement range selected.
• The pointer swings with both the connections of A and B: Defective (Internal short circuit)
• The pointer does not swing with both the connections of A and B: Defective (Internal breaking of wire)
PC350LC/HD-8 30-65 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
MACHINE MONITOR - SPECIAL FUNCTIONS
Air conditioner specification
30-66 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Upper section of machine monitor (Display section) Heater specification
(a): Multi-display
★ When the engine is started, the battery voltage may lower suddenly,
depending on the ambient temperature and the condition of the
battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
Upper section of machine monitor (Switch section)
PC350LC/HD-8 30-67 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Ordinary Functions and Special Functions of Machine Monitor
The machine monitor has the ordinary function and special functions and displays information of various types on the
multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed
according to the operation of the switches.
30-68 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
★ Classification of operator mode:
A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and
display after starting switch is turned OFF.
B: Display/Function when switch of machine monitor is operated.
C: Display/Function when certain condition is satisfied.
D: Display/Function which needs special operation of switch.
PC350LC/HD-8 30-69 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Operator Mode (Outline)
★ Only outline of the operator mode is described in this section. For details of contents/operation of each function/display,
see the Structure, function and maintenance standard, or Operation and Maintenance Manual.
★ The following are the displays or functions of the operator mode explained in this section (including some items which
need special operations).
Display pattern
A B C D E
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 - - - -
Display of check of breaker mode - - 2 - -
Display of check before starting 3 2 3 2 2
Display of warning after check before starting - - - 3 -
Display of ending of maintenance interval - - - - 3
Display of check of working mode and travel speed 4 3 4 4 4
Display of ordinary screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner/heater
30-70 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of Komatsu Logo
When the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds.
★ After the KOMATSU logo is displayed for 2 seconds, the screen
changes to “Display of inputting password”, “Display of check of
breaker mode (if B mode is set)”, or “Display of check before
starting”.
PC350LC/HD-8 30-71 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of Check of Breaker Mode
When the starting switch is turned ON, if the working mode is set to the
breaker mode [B], a message to inform the operator of starting in the
breaker mode is displayed on the screen.
30-72 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of Ending of Maintenance Interval
When the check before starting is carried out, if a maintenance item is
near or after the end of the set interval, the maintenance monitor is
displayed for 30 seconds to urge the operator to maintenance.
★ This screen is displayed only when the maintenance function is
effective. The color of the maintenance monitor (yellow or red)
indicates the length of the time after the maintenance interval.
★ Set or change the maintenance function in the service mode.
★ After display of this screen is finished, the screen changes to
“Display of check of working mode and travel speed”.
PC350LC/HD-8 30-73 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of End Screen
When the starting switch is turned OFF, the end screen is displayed for 5
seconds.
★ Another message may be displayed on the end screen, depending on
the message display function of KOMTRAX.
Selection of Auto-deceleration
While the ordinary screen is displayed, if the auto-deceleration switch is
pressed, large auto-deceleration monitor (a) is displayed for 2 seconds
and the setting of the auto-deceleration is changed.
★ Each time the auto-deceleration switch is pressed, the
auto-deceleration is turned ON and OFF alternately.
★ If the auto-deceleration is turned ON, large monitor (a) and
auto-deceleration monitor (b) are displayed simultaneously.
★ If the auto-deceleration is turned OFF, auto-deceleration monitor (b)
goes off.
30-74 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
3. When the ordinary screen is displayed again, large working mode
monitor (a) is displayed for two seconds, and then the setting of the
working mode is changed.
★ When large monitor (a) is displayed, the display of working
mode monitor (b) is changed, too.
PC350LC/HD-8 30-75 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Operation of Windshield Wiper
While the ordinary screen is displayed, if the wiper switch is pressed,
large wiper monitor (a) is displayed for 2 seconds and the windshield
wiper starts or stops.
★ Each time the wiper switch is pressed, the windshield wiper setting
is changed to INT, ON, OFF, and INT again in order.
★ When large monitor (a) is displayed, the display of wiper monitor (b)
is changed or turned OFF, too.
★ If the windshield wiper is turned OFF, large monitor (a) is not
displayed.
★ Heater specification
30-76 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Operation to Display Camera Mode (if CameraiIs Installed)
When a camera is installed, if [F3] is pressed, the multi-display changes
to the camera image (Set the connection of the camera in the service
mode).
PC350LC/HD-8 30-77 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Check of Maintenance Information
While the maintenance monitor or ordinary screen is displayed, press
[F5], and the maintenance table screen is displayed.
Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
30-78 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX Message
• There are two types of KOMTRAX message; one is for the user and the other is for the service.
• For user:
A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is
displayed on the ordinary screen. To see the contents of the message, operate "User Message" in the above user menu.
• For service:
A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed
on the ordinary screen. To see the contents of the message, operate "KOMTRAX message" display in the service
menu.
PC350LC/HD-8 30-79 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of Automatic Judgment of Breaker
If the operator performs breaker work in an improper working mode, the
breaker automatic judgment screen is displayed to urge the operator to
select a proper working mode.
★ The breaker automatic judgment is displayed when the following
condition is satisfied while the display setting is set effective in the
service mode.
★ Condition for display:
When the pump controller measures the rear pump pressure for a
certain time, the obtained value is similar to the pulsation wave form
of breaker operation which is held in the controller in advance.
★ The breaker automatic judgment function is set to Not used (Not
displayed) when delivered.
★ If this screen is displayed, check the setting of the working mode. If
the breaker is being used, select the breaker mode [B].
★ To return to the ordinary screen, press [F5].
30-80 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
★ Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and
Maintenance Manual)
PC350LC/HD-8 30-81 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Function of Checking Display of LCD (Liquid Crystal Display)
While the ordinary screen is displayed, if the following numeral input
switch and function switch are operated as follows, all the LCD (Liquid
Crystal Display) lights up in white.
• Operation of switches (simultaneous): [4] + [F2]
★ When finishing the operation of the switches, release [F2] first.
★ If there is a display error in the LCD, only that part is indicated in
black.
★ The LCD panel sometimes has black points (points which are not
lighted) and bright points (points which do not go off) for the reason
of its characteristics. If the number of the bright points and black
points does not exceed 10, those points are not a failure or a defect.
★ To return to the former screen, press the function switch.
30-82 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Function of Changing Attachment/Maintenance Password
When changing the attachment/maintenance password used for the
attachment setting function and maintenance setting function, follow
these procedures.
4. After the New password input screen is displayed again, input a new
password again with the numeral input switches and confirm it with
the function switch.
• [F5]: Reset input numeral/Return to ordinary screen
• [F6]: Confirm input numeral
★ If a password different from the password input before is input,
the message to input again is displayed.
PC350LC/HD-8 30-83 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
5. If the screen to notify completion of setting is displayed and then the
ordinary screen is displayed, the password is changed successfully.
30-84 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Service Mode
To change the operator mode to the service mode, perform the following
operation.
This operation is always required when you use the service mode.
PC350LC/HD-8 30-85 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 ★ The items which can be selected in the service menu are as follows (including some items which need special
operations).
01 Monitoring
Mechanical Systems
02 Abnormality Record Electrical Systems
Air-conditioning System/Heater System
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Unit
With/Without Attachment
06 Default Attachment/Maintenance Password
Camera
ECO Display
Breaker Detect
Pump Absorption Torque
07 Adjustment Low Speed
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
GPS & Communication Status
11 KOMTRAX Settings
MODEM S/N (TH300)
MODEM IP Address (TH200)
12 Display of KOMTRAX message
30-86 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
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.
PC350LC/HD-8 30-87 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
4. Executing monitoring.
After the “Executing monitoring screen” is displayed, perform the
necessary operation of the machine and check the monitoring
information.
★ Monitoring information is indicated by value, ON/OFF, or
special display.
★ The unit of display can be set to SI unit, metric unit, or inch unit
with the Initialization function in the service mode.
30-88 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 Monitoring items table
Unit (Initial setting: ISO) Component in
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch charge
00200 Controller Model Select - PUMP
00201 Machine ID - ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
R Pump Pressure MPa 2 psi PUMP
01101 kg/cm
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
Bucket Curl PPC Pressure MPa 2 psi PUMP
07300 kg/cm
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01302 PC-EPC Sol. Curr.(R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr.(Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr.(LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value
36500 Boost Pressure kPa kg/cm2 psi ENG indication (including
atmospheric pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque N•m kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sensor Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode - ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque N•m kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
PC350LC/HD-8 30-89 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Unit (Initial setting: ISO) Component
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch in charge
Swing ON/OFF PUMP
Travel ON/OFF PUMP
Boom Lower ON/OFF PUMP
01900 Pressure Switch 1
Boom Raise ON/OFF PUMP
Arm Curl ON/OFF PUMP
Arm Dump ON/OFF PUMP
Bucket Curl ON/OFF PUMP
Bucket Dump ON/OFF PUMP
01901 Pressure Switch 2
Service ON/OFF PUMP
Travel Steering ON/OFF PUMP
Travel Junction ON/OFF PUMP
Swing Brake ON/OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON/OFF PUMP
2-Stage Relief ON/OFF PUMP
Travel Speed ON/OFF PUMP
02301 Solenoid Valve 2 Service Return ON/OFF PUMP
Lever Sw. ON/OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON/OFF PUMP
Swing Brake Sw. ON/OFF PUMP
Model Select 1 ON/OFF PUMP
Model Select 2 ON/OFF PUMP
Model Select 3 ON/OFF PUMP
02201 Switch Input 2
Model Select 4 ON/OFF PUMP
Model Select 5 ON/OFF PUMP
Overload Alarm ON/OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON/OFF PUMP
Window Limit SW. ON/OFF PUMP
02204 Switch Input 5 P Limit SW. ON/OFF PUMP
W Limit SW. ON/OFF PUMP
Key Switch ON/OFF MON
Start ON/OFF MON
04500 Monitor input 1 Preheat ON/OFF MON
Light ON/OFF MON
Rad. Level ON/OFF MON
Air cleaner ON/OFF MON
04501 Monitor Input 2 Eng. Oil Level ON/OFF MON
Battery Charge ON/OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON/OFF MON
F1 ON/OFF MON
F2 ON/OFF MON
Monitor Function F3 ON/OFF MON
04503 Switches F4 ON/OFF MON
F5 ON/OFF MON
F6 ON/OFF MON
SW1 ON/OFF MON
SW2 ON/OFF MON
Monitor 1st & 2nd SW3 ON/OFF MON
04504 Row Switches SW4 ON/OFF MON
SW5 ON/OFF MON
SW6 ON/OFF MON
30-90 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Unit (Initial setting: ISO) Component in
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch charge
SW7 ON/OFF MON
SW8 ON/OFF MON
Monitor 3rd & 4th SW9 ON/OFF MON
04505
Row Switches SW10 ON/OFF MON
SW11 ON/OFF MON
SW12 ON/OFF MON
SW13 ON/OFF MON
04506 Monitor 5th Row SW14 ON/OFF MON
Switches
SW15 ON/OFF MON
18800 Water In Fuel ON/OFF ENG WIF: Water In Fuel
20216 ECM Build Version - ENG
20217 ECM CAL Data Ver - ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No - ENG
20227 Monitor Ass'y P/N - MON
20402 Monitor Serial No - MON
20228 Monitor Prog. P/N - MON
20229 Pump Con. Ass'y P/N - PUMP
20403 Pump Con. Serial No - PUMP
20230 Pump Con. Prog. P/N - PUMP
PC350LC/HD-8 30-91 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Abnormality Record (Mechanical Systems)
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into
the mechanical systems, electrical systems, and air-conditioning system or heater system.
To check the mechanical system abnormality record, perform the following procedures.
1. Selecting menu.
Select “Abnormality Record” on the “Service Menu” screen.
30-92 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
4. Resetting abnormality record.
The contents of the mechanical system abnormality record cannot be reset.
1. Selecting menu.
Select “Abnormality Record” on the “Service Menu” Screen.
PC350LC/HD-8 30-93 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
3. Information displayed on “abnormality record” screen.
On the “Electrical Systems” screen, the following information is
displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time (Displayable range: 0 – 65,535
times)
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
• [F1]:Move to next page (screen) (if displayed)
• [F2]:Move to previous page (screen) (if displayed)
• [F3]:Move to lower item
• [F4]:Move to upper item
• [F5]: Return to “abnormality record” screen
★ If no abnormality record is recorded, "No abnormality record" is displayed.
★ If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at
the last occurrence are the same.
★ If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been
confirmed.
★ For all the failure codes that the machine monitor can record, see the failure codes table.
B. Check that the screen is set in the reset mode, and then reset the
items one by one or together with the function switches.
★ If the screen is set in the reset mode, [CLEAR] graphic
mark is indicated at [F2].
• [F2]: Reset all items
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to abnormality record screen
• [F6]: Reset selected item
★ To reset items one by one: Select the item to be reset with
[F3] or [F4] and press [F6].
★ To reset all items together: Press [F2], and all the items are
reset, regardless of selection of the items.
★ If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.
30-94 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
C. After the “Electrical Sys. Error Reset” screen is displayed,
operate the function switches.
• [F5]: Return to “Electrical systems” screen (Reset mode).
• [F6]: Execute reset.
★ The following figure shows the screen displayed when the
items are reset one by one (which is a little different from
the screen displayed when all the items are reset together).
PC350LC/HD-8 30-95 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
30-96 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
PC350LC/HD-8 30-97 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
30-98 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
PC350LC/HD-8 30-99 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
★ This table lists the failed sections in the order of the failure code.
★ 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.
★ The category of record is used for indicating to which of the electrical and mechanical system of the service menu's
abnormality record a given failure is classified.
★ E of at beginning the action code indicates the following state.
• With E: The failure still remains without being resolved.
• Without E: The failure is already resolved.
30-100 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Abnormality Record (Air-conditioning System/Heater System)
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into
the mechanical systems, electrical systems, and air-conditioning abnormalities or heater abnormalities. To check the
air-conditioning abnormality record or heater abnormality record, perform the following procedures.
★ All the following figures show the air conditioner specification.
1. Selecting menu.
Select “Abnormality Record” on the “Service Menu” screen.
PC350LC/HD-8 30-101 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Maintenance Record
The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by
the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu.
Select “Maintenance Record” on the “Service Menu” screen.
30-102 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
3. Items displayed on maintenance record screen.
The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous replacement
PC350LC/HD-8 30-103 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 ★ The following items can be selected on the Change of maintenance mode screen.
00 Maintenance mode on/off
01 Engine oil change int.
02 Engine oil filter change int.
03 Fuel main filter change int.
41 Fuel pre filter change int.
04 Hyd oil filter change int.
05 Hyd tank breather change int.
06 Corrosion resistor change int.
07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Initialize all items
30-104 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
• Initial value: Maintenance interval set in machine monitor
(Recommended by manufacturer and not changeable).
• Set value: Maintenance interval which can be set freely.
Maintenance functions in operator mode operate on basis of this
set time (which is increased or decreased by 50 hours).
• ON: Maintenance function of this item is set effective in
operator mode.
• OFF: Maintenance function of this item is set ineffective in
operator mode.
• [F3]: Select Reduce set value (Upper) or OFF (Lower).
• [F4]: Select Increase set value (Upper) or ON (Lower).
• [F5]: Cancel setting before confirmation and return to Mainte-
nance mode change screen.
• [F6]: Confirm setting of upper or lower line.
★ After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode
change screen with [F5], the setting is effective.
★ If the set value of an item set to “ON” is changed after 1 or more operating hours since the start of setting, the change
is recognized as a resetting operation.
PC350LC/HD-8 30-105 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Phone Number Entry
The telephone No. displayed when the user code/failure code is displayed in the operator mode can be input and changed
according to the following procedure.
If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode.
1. Selecting menu.
Select “Phone Number Entry” on the “Service Menu” screen.
30-106 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (Key-ON Mode)
Check or change various settings related to the machine monitor and machine by "Default". The function of working mode
with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON.
1. Selecting menu.
Select “Default” on the “Service Menu” screen.
3. Selecting mode.
After the “Key-on Mode” screen is displayed, select the mode to be
set with the function switches.
• Power Mode: [P] is displayed when key is ON
• Economy Mode: [E] is displayed when key is ON
• Lifting Mode: [L] is displayed when key is ON
• Breaker Mode: [B] is displayed when key is ON
• Attachment Mode: [ATT] is displayed when key is ON
• Mode at Previous Key-off: Final mode in previous operation is
displayed when key is ON
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to “Default” screen
• [F6]: Confirm selection and return to “Default” screen
★ When the machine is delivered, Mode at previous key-OFF is set.
★ If "With attachment" is not set, the attachment mode cannot be selected.
★ While Attachment mode [ATT] is selected, if "Without attachment" is set, Power mode [P] is displayed when the key
is turned ON.
★ If the engine is stopped while breaker mode [B] is selected in the operator mode, Breaker mode [B] is always
displayed, regardless of the above setting.
PC350LC/HD-8 30-107 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (Unit)
Check or change various settings related to the machine monitor and machine by "Default". The unit selecting function is used
to select the unit of the data displayed for monitoring, etc.
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.
• [F3]: Move to lower unit
• [F4]: Move to upper unit
• [F5]: Cancel selection and return to “Default” screen
• [F6]: Confirm selection and return to “Default” screen
★ When the machine is delivered, the SI unit system is set.
30-108 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (With/Without Attachment)
Check or change various settings related to the machine monitor and machine by "Default". The "With/Without attachment"
function is used to set an installed or a remove attachment.
1. Selecting menu.
Select "Default" on the “Service Menu” screen.
3. Selecting With/Without.
After the “With/Without Attachment” screen is displayed, select the
setting with the function switches.
• Without Attachment: When attachment is not installed
• With Attachment: When attachment is installed
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to Default screen
• [F6]: Confirm selection and return to Default screen
★ When an attachment is installed, if this setting is not carried out
normally, the attachment cannot be set in the operator mode. As
a result, the attachment may not work normally or the hydraulic
components may have trouble.
PC350LC/HD-8 30-109 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (Attachment/Maintenance Password)
Check or change various settings related to the machine monitor and machine by "Default". The function of setting
attachment/maintenance password is used to set the display of the password screen when the functions related to the
attachment and maintenance are used in the operator mode.
1. Selecting menu.
Select “Default” on the “Service Menu” screen.
3. Selecting Disable/Enable.
After the Attachment/Maintenance Password screen is displayed,
select the setting with the function switches.
• Disable: Password screen is not displayed
• Enable: Password screen is displayed
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to "Default" screen
• [F6]: Confirm selection and return to "Default" screen
4. Displaying attachment/maintenance password screen.
When the following operation is performed, the password screen is
displayed in the operator mode.
• Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen.
• User mode: On the User menu screen, the Breaker/Attachment setting menu is selected and the screen is changed to
the Attachment setting menu screen.
5. Changing attachment/maintenance password.
The password can be changed by operating the switches specially in the operator mode.
★ See Attachment/Maintenance password changing function in the operator mode.
★ Default password: [000000]
★ If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set
again, be sure to set a new password.
★ The attachment/maintenance password is different from the engine start lock password.
30-110 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (Camera)
Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is
used to set installation and removal of a camera.
1. Selecting menu.
Select “Default” on the “Service Menu” screen.
PC350LC/HD-8 30-111 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (ECO Display)
Check or change various settings related to the machine monitor and machine by "Default". The ECO display setting function
is used to set the display of the ECO gauge and energy saving guidance.
1. Selecting menu.
Select “Default” on the “Service Menu” screen.
30-112 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
★ Display of ECO gauge (a).
PC350LC/HD-8 30-113 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Default (Breaker Detect)
Check or change various settings related to the machine monitor and
machine by "Default". The function of setting breaker automatic
judgment is used to set the display to give warning when the breaker is
used in an improper working mode.
1. Selecting menu.
Select “Default” on the “Service Menu” screen.
30-114 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Adjustment (Pump Absorption Torque)
The operator can adjust various items related to the machine with the
machine monitor. The pump absorption torque function is used to finely
adjust the absorption torque on the rear side of the hydraulic pump.
1. Selecting menu.
Select “Adjustment” on the “Service Menu” screen.
PC350LC/HD-8 30-115 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Adjustment (Low Speed)
The operator can adjust various items related to the machine with the
machine monitor. The travel Low speed setting function is used to finely
adjust the travel Low speed.
1. Selecting menu.
Select “Adjustment” on the “Service Menu” screen.
30-116 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Adjustment (Attachment Flow Adjustment)
The operator can adjust various items related to the machine with the
machine monitor. The function of "Attachment Flow Adjustment" is used
to finely adjust the oil flow to the attachment in compound operation.
1. Selecting menu.
Select “Adjustment” on the “Service Menu” screen.
PC350LC/HD-8 30-117 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" operation with the machine
monitor.
"Cylinder Cut-Out" operation means to run the engine with 1 or more
fuel injectors disabled electrically 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.
30-118 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
[Reference]
No Injection
If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with
oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set
the no-injection cranking while the engine is stopped.
1. Selecting menu.
Select “No Injection” on the “Service Menu” screen.
PC350LC/HD-8 30-119 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
4. Finishing no injection cranking.
After completing the no injection cranking operation, press [F6], and
finish of no injection cranking is displayed and the screen returns to
the “Service Menu” screen automatically.
30-120 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Fuel Consumption
This function calculates the hourly fuel consumption from the actual fuel
consumption in a measuring period and indicates it.
1. Selecting menu.
Select “Fuel Consumption” on the “Service Menu” screen.
2. Starting measurement.
After the screen of “Fuel Consumption” is displayed, start
measurement with the function switches.
• [F1]: Start
• [F2]: Clear
• [F5]: Return to Service menu screen
★ When the screen of Fuel consumption is displayed, if data is
indicated, it is the data of the previous measurement. This data is
not an obstacle to new measurement and can be reset by
pressing [F2].
★ If [F1] is pressed, the data is displayed on the starting date and
time side and measurement starts.
★ The display unit of the fuel changes according to the unit set
with the default (unit setting) function.
SI and meter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/h
inch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gal/h
3. Display and function during measurement.
Clock mark (a) flashes during measurement.
★ While the fuel consumption is being measured, the operator can
work with the operator mode and other functions. Measurement
is not finished until this screen is displayed again and [F1] is
pressed (Even if the starting switch is turned OFF, this function
is kept effective, although fuel consumption is measured only
while the engine is running).
4. Finishing measurement.
Press [F1], and measurement is finished and the data are displayed
on the finishing date and time side.
PC350LC/HD-8 30-121 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX Settings (Terminal Status)
The setting condition and operating condition of KOMTRAX can be checked with Display of KOMTRAX setting. Setting
condition of terminal is used to check the setting condition of the KOMTRAX terminal.
1. Selecting menu.
Select “KOMTRAX Settings” on the “Service Menu” screen.
30-122 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX Settings (GPS & Communication Status)
The setting condition and operating condition of KOMTRAX can be checked with “KOMTRAX Settings”. GPS &
communication status is used to check the condition of positioning and communication of the KOMTRAX terminal.
1. Selecting menu.
Select “KOMTRAX Settings” on the “Service Menu” screen.
PC350LC/HD-8 30-123 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX Setting (Modem S/N: TH300)
The setting condition and operating condition of KOMTRAX can be checked with Display of KOMTRAX setting. MODEM
S/N is used to check the serial No. of the KOMTRAX communication MODEM.
1. Selecting menu.
Select “KOMTRAX Settings” on the “Service Menu” screen.
30-124 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Display of KOMTRAX Service Message
Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this
function. If there is setting in a message, a return mail can be sent by using numeral input switches.
PC350LC/HD-8 30-125 B
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Long Distance Transport Mode
NORMAL MODE DISPLAY
The Long Distance Transport Mode must be turned off before connection
to KOMTRAX. Do this with the following steps.
1. Operation of switches.
While press [4], preform the operation in order.
[4] + [1] -> [2] -> [3]
30-126 B PC350LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
2. Select "KOMTRAX" Setting on the service screen.
PC350LC/HD-8 30-127 B
TESTING AND ADJUSTING HANDLING VOLTAGE CIRCUIT OF ENGINE
12
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
1. Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting
switch OFF.
2. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do
not start the engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-128 B PC350LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRI-
CAL SYSTEM
★ When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, pump
controller, or KOMTRAX communication MODEM, expose the related connectors according to the following procedure.
★ Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below.
1. Machine monitor.
A. Remove 2 mounting bolts and cover (1).
★ One of the mounting bolts is installed in the cover on the right of the daylight sensor.
★ While removing the mounting bolts, disconnect connector P31 of the daylight sensor.
B. Remove cover (2).
★ The cover is fixed with clips. Remove it by pull it up.
★ While removing the cover, disconnect connector M04 of
the cigarette lighter.
PC350LC/HD-8 30-129 B
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
2. Engine controller.
★ The engine controller is installed in the left side of the engine.
A. Open the engine hood.
B. Insert or connect troubleshooting T-adapter in or to connectors
ENGINE, CE02 and CE03 of engine controller (3).
★ Connectors are fixed with screw.
Loosen the screws before disconnecting them.
★ When returning the connectors back to their position,
tighten them to the specified torque.
3. Pump controller.
A. Slide the operator's seat and seat stand to the forward end.
B. Remove the 5 mounting bolts and cool & hot box (6).
★ While removing the cool & hot box, disconnect the drain
hose.
C. Remove the 2 mounting bolts, 1 fastener, and magazine box (7).
D. Remove the 3 mounting bolts and cover (8).
E. Remove fuse box cover (9) and cover (10).
★ Since the underside of cover (10) is clamped, pull it up.
F. Remove the 7 mounting bolts and cover (11).
G. Connect the troubleshooting adapters to connectors C01 and
C02 of pump controller (12).
★ Install the adapters to only the wiring harness side.
30-130 B PC350LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
4. KOMTRAX communication module.
A. Slide the operator's seat and seat stand to the forward end.
B. Remove the 5 mounting bolts and cool & hot box (6).
★ While removing the cool & hot box, disconnect the drain
hose.
C. Remove the 2 mounting bolts, 1 fastener, and magazine box (7).
D. Remove the 3 mounting bolts and cover (8).
E. Remove fuse box cover (9) and cover (10).
★ Since the underside of cover (10) is clamped, pull it up.
F. Remove the 7 mounting bolts and cover (11).
G. Connect troubleshooting T-adapters to connectors CK01 and
CK02 of KOMTRAX communication module (13).
★ Cable (14) is for the communication antenna.
PC350LC/HD-8 30-131 B
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
6. Boost pressure and temperature sensor (BOOST PRESS & IMT).
★ Disconnection and connection of connector.
The connector of the boost pressure and temperature sensor has
a special locking mechanism. Disconnect it according to steps
(a) – (b) and connect it according to steps (c) – (d) as shown
below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.
★ Removal and installation of sensor.
A torque wrench is necessary for removal and installation of the
boost pressure and temperature sensor. See "Tools for testing,
adjusting, and troubleshooting".
30-132 B PC350LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
9. Engine coolant temperature sensor (COOLANT TEMP).
★ Disconnection and connection of connector.
The connector of the engine coolant temperature sensor has a
special locking mechanism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.
★ Removal and installation of sensor.
A deep socket is necessary for removal and installation of
the engine coolant temperature sensor. See "Tools for
testing, adjusting, and troubleshooting".
PC350LC/HD-8 30-133 B
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODES
12
PROCEDURE FOR TESTING DIODES
★ Test the assembled-type diode (8-pin) and the single diode (2-pin)
according to the following procedure.
★ The conductive directions of the assembledtype diode are as follows.
i. Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode
(N) side.
ii. Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode
(P) side.
C. Judge the condition of the diode by the movement of the pointer.
• The pointer does not move in i but moves in ii: The diode is normal (The moving range (resistance) depends on
the type and selected range of the tester, however).
• The pointer moves in both i and ii: The diode is defective (Internal short circuit).
• The pointer moves in neither of i and ii: The diode is defective (Internal disconnection).
