PC350-8 Testing & Adjusting Part1

SEN02625-06
HYDRAULIC EXCAVATOR
PC300, 350-8
SEN02625-03
PC300-8
Shop Manual
PC300LC-8
PC350-8
PC350LC-8
PC300-8 60001 and up
PC300LC-8 60001 and up
PC350-8 60001 and up
PC350LC-8 60001 and up
30 Testing and adjusting

Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting . ........................................................................................ 3

Sketches of special tools ............................................................................................................................ 7
Testing engine speed.................................................................................................................................. 8
Testing air boost pressure .......................................................................................................................... 9
Testing exhaust gas color ........................................................................................................................... 10
Adjusting valve clearance ........................................................................................................................... 12
Testing compression pressure .................................................................................................................... 14
Testing blow-by pressure ............................................................................................................................ 18
Testing engine oil pressure ......................................................................................................................... 19
Testing fuel pressure .................................................................................................................................. 20
Handling during cylinder cut-out operation ................................................................................................. 25
Handling during no injection cranking operation ......................................................................................... 25
Testing fuel return rate and leakage ........................................................................................................... 26
Bleeding air from fuel circuit........................................................................................................................ 28
Checking fuel circuit for leakage ................................................................................................................. 29
Testing and adjusting air compressor belt tension...................................................................................... 30
Replacing fan belt ....................................................................................................................................... 31
Replacing alternator belt ............................................................................................................................. 32
Testing clearance in swing circle bearings ................................................................................................. 33
Testing and adjusting track shoe tension.................................................................................................... 34
PC300, 350-8 1
SEN02625-06 30 Testing and adjusting
Testing and adjusting oil pressure in work equipment, swing and travel circuit.......................................... 35
Testing and adjusting control circuit oil pressure ........................................................................................ 39
Testing and adjusting pump PC control circuit oil pressure ........................................................................ 40
Testing and adjusting pump LS control circuit oil pressure......................................................................... 43
Testing solenoid valve output pressure....................................................................................................... 48
Testing PPC valve output pressure............................................................................................................. 52
Adjusting play of work equipment and swing PPC valves........................................................................... 53
Inspecting locations of hydraulic drift of work equipment............................................................................ 54
Releasing remaining pressure in hydraulic circuit ....................................................................................... 56
Testing oil leakage amount ......................................................................................................................... 56
Bleeding air from various parts ................................................................................................................... 59
Diode inspection procedures....................................................................................................................... 61
Installation and adjustment of mirrors ......................................................................................................... 62
2 PC300, 350-8
30 Testing and adjusting SEN02625-06
Tools for testing, adjusting and troubleshooting
Testing and adjusting Sym- Q't

Part No. Part name Remarks
item bol y
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%
Checking exhaust gas (with the standard color)
B Commercially
color 2 Smoke meter 1 (Degree of contamination x 1/10
available
Bosch index)
1 795-799-1131 Gear 1
Adjusting valve clear-
C Commercially
ance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1
Testing compression 2 795-502-1590 Compression gauge 1 0–7.0 MPa {0–70 kg/cm 2}
D
pressure 3 795-790-6110 Adapter 1
4 6754-11-3130 Gasket 1
0–5.0 kPa
Testing blow-by pres- 1 799-201-1504 Blow-by checker 1
E {0–500 mmH2O}
sure
2 795-790-3300 Tool (nozzle) 1
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm 2}
Pressure gauge:
Testing engine oil pres- 790-261-1204 Digital hydraulic tester 1
F 60 MPa {600 kg/cm2}
sure
Pressure gauge:
2 799-401-2320 Gauge 1
1 MPa {10 kg/cm2}
6732-81-3170 Adapter 1 Size: 10 x 1.0 mm
3
6215-81-9710 O-ring 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm 2}
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
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
1 MPa {10 kg/cm2}
Male: 7/8-14UNF
795-790-1500 1
Female: 7/8-14UNF
4 Fuel vacuum gauge
Male: 3/4-16UNF
799-201-1201 1
Female: 3/4-16UNF
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
Pressure gauge:
Oil pressure in work
equipment, swing and
1 {25, 60, 400, 600 kg/cm 2}
travel circuits, basic
L Pressure gauge:
pressure of control cir- 790-261-1204 Digital hydraulic tester 1
cuit and oil pressure of 60 MPa {600 kg/cm2}
pump PC control circuit 799-101-5220 Nipple 1 Size: 10 x 1.0 mm
2
07002-11023 O-ring 1
PC300, 350-8 3

item bol y
Pressure gauge:
1 {25, 60, 400, 600 kg/cm 2}
Oil pressure of pump LS Pressure gauge:
M 790-261-1204 Digital hydraulic tester 1
control circuit 60 MPa {600 kg/cm2}
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3 799-401-1340 Differential pressure gauge 1
Pressure gauge:
1 {25, 60, 400, 600 kg/cm 2}
Pressure gauge:
Testing solenoid valve 790-261-1204 Digital hydraulic tester 1
N 60 MPa {600 kg/cm2}
output 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:
PPC valve output pres-
P {25, 60, 400, 600 kg/cm 2}
sure
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
60 MPa {600 kg/cm2}
Oil leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4130 T-adapter 1 Ne sensor
Troubleshooting for 799-601-4150 T-adapter 1 For oil pressure sensor
799-601-4211 T-adapter 1 Engine controller
engine controller/sen- —
sors/actuators
799-601-4240 Socket 1 For ambient pressure sensor
799-601-4250 Socket 1 For boost pressure sensor
799-601-9040 T-adapter 1 For injector
799-601-9430 Socket 1 For supply pump PCV
799-601-2500
or
799-601-2700
or
799-601-2800
or
Troubleshooting for 799-601-2900 T-adapter assembly 1
chassis sensors/wiring — or
harnesses 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
4 PC300, 350-8

item bol y
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
799-601-9020 Adapter for DT 1 For DT2P
799-601-9030 Adapter for DT 1 For DT3P
For A3P (Does not include
799-601-9420 Adapter for AMP 1
799-601-9000 and 799-601-9200)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
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 SW6P (Does not include
Troubleshooting for 799-601-7060 Adapter for SWP 1
799-601-8000)
chassis sensors/wiring — For SW14P (Does not include
harnesses 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
799-601-7140 Adapter for S 1 For S8P
799-601-7210 Adapter for AMP040 1 For A16P
799-601-7220 Adapter for AMP040 1 For A20P
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7360 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
799-601-9000
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 tempera-
— 799-101-1502 Digital thermometer 1 -99.9 – 1,299°C
ture
Operating effort andde- 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Commercially
Stroke and hydraulic drift — Ruler 1
available
Commercially
Work equipment speed — Stopwatch 1
available
Voltage and resistance Commercially
— Circuit tester 1
value available
PC300, 350-8 5

item bol y
21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
Socket 1
available Applicable engine serial No.:
Removal and installa-
26850001-26857026
tion of engine coolant —
19 mm deep socket
temperature sensor
(MITOLOY 4ML-19 or equivalent)
795T-981-1010 Socket 1
Applicable engine serial No.:
26857027 and up
6 PC300, 350-8
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
PC300, 350-8 7
Testing engine speed 3. Measuring high idle speed

1) Start the engine and set the fuel control dial
to the high idle (MAX) position.
Measure the engine speed with the monitoring 2) Set the working mode in the power mode (P)
function of the machine monitor. and turn the auto-decelerator OFF.
Measure the engine speed under the following 3) Set all the control levers and pedals for work
condition. equipment, swing and travel to the neutral
Engine coolant temperature: Within operat- and measure the engine speed.
ing range
Hydraulic oil temperature: Within operating 4. Measuring the engine speed when 2-pumps are
range relieved
1) Start the engine and move the arm cylinder to
1. Preparation work the IN stroke end.
Operate the machine monitor so that the engine 2) Set the fuel control dial in the high idle (MAX)
speed can be monitored. position and set the working mode in the
For the operating method of the machine power mode (P).
monitor, see “Special functions of machine 3) Operate the left work equipment control lever
monitor”. to relieve the arm circuit at the IN stroke end
Monitoring code: 01002 Engine speed and measure the engine speed.
5. Measuring the engine speed when 2-pumps

relief and power maximizing (near rated
speed)
1) Start the engine and move the arm cylinder to
the IN stroke end.
2) Set the fuel control dial in the high idle (MAX)
position and set the working mode in the
power mode (P).
3) While operating the left work equipment
control lever to relieve the arm at the IN
stroke end and depressing the power maxi-
mizing switch, measure the engine speed.
The power maximizing function is reset
2. Measuring low idle speed automatically in about 8.5 seconds even if
1) Start the engine and set the fuel control dial the switch is being depressed. Thus mea-
to the low idle (MIN) position. surement of the engine speed must be
2) Set all the control levers and pedals for work completed within that period.
equipment, swing and travel to the neutral
and measure the engine speed. 6. Measuring the speed when auto-deceleration
speed is in operation
1) Start the engine, set the fuel control dial in
the high idle position (MAX), and turn the
auto-decelerator ON.
2) Set all the control levers and pedals for work
equipment, swing and travel to neutral and
measure the engine speed when the
auto-decelerator is operated.
The engine speed is slowed down to a
certain level in about 5 seconds from set-
ting all the control levers and pedals to the
neutral. This level is the engine speed
when operation of the auto-deceleration
is turned on.
8 PC300, 350-8
Testing air boost pressure 5. Run the engine at middle or higher speed and
drain oil from the hose.
When draining the oil, open the self seal of
Air boost pressure measuring tools the hose by insert approximately half of the
Symbol Part No. Part name gauge and hose connection. Repeat opera-
A 1 799-201-2202 Boost gauge kit
tion until the oil is drained out.
If Pm kit (A) is available, you may use the air
1. Open the engine hood. bleeding coupling (790-261-1130) in that kit.
If oil is left in the hose, the gauge does not
2. Remove intake air pressure pickup plug (1) (R work. Accordingly, be sure to drain the oil.
1/8).
6. Measure the air boost pressure at high idle
under the following conditions.
Working mode: P-mode
Swing lock switch: ON (high pressure relief)
Work equipment, swing and travel: Arm IN
relief position
3. Install nipple [1] of boost gauge kit A and

connect them to gauge [3].
7. Remove the measurement tools after the

measurement, and make sure that the machine
is back to normal condition.
4. Start the engine and keep it running until temper-

ature of the engine coolant and hydraulic oil rise
to the operating range.
PC300, 350-8 9
Testing exhaust gas color 2. Measuring with smoke meter B2

