SEN01985-15 00 Index and foreword

Table of contents 1
00 Index and foreword
Index SEN01985-15
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4

Foreword and general information SEN01986-02

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36

01 Specification
Specification and technical data SEN01988-01
Specification dimension drawings ............................................................................................... 2
Dimensions.................................................................................................................................. 2
Working ranges ........................................................................................................................... 3
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 10
Table of fuel, coolant and lubricants ............................................................................................ 12

10 Structure, function and maintenance standard

Engine and cooling system SEN01990-00
Engine related parts .................................................................................................................... 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train SEN01991-00
Power train .................................................................................................................................. 2
Swing circle ................................................................................................................................. 3
Swing machinery ......................................................................................................................... 4
Final drive.................................................................................................................................... 6
Sprocket ...................................................................................................................................... 8
Undercarriage and frame SEN01992-00
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................. 4
Carrier roller ................................................................................................................................ 6
Track roller................................................................................................................................... 7
Track shoe................................................................................................................................... 8
Hydraulic system, Part 1 SEN01993-00
Hydraulic equipment layout drawing ........................................................................................... 2
Hydraulic tank and filter............................................................................................................... 4
Hydraulic pump ........................................................................................................................... 6
Hydraulic system, Part 2 SEN01994-01
Control valve ............................................................................................................................... 2
CLSS ........................................................................................................................................... 14
Functions and operation by valve................................................................................................ 18
Merge-divider valve ..................................................................................................................... 33
Attachment circuit selector valve ................................................................................................. 58
Hydraulic drift prevention valve ................................................................................................... 60

4 PC300, 350-8
50 Disassembly and assembly SEN02637-02

Disassembly and assembly of 2) Remove cover (1) using eyebolt [2].

final drive assembly 1
Special tools

Necessity
Symbol

Sketch
Q’ty
N/R
Part number Part name

796-627-1610 Wrench assembly t 1

796-627-1620 • Wrench 1
1
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-627-1630 Push tool t 1 Q
790-101-2510 Block t 1 3. Spacer
791-830-1320 Rod t 2 Remove spacer (2).
D
01580-11613 Nut t 2
2
790-101-2570 Washer t 2
01643-31645 Washer t 2
790-101-2570 Jack assembly t 1
790-101-1102 Pump t 1
3 791-508-1510 Installer t 1
4 790-331-1110 Wrench q 1

Disassembly
1. Oil draining
Remove drain plug and drain oil from final 4. No.1 carrier assembly
drive case. 1) Remove No.1 carrier assembly (3).
6 Final drive case: Approx. 9 l

2. Cover
1) Remove the mounting bolts.
Then, using forcing screws [1], separate
cover (1) from the case.

PC300, 350-8 3
SEN02637-02 50 Disassembly and assembly

2) Disassemble No. 1 carrier assembly as 8. Ring gear

follows. Remove ring gear (14) using eyebolt [3].
1] Insert pin (4) and drive shaft (5) out of
carrier (6).
a After removing the shaft, remove
pin (4).
2] Remove thrust washer (7), gear (8),
bearing (9), and thrust washer (10).

9. No.2 carrier assembly

1) Remove No.2 carrier assembly (15).

5. No.1 sun gear shaft

Remove No. 1 sun gear shaft (11).

6. No.2 sun gear shaft

Remove No. 2 sun gear shaft (12).

2) Disassemble No. 2 carrier assembly as

follows.
1] Insert pin (16) and drive shaft (17) out
of carrier (18).
a After removing the shaft, remove
pin (16).
2] Remove thrust washer (19), gear (20),
bearing (21), and thrust washer (22).

7. Thrust washer
Remove thrust washer (13).

4 PC300, 350-8
50 Disassembly and assembly SEN02637-02

10. Nut 2) Disassemble the hub assembly as follows.

1) Remove lockplate (23). 1] Remove floating seal (26).

2) Use tool D1 to remove nut (24). 2] Remove bearings (27) and (28) from
hub (29).

11. Hub assembly

1) Using eyebolts [4], remove hub assembly 3) Remove floating seal (30) from travel
(25) from travel motor. motor (31).

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SEN02637-02 50 Disassembly and assembly

Assembly 3) Using tool D3, install floating seal (30)

a Clean all parts and check for dirt or damage. onto travel motor (31).
Coat the sliding surfaces of all parts with a The procedure for installation is the
engine oil before installing. same as in Step 2) above.

1. Hub assembly
1) Using the push tool, press-fit bearings (27)
and (28) to hub (29).

4) Using eyebolts [4], set hub assembly (25)

onto the travel motor. Then tap the bear-
ing using the push tool to press-fit it.

2) Use tool D3 to install floating seal (26).

a Remove all oil and grease from the
O-ring and O-ring contact surface and
dry up these sections before installing
the floating seal.
a After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
a After installing the floating seal, coat
the sliding surface thinly with engine
oil (EO30).

2. Nut
1) Install nut as follows.
1] Use tool D2 to press the inner race of
bearing (27).
a Pressing force
12.7 – 16.7 kN {1.3 – 1.7 ton}
a Rotate the hub 2 – 3 turns before
pressing the bearing inner race.