30-134 B PC350LC/HD-8
TESTING AND ADJUSTING PM CLINIC SERVICE
12
PM CLINIC SERVICE
PC350LC/HD-8 30-135 B
TESTING AND ADJUSTING PM CLINIC SERVICE
12
Items related to engine
30-136 B PC350LC/HD-8
TESTING AND ADJUSTING PM CLINIC SERVICE
12
Items related to oil pressure
PC350LC/HD-8 30-137 B
TESTING AND ADJUSTING PM CLINIC SERVICE
12
Check sheet (PC350LC/HD-8)
Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Checking condition
Standard Service limit Mea-
Good
Fuel Work- Auto- Operation of
Bad
No. Check item Leftknob Unit value for new sured
control ing decel- work machine value 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 OFF {kg/cm2} {3.5 - 6.0} {2.1}
P OFF All levers in
3 Engine speed rpm 975 - 1,025 975 - 1,025
neutral
MIN
Engine oil MPa Min. 0.15 0.08
4 pressure {kg/cm2} {Min. 1.5} {0.8}
5 Engine speed rpm 1,830 - 2,030 1,830 - 2,030
Blow-by kPa Max. 1.57 Max. 2.55
6 ON Arm IN relief {mmH2O}
pressure {Max. 160} {Max. 260}
Good
Fuel Work-
Unit
Bad
No. Check item value for sured
control ing Checking posture, etc. new machine value value
dial mode
1 Boom RAISE No load, work equipment PC350-8 3.3 - 4.1 Max. 4.5
extended fully
P
2 Arm IN PC350-8 2.6 - 3.2 Max. 3.5
30-138 B PC350LC/HD-8
TESTING AND ADJUSTING PM CLINIC SERVICE
12
3. Hydraulic drift of work equipment
Checking condition Standard
value for Service limit Measured
Good
Fuel
Bad
No. Check item Working Unit new value value
control Checking posture, etc.
mode machine
dial
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Working
Left Operation of work F pump R pump F pump R pump
control switch knob equipment main main LS LS Control
dial mode
Self pressure
1 All lever in neutral - - - - A
reducing valve
OFF
Main relief valve
2 (Low pressure) B B B B -
Arm out relief
3 Main relief valve ON C C C C -
(Low pressure)
4 Unload valve All levers in neutral D D D D -
Right track driven idle E - E - -
Lever moved halfway
5 LS valve
Left track driven idle
- E - E -
Lever moved halfway
MAX P Swing lock
Right swing relief F F - - -
Swing motor
6
safety valve Swing lock
OFF F F - - -
Left swing relief
Right travel lock
G - - - -
Right forward relief
Main relief valve Right travel lock
Travel motor Right reverse relief G - - - -
7 Safety valve
Travel junction Left travel lock - G - - -
valve Left forward relief
Left travel lock
- G - - -
Left reverse relief
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 31 - 35 (441 - 498) 29 - 35 (412 - 498)
B (Work equipment relief pressure, 345 - 370 (4907 - 5263) 340 - 375 (4836 - 5334)
low)
Standard value
PC350LC/HD-8 30-139 B
TESTING AND ADJUSTING PM CLINIC SERVICE
12
* Gauge changing work: Change hoses of gauges [3] and [4].
[1] [2] [3a] [4a] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel control Working Left knob Operation of work F pump R pump F pump R pump
Control
dial mode switch equipment main main servo servo
8 Servo piston MAX P OFF Arm out relief H1 H1 H2 H2 -
Checked oil pressure Unit Standard value for new machine Service limit value
Standard 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].
Good
Bad
[1] [2] [3b] [4b] [5a]
Checking condition
No. Check item 600K 600K 60K 60K 60K
Fuel Work- Left Operation of work F pump R pump F pump R pump
control ing knob LS-EPC
dial mode switch equipment main main (F) (R)
MIN - - J1 J1 -
P
PC-EPC (F) - - J2 J2 -
9 valve E All levers in neutral - - J3 J3 -
PC-EPC (R)
valve L - - J4 J4 -
B - - J5 J5 -
P Travel speed: Mi
10 LS-EPC valve Travel lever oper- - - - - K2
ated
Travel speed: Hi
Travel lever oper- - - - - K3
ated
Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output pressure 1) Approximately 1.1 {Approximately 11}
J2 (PC-EPC valve output pressure 2) Approximately 0.3 {Approximately 3}
J3 (PC-EPC valve output pressure 3) Approximately 0.7 {Approximately 7}
Standard J4 (PC-EPC valve output pressure 4) Approximately 1.1 {Approximately 11}
value MPa
J5 (PC-EPC valve output pressure 5) {kg/cm2} Approximately 0.9 {Approximately 9}
K1 (LS-EPC valve output pressure 1) Approximately 2.1 {Approximately 21}
K2 (LS-EPC valve output pressure 2) Approximately 2.3 {Approximately 23}
K3 (LS-EPC valve output pressure 3) 0 {0}
30-140 B PC350LC/HD-8
40 TROUBLESHOOTING
Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.
PC350LC/HD-8 40-1 1
TROUBLESHOOTING TABLE OF CONTENTS
CA238 - NE Speed Sensor Supply Voltage Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-119
CA271 - IMV/PCV1 Short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120
CA272 - IMV/PCV1 Open Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
CA281 - Pump Press Balance Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124
CA322 - Injector #1 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
CA323 - Injector #5 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
CA324 - Injector #3 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
CA325 - Injector #6 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132
CA331 - Injector #2 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
CA332 - Injector #4 Open/short Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
CA342 - Calibration Code Incompatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
CA351 - Injectors Drive Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
CA352 - Sensor Supply One Volt Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142
CA386 - Sensor Supply One Volt High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
CA428 - Water in Fuel Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
CA429 - Water in Fuel Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
CA435 - Eng Oil Press Sw Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
CA441 - Battery Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
CA442 - Battery Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
CA449 - Rail Pressure Very High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156
CA451 - Rail Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160
CA452 - Rail Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162
CA488 - Chg Air Temp High Torque Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164
CA553 - Rail Pressure High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-165
CA559 - Rail Pressure Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
CA689 - Engine NE Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
CA731 - Engine BKUP Speed Sensor Phase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
CA757 - All Persistent Data Lost Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
CA778 - Engine BKUP Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
CA1633 - KOMNET Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
CA2185 - Throttle Sensor Supply Volt High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
CA2186 - Throttle Sensor Supply Volt Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180
CA2249 - Rail Pressure Very Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-181
CA2265 - Electric Lift Pump High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
CA2266 - Electric Lift Pump Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
CA2311 - IMV Solenoid Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
CA2555 - Grid Htr Relay Volt High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
CA2556 - Grid Htr Relay Volt Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
D110KB - Battery Relay Drive Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
D19JKZ - Personal Code Relay Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
D862KA - GPS Antenna Discon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
DA22KK - Pump Solenoid Power Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
DA25KP - 5 V Sensor 1 Power Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
DA29KQ - Model Selection Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
DA2RMC - Pump Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
DAF8KB - Short Circuit in Camera Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
DAFGMC - GPS Module Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210
DAFRMC - CAN Discon (Monitor Detected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
DGH2KB - Hyd Oil Sensor Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214
DHPAMA - F Pump Pressure Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
DHPBMA - R Pump Pressure Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
DHS3MA - Arm Curl PPC Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
DHX1MA - Overload Sensor Abnormality (Analog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
DW43KA - Travel Speed Solenoid Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
DW43KB - Travel Speed Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
DW45KA - Swing Brake Solenoid Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
40-2 1 PC350LC/HD-8
TROUBLESHOOTING TABLE OF CONTENTS
DW45KB - Swing Brake Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
DW91KA - Travel Junction Solenoid Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
DW91KB - Travel Junction Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
DWA2KA - Attachment Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
DWA2KB - Attachment Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241
DWJ0KA - Merge-Divider Solenoid Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
DWJ0KB - Merge-Divider Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
DWK0KA - 2-Stage Relief Sol. Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
DWK0KB - 2-Stage Relief Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
DXA0KA - PC-EPC Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
DXA0KB - PC-EPC Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
DXE0KA - LS-EPC Solenoid Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
DXE0KB - LS-EPC Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
DXE4KA - Service Current EPC Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
DXE4KB - Service Current EPC Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-259
DY20KA - Wiper Working Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
DY20MA - Wiper Parking Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
DY2CKA - Washer Drive Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
DY2CKB - Washer Drive Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
DY2DKB - Wiper Motor Drive Forward System Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
DY2EKB - Wiper Drive Reverse Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
E-MODE (ELECTRICAL SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
Information Contained in Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
E-1 Engine Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274
E-2 Auto-decelerator Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-277
E-3 Automatic Warming-up System Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-279
E-4 Preheater Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280
E-5 All Work Equipment, Swing, and Travel Mechanism do not move . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
E-6 Power Maximizing Function Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
E-7 Machine Monitor Does Not Display At All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286
E-8 Machine Monitor Does Not Display Some Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
E-9 Contents of Display by Machine Monitor are Different from Applicable Machine . . . . . . . . . . . . . . . 40-288
E-10 Fuel Level Monitor Was Lit in Red While Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-289
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
E-13 Fuel Level Gauge Does Not Indicate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-293
E-14 Swing Lock Monitor Does Not Indicate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
E-15 When Monitor Switch is Operated, Monitor Displays Nothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
E-16 Windshield Wiper and Window Washer do not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
E-17 Machine Push-up Function Does Not Operate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
E-18 Monitoring Function Fails to Display “Boom Raise” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
E-19 Monitoring Function Fails to Display “Boom Lower” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
E-20 Monitoring Function Fails to Display “Arm In” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
E-21 Monitoring Function Fails to Display “Arm Out” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
E-22 Monitoring Function Fails to Display “Bucket Curl” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
E-23 Monitoring Function Fails to Display “Bucket Dump” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
E-24 Monitoring Function Fails to Display “Swing” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
E-25 Monitoring Function Fails to Display “Travel” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318
E-26 Monitoring Function Fails to Display “Travel Differential Pressure” Normally . . . . . . . . . . . . . . . . 40-320
E-27 Monitoring Function Fails to Display “Service” Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
E-28 KOMTRAX System Does Not Operate Normally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
E-29 Air Conditioner Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
E-30 Travel Alarm Does Not Sound or Does Not Stop Sounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
E-31 Horn Does Not Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
System Chart for Hydraulic and Mechanical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
Information Contained in Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
PC350LC/HD-8 40-3 1
TROUBLESHOOTING TABLE OF CONTENTS
H-1 All Work Equipment Lack Power, or Travel and Swing Speeds are Slow . . . . . . . . . . . . . . . . . . . . . 40-336
H-2 Engine Speed Sharply Drops or Engine Stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
H-3 No Work Equipment, Swing or Travel Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-339
H-4 Abnormal Noise is Heard from Around Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-339
H-5 Auto-decelerator Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
H-6 Fine Control Mode Does Not Function or Responds Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
H-7 Boom Moves Slowly or Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-341
H-8 Arm Moves Slowly or Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
H-9 Bucket Moves Slowly or Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-343
H-10 Work Equipment Does Not Move in its Single Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-343
H-11 Work Equipment has a bit too Fast Hydraulic Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
H-12 Work Equipment Has Big Time Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
H-13 Other Work Equipment Moves When Relieving Single Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
H-14 Power Max. Switch Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-347
H-15 In Compound Operation, Work Equipment with Larger Load Moves Slowly . . . . . . . . . . . . . . . . . 40-347
H-16 In Swing + Boom Raise Operation, Boom Moves Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
H-17 In Swing + Travel Operation, Travel Speed Drops Sharply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
H-18 Machine Swerves in Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-349
H-19 Machine Travels Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
H-20 Machine Cannot Be Easily Steered or Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-351
H-21 Travel Speed Does Not Shift, or it is too Slow or Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352
H-22 Track Shoe Does Not Turn (On One Side Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-353
H-23 Machine Does Not Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
H-24 Swing Acceleration is Poor, or Swing Speed is Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
H-25 Excessive Overrun When Stopping Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
H-26 There is Big Shock when Stopping Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-359
H-27 Large Sound is made when Upper Structure Stops Swinging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-359
H-28 Swing Hydraulic Drift is too big . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-360
★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3. These standard values are not the standards used in dealing with claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
40-4 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODES TABLE
12
FAILURE CODES TABLE
Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
- 989L00 Engine Controller Lock Caution 1 MON Mechanical system
- 989M00 Engine Controller Lock Caution 2 MON Mechanical system
- 989N00 Engine Controller Lock Caution 3 MON Mechanical system
- AA10NX Air cleaner Clogging MON Mechanical system
- AB00KE Charge Voltage Low MON Mechanical system
- B@BAZG Eng. Oil Press. Low ENG Mechanical system
- B@BAZK Eng Oil Level Low MON Mechanical system
- B@BCNS Eng. Water Overheat ENG Mechanical system
- B@BCZK Eng. Water Lvl Low MON Mechanical system
- B@HANS Hydr. Oil Overheat PUMP Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E11 CA155 Chg Air Temp Temp High Speed Derate ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error ENG Electrical system
E11 CA323 Inj #5 (L#5) Open/Short Error ENG Electrical system
E11 CA324 Inj #3 (L#3) Open/Short Error ENG Electrical system
E11 CA325 Inj #6 (L#6) Open/Short Error ENG Electrical system
E11 CA331 Inj #2 (L#2) Open/Short Error ENG Electrical system
E11 CA332 Inj #4 (L#4) Open/Short Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E15 CA428 Water in Fuel Sensor High Error ENG Electrical system
E15 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E15 CA435 Eng Oil Press Sw Error ENG Electrical system
E10 CA441 Battery Voltage Low Error ENG Electrical system
PC350LC/HD-8 40-5 1
TROUBLESHOOTING FAILURE CODES TABLE
Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
E10 CA442 Battery Voltage High Error ENG Electrical system
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 CA451 Rail Press Sensor High Error ENG Electrical system
Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA488 Chg Air Temp High Torque Derate ENG Electrical system
E15 CA553 Rail Press High Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Ne Speed Sensor Error ENG Electrical system
E15 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E15 CA778 Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E15 CA2265 Electric Lift Pump High Error ENG Electrical system
E15 CA2266 Electric Lift Pump Low Error ENG Electrical system
E11 CA2311 IMV Solenoid Error ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
- D110KB Battery Relay Drive Short Circuit PUMP Electrical system
E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical system
- D862KA GPS Antenna Dicon MON2 Electrical system
E0E DA22KK Pump Solenoid Power Low Error PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality PUMP Electrical system
- DA29KQ Model Selection Abnormality PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
- DAF8KB Short Circuit In Camera Power Supply PUMP Electrical system
- DAFGMC GPS Module Error PUMP Electrical system
E0E DAFRMC CAN Discon (Monitor Detected) PUMP Electrical system
- DGH2KB Hyd Oil Short PUMP Electrical system
- DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
- DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
- DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
- DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system
- DHX1MA Overload Sensor Abnormality (Analog) PUMP Electrical system
- DW43KA Travel Speed Sol. Disc. PUMP Electrical system
- DW43KB Travel Speed Sol. Short Circuit PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. Short Circuit PUMP Electrical system
- DW91KA Travel Junction Sol. Disc. PUMP Electrical system
- DW91KB Travel Junction Sol. Short Circuit PUMP Electrical system
40-6 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODES TABLE
Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
- DWA2KA Attachment Sol Open Circuit PUMP Electrical system
- DWA2KB Attachment Sol Short Circuit PUMP Electrical system
- DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
- DWJ0KB Merge-divider Sol. Short Circuit PUMP Electrical system
- DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
- DWK0KB 2-stage Relief Sol. Short Circuit PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Open Circuit. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. Short Circuit PUMP Electrical system
- DXE0KA LS-EPC Sol. Open Circuit. PUMP Electrical system
- DXE0KB LS-EPC Sol. Short Circuit PUMP Electrical system
- DXE4KA Service Current EPC Open Circuit. PUMP Electrical system
- DXE4KB Service Current EPC Short Circuit PUMP Electrical system
- DY20KA Wiper Working Abnormality MON Electrical system
- DY20MA Wiper Parking Abnormality MON Electrical system
- DY2CKA Washer Drive Open Circuit MON Electrical system
- DY2CKB Washer Drive Short Circuit MON Electrical system
- DY2DKB Wiper Drive (Fwd) Short Circuit MON Electrical system
- DY2EKB Wiper Drive (Rev) Short Circuit MON Electrical system
★ This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
PC350LC/HD-8 40-7 1
TROUBLESHOOTING FUSE LOCATIONS
12
FUSE LOCATIONS
40-8 1 PC350LC/HD-8
TROUBLESHOOTING FUSE LOCATIONS
12
Locations of Fusible Links
PC350LC/HD-8 40-9 1
TROUBLESHOOTING FUSE LOCATIONS
12
Troubles that occur when controller power supply of pump controller is defective
★ 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 simultaneously (The following is an example
of the troubles).
• The working mode cannot be changed.
• The auto-decelerator does not work or is not reset.
• The travel speed does not change.
• The power maximizing function does not work.
• The swing holding brake cannot be reset automatically.
• The machine deviates during travel.
Troubles that occur when solenoid power supply of pump controller is defective
★ 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.
• DW43KA, DW43KB: Travel speed solenoid system
• DW45KA, DW45KB: Swing holding brake solenoid system
• DW91KA, DW91KB: Travel junction solenoid system
• DWA2KA, DWA2KB: Service solenoid system
• DWK0KA, DWK0KB: 2-stage relief solenoid system
• DXA0KA, DXA0KB: PC-EPC (F) solenoid system
• DXE0KA, DXE0KB: LS-EPC solenoid system
• DXE4KA, DXE4KB: Service current EPC system (if attachment is installed)
• DWJ0KA, DWJ0KB: Merge-divider main solenoid system
★ If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
A. Disconnect connectors CP01 and CP02 of the controller and connect a T-adapter to the wiring harness side.
C. Measure the voltage between each of pins CP02 (116), (118), (121) and each of pins CP01 (2), (5).
Remark
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.
40-10 1 PC350LC/HD-8
TROUBLESHOOTING FUSE LOCATIONS
12
★ Power supply connector (CP01, CP02) of pump controller.
PC350LC/HD-8 40-11 1
TROUBLESHOOTING GENERAL INFORMATION
12
GENERAL INFORMATION
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure. When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of
possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
40-12 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
3. Check before troubleshooting.
D. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
5. Troubleshooting.
Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
★ The basic procedure for troubleshooting is as follows.
PC350LC/HD-8 40-13 1
TROUBLESHOOTING GENERAL INFORMATION
12
Sequence of Events in Troubleshooting
40-14 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Handling Electric Equipment and Hydraulic Components
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals
particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose,
it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic
oil).
Points to remember when handling electric equipment
PC350LC/HD-8 40-15 1
TROUBLESHOOTING GENERAL INFORMATION
12
C. Disconnections in wiring.
If the wiring is held and the connectors are pulled apart, or
components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping of the
connector may separate, or the soldering may be damaged, or
the wiring may be broken.
40-16 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors.
PC350LC/HD-8 40-17 1
TROUBLESHOOTING GENERAL INFORMATION
12
B. Connecting connectors.
40-18 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
C. Heavy duty wire connector (DT 8-pole, 12-pole).
Disconnection (Left of figure).
While pressing both sides of locks (a) and (b), pull out
female connector (2).
Connection (Right of figure)
ii. 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)
★ Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.
i. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with compressed air,
there is the risk that oil in the air may cause defective
contact, so remove all oil and water from the
compressed air before blowing with air.
PC350LC/HD-8 40-19 1
TROUBLESHOOTING GENERAL INFORMATION
12
iii. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, blow it with
contact restorer and reassemble.
4. Handling controller.
C. Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be
generated.
D. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the
related wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.
40-20 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Points to remember when handling hydraulic equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
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.
PC350LC/HD-8 40-21 1
TROUBLESHOOTING GENERAL INFORMATION
12
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an
extremely effective device.
40-22 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Connectors for Tier 3 Engines
1. Slide lock type.
(FRAMATOME-3, FRAMATOME-2)
• 107 – 170, 12V140 engines
• Various pressure sensors and NE speed sensor
Examples:
Intake air pressure in intake manifold: . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .PIM (125, 170, 12V140 engines)
Oil pressure sensor: . . . . . . . . . POIL (125, 170, 12V140 engines)
Oil pressure switch: . . . . . . . . . . . . . . . . . . . . . (107, 114 engines)
Ne speed sensor of flywheel housing: . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . NE (107 – 170, 12V140 engines)
Ambient pressure sensor: . . . PAMB (125, 170, 12V140 engines)
B. While pressing lock (L2), pull out connector (1) toward you.
★ Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case,
float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
PC350LC/HD-8 40-23 1
TROUBLESHOOTING GENERAL INFORMATION
12
3. Push lock type.
• 107, 114 engines
Example:
Fuel pressure sensor in common rail (BOSCH-03)
Disconnect connector (3) according to the following procedure.
A. While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 engine
• 107 engine
40-24 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
C. While pressing lock (D), pull out connector (4) in the direction
of the arrow.
Example:
Injection pressure control valve of fuel supply pump: . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCV (SUMITOMO-2)
Example:
Speed sensor of fuel supply pump: . . . . . . . . . G (SUMITOMO-3)
★ Pull the connector straight up.
PC350LC/HD-8 40-25 1
TROUBLESHOOTING GENERAL INFORMATION
12
4. Turn-housing type (Round green connector)
• 140 engine
Example:
Intake air pressure sensor in intake manifold (CANNON-04): . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIM etc.
40-26 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Checks Before Troubleshooting
Item Criterion Remedy
1. Check of level and type of fuel - Add fuel
2. Check of fuel for foreign matter - Clean and drain
3. Check of hydraulic oil level - Add oil
4. Check of hydraulic oil strainer - Clean and drain
Lubricating oil/ 5. Check of swing machinery oil level - Add oil
Coolant
6. Check of level and type of engine oil (in oil pan) - Add oil
7. Check of coolant level - Add coolant
8. Check of dust indicator for clogging - Clean or replace
9. Check of hydraulic oil filter - Replace
1. Check of battery terminals and wiring for - Retighten or replace
looseness and corrosion
Electrical 2. Check of alternator terminals and wiring for - Retighten or replace
equipment looseness and corrosion
3. Check of starting motor terminals and wiring for - Retighten or replace
looseness and corrosion
1. Check for abnormal noise and smell - Repair
Hydraulic/
Mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air
1. Check of battery voltage (with engine stopped) 20 - 30 V Replace
2. Check of electrolyte level - Add or replace
3. Check of wires for discoloration, burn, and - Replace
removal of cover
4. Check for released wire clamp and drooping wire - Repair
Electric, electrical 5. Check of wires for wetness (Check connectors Disconnect the
equipment -
and terminals for wetness, in particular) connectors and dry
6. Check of fuse for disconnection and corrosion - Replace
7. Check of alternator voltage (while engine speed After operating for several Replace
is at middle or higher) minutes: 27.5 - 29.5 V
8. Check of battery relay for operating sound (when - Replace
starting switch is turned ON or OFF)
PC350LC/HD-8 40-27 1
TROUBLESHOOTING GENERAL INFORMATION
12
Classification and Troubleshooting Steps
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
Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.
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.
★ If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is
still detected.
★ 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 troubleshooting corresponding to that
phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
40-28 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
MEMORANDUM
PC350LC/HD-8 40-29 1
TROUBLESHOOTING GENERAL INFORMATION
12
Information in Troubleshooting Table
★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble name displayed in abnormality record machine
Display on machine Trouble
machine monitor
monitor
monitor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine
machine moni-
controller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or 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
broken.
• 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
2 (24 V) circuit is in contact with power source (24 V) circuit.
• 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
state reference numbers, which do <Precautions for troubleshooting>
not indicate priority) (1) Method of indicating connector No. and handling of
T-adapter
Insert or connect T-adapter as explained below for
3 troubleshooting, 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”,
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.
• 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.
40-30 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
PC350LC/HD-8 40-31 1
TROUBLESHOOTING GENERAL INFORMATION
12
Possible Problems and Troubleshooting No.
Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to action code/failure code
1 An action code is displayed on machine monitor.
According
When abnormality record is checked, failure code is displayed in
2 to
electrical system abnormality record
displayed
When abnormality record is checked, failure code is displayed in code
3
mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 a)
Engine does
6 Engine rotates, but exhaust gas does not come out S-2 b)
not start
7 Engine emits exhaust gas, but it does not start S-2 c)
8 Engine does not pick up smoothly (follow-up performance is poor) S-3
9 Engine stops during operations H-2 S-4
10 Engine rotation is unstable (it hunts). S-5
11 Engine lacks output or power H-1 S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant or fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Auto-decelerator does not operate E-2 H-5
23 Automatic warm-up system does not operate E-3
24 Preheater does not operate E-4
Phenomena related to work equipment, swing, and travel
25 Speed or power of whole work equipment, travel, and swing is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment, swing, and travel mechanism do not move E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
Phenomena related to work equipment
30 Speed or power of boom is low E-18,19 H-7
31 Speed or power of arm is low E-20,21 H-8
32 Speed or power of bucket is low E-22,23 H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
40-32 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
35 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work
36 H-13
equipment move
37 Power maximizing function does not work. E-6, 18 - 23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part loaded
38 H-15
more is low
When machine swings and raises boom simultaneously, boom rising
39 H-16
speed is low
When machine swings and travels simultaneously, travel speed
40 H-17
lowers largely
Phenomena related to travel
41 Machine deviates during travel H-18
42 Travel speed is low E-25 H-19
43 Machine is not steered well or steering power is low E-25,26 H-20
44 Travel speed does not change or travel speed is low or high E-25 H-21
45 Travel system does not move (only one side) H-22
Phenomena related to swing
46 Upper structure does not swing E-24 H-23
47 Swing acceleration or swing speed is low H-24
48 Upper structure overruns remarkably when it stops swinging H-25
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 monitor does not display some items E-8
Contents of display by machine monitor are different from applicable
54 E-9
machine
Radiator coolant level monitor lights up in red during check before
55 B@BCZK
starting
56 Engine oil level monitor lights up in red during check before starting B@BAZK
Maintenance interval monitor lights up in red during check before See the Operation and Maintenance
57
starting Manual.
58 Charge level monitor lights up in red while engine is running AB00KE
59 Fuel level monitor lights up in red while engine is running E-10
60 Air cleaner clogging monitor lights up in red while engine is running AA10NX
Engine coolant temperature monitor lights up in red while engine is
61 B@BCNS
running
Hydraulic oil temperature monitor lights up in red while engine is
62 B@HANS
running
63 Engine coolant temperature gauge does not indicate normally E-11
64 Hydraulic oil temperature gauge does not indicate normally E-12
65 Fuel level gauge does not indicate normally E-13
66 Swing lock monitor does not indicate normally E-14
PC350LC/HD-8 40-33 1
TROUBLESHOOTING GENERAL INFORMATION
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Machine monitor display anything even when operated on monitor
67 E-15
switch section
68 Windshield wiper and window washer do not operate E-16
69 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
70 Monitoring function does not display “Boom RAISE” normally E-18
71 Monitoring function does not display “Boom LOWER” normally E-19
72 Monitoring function does not display “Arm IN” normally E-20
73 Monitoring function does not display “Arm OUT” normally E-21
74 Monitoring function does not display “Bucket CURL” normally E-22
75 Monitoring function does not display “Bucket DUMP” normally E-23
76 Monitoring function does not display “Swing” normally E-24
77 Monitoring function does not display “Travel” normally E-25
78 Monitoring function does not display “Travel Steering” normally E-26
79 Monitoring function does not display “Service” normally E-27
Phenomena related to KOMTRAX
80 KOMTRAX system does not operate normally E-28
Other phenomena
81 Air conditioner does not operate E-29
82 Travel alarm does not sound or does not stop sounding E-30
83 Horn does not sound E-31
40-34 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Connection Table for Connector Pin Numbers
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
PC350LC/HD-8 40-35 1
TROUBLESHOOTING GENERAL INFORMATION
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
40-36 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
SWP Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
16 799-601-7320
M Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
PC350LC/HD-8 40-37 1
TROUBLESHOOTING GENERAL INFORMATION
4 799-601-7120
6 799-601-7130
8 799-601-7340
40-38 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
PC350LC/HD-8 40-39 1
TROUBLESHOOTING GENERAL INFORMATION
12
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
40-40 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
MIC Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
Body part number: 79A-222-2680 Body part number: 79A-222-2670
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —
5 799-601-2710
9 799-601-2950
13 799-601-2720
PC350LC/HD-8 40-41 1
TROUBLESHOOTING GENERAL INFORMATION
12
MIC Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
17 799-601-2730
21 799-601-2740
40-42 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
AMP040 Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
PC350LC/HD-8 40-43 1
TROUBLESHOOTING GENERAL INFORMATION
40-44 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-45 1
TROUBLESHOOTING GENERAL INFORMATION
12
L Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
2 —
— —
PA Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
9 —
— —
10 799-601-3460
— —
40-46 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
KES1 Automobile Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
PC350LC/HD-8 40-47 1
TROUBLESHOOTING GENERAL INFORMATION
12
KES1 Automobile Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
40-48 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-49 1
TROUBLESHOOTING GENERAL INFORMATION
12
799-601-9210
799-601-9210
799-601-9220
799-601-9220
40-50 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9230
799-601-9230
799-601-9240
799-601-9240
PC350LC/HD-8 40-51 1
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9250
799-601-9250
799-601-9260
799-601-9260
40-52 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9270
799-601-9270
799-601-9280
799-601-9280
PC350LC/HD-8 40-53 1
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)
799-601-9290
799-601-9290
40-54 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
PC350LC/HD-8 40-55 1
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
2 799-601-9010
40-56 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC350LC/HD-8 40-57 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-58 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-59 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-60 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-61 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-62 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-63 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-64 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-65 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-66 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-67 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-68 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-69 1
TROUBLESHOOTING GENERAL INFORMATION
12
T-adapter Box and T-adapter Table
★ The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a
part number of harness checker assembly.