1) Insert probe [1] of smoke meter B2 to the
outlet of the exhaust pipe and secure it to the
Exhaust gas color measurement tools exhaust pipe with a clip.
Symbol Part No. Part name
1 799-201-9001 Handy smoke checker
B Commercially
2 Smoke meter
available
Be careful not to touch any hot part when re-

moving or installing the measuring instru-
ments.
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.
1. Measuring with handy smoke checker B1

1) Fit a sheet of filter paper to smoke checker
B1. 2) Connect the probe hose, receptacle of the
accelerator switch and air hose to smoke
2) Insert the exhaust gas intake pipe into the
meter B2.
exhaust pipe.
3) Start the engine and keep it running until the Limit the supplied air pressure to 1.5 MPa
engine coolant temperature rises to the oper- {15 kg/cm 2}.
ating range. 3) Connect the power cable to an AC recep-
4) Start the engine and accelerate it suddenly or tacle.
run it at high idle and then operate the handle Confirm that the smoke meter power
of smoke checker B1 in order to suction switch is in the OFF position, before con-
exhaust gas to the filter paper. necting the power cable to an outlet.
4) 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.
5) Turn on the power switch of smoke meter B2.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
6) Start the engine and keep it running until the
engine coolant temperature rises to the oper-
ating range.
10 PC300, 350-8
7) Start the engine and accelerate it suddenly or

run it at high idle and then depress the accel-
erator pedal of smoke meter B2 to collect the
exhaust gas into the filter paper.
8) Put the polluted filtering paper on
non-polluted filtering paper (more than 10
sheets) in the filtering paper holder, and read
the indicated value.
9) Remove the measurement tools after the
PC300, 350-8 11
Adjusting valve clearance 4. Remove cap (6), set gear C1 and rotate the
crank shaft forward to set No.1 cylinder to the
compression top dead center.
Valve clearance adjustment tools
1 795-799-1131 Gear
C Commercially
2 Clearance gauge
available
1. Remove air intake tube (1).
2. Disconnect blow-by tube (2) and breather tube

(3) and remove cylinder head cover (4).
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.
3. Remove cap (5).
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.
12 PC300, 350-8
6. Adjust the valve clearance in the following 4) Turn the crankshaft forward by 360 ° and
procedure. align the counter mark applied in step 5
When No.1 cylinder is at the compression top above accurately to the pointer.
dead center, adjust the valve clearance indi- This alignment moves the supply pump
cated with mark in the valve arrangement gear stamp line (b) to the position of
drawing. stamp line (c) situated directly below.
5) Adjust the valve clearance indicated with
mark in the above valve arrangement
drawing.
Firing order: 1 - 5 - 3 - 6 - 2 - 4
The adjustment procedure is the same as
that employed for adjustment of mark.
1) Insert clearance gauge C2 to the clearance

between rocker lever (8) and cross head (9).
2) Loosen locknut (10) and adjust the valve
clearance using adjustment screw (11).
With the clearance gauge being inserted,
turn the adjustment screw until it allows
clearance gauge C2 to move slightly. 7. After finishing adjustment, return the removed
3) Fix adjustment screw (11) and tighten parts.
locknut (10). Cylinder head cover mounting bolt:
Locknut: 11.8 1.96 Nm {1.2 0.2 kgm}
24 4 Nm {2.45 0.41 kgm}
After tightening the locknut, check the
valve clearance again.
PC300, 350-8 13
Testing compression pressure 5. Move fuel filter and corrosion resistor assembly
(8) to the control valve side along with the hose
being connected to it.
Testing tools for compression pressure
Symbol Part number Part name
1 795-799-6700 Puller
2 795-502-1590 Compression gauge
D
3 795-790-6110 Adapter
4 6754-11-3130 Gasket
Care must be exercised in measuring the

compression pressure in order to avoid burn
injury from touching the exhaust manifold or
muffler, or pinching by rotating part.
Measuring the compression pressure under the
following condition.
(Engine oil temperature: 40 - 60°C)
1. Open the engine hood. 6. Remove bracket (9).
2. Remove air intake connector (1).
3. Disconnect harness (2) and remove bracket (3)

and air heater (4).
7. Disconnect air intake connector (10) and wiring

harness connectors (11) and (12).
8. Remove blow-by hose (13) and breather hose

(14) to remove cylinder head cover (15).
4. Disconnect wiring harness connectors (5), (6)
and (7).
14 PC300, 350-8
9. Disconnect high-pressure fuel tube (16). 13. Remove retainer (19) and remove fuel inlet
connector (20).
14. Remove holder (21).
15. Remove injector (22).

Remove the injector by use of impacts of the
tool, slide hammer D1.
Do not unclench the upper part of the injec-
tor.
10. Loosen injector terminal nuts (17) and remove

the terminal from the injector.
11. Move the cylinder to be tested to the compres-

sion top dead center.
For the adjustment, refer to the section,"Ad-
justing valve clearance".
12. Remove rocker arm assemblies (18).
PC300, 350-8 15
16. Install gasket D4 to the tip of adapter D3 and 21. Select the no-injection cranking operation from
connect it to the injector mount. the machine monitor.
See the section of "Special functions of ma-
chine monitor".
Be sure to select the no-injection crank-
ing operation. Otherwise, the engine can
be started during the inspection, poten-
tially inducing risks to the inspecting per-
sonnel.
22. Rotate the engine with cranking the starting

motor and measure the compression pressure.
Read the pressure gauge pointer when it is
stabilized.
23. After finishing testing, remove the testing tools

and return the removed parts.
17. Fix adapter D3 with the injector holder.
Install the injector and fuel high-pressure
Holder mounting bolt:
tube according to the following procedure.
1st time: 9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
1) Mate the injector's projection (a) to notch (b)
2nd time: 40.2 ± 3.9 Nm {4.1 ± 0.4 kgm} of the holder and then set them to the
cylinder head.
18. Connect compression gauge D2 to adapter D3. Set the injector with the above mating po-
Apply a little amount of engine oil to the con- sition toward the fuel inlet connector in-
necting parts of the adapter and gauge so sertion side.
that air will not leak easily.
19. Install rocker arm assembly.

Rocker arm assembly mounting bolt :
64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
20. Adjust the valve clearances.

For the adjustment, refer to the section, "Ad-
justing valve clearance".
2) Tighten the injector holder mounting bolt by 3

or 4 threads.
3) Set fuel inlet connector (20).
Press it in until you feel the O-ring clicks
in.
Install it in place temporarily using retain-
ing nut (19).
Retaining nut:
14.7 ± 5.0 Nm {1.5 ± 0.51 kgm}
4) Tighten the injector holder mounting bolt.
Holder mounting bolt:
1st time:
9.8 ± 2.0 Nm {1.0 ± 0.2 kgm}
2nd time:
40.2 ± 3.9 Nm {4.1 ± 0.4 kgm}
5) Tighten retaining nut (19) of the fuel inlet

connector.
16 PC300, 350-8
Retainer: After installing the rocker arm assembly, adjust

40.2 ± 3.9 Nm {4.1 ± 0.4 kgm} the valve clearance. For details, see "Adjusting
Apply the caulking compound (e) valve clearance".
(hatched section) to retaining nut (19) Rocker arm assembly mounting bolt :
and the cylinder head. 64.7 ± 4.9 Nm {6.6 ± 0.5 kgm}
Caulking compound: Install the injector wiring harness terminal (5) in
GE TOSHIBA SILICON TOSSEAL a direction where it will not interfere with the
381 rocker arm (6) which moves up and down.
6) Tighten the sleeve nut of high-pressure fuel Tighten the injector terminal nut with the follow-
hose (16) sequentially in the order of head ing torque.
side and common rail side. Terminal nut :
Sleeve nut : 1.25 ± 0.25 Nm {0.13 ± 0.03 kgm}
37.3 ± 4 Nm {3.8 ± 0.4 kgm} Tighten the head cover with the following torque.
Head cover mounting nut :
11.8 ± 1.96 Nm {1.2 ± 0.2 kgm}
PC300, 350-8 17
Testing blow-by pressure
Blow-by pressure measurement tools

1 799-201-1504 Blow-by checker
E
2 795-790-3300 Tool (Nozzle)
1. Remove the under cover of the engine block.
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 temper-

ature 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.
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.