6 PC300, 350-8
50 Disassembly and assembly SEN02637-02

2] Under the above condition, measure 7] Install lockplate (23).

dimension (a).

a When installing the lockplate, avoid notch

3] Measure thickness (b) off the inde- (j) of the travel motor and fit it to the spline
pendent nut (24). totally (under the condition of (k))
4] Determine Calculate a – b = c 2 Thread of mounting bolt:
5] Using tool D1, tighten nut (24) until Adhesive (LT-2)
dimension (d) becomes the value of 3 Mounting bolt:
(c) calculated above. 59 – 74 Nm {6 – 7.5 kgm}
a Do not apply the adhesive (LT-2) to the
tapped portion of the nut.

6] Using push-pull scale [5], measure

tangential force of the hub to the
motor case in the rotation direction. 3. No.2 carrier assembly
a Tangential force: 1) Assemble No. 2 carrier assembly as fol-
Max. 490 N {50 kg} lows.
a The tangential force denotes the a Replace thrust washers (19) and (22)
maximum force at start of the as well as pin (16) with new ones.
rotation. a There are traces of expansion on the
end surface of carrier side hole (e)
which were originally caused when
the pin was inserted. Make such the
end surfaces are smooth enough
before reassembly.
1] Assemble bearing (21) to gear (20), fit
top and bottom thrust washers (19)
and (22) and then set the gear
assembly on carrier (18).

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SEN02637-02 50 Disassembly and assembly

2] Align the position of pin holes on the 2) Install No.2 carrier assembly (15).
shaft and carrier, then tap with a plas- a Align the position so that the 3 tips of
tic hammer to install shaft (17). the gear shafts of carrier assembly
a Install the shaft, rotating the plan- (15) enter the 3 hollows in the end
etary gear. Take care so that face of the motor case, then install.
thrust washer is not damaged.
3] Insert pin (16).
a When inserting the pin, take care
that the 3 claws (parts (f)) on the
periphery of the pin will not be
placed on the thin parts of the
carrier (parts (g)).
Since the thin parts may be on
the opposite side, confirm them
on each carrier.
If there is a groove, avoid placing
the claws on that groove.

4. Ring gear
Fit the O-ring to the hub. Using eyebolts [3],
sling ring gear (14) and install it to the hub,
matching their bolt holes to each other.
a Remove all grease and oil from the mating
surface of the ring gear and hub.
a Do not put any gasket sealant on the mat-
ing surface of the ring gear and hub under
any circumstances.

a After inserting the pin, caulk the

pin portion of the carrier.
a After assembling the carrier
assembly, check that gear (20)
rotates smoothly.

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50 Disassembly and assembly SEN02637-02

5. Thrust washer 3] Insert pin (4).

Install thrust washer (13). a When inserting the pin, take care
that the 3 claws (parts (f)) on the
6. No.2 sun gear periphery of the pin will not be
Install No. 2 sun gear (12). placed on the thin parts of the
carrier (parts (g)).
Since the thin parts may be on
the opposite side, confirm them
on each carrier.
If there is a groove, avoid placing
the claws on that groove.

7. No.1 carrier assembly

1) Assemble No. 1 carrier assembly as fol-
lows.
a Replace thrust washers (7) and (10)
as well as pin (4) with new ones (For
pin (4), see the Step 3] below).
a There are remains of caulking when a After inserting the pin, caulk the
the pin is inserted at the end face of pin portion of the carrier.
hole (h) at the side of the carrier. a After assembling the carrier
Remove the caulked metal from the assembly, check that gear (8)
inside diameter of the hole before rotates smoothly.
starting to assemble.
1] Assemble bearing (9) to gear (8), fit
top and bottom thrust washers (7)
and (10) and then set the gear
assembly on carrier (6).

2) Install No.2 carrier assembly (3).

2] Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (5).
a Install the shaft, rotating the plan-
etary gear. Take care so that
thrust washer is not damaged.

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SEN02637-02 50 Disassembly and assembly

8. No.1 sun gear shaft 10. Cover

Assemble No. 1 sun gear shaft (11). 1) Using eyebolts [2], install cover (1).
2 Cover mounting surface:
Gasket sealant (LG-6)

9. Spacer
Install spacer (2).
a After installing spacer (2), measure dis- 2)Tighten the mounting bolts according to
tance (i) from the top of planetary gear (8) the following procedure.
to the top of ring gear (14) and check the 3 Mounting bolt:
assembly condition. 1st step : 98 Nm {10 kgm}
a If dimension (i) is less than 1.3 mm or the 2nd step: Using tool D4, retighten each
top of planetary gear (8) is projected from mounting bolt by 100 – 110°.
the top of ring gear (14), they are not a If tool D4 is not available, make a
assembled correctly. In this case, check match mark on the cover and the bolt
again. with paint and then tighten the bolt by
100 – 110°.

11. Refilling with oil

Tighten the drain plug and feed engine oil
through oil filler.
5 Final drive case: 9 l
a Do a final check of the oil level at the
determined position after installing the
final drive assembly to the chassis.

10 PC300, 350-8