40-70 1 PC350LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
PC350LC/HD-8 40-71 1
TROUBLESHOOTING GENERAL INFORMATION
12
40-72 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-73 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
989L00 - Engine Controller Lock Caution 3
Action code Failure code Engine controller lock caution 3
Trouble
— 989N00 Machine monitor system
Contents of
• Engine controller lock is detected (Factor 3).
trouble
Action of
• Tries automatic resetting.
machine
• If cause of failure disappears, system resets itself.
monitot
Problem that
appears on
machine
Related • Method of reproducing failure code: Failure code is not reproduced since system is reset
information automatically.
40-74 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-75 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
AA10NX - Air Cleaner Clogging
Action code Failure code Air cleaner clogging
Trouble
— AA10NX (Mechanical system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch detected clogging of air cleaner
trouble (sensor contact opened).
Action of
• Displays air cleaner clogging monitor on machine monitor.
machine
• If cause of failure disappears, system resets itself.
monitor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related
(Code: 04501 Monitor input 2)
information
• Method of reproducing failure code: Start engine.
40-76 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to air cleaner clogging switch of machine monitor
PC350LC/HD-8 40-77 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
AB00KE - Charge Voltage Low
Action code Failure code Charge voltage low
Trouble
— AB00KE (mechanical system)
Contents of
• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble
Action of
• Displays charge level monitor on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
Related • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
information • Method of reproducing failure code: Start engine.
40-78 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to starting and charge of machine monitor
PC350LC/HD-8 40-79 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BAZG - Engine Oil Pressure Low
Action code Failure code Engine oil pressure low
Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil
trouble pressure (sensor contact opened).
Action of • Displays engine oil pressure monitor on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine
Related
monitor.
information
• Method of reproducing failure code: Start engine
40-80 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine oil pressure of machine monitor
PC350LC/HD-8 40-81 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BAZK - Engine Oil Level Low
Action code Failure code Engine oil level low
Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of
• Displays engine oil level monitor on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil level switch signal can be checked with monitoring function.
Related
(Code 04501: Monitor Input 2)
information
• Method of reproducing failure code: Turn starting switch ON.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
CM02 Engine oil level Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
Between (2) –
chassis ground Value when oil level is
20 – 30 V
low
40-82 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine oil level switch of machine monitor
PC350LC/HD-8 40-83 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BCNS - Engine Coolant Overheat
Action code Failure code Engine coolant overheat
Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating of
trouble engine coolant (above 102°C [215.6°F]).
Action of • Displays engine coolant temperature monitor with red on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine
monitor.
Related
• Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant
information
temperature)
• Method of reproducing failure code: Start engine
40-84 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor of machine monitor
PC350LC/HD-8 40-85 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BCZK - Engine Coolant Level Low
Action code Failure code Engine coolant level low
Trouble
— B@BCZK (Mechanical system)
Contents of • When starting switch is turned ON, signal circuit of radiator coolant level sensor detected low radiator
trouble coolant level (sensor contact opened).
Action of
• Displays radiator coolant level monitor on machine monitor.
machine
• Even if cause of failure disappers, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• Condition of radiator coolant level switch can be checked with monitoring function
Related
(Code: 04500 Monitor input 1)
information
• Method of reproducing failure code: Turn starting switch ON.
40-86 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to radiator coolant level switch of machine monitor
PC350LC/HD-8 40-87 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@HANS - Hydraulic Oil Overheat
Action code Failure code Hydraulic oil overheat
Trouble
- B@HANS (Mechanical system)
Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of
trouble hydraulic oil (above about 102°C [215.6°F]).
Action of • Displays hydraulic oil temperature monitor with red on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, hydraulic components may be seized.
machine
• Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine
monitor.
Related
• Hydraulic oil temperature can be checked with monitoring function
information
(Code: 04401 Hydraulic oil temperature)
• Method of reproducing failure code: Start engine.
40-88 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to hydraulic oil temperature sensor of machine monitor
PC350LC/HD-8 40-89 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA111 - EMC Critical Internal Failure
Action code Failure code EMC critical internal failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Memory or power supply circuit in engine controller is defective.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start.
machine
Related
information
40-90 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA115 - Engine NE and BKUP Speed Sensor Error
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
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Start engine
information
PC350LC/HD-8 40-91 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA122 - Charge Air Pressure Sensor High Error
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
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-92 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC350LC/HD-8 40-93 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA123 - Charge Air Pressure Sensor Low Error
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
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-94 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC350LC/HD-8 40-95 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA131 - Throttle Sensor High Error
Action code Failure code Throttle sensor high error
Trouble
E14 CA131 (Engine controller system)
Contents of
• Signal circuit of fuel control dial detected high voltage.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before
Action of detection of trouble and continues operation.
controller • 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
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial
Related
voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-96 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial
PC350LC/HD-8 40-97 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA132 - Throttle Sensor Low Error
Action code Failure code Throttle sensor low error
Trouble
E14 CA132 (Engine controller system)
Contents of
• Signal circuit of fuel control dial detected low voltage.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before
Action of detection of trouble and continues operation.
controller • 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
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel control dial
Related
voltage)
information
• Method of reproducing failure code: Turn starting switch ON.
40-98 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial
PC350LC/HD-8 40-99 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA144 - Coolant Temperature Sensor High Error
Action code Failure code Coolant temperature sensor high error
Trouble
E15 CA144 (Engine controller system)
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not function.
machine
Related
• Method of reproducing failure code: Starting switch ON.
information
40-100 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor
PC350LC/HD-8 40-101 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA145 - Coolant Temperature Sensor Low Error
Action code Failure code Coolant temperature sensor low error
Trouble
E15 CA145 (Engine controller system)
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not work.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard Short circuit in wiring turning starting switch ON.
value in normal 3 harness Between CE01 (female) (15) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between coolant temperature sensor – 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
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
CE01(female) Coolant temperature Resistance
0°C (0°F) 30 - 37 kΩ
25°C (77°F) 9.3 - 10.7 kΩ
5 Defective engine controller
Between (15) – (38) 50°C (122°F) 3.2 - 3.8 kΩ
80°C (176°F) 1.0 - 1.3 kΩ
95°C (203°F) 700 - 800 Ω
Between (15) –
All range Min. 100 kΩ
chassis ground
40-102 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor
PC350LC/HD-8 40-103 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA153 - Charge Air Temperature Sensor High Error
Action code Failure code Charge air temperature sensor high error
Trouble
E15 CA153 (Engine controller system)
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-104 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC350LC/HD-8 40-105 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA154 - Charge Air Temperature Sensor Low Error
Action code Failure code Charge air temperature sensor low error
Trouble
E15 CA154 (Engine controller system)
Contents of
• Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of
• Fixes charge temperature (46°C [114.8°F]) and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (23) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between boost pressure, temperature sensor – 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
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
CE01 (female) Charge temperature Resistance
0°C (0°F) 29 - 36 kΩ
5 Defective engine controller 25°C (77°F) 9 - 11 kΩ
Between (23) – (47)
40°C (104°F) 4.9 - 5.8 kΩ
100°C (212°F) 600 - 700 Ω
Between (23) -
All range Min. 100 kΩ
chassis ground
40-106 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC350LC/HD-8 40-107 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA155 - Chg Air Temp High Speed Derate
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 control upper temperature limit.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine stops.
machine
Related • Boost temperature can be checked with monitoring function. (Code: 18500 Boost Temperature)
information • Method of reproducing failure code: Start engine
40-108 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-109 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA187 - Sensor Power Supply Two Volt Low Error
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 • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Boost pressure,
C4
Disconnect sensor and wiring temperature sensor
harness at right in order and
Defective sensor or wiring Common rail
1 carry out operation to C8
harness pressure sensor
reproduce trouble. If “E” of
Possible causes failure code goes off when
and standard sensor or wiring harness is Bkup sensor C13
value in normal disconnected, that sensor or
state wiring harness is defective. Engine wiring
CE01
harness
40-110 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 2
PC350LC/HD-8 40-111 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA221 - Ambient Pressure Sensor High Error
Action code Failure code Ambient pressure sensor high error
Trouble
E11 CA221 (Engine controller system)
Contents of
• High voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine starting performance becomes deteriorated.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-112 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to atmospheric pressure sensor
PC350LC/HD-8 40-113 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA222 - Ambient Pressure Sensor Low Error
Action code Failure code Ambient pressure sensor low error
Trouble
E11 CA222 (Engine controller system)
Contents of
• Low voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine starting performance becomes deteriorated.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-114 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to atmospheric pressure sensor
PC350LC/HD-8 40-115 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA227 - Sensor Supply Two Volt High Error
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 • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-116 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 2
PC350LC/HD-8 40-117 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA234 - Engine Overspeed
Action code Failure code Engine overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded control upper speed limit.
trouble
Action of
• Stops injection until engine speed lowers to normal level.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
• Method of reproducing failure code: Run engine at high idle.
information
40-118 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA238 - NE Speed Sensor Supply Voltage Error
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
• Controls the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine does not start easily.
appears on
• Engine hunts.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
PC350LC/HD-8 40-119 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA271 - IMV/PCV1 Short Error
Action code Failure code IMV/PCV1 short error
Trouble
E10 CA271 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of supply pump actuator.
trouble
Action of
• None in particular.
controller
Problem that • Engine speed does not rise from low idle.
appears on • Engine output lowers.
machine • Common rail fuel pressure rises above command value.
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (2) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors 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
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (2) – chassis ground Min. 100 kΩ
40-120 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to supply pump actuator (metering unit)
PC350LC/HD-8 40-121 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA272 - IMV/PCV1 Open Error
Action code Failure code IMV/PCV1 open error
Trouble
E10 CA272 (Engine controller system)
Contents of
• Opening was detected in drive circuit of supply pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
• Engine runs but its operation is unstable.
appears on
• Common rail fuel pressure rises above command value.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-122 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to supply pump actuator (metering unit)
PC350LC/HD-8 40-123 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA281 - Pump Press Balance Error
Possible causes Connections in between common rail pressure sensor and engine wiring
and standard harness and engine controller may be defective. Check the following.
Defective wiring harness
value in normal 2 • Loose connector, broken lock, broken seal
connector
state • Corrosive, bent, broken, forced-in, or extended pin
• Water, dirt or dust in connector, or poor insulation
Engine controller is possibly defective if no problem is found in causes 1 -
3 Defective engine controller 2.
(Since the trouble is in system, troubleshooting cannot be performed.)
40-124 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-125 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA322 - Injector #1 Open/short Error
Action code Failure code Injector #1 open/short circuit error
Trouble
E11 CA322 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information
40-126 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 1
PC350LC/HD-8 40-127 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA323 - Injector #5 Open/short Error
Action code Failure code Injector #5 open/short circuit error
Trouble
E11 CA323 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 5 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information
40-128 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
Circuit diagram related to injector No. 5
PC350LC/HD-8 40-129 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA324 - Injector #3 Open/short Error
Action code Failure code Injector #3 open/short circuit error
Trouble
E11 CA324 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 3 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information
40-130 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 3
PC350LC/HD-8 40-131 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA325 - Injector #6 Open/short Error
Action code Failure code Injector #6 open/short circuit error
Trouble
E11 CA325 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 6 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • Combustion becomes irregular or engine hunts.
machine
Related
• Method of reproducing failure code: Start engine
information
40-132 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 6
PC350LC/HD-8 40-133 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA331 - Injector #2 Open/short Error
Action code Failure code Injector #2 open/short circuit error
Trouble
E11 CA331 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 2 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information
40-134 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 2
PC350LC/HD-8 40-135 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA332 - Injector #4 Open/short Error
Action code Failure code Injector #4 open/short circuit error
Trouble
E11 CA332 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 4 injector.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information
40-136 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 4
PC350LC/HD-8 40-137 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA342 - Calibration Code Incompatibility
Action code Failure code Calibration code incompatibility
Trouble
E10 CA342 (Engine controller system)
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Normal operation, engine stopped, or start disabled
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-138 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-139 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA351 - Injectors Drive Circuit Error
Action code Failure code Injectors drive circuit error
Trouble
E10 CA351 (Engine controller system)
Contents of
• There is error in drive power circuit of injector.
trouble
Action of
• Limits output and continues operation.
controller
• Exhaust gas becomes black.
Problem that
• Combustion becomes irregular.
appears on
• Engine output lowers.
machine
• Engine cannot be started.
Related
• Method of reproducing failure code: Start engine.
information
40-140 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine controller power supply
PC350LC/HD-8 40-141 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA352 - Sensor Supply One Volt Low Error
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
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-142 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 1
PC350LC/HD-8 40-143 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA386 - Sensor Supply One Volt High Error
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
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-144 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-145 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA428 - Water in Fuel Sensor High Error
Action code Failure code Water-in-fuel sensor high error
Trouble
E15 CA428 (Engine controller system)
Contents of
• High voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-146 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to water-in-fuel sensor
PC350LC/HD-8 40-147 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA429 - Water in Fuel Sensor Low Error
Action code Failure code Water-in-fuel sensor low error
Trouble
E15 CA429 (Engine controller system)
Contents of
• Low voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (14) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between water-in-fuel sensor – 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
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller CE01 (female) Resistance
Between (14) – (47) Max. 10 Ω
Between (14) – chassis ground Min. 100 kΩ
40-148 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to water-in-fuel sensor
PC350LC/HD-8 40-149 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA435 - Eng Oil Press Sw Error
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness (with another wiring Between CE01 (female) (17) – each of CE01
state harness) Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between engine oil pressure – 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
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (17) – chassis ground Max. 10 Ω
40-150 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine oil pressure switch
PC350LC/HD-8 40-151 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA441 - Battery Voltage Low Error
Action code Failure code Battery voltage low error
Trouble
E10 CA441 (Engine controller system)
Contents of
• There is low voltage in controller power supply circuit.
trouble
Action of
• None in particular.
controller
Problem that
• Engine stops.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-152 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-153 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA442 - Battery Voltage High Error
Action code Failure code Battery voltage high error
Trouble
E10 CA442 (Engine controller system)
Contents of
• There is high voltage (36 V or higher) in controller power supply circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine may stop.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-154 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine controller power supply
PC350LC/HD-8 40-155 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA449 - Rail Pressure Very High Error
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
• Limits output and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information
40-156 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-157 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor and engine controller ground line
40-158 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-159 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA451 - Rail Pressure Sensor High Error
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
• Limits output and continues operation.
controller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-160 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor
PC350LC/HD-8 40-161 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA452 - Rail Pressure Sensor Low Error
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
• Limits output and continues operation.
controller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-162 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor
PC350LC/HD-8 40-163 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA488 - Chg Air Temp High Torque Derate
Action code Failure code Change 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 • Boost temperature can be checked with monitoring function. (Code: 185000 Boost Temperature)
information • Method of reproducing failure code: Start engine.
40-164 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA553 - Rail Pressure High Error
Action code Failure code Common rail pressure high error
Trouble
E15 CA553 (Engine controller system)
Contents of
• There is high pressure error (1) in common rail circuit.
trouble
Action of
• None in particular.
controller
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information
PC350LC/HD-8 40-165 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA559 - Rail Pressure Low Error
Action code Failure code Common rail pressure low error
Trouble
E15 CA559 (Engine controller system)
Contents of
• There is low pressure error (1) in common rail circuit.
trouble
Action of
• None in particular.
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
Related
• Method of reproducing failure code: Start engine.
information
Possible causes ★ For check of pressure in fuel low pressure circuit, see Testing and
and standard adjusting, Checking fuel pressure.
value in normal • Measured in fuel filter inlet and outlet sides.
state Defect in low pressure • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure —
2 Fuel filter outlet pressure
circuit parts
Pressure drop in fuel Max. 1.4 kg/cm2
During high idle
low-pressure circuit (Max. 20 psi)
★ For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 254 mmHg
pressure (gear pump During high idle
(Max. 4.9 psi)
side)
★ For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in fuel connector side.
Fuel suction circuit
Max. 203 mmHg
pressure (fuel During high idle
(Max. 3.9 psi)
connector side)
40-166 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-167 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA689 - Engine NE Speed Sensor Error
Action code Failure code Engine Ne speed sensor error
Trouble
E15 CA689 (Engine controller system)
Contents of
• There is error in signal from engine Ne speed sensor.
trouble
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Problem that • Engine hunts.
appears on • Engine does not start easily.
machine • Engine output lowers.
Related
• Method of reproducing failure code: Start engine.
information
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
6
(Short circuit with GND Wiring harness between CE01 (female) (27) Min.
circuit) Resistance
– C15 (female) (3) and chassis ground 100 kΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
7 5V/24V circuit) in wiring
harness Wiring harness between CE01 (female) (27)
Voltage Max. 1 V
– C15 (female) (3) and chassis ground
40-168 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-169 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA731 - Engine BKUP Speed Sensor Phase Error
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 • Controls the engine with signal from engine Ne speed sensor.
controller • 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
• Method of reproducing failure code: Start engine.
information
40-170 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-171 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA757 - All Persistent Data Lost Error
Action code Failure code All persistent data lost error
Trouble
E10 CA757 (Engine controller system)
Contents of
• All data in engine controller are lost.
trouble
Action of
• None in particular.
controller
Problem that
• Engine may stop and may not be started again.
appears on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-172 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine controller power supply
PC350LC/HD-8 40-173 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA778 - Engine BKUP Speed Sensor Error
Action code Failure code Engine Bkup speed sensor error
Trouble
E15 CA778 (Engine controller system)
Contents of
• There is error in signal from engine Bkup speed sensor.
trouble
Action of
• Continues control with signal from engine Ne speed sensor.
controller
Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
6
(Short circuit with GND Wiring harness between CE01 (female) (26) Min.
circuit) Resistance
– C13 (female) (3) and chassis ground 100 kΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
7 5V/24V circuit) in wiring
harness Wiring harness between CE01 (female) (26)
Voltage Max. 1 V
– C13 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CE01 (female) (26)
Short circuit in wiring Min.
– C13 (female) (3) and between CE01 Resistance
8 harness 100 kΩ
(female) (37) – C13 (female) (1)
(with another wiring harness)
Wiring harness between CE01 (female) (26)
Min.
– C13 (female) (3) and between CE01 Resistance
100 kΩ
(female) (47) – C13 (female) (2)
40-174 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-175 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA1633 - KOMNET Datalink Timeout Error
Action code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine controller system)
Contents of • Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of • Continues operation in default mode.
controller • If cause of failure disappears, system resets itself.
Problem that • Information may not transmitted normally by KOMNET communication and machine may not operate
appears on normally.
machine (Trouble phenomenon depends on failed section.)
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Defective CAN terminal ★ Prepare with starting switch OFF, then carry out troubleshooting
resistance without turning starting switch ON.
4
(Internal short circuit or K02 (male) Resistance
disconnection) Between (A) – (B) 120±12 Ω
If causes 1 – 4 are not detected, pump controller, engine controller or
5 Defective pump controller machine monitor may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
40-176 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to KOMNET communication
PC350LC/HD-8 40-177 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2185 - Throttle Sensor Supply Volt High Error
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 before
Action of detection of trouble and continues operation.
controller • 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
• Method of reproducing failure code: Turn starting switch ON.
information
40-178 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial
PC350LC/HD-8 40-179 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2186 - Throttle Sensor Supply Volt Low Error
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 before
Action of detection of trouble and continues operation.
controller • 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
• Method of reproducing failure code: Turn starting switch ON.
information
40-180 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial
PC350LC/HD-8 40-181 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2265 - Electric Lift Pump High Error
Action code Failure code Electric lift pump high error
Trouble
E15 CA2265 (Engine controller system)
Contents of
• Opening was detected in drive circuit of electric lift pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-182 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to electric lift pump actuator
PC350LC/HD-8 40-183 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2266 - Electric Lift Pump Low Error
Action code Failure code Electric lift pump low error
Trouble
E15 CA2266 (Engine controller system)
Contents of
• Opening was detected in electric lift pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-184 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to electric lift pump actuator
PC350LC/HD-8 40-185 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2311 - IMV Solenoid Error
Action code Failure code IMV solenoid error
Trouble
E11 CA2311 (Engine controller system)
Contents of
• Resistance of supply pump actuator circuit is abnormally high or low.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine output lowers
machine
Related
• Method of reproducing failure code: Start engine
information
40-186 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to supply pump actuator (metering unit)
PC350LC/HD-8 40-187 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2555 - Grid Htr Relay Volt High Error
Action code Failure code Grid heater relay volt high error
Trouble
E15 CA2555 (Engine controller system)
Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of
• None in particular.
controller
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 • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below -4°C (39°F).
40-188 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to preheating, starting and charging engine
PC350LC/HD-8 40-189 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2556 - Grid Htr Relay Volt Low Error
Action code Failure code Grid heater relay volt low error
Trouble
E15 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of
• None in particular.
controller
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 • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below –4°C (39°F).
40-190 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to preheating, starting and charging engine
PC350LC/HD-8 40-191 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D110KB - Battery Relay Drive Short Circuit
Action code Failure code Battery relay drive short
Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not stop.
machine
Related • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
information Code 03700: Controller Output)
40-192 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to battery relay drive
PC350LC/HD-8 40-193 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D19JKZ - Personal Code Relay Abnormality
Action code Failure code Personal code relay abnormality
Trouble
E01 D19JKZ (KOMTRAX system in machine monitor)
Contents of
• Disconnection or short circuit was detected in personal code relay circuit.
trouble
• None in particular (when disconnection is detected).
• Turns output to personal code relay OFF (when short circuit is detected).
Action of
• If cause of failure disappears, system resets itself (when disconnection is detected).
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF (when
disconnection is detected).
Problem that
appears on
machine
• This failure code is displayed only when engine lock function is effective.
Related
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be
information
reproduced on machine (Short circuit).
40-194 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine preheater/starting motor/charging system
PC350LC/HD-8 40-195 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D862KA - GPS Antenna Discon
User code Failure code GPS module operation error
Trouble
- D862KA (KOMTRAX system in machine monitor)
40-196 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Configuration drawing
PC350LC/HD-8 40-197 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA22KK - Pump Solenoid Power Low Error
Action code Failure code Lowering of solenoid power supply voltage
Trouble
E0E DA22KK (Pump controller system)
Contents of
• Solenoid power supply voltage of controller is below 20V.
trouble
• While this failure code is displayed, detection of failure codes (disconnection / short circuit) of all the
Action of
solenoid systems is stopped.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Since no solenoid valve is driven normally, machine does not operate normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-198 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to pump controller power supply
PC350LC/HD-8 40-199 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA25KP - 5 V Sensor 1 Power Abnormality
Action code Failure code 5 V sensor 1 power abnormality
Trouble
E02 DA25KP (Pump controller system)
Contents of
• Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of • Turns output of 5 V sensor power supply output 1 OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Automatic gear shifting function does not work (pump pressure sensor system).
appears on • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is lowered
machine (PPC pressure sensor system).
Related
• Method of reproducing failure code; Turn starting switch ON.
information
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between CP01 (female) (34)
state – P01 (female) (2), P01 (female) (1) – J03 –
Resistance Min. 1 MΩ
ground (T08)
[Bucket DUMP PPC pressure switch system]
Wiring harness between CP01 (female) (53)
– P03 (female) (2), P03 (female) (1) – J03 –
Resistance Min. 1 MΩ
ground (T08)
Ground fault in wiring Boom RAISE PPC pressure switch system]
harness Wiring harness between CP01 (female) (73)
2
(Short circuit with GND – P04 (female) (2), P04 (female) (1) – J03 –
circuit) Resistance Min. 1 MΩ
ground (T08)
[Bucket CURL PPC pressure switch system]
Wiring harness between CP01 (female) (17)
– P05 (female) (2), P05 (female) (1) – J03 –
Resistance Min. 1 MΩ
ground (T08)
[Arm IN PPC pressure switch system]
Wiring harness between CP01 (female) (16)
– P07 (female) (2), P07 (female) (1) – J03 –
Resistance Min. 1 MΩ
ground (T08)
[Swing RIGHT PPC pressure switch system]
40-200 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-201 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to pressure sensor power supply of pump controller
40-202 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-203 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA29KQ - Model Selection Abnormality
Action code Failure code Model selection abnormality
Trouble
- DA29KQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC350) and continues control.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Since control is carried out on assumption that model is PC350, no particular problem occurs.
machine
• Model code of pump controller can be checked with monitoring function.
(Code: 00200 Controller model code)
Related
• Condition of model selection signal can be checked with monitoring function.
information
(Code: 02201 Switch input 2)
• Method of reproducing failure code: Turn starting switch ON.
40-204 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to model selection connector
PC350LC/HD-8 40-205 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA2RMC - Pump Communication Abnormality
Action code Failure code Pump communication abnormality
Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine monitor
trouble and engine controller.
Action of • Fix engine output to E-mode, and limit pump absorption torque to about 80%.
controller • If cause of failure disappears, system resets itself.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information
40-206 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to CAN communication of pump controller
PC350LC/HD-8 40-207 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DAF8KB - Short Circuit in Camera Power Supply
Action code Failure code Short circuit in camera power supply
Trouble
- DAF8KB (Machine monitor system)
Contents of
• Output power supply voltage (Rating: 8 V) from machine monitor to camera is below 6.0 V or above 10 V.
trouble
Action of
• Turns output power supply voltage (Rating: 8 V) to camera OFF.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • Camera image is not displayed on monitor screen.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-208 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to camera
PC350LC/HD-8 40-209 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DAFGMC - GPS Module Error
Action code Failure code GPS module operation error
Trouble
- DAFGMC (KOMTRAX system in machine monitor)
Contents of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication MODEM in
trouble 50 seconds after KOMTRAX is started.
Action of
• None in particular.
machine
• If cause of failure disappears, system resets itself.
monitor
Problem that
appears on
machine
Related • Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting switch is
information turned ON).
40-210 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-211 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DAFRMC - CAN Discon (Monitor Detected)
Action code Failure code CAN disconnection (Monitor detected)
Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump controller
trouble and engine controller.
Action of
machine • If cause of failure disappears, system resets itself.
monitor
Problem that
• Information may not transmitted normally by CAN communication and machine may not operate normally.
appears on
(Trouble phenomenon depends on failed section.)
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-212 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to CAN communication of machine monitor
PC350LC/HD-8 40-213 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DGH2KB - Hyd Oil Sensor Short
Action code Failure code Hydraulic oil temperature sensor short
Trouble
- DGH2KB (Pump controller system)
Contents of
• Ground fault was defective in hydraulic oil temperature sensor circuit.
trouble
Action of • Fixes hydraulic oil temperature value at 40°C (104°F) and continues operation.
controller • If cause of failure disappears, system resets itself.
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from top of
appears on
white range (bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related
(Code: 04402 Hydraulic oil temperature sensor voltage)
information
• Method of reproducing failure code: Start engine.
40-214 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to hydraulic oil temperature sensor
PC350LC/HD-8 40-215 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHPAMA - F Pump Pressure Sensor Abnormality
Action code Failure code F pump press sensor abnormality
Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will
Related be broken. Accordingly, take extreme care when checking.
information • Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure
Defective F pump pressure ★ If the power supply voltage is normal and the signal voltage is not
2 sensor 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 electrical 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
★ After the troubleshooting, restore the connector.
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (9) –
harness Resistance Max. 1 Ω
P25 (female) (3)
3 (Disconnection in wiring or
defective contact in Wiring harness between CP01 (female) (18)
Resistance Max. 1 Ω
connector) – P25 (female) (1)
Wiring harness between CP01 (female) (49)
Resistance Max. 1 Ω
– P25 (female) (2)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between CP01 (female) (49)
circuit) Resistance Min. 1 MΩ
– P25 (female) (2) and chassis ground
★ 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
40-216 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes troubleshooting.
and standard CP01 Voltage
6 Defective pump controller
value in normal
state Between (9) – (18) 4.5 – 5.5 V
Between (49) – (18) 0.5 – 4.5 V
PC350LC/HD-8 40-217 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHPBMA - R Pump Pressure Sensor Abnormality
Action code Failure code R pump pressure sensor abnormality
Trouble
— DHPBMA (Pump controller system)
Contents of
• Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes R pump pressure at 0 kg/cm2 (0 psi)and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting.
machine
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be
Related broken. Accordingly, take extreme care when checking.
information • Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure)
Defective R pump pressure ★ If the power supply voltage is normal and the signal voltage is not
2 sensor 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 electrical 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
★ After the troubleshooting, restore the connector.