18 PC300, 350-8
Testing engine oil pressure 5. Run the engine at the rated output and low idle
and test the oil pressure.
Measuring tools for engine oil pressure

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
6215-81-9710 O-ring
The test point is subject to machine models.
1. Open the engine hood.
2. Remove oil pressure pickup plug (1).
6. After finishing testing, remove the measuring

tools and return the removed parts.
3. Install adapter F3 and nipple (R1/8) [1] of

hydraulic tester F1 to the plug installation posi-
tion.
4. Connect hose of hydraulic tester F1 to nipple [1]

and gauge F2.
PC300, 350-8 19
Testing fuel pressure

1
Adapter
6732-81-3170
2 (10 × 1.0 mm R1/8)
G
6215-81-9710 O-ring
3 799-401-2320 Gauge: 1.0 MPa {10 kg/cm 2}
795-790-1500
4 Fuel vacuum gauge
799-201-1201
Fuel pressure shall be checked only in the fol-

lowing 2 circuits. Negative pressure circuit be-
tween the fuel supply connector and feed pump 3) Run the engine at high idle and measure the
inlet and the low pressure circuit from the feed pressure in the fuel negative pressure circuit.
pump through the fuel main filter and up to the If the pressure in the fuel negative pres-
supply pump. sure circuit is in the following range, it is
Measurement in the high-pressure circuit is normal.
not available because of very high pressure Standard pressure value in the fuel nega-
generated in this circuit covering the supply tive pressure circuit (fuel supply connec-
pump through the common rail to the fuel in- tor) Max. 27.1 kPa {Max. 203 mmHg}
jector.
4) After finishing measurement, remove the
1. Measuring pressure in the fuel negative pres- measuring tools and return the removed
sure circuit (fuel supply connector) parts.
1) Remove fuel pressure pickup plug (1) of the Fuel pressure pickup plug:
fuel supply connector. 20 - 22 Nm {2.0 - 2.2 kgm}
2. Measuring pressure in the fuel negative pres-

sure circuit (supply pump)
1) Remove fuel pressure pickup plug (2) of the
supply pump.
2) Connect adapterG2 and fuel vacuum gauge

G4.
2) Connect adapter G2 and fuel vacuum gauge

G4.
20 PC300, 350-8
3) Run the engine at high idle and measure the 3) Measure pressure in the fuel low-pressure
pressure in the fuel negative pressure circuit. circuit when the engine is cranked.
If the pressure in the fuel negative pres- If the pressure in the fuel low-pressure cir-
sure circuit is in the following range, it is cuit (at the fuel filter inlet side) is in the fol-
normal. lowing range, it is normal.
Standard pressure value in the fuel nega- Standard pressure values of the fuel
tive pressure circuit (supply pump) Max. low-pressure circuit (fuel filter inlet side)
33.9 kPa {Max. 254 mmHg} Min. 0.14 MPa {Min. 1.4 kg/cm2}
4) After finishing measurement, remove the In order to protect the starting motor, it
measuring tools and return the removed is prohibited to continue cranking for
parts. more than 20 seconds.
Fuel pressure pickup plug:
20 - 22 Nm {2.0 - 2.2 kgm}
3. Measuring pressure in the fuel low-pressure

circuit (fuel filter inlet side)
1) Remove fuel pressure pickup plug (3) situ-
ated at the fuel main filter inlet side.

measuring tools and return the removed
parts.
20 - 22 Nm {2.0 - 2.2 kgm}
2) Install adapterG2 and nipple [1] of hydraulic

tester G1 and connect them to gauge G3.
PC300, 350-8 21
4. Measuring pressure in the fuel low-pressure

circuit (fuel filter outlet side)
1) Remove fuel pressure pickup plug (4) situ-
ated at the fuel main filter outlet side.

parts.
2) Install adapter G2 and nipple [1] of hydraulic 20 - 22 Nm{2.0 - 2.2 kgm}
tester G1 and connect them to gauge G3.
5. Measuring drop of pressure in fuel lowpres-
sure circuit
1) Remove fuel pressure pickup plug (3) at the
fuel main filter inlet side and fuel pressure
pickup plug (4) at the outlet side.
3) Run the engine at high idle and measure the

pressure of the fuel low-pressure circuit.
If the pressure in the fuel low-pressure cir-
cuit (at the fuel filter outlet side) is in the
following range, it is normal.
Standard pressure values of the fuel 2) Install adapter G2 and nipple [1] of hydraulic
low-pressure circuit (fuel filter outlet side) tester G1 and connect them to gauge G3.
Min. 0.48 MPa {Min. 4.9 kg/cm2}
22 PC300, 350-8
3) Run the engine at high idle and measure 2) Connect M10 computer check fitting G4to
drop of the pressure of the fuel low-pressure gauge G3.
circuit.
Pressure drop in the fuel low-pressure cir-
cuit =
Fuel filter inlet pressure - Fuel pressure
outlet pressure
If the pressure drop in the fuel low-pres-
sure circuit is in the following range, it is
normal.
Standard pressure drop values for the
fuel low-pressure circuit:
Max. 0.14 MPa {Max. 1.4 kg/cm 2}
When the measured pressure drop ex-
ceeded the standard value, clogging of
the fuel filter should be suspected.
3) Turn the starting switch ON, operate fuel lift
pump (5), and measure the fuel lift pump
outlet pressure.
Reference: Fuel lift pump (5) is installed to
cooling plate (7) on the back side of engine
controller (6).

parts.
20 - 22 Nm {2.0 - 2.2 kgm}
6. Testing fuel lift pump outlet pressure (supply The fuel lift pump operates for 30 sec-
pump section) onds after the starting switch is turned ON
1) Remove fuel pressure pickup plug (2) of the and then stops. Measure the pressure
supply pump. while the pump is operating.
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. 34 kPa {0.35 kg/cm2}
If the fuel lift pump outlet pressure is not
in the standard range, perform the follow-
ing checks.
Check that fuel is in the fuel lift pump.
If fuel is not in the fuel lift pump just af-
ter the fuel filter is replaced or a fuel
system part is removed and returned,
operate the fuel lift pump 3 - 4 times
with the starting switch to bleed air
from the fuel circuit and fill the pump
with fuel and then measure the outlet
pressure again.
PC300, 350-8 23
If the fuel lift pump outlet pressure is

not in the standard range while fuel is
in the fuel lift pump, remove check
valve (8) of engine controller cooling
plate (7) and check to see if the valve
is seized.

measuring instruments and return the
removed parts.
20 - 22 Nm {2.0 - 2.2 kgm}
24 PC300, 350-8
Handling during cylinder cut-out Handling during no injection

operation cranking operation
Reduced cylinder mode operation means to run The no injection cranking operation denotes to
the engine with the fuel injectors of 1 or more cyl- crank the engine from the starting motor after
inders disabled electrically to reduce the number setting all cylinders to no injection mode. Follow-
of effective cylinders. The purposes and effects ing describes the objective and effects of this op-
of this operation are as follows. eration.
1. This operation is used to find out a cylinder
which does not output power normally (or, When a machine or engine has been stored for
combustion in it is abnormal). a long period of time, implementing the no injec-
2. If the engine speed and output remain the same tion cranking operation before restarting the
as the normal operation (full-cylinder mode oper- engine lubricates the engine respective parts
ation) when a cylinder is set to noinjection in the and thus helps preventing seizure of the engine.
cylinder cut-out operation, existence of a failure See the section of “Special functions of machine
on the subject cylinder should be suspected. monitor” when turning on the no injection crank-
Followings are the potential causes. ing operation.
Leakage from the cylinder head gasket
Defective injection from the injector
Failure on the piston, piston ring or cylinder
liner
Failure on the valve mechanism (valve oper-
ating system)
Failure in the electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
See the section of “Special functions of ma-
chine monitor” when turning on the cylinder
cut-out operation.
PC300, 350-8 25
Testing fuel return rate and If the engine cannot be started, you
leakage may measure the fuel return rate while
rotating the engine with the starting
motor. Do not rotate for more than 30
Testing tools for leakage from pressure limiter seconds continuously, however, for
and return rate from injector protection of the starting motor.
1 795-790-4800 Hose KIT
2 795-790-6700 Adapter
H
Commercially
3 Measuring cylinder
available
Park the machine in a level ground and lower

the work equipment to the ground.
1. Testing supply pump return rate

1) Disconnect return tube (1) of the supply
pump.
Before starting the work, remove the re-
turn hose from the aftercooler so that it
may not interfere with the inspection.
5) After finishing testing, remove the testing
Joint bolt (M14):
36 ± 5 Nm {3.67 ± 0.51 kgm}
2. Testing leakage from pressure limiter

Before displaying failure code [CA449], its
troubleshooting must be done beforehand.
1) Disconnect joint bolt (3) of return tube (2) of
the pressure limiter.
2) Connect testing tool H1 to the supply pump

side, and insert its tip into measuring cylinder
H3.
3) Connect blocking tool H2 to the fuel return
connector side to prevent leakage of the fuel.
4) 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.
2) Screw in adapter H2 together with return
At low idle Max. 300 cc/30 sec. tube (2), and insert its tip into measuring
At cranking Max. 200 cc/30 sec. cylinder H3.
3) Connect blocking tool H1 to the return tube
joint connection of the cylinder block side to
prevent leakage of the fuel.
26 PC300, 350-8
4) Run the engine at low idle and test the return 4) Run the engine at low idle and test the return
rate from the pressure limiter. rate from the injector.
If the leakage from the pressure limiter is If the return rate from the injector is in the
in the following range, it is normal. following range, it is normal.
At low idle Below 30 droppings/min. At low idle Max. 300 cc/45 sec.
At cranking Max. 100 cc/30 sec.
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.

