30 Testing and adjusting SEN02662-02

Pm Clinic service 1
Model name Serial No. Service meter
T PC400-8
h
T PC450-8 T LC
User's name Date of execution Inspector

/ /

Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm T 800 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude

°C m

Operator's opinion

Result of visual inspection

Mechanical equipment system fault history Electrical equipment system fault history
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h

Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge

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SEN02662-02 30 Testing and adjusting

Items related to engine

10 PC400, 450-8
30 Testing and adjusting SEN02662-02

Items relItems related to oil pressure

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SEN02662-02 30 Testing and adjusting

Check sheet (PC400/450-8)

Model Serial No. Service meter User's name Date of execution Inspector
/ /

1. Engine
Checking condition
Standard Mea-

Good
Service limit

Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
1 Engine speed rpm 1,880 – 1,980 1,880 – 1,980
All levers in
Engine oil MAX MPa 0.29 – 0.69 0.18
2 neutral
pressure {kg/cm2} {3.0 – 7.0} {1.8}
OFF
3 Engine speed rpm 975 – 1,025 975 – 1,025
All levers in
Engine oil MIN OFF MPa Min. 0.08 0.05
4 neutral
pressure P {kg/cm2} {Min. 0.8} {0.5}
5 Engine speed rpm 1,730 – 1,930 1,730 – 1,930
Blow-by ON Arm IN relief kPa Max. 1.76 2.94
6
pressure MAX {mmH2O} {Max. 180} {300}
Engine oil All levers in
7 ON OFF rpm 1,200 – 1,400 1,200 – 1,400
pressure neutral

2. Work equipment speed

Checking condition
Standard Mea-

Good
Service limit

Bad
No. Check item Fuel Work- Unit value for sured
control ing Checking posture, etc. value
new machine value
dial mode
No load, work equipment PC400-8 3.6 – 4.4 Max. 4.8
1 Boom RAISE
extended fully PC450-8 3.8 – 4.6 Max. 5.0
PC400-8 3.2 – 4.0 Max. 4.3
2 Arm IN P
PC450-8 3.2 – 4.0 Max. 4.3
PC400-8 3.9 – 4.7 Max. 5.0
3
PC450-8 4.2 – 5.2 Max. 5.4
Boom top horizontal
PC400-8 3.9 – 4.7 Max. 5.0
4 Arm OUT E
PC450-8 4.2 – 5.2 Max. 5.4
PC400-8 4.7 – 5.7 Max. 6.0
5 L
MAX PC450-8 sec 5.1 – 6.1 Max. 6.3

Boom and arm top horizontal PC400-8 3.2 – 4.0 Max. 4.3
6 Bucket CURL
Arm cylinder retracted fully PC450-8 3.2 – 4.0 Max. 4.3
7 Swing (5 turns) Work equipment extended fully 29.7 – 36.3 Max. 3.8
STD 50.6 – 75.8 42.0 – 80.0
LO
P LC 53.8 – 80.8 45.0 – 84.5
STD 38.3 – 51.9 31.5 – 55.0
8 Travel (5 turns) One side of track pushed up MI
LC 40.9 – 55.3 34.0 – 58.0
STD 31.0 – 38.0 28.0 – 41.5
HI
LC 33.1 – 40.3 32.0 – 44.0

12 PC400, 450-8
30 Testing and adjusting SEN02662-02

3. Hydraulic drift of work equipment

Checking condition Standard
Mea-

Good
value for Service limit

Bad
No. Check item Fuel Work- Unit sured
control ing Checking posture, etc. new value
value
dial mode machine

Boom top horizontal PC400-8 Max. 600 Max. 900

Hydraulic drift of mm/
1 Engine stopped Arm cylinder retracted fully
bucket tip PC450-8 15 min Max. 700 Max. 1,050
Bucket loaded

4. Hydraulic circuit
[1] [2] [3] [4] [5]

Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/

Good
Bad
No. Checked part cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral —

Right track driven idle E1 E2

— — —
Lever moved halfway
5 LS valve
Left track driven idle E1 E2
— — —
Lever moved halfway
MAX P
Swing lock F F
— — —
Swing motor Right swing relief
6
safety valve Swing lock F F
OFF — — —
Left swing relief
Right travel lock G
— — — —
Right forward relief
Main relief valve Right travel lock G
Travel motor — — — —
Right reverse relief
7 Safety valve
Travel junction Left travel lock G
— — — —
valve Left forward relief
Left travel lock G
— — — —
Left reverse relief

Checked oil pressure
A (Control circuit basic pressure)
B (Work equipment relief pressure,
Standard value
Unit Standard value for new machine Service limit value
3.04 – 3.44 {31 – 35} 2.84 – 3.43 {29 – 35}
33.83 – 36.28 {345 – 370} 33.34 – 36.77 {340 – 375}

low)
C (Work equipment relief pressure,
MPa 36.29 – 38.74 {370 – 395} 35.79 – 39.23 {365 – 400}
high)
{kg/cm2}
D (Unload pressure) 3.2 – 5.2 {43 – 53} 3.2 – 5.2 {43 – 53}
E (LS differential pressure) 2.55 – 2.75 {26 – 28} 2.55 – 2.75 {26 – 28}
F (Swing relief pressure) 28.44 – 32.36 {300 – 340} 27.95 – 32.85 {285 – 335}
G (Travel relief pressure) 36.29 – 40.21 {370 – 410} 35.79 – 40.7 {365 – 415}

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SEN02662-02 30 Testing and adjusting

* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]

Checking condition 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/

Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value

Checked oil pressure Unit Standard value for new machine Service limit value

H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)

* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]

Checking condition 60 MPa 60 MPa 6 MPa 6 MPa 6 MPa

{600 kg/ {600 kg/ {60 kg/ {60 kg/ {60 kg/

Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve J4 J4
L — — —

OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
Travel lever oper- — — — —
10 LS-EPC valve P
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated

Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output pressure 1) Approx. 1.5 {Approx. 15}
J2 (PC-EPC valve output pressure 2) Approx. 0.4 {Approx. 4}
Standard value

J3 (PC-EPC valve output pressure 3) Approx. 0.7 {Approx. 7}

J4 (PC-EPC valve output pressure 4)
J5 (PC-EPC valve output pressure 5)
K1 (LS-EPC valve output pressure 1)
K2 (LS-EPC valve output pressure 2)
K3 (LS-EPC valve output pressure 3)
MPa Approx. 1.2 {Approx. 12}
{kg/cm2} Approx. 0.9 {Approx. 9}
Approx. 2.0 {Approx. 20}
Approx. 2.6 {Approx. 27}
0 {0}

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30 Testing and adjusting SEN02662-02

Visual check of welded structure

a If a crack is found, illustrate its shape in the drawing.

Arm Boom Revolving frame

1. Arm cylinder bracket 4. Arm top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T Left T Right Track frame
T Edge plate 6. Arm cylinder bracket 10. Circle bracket
3. Arm top boss T Left T Right T Front T Rear
T Left T Right 7. Boom lower plate T Left T Right
T Left T Right
8. Boom foot
T Left T Right

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