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (9) –
harness Resistance Max. 1 Ω
P26 (female) (3)
3 (Disconnection in wiring or
defective contact in Wiring harness between CP01 (female) (18)
Resistance Max. 1 Ω
connector) – P26 (female) (1)
Wiring harness between CP01 (female) (68)
Resistance Max. 1 Ω
– P26 (female) (2)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between CP01 (female) (68)
circuit) Resistance Min. 1 MΩ
– P26 (female) (2) and chassis ground
★ 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
40-218 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
★ Prepare with starting switch OFF, then start engine and carry out
Possible causes troubleshooting.
and standard CP01 Voltage
6 Defective pump controller
value in normal
state Between (9) – (18) 4.5 – 5.5 V
Between (68) – (18) 0.5 – 4.5 V
PC350LC/HD-8 40-219 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHS3MA - Arm Curl PPC Sensor Abnormality
Action code Failure code Arm IN PPC pressure sensor abnormality
Trouble
— DHS3MA (Pump controller system)
Contents of
• Signal voltage from arm IN PPC pressure sensor is below 0.3 V or above 4.72 V.
trouble
Action of • Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting.
machine
★ If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will
Related be broken. Accordingly, take extreme care when checking.
information • Input from arm IN PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm IN PPC pressure)
40-220 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to arm IN PPC pressure sensor of pump controller
PC350LC/HD-8 40-221 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality
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 • Fixes bucket curl PPC pressure at 0 kg/cm2 (0 psi) and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will
Related be broken. Accordingly, take extreme care when checking.
information • Input from bucket curl PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC pressure)
40-222 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC350LC/HD-8 40-223 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHX1MA - Overload Sensor Abnormality (Analog)
Action code Failure code Overload sensor (analog)
Trouble
— DHX1MA (Pump controller system)
Contents of
• Monitor which is not set to be displayed (Overload alarm monitor) is displayed.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information
40-224 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-225 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW43KA - Travel Speed Solenoid Disconnection
Action code Failure code Travel speed solenoid disconnection
Trouble
— DW43KA (Pump controller system)
Contents of
• No current flows at output to travel speed solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
• Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW43KB].)
40-226 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel speed solenoid of pump controller
PC350LC/HD-8 40-227 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW43KB - Travel Speed Solenoid Short Circuit
Action code Failure code Travel speed solenoid short
Trouble
— DW43KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel speed solenoid circuit.
trouble
Action of • Turns output to travel speed solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
Related • Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)
40-228 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel speed solenoid of pump controller
PC350LC/HD-8 40-229 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW45KA - Swing Brake Solenoid Disconnection
Action code Failure code Swing holding brake solenoid disconnection
Trouble
E03 DW45KA (Pump controller system)
Contents of
• No current flows at output to swing holding brake solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring
function. (Code 02300: Solenoid 1)
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake
Related release switch in release position (Swing holding brake does not work, however, when machine stops).
information • Turn both of swing lock and emergency swing release switches OFF during troubleshooting.
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW45KB].)
40-230 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
PC350LC/HD-8 40-231 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to swing holding brake solenoid of pump controller
40-232 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
MEMORANDUM
PC350LC/HD-8 40-233 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW45KB - Swing Brake Solenoid Short Circuit
Action code Failure code Swing holding brake solenoid short
Trouble
E03 DW45KB (Pump controller system)
Contents of
• Abnormal current flowed at output to swing holding brake solenoid circuit.
trouble
Action of • Turns output to swing holding brake solenoid circuit OFF.
controller • 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 function.
Related (Code 02300: Solenoid 1)
information • If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake
release switch in release position (Swing holding brake does not work, however, when machine stops).
40-234 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to swing holding brake solenoid of pump controller
PC350LC/HD-8 40-235 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW91KA - Travel Junction Solenoid Disconnection
Action code Failure code Travel junction solenoid disconnection
Trouble
— DW91KA (Pump controller system)
Contents of
• No current flows at output to travel junction solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Hard to turn when operating travel steering.
machine
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW91KB].)
40-236 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel junction solenoid of pump controller
PC350LC/HD-8 40-237 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW91KB - Travel Junction Solenoid Short Circuit
Action code Failure code Travel junction solenoid short
Trouble
— DW91KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of • Turns output to travel junction solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Hard to turn when operating travel steering.
machine
Related • Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)
40-238 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel junction solenoid of pump controller
PC350LC/HD-8 40-239 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWA2KA - Attachment Sol Open Circuit
Action code Failure code Attachment solenoid disconnection
Trouble
— DWA2KA (Pump controller system)
Contents of
• When output to service solenoid is turned off, disconnection was detected in circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Operating condition of service solenoid can be checked with monitoring function.
Related (Cide: 02301 Solenoid 2)
information • Method of reproducing failure code: Tun starting switch ON + Set machine in mode other than breaker
mode (B).
40-240 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWA2KB - Attachment Sol Short Circuit
Action code Failure code Attachment solenoid short circuit
Trouble
— DWA2KB (Pump controller system)
Contents of
• When output to service solenoid is turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to service solenoid OFF
controller • If cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Operating condition of service solenoid can be checked with monitoring function.
Related (Cide: 02301 Solenoid 2)
information • Method of reproducing failure code: Tun starting switch ON + Set machine in mode other than breaker
mode (B).
PC350LC/HD-8 40-241 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWJ0KA - Merge-Divider Solenoid Disconnection
Action code Failure code Merge-divider solenoid disconnection
Trouble
— DWJ0KA (Pump controller system)
Contents of
• No current flows at output to merge-divider solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DWJ0KB].)
40-242 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to merge-divider solenoid of pump controller
PC350LC/HD-8 40-243 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWJ0KB - Merge-Divider Solenoid Short Circuit
Action code Failure code Merge-divider solenoid short
Trouble
— DWJ0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to merge-divider solenoid circuit.
trouble
Action of • Turns output to merge-divider solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related • Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)
40-244 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to merge-divider solenoid of pump controller
PC350LC/HD-8 40-245 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWK0KA - 2-Stage Relief Sol. Open Circuit
Action code Failure code 2-stage relief solenoid disconnection
Trouble
— DWK0KA (Pump controller system)
Contents of
• No current flows at output to 2-stage relief solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Power maximizing function does not work.
machine
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DWK0KB].)
40-246 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to 2-stage relief solenoid of pump controller
PC350LC/HD-8 40-247 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWK0KB - 2-Stage Relief Solenoid Short Circuit
Action code Failure code 2-stage relief solenoid short circuit
Trouble
— DWK0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of • Turns output to 2-stage relief solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Power maximizing function does not work.
machine
Related • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)
40-248 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to 2-stage relief solenoid of pump controller
PC350LC/HD-8 40-249 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXA0KA - PC-EPC Solenoid Open Circuit
Action code Failure code PC-EPC solenoid disconnection
Trouble
E02 DXA0KA (Pump controller system)
Contents of
• No current flows to PC-EPC solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related
• If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate
information
the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed, but it is not
defective.)
40-250 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC350LC/HD-8 40-251 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXA0KB - PC-EPC Solenoid Short Circuit
Action code Failure code PC-EPC solenoid short circuit
Trouble
E02 DXA0KB (Pump controller system)
Contents of
• Abnormal current flowed to PC-EPC solenoid circuit.
trouble
Action of • Sets output to PC-EPC solenoid circuit to 0.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related • If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate
information the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed, but it is not
defective.)
★ Turn emergency pump drive switch OFF during troubleshooting.
40-252 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC350LC/HD-8 40-253 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE0KA - LS-EPC Solenoid Disconnection
Action code Failure code LS-EPC solenoid disconnection
Trouble
— DXE0KA (Pump controller system)
Contents of
• No current flows to LS-EPC solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Speed of work equipment and swing is high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC solenoid current)
40-254 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC350LC/HD-8 40-255 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE0KB - LS-EPC Solenoid Short Circuit
Action code Failure code LS-EPC solenoid short circuit
Trouble
— DXE0KB (Pump controller system)
Contents of
• Abnormal current flowed to LS-EPC solenoid circuit.
trouble
Action of • Sets output to LS-EPC solenoid circuit to 0.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC solenoid current)
40-256 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC350LC/HD-8 40-257 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE4KA - Service Current EPC Disconnection
40-258 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE4KB - Service Current EPC Short Circuit
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 • Sets output to service current EPC solenoid circuit to 0.
controller • 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
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
information
(Code 01700: Service solenoid current)
PC350LC/HD-8 40-259 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY20KA - Wiper Working Abnormality
Action code Failure code Wiper working abnormality
Trouble
— DY20KA (Pump controller system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of • Turns working output to wiper motor OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Wiper motor does not work.
machine
• Condition of W contact signal of wiper working area can be checked with monitoring function.
Related
(Code: 02204 switch 5)
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
40-260 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor
PC350LC/HD-8 40-261 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY20MA - Wiper Parking Abnormality
Action code Failure code Wiper parking abnormality
Trouble
— DY20MA (Pump controller system)
Contents of
• When windshield wiper parks, P signal of storage area is not input.
trouble
Action of • Turns parking output to wiper motor OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Wiper motor does not park.
machine
• Condition of P contact signal of wiper parking area can be checked with monitoring function.
Related
(Code: 02204 switch 5)
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.
40-262 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor
PC350LC/HD-8 40-263 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2CKA - Washer Drive Open Circuit
Action code Failure code Window washer drive system disconnection
Trouble
- DY2CKA (Pump controller system)
Contents of • When output to window washer drive system was turned ON (When ground circuit was connected),
trouble disconnection was detected in circuit.
Action of • None in particular (Since no current flows, washer motor does not operate).
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Window w3asher does not operate.
machine
• Method of reproducing failure code: Turn starting switch ON.
• DY2CKA code may also be associated with frequent replacement of the 10 Amp fuse located in fuse
Related socket #4 of the fuse panel.
information • The technician is advised to check the condition of the heating coil element in the cigarette lighter. If the
heating coil element is heavily worn and damaged, short circuit can occur and the #4 fuse will blow. When
this happens, the monitor panel registers abnormality code. DY2CKA.
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring without turning starting switch ON.
value in normal harness (Disconnection in Wiring harness betweenF01 (4) - J03 - M06
4 Resistance Max. 1 Ω
state wiring or defective contact in (female) (1)
connector) Wiring harness between CP01 (female) (3) -
Resistance Max. 1 Ω
J04 - M06 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring
Wiring harness between F01 (4) - J03 - M06 MIN.
5 harness (Short circuit with Resistance
(female) (1) - D02 (female) (3) 1 MΩ
GND circuit)
Wiring harness between CP01 (female) (3) - MIN.
Resistance
J04 - M06 (female) (2) - D02 (female) (7) 1 MΩ
★ Prepare with starting switch OFF, the turn starting switch ON and
carry out troubleshooting
6 Defective pump controller
CP01 (female) Voltage
Between (3) - chassis ground 20 - 30 V
40-264 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to windshield wiper and window washer
PC350LC/HD-8 40-265 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2CKB - Washer Drive Short Circuit
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 ON (ground circuit was disconnected), short
trouble 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
• Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
information
40-266 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to window washer motor of pump controller
PC350LC/HD-8 40-267 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2DKB - Wiper Motor Drive Forward System Short
Action code Failure code Wiper motor drive forward system short
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
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information
40-268 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor
PC350LC/HD-8 40-269 1
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2EKB - Wiper Drive Reverse Short Circuit
Action code Failure code Wiper motor drive reverse system short
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
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.
information
40-270 1 PC350LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor
PC350LC/HD-8 40-271 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-MODE (ELECTRICAL SYSTEM)
Failure
Phenomenon occurring on machine
phenomenon
Relative
Information on the failure occurred as well as the troubleshooting
information
<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 broken.
• 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 abnor-
Possible causes mally.
and standard Possible causes of trouble
value in normal (Given numbers are
state reference numbers, which do
not indicate priority)
<Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for
3 troubleshooting, 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”, disconnect con-
nector 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 specified.
4 • 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.
40-272 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
Relative Electrical Circuit Diagram
PC350LC/HD-8 40-273 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-1 Engine Does Not Start
Trouble • Engine does not start (Engine does not turn).
• Engine starting circuit has following 2 start lock mechanisms:
Related 1) Start lock by the machine monitor password
information 2) Start lock by the lock lever
• In the case no error code for the engine controller mechanism is indicated
40-274 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Cause Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01-17 – H15
Resistance Max. 1 Ω
(female) (1)
Wiring harness between H06 (female) (4) –
Resistance Max. 1 Ω
J01 – R06 (female) (6)
Disconnection in wiring Wiring harness between R06 (female) (3) –
harness Resistance Max. 1 Ω
M17 (female) (1)
8 (Disconnection in wiring or
defective contact in Wiring harness between F01-3 outlet – S14
Resistance Max. 1 Ω
connector) (female) (1)
Wiring harness between S14 (female) (3) –
Resistance Max. 1 Ω
R06 (female) (1)
Wiring harness between R06 (female) (3) –
Resistance Max. 1 Ω
R07 (female) (4)
Wiring harness between R06 (female) (2) –
Resistance Max. 1 Ω
J04 – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
without turning starting switch ON.
and standard
value in normal Wiring harness between battery relay
state terminal B (R04) – F05 – F01-16D and Resistance Min. 1 MΩ
chassis ground
Wiring harness between F01-17 – H15
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Ground fault in wiring Wiring harness between H15 (female) (4) –
harness Resistance Min. 1 MΩ
9 J01 – R06 (female) (6) and chassis ground
(Short circuit with GND
circuit) Wiring harness between R06 (female) (3) –
Resistance Min. 1 MΩ
M17 (female) (1) and chassis ground
Wiring harness between F01-3 – S14
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Wiring harness between S14 (female) (3) –
Resistance Min. 1 MΩ
R06 (female) (1) and chassis ground
Wiring harness between R07 (female) (2) –
Resistance Min. 1 MΩ
CM01 (female) (8) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
10
24V circuit) in wiring harness Wiring harness between CM01 (female) (11)
– J02 – M17 (female) (2), – D01 (female) (6), Voltage Max. 1 V
– alternator terminal R and chassis ground
PC350LC/HD-8 40-275 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine start and battery charging
40-276 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-2 Auto-decelerator Does Not Operate
Trouble • Auto-decelerator does not operate.
• Set speed of auto-decelerator is 1,300 rpm. Accordingly, set the fuel control dial to a higher rpm than this
Related
speed. If set speed is under 1,300 rpm, the auto-decelerator will not operate.
information
• Check all the monitoring indications after starting the engine.
PC350LC/HD-8 40-277 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
40-278 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-3 Automatic Warming-up System Does Not Operate
Trouble • Automatic warming-up system does not operate
• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to 1,250
Related rpm.
information • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned ON or
after engine is started, automatic warm-up system is turned OFF.
PC350LC/HD-8 40-279 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-4 Preheater Does Not Operate
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Related Input of preheating signal (ON/OFF) can be checked with monitoring function.
information (Code 04500: Monitor Input 1)
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related • During low temperature (coolant temperature below 30°C), pump controller drives the heater relay for 100
information sec. after engine start to automatically preheat.
40-280 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine preheater
PC350LC/HD-8 40-281 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-5 All Work Equipment, Swing, and Travel Mechanism do not move
Trouble • All travel, swing, and work equipment mechanism do not move.
Related
—
information
40-282 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to PPC lock solenoid
PC350LC/HD-8 40-283 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-6 Power Maximizing Function Does Not Operate
Trouble • Power maximizing function does not work.
• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed during
Related work equipment operation while the engine is running in P- or E-mode.
information • Input state of power maximizing switch (left knob switch) can be checked with monitoring function (Code
02200: Switch Input 1)
40-284 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to power max. switch
PC350LC/HD-8 40-285 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-7 Machine Monitor Does Not Display At All
Trouble • Machine monitor does not display at all when starting switch is turned ON
Related
—
information
40-286 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to power source in monitor panel
PC350LC/HD-8 40-287 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-8 Machine Monitor Does Not Display Some Items
Trouble • Machine monitor does not display some items when starting switch is turned ON
Related
—
information
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
—
information
40-288 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-10 Fuel Level Monitor Was Lit in Red While Engine Running
Trouble • Fuel level monitor was lit in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
information
(Code 04200: Fuel level sensor voltage)
PC350LC/HD-8 40-289 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally
• While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• 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 function.
Related (Code: 04105: Engine coolant temperature)
information • Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated (if
yes, diagnose that failure first.)
40-290 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine coolant temperature sensor
PC350LC/HD-8 40-291 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally
• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
information (Code 04402: Hydraulic oil temperature)
40-292 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
PC350LC/HD-8 40-293 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-14 Swing Lock Monitor Does Not Indicate Normally
• 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 • Input from swing lock switch (ON/OFF) can be checked with monitoring function.
information (Code 04502: Monitor Input 3)
40-294 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to swing lock switch
PC350LC/HD-8 40-295 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-15 When Monitor Switch is Operated, Monitor Displays Nothing
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related
—
information
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related
★ If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
information
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related
★ If travel speed selection fails, proceed with troubleshooting No. H-21.
information
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related
★ If wiper fails to operate, proceed with troubleshooting No. E-16.
information
40-296 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
MEMORANDUM
PC350LC/HD-8 40-297 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-16 Windshield Wiper and Window Washer do not Operate
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)
Cause Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
W03 (female) Front window Resistance
Defective window rear limit
1 When installed to
switch (Internal short circuit) Min. 1 MΩ
front
Between (1) – (2)
When retracted to
Max. 1 Ω
rear
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective wiper motor without turning starting switch ON.
2 (Internal disconnection or
M05 (female) Continuity
short circuit)
Between (1) – (3) There is continuity
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP02 (female)
Possible causes 3 (Disconnection in wiring or Resistance Max. 1 Ω
(119) – M05 (male) (3)
and standard defective contact in
value in normal connector) Wiring harness between CP02 (female)
Resistance Max. 1 Ω
state (114) – M05 (male) (1)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND
circuit) CP01 (female) (57) – W03 (male) (1) Resistance Min. 1 MΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
CP01 (female) Front window Resistance
Defective pump controller
(Rear limit switch system) When installed to
Min. 1 MΩ
Between (57) – front
5 chassis ground When retracted to
Max. 1 Ω
rear
★ Prepare with starting switch OFF, then turn starting switch ON and
Defective pump controller carry out troubleshooting.
(Wiper motor system) CP02 (female) Continuity
Between (119) – (114) There is continuity
40-298 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to windshield wiper motor
PC350LC/HD-8 40-299 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
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)
40-300 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
MEMORANDUM
PC350LC/HD-8 40-301 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-17 Machine Push-up Function Does Not Operate Normally
• Machine push-up function does not oper-
Trouble (1) Machine push-up function does not operate.
ate normally
Related
• When machine push-up function is set to high pressure, solenoid is de-energized.
information
40-302 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
• Machine push-up function does not operate
Trouble (2) Machine push-up function does not release.
normally
Related
• When machine push-up function is set to low pressure, solenoid is energized.
information
PC350LC/HD-8 40-303 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-18 Monitoring Function Fails to Display “Boom Raise” Normally
Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Pressure Switch 1)
information
40-304 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to boom RAISE PPC oil pressure switch
PC350LC/HD-8 40-305 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-19 Monitoring Function Fails to Display “Boom Lower” Normally
Trouble • Boom LOWER operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information
40-306 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to boom LOWER PPC oil pressure switch
PC350LC/HD-8 40-307 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-20 Monitoring Function Fails to Display “Arm In” Normally
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information
40-308 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to arm IN PPC oil pressure switch
PC350LC/HD-8 40-309 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-21 Monitoring Function Fails to Display “Arm Out” Normally
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information
40-310 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to arm OUT PPC oil pressure switch
PC350LC/HD-8 40-311 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-22 Monitoring Function Fails to Display “Bucket Curl” Normally
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code:01901 (Output Switch 2)
information
40-312 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to Bucket CURL PPC oil pressure switch
PC350LC/HD-8 40-313 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-23 Monitoring Function Fails to Display “Bucket Dump” Normally
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 2)
information
40-314 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to bucket DUMP PPC oil pressure switch
PC350LC/HD-8 40-315 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-24 Monitoring Function Fails to Display “Swing” Normally
Trouble • Swing is not displayed normally by machine monitoring function (Special function)
Related
• Monitoring code: 01900 (Output Switch 1)
information
40-316 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to right and left swing PPC oil pressure switches
PC350LC/HD-8 40-317 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-25 Monitoring Function Fails to Display “Travel” Normally
Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information
40-318 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC350LC/HD-8 40-319 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-26 Monitoring Function Fails to Display “Travel Differential Pressure” Nor-
mally
Trouble • Travel differential pressure is not displayed normally by machine monitoring function (Special functions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left travel
Related
PPC circuits (during steering).
information
• Monitoring code: 01901 (Output Switch 2)
40-320 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to travel steering PPC oil pressure switch
PC350LC/HD-8 40-321 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-27 Monitoring Function Fails to Display “Service” Normally
Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01901 (Output Switch 2)
information
40-322 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to service PPC oil pressure switch
PC350LC/HD-8 40-323 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-28 KOMTRAX System Does Not Operate Normally
• If KOMTRAX system administrator makes request for checking system on machine side for
trouble, carry out following troubleshooting.
Related information
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.
• Carry out all troubleshooting on service menu screen of machine monitor.
40-324 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
★ Select “Terminal Status” from “12 Display of KOMTRAX setting”
in the service menu of the machine monitor.
PC350LC/HD-8 40-325 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-29 Air Conditioner Does Not Operate
Trouble • Air conditioner does not start.
Related • For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance stan-
information dard, “Air conditioner system.”
Defective A/C Hi/Lo pressure ★ Prepare with starting switch OFF, then carry out troubleshooting with-
switch out turning starting switch ON.
2
(Internal disconnection or P17 (male) Resistance
defective contact) Between (1) – (2) Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01-11 outlet –
Disconnection in wiring Resistance Max. 1 Ω
AC01 (male) (4)
harness
Wiring harness between AC01 (male) (7) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
P17 (female) (1)
Possible causes defective contact in
and standard connector) Wiring harness between AC01 (male) (5) –
Resistance Max. 1 Ω
value in normal chassis ground
state Wiring harness between P17 (female) (2) –
Resistance Max. 1 Ω
J04 – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between F01-11 outlet –
4 Resistance Min. 1 MΩ
(Short circuit with GND AC01 (male) (4) and chassis ground
circuit) Wiring harness between AC01 (male) (7) –
Resistance Min. 1 MΩ
P17 (female) (1) and chassis ground
★ 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
Remark
See Section 60, Air Conditioning.
40-326 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to air conditioner
PC350LC/HD-8 40-327 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-30 Travel Alarm Does Not Sound or Does Not Stop Sounding
• Alarm does not sound during travel.
Trouble
• Alarm sounds in stopped state.
Related
—
information
40-328 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC350LC/HD-8 40-329 1
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-31 Horn Does Not Sound
Trouble Horn does not sound
Related
—
information
40-330 1 PC350LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to horn
PC350LC/HD-8 40-331 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)
40-332 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
★ 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.
PC350LC/HD-8 40-333 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
Information Contained in Troubleshooting Table
★ Troubleshooting table and related circuit diagram collectively carry the following information. Carry out troubleshooting
work after fully grasping their contents.
Failure
Phenomenon occurring on machine
phenomenon
Relative
Information on the failure occurred as well as the troubleshooting
information
2
Presumed Cause for presumed failure
cause and [Contents]
(The attached No. is for filing
standard value • The standard values in normalcy by which to judge “Good” or “No
3 and reference purpose only. It
in normalcy Good” about presumed causes.
does not stand for any
• References for making judgement of “good” or “No Good”
priority.)
4
40-334 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
MEMORANDUM
PC350LC/HD-8 40-335 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-1 All Work Equipment Lack Power, or Travel and Swing Speeds are Slow
Trouble • Speed or power of whole work equipment, travel, and swing is low
Related
• Set the working mode in P-mode before start.
information
40-336 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
PC350LC/HD-8 40-337 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-2 Engine Speed Sharply Drops or Engine Stalls
Trouble • Engine speed lowers extremely or engine stalls.
Related
• Set the working mode in P-mode before start.
information
40-338 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-3 No Work Equipment, Swing or Travel Move
Trouble • All work equipment, swing, and travel mechanism do not move.
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-339 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-5 Auto-decelerator Does Not Work
Trouble • Auto-decelerator does not operate.
• Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated. (Shuttle
Related
valve (in PPC valve) is installed between PPC valve and oil pressure switch in travel circuit.)
information
• Set the working mode in P-mode before start.
Possible causes ★ Prepare with engine stopped, then run engine at high idle and carry
and standard out troubleshooting.
value in normal Malfunction of travel PPC Travel lever PPC valve output pressure
1
state valve (shuttle valve)
Neutral 0 kg/cm2 (0 psi)
Operated Min. 28 kg/cm2 (398 psi)
40-340 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-7 Boom Moves Slowly or Lacks Power
Trouble • Speed or power of boom is low
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-341 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-8 Arm Moves Slowly or Lacks Power
Trouble • Speed or power of arm is low
Related
• Set the working mode in P-mode before start.
information
40-342 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-9 Bucket Moves Slowly or Lacks Power
Trouble • Speed or power of bucket is low
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-343 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-11 Work Equipment has a bit too Fast Hydraulic Drift
Trouble (1) • Hydraulic drift of boom is large.
Related
• Set the working mode in P-mode before start.
information
40-344 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
PC350LC/HD-8 40-345 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-12 Work Equipment Has Big Time Lag
Trouble Time lag of work equipment is large.
Related
Set the working mode in P-mode before start.
information
40-346 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-14 Power Max. Switch Does Not Operate
Trouble • The power maximizing function does not work.
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-347 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-16 In Swing + Boom Raise Operation, Boom Moves Slowly
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related
• If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
information
40-348 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-18 Machine Swerves in Travel
Trouble • Machine deviates during travel.
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-349 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-19 Machine Travels Slowly
Trouble • Travel speed is low.
Related
• Set the working mode in P-mode before start.
information
40-350 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-20 Machine Cannot Be Easily Steered or Lacks Power
Trouble • Machine is not steered well or steering power is low
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-351 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
40-352 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-22 Track Shoe Does Not Turn (On One Side Only)
PC350LC/HD-8 40-353 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-23 Machine Does Not Swing
Trouble (1) • Upper structure does not swing in either direction.
Related
• Set the working mode in P-mode before start.
information
40-354 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
PC350LC/HD-8 40-355 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-24 Swing Acceleration is Poor, or Swing Speed is Slow
Trouble (1) • Swing acceleration or swing speed is low in both directions.
Related
• Set the working mode in P-mode before start.
information
40-356 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
Trouble (2) • Swing acceleration or swing speed is low in only one direction.
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-357 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-25 Excessive Overrun When Stopping Swing
Trouble (1) • Upper structure overruns remarkably when it stops swinging in both directions.
Related
• Set the working mode in P-mode before start.
information
Trouble (2) • Upper structure overruns remarkably when it stops swinging in only one direction.
Related
• Set the working mode in P-mode before start.
information
40-358 1 PC350LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-26 There is Big Shock when Stopping Swing
Trouble • Large shock is made when upper structure stops swinging.
Related
• Set the working mode in P-mode before start.
information
PC350LC/HD-8 40-359 1
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-28 Swing Hydraulic Drift is too big
Trouble (1) • Hydraulic drift of swing is large (when swing holding brake is applied).
Related • When swing emergency reset switch is turned OFF (normal position), swing holding brake operates and
information upper structure is fixed with disc brake.
Trouble (2) • Hydraulic drift of swing is large (when swing holding brake is released).
Related • When swing emergency reset switch is turned ON (in an emergency), swing holding brake is released and
information upper structure is secured by only hydraulic pressure.
40-360 1 PC350LC/HD-8
50 DISASSEMBLY AND ASSEMBLY
PC350LC/HD-8 50-1 B
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-85
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90
RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-93
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-93
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-94
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-96
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-97
Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-98
REVOLVING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-104
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-105
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-106
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-107
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-119
Oil Seal in Hydraulic Pump input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-124
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-124
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-125
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-127
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-127
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-136
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
50-2 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140
Cab Glass (Stuck Glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-143
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-153
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-156
Floor Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-161
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-161
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-165
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-166
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-166
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-166
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-169
KOMTRAX Communication Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-171
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-171
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-172
Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-173
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-173
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-174
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-176
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-176
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-176
PC350LC/HD-8 50-3 B
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
1. Removal and installation of assemblies
Special tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.
Removal
• The [Removal] section contains procedures and precautions for implementing the work, know how and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• Marks shown in the Installation Section stand for the following.
50-4 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
★ :This mark gives guidance or precautions when doing the procedure.
Tightening torque.
• Various special tools are illustrated for the convenience of local manufacture.
• Special tools which are deemed necessary for disassembly or assembly of parts are described as A1, ••• X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.
• In Disassembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity
of the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• The meanings of the symbols used in Disassembly section are as follows.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
PC350LC/HD-8 50-5 B
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
Assembly
• In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of
the oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• The meanings of the symbols used in Assembly section are as follows.
Tightening torque.
• Various special tools are illustrated for the convenience of local manufacture.
50-6 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12
SPECIAL TOOLS LIST
★ Tools with part number 79❍T-❍❍❍-❍❍❍❍ cannot be supplied (they are items to be locally manufactured).