Joint bolt (M12):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Testing return rate from injector

1) Disconnect return tube (4) of the injector.

Joint bolt (M12):
24 ± 4 Nm {2.45 ± 0.41 kgm}
2) Connect testing tool H1 to the cylinder head

side, and insert its tip into measuring cylinder
H3.
3) Connect blocking tool H2 to the return tube
joint connection of the cylinder block side to
prevent leakage of the fuel.
PC300, 350-8 27
Bleeding air from fuel circuit 3. Fill up the fuel tank with fuel.
4. Keep the starting switch at the ON position for 30

If fuel is used up or if a fuel circuit part is removed seconds and keep it at the OFF position for 10
and installed, bleed air from the fuel circuit using seconds.
the electric priming pump according to the fol-
lowing procedure. 5. Repeat Step 3 above four times.
1. If fuel main filter (1) is removed and installed or 6. Start the engine with the starting motor.
replaced, install it back without filling fuel into the The air in the high-pressure circuit is bled au-
fuel main filter. tomatically if the engine is cranked.
If the engine does not start, there may be still
air in the low-pressure circuit. In this case, re-
peat the above procedure from step 2.
Operating the machine with air left in the fuel
circuit may cause a fuel system error
(CA449,CA559). If either error occurs, run
the engine at low idle after performing the
above steps, and continue engine operation
approximately 3 minutes. When air is bled
from the fuel circuit, engine speed becomes
stable and the error indication disappears.
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 op-
erating priming pump.
Do not add fuel to fuel main filter (1) from out-
side.
28 PC300, 350-8
Checking fuel circuit for leakage 8. Run the engine at high idle and load it.
When checking while the components to be
checked are mounted on the machine, stall
Very high pressure is generated in the high- the torque converter or relieve the hydraulic
pressure circuit of the fuel system. If fuel pump.
leaks while the engine is running, it is dan-
gerous since it can catch fire. 9. Inspect the fuel piping and devices for fuel
After testing the fuel system or removing its leakage.
parts, test it for fuel leakage according to the Check mainly around the high-pressure cir-
following procedure. cuit parts coated with the color checker for
Clean and degrease the engine and the parts fuel leakage.
around it in advance so that you can test it easily If any fuel leakage is detected, repair it and
for fuel leakage. check again from step 1.
If no fuel leakage is detected, check is com-
1. Spray color checker (developer) over the fuel pleted.
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
Check mainly around the high-pressure cir-
cuit parts coated with the color checker for
fuel leakage.
If any fuel leakage is detected, repair it and
check again from step 1.
4. Run the engine at low idle.

leakage.
fuel leakage.
6. Run the engine at high idle.

leakage.
fuel leakage.
PC300, 350-8 29
Testing and adjusting air

compressor belt tension
Inspection
Test belt deflection amount (a) when depressing the
mid point between the fan pulley and the compres-
sor pulley with your finger.
Belt depressing force:
58.8 N {6 kg} or equivalent
Adjustment
If the belt deflection amount is not proper, adjust
it in the following manner.
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).
3. Tighten mounting bolt (2) of compressor bracket

(1).
Check the belt tension again after the adjust-
ment.
30 PC300, 350-8
Replacing fan belt

3. Replace the fan belt (4).
The auto-tensioner is provided for the fan belt. Check each pulley for breakage and crack.
Thus, testing and adjustment of the belt is usual-
ly not necessary.
Disconnect air conditioner compressor belt be-
fore replacing the fan belt.
Stop the machine on a level ground and low-

er the work equipment to the ground.
1. Open engine hood and remove fan belt cover (1)

and fan guard (2).
2. Insert wrench (a) to the portion (A) (width across

flats T 12.7 mm) of the tensioner assembly (3),
and rotate it to the direction of the arrow to
decrease the fan belt (4) tension.
Make sure that the wrench is secured at
the portion (A) of the tensioner assembly
(3) before rotating it. (The spring of the
tensioner assembly (3) is strong. If the
wrench is loosely inserted, the wrench
may accidentally come off while being ro-
tated and it is extremely dangerous.)
After removing the fan belt (4), return the
tensioner assembly (3) slowly with care.
Be careful not to get your fingers caught
between the pulley and fan belt (4) during
work.
PC300, 350-8 31
Replacing alternator belt

3. Replace the alternator belt (6).
The auto-tensioner is provided for the alternator Check each pulley for breakage and crack.
belt. Thus, testing and adjustment of the belt is
usually no necessary.
Disconnect air conditioner compressor belt be-
fore replacing the fan belt.
Stop the machine on a level ground and low-

er the work equipment to the ground.
1. Open engine hood and remove fan belt cover (1)

and fan guard (2).
2. Insert wrench (a) to the portion (B) (width across

flats T 12.7 mm) of the tensioner assembly (5),
and rotate it to the direction of the arrow to
decrease the alternator belt (6) tension.
Make sure that the wrench is secured at
the portion (B) before rotating it. (The
spring of the tensioner assembly (5) is
strong. If the wrench is loosely inserted,
the wrench may accidentally come off
while being rotated and it is extremely
dangerous.)
After removing the alternator belt (1), re-
turn the tensioner assembly (5) slowly
with care.
Be careful not to get your fingers caught
between the pulley and alternator belt (6)
during work.
32 PC300, 350-8
Testing clearance in swing circle

bearings
Swing circle bearing clearance measurement

tool
Mark Part No. Part Name

Commercially Dial gauge
J
available
Follow the steps explained below when measur-

ing clearance in the swing circle bearing on the
actual machine. 4. Hold the arm nearly perpendicular to the ground,
Be careful not to put a hand or foot under the and lower the boom until the track shoes will be
undercarriage, while taking measurement. lifted at the machine front.
The upper structure is raised at the front and
1. Fasten dial gauge J to swing circle outer race (1) lowered at the rear at that time.
or inner race (2), and contact the probe against
the end surface of inner race (2) or outer race (1) 5. Read the value indicated by dial gauge J in this
on the opposite side. condition.
Set dial gauge J at the machine front or rear The value indicated by dial gauge J repre-
side. sents the clearance in the bearings.
2. Keep the work equipment in the max. reach 6. Return the machine to the posture in Item 2
posture and keep the height of the bucket teeth above, and confirm dial gauge J reading returns
tip level with the lower height of the revolving to zero.
frame. If zero value is not indicated, repeat the steps
The upper structure is lowered at the front in Items 3 through 5.
and raised at the rear at that time.
3. Set dial gauge to the zero point.
PC300, 350-8 33
Testing and adjusting track shoe Adjustment

tension If the track shoe tension is not proper, adjust it in
the following manner.
Inspection 1. When the tension is too strong

1. Travel the machine forward by the length of track Loosen valve (1) to discharge the grease.
on ground with the engine at low idle and then Do not loosen the valve more than 1 turn.
stop the machine slowly. Otherwise, the valve may jump out be-
cause of the high-pressure grease inside.
2. Place straight bar [1] on the track shoe between
the idler and the 1st carrier roller. 2. When the tension is too weak
L beam is recommended for bar [1] because Push in grease through grease fitting (2).
of its deflection-free nature. If the normal track shoe tension is not re-
stored even after greasing, move the ma-
3. Measure maximum clearance (a) between bar chine slowly back and forth.
[1] and the track shoe.
Standard clearance (a): 10 - 30 mm
34 PC300, 350-8
Testing and adjusting oil pressure 2) Fit nipple L2 and connect it to oil pressure
in work equipment, swing and gauge [1] of hydraulic tester L1.
travel circuit Use the oil pressure gauge with capacity
60 MPa {600 kg/cm 2}.
Testing and adjusting tools for hydraulic oil pres-

sure in hydraulic circuit for work equipment,
swing and travel

1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Checkup of the oil pressure in the work equip-

ment, swing, and travel circuits (pump discharge
pressure) is also available from the monitoring
function of the machine monitor (Special func-
tions of machine monitor). 3) Start the engine and keep it running until the
hydraulic oil temperature rises to the oper-
Measurement ating range.
1. Preparation work
Lower the work equipment to the ground
and, after stopping the engine, release re-
sidual pressure in the piping by operating
the control lever several times. Then loos-
en the oil filler cap gradually to release
pressure inside the tank.
1) Remove hydraulic oil pressure measuring
plugs (1) and (2).
Plug (1): For the front pump circuit (situat-
ed in the rear side of the machine)
Plug (2): For the rear pump circuit (situat-
ed in the front side of the machine)
2. Combination of pump, actuator, and valve