★ Necessity:
■ ...........Cannot be substituted, must always be installed (used).
● ...........Extremely useful if available or can be substituted with commercially available part.
★ New/Remodel:
N...........Tools with new part numbers, newly developed for this model.
R:...........Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: ...Tools already available for other models, can be used without any modification.
★ Tools marked ❍ in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special
tools).
New/remodel
Necessity
Sketch
Q'ty
Component Symbol Part number Part name Nature of work, remarks
01314-20612 • Screw 3
796T-627-1630 Push tool ■ 1 ❍
790-101-2510 Block ■ 1
PC350LC/HD-8 50-7 B
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
790-101-1102 Pump ■ 1
790-101-2501 Push puller ■ 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Center swivel joint Disassembly and assembly of
L 790-101-2540 • Washer 1
assembly center swivel joint assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
50-8 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
796-946-1310 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
■ 1
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
■ 1
(For 723-46-44100)
796-946-2210 Guide
■ 1
(For 723-46-45100)
796-946-1320 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1820 Guide
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2 ■ 1
Control valve (For 723-46-44100) Replacement of pressure
assembly 796-946-2220 Guide compensation valve seal
■ 1
M (For 723-46-45100)
796-946-1420 Guide
■ 1
(For 723-46-42800)
796-946-1330 Sleeve
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve
3 ■ 1
(For 723-46-44100)
796-946-2230 Sleeve
■ 1
(For 723-46-45100)
796-946-1430 Sleeve
■ 1
(For 723-46-42800)
4 796T-416-1010 Push tool ■ 1 N ❍ Press fitting of bushing
Travel PPC valve 5 796T-416-1030 Push tool ■ 1 N ❍ Press fitting of bushing
6 796T-416-1020 Push tool ■ 1 N ❍ Press fitting of pin
PC350LC/HD-8 50-9 B
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
3 790-720-1000 Expander ● 1
796-720-1680 Ring ● 1 Installation of bearing
4
07281-01589 Clamp ● 1
790-201-1702 Push tool kit ■ 1
Hydraulic Push tool
790-201-1851 1
cylinder N (for bucket and boom)
assembly 5 Press fitting of bushing
790-201-1861 Push tool (for arm) 1
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit ■ 1
790-101-5021 Grip 1
50-10 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.
D2. Push tool
PC350LC/HD-8 50-11 B
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
E5. Push tool
50-12 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
M5. Push tool
PC350LC/HD-8 50-13 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will
hinder wire removal and may damage the connector or
removal tool. Always use the correct removal tool size for
the wire gauge you are servicing.
3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or
connector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
50-14 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Striping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
Wire Inspection
PC350LC/HD-8 50-15 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Crimping Contact Terminal (HD30 Type)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
6. Release the tool handle and remove the crimped contact terminal.
Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.
50-16 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Insertion Of Contact Terminal (HD30 Type)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
PC350LC/HD-8 50-17 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Contact Terminal Removal (DT Type)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.
2. Pull the wedge lock straight out and save for reinstallation.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
50-18 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
ENGINE COMPONENTS
Necessity
Sketch
Symbol Part number Part name Q’ty N/R
A 1 795-799-1390 Remover ●
Removal
WARNING! Disconnect the cable from the negative (–) terminal of the battery.
2. Remove clamps (1) and (2), U-bolt (3), and air intake tube (4). [*1]
6. Loosen air conditioner compressor belt (9) and remove it. [*2]
PC350LC/HD-8 50-19 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
15. Disconnect feed pump hoses (18) and (19). [*4]
17. Rotate the crankshaft forward to set stamp (a) of supply pump drive
gear (21) to the top and set the No. 1 cylinder to the compression top
dead center (TDC).
50-20 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
20. Remove 4 nuts (24).
21. Push in tool A1 installed in step nineteen and remove fuel supply
pump assembly (25).
Installation
Carry out installation in the reverse order to removal.
[*1]
★ Tighten the hose clamps before and after the air intake tube to the
following torque.
[*2]
★ Adjust the belt tension. For details, see "Testing and adjusting air
conditioner compressor belt".
[*3]
WARNING! Always use genuine clamp for fixing highpressure pipe. Strictly observe the tightening
torque requirements.
WARNING! Keep the harness assembly and other harnesses 10 mm and above away from the
high-pressure tube.
★ 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.
• Check the taper seal of the connecting part (Part (a): Part 2 mm (0.078 in) from the end) for visible lengthwise slit (b) and
dent (c).
• Check part (d) (end of the taper seal: Part at 2 mm (0.078 in) from the end) for stepped-type wear (fatigue) which your nail
can feel.
★ Tighten the No. 1 injector and outlet high-pressure pipe to the
following torque.
A. Push in supply pump drive shaft (26), matching its pin to key way (b) of supply pump drive gear (21), and tighten nut
(22) and washer (23) temporarily.
B. Install fuel supply pump assembly (25) with four mounting nuts
(24) and bracket mounting bolts (27).
50-22 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
Engine Front Seal
Special tools
Necessity
Sketch
Symbol Part number Part name Qíty N/R
A 2 795-799-8120 Installer ● 1
Removal
1. Remove the radiator assembly and hydraulic oil cooler assembly. For
details; See “RADIATOR” on page 50-48 and See “HYDRAULIC
OIL COOLER” on page 50-50.
WARNING! 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.)
WARNING! After removing the fan belt (3), return the tensioner assembly (2) slowly with care.
WARNING! Be careful not to get your fingers caught between the pulley and fan belt (3) during work.
PC350LC/HD-8 50-23 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
5. Remove pulley (6).
7. Remove front seal and carrier assembly (8) from front cover (9).
50-24 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
Installation
★ Since pilot tool [1] inside the front seal is used to guide the
crankshaft, do not remove it from the front seal.
★ Pilot tool [1] is in the spare front seal.
4. Using A2, insert front seal (10) in carrier (11) from the front cover
fitting face.
★ Insert front seal (10) so that the front cover fitting face of carrier
(11) will be flush with the bottom of the front seal.
5. Install front seal and carrier assembly (8) to front cover (9).
B. Apply the pilot tool of the front seal to the crankshaft and push
in the whole carrier.
[*1] [*2]
• Install alternator belt (5) and fan belt (3) as follows.
WARNING! 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.)
PC350LC/HD-8 50-25 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
WARNING! After installing the fan belt (5), return the tensioner assembly (4) slowly with care.
WARNING! Be careful not to get your fingers caught between the pulley and fan belt (5) during work.
[*3]
★ Tighten the vibration damper to the following torque.
50-26 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
Engine Rear Seal
Removal
3. Install the sling to flywheel (2) and lift off the flywheel. [*2]
6. Remove twelve mounting bolts (4) and lift off flywheel housing (5).
[*3]
PC350LC/HD-8 50-27 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
7. Remove four mounting bolts (indicated by the arrows) of the oil pan,
eight mounting bolts (6), and rear seal and housing assembly (7).
50-28 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
Installation
2. Check the ends and seal inserting parts of the crankshaft for burrs
and rust and clean them thoroughly.
4. Install guide pin [2] to the cylinder block and then install gasket (10)
and rear seal and housing assembly (7).
★ Cut bottom (A) of gasket (10) at the end of the seal housing (at
both right and left sides).
PC350LC/HD-8 50-29 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
7. Tighten the mounting bolts according to the following procedure.
A. Sling flywheel housing (5) and install it with mounting bolts (4).
★ Apply a string of gasket sealant 1 - 3 mm (0.03936 -
0.11810 in) in diameter to the housing mounting flange face
and around each mounting bolt hole.
ii. Set the probe of the dial gauge perpendicular to the spigot
joint portion of the flywheel housing.
iii. Set the dial gauge reading to "0", rotate the crankshaft by
one turn, and measure the difference between the lowest
and highest values indicated by the dial gauge.
★ After the crankshaft is rotated by one turn, check that the
dial gauge indicates the value at the start of rotation.
50-30 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
• Measuring facial runout
ii. Set the dial gauge reading to "0", rotate the crankshaft by
one turn, and measure the difference between the lowest
and highest values indicated by the dial gauge.
PC350LC/HD-8 50-31 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
E. After installing the flywheel, measure the radial run out and facial run out with tool [4].
Radial run out: . . . . . . . . . . . . . . . . . Max. 0.13 mm (0.005118 in)
Facial run out: . . . . . . . . . . . . . . . . . Max. 0.20 mm (0.007873 in)
• Measuring radial run out
ii. Set the probe of the dial gauge perpendicular to spigot joint
portion (a) or periphery of the flywheel.
iii. Rotate the flywheel by one turn and measure the difference
between the lowest and highest values indicated by the dial
gauge.
★ After the flywheel is rotated by one turn, check that the dial
gauge indicates the value at the start of rotation.
• Measuring facial run out
i. Similarly to measurement of the radial run out, set the probe of the dial gauge perpendicular to end face (b) of the
flywheel near the periphery.
★ When measuring, bring the crankshaft to the front or rear side so that an error will not be caused by the end
play.
ii. Rotate the flywheel by one turn, and measure the difference between the lowest and highest values indicated by
the dial gauge.
• Carry out the following installation in the reverse order to removal.
[*1]
50-32 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
Cylinder Head
Special tools
Necessity
Symbol
Sketch
Part number Part name Qíty N/R
1 795-799-8150 Remover ● 1
B 2 795-799-6700 Puller ■ 1
3 760-331-1110 Wrench ● 1
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting with the work.
3. Remove clamps (1) and (2), U-bolt (3), and air intake tube (4). [*1]
7. Loosen air conditioner compressor belt (9) and remove it. [*2]
9. Disconnect hoses (11) and (12) and tubes (13) and (14). [*3]
10. Remove the fuel filter and corrosion resistor head assembly (15).
13. Disconnect connectors CYL1 and CYL2 (19), CP3 (20), and FUEL
(21).
PC350LC/HD-8 50-33 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
14. Remove air intake connector (22) and air heater together.
50-34 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
21. Remove clamps (37) and (38).
25. Remove U-clamp (47) and U-bolts (48) and (49). [*8]
31. Disconnect lubrication hoses (58) and lubrication tube (59). [*12]
33. Remove twelve mounting bolts (60) and turbocharger and exhaust
manifold assembly (61). [*13]
PC350LC/HD-8 50-35 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
34. Remove cap (62) of front gear cover.
35. Rotate the crankshaft forward to set stamp (a) of supply pump drive
gear (63) to the top and set the No. 1 cylinder to the compression top
dead center (TDC).
36. Disconnect hoses (64) and (65) and remove cylinder head cover (66).
37. Remove twelve bolts (67) and rocker arm assemblies (68). [*14]
★ Loosen the locknut and then loosen the adjustment screw fully
so that an excessive force will not be applied to the push rod
when the rocker arm is installed.
50-36 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
★ Record the position of each crosshead and the positions of holes
(a) and (b) for the valve.
C. Tighten tool B1 into inlet connector (71) and remove the inlet
connector.
PC350LC/HD-8 50-37 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
E. Remove bolt (74) and holder (75).
41. Remove seven mounting bolts (78) and rocker housing assembly
(79). [*18]
50-38 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
42. Remove twenty six mounting bolts (80) and cylinder head assembly
(81). [*19]
Installation
Carry out installation in the reverse order to removal.
[*1]
★ Tighten the hose clamps before and after the air intake tube to the following torque.
[*2]
★ Adjust the belt tension. For details; See “AIR COMPRESSOR BELT TENSION” on page 30-29.
[*3]
★ Clean the inside of the hose connector and insert the connector securely.
[*4]
★ Tighten bracket (16) to the following torque.
[*5]
★ Do not remove fuel pressure sensor (36a) from common rail (36) for
a purpose other than replacement.
★ Once the fuel pressure sensor is removed from the common rail, be
sure to replace it.
★ Replace fuel pressure sensor (36a), if necessary, according to the
following procedure.
A. Before removing the fuel pressure sensor, remove mud etc. from
around it thoroughly and clean it.
PC350LC/HD-8 50-39 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
E. Connect the engine wiring harness. At this time, take care not to connect the wiring harness in reverse.
F.Start the engine and check that fuel does not leak.
For the testing procedure, see Testing and adjusting, “Testing fuel system for leakage”.
★ Replace relief valve (36b), if necessary, according to the following procedure.
A. Before removing the relief valve (36b), remove mud etc. from around it thoroughly and clean it.
C. If the leakage from the relief valve exceeds the specified value, do not reuse it.
D. Check that high-pressure seal surfaces (a) of the relief valve and rail are free from damage.
Remark
Excessive tightening can cause leakage.
Take care not to tighten too strongly.
WARNING! Always use genuine clamp for fixing highpressure pipe. Strictly observe the tightening
torque requirements.
WARNING! Keep the harness assembly and other harnesses 10 mm (0.3936 in) and above away
from the high-pressure tube.
50-40 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
★ 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.
• Check the taper seal of the connecting part (Part (a): Part of 2 mm
(0.0787 in) from the end) for visible lengthwise slit (b) and dent (c).
• 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.
E. Install six high-pressure pipes (28) between the common rail and injectors.
★ Install the high-pressure pipes of the No. 1, No. 3, and No. 5 cylinders while the injector wiring harness
connectors are disconnected.
PC350LC/HD-8 50-41 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
[*8]
★ Tighten the U-clamp and U-bolt to the following torque.
[*9]
★ Tighten the clamp of the turbocharger connecting part of the joint to the following torque.
[*10]
★ Tighten the clamp to the following torque.
[*11]
★ Tighten the clamp according to the following procedure.
A. Set punch mark (a) as shown in the figure and set bridge (83)
under band (84).
[*12]
★ Tighten the lubrication hose and lubrication tube to the following
torque.
[*13]
★ Tighten the exhaust manifold mounting bolts according to the
following procedure.
1st time: Tighten all the bolts to 23.5 ±4 N•m (17.3 ±2.9 lbf ft) in the order of the numbers shown in
the figure.
2nd time: Tighten only bolts 1 – 4 in the figure to 23.5 ±4 N•m (17.3 ±2.9 lbf ft).
3rd time: Tighten all the bolts to 43.1 ±6 N•m (31.7 ±4.4 lbf ft) in the order of the numbers shown
in the figure.
4th time: Tighten only bolts 1 – 4 in the figure to 43.1 ±6 N•m (31.7 ±4.4 lbf ft).
50-42 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
[*14]
★ When installing the crosshead and rocker arm assembly, observe the
following precautions.
★ Install the crosshead so that parts (a) and (b) on its back side will be
at the positions checked when removed.
When installing a new crosshead, you do not need to take care of the
positions of parts (a) and (b).
★ Check that the adjustment screw is loosened fully.
★ After checking that the ball of adjustment screw (85) is set in the
socket of push rod (77) securely, tighten mounting bolt (86).
★ After tightening the mounting bolt, adjust the valve clearance. For
details, see Testing and adjusting, “Adjusting valve clearance.”
[*15]
★ Install the fuel injector assembly according to the following
procedure.
★ Check that the injector sleeve is free from flaw and dirt.
PC350LC/HD-8 50-43 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
D. Install holder (75) and tighten bolts (74) by three – four turns
with the fingers.
50-44 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
H. Tighten inlet connector (71) permanently.
Caulking compound:
GE TOSHBA SILICON TOSSEAL 381
[*16]
★ Install the injector wiring harness terminal (73) in a direction where
it will not interfere with the rocker arm (68) which moves up and
down.
PC350LC/HD-8 50-45 B
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
★ Take care that wiring harness (73) will not be pressed strongly
against the inside wall of the housing, will not come off guide (e), or
will not be bent sharply.
★ Setting positions of wiring harnesses.
Cylinder No. Color of wiring harness
[*17]
★ Check that the push rod end is in the tappet.
[*18]
★ Tighten the rocker housing mounting bolts in the order of the
numbers shown in the figure.
[*19]
★ Install the cylinder head assembly according to the following
procedure.
50-46 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
C. Install cylinder head assembly (81) to the cylinder block.
D. Tighten the mounting bolts at least two – three turns with the
fingers.
★ When not using tool B3 at the 5th time, make a mark on the
cylinder head and each bolt with paint and then tighten the bolt
by 120° ±5°.
• Refilling with coolant.
Add coolant through the coolant filler to the specified level. Run the
engine to circulate the coolant through the system. Then, check the
coolant level again.
PC350LC/HD-8 50-47 B
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR
Removal
WARNING! When the coolant temperature in the radiator is high, you may be scaled. In this case,
wait until the coolant temperature lowers and then drain the coolant.
4. Set hole (3) to the position of bolt (2) to fix the engine hood.
9. Disconnect hoses (6) – (9) from the top of the radiator. [*1]
50-48 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY RADIATOR
10. Remove two mounting bolts (10).
Installation
• Carry out installation in the reverse order to removal.
[*1]
Apply ThreeBond 4324 or equivalent to the adapters of hoses (4), (7), (8), and (9).
PC350LC/HD-8 50-49 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
12
HYDRAULIC OIL COOLER
Removal
WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure.
4. Open the engine hood and sling the hydraulic oil cooler temporarily.
5. Remove the mounting bolts of cover (1) and move the cover down.
7. Set hole (3) to the position of bolt (4) to fix the engine hood.
8. Remove drain plug (5) from the bottom of the hydraulic oil cooler to
drain the oil from the piping.
50-50 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
11. Disconnect tube (8) from the top of the hydraulic oil cooler.
Installation
• Carry out installation in the reverse order to removal.
• Refilling with oil
Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the
oil level again.
PC350LC/HD-8 50-51 B
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
12
AFTERCOOLER
Removal
Installation
• Carry out installation in the reverse order to removal.
[*1]
50-52 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12
ENGINE AND HYDRAULIC PUMP
Removal
Special tools
Necessity
Symbol
Sketch
Part number Part name Q’ty N/R
WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure.
1. Remove the hydraulic tank strainer and stop the flow of oil using
tool C.
★ When not using tool C, remove the drain plug to drain oil from
the hydraulic tank and piping.
4. Remove clamps (1) and (2), U-bolt (3), and air intake tube (4). [*1]
PC350LC/HD-8 50-53 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
7. Disconnect hoses (8), (9), and (10) from the top of the radiator. [*2]
9. Loosen bolt (12) and remove air conditioner compressor belt (13).
[*3]
10. Remove air conditioner compressor (14) and bracket together and
move them to a place where they will not obstruct work.
50-54 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
16. Remove clamp (25). [*4]
17. Loosen clamp (26) and remove tube (27) and hose together. [*5]
21. Remove the bottom cover of the radiator and disconnect hose (35).
[*6]
PC350LC/HD-8 50-55 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
22. Open cover (36).
23. Remove the divider board between the engine and hydraulic pump.
25. Disconnect hoses (41) and (42) from the engine oil filter.
50-56 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
28. Disconnect tube (53).
★ Prepare a container to receive hydraulic oil which will leak.
PC350LC/HD-8 50-57 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12
Installation
• Carry out installation in the reverse order to removal.
[*1]
★ Tighten the hose clamps before and after the air intake tube to the following torque.
[*2] [*6]
[*3]
★ Adjust the belt tension. For details, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt”.
[*4]
★ Tighten the clamp to the following torque.
[*5]
★ Tighten the clamp according to the following procedure.
50-58 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
Removal
1. Remove the sprocket, referring to the "Removal and installation of
sprocket" section in this manual.
3. Disconnect drain hose (2), travel speed shifting hose (3) and motor
hoses (4) and (5).
4. Remove twenty one mounting bolts and then lift off final drive
assembly (6). [*1]
★ Be careful so that the nipple sealing surface on the hose
mounting block may not be damaged.
★ When lifting off the final drive assembly, do not use a tapped
hole for lifting the cover.
Installation
• Installation is done in the reverse order of removal.
[*1]
PC350LC/HD-8 50-59 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
Disassembly
Special tools
Necessity
Sketch
N/
Symbol Part number Part name Qíty R
1. Oil draining
Remove drain plug and drain oil from final drive case.
2. Cover
50-60 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
3. Remove spacer (2).
i. Insert pin (4) and drive shaft (5) out of carrier (6).
★ After removing the shaft, remove pin (4).
ii. Remove thrust washer (7), gear (8), bearing (9), and thrust
washer (10).
PC350LC/HD-8 50-61 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
7. Remove thrust washer (13).
i. Insert pin (16) and drive shaft (17) out of carrier (18).
★ After removing the shaft, remove pin (16).
ii. Remove thrust washer (19), gear (20), bearing (21), and
thrust washer (22).
50-62 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
10. Nut
PC350LC/HD-8 50-63 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
ii. Remove bearings (27) and (28) from hub (29).
50-64 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
Assembly
★ Clean all parts and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing.
1. Hub assembly
A. Using the push tool, press-fit bearings (27) and (28) to hub (29).
C. Using tool D3, install floating seal (30) onto travel motor (31).
★ The procedure for installation is the same as in Step B
above.
D. Using eyebolts [4], set hub assembly (25) onto the travel motor.
Then tap the bearing using the push tool to press-fit it.
PC350LC/HD-8 50-65 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
2. Install nut as follows.
D. Determine Calculate a - b = c
E. Using tool D1, tighten nut (24) until dimension (d) becomes the
value of (c) calculated above.
50-66 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
G. Install lock plate (23).
★ When installing the lock plate, avoid notch (j) of the travel
motor and fit it to the spline totally (under the condition of (k))
ii. Align the position of pin holes on the shaft and carrier, then
tap with a plastic hammer to install shaft (17).
★ Install the shaft, rotating the planetary gear. Take care so
that thrust washer is not damaged.
PC350LC/HD-8 50-67 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
★ After inserting the pin, caulk the pin portion of the
carrier.
★ After assembling the carrier assembly, check that gear
(20) rotates smoothly.
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.
★ Remove all grease and oil from the mating surface of the ring
gear and hub.
★ Do not put any gasket sealant on the mating surface of the ring
gear and hub under any circumstances.
50-68 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7. No.1 carrier assembly.
i. Assemble bearing (9) to gear (8), fit top and bottom thrust
washers (7) and (10) and then set the gear assembly on
carrier (6).
ii. Align the position of pin holes on the shaft and carrier, then tap with a plastic hammer to install shaft (5).
★ Install the shaft, rotating the planetary gear. Take care so that thrust washer is not damaged.
PC350LC/HD-8 50-69 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
8. Assemble No. 1 sun gear shaft (11).
10. Cover.
50-70 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
B. Tighten the mounting bolts according to the following
procedure.
★ Do a final check of the oil level at the determined position after installing the final drive assembly to the chassis.
PC350LC/HD-8 50-71 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
SWING MOTOR AND SWING MACHINERY
Removal
5. Lift and remove swing motor and swing machinery assembly (7).
★ When lifting off the swing motor and swing machinery
assembly for removal, do so slowly so that the hoses and other
parts may not be damaged.
★ Take care in the lift until you can pull out the pilot.
50-72 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
Installation
• Installation is done in the reverse order of removal.
[*1]
PC350LC/HD-8 50-73 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
Disassembly
Special tools
Necessity
Symbol
Sketch
Part number Part name Qíty N/R
1. Oil drain.
Loosen the drain plug and drain oil from the swing machinery case.
50-74 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
4. No.1 carrier assembly.
PC350LC/HD-8 50-75 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
7. No.2 carrier assembly.
i. Insert pin (14) and drive shaft (15) out of carrier (16).
★ After removing the shaft, remove pin (14).
ii. Remove thrust washer (17), gear (18), bearing (19), and
thrust washer (20).
8. Shaft assembly.
B. Set the shaft and case assembly on the press and then, using
push tool [2], remove shaft assembly (24) from case assembly
(25).
50-76 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
9. Using push tool, take bearing (31) out of case (32).
PC350LC/HD-8 50-77 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
Assembly
★ Clean all related parts and check that there is no dust or damage on
the surface. Coat sliding surfaces with engine oil and then assemble
the parts.
1. Bearing.
Using push tool E3 [4], press fit bearing (27) to case (32).
★ Use a new bearing.
Press fitting force (Reference value):. . .0 - 26.4 kN (0 - 5,934 lbf)
2. Cover assembly.
A. Using push tool E4, press fit oil seal (29) to cover (30).
★ Use a new oil seal.
★ If push tool E4 is not available, use another push tool to
push the frame around the oil seal evenly.
★ Take care that oil seal (29) will not slant.
★ Make sure gasket sealant (LG-6) does not get on the oil lip
and shaft.
★ Insure that gasket sealant does not press into hole (A).
3. Case assembly.
B. Using push tool E5 [5] and guide [7], press fit the bearing inner
race.
★ First, using push tool E5 [5], be sure the bearing is centered
and straight on the shaft, then hit the bearing inner race with
a hammer so that the shaft will not fall, and then set it to the
press to press fit.
Press fitting force (Reference value):. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 110 kN (8,768 - 24,728 lbf)
50-78 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Use guide [7] to prevent case assembly (25) from slanting.
★ Hit the flange of case assembly (25) frequently and lightly
to correct the lean of case assembly (25). In particular,
adjust the flange so that oil seal mating face (B) of the shaft
will be at the center oil seal (29).
ii. Assemble bearing (19) to gear (18), fit top and bottom
thrust washers (17) and (20) and then set the gear assembly
on carrier (16).
PC350LC/HD-8 50-79 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
iii. Match the pin hole of shaft (15) to that of the carrier and
install the shaft by hitting it lightly with a plastic hammer,
etc.
★ While rotating the planetary gear, install the shaft and
take care not to damage the thrust washer.
v. After inserting the pin, stake two places (h) around the pin.
5. Set No. 2 carrier assembly (13) and tighten mounting bolt (12).
50-80 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Install the No. 2 sun gear with press-fit plate (P) down.
7. Install the O-ring to ring gear (10) using eyebolt attached to case
(29).
★ Degrease the mating faces of ring gear (10) and case (29).
★ Align the convex portion on the case flange (Portion c) and the
counter mark on the ring gear (Portion d) in the position
illustrated in the following figure, and then install it.
PC350LC/HD-8 50-81 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
8. No.1 carrier assembly.
ii. After installing snap ring (4), push it back from the opposite
side until it is fitted to face (P) of the carrier.
★ At this time, take care not to push back the snap ring too
much.
iv. Install thrust washer (8), bearing (7), gear (6), and snap ring
(4).
50-82 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Install the No. 1 sun gear with press-fit plate (P) down.
C. Install ring gear (10) and swing motor assembly (1) to the
following positions.
PC350LC/HD-8 50-83 B
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
SWING CIRCLE
Removal
1. Disassemble the revolving frame assembly referring to the "Removal
and installation of revolving frame assembly" section in this manual.
2. Sling swing circle assembly (1) at 3 points and remove the mounting
bolt to remove the assembly. [*1]
Installation
• Installation is done in the reverse order of removal.
[*1]
★ 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.
50-84 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
12
CARRIER ROLLER
Special tools
Necessity
Symbol
Sketch
Part number Part name Q’ty N/R
1 791-430-3230 Installer ■ 1
F
2 791-601-1000 Oil pump assembly ■ 1
Disassembly
★ Disassemble according to the following figure.
Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below.
• Floating seal.
★ Before installing floating seals (7) and (8), completely degrease
both contact surfaces of the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take care so that no dust
will stick to the contact surface of the floating seal.
★ After inserting the floating seal with tool F1, check that its slant
is less than 1 mm (0.0393 in) and its projection (a) is 5 - 7 mm
(0.1968 - 0.2755 in).
• Carrier roller.
★ Check the amount of air leakage from the seal with tool F2 by
applying the standard pressure to the oil filler port.
★ Check that the gauge needle does not go down, when the
following standard pressure is applied for ten seconds.
Standard pressure:. . . . . . . . . . . . . . . . . . . . . . 1 kg/cm2 (14.2 psi)
PC350LC/HD-8 50-85 B
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
★ Fill the carrier roller assembly with oil, using tool F2, and then
tighten the plug.
50-86 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
TRACK ROLLER
Special tools
Necessity
Symbol
Sketch
Part number Part name Q’ty N/R
1 796-670-1010 Installer ■ 1
G
2 791-601-1000 Oil pump assembly ■ 1
Disassembly
• Disassemble according to the following figure.
Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below.
• Floating seal.
★ Before installing floating seals (5) and (6), completely degrease
both contact surfaces of the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take care so that no dust
will stick to the contact surface of the floating seal.
★ After inserting the floating seal with tool F1, check that its slant
is less than 1 mm (0.0393 in) and its projection (a) is 5 - 7 mm
(0.1968 - 0.2755 in).
• Mounting roller cover mounting bolt.
PC350LC/HD-8 50-87 B
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
• Track roller.
★ Check the amount of air leakage from the seal with tool G2 by
applying the standard pressure to the oil filler port.
★ Check that the gauge needle does not go down, when the
following standard pressure is applied for 10 seconds.
Standard pressure:. . . . . . . . . . . . . . . . . . . . . 1 kg/cm2 (14.2 psi)
★ Fill the track roller assembly with oil, using tool G2, and tighten
the plug.
50-88 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY IDLER
12
IDLER
Special tools
Necessity
Symbol
Sketch
Part number Part name Qíty N/R
1 796-670-1020 Installer ■ 1
H
2 791-601-1000 Oil pump assembly ■ 1
Disassembly
2. Remove floating seal (3) from support (2) and idler (4).
3. Remove idler (4) from shaft (5) and support assembly (7).
4. Remove floating seal (6) on the opposite side from idler (4), shaft (5)
and support assembly (7).
5. Remove dowel pin (8) to remove support (7) from shaft (5).
PC350LC/HD-8 50-89 B
DISASSEMBLY AND ASSEMBLY IDLER
12
Assembly
1. Press fit bushings (9) and (10) to idler (4).
2. Fit O-ring and install support (7) to shaft (5) using dowel pin (8).
3. Using tool H1, install floating seal (6) to idler (4), shaft (5) and
support (7) assembly.
50-90 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY IDLER
5. Using tool H1, install floating seal (3) to idler (4), shaft (2) and
support (7) assembly.
★ Coat the sliding surface of the floating seal with oil, and be
careful not to let any dirt or dust get stuck to it.
★ Remove all grease and oil from the contact surfaces of the
O-ring and the floating seal.
PC350LC/HD-8 50-91 B
DISASSEMBLY AND ASSEMBLY IDLER
6. Install O-ring, then install support (2) using dowel pin (1).
★ Stake the pin of the support after insertion.
7. Using tool H2, fill the idler assembly with oil and tighten the plug.
50-92 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
RECOIL SPRING
Special tools
Necessity
Sketch
Symbol Part number Part name Qíty N/R
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
1 Cylinder
790-101-1600 ■ 1
(686 kN {70 t})
J 790-101-1102 Pump ■ 1
790-201-1500 Push tool kit ■ 1
790-201-1620 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly
C. Remove yoke (6), cylinder (7), collar (8) and dust seal (9) from spring (5).
A. Remove lock plate (11) from piston (10), then remove valve (12).
B. Remove snap ring (13), then remove U-packing (14) and ring (15).
PC350LC/HD-8 50-93 B
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
Assembly
A. Assemble ring (15) and U-packing (14) to piston (10) and secure
with snap ring (13).
B. Tighten valve (12) temporarily, and secure with lock plate (11).
B. Assemble cylinder (7), collar (8) and yoke (6) to spring (5), and
set it on tool J1.
50-94 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
C. Apply hydraulic pressure slowly to compress the spring, and
then tighten nut (4) so that the installed length of the spring is
dimension (a) and secure it with lock plate (3).
Installed length (a) of spring: . . . . . . . . . . . . . . 655 mm (25.78 in)
PC350LC/HD-8 50-95 B
DISASSEMBLY AND ASSEMBLY SPROCKET
12
SPROCKET
Removal
1. Expand the track shoe assembly referencing “Expansion and installation of track shoe assembly”.
3. Remove the mounting bolt and then lift off sprocket (1). [*1]
Installation
• Installation is done in the reverse order of removal.
[*1]
Sprocket mounting bolt: 640 - 785 N•m (472 - 578 lbf ft)
50-96 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
TRACK SHOE
Special tools
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
Expansion
1. Set the master pin position.
★ Start the engine and rotate tracks so the master pin position is on the front side of the idler.
★ Set block [1] in front of the idler.
2. Lower the work equipment to the ground, and loosen lubricator (1) in order to loosen track shoe tension. [*1]
PC350LC/HD-8 50-97 B
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
Installation
• Installation is done in the reverse order of expansion.
[*1]
★ Refer to the “Checking and adjusting track shoe tension” section in the Testing and adjusting chapter of this manual.
[*2]
[*3]
★ 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 (0.165 ±0.078 in)
50-98 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
12
REVOLVING FRAME
Removal
5. Remove plate (3) and pin (4), and then lift boom cylinder assembly
(2) to remove.
★ Remove the boom cylinder assembly on the opposite side in the
same manner.
PC350LC/HD-8 50-99 B
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
7. Remove the engine hood mounting bolt and then remove pin (6).
12. Pull out pin (19) on the side of center swivel joint and remove the
jam plate from the center swivel joint.
13. Remove forty mounting bolts and then lift off revolving frame
assembly (20). [*1]
★ Using the lever block, adjust fore and aft as well as right and left
balance of the revolving frame assembly, with only two
mounting bolts being left in the front and rear side of the
assembly. After the adjustment, remove the remaining two bolts.
50-100 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
Installation
• Installation is done in the reverse order of removal.
[*1]
Revolving frame mounting bolt: 926.7 ±103 N•m (683.4 ±75.9 lbf ft)
PC350LC/HD-8 50-101 B
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
COUNTERWEIGHT
Special tools
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
Removal
1. Remove the accessories on the counterweight according to the
following procedure.
(Mirror specification)
50-102 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
Installation
• Install in reverse order of removal.
[*1]
Counterweight mounting bolt: 1,715 - 1,911 N•m (1,264.9 - 1,409.4 lbf ft)
[*2]
★ Installing and adjusting counterweight.
A. Adjust the level difference from the exterior part (vertical clearance) with the shim between the counterweight and
revolving frame.
Set shim thickness: . . . . . . . . . . . . . . . . . . . . . . .1.0 mm, 2.0 mm
B. Install counterweight in such a way that clearance between the door and counterweight as well as clearance between
the revolving frame and counterweight is 10 ±5 mm (0.3936 ±0.1968 in).
PC350LC/HD-8 50-103 B
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
Removal
★ Attach an identification tag to each piping to avoid a mistake in the position of installation later.
1. Disconnect eight hoses (1) through (8) of the travel motor center
swivel joint.
• (1): Center swivel joint (T port) – LH travel motor (T port)
• (2): Center swivel joint (T port) – RH travel motor (T port)
• (3): Center swivel joint (B port) – LH travel motor (PA port)
• (4): Center swivel joint (D port) – RH travel motor (PB port)
• (5): Center swivel joint (A port) – LH travel motor (PB port)
• (6): Center swivel joint (C port) – RH travel motor (PA port)
• (7): Center swivel joint (E port) – LH travel motor (P port)
• (8): Center swivel joint (E port) – RH travel motor (P port)
3. Pull out pin (16) on the side of center swivel joint and remove the jam plate from the center swivel joint.
50-104 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
5. Lift and remove center swivel joint assembly (18). [*1]
Installation
• Installation is done in the reverse order of removal.
[*1]
★ 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.)
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level.
Let the oil circulate in the hydraulic system by starting the engine.
Then check the oil level again.
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic
cylinder. For details, see Testing and adjusting, “Bleeding air from
various parts”.
PC350LC/HD-8 50-105 B
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
Special
12 tools
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
Disassembly
3. Using tool L, pull out swivel rotor (4) and ring (3) from swivel shaft
(5).
5. Remove O-ring (8) and slipper seal (9) from swivel rotor (4).
50-106 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
Assembly
1. Assemble slipper seal (9) and O-ring (8) to swivel rotor (4).
4. Set swivel shaft (5) to block, then using push tool, tap swivel rotor
(4) with a plastic hammer to install.
★ When installing the rotor, take care not to damage the slipper
seal and the O-ring.
PC350LC/HD-8 50-107 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK
Removal
1. Remove covers (1) and (2).
50-108 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
7. Disconnect hoses (10), (11) and (12).
9. Sling the hydraulic oil tank assembly and remove six mounting bolts
(14).
PC350LC/HD-8 50-109 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
Installation
• Installation is done in the reverse order of removal.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting,
“Bleeding air from various parts”.
50-110 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
CONTROL VALVE
Removal
1. Open up engine hood and remove top control valve cover (1).
2. Remove partition covers (3) and (4) provided between the engine
and control valve.
PC350LC/HD-8 50-111 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
6. Disconnect eight hoses and eight tubes on the control valve.
• (9): TSW port hose (Swing motor S port)
• (10): T1 port hose (connected to the tank)
• (11): From the top:
A1 port tube (boom Hi bottom side)
A1 port tube (bucket bottom side),
A2 port hose (swivel joint A port)
A3 port tube (boom bottom side),
A4 port hose (swing motor MB port)
A5 port hose (swivel joint C port),
A6 port tube (arm head side)
• (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)
50-112 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
10. Disconnect seven left side PPC hoses and five control valve hoses.
• (22): PLS2 port hose (Hose band: Red)
• (23): PLS1 port hose
• (24): PLS2 port hose (Hose band: Blue)
• (25): From the top: Bucket digging (Hose band: White)
LH reverse
Boom RAISE (Hose band: Green)
Swing LS separator valve
BP5 port hose (to solenoid)
Left swing (Hose band: Red)
RH reverse (Hose band: Blue)
Arm dump (Hose band: Yellow)
• (26): PX2 port hose
11. Disconnect the seven hoses and the wiring connectors (two
locations).
• (27): PPS1 port hose (Front pump)
• (28): PPS2 port hose (Rear pump)
• (29): PR port hose (Solenoid)
• (30): PR port hose (Pump)
• (31): PP1 port hose (Front pump)
• (32): PP2 port hose (Rear pump)
• (33): T port hose (Oil cooler)
• (34): A51 (Front pump pressure sensor)
12. Remove the three mounting bolts, and then lift and remove control
valve assembly (36).
PC350LC/HD-8 50-113 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
Installation
• Installation is done in the reverse order of removal.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, “
Bleeding air from various parts”.
Disassembly
★ This section deals with only precautions to be followed when reassembling the control valve assembly.
Assembly
Special tools Necessity
Sketch
Qíty
N/R
Symbol Part number Part name
796-946-1310 Guide
■ 1
(For 723-46-40100 and 723-46-40601)
796-946-1810 Guide
■ 1
(For 723-46-43100 and 723-46-43400)
1
796-946-2110 Guide
■ 1
(For 723-46-44100)
796-946-2210 Guide
■ 1
(For 723-46-45100)
796-946-1320 Guide
■ 1
(For 723-46-40100 and 723-46-43601)
796-946-1820 Guide
■ 1
(For 723-46-43100 and 723-46-43400)
796-946-2120 Guide
2 ■ 1
(For 723-46-44100)
M
796-946-2220 Guide
■ 1
(For 723-46-45100)
796-946-1420 Guide
■ 1
(For 723-46-42800)
796-946-1330 Sleeve
■ 1
(For 723-46-40100 and 723-46-40601)
796-946-1830 Sleeve
■ 1
(For 723-46-43100 and 723-46-43400)
796-946-2130 Sleeve
3 ■ 1
(For 723-46-44100)
796-946-2230 Sleeve
■ 1
(For 723-46-45100)
796-946-1430 Sleeve
■ 1
(For 723-46-42800)
50-114 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
3. Set tool M1 to piston (1) and push it in slowly by hand so that seal
(2) may spread out evenly.
★ The seal may be also fitted by pushing it down to the flat surface
of the tool and then pushing it in with the tool fitted to the
piston.
4. Likewise, set tool M2 to piston (1) in the same direction and push it
slowly by hand so that seal (3) may be spread out evenly.
★ The seal may be also fitted by pushing it down to the flat surface
of the tool and then pushing it in with the tool fitted to the
piston.
5. Set correction tool M3 to piston (1) for about one minute in order to
make seals (2) and (3) securely adhered to the piston.
★ Check that there is no protrusion or cut on the seal.
PC350LC/HD-8 50-115 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
Assembly of control valve assembly
• Coat the sliding surface with engine oil and then reassemble the control valve assembly.
• Upper and lower control valve covers.
Mating face of the upper and lower control valve cover: Seal End 242 or equivalent
• Tighten the mounting bolts for the upper and lower control covers in
the sequence of A, D, C, B below.
• Tighten the mounting bolts for the merge divider valve in the same
sequence as that for the control valve cover mounting bolts.
Back pressure valve mounting bolt: 58.8 - 73.8 N•m (43.3 - 54.4 lbf ft)
• Tighten the mounting bolts for the boom Hi check valve, quick return valve, lock valve and arm plate in the same
sequence as that for the control valve cover mounting bolts.
Boom Hi check valve mounting bolt: 58.8 - 73.8 N•m (43.3 - 54.4 lbf ft)
Mounting bolt for quick return valve, lock valve and arm plate: 58.8 – 73.8 N•m (43.3 - 54.4 lbf ft)
Assemble the main relief valve assembly with the control valve and install them to the machine. Then, test and adjust the main
relief pressure. For details, see Testing and adjusting, “Testing and adjusting oil pressure in work equipment, swing, and travel
circuit”.
50-116 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP
Special tools
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
Removal
1. Remove the hydraulic tank strainer and stop the flow of oil using
tool C.
★ When not using tool C, remove the drain plug to drain oil from
the hydraulic tank and piping.
PC350LC/HD-8 50-117 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
5. Remove covers (6) and (7).
10. Remove muffler clamp (23) and two U-bolts (24) to remove muffler
(25).
50-118 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12. Lift and remove hydraulic pump assembly (27). [*1]
Installation
• Installation is done in the reverse order of removal.
[*1]
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting,
“Bleeding air from various parts”.
PC350LC/HD-8 50-119 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
Oil Seal in Hydraulic Pump input Shaft
Removal
Installation
• Installation is done in the reverse order of removal.
[*1]
50-120 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
12
WORK EQUIPMENT PPC VALVE
★ Only precautions for assembling the work equipment PPC valve assembly are explained below.
Disassembly
★ Spring (6) and spring (7) consist of each one of two types of springs with different installed loads in four places, so check
the mounting position (oil pressure port) and mark with tags to prevent mistakes when installing.
Assembly
★ The head of plug (2) must not be projected from the body (1) surface.
★ When installing plug (3) to body (1), check the insertion depth so that the tip of plug does not enter the inside Ø20 hole of
the body.
★ Install spring (5) with its small diameter side on the shim (4) side.
• Diameter of spring (Inside diameter)
Small diameter side: Ø4.9 mm
Large diameter side: Ø5.55 mm
★ When installing springs (6) and (7), note that they are different and they must be installed to different hydraulic ports.
• Installed height: 31.8 mm (Common to both springs)
• Installed load:
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
PC350LC/HD-8 50-121 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
★ When installing piston (8), apply grease (G2-LI) to its outside and the inside of the body (1) hole.
★ When installing joint (12) to body (1), apply LOCTITE as shown below.
A. When installing the joint, apply 1 drop (approx. 0.02 g) of LOCTITE (No. 648) each to 2 places of the female screw
(A) of the body. Before installing the joint, thoroughly degrease and dry its male screw and the female screw of the
body with DRYSOL.
★ Apply grease (G2-LI) to the sliding parts of joint (12) and contact
surfaces of disc (13) and piston (8).
50-122 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
★ See Testing and adjusting, "Adjusting play of work equipment and swing PPC valve".
★ Tighten nut (14) to the following tightening torque.
PC350LC/HD-8 50-123 B
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
12
TRAVEL PPC VALVE
Special tool
Necessity
Symbol
Sketch
Qíty
N/R
Disassembly
1. Remove screw (20) and damper assembly (16).
2. Remove mounting bolt (21) to remove case (12), shaft (14) and lever (15) assembly.
4. Remove lever (15), bushing (10), (11) and shaft (14) from the case.
7. Remove piston (7) to remove retainer (6), springs (5) and (4) and shim (3).
★ Store shim (3) after checking the thickness and the number of shims at each mounting position.
50-124 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
8. Remove valve (2) from body (1).
Assembly
Only the precautions for assembling the travel PPC valve assembly are described.
★ When assembling, clean and inspect the parts closely and take care fully so that dirt, rust, flaw, etc. will not cause a
trouble.
★ When installing piston (7), apply grease (G2-LI) to its outside and the inside of the body hole.
★ Install spring (4) with its small diameter side on the shim (3) side.
• Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm,
Large diameter side: 5.55 mm
★ Assemble shaft (14) in the following procedure.
PC350LC/HD-8 50-125 B
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
12
★ Apply grease (G2-LI) to the rocking part of shaft (14) and the contact surfaces of lever (15) and piston (7) and the contact
surfaces of damper (16) and pin (17).
★ Install washer (18) 1.6 mm thick first. If the difference between both sides at the stroke end of the lever exceeds 0.7°,
change the washer thickness to reduce the difference to below 0.7°. (If the washer thickness is reduced by 0.3 mm, the
stroke end angle is increased by 0.39°.)
• Thickness of washer (t): 1.0, 1.3, 1.6, 1.9, 2.2 mm
★ Tighten each part to the following torque.
50-126 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
Special tools
Necessity
Sketch
Q’ty
N/R
Symbol Part number Part name
Disassembly
1. Piston rod assembly
PC350LC/HD-8 50-127 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ii. Remove stopper screw (3) of piston assembly.
★ Common to the boom, arm and bucket cylinder.
Screw size:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 × Pitch 1.75
50-128 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
vii. Remove cap (8), pull twelve balls (9) and then remove
plunger (10).
• Arm cylinder only.
B. Remove snap ring (16) and then remove dust seal (17).
PC350LC/HD-8 50-129 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
Assembly
★ Be careful not to damage the packing, dust seal and O-ring.
★ Clean each part, then cover the piping ports and pin-inserting hole to
prevent dust from entering them.
★ Do not try to force the backup ring into position. Warm it in warm
water 50 - 60°C (122 - 140°F) before installing it.
D. Using tool N6, install dust seal (17) and then secure it with snap
ring (16).
50-130 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3. Piston rod assembly.
C. Assemble collar (6) after installing O-ring and backup ring to it.
• Boom and arm cylinder only
E. Set plunger (10) on the piston rod, assemble twelve balls (9) to it
and secure with cap (8).
★ Check that there is a small amount of play at the tip of the
plunger.
• Arm cylinder only.
PC350LC/HD-8 50-131 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ii. Tighten screw (3).
iii. After machining, wash thoroughly to eliminate metal particles and dust.
50-132 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
G. Assemble piston rod assembly (2).
★ Set the ring end gap (C) horizontally (sideways), and then
insert it aligning the axial center of cylinder tube.
★ After inserting, make sure that the ring is not broken and is
present in its place. Then push in the assembly fully.
Mounting bolt:
I. Install piping.
PC350LC/HD-8 50-133 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT
Special tools
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
796-670-1100 Remover ■ 1
796-670-1110 • Sleeve 1
796-670-1120 • Plate 1
796-670-1130 • Screw 1
791-775-1150 • Adapter 1
P
01643-33080 • Washer 1
01803-13034 • Nut 1
Puller
790-101-4000 ■ 1
(490 kN {50 t} long)
Pump
790-101-1102 ■ 1
(294 kN {30 t})
Removal
2. Sling boom cylinder assembly (2), and remove lock bolt and nut (3).
[*1]
50-134 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
★ Remove the boom cylinder on the other side in the same
manner.
★ When the work equipment assembly is lifted up, if the sling
touches the working lamp, remove the working lamp.
6. Disconnect three arm cylinder hoses (7) and two bucket cylinder
hoses (8).
★ Apply the oil restraining plug and then fix the hoses to the valve
side by use of ropes.
PC350LC/HD-8 50-135 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
Installation
• Installation is done in the reverse order of removal.
[*1]
★ 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]
★ Adjust the clearance (b) between cylinder rod (12) and plate (4) to
1.5 mm or less using shims.
Thickness of standard shim: . . . . . . . . . . . . . . . . 1.0 and 2.0 mm
[*3]
★ 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
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic
cylinder. For details, see Testing and adjusting, “Bleeding air from various parts”.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
50-136 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
CAB
Removal
7. Insert key (8), turn it right, and open the outside-air filter cover.
PC350LC/HD-8 50-137 B
DISASSEMBLY AND ASSEMBLY CAB
13. Remove plate (17).
25. Remove harness (35) and antenna (36) from the cab wall.
★ Cut two points of tie-wrap.
50-138 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
26. Remove duct (37).
31. Detach harness clamp (41) from the right back side of cab.
32. Remove bolt (42) under the cab and remove lock plate (43). [*1]
PC350LC/HD-8 50-139 B
DISASSEMBLY AND ASSEMBLY CAB
34. Dismount six mounting bolts (45) and four mounting nuts (46).
★ Check the bolt length after removal, do not reuse if stretched.
Installation
• Installation is done in the reverse order of removal.
[*1]
[*2]
50-140 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Cab Glass (Stuck Glass)
★ Among the panes of window glass on the four sides of the cab, five panes (1) to (4) and (18) are stuck.
★ In this section, the procedure for replacing the stuck glasses is explained.
★ When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front
window glass while the front window assembly is installed to the cab.)
★ For the procedure for replacing the front window assembly, see “Removal and installation of front window assembly”.
PC350LC/HD-8 50-141 B
DISASSEMBLY AND ASSEMBLY CAB
12
Special tool
Necessity
Symbol
Sketch
Qíty
N/R
Part number Part name
Removal
★ Remove the window glass to be replaced according to the following
procedure.
1. Using seal cutter [1], cut the adhesive between broken window glass
(7) and cab (metal sheet)(8).
50-142 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Installation
1. Using a knife and scraper [5], remove the remaining adhesive and
seal rubber from the metal sheets (glass sticking surfaces) of the cab.
★ Remove the adhesive and seal rubber to a degree that they will
not affect adhesion of the new adhesive. Take care not to scratch
the painted surfaces.
(If the painted surfaces are scratched, adhesion will be lowered.)
(The figure shows the cab of a wheel loader.)
2. Remove oil, dust, and dirt, etc. form the sticking surfaces of cab (8)
and window glass (9) with white gasoline.
★ If the sticking surfaces are not cleaned well, the glass may not
be stick correctly.
★ Clean the all black part on the back side of the window glass.
★ After cleaning the sticking surfaces, leave them for at least five
minutes to dry.
(The figure shows the cab of a wheel loader.)
A. Stir the primers for both of paint and glass sufficiently before
using them.
★ If the primer has been stored in a refrigerator, leave it at the
room temperature for at least half a day before stirring it.
(If the primer is unpacked just after taken out of the
refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient
time.)
PC350LC/HD-8 50-143 B
DISASSEMBLY AND ASSEMBLY CAB
C. Evenly apply the paint primer to the surfaces to stick seal rubber
to the cab (8).
50-144 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
★ Never apply the wrong primer.
If the glass primer, etc. is applied by mistake, wipe it off
with white gasoline.
4. Stick seal rubber (both-sided adhesive tape) (6) along the inside edge
of the glass sticking section.
★ Do not remove the release tape of seal rubber on the glass
sticking side before sticking the glass.
★ When sticking the seal rubber, do not touch the cleaned surface .
★ Care should be taken not to float the seal rubber of each sticking
corner.
A. Stick seal rubber (6) for right side window glass (1) to the
position as shown in the figure.
PC350LC/HD-8 50-145 B
DISASSEMBLY AND ASSEMBLY CAB
★ Stick seal rubber (6a) additionally to right side window
glass (1).
• Positions to stick additional seal rubber to the right side
window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
B. Stick seal rubber (6) for left side window glass (2) to the
position as shown in the figure.
C. Stick seal rubber (6) for door lower window glass (3) to the
position as shown in the figure.
50-146 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
D. Stick seal rubber (6) for front window glass (4) to the position as
shown in the figure.
★ Stick seal rubber (6c) of the lower side of the front window
glass along the outside edge of the lower line, differently
from other seal rubbers (6). (If it is stuck along the inside, it
will be seen through the transparent part of the glass.)
A. Check the clearance between the window glass and the cab on
the right, left, upper, and lower sides, and then position the
window glass to be the clearances evenly.
B. Stick tapes [6] between window glass (9) and cab (8) and draw
positioning line (n).
★ Stick tapes [6] for positioning to three points, that is, right,
left and lower parts of the right side window glass, left side
rear window glass, and door lower window glass for
accurate positioning.
C. Cut the tape between window glass (9) and cab (8) with a knife,
etc. and then remove the window glass.
★ Do not remove the tapes left on the window glass and the
cab before installing the window glass.
PC350LC/HD-8 50-147 B
DISASSEMBLY AND ASSEMBLY CAB
12 ★ When positioning front window glass (4), set its horizontal
position to the frame width.
And set its vertical position to make the height difference
(p) between the frame top and the front window glass 3
mm.
6. Apply adhesive.
★ Use either of two types of adhesives according to the season.
★ The maximum age of the adhesive is four months after the date
of manufacture. Do not use the adhesive after this limit.
★ Keep the adhesive in a dark place where the temperature is
below 25°C (77°F).
★ Never heat the adhesive higher than 30°C (86°F).
★ When reusing the adhesive, remove the all hardened part form the nozzle tip.
A. Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.
B. Cut the tip of the adhesive nozzle (14) so that dimensions (q)
and (r) will be as follows.
Dimension (q): 10 mm
Dimension (r): 15 mm
50-148 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
C. Set adhesive cartridge (12) to caulking gun [7].
★ An electric caulking gun is more efficient.
E. Apply adhesive (15) to the outside of seal rubber (6) of the cab.
★ Apply adhesive (15) with dimensions (s) and (t) for seal
rubber (6) of cab (8).
Dimension (s): 10 mm
Dimension (t): 15 mm
★ Apply adhesive (15) higher than seal rubber (6).
★ Apply the adhesive evenly with same height level.
PC350LC/HD-8 50-149 B
DISASSEMBLY AND ASSEMBLY CAB
12 ★ Apply adhesive (15) additionally to additional seal rubber
(6a) of right side window glass and additional seal rubber
(6b) of door lower window glass.
B. After sticking window glass (9), press all the way around until it
sticks to the seal rubber.
★ Press the corners of the window glass firmly.
50-150 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
★ After installing front window glass (4), fill the clearances
between it and center trim seal (16) with caulking material
in range (s) with dimensions (t) and (u).
After applying the primer to glass (4) of section A-A, apply
the adhesive as caulking material.
Caulking dimension (t): 2 mm
Caulking dimension (u): 5 mm
★ When caulking, mask the glass side and form the adhesive
with a rubber spatula as shown in the figure.
★ Wipe off the projected adhesive.
Glass primer:
Sunstar primer for glass 580 super or equivalent
Adhesive:
SUNSTAR penguine seal 580 super “S” or “W” or
equivalent
A. After installing right window glass (1) to the cab, insert stopper
rubbers X3 to two places (v) at the bottom of the glass to fix the
glass.
PC350LC/HD-8 50-151 B
DISASSEMBLY AND ASSEMBLY CAB
B. By using styrene foam blocks [9] and rubber bands [10], fix the
window glass and the seal rubber to fit them completely.
9. After installing the window glass, remove any excess of the primer
and adhesive from the cab and window glass.
★ By using the white gasoline, wipe off the adhesive before it is
dried up.
★ When cleaning the glass, do not give an impact on it.
B. After removing the stopper rubbers, styrene foam blokes, and rubber bands, wait at least fourteen hours, that is, at
least twenty four hours in total, before operating the machine actually.
50-152 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Front Window
★ To replace the front window glass, the front window assembly must
be removed from the cab. The procedure for removing and installing
the front window assembly (front frame and front window glass) is
explained below.
Removal
1. Raise the front window assembly to the ceiling and fix it with the
rear locks (on both sides).
2. Remove left corner block (1) and right corner block (2). [*1]
★ Mounting bolt (4) and washer (3) for left corner block are used
to hang the pull-up assist cable in the following step 6.
4. Lower the front window assembly carefully. Put rollers (5) and (6)
under both sides of the front window through the portion from which
the corner blocks were removed in the above step two. (The portion
where the rail is open) and hold them.
5. Remove rollers (5) and (6) under the both sides of the front window.
PC350LC/HD-8 50-153 B
DISASSEMBLY AND ASSEMBLY CAB
12
7. Pull out the bottom of front window assembly (10) though the rail
opening portion and lower it gradually.
50-154 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
9. Twist front window assembly (10) to the right and left to remove
both upper rollers (11) and (12) from the rails, and then remove front
window assembly (10).
PC350LC/HD-8 50-155 B
DISASSEMBLY AND ASSEMBLY CAB
12
Installation
• Carry out installation in the reverse order to remove.
[*1]
• Adjust opening and closing of the front window assembly according
to the following procedure.
1. Open and close the front window to check that it does not interfere
with the rails and that the rollers are not hitched.
3. Raise the front window assembly and fix it with the rear locks (on
both sides).
★ Check that the locks in the rear of the cab are securely fastened.
50-156 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
5. Install left corner block (1).
★ Fully tighten the block after adjusting the “Close” position in the
following step 6.
★ Install the left corner block so that clearance (b) between the rail
and left corner block (1) becomes 0 - 2.0 mm.
★ Install the left corner block so that there is no level difference at
the rolling surface (R) of the roller.
A. Tighten left and right corner blocks (1) and (2) at roughly right
positions so that front window glass (14) is attached firmly to
cab-side trim seal (15).
B. Check the working condition of right and left locks (16) and
(17) when opening and closing the front window assembly.