Care must be exercised when the oil from the
pump is diverted since, at this time, the actu-
ators of the front pump and rear pump work
independently, relieving different valves.
When the work equipment circuit or swing cir-
cuit is relieved singly, the oil of the pumps is
diverted.
The actuators in the table are arranged in the
order when the control valve is seen from the
front of the machine.
PC300, 350-8 35
Pump Actuator Valve to be relieved When the boom LOWER is selected, the
(Unload) F unload valve relief pressure is lower than the main re-
Service Safety valve lief pressure.
Boom Hi Arm Hi F main relief valve When the boom LOWER is selected,
Front
Bucket F main relief valve
pump turning off the machine push-up switch in-
L.H travel F main relief valve
RAISE: R main relief valve troduces the low-pressure relief pressure
Boom Lo and turning it on introduces the high-pres-
LOWER: Safety valve
Swing Swing motor safety valve sure relief pressure.
Rear R.H travel R main relief valve
pump Arm Lo R main relief valve 5. Measurement of swing relief pressure
(Unload) R unload valve 1) Start the engine and move the swing lock
switch to the ON position.
3. Measurement of unload pressure 2) Measure hydraulic oil pressure when the
1) Start the engine. engine is running at high idle and the swing
2) Measure hydraulic oil pressure, when the circuit is relieved.
engine is running at high idle and all the Hydraulic oil pressure when the swing
control levers are moved to the NEUTRAL motor safety valve is relieved is dis-
position. played.
Hydraulic oil pressure when the unload The relief pressure of the swing motor is
valve unloads is displayed. lower than the main relief pressure.
4. Measurement of work equipment relief pres- 6. Measurement of travel circuit relief pressure
sure 1) Start the engine, and lock the travel.
1) Start the engine and move the cylinder to be Insert pin [2] between the sprocket and
measured to its stroke end. the track frame to positively lock the
2) Measure hydraulic oil pressure when the travel circuit.
cylinder is relieved while the engine is
running at high idle.
Except when the boom LOWER is select-
ed, the pressure at which the main relief
valve was relieved is displayed.
ed, releasing the power max. switch intro-
duces the low-pressure relief pressure
and pushing this switch introduces the
high-pressure relief pressure.
ed, keep the swing lock switch in the OFF
position during the inspection. If it is
moved to the ON position, hydraulic oil
pressure is turned to high relief pressure, 2) Measure the pressure when the engine is set
as the constant 2-stage relief valve is to high idle and the travel circuit is relieved.
moved to the ON position. Hydraulic oil pressure with the main relief
When the boom LOWER is selected, the valve in relief condition is displayed. In
pressure at which the safety valve was re- the travel circuit relief, the pressure is
lieved is displayed. high pressure relief all the time.
36 PC300, 350-8
Adjustment 3) Check the pressure again after the adjust-

Adjustment of the unload valve is not available. ment, following the aforementioned steps for
measurement.
1. Adjustment of main relief pressure Connect the pilot hose when measuring
When the relief pressure of the work equip- the oil pressure.
ment circuit or travel circuit is abnormal, ad-
just main relief valves (3) and (4) according to 2. Adjustment of boom LOWER relief pressure
the following procedure. (on the side where high pressure is set)
(3): For the front pump circuit When the high-pressure relief pressure for
(4): For the rear pump circuit the boom LOWER is not normal, adjust the
As for the main relief valve, be sure to adjust high pressure side of the safety and suction
its low-pressure relief pressure alone (adjust- valve (7) for the boom LOWER in the follow-
ing the low-pressure relief pressure automat- ing procedure.
ically sets the high-pressure relief pressure, The high-pressure relief pressure mode de-
too.). notes the state in which the machine push-up
When the low-pressure relief pressure is switch is turned on, disabling to apply the pi-
turned on, the 2-stage relief valve is OFF and lot pressure to the switching port.
thus the pilot pressure is not applicable to the
switching port.
1) Disconnect the pilot hose.

2) Loosen locknut (8) and turn holder (9) to
1) Disconnect the pilot hose. adjust the relief pressure.
2) Loosen locknut (5) and turn holder (6) to Turning the holder clockwise increases
adjust the relief pressure. the pressure. Turning it counterclockwise
Turning the holder clockwise increases decreases the pressure.
the pressure. Turning it counterclockwise Pressure adjustable from a single turn of
decreases the pressure. the holder:
Quantity of adjustment per turn of holder: Approx. 21.8 MPa {Approx.222 kg/cm 2}
Approx.20.5 MPa {Approx.209 kg/cm2} Locknut:
Locknut: 93 - 123 Nm {9.5 - 12.5 kgm}
49.0 - 58.8 Nm {5 - 6 kgm}
PC300, 350-8 37
3) Check the pressure again after the adjust- 4. Adjustment of swing relief pressure
ment, following the aforementioned steps for If the swing relief pressure is not normal, ad-
measurement. just the swing motor safety valve (12) in the
Connect the pilot hose when measuring following manner.
the oil pressure.
3. Adjustment of 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 adjust-
ment is made of the high pressure setting
side, adjust the low pressure side of the safe-
ty and suction valve for the boom LOWER in
the following procedure.
The low-pressure relief pressure mode de-
notes the state in which the machine push-up
switch is turned off, disabling to apply the pi-
lot pressure to the switching port.
1) Disconnect the pilot hose. 1) Loosen locknut (13) and turn adjustment
2) Loosen locknut (10) and turn holder (11) to screw (14) to adjust the relief pressure.
adjust the relief pressure. Turning the holder clockwise increases
Turning the holder clockwise increases the pressure. Turning it counterclockwise
the pressure. Turning it counterclockwise decreases the pressure.
decreases the pressure. Quantity of adjustment per turn of adjust-
Pressure adjustable from a single turn of ing screw:
the holder: Approx. 4.70 MPa {Approx. 47.9
Approx. 21.8 MPa{Approx. 222 kg/cm2} kg/cm2}
Locknut: Locknut:
78 - 93 Nm {8.0 - 9.5 kgm} 147 - 196 Nm {15 - 20 kgm}
2) Check the pressure again after the adjust-

3) Check the pressure again after the adjustment, following the aforementioned steps for
ment, following the aforementioned steps for measurement.
measurement.
Connect the pilot hose when measuring
the oil pressure.
38 PC300, 350-8
Testing and adjusting control 3. Start the engine and keep it running until the
circuit oil pressure hydraulic oil temperature rises to the operating
range.
Control circuit oil pressure testing and adjusting 4. Measure hydraulic oil pressure, when the engine
tools is running at high idle and all the control levers
are moved to the NEUTRAL position.
1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measurement
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the
oil filler cap gradually to release pressure in-
side the tank.
1. Remove oil pressure measurement plug (1).

5. Remove the measurement tool after the
It is not allowed to adjust the relief valve of
the control circuit source pressure.
2. Fit nipple L2 and connect it to oil pressure gauge

[1] of hydraulic tester L1.
Use the oil pressure gauge with capacit 6.0
MPa {60 kg/cm 2}.
PC300, 350-8 39
Testing and adjusting pump PC

control circuit oil pressure
Pump PC control circuit oil pressure testing and

adjusting tools

1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measurement
Measurement of the oil pressure in the pump PC
control circuit shall be conducted after making 2) Fit nipple L2 and connect it to oil pressure
sure that oil pressure of the work equipment, gauge [1] of hydraulic tester L1.
swing, and travel circuits as well as basic pres- Use the oil pressure gauge with capacity
sure of the control circuit is normal. 60 MPa {600 kg/cm2}.
side the tank.
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
PC valve output pressure (servo piston inlet
pressure) is measured along with that of the
pump discharge pressure and the result of
the two is compared to each other.
1) Remove oil pressure measurement plugs (1),
(2), (3) and (4).
(1): For the front pump discharge pres-
sure (situated in the rear side of the ma-
chine)
(2): For the rear pump discharge pressure
(situated in the front side of the machine)
(3): For the front pump PC valve output
pressure
(4): For the rear pump PC valve output
pressure
40 PC300, 350-8
3) Start the engine and keep it running until the 2. Measurement of PC-EPC valve output pres-
hydraulic oil temperature rises to the oper- sure
ating range. 1) Remove oil pressure measurement plug (5).
The plug is installed in the front side of the
machine.
4) Measure the pump discharge pressure and