• If right and left locks (16) and (17) do not work normally.
i. Loosen lock fitting bolt (18), move lock (16) forward, and
then tighten the bolt again.
★ The same applies to the right side.
ii. After moving the lock, recheck the fit of front window glass
(14) and cab-side trim seal (15) which was checked in step
A.
iii. Repeat the work in i and ii until the fit of the front window
glass and the working condition of locks (16) and (17) are
both acceptable, and then tighten the mounting bolts of the
right and left corner blocks.
7. After the adjustment, splash water over the front window glass and
check that the water does not leak into the cab.
PC350LC/HD-8 50-157 B
DISASSEMBLY AND ASSEMBLY CAB
12
8. Adjust the “Open” position of the front window assembly lock.
B. Set the front window assembly locks at both sides of rear of the
cab to the “Open” position, and then check the following items.
• Check the working condition of right and left locks (16) and
(17) (as explained above).
• 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.
• The front window assembly must be pushing the limit switch backward for 4 - 7 mm.
★ The position of limit switch (19) cannot be adjusted. Therefore, the “Open” position of the front window
assembly is decided within the range where this switch works.
★ Limit switch (19) is used to prevent the windshield wiper from moving when turning the wiper switch on by
mistake when the front window 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 “Open” position.
• After checking the above items, adjust if necessary.
50-158 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
i. Front window assembly (10) must be pushing the limit
switch backward for 4 - 7 mm (at “Open” position).
iii. Turn right and left rubber stoppers (18) to the left for one
and a half rotations.
★ One turn of rubber stopper (18) to the left is equivalent
to squashing the rubber for approximately 1.5 mm.
★ When the front window assembly is in “Open” position,
the front window assembly must be pushing right and
left rubber stoppers (18) 1.5 - 3.0 mm.
PC350LC/HD-8 50-159 B
DISASSEMBLY AND ASSEMBLY CAB
9. Adjust and lock both sides of stopper (24) so that when pulling up
the front window assembly, surface (d) of stopper (D) of front
window assembly (10) is in contact with surface (c) of stopper (24).
50-160 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Floor Frame
Removal
WARNING! Disconnect the negative terminal (–) of the battery before starting the work.
WARNING! In the case that you do not drain the coolant, if you disconnect the heater hose when the
coolant temperature in the radiator is high, you may be scalded. In this case, wait until
the coolant temperature lowers and then disconnect the heater hose.
WARNING! Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance.
★ Ask professional traders for collecting and filling operation of refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.
WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on
protective goggles while you are collecting the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant (R134a). Collecting and filling work must be
conducted by a qualified person.
PC350LC/HD-8 50-161 B
DISASSEMBLY AND ASSEMBLY CAB
6. Disconnect the following PPC hoses from the travel PPC valve. The
color of the band is;
• (3): Red
• (4): No color
• (5): Green
• (6): Blue
★ Prepare an oil sump.
8. Disconnect the following PPC hoses from the PPC valve. The color
of the band is;
• (8): Yellow
• (9): No color
★ Plug the hose to stop oil flow-out.
11. Disconnect ground (14). From the left, T04, T05, T06, T07, T09,
T10.
14. Disconnect connector P17 (17) from the air conditioner tube.
19. Remove mounting bolt (22) and disconnect air conditioner tube (23).
[*1]
50-162 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
22. Disconnect connectors N10 (27) and AC01 (28).
23. Disconnect connectors ECU10 and ECU11 (29) from the air
conditioner controller (ACCONT).
28. Move wiring harness (35) to the outside of the floor frame.
★ (SP) is made of sponge.
30. Move plates (36) and (37) together with wiring harness (35) to the
boom side.
PC350LC/HD-8 50-163 B
DISASSEMBLY AND ASSEMBLY CAB
32. Disconnect clamp (39).
33. Disconnect PPC hose (40) of the work equipment. From the top, the
color of the band is:
White
Brown
None
Blue
Black
Green
Red
Yellow
★ Prepare an oil sump.
34. Pull out PPC hose assembly (41) of the work equipment.
50-164 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Installation
• Installation is done in the reverse order of removal.
[*1]
★ When installing the air conditioner circuit hoses, take care so that dirt, water, may not enter.
★ Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose.
★ Check that there is no defect or deterioration on the O-ring.
★ When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: ND-
OIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)).
[*2]
★ Make sure that the hoses do not overlap.
• Fill air conditioner circuit with refrigerant (R134a).
PC350LC/HD-8 50-165 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
WARNING! In the case that you do not drain the coolant, if you disconnect the heater hose when the
coolant temperature in the radiator is high, you may be scalded. In this case, wait until
the coolant temperature lowers and then disconnect the heater hose.
WARNING! Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance.
★ Ask professional traders for collecting and filling operation of refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.
WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on
protective goggles while you are collecting the refrigerant (R134a) or filling the air condi-
tioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted
by a qualified person.
7. Pull down opening and closing lever (8) of the outside air filter
cover.
50-166 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
9. Remove rear covers (10) to (13).
PC350LC/HD-8 50-167 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
21. Disconnect connectors ECU10 and ECU11 (29) from the air
conditioner controller (ACCONT).
50-168 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
24. Remove mounting bolt (33) and disconnect air conditioner tube (34).
[*1]
26. Remove the seven mounting bolts and air conditioner unit assembly
(36).
Installation
• Installation is done in the reverse order of removal.
[*1]
★ When installing the air conditioner circuit hoses, take care so that dirt, water, may not enter.
★ Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose.
★ Check that there is no defect or deterioration on the O-ring.
★ When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: ND-
OIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)).
[*2]
★ Make sure that the hoses do not overlap.
• Fill air conditioner circuit with refrigerant (R134a).
PC350LC/HD-8 50-169 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
KOMTRAX Communication Modem
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.
Installation
• Installation is done in the reverse order of removal.
50-170 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Monitor
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.
2. Remove cover (2) and then disconnect wiring connector P31 (3) for
air conditioner sunlight sensor (S).
5. Remove the four mounting bolts and lift monitor assembly (6). [*2]
PC350LC/HD-8 50-171 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
Installation
[*1], [*2]
A. Temporarily install monitor assembly (6) with four mounting bolts, and then install cover (5).
B. With cover (5) installed, tighten the mounting bolts of monitor assembly.
• Carry out the rest of installation in the reverse order to removal.
50-172 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Pump Controller
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.
5. Remove the four mounting bolts and pump controller assembly (8).
PC350LC/HD-8 50-173 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Installation
• Installation is done in the reverse order of removal.
★ Reference
C. Lightly push part (A) of connector cover (1) from both sides to
unfasten claw (B).
50-174 B PC350LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
★ Right and left sliders (4) pushed in as far as possible (Left
figure)
B. Move lever (3) of connector cover (1) from the upper position to
the left position (lock position) in the figure.
★ (B), (C): Claws
★ If the sliders and lever are not set as shown in the following
figure, the connector is not disconnected or locked securely
with the lever. Accordingly, check their positions again.
C. Set claw (C) to the connector and place connector cover (1).
★ Take care that wiring harness (5) will not be caught.
E. Bind connector cover (1) and wiring harness with a new cable
tie.
PC350LC/HD-8 50-175 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Engine Controller
Removal
WARNING! Disconnect the cable from the negative (–) terminal of the battery.
Installation
• Carry out installation in the reverse order to removal.
50-176 B PC350LC/HD-8
60 AIR CONDITIONER
PC350LC/HD-8 60-1 B
AIR CONDITIONER TABLE OF CONTENTS
60-2 B PC350LC/HD-8
AIR CONDITIONER
12
MEMORANDUM
PC350LC/HD-8 60-3 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
STRUCTURE AND FUNCTION
60-4 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
7. (Dual) pressure
3. Receiver drier 11. Machine monitor C. HOT/COOL air
switch
Specifications
PC350LC/HD-8 60-5 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Configuration and Function of Refrigerating cycle
Component
Compressor Condenser Expansion valve Evaporator
Item
60-6 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Outline of Refrigerating Cycle
The refrigerating cycle performs the following four actions. The refrigerant is liquefied and gasified repeatedly while it is
circulated in the cycle.
1. Compression (Compressor)
The refrigerant gas is compressed by the compressor to the state where it can be liquefied easily at the normal temperature
(ambient temperature). The refrigerant evaporated in the evaporator is sucked into the compressor.
This action is performed to keep the refrigerant pressure in the evaporator low so that the refrigerant liquid can continue
evaporation actively even if the ambient temperature is close to 0° C (32° F).
The refrigerant gas sucked into the compressor is compressed in the cylinder and its pressure and temperature are so
changed that is can be liquefied easily when it is cooled with the external air at the normal temperature.
2. Condensation (Condenser)
The refrigerant gas in the condenser is cooled to be liquefied with the external air.
The refrigerant gas of high temperature and high pressure discharged from the compressor is cooled to be liquefied with
the external air and then stored in the receiver drier. The heat discharged from the refrigerant of high temperature and high
pressure discharged from the compressor is called the condensation heat, which is the total of the heat that the refrigerant
absorbed from the operator’s cab through the evaporator (vaporization heat) and the work performed to compress the
refrigerant (the value converted into heat). During condensation, the refrigerant gas and refrigerant liquid are mixed
together in the condenser. While the refrigerant gas changes to the refrigerant liquid, the relationship between the pressure
(condensation pressure) and temperature (condensation temperature) is kept constant.
Reference: The pressure varies with the type of refrigerant and the condensation temperature.
3. Receiver drier
The refrigerant liquefied in the condenser is reserved in the receiver drier temporarily so that it can be supplied to the
evaporator according to the cooling load. A strainer and a drying agent are sealed in the receiver drier to remove “dirt”
and “water” in the refrigerating cycle.
If any water is in the refrigerating cycle, it is frozen in the small hole of the expansion valve and retards the flow of the
refrigerant. It can cause a cooling trouble.
5. Evaporation (Evaporator)
The refrigerant changes from liquid to gas (superheated vapor) in the evaporator. The refrigerant mist in the evaporator
evaporates actively.
At this time, the refrigerant evaporates quickly, absorbing heat necessary for evaporation (latent heat of vaporization)
from the air around the cooling fins (air in the operator’s cab). The cooled air is spread in the operator’s cab by the fan to
lower the temperature in the operator’s cab.
The refrigerant mist sent through the expansion valve and the evaporated refrigerant are mixed together in the evaporator.
While the refrigerant liquid changes to the refrigerant gas, the relationship between the pressure (evaporation pressure)
and temperature (evaporation temperature) is kept constant. If the pressure is set, the temperature is decided automatically.
That is, the relationship between the above pressure and temperature is equal to the relationship between saturation
pressure and saturation temperature.
To evaporate the refrigerant at lower temperature, the pressure in the evaporator must be kept lower. Accordingly, the
evaporated refrigerant is sucked into the compressor. The refrigerant circulates in the refrigerating cycle, repeating the
above four actions, to move the heat from the operator’s cab where the temperature is low to the outside where the
PC350LC/HD-8 60-7 B
AIR CONDITIONER STRUCTURE AND FUNCTION
temperature is high.
If the amount of the refrigerant is insufficient, all of the refrigerant is evaporated while it is passing through the evaporator
and the evaporator capacity decreases. It can cause a cooling trouble.
To the contrary, if the amount of the refrigerant is too much, a part of it is not evaporated in the evaporator and is absorbed
in the compressor. As a result, the compressor compresses the liquid and may be broken.
60-8 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
MEMORANDUM
PC350LC/HD-8 60-9 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Air Conditioner Unit
★ This air conditioner unit is auto temperature control type.
60-10 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Outline
• The air conditioner unit consists of the evaporator, heater core and fan (blower) and generates cool air and hot air.
• Temperature control
The machine monitor sends temperature setting data to the control amplifier (see “Control Plate” on page 60-14)
according to the temperature control switch operation.
The control amplifier controls the air mix servomotor to adjust the angle of the cool door, hot door and sub hot door for
temperature control.
• Over-cooling (Freezing) prevention
The evaporator temperature sensor senses evaporator temperature by the change of resistance. The control amplifier
converts the change of resistance of the evaporator temperature sensor into a change of voltage and detects the evaporator
temperature by the change of voltage.
The control amplifier turns OFF the compressor clutch relay so that the evaporator will not be frozen.
• Air flow adjustment
The machine monitor sends air flow data to the control amplifier (described later) according to the air flow adjustment
switch. The control amplifier controls the air flow with the power transistor.
• Vent (mode) changeover
The machine monitor sends mode data to the control amplifier according to the vent selector (mode) switch. The control
amplifier controls the blowing out (mode) servomotor to adjust the angles of the foot door, defroster door, front door and
rear door for vent changeover.
• Automatic air conditioner
The inner temperature sensor senses the room temperature by the change of resistance. The control amplifier converts the
change of resistance of the inner temperature sensor into a change of voltage and detects the room temperature by the
change of voltage. The control amplifier checks the inner air temperature sensor voltage so that the room temperature will
be kept at the temperature set with the machine monitor.
★ The 5 A fuse for the air conditioner unit is installed to the wiring harness.
★ The door is the same as the damper.
PC350LC/HD-8 60-11 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Functions of Major Components in the Air Conditioner Unit
• Evaporator
Evaporator fins are cooled by low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air
from the blower motor is cooled and dehumidified when passing through the fins.
• Heater core
Fins of the heater core are heated by the hot water (cooling water) being sent from the engine. Air from the blower motor
is heated as it passes through the fins.
• Expansion valve
This valve converts high-pressure, high-temperature liquid refrigerant coming from the condenser to low-pressure,
low-temperature misty refrigerant through the throttling function. It controls the flow rate of the refrigerant by changing
the level of throttling depending on the thermal load (heat) in the operator's cab. As a result, temperature of the air blown
out of the grill is adjusted depending on the volume of refrigerant circulated in evaporator.
A. Structure
The box-type expansion valve consists of the diaphragm, thermosensing rod, needle valve (ball), spring, etc. The
outside of diaphragm (hatched part) is pre-enclosed with refrigerant gas.
The spring is installed on the needle valve (ball) side of the thermosensing rod. The needle valve opening ratio is
decided when the constant force of the spring to push the ball to the right is balanced with the force (Fg) of the
refrigerant gas to push the thermosensing rod to the left through the diaphragm. As a result, the refrigerant flow rate
to the evaporator is decided and the temperature is controlled.
B. Operation
The thermosensing rod senses the temperature of the refrigerant which passed the evaporator. The temperature at this
time is conducted through the thermosensing rod to the refrigerant gas in the diaphragm chamber (hatched part). As
the pre-enclosed refrigerant gas temperature changes, the gas pressure changes and pressing force (Fg) also changes.
The thermosensing rod attached directly to the diaphragm so moves that the constant force of the spring to push the
ball will be balanced with variable force (Fg) to adjust the needle valve opening ratio.
i. When the evaporator outlet temperature is high (at start of cooling (air is not cooled yet)) The gas pressure in the
diaphragm chamber increases and the gas volume increases. Pushing force (Fg) of the refrigerant gas increases
and the thermosensing rod (ball) moves to the left and the needle valve opens wide. Much refrigerant is supplied
to the evaporator and the cooling capacity increases.
ii. When the evaporator outlet temperature is low (during cooling (air is cooled already)) The gas pressure in the
diaphragm chamber decreases and the gas volume decreases. Since pushing force (Fg) of the refrigerant gas is
small, the thermosensing rod (ball) moves to the right and the needle valve is narrowed. Accordingly, refrigerant
supply and the cooling capacity decrease.
60-12 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
3. If the potential difference (PT) does not reach the voltage set for the servomotor control, the control amplifier notifies the
error to the machine monitor.
Then, the letters of “A/C Controller Error” are displayed red on the air conditioner operation screen of the machine
monitor.
★ The Recirc/Fresh changeover servomotor does not have this potential difference (PT). Accordingly, it does not have
the self-diagnosis function.
PC350LC/HD-8 60-13 B
AIR CONDITIONER STRUCTURE AND FUNCTION
Control Plate
60-14 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Functions of main component parts
A. Communicates with the machine monitor through CAN communication system and controls the air conditioner unit
with the switch inputs related to the air conditioner.
B. Controls the three servomotors in the air conditioner unit to adjust the temperature, changeover the vent (mode), and
changeover the recirculated air or fresh air.
C. Turns ON and OFF blower main relay (3) (switch to blow air) and compressor clutch relay (2) (switch to operate the
compressor).
D. Has the self-diagnosis function. If any abnormality is detected, the control amplifier notifies it to the machine monitor
by the CAN communication. Then, the letters of “A/C Controller Error” are displayed red on the air conditioner
operation screen of the machine monitor.
E. Adjusts the room temperature to the set temperature on the basis of the data of the sunlight sensor and inner air sensor
in the automatic air conditioner mode.
PC350LC/HD-8 60-15 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
• Compressor clutch relay (2)
The control amplifier controls the relay coil on the basis of the three data of
1) “A/C” switch or “AUTO” switch (automatic air conditioner switch) on the machine monitor,
2) Evaporator temperature sensor, and
3) (Dual) pressure switch.
If the relay coil is energized and the relay is turned “ON”, the magnet clutch in the compressor is engaged (the compressor
operates).
• Blower main relay (3)
The control amplifier controls the relay coil. If the relay coil is energized and the relay is turned “ON”, power is supplied
to the blower motor.
• (Dual) pressure switch (under the operator cab)
If abnormally low or high pressure is generated in the refrigerant circulation circuit, the (dual) pressure switch is turned
“OFF”. (it is normally turned “ON”.) When the (dual) pressure switch become “OFF”, the control amplifier turns the
compressor clutch relay “OFF”. So the magnetic clutch of the compressor is disengaged and the devices related to the air
conditioner are protected.
60-16 B PC350LC/HD-8
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Compressor
• Other than circulating the refrigerant, compressor compresses the refrigerant gas from the evaporator to a high-pressure,
high-temperature misty refrigerant so that it may be easily regenerated (liquefied) at normal temperature.
• The magnetic clutch in the compressor is engaged depending on the evaporator temperature and refrigerant pressure.
If the magnetic clutch is engaged, the shaft in the compressor rotates to operate the compressor.
Specifications
PC350LC/HD-8 60-17 B
AIR CONDITIONER STRUCTURE AND FUNCTION
12
Condenser and Receiver Drier
• Condenser (1)
It cools and liquefies the high-pressure, high temperature misty refrigerant from the compressor.
★ If the fins are crushed or clogged with dirt, heat exchange efficiency is degraded and complete liquefaction of refrigerant
becomes unavailable. As a result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the
engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
Specifications
60-18 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
WARNING! Before disconnecting air conditioner hose, collect the air conditioner refrigerant (R134a)
from air conditioner circuit before replacing air conditioner unit, air compressor or receiver
drier and so on.
★ Ask a qualified shop for collecting, appending and filling operation of refrigerant (R134a).
★ Never release the refrigerant (R134a) to the atmosphere.
WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches
your skin, you may suffer from frostbite. Accordingly, put on protective goggles, gloves
and working suit with long sleeves while you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the refrigerant (R134a). Collecting and filling work
must be conducted by a qualified person.
PC350LC/HD-8 60-19 B
AIR CONDITIONER TESTING AND ADJUSTING
12
The air conditioner has a self-diagnosis function for inspecting the main component parts. With this function, you can inspect
the operation of sensors and servomotors in the system.
If a troubled section is detected, every part of that section must be inspected.
Troubleshooting Procedure
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Find the troubled section with the self-diagnosis function (See “Testing with Self-diagnosis Function” on page 60-32). If
the air conditioner unit does not operate at all, check that the power supplied to the control amplifier is normal and that
CAN communication between machine monitor and the control amplifier is normal.
If any part of the air conditioner unit operates, the power supply and CAN communication do not need to be checked.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled part.
Basic flow of troubleshooting
60-20 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
Block Diagram
★ This air conditioner unit is auto temperature control type.
PC350LC/HD-8 60-21 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Circuit Diagram and Arrangement of Connector Pins
60-22 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
★ INSIDE TEMP. SENSOR means “Inner sensor” on “Abnormality Record” screen: “03 Air-conditioning System”.
★ BLOWING OUT (MODE) SERVOMOTOR means BLOWING OUT (MODE) CHANGEOVER SERVOMOTOR.
PC350LC/HD-8 60-23 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Detail of Air Conditioner Unit
60-24 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
PC350LC/HD-8 60-25 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Part and Connector Locations
★ There are two fuses. One is in the fuse box at the right rear of the
operator seat and the other is rolled onto the wiring harness between
the air conditioner unit and control amplifier.
★ The air conditioner unit is under the rear of the operator seat.
1. Open the fuse box cover at the right rear of the operator seat. (See
Troubleshooting, Fuse locations.)
• No. 11 in fuse box, 20 A
For power supply of blower (fan), air conditioner compressor
and air conditioner unit (all components related to the air
conditioner)
• Fuse part No. 20 A: 08041-02000
• Fu5A: Fuse 5 A
For power supply of air conditioner unit (including primary side
of relays for blower (fan) and air conditioner compressor)
• Fuse Part Nos.
Fu5A: ND93950-05003
• CNTAMP: Control amplifier
• [1], [2]: Control amplifier connector
• R30: Blower main relay
• R31: Compressor clutch relay
• N10: Connector to air conditioner unit for 24 V power supply
and CAN communication (communication circuit common to
engine controller and pump controller)
• AC01: Connector to air conditioner unit for GND, compressor,
pressure switch, relay and sunlight sensor
60-26 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
• A/C: Air conditioner unit
• CNTAMP: Control amplifier
• [1], [2]: Control amplifier connector
• [5]: Blowing out (Mode) servomotor connector
• [6]: Temperature control (Air mix) servomotor connector
• [9]: Evaporator temperature sensor connector
PC350LC/HD-8 60-27 B
AIR CONDITIONER TESTING AND ADJUSTING
• P17: Pressure switch connector
B. Remove cover (2) and then disconnect wiring connector P31 (3)
for air conditioner sunlight sensor (S).
60-28 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
D. Remove cover (5) as follows. [*1]
E. Remove the four mounting bolts and lift monitor assembly (6).
[*2]
[*1], [*2]
A. Temporary install monitor assembly (6) with four mounting bolts, and then install cover (5).
B. With cover (5) installed, tighten the mounting bolt of monitor assembly.
• Carry out the rest of installation in the reverse order to removal.
PC350LC/HD-8 60-29 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Air Leakage (Ducts)
1. Remove front window (1).
7. Foot duct.
★ Duct to under operator seat.
D. Check that the packing (A) is attached. See next page for
packing (A) illustration.
8. Rear duct.
Check ducts (12) and (13) for disconnection.
60-30 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
9. Face duct and defroster duct.
Check ducts (14) – (20) for disconnection.
PC350LC/HD-8 60-31 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing with Self-diagnosis Function
Outline
Normal screen
↓ While pressing [4], press [1], [2] and [3] in order.
Service menu (Mode)
↓ Press [F3] once. Press [F6].
02 Abnormality Record
↓ Press [F3] twice. Press [F6].
03 Air-conditioning system “Abnormality Record” screen
Explanation of machine monitor operating procedure
1. While pressing numeral key [4] on the normal screen, press [1], [2]
and [3] in order.
60-32 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
4. On the “Abnormality Record” screen, press [F3] (∇) twice to select
“03 Air-conditioning System”.
Inner Sensor means inside temperature sensor on “block diagram” or “circuit diagram”. “Ventilating Sensor is abnormal”
means that evaporator temperature sensor is short circuit or disconnected. “Sunlight Sensor is abnormal” means that Sunlight
Sensor is short circuit only. “Ventilation is abnormal” means servomotor for blowing out changeover (mode) damper does not
rotate judging from the servomotor potentiometer voltage.
★ Damper is the same as door.
“Air Mix is abnormal” means servomotor for Air Mix (temperature adjustment) damper does not rotate judging from
the servomotor potentiometer voltage.
“Refrigerant” means refrigerant pressure from (dual) pressure switch. Namely, “refrigerant is abnormal” means that
(dual) pressure switch of refrigerant is OFF.
2. Setting abnormal
The software of the air conditioner amplifier does not match that of the monitor. Check the part numbers of those
components.
PC350LC/HD-8 60-33 B
AIR CONDITIONER TESTING AND ADJUSTING
★ There is a Disconnection or a short circuit in the line between the control amplifier and Inside temperature sensor.
★ Action of air conditioner amplifier: The air conditioner amplifier controls with only the set temperature since the data
of the Inside temperature sensor are not available.
★ Trouble: The air conditioner does not function automatically but functions when operated manually.
★ See “Testing Inner Sensor” on page 60-44.
6. Ventilation is abnormal
Servomotor for blowing out changeover (mode) damper does not rotate judging from the servomotor potentiometer volt-
age.
★ Damper is the same as door.
★ Trouble: Blowing out is not changed.
★ Action of control amplifier:
The control amplifier stops outputting to the servomotor for blowing out changeover (mode).
★ Even if the link is disconnected and the damper does not rotate, the self-diagnosis system judges the damper normal
since the servomotor potentiometer voltage changes normally.
(For mechanical troubles, see “Testing Vent (Mode) Changeover” on page 60-38.
8. Refrigerant is abnormal
(Dual) pressure switch signal for refrigerant is abnormal. Namely pressure switch for refrigerant is OFF.
★ Trouble: The air conditioner does not work.
★ Action of control amplifier: The control amplifier stops outputting to the compressor.
WARNING! When replacing the pressure switch, be sure to collect the refrigerant. See “Caution
About Refrigerant” on page 60-19.
60-34 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Temperature Control
Outline
• Temperature is controlled by mixing ratio of the hot air from the heater and cooled air from the evaporator by changing
the angles of the four doors (dampers) in the air mix section. The angle of each door (damper) is set changed by the air
mix servomotor through plate (P1), lever 1 (L1) – lever 6 (L6) and rod (RODAM). Only rod (RODAM), lever 5 (L5) and
lever 6 (L6) are seen from outside. (For the figure, see item 5.)
★ If lever 5 (L5) and lever 6 (L6) move smoothly between COOL MAX and HOT MAX, plate (P1) and lever 1 (L1) – lever
4 (L4) operate normally, too.
★ Control amplifier (CNTAMP) control temperature is automatically based on inside temperature sensor. So to operate
between COOL MAX and HOT MAX inside temperature sensor connector may have to be disconnected.
★ To reset the self-diagnosis system (To clear the air conditioner error displayed on the air conditioner screen of the machine
monitor), the starting switch must be turned OFF (While the self-diagnosis system is indicating a problem, no signals are
output to the servomotor).
5. Start the engine and turn the air conditioner power ON.
6. Set the temperature to 18°C (64.5°F) and 32°C (89.6°F) on the air
conditioner screen of the monitor and check visually that lever 5
(L5) and lever 6 (L6) move smoothly between COOL MAX and
HOT MAX.
★ For COOL MAX and HOT MAX, see the following page.
PC350LC/HD-8 60-35 B
AIR CONDITIONER TESTING AND ADJUSTING
12
• When Lever 5 (L5) and Lever 6 (L6) do not move between COOL
MAX and HOT MAX.
• When lever 5 (L5) and lever 6 (L6) do not move smoothly through the range shown in the figure
E. Make match marks on servomotors (5) and (6) to show which connector has been connected to which servomotor.
(The servomotor will be exchanged with each other later.)
60-36 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
G. Remove cover (7).
H. Rotate plate (P1) with the hand between COOL MAX and HOT
MAX to see where lever 1 (L1) – lever 6 (L6) are hitched and
then repair.
★ If the levers do not move smoothly, clean them and apply
grease to the links.
I. When plate (P1) is rotated with the hand between COOL MAX
and HOT MAX, if lever 1 (L1) – lever 6 (L6) move smoothly,
the servomotor may have trouble. In this case, exchange servomotors (5) and (6) and operate them.
★ For electrical problems, see “E-4 Temperature Cannot be Controlled” on page 60-68.
PC350LC/HD-8 60-37 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Vent (Mode) Changeover
Outline
The vent (modes) are selected by changing the angles of the four internal
doors (dampers). The angles of the doors (dampers) are changed by the
servomotor through plate (P2), defroster rod (RODD), front face rod
(RODF) and lever seven (LEVER 7) – lever twelve (LEVER 12). Only
defroster rod (RODD), front face rod (RODF), lever seven (L7) and lever
eight (L8) are seen from outside. (For the figure, see item 5.) Visually
check the positions of the levers and opening and closing operations of
the doors (dampers) of the front face and rear face.
The rear face door (damper) angle is changed by the servomotor through
lever (L13) and rod (RODR). Since lever (L11) of the front face and lever
(L13) and rod (RODR) of the rear face are not seen from outside, remove
the duct and check the revolution of the door (damper) directly.
★ To reset the self-diagnosis system (To delete the air conditioner error
displayed on the air conditioner screen of the machine monitor), the
starting switch must be turned OFF (While the self-diagnosis system
is indicating a trouble, no signals are output to the servomotor).