PC valve output pressure (pressure at servo
piston inlet) at the same time after setting 2) Fit nipple L2 and connect it to oil pressure
following conditions with the engine running gauge [1] of hydraulic tester L1.
at high idle. Use the oil pressure gauge with capacity
Working mode: P-mode 6.0 MPa {60 kg/cm2}.
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 be-
tween the pump discharge pressure and
PC valve output pressure (servo piston
input pressure) reaches the following val-
ues, both pressures are judged normal.
Measured oil pres- Ratio between oil

sure pressures
Pump discharge
1
pressure
PC Valve output 3) Start the engine and keep it running until the
Approx. 3/5
pressure hydraulic oil temperature rises to the oper-
ating range.
If there is any abnormality with PC valve
or servo piston, the PC valve output pres-
sure (servo piston input pressure) be-
comes identical with the pump discharge
pressure or comes to neighborhood of 0
pressure.
PC300, 350-8 41
4) Measure the hydraulic oil pressure with all

the control levers kept in the NEUTRAL posi-
tion and the engine running at high idle and
at low idle.
You can assume that the PC-EPC valve
output pressure is normal when the fol-
lowing changes are observed.
Engine Control lever Hydraulic oil

speed pressure
2.9 MPa
Low idle
{30 kg/cm2}
Neutral
0 MPa {0
High idle
kg/cm2}
2. After the adjustment, make sure that the PC
Adjustment valve output pressure (servo piston inlet pres-
When a trouble on the PC valve is suspected be- sure) is normal using the measurement steps
cause of the following phenomena, adjust PC explained earlier.
valves (6) and (7) in the following manner.
As workload increases, the engine rpm
sharply drops.
The engine rpm is normal but the work equip-
ment speed is low.
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 ab-
sorption torque.
Following indicates the range of adjustment
available from the adjusting screw.
Counterclockwise: Within 1 turn
Clockwise: Within 1/2 turn (Within 180 °)

Locknut: 27 - 34 Nm {2.8 - 3.5 kgm}
42 PC300, 350-8
Testing and adjusting pump LS

control circuit oil pressure
Pump LS control circuit oil pressure testing and

adjusting tools

1
M 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-1340 Differential pressure gauge
Measurement
Measurement of the oil pressure in the pump LS
control circuit shall be conducted after making
sure that oil pressure of the work equipment,
swing, and travel circuits as well as basic pres-
sure of the control circuit is normal.
side the tank.
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
Measure the LS valve output pressure (servo 2) Fit nipple M2 and connect it to oil pressure
piston inlet pressure) and pump discharge gauge [1] of hydraulic tester L1.
pressure simultaneously tocompare them. Use the oil pressure gauge with capacity
1) Remove oil pressure measurement plugs (1), 60 MPa {600 kg/cm 2}.
(2), (3) and (4).
(1): For the front pump discharge pres-
sure (situated in the rear side of the ma-
chine)
(3): For the front pump LS valve output
pressure
(4): For the rear pump LS valve output
pressure
PC300, 350-8 43
Measurement conditions and judgment

method:
When the ratio between the pump
discharge pressure and LS valve output
pressure (servo piston input pressure)
reaches the following values, both pres-
sures are judged normal.
Lever operating condition

Travel lever at
All levers and half stroke posi-
pedals in neutral tion (Travel with
no load)
Pump dis-
3) Start the engine and push up the track shoe Set measured
charge pres-
valve as 1
on the measurement side using work equip- sure
Almost the same
ment.
pressure
When measuring the front circuit: Left LS valve out- Approx. 3/5 of
track shoe put pressure above pressure
When measuring the rear circuit: Right
track shoe
Provide a working area of sufficient 6) Remove the measurement tools after the
space, as the raised track shoe will be measurement, and make sure that the
idly rotated. machine is back to normal condition.
4) Increase the hydraulic oil temperature to the
operating range.

LS valve output pressure (pressure at servo
piston inlet) at the same time after setting
following conditions with the engine running
at high idle.

Work equipment, swing and travel: When
all levers are at neutral and when travel
lever is at half stroke (one side of travel is
at idle)
Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
44 PC300, 350-8
2. Measurement of LS differential pressure 2) Fit nipple M2 and connect it to oil pressure

LS differential pressure can be obtained by gauge [1] or differential pressure gauge M3
measuring the pump discharge pressure and of hydraulic tester M1.
LS pressure (actuator load pressure) at the When using a differential pressure gauge:
same time and computing the difference be- Connect pump discharge pressure to the
tween the 2 pressures. high pressure side and LS pressure to the
1) Remove oil pressure measurement plugs (1), low pressure side.
(2), (5) and (6). When using an oil pressure gauge:
(1): For the front pump discharge pres- Use the oil pressure gauge with capacity
sure (situated in the rear side of the ma- 60 MPa {600 kg/cm 2}.
chine)
(5): For the front pump LS pressure (situ-
ated in the rear side of the machine)
(6): For the rear pump LS pressure (situ-
ated in the rear side of the machine)
3) Start the engine and push up the track shoe

on the measurement side using work equip-
ment.
When measuring the front circuit: Left
track shoe
When measuring the rear circuit: Right
track shoe
Provide a working area of sufficient
space, as the raised track shoe will be
idly rotated.
PC300, 350-8 45
4) Increase the hydraulic oil temperature to the 3. Measurement of LS-EPC valve output pres-
operating range. sure
1) Remove oil pressure measurement plug (7).
The plug is installed on the rear pump.

LS pressure (actuator load pressure) at the
same time after setting the following condi- 2) Fit nipple M2 and connect it to oil pressure
tions with the engine running at high idle. gauge [1] of hydraulic tester M1.
Working mode: P-mode Use the oil pressure gauge with capacity
Travel speed: Hi 6.0 MPa {60 kg/cm2}.
Work equipment, swing and travel: When
all levers are at neutral and when travel
lever is at half stroke (one side of travel is
at idle)
Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
Calculation of LS differential pressure:
LS differential pressure = Pump
discharge pressure - LS pressure
If LS differential pressure is in the follow-
ing conditions, it is judged normal.
LS differential
Lever operation
pressure
Unload pressure 3) Start the engine and keep it running until the
When all levers are set hydraulic oil temperature rises to the oper-
(See standard
to neutral
value) ating range.
Maximum LS
Travel lever set at half
differential pres-
stroke
sure

46 PC300, 350-8
4) Measure the oil pressure when the engine is Adjustment

running at high idle and the travel speed When the LS differential pressure is not normal,
switch and travel control lever are operated. adjust LS valves (8) and (9) in the following pro-
If LS-EPC valve output pressure changes cedure.
to the following values, the pressure is
normal.
Travel Travel con-

Oil pressure
speed trol lever
Approx. 1.4 MPa
Lo Neutral {approx. 14
kg/cm2}
Fine opera-
Hi 2
tion (Note) 0 MPa {0 kg/cm }
Note: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).
1. Loosen locknut (10) and turn adjustment screw
5) Remove the measurement tool after the (11) to adjust the differential pressure.
measurement, and make sure that the Adjustment screw
machine is back to normal condition. Turned to the right, the differential pres-
sure is increased.
Turned to the left, the differential pressure
is decreased.
Quantity of adjustment per turn of adjusting
screw:
Quantity of pressure adjustment (LS differen-

tial pressure) 1.3 MPa {13.3 kg/cm2}
Lock nut: 49 - 64 Nm {5 - 7 kgm}
2. After the adjustment, confirm that LS differential

pressure is normal, following the steps for
measurement explained earlier.
PC300, 350-8 47
Testing solenoid valve output

pressure
Solenoid valve output pressure measurement

tools

1
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 af- 2. Fit adapter N2 or N3 and then connect hose
ter confirming that the control circuit source pres- currently disconnected.
sure is normal.
Lower the work equipment to the ground 3. Fit nipple [1] of hydraulic tester N1 and then
and, after stopping the engine, release resid- connect it to oil pressure gauge [2].
ual pressure in the piping by operating the Use the oil pressure gauge with capacity 6.0
control lever several times. Then loosen the MPa {60 kg/cm2}.
side the tank.
1. Disconnect the hoses of solenoid valve to be

measured at the outlet side.
No Target solenoid valves of measurement

1 PPC lock solenoid valve
2 Travel junction solenoid valve
3 Merge-divider solenoid valve
4 Travel speed switching solenoid valve
5 Swing holding brake solenoid valve
6 Machine push up solenoid valve
7 2-stage relief solenoid valve
Hose (1) is installed in the back side of oper- 4. Start the engine and keep it running until the
ator's cab, and hoses (2) through (7) are in- hydraulic oil temperature rises to the operating
stalled at the center of revolving frame. range.
48 PC300, 350-8
5. Run the engine at full throttle, then turn each When each output pressure shows the fol-
solenoid valve ON or OFF by operating the lowing values, it is judged normal.
control levers and switches, and measure the
pressure. Solenoid valve Output pressure
For conditions for turning each solenoid OFF (De-energized) 0 MPa {0 kg/cm 2}
valve ON or OFF, refer to the ensuing “Table ON (Energized) 3 MPa {30 kg/cm2}
for functioning conditions” for each solenoid
valve.
You can check operation of the solenoid 6. Remove the measurement tools after the
valves from the monitoring function of the measurement, and make sure that the machine
monitor panel (Special Function of Machine is back to normal condition.
Monitor).
Table for functioning conditions - PPC lock solenoid valve
Func-
Functioning conditions
tion
Lock OFF
Lock lever
Released ON
Table for functioning conditions - Machine push up solenoid valve
Opera-
Operating condition
tion
ON ON
Machine push-up switch
OFF OFF
Table for functioning conditions - Swing holding brake solenoid valve
Func-
tion
When all signals are turned
OFF
OFF
Signal of work equipment, swing and travel
When one of the signals is
ON
turned ON
PC300, 350-8 49
Table for functioning conditions - Travel junction solenoid valve
Func-
tion
When the travel steering signal is ON
When travel steering When F or R pump pressure is 34.3 MPa {350 ON
When the travel steering signal is independently oper-
OFF ated kg/cm2}
Any other condition than above OFF
Table for functioning conditions - Travel speed shifting solenoid valve
Func-
tion
When the overheat 2nd setting is ON
When the fuel dial is at 1,200 rpm or lower
When the travel speed switch is at Lo
When signal of the travel is OFF OFF
When F or R pump pressure is 32.3 MPa {330
When the travel speed switch is
When signal of the kg/cm2}
at Mi or Hi
travel is ON When F or R pump pressure is 18.6 MPa {190
kg/cm2} ON
Any other condition than above
Table for functioning conditions - 2-stage relief solenoid valve
Opera-
Operating condition
tion
Overheat 1st setting is ON
OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L mode is selected
ON
Boom LOWER signal is ON
Signals other than swing independent signal are
P or E mode is selected Left knob switch is ON ON
Swing independent signal is ON
OFF
Other than above conditions
50 PC300, 350-8
Table for functioning conditions - Merge-divider solenoid valve
Func-
tion
When B mode is turned on When the service signal is ON
When independent signal of the travel is ON
When F or R pump pressure is 19.6 MPa {200 ON
When any
mode other 2
kg/cm } or above
When signals than L mode When F or R pump pressure is 14.7 MPa {150
of the work OFF
When signal of the travel is is turned on kg/cm2} or lower
equipment
OFF When F or R pump pressure is 16.7 MPa {170
and swing are ON
ON kg/cm2} or above
L mode
When F or R pump pressure is 11.8 MPa {120
kg/cm2} or lower OFF
Any other condition than above
PC300, 350-8 51
Testing PPC valve output pres- 2. Fit nipple [1] of the hydraulic tester P and then
sure connect it to oil pressure gauge [2].
Use the oil pressure gauge with capacity 6.0
MPa {60 kg/cm2}.
PPC valve output pressure measurement tools

P
Measure PPC valve output pressure after con-

firming that control circuit original pressure is
normal.
1. Remove PPC hydraulic switches (1) to (10) of

the target circuit of measurement.
Circuit to be mea- Circuit to be mea-

No No
sured sured
1 Boom RAISE 6 Bucket DUMP 3. Start the engine and keep it running until the
2 Boom LOWER 7 Swing right hydraulic oil temperature rises to the operating
3 Arm IN 8 Swing left range.
4 Arm OUT 9 Travel (black)
5 Bucket CURL 10 Steering (red)
(1) through (8) are installed in the PPC relay

block, and (9) and (10) are installed in the
back side of operator cab.
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.
Lever operation Hydraulic oil pressure

When set to NEU-
TRAL 0 MPa {0 kg/cm2}
Almost the same with the
control circuit source
At full stroke
pressure (refer to the
standard value table)

52 PC300, 350-8
Adjusting play of work equipment

and swing PPC valves
If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
1. Remove the work equipment and swing PPC

valve assembly.
2. Remove boot (1).
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.
Locknut: 69 - 88 Nm {7 - 9 kgm}
5. Install boot (1).
6. Install the work equipment and swing PPC valve

assembly.
PC300, 350-8 53
Inspecting locations of hydraulic 2. Inspection of arm cylinder

drift of work equipment 1) Operate the arm cylinder to move the arm to
the position 100 mm before the digging
stroke end, and stop the engine.
If hydraulic drift occurred on the work equipment
(cylinder), check to see if the cause is on the cyl-
inder packing side or control valve side accord-
ing to the following procedure.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Shift the arm control lever to IN 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
starting switch in the ON position.
If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator
2) When inspecting the boom cylinder, shift the again.
boom control lever to RAISE side and when
inspecting the bucket cylinder, shift the [Reference] When the cause of the hydraulic
bucket control lever to CURL side. drift is in the defective packing, following
If, as the result, drifting speed increases, explains why such occurred.
failure on the cylinder packing should be 1] If the work equipment is set to the above
suspected. posture (holding pressure applied to the
If the speed remains unchanged, failure on bottom end), the oil at the bottom end
the control valve should be suspected. leaks to the head end. However, the
Operate the control lever with the engine volume at the head end is smaller than
starting switch in the ON position. the volume at the bottom end by the
If pressure in the accumulator has volume of the rod end, so the internal
dropped, run the engine for approx. 10 pressure at the head end increases
seconds to charge the accumulator because of the oil flowing in from the
again. bottom end.
54 PC300, 350-8
2] If the internal pressure of the head end 4. Inspection of PPC valve

increases, the pressure at the bottom end Measure the amount of hydraulic drift of the work
also rises in proportion to this and equipment when the accumulator is charged
balanced at certain level (this level with pressure and the lock lever is put to the
depends on the volume of leakage). As LOCK and FREE positions.
the pressure is balanced, the drifting Operate the control lever with the engine
speed is decreased. starting switch in the ON position.
3] If the lever is then operated according to If pressure in the accumulator has dropped,
the procedure given above, the circuit at run the engine for approx. 10 seconds to
the head end is opened to the drain circuit charge the accumulator again.
(the bottom end is closed by the check If the lock and free position cause any differ-
valve), so the oil at the head end flows to ence in the hydraulic drift volume, the PPC
the drain circuit and the downward move- valve is defective (internal failure).
ment becomes faster.
3. Inspection of boom lock valve

1) Set the work equipment at the maximum
reach and the boom top horizontal. Then
stop the engine.
Lock the work equipment control le-
vers and release the pressure inside
the hydraulic tank.
Do not allow anyone to come under the
work equipment during the work.
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 accompa-
nying hydraulic drift of the work equip-
ment, failure on the boom lock valve
should be suspected (loose contact).
PC300, 350-8 55
Releasing remaining pressure in Testing oil leakage amount

hydraulic circuit
1. Measurement of oil leakage amount from
When disconnecting the piping routed from boom cylinder
the hydraulic cylinder and the hydraulic mo- 1) Start the engine and keep it running until the
tor to the control valve, release the residual hydraulic oil temperature rises to the oper-
pressure in the circuit according to the fol- ating range. Then extend the boom cylinder
lowing procedure. to the stroke end.
The swing motor circuit and travel motor circuit Release the pressure remaining in the
are free from residual pressure. However, since piping referring to “Releasing remain-
these circuits are affected by the pressure inside ing pressure in hydraulic circuit”.
the hydraulic tank, the operation up to opening of 2) Disconnect hose (1) on the cylinder head end
the hydraulic tank cap must be implemented. and block the hose end with a plate.
Be careful not to disconnect the hose
1. Stop the engine and then gradually loosen the oil at the cylinder bottom end.
filler cap of the hydraulic tank to release the 3) Run the engine at high idle and relieve the
pressure in the tank. boom circuit by raising the boom.
4) Continue this condition for 30 seconds, then
2. Turn the engine starting switch to the ON posi- measure the oil leakage amount for 1 minute.
tion and operate the control levers several times.
Power must be conducted to PPC lock valve,
thus the starting switch must be set to ON po-
sition prior to the lever operation.
When the levers are operated 2 - 3 times, the
pressure stored in the accumulator is re-
moved.
3. Start the engine, run at low idle for approx. 10

seconds to accumulate pressure in the accumu-
lator, then stop the engine.
4. Repeat the steps in Item 2 to 3 above several

times.
2. Measurement of oil leakage amount from arm

cylinder
ating range. Then extend the arm cylinder to
the IN stroke end.
Release the pressure remaining in the
piping referring to “Releasing remain-
ing pressure in hydraulic circuit”.
2) Disconnect hose (2) on the cylinder head end
and block the hose end with a plate.
Be careful not to disconnect the hose
at the cylinder bottom end.
3) Run the engine at high idle and relieve the
arm circuit by moving the arm IN.
56 PC300, 350-8
4) Continue this condition for 30 seconds, then 4. Measurement of oil leakage amount from
measure the oil leakage amount for 1 minute. swing motor
1) Disconnect drain hoses (4) and install the oil
stopper plug in the hoses.
2) Turn the swing lock switch to the ON position.
3) Run the engine at high idle, relieve the swing
circuit, and measure the oil leakage.
Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
After measuring 1 time, swing 180 °, and
then measure again.