3. Check the defroster rod (RODD) and foot rod (RODF) for
disconnection.
4. Start the engine and turn the air conditioner power ON.
5. Press the vent selector switch on the air conditioner screen of the
monitor and check visually that lever seven (L7) and lever eight (L8)
move smoothly between the foot mode and defroster mode shown in
the figure.
8. Referring to “Testing Air Leakage (Ducts)” on page 60-30”, remove the ducts in order from the one on the monitor side
and remove front face duct (FFD).
60-38 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
9. Start the engine and turn the air conditioner power ON.
10. Press the vent selector switch on the air conditioner screen of the
monitor and check the opening and closing operations of the front
face door and rear face door (damper).
• When lever seven (L7) and lever eight (L8) do not move smoothly
through the range shown in the figure or the front face door and rear
face door (damper) do not open or close.
PC350LC/HD-8 60-39 B
AIR CONDITIONER TESTING AND ADJUSTING
12
E. Rotate plate (P2) with the hand to see where lever seven (L7) –
lever twelve (L12) are hitched and then repair.
★ If the levers do not move smoothly, clean them and apply
grease to the links.
F.
When plate (P2) is rotated with the hand, if lever seven (L7) –
lever twelve (L12) move smoothly, the servomotor may have
trouble. In this case, exchange servomotors (5) and (6) and
operate them.
★ The figures of the foot mode and defroster mode are shown before.
★ For electrical problem, see “E-5 Vent (Mode) Cannot be Changed
Over” on page 60-71.
60-40 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
PC350LC/HD-8 60-41 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Recirc/Fresh Changeover
Outline
2. Start the engine and turn the air conditioner power ON.
4. When door (damper) (F/R D) does not open and close, check contacts
of connector [7] of the servomotor (for disconnection) in following
procedure.
60-42 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
8. Remove pin (9) and fresh air duct (10).
★ You can see the door (damper) with mirror.
★ For electric problems, see “E-6 Recirc/Fresh Air Cannot be
Changed Over” on page 60-74.
PC350LC/HD-8 60-43 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Inner Sensor
★ Inner Sensor is the same as inside temperature sensor on “block
diagram” or “circuit diagram”.
• If “Inner Sensor abnormal” is displayed by the self-diagnosis
(“Abnormality Record” screen on machine monitor: “03 Air-
conditioning System”), test the inner sensor.
• To reset the self-diagnosis system (detection of abnormality), the
starting switch must be turned OFF.
3. Referring to “Testing Recirc/Fresh Changeover” on page 60-42, remove the fresh air duct.
4. Referring to “Method of replacing Recirc/Fresh changeover servomotor”, remove box assembly (11).
6. Referring to “Testing evaporator temperature sensor item 1, 5.”, disconnect connectors [1] and [2] from control amplifier
(CNTAMP).
7. Check that the female terminals (on the wiring harness side) of connector [8] are not shorted to each other. (If they are
shorted, the wiring harness is defective.)
8. Check that the resistance between female connector [8] (2) (PB) (on the wiring harness side) and connector [1] (11) (PB)
(on the wiring harness side) is 1 Ω or below. (If not, the wiring harness is defective.)
9. Check that the resistance between female connector [8] (1) (BrR) (on the wiring harness side) and connector [2] (27)
(BrR) (on the wiring harness side) is 1Ω or below. (If not, the wiring harness is defective.)
11. Turn the starting switch ON and carry out self diagnosis (“Abnormality Record” screen on the machine monitor: “03 Air-
conditioning System”). If “Inner Sensor abnormal” is still displayed, replace the control amplifier.
60-44 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Evaporator Temperature Sensor
• If “Ventilating Sensor abnormal” is displayed by the self-diagnosis
(“Abnormality Record” screen on machine monitor: “03 Air-
conditioning System”), test the evaporator temperature sensor.
• To reset the self-diagnosis system (detection of abnormality), the
starting switch must be turned OFF.
4. Measure the resistance between the mate (female) of connector [9] and the terminal on the evaporator temperature sensor
side.
Normal value: . . . . . . . . . . . . . . . . . . . . . . 0°C (32°F)----- 4.8 kΩ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15°C (59°F) --- 2.3 kΩ
★ If an error is detected by the self-diagnosis and evaporator temperature sensor is normal, control amplifier
(CNTAMP) or the wiring harness is defective.
1. Remove air conditioner unit assembly (A/C U). For details, see Shop Manual, Chapter 50, “Air conditioner unit,
Removal”.
2. Remove wiring harness. (For each connector, see the “Part and Connector Locations” on page 60-26.)
5. Remove the link section. For details, see “Air Conditioner Unit” on page 60-10.
PC350LC/HD-8 60-45 B
AIR CONDITIONER TESTING AND ADJUSTING
12
7. Remove the evaporator.
8. Remove the holder from part (P) and remove the evaporator temperature sensor.
Installation
1. Install the evaporator temperature sensor to the position shown in the previous figure with the holder.
60-46 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Sunlight Sensor
• If “Sunlight Sensor abnormal” is displayed by the self-diagnosis (“Abnormality Record” screen on machine monitor: “03
Air-conditioning System”), test sunlight sensor connector P31.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
★ A short circuit between the terminals of the sunlight sensor unit is a defect. Whether the sunlight sensor is normal
cannot be checked by measuring resistance, etc., however. Accordingly, if the wiring is normal, presume the sunlight
sensor to be abnormal and replace it. If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier.
2. Remove cover (2) and check connector P31 (3) of sunlight sensor (S)
on the rear side of the cover (for disconnection).
3. Ensure that the terminals of male connector P31 (3) (on the sunlight
sensor (S) side) are not shorted to each other. (If they are shorted, the
sunlight sensor is defective.)
5. Ensure that the terminals of female connector P31 (on the wiring
harness side) are not shorted to each other. (If they are shorted, the
wiring harness is defective.)
6. Check that the resistance between female connector P31 (2) (YW) (on
the wiring harness side) and connector [1] (3) (YW) (on the wiring
harness side) is 1 Ω or below. (If not, the wiring harness is defective.)
★ If the result of item 6 or item 7 is abnormal, check the contact of
connector CN-AC01.
(See “Part and Connector Locations” on page 60-26)
7. Check that the resistance between female connector P31 (1) (RB) (on
the wiring harness side) and connector [1] (15) (RB) (on the wiring
harness side) is 1 Ω or below. (If not, the wiring harness is defective.)
9. Turn the starting switch ON and carry out self diagnosis (on the air conditioner fault history screen of the machine
monitor). If “Sunlight Sensor abnormal” is still displayed, replace the control amplifier.
PC350LC/HD-8 60-47 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing (Dual) Pressure Switch for Refrigerant
• If “Refrigerant abnormal” is displayed by the self diagnosis (“Abnormality Record” screen on machine monitor:
“03 Air-conditioning System”), test pressure switch connector P17.
• To reset the self diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The pressure switch unit is turned ON when the refrigerant pressure is normal and OFF when the refrigerant pressure is
abnormal.
★ The pressure switch unit may be OFF when ambient temperature below 0°C (32°F) because the refrigerant pressure
becomes down. The pressure switch unit is not defective but normal.
3. Ensure that the terminals on the switch side of connector P17 are
shorted to each other (ON). (When they are not shorted (OFF), the
pressure switch detects abnormal refrigerant pressure.)
★ When the pressure switch is OFF, connect a pressure gauge to the
high pressure side of the air conditioner compressor and check the
refrigerant pressure. See “Connection of Service Tool” on page
60-80 and “Troubleshooting With Gauge Pressure” on page 60-
77.
★ If refrigerant pressure is normal, the pressure switch is defective.
60-48 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
12
• When the terminals on the switch side of connector P17 are shorted (ON) (See E-2 for circuit)
A. Referring to “Testing Evaporator Temperature Sensor” on page 60-45 item 1, 5.”, disconnect connector [1] from
control amplifier (CNTAMP).
B. Check that the resistance between female connector P17 (2) (B) (on the wiring harness side) and the ground is 1 Ω or
below. (If not, the wiring harness is defective.)
C. Check that the resistance between female connector P17 (1) (GB) (on the wiring harness side) and connector [1] (4)
(GB) (on the wiring harness side) is 1 Ω or below. (If not, the wiring harness is defective.)
★ If the result of item C is abnormal, check the contact of connector CNAC01.
(See “Part and Connector Locations” on page 60-26)
E. Turn the starting switch ON and carry out self diagnosis (“Abnormality Record” screen on machine monitor:
“03 Air-conditioning System”). If “Refrigerant abnormal” is still displayed, replace the control amplifier.
PC350LC/HD-8 60-49 B
AIR CONDITIONER TESTING AND ADJUSTING
12
Testing Relays
★ If the air conditioner compressor is normal (air is cooled) and air comes out, the relays are normal. Accordingly, skip these
relay tests.
★ Bring your ear to each relay to check its operation by sound.
1. Remove covers (1) – (3) according to “Testing Temperature Control” on page 60-35, 1.
3. Turn the starting switch ON (do not start the engine) and turn the main power of the air conditioner ON. If the blower-off
relay is normal, it is turned ON. Check its click.
4. If the air conditioner switch is turned ON at this time, the compressor relay is turned ON if it is normal. Check its click.
★ Control amplifier (CNTAMP) does not turn the compressor relay
ON in the following cases.
A. The resistance of the coil between terminals (1) and (2) is 140 –
340 Ω.
60-50 B PC350LC/HD-8
AIR CONDITIONER TESTING AND ADJUSTING
Compressor clutch relay (R31)
A. The resistance of the coil between terminals (1) and (3) is 140 –
340 Ω.
PC350LC/HD-8 60-51 B
AIR CONDITIONER TROUBLESHOOTING
12
TROUBLESHOOTING
Troubleshooting Chart 1
★ The numbers in the boxes are the item numbers in the troubleshooting table.
★ E-2, E-3 means Troubleshooting for electrical system (E mode).
1. Cooling trouble.
2. Heating trouble.
60-52 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
Troubleshooting Chart 2
1. Blower fan motor does not revolve or its speed is different from set value.
★ See troubleshooting “E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)” on page 60-64 for
troubleshooting for the electrical system.
Possible cause Check method Remedy
Large duct resistance Check duct for crushing and filter for clogging. Repair
Air leakage See “Testing Air Leakage (Ducts)” on page 60-30. Repair or replace
Defective evaporator
temperature sensor, Evaporator is frozen. Check sensor clip. Check Repair or replace
defective contact of sensor for dirt. (Evaporator temperature sensor and
evaporator temperature Check the frost on the hose near pressure switch expansion valve are in air conditioner
sensor or defective (when freezing advances furthermore.). unit).
expansion valve.
3. Low/high pressure.
Possible cause Check method Remedy
PC350LC/HD-8 60-53 B
AIR CONDITIONER TROUBLESHOOTING
4. Compressor does not revolve at all or its speed is low.
★ See “E-2 Compressor System (Air is Not Cooled)” on page 60-61 for troubleshooting for the electrical system.
Trouble part Possible cause Check method Remedy
Compressor belt Loosened compressor belt Vibration amplitude of belt is large Adjust tension
Large duct resistance Check duct for crushing and filter for clogging Repair
Air leakage through duct Check duct joints for defective duct seal and
Repair
joints disconnection of duct
Clogging of heater core fins Check heater core fins for clogging Repair
Low engine coolant temper- Warm up engine and then check engine coolant
Find out cause
ature temperature
Low engine coolant level Check coolant level in radiator Add coolant
Contrary connection of IN
Check the destination of heater hoses Repair
and OUT heater hoses
60-54 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
8. Other items
Possible cause Check method Remedy
PC350LC/HD-8 60-55 B
AIR CONDITIONER TROUBLESHOOTING
12
Troubleshooting for Electrical System (E mode)
★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
troubleshooting, understand the information fully.
60-56 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12 Power Supply System (Air Conditioner does not Operate)
E-1
Problem Air conditioner does not operate due to power supply system failure.
Indication of
• “A/C Controller Error” is displayed red on air conditioner screen of machine monitor.
problem on
• No air blows out (Blower motor does not rotate).
machine
• If failure code [DAFRMC] is displayed on machine monitor, see Chapter 40 Troubleshooting first and
repair so that [DAFRMC] will not be displayed.
★ AN communication is connected to machine monitor, engine controller, pump controller and air
conditioner controller.
• “A/C Controller Error” is displayed on air conditioner operation screen of machine monitor in following
cases. In E-1, 1), 2) and 3) of following cases are explained.
1) Power is not supplied to control amplifier.
2) Control amplifier is broken.
3) Control amplifier (CNTAMP) cannot communicate with machine monitor.
4) Blowing out door (damper) servomotor does not rotate.
5) Temperature control (AIRMIX) door (damper) servomotor does not rotate.
6) Refrigerant pressure is abnormal.
• Referring to “Testing with self-diagnosis function”, display “Abnormality Record” screen on machine
Related information monitor: “03 Air-conditioning System” and check to see if “CAN Status” is abnormal. Abnormality of
“CAN Status” indicates that control amplifier at rear of air conditioner unit cannot communicate with
machine monitor.
“CAN Status” is indicated as abnormal in any case of 1), 2) and 3) above.
• Referring to“Part and Connector Locations” on page 60-26, check fuse No. 11 (20 A) and Fu5A in fuse
box F01 for breakage.
• Ground cable of air conditioner is grounded together with that of machine wiring harness for electrical
equipment of machine.
• For each connector and relay, see “Part and Connector Locations” on page 60-26.
• If fuse is broken when A/C switch is pressed, see “E-2 Compressor System (Air is Not Cooled)” on
page 60-61.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
★ T-adapter is not prepared for other connectors.
PC350LC/HD-8 60-57 B
AIR CONDITIONER TROUBLESHOOTING
12
Causes Standard value in normal state/Remarks on troubleshooting
Disconnection in wiring ★ If fuse described in related information is not broken and test
5
harness result A for cause 3 is abnormal, check with circuit diagram.
60-58 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Causes Standard value in normal state/Remarks on troubleshooting
Resis-
Between connector [2] (17) – (18) 60 Ω H
Disconnection in CAN tance
communication circuit
(Communication ★ If result H above is abnormal, perform following procedure.
Possible causes 6
between control panel ★ If result H above and J below are abnormal, operator cab wiring
and standard and control amplifier is harness is abnormal.
value in normal defective) ★ If result H above is abnormal and J below is normal, air
state conditioner wiring harness (on plate) is abnormal.
★ Terminal resistors of about 120 Ω are in machine monitor and on
engine. Since they are connected in parallel, combined
resistance is about 60 Ω.
1) Turn starting switch OFF.
2) Disconnect battery ground cable.
3) Disconnect control amplifier connectors [1] and [2] and connect
T-adapter to wiring harness side.
4) Carry out troubleshooting without turning starting switch ON.
Defective control When test result A for causes 1, 2 and 3 and result H for cause 6 are
7
amplifier normal, replace control amplifier.
Defective machine When test results for causes 1 – 7 are normal, machine monitor is
8
monitor defective.
PC350LC/HD-8 60-59 B
AIR CONDITIONER TROUBLESHOOTING
Related circuit diagram
60-60 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12 Compressor System (Air is Not Cooled)
E-2
Problem Air is not cooled due to compressor system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine monitor, air is
Indication of not cooled as displayed on screen.
problem on • Air conditioner compressor does not operate.
machine • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. Causes of
this phenomenon are 1) – 6). For 1) – 5), see “Related information” in E-1.
In E-2, “6) Refrigerant pressure is abnormal” of “Related information” in E-1 is explained.
• Referring to “Testing with self-diagnosis function”, display air conditioner fault history screen on
machine monitor and check to see if refrigerant pressure is abnormal. If refrigerant pressure is
abnormal, compressor is not turned ON and air is not cooled consequently.
★ Abnormal refrigerant pressure indicates that “Signal (connector [1] (4)) from pressure switch is not
Related information
grounded”.
• Air conditioner may not be turned ON even when ambient temperature is below 5°C (Normal).
• For each connector, see “Part and Connector Locations” on page 60-26.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
★ T-adapter is not prepared for other connectors.
PC350LC/HD-8 60-61 B
AIR CONDITIONER TROUBLESHOOTING
Disconnection in wiring
7 Check with circuit diagram.
harness
Max.
Between connector [2] (35) – [1] (16) Voltage
1V
60-62 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Related circuit diagram
PC350LC/HD-8 60-63 B
AIR CONDITIONER TROUBLESHOOTING
12
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
Problem No air comes out or air flow is abnormal due to blower motor system failure.
Indication of
• LCD of machine monitor on air conditioner operation screen lights normally but air does not come out.
problem on
• Air flow does not match fan switch setting on air conditioner operation screen.
machine
• This trouble is not checked with self-diagnosis function.
• If air flow becomes abnormal after a while in cooling mode, evaporator may be frozen. Possible
causes for this trouble are as follows.
1) Compressor clutch relay is defective (Stuck closed). (See E-2, 4, A.)
2) Evaporator temperature sensor mounting holder has come off. (Remove and disassemble air
conditioner unit.)
Related information
3) Expansion valve is adjusted improperly. (Remove air conditioner unit and replace expansion valve.)
• If air comes out, fuse and relay are normal and wiring harness is seldom abnormal.
• If air comes out but its flow is abnormal in heating mode, replace power transistor first.
• For each connector, relay, and power transistor, see “Part and Connector Locations” on page 60-26.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
★ T-adapter is not prepared for other connectors.
60-64 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
★ If air does not come out even when blower is turned ON forcibly
without using relay, cause is part other than relay.
PC350LC/HD-8 60-65 B
AIR CONDITIONER TROUBLESHOOTING
Defective blower (fan) When test results D for cause 5 are normal (voltage is normal but
6
motor motor does not rotate), blower (fan) motor is defective.
Possible
causes and 1) Turn starting switch OFF.
standard value 2) Disconnect connectors R30 and [1] and carry out troubleshooting
in normal state without turning starting switch ON.
Short circuit in wiring har-
7 ness (with another wiring Between (2) – (1) on wiring Resis- Min. 1
J
harness) harness side of connector R30 tance MΩ
Disconnection in wiring
9 Check with circuit diagram.
harness
60-66 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Related circuit diagram
PC350LC/HD-8 60-67 B
AIR CONDITIONER TROUBLESHOOTING
12
E-4 Temperature Cannot be Controlled
Problem Temperature cannot be controlled.
Indication of • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.)
problem on • While air conditioner operation screen of machine monitor is displayed, temperature does not change
machine even if temperature control switch is operated.
★ Temperature control means “Air Mix” of cooled air and hot air.
• Referring to “Testing with Self-diagnosis Function” on page 60-32, display “Abnormality Record”
screen on machine monitor: “03 Air-conditioning System” and check to see if “Air Mix is abnormal” and
“Inner sensor is abnormal”.
See “Testing Inner Sensor” on page 60-44 when “Inner sensor is abnormal”.
• Even if rod etc. is disconnected (See “Testing Temperature Control” on page 60-35), if current is
supplied to air mix servomotor by operating switches and potentiometer in servomotor reaches normal
voltage, self diagnosis function judges system normal.
• Referring to “Testing Temperature Control” on page 60-35, check that there is not contact of connector
[6] or mechanical trouble (removal or interference of link, etc.)
Related information
• Air mix servomotor and air blowing out (mode) servomotor are same part number. Operating angle of
temperature control (air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by
connecting connector [5] to connector [6]. It is allowed, however, to exchange air mix servomotor and
blowing out (mode) servomotor to see if they are normal.
• Air mix servomotor can be checked for trouble by connecting new servomotor to connector [6] and see
if it operates normally.
• For each connector, see “Part and Connector Locations” on page 60-26.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
★ Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
60-68 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
PC350LC/HD-8 60-69 B
AIR CONDITIONER TROUBLESHOOTING
12
Related circuit diagram
60-70 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12 Vent (Mode) Cannot be Changed Over
E-5
Problem Vent (mode) cannot be changed over.
Indication of • “A/C Controller Error” may be displayed red on air conditioner screen of machine monitor. (See E-1.)
problem on • When vent selector switch on air conditioner operation screen of machine monitor is operated, vent
machine does not change.
• Referring to “Testing with Self-diagnosis Function” on page 60-32, display “Abnormality Record” screen on
machine monitor: “03 Air-conditioning System” and check to see if “Ventilating sensor is abnormal”.
• Even if rod etc. is disconnected (See “Testing Vent (Mode) Changeover” on page 60-38), if current is
supplied to blowing out (mode) servomotor by operating switches and potentiometer in servomotor reaches
normal voltage, self-diagnosis function judges system normal.
• Referring to “Testing vent (mode) changeover”, check that there is not contact of connector [5] or
mechanical trouble (removal or interference of link, etc.)
• Air mix servomotor and blowing out (mode) servomotor are same. Operating angle of temperature control
Related infor-
(air mix) is less, however. Accordingly, do not test servomotor to see if it rotates by connecting connector [5]
mation
to connector [6]. It is allowed, however, to exchange air mix servomotor and blowing out (mode) servomotor
to see if they are normal.
• Blowing out servomotor can be checked for trouble by connecting new servomotor to connector [5] and see
if it operates normally.
• For each connector, see “Part and Connector Locations” on page 60-26.
• T-adapter for connector [1]: 799-601-7210, T-adapter for connector [2]: 799-601-7220
★ Since T-adapter is not prepared for other connectors, check signals with control amplifier during
operation.
PC350LC/HD-8 60-71 B
AIR CONDITIONER TROUBLESHOOTING
60-72 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Related circuit diagram
PC350LC/HD-8 60-73 B
AIR CONDITIONER TROUBLESHOOTING
12
E-6 Recirc/Fresh Air Cannot be Changed Over
60-74 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
PC350LC/HD-8 60-75 B
AIR CONDITIONER TROUBLESHOOTING
12
Related circuit diagram
60-76 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Troubleshooting With Gauge Pressure
Referring to “Connection of Service Tool” on page 60-80, carry out troubleshooting by reading the high and low gauge
pressures of the cooling cycle.
★ The gauge pressure varies largely with the weather condition and operating condition of the machine. Take care.
High pressure is too high: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Above approximately 25 kg/cm2 (355.5 psi)
High pressure is too low: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . Below approximately 10 kg/cm2 (142.2 psi)
Low pressure is too high: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Above approximately 3 kg/cm2 (42.6 psi)
Low pressure is too low: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Below approximately 0.5 kg/cm2 (7.1 psi)
★ (Dual) pressure switch on high pressure side protects air conditioner circuit with OFF:
See right
LA: 2 kg/cm2 (28.4 psi)
LB: 0.2 kg/cm2 (2.8 psi)
HA: 32 kg/cm2 (455 psi)
HB: 6 kg/cm2 (85.3 psi)
• Dual pressure switch
★ Normally "ON", abnormal pressure "OFF" for compressor.
Fan switch Hi
PC350LC/HD-8 60-77 B
AIR CONDITIONER TROUBLESHOOTING
12
Indicated gauge pressure Cause Check method Remedy
Repair or replace
Defective evaporator Evaporator is frozen Air flow
Replace receiver drier
sensor or defective contact is down by freezing (At cool
Collect refrigerant, then fill
Pressure is normal of sensor (removal of max. and HI speed of fan,
up with proper quantity of
Both high pressure and low mounting clip) later it becomes not to cold.)
refrigerant again (*2)
pressure are too low
Piping between receiver
Low pressure becomes drier and compressor is
vacuum Clogging or flattening or clogged or flattened. If
Clean or replace (*2)
piping clogged completely, low
gauge pressure becomes
vacuum
Stain of condenser,
Defective cooling of clogging or crushing of fins, Clean, repair fins, or repair
condenser or defective revolution of or replace condenser (*2)
Both high pressure and low cooling fan
pressure are too high
Defective adjustment of
Bubble can be seen in the
expansion valve (Valve is Replace (*2)
sight glass
opened too wide)
There is a remarkable
Clogging or flattening of
High pressure is too high temperature difference Clean inside of cycle or
piping between compressor
and low pressure is too low between before and after replace (*2)
and condenser
clogged part
60-78 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
*1 If refrigerant leaks, internal oil always leaks, too. So perform the check mainly on pipe joints and parts which are stained
with oil. Increase tightening of the joints or replace parts.
WARNING! *2. When replacing a cooling cycle part, see “Caution About Refrigerant” on page 60-19
and collect refrigerant. After replacing it, fill up the air conditioner system with refrigerant
again.
PC350LC/HD-8 60-79 B
AIR CONDITIONER TROUBLESHOOTING
12
Connection of Service Tool
Symbol Part No. Part name
1. Gauge manifold
2. High pressure charging hose (red)
3. Low pressure charging hose (blue)
4. Quick joint (Hi) (Large diameter)
5. Quick joint (Lo) (Small diameter)
• The thread is rough. So be careful not to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close the high-pressure valve (HI) and low pressure valve (LO) of gauge manifold (1).
2. Connect red charging hose (2) to the (HI) side and blue charging hose (3) to the (LO) side.
4. Connect the quick joints to the service valves of the high and low-pressure pipings.
60-80 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
PC350LC/HD-8 60-81 B
AIR CONDITIONER TROUBLESHOOTING
12
Precautions for connecting air conditioner piping
• When connecting the piping, apply compressor oil ND-OIL8 for
R134a to the O-rings. (See item 4. in “Handling of Compressor Oil”
on page 60-83) Do not apply oil to the threads of a bolt, nut or union,
however.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly,
do not reuse it. When removing it, use a soft tool (such as a tooth-
pick) so that the piping will not be damaged.
• Push in each pipe to the stopper (until it clicks) and tighten the bolt
or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut (Apply a torque
wrench to the tightening side). Place one wrench and tighten the nut
with the other wrench to the specified torque.
60-82 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Handling of Compressor Oil
Control of Compressor Oil
(Denso: ND-OIL8: For R134a)
Compressor oil does not need to be checked or added so frequently as engine oil. Insufficiency or excess of compressor oil can
cause the following troubles.
Condition Contents
WARNING! If refrigerant gets in your eyes, you may lose your sight. (Put on protective goggles.)
★ If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use the specified oil for R134a (Denso: ND-OIL8)
★ Oil for R134a absorbs moisture very easily. Accordingly, fit the cap immediately after using oil to stop the atmosphere.
Store the oil can in a dry and ventilated place.
★ Precautions for using oil
Oil for R134a (Denso: ND-OIL8 in particular) may dissolve acrylic resin and polystyrene (excluding baked polystyrene
paint film).
Accordingly, do not stick oil to those plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
• When a cycle parts such as the air conditioner unit, condenser, receiver drier, evaporator unit, etc. is replaced.
Quantity of oil to be added when cycle part is replaced.
Air conditioner part Quantity to be added cm3 (oz)
PC350LC/HD-8 60-83 B
AIR CONDITIONER TROUBLESHOOTING
12
Compressor Replacement
• In case of compressor seizure or breakage. Metal chips will circulate through the air conditioner circuit and
contaminate the compressor oil extremely. In this case, flush the air conditioner circuit and replace the compressor and
receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
New compressor has 180 cc compressor oil in it. So drain excessive compressor oil before installing new compressor in
the following.
60-84 B PC350LC/HD-8
AIR CONDITIONER TROUBLESHOOTING
12
Desiccant Replacement Procedure
1. Condenser
2. Receiver drier
★ The desiccant is in receiver drier (2).
★ Prepare desiccant replacement kit (20Y-810-1250).
2. Remove cap (C) from receiver drier (2). Hold boss (B) of cap (C)
with pliers etc. to remove.
★ Cap (C) may be hard to remove. When removing it, take care
not to damage or deform the seal or receiver drier (2).
PC350LC/HD-8 60-85 B
AIR CONDITIONER TROUBLESHOOTING
12
Installing new desiccant
4. Install cap (C) fitted with filter (F) to receiver drier (2).
60-86 B PC350LC/HD-8
90 DIAGRAMS AND DRAWINGS
PC350LC/HD-8 90-1 1
DIAGRAMS AND DRAWINGS TABLE OF CONTENTS
12
MEMORANDUM
90-2 1 PC350LC/HD-8
Hydraulic circuit diagram
Hydraulic circuit diagram PC350LC/HD-8
SEN02004-00
PC350LC/HD-8 90-3 (1)
Electrical circuit diagram (1/5)
Electrical circuit diagram (1/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-03
PC300, 350-8 90-5 (1)
Electrical circuit diagram (2/5)
Electrical circuit diagram (2/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-03
PC300, 350-8 90-7 (1)
Electrical circuit diagram (3/5)
Electrical circuit diagram (3/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-03
PC300, 350-8 90-9 (1)
Electrical circuit diagram (4/5)
Electrical circuit diagram (4/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-03
PC300, 350-8 90-11 (1)
Electrical circuit diagram (5/5)
Electrical circuit diagram (5/5) PC300, 300LC-8, PC350, 350LC-8
SEN02005-03
PC300, 350-8 90-13 (1)