3. Measurement of oil leakage amount from

bucket cylinder
ating range. Then extend the bucket cylinder
to the CURL stroke end.
Release the pressure remaining in the 4) After the measurement, make sure that the
piping referring to “Releasing remain- machine is back to normal condition.
ing pressure in hydraulic circuit”.
2) Disconnect hose (3) on the cylinder head end 5. Measurement of oil leakage amount from
and block the hose end with a plate. travel motor
Be careful not to disconnect the hose 1) Take off the travel motor cover.
at the cylinder bottom end. 2) Start the engine, and lock the travel.
3) Run the engine at high idle and relieve the Insert pin [1] between the sprocket and
bucket circuit by moving the bucket CURL. the track frame to positively lock the
4) Continue this condition for 30 seconds, then travel circuit.
measure the oil leakage amount for 1 minute.
5) After the measurement, make sure that the

PC300, 350-8 57
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.
Wrong operation of the lever can
cause an accident. Accordingly, make
signs and checks securely.
Start measuring the oil leakage 30 sec-
onds after relieving is started and mea-
sure for 1 minute.
Measure several times, moving the motor
a little (changing the position of the valve
plate and cylinder and that of the cylinder
and piston) each time.
5) After the measurement, make sure that the

58 PC300, 350-8
Bleeding air from various parts

Air bleeding procedure
Air bleeding items 1 2 3 4 5 6
Bleeding air Bleeding air Bleeding air
Starting Bleeding air
Contents of work from hydrau- from swing from travel Operation
engine from cylinder
lic pump motor motor
Replacement of hydraulic oil
Cleaning of strainer (See note) (See note)
Replacement of return filter ele-
ment
Replacement and repair of hy-
draulic pump
Removal of suction piping
Replacement and repair of con-
trol valve
Replacement of cylinder
Removal of cylinder piping
Replacement of swing motor
Removal of swing motor pipe
Replacement of travel motor
and swivel
Removal of travel motor and
swivel piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Bleeding air from hydraulic pump 2. Bleeding air from hydraulic cylinder
1) Loosen air bleeder (1) and check that oil 1) Start the engine and keep running at low idle
oozes out through the air bleeder. for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeder (1). the engine running at low idle.
Air bleeder: Stop the piston approximately 100 mm in
7.8 - 9.8 Nm {0.8 - 1.0 kgm} front of the stroke end so that it may not
Precautions on starting engine: be relieved.
When starting the engine after above 3) While running the engine at high idle,
operations, be sure to run the engine at perform step 2).
low idle for 10 minutes. If the engine 4) Set the piston rod to the stroke end at low idle
coolant temperature is low and an auto- and allow it to relieve.
matic engine warming-up function is 5) For bleeding air from the arm cylinder and
relied on, use the fuel dial, when it bucket cylinder, follow the same steps
becomes necessary to cancel it. explained in Item 2) through 4) above.
In case a cylinder is replaced with new
one, it is advised to bleed air from the new
one before mounting the work equipment.
It is especially so with the boom cylinder,
because its rod does not extend to the
stroke end of LOWER side, after the work
equipment is mounted.
PC300, 350-8 59
3. Bleeding air from swing motor

1) Start the engine and run it at low idle.
2) Swing slowly to bleed air.
4. Bleeding air from travel motor

1) Start the engine and run it at low idle.
2) Loosen air bleeder (2) and confirm that oil
seeps out from the plug.
3) If the oil seepage is confirmed, tighten air
bleeder (2).
Air bleeder:
27.5 - 35.3 Nm {2.8 - 3.6 kgm}
60 PC300, 350-8
Diode inspection procedures

Check an assembled-type diode (8 pins) and in-
dependent diode (2 pins) in the following man-
ner.
The conduction direction of an assembled-type
diode is as shown in the diagram below.
The conduction direction of an independent di-
ode is shown on the diode surface.
2. When using analog type circuit tester

When the diode range is set, the testing
method is the same as that done by use of
the digital type circuit tester.
1) Switch the testing mode to resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead to the
anode (P) and the black probe (-) to the
cathode (N) of diode.
2] Put the red probe (+) of the test lead to the
cathode (N) and the black probe (-) to the
anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
With the connection 1] above, the pointer
is not moved. It swings, however, when
the connection 2] is employed. Normal
(However, magnitude of the pointer's
move (indicating the resistance value)
varies depending on the given tester
1. When using digital type circuit tester
model and the measurement range se-
1) Switch the testing mode to diode range and
lected).
confirm the indicated value.
The pointer swings with both the connec-
Voltage of the battery inside is displayed
tions of 1] and 2]: Defective (Internal short
with conventional circuit testers.
circuit)
2) Put the red probe (+) of the test lead to the
The pointer does not swing with both the
anode (P) of and the black probe (-) to the
connections of 1] and 2]: Defective (Inter-
cathode (N) of diode, and confirm the indi-
nal breaking of wire)
cated value.
3) Determine acceptability of the diode from the
indicated value.
Indicated value remains unchanged:
Conduction is absent (Failure)
Indicated value changes: Conduction is
present (Normal) (See Note)
Note: A value between 0.46 V to 0.60 V is
indicated for silicon diodes.
A value between 460 to 600 is indicated
for silicon diodes.
PC300, 350-8 61
Installation and adjustment of

mirrors 1
Retract the mirror into position (C) when

transporting the machine.
Retractable mirror (b1): Install at 33 mm

1. Installation of retractable mirrors (from the top of the stay). Install mirror
Install retractable mirrors (a1) and (b1) as stay (4) so that the mirror will be fixed at
shown in the figure. (A) of the 3 stopping positions where the
Retractable mirror (a1): Install at 20 mm mirror is extracted most and at an angle of
(from the bottom of the intermediate stay). 35° to the side of the machine body.
Install mirror stay (1) so that the mirror will If the mirrors are not installed to the cor-
be fixed at (A) of the 3 stopping positions rect positions, they may interfere with the
where the mirror is extracted most and at exterior parts.
an angle of about 13° to the intermediate
stay.
If the mirrors are not installed to the cor-
rect positions, they may interfere with the
exterior parts.
Tightening torque of mirror bolt (5):

4.0 – 5.4 Nm {0.41 – 0.55 kgm}
Tightening torque of mirror stay bolt (6):
15 – 19.6 Nm {1.5 – 2 kgm}
If the tightening torque is low, the bolts
Tightening torque of mirror bolt (2): may be dragged. If the former is too high,
4.0 – 5.4 Nm {0.41 – 0.55 kgm} the body may be broken.
Tightening torque of mirror stay bolt (3):
15 – 19.6 Nm {1.5 – 2 kgm}
If the tightening torque is low, the bolts
may be dragged. If the former is too high,
the body may be broken.
62 PC300, 350-8
Retract the mirror into position (C) when

transporting the machine.
2. Adjustment of retractable mirrors

1) Adjust the retractable mirrors at position
(A).
2) With retractable mirrors (a1) and (b1)
open, loosen mirror bolts (1) and (2) and
stay mounting bolts (3) and (4) and adjust
the mirrors so that the operator can see
the right and left rear views best which are
blind corners from the operator’s seat.
Adjust the mirror so that the operator can
see persons (or things 1 m high and about
30 cm in diameter) at the right and left rear
ends of the machine.
Take care not to tighten stay mounting
bolts (3) and (4) (If they are tightened too
strongly, the stay may be broken since it is
made by die-casting).
PC300, 350-8 63
3) Tighten the stay mounting bolts so that the

clearance to the stay mating face will be
even.
64 PC300, 350-8
PC300, 350-8 65
PC300, 350(LC)-8 Hydraulic excavator
Form No. SEN02625-06
©2011 KOMATSU
All Rights Reserved
Printed in Japan 12-11
66

PC350-8 Testing & Adjusting Part1

Uploaded by

Copyright:

Available Formats

PC350-8 Testing & Adjusting Part1

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PC350-8 Testing & Adjusting Part1

Uploaded by

Copyright:

Available Formats

SEN02625-06

30 Testing and adjusting

Tools for testing, adjusting and troubleshooting . ........................................................................................ 3

Tools for testing, adjusting and troubleshooting

Testing and adjusting Sym- Q't

Testing and adjusting Sym- Q't

Testing and adjusting Sym- Q't

Testing and adjusting Sym- Q't

Sketches of special tools

Testing engine speed 3. Measuring high idle speed

5. Measuring the engine speed when 2-pumps

3. Install nipple [1] of boost gauge kit A and

7. Remove the measurement tools after the

4. Start the engine and keep it running until temper-

Testing exhaust gas color 2. Measuring with smoke meter B2

Be careful not to touch any hot part when re-

1. Measuring with handy smoke checker B1

5) Take out the filtering paper and compare it

7) Start the engine and accelerate it suddenly or

1. Remove air intake tube (1).

2. Disconnect blow-by tube (2) and breather tube

Aligning TDC stamp line (a) of gear cover (7)

3. Remove cap (5).

5. After setting No.1 cylinder to the compression

1) Insert clearance gauge C2 to the clearance

Care must be exercised in measuring the

1. Open the engine hood. 6. Remove bracket (9).

2. Remove air intake connector (1).

3. Disconnect harness (2) and remove bracket (3)

7. Disconnect air intake connector (10) and wiring

8. Remove blow-by hose (13) and breather hose

14. Remove holder (21).

15. Remove injector (22).

10. Loosen injector terminal nuts (17) and remove

11. Move the cylinder to be tested to the compres-

12. Remove rocker arm assemblies (18).

22. Rotate the engine with cranking the starting

23. After finishing testing, remove the testing tools

19. Install rocker arm assembly.

20. Adjust the valve clearances.

2) Tighten the injector holder mounting bolt by 3

5) Tighten retaining nut (19) of the fuel inlet

Retainer: After installing the rocker arm assembly, adjust

Testing blow-by pressure

Blow-by pressure measurement tools

1. Remove the under cover of the engine block.

2. Install tool E2 to blow-by hose (1) and connect

3. Start the engine and keep it running until temper-

4. Measure the blow-by pressure at high idle and

5. Remove the measurement tools after the

Measuring tools for engine oil pressure

The test point is subject to machine models.

1. Open the engine hood.

2. Remove oil pressure pickup plug (1).

6. After finishing testing, remove the measuring

3. Install adapter F3 and nipple (R1/8) [1] of

4. Connect hose of hydraulic tester F1 to nipple [1]

Testing fuel pressure

Symbol Part number Part name