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Komatsu PC500LC-10R Shop Manual

Komatsu PC500LC-10R Shop Manual

Hydraulic excavator
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Table of Contents

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SEN06722-00
HYDRAULIC
PC500LC
-10R
EXCAVATOR
100001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu PC500LC-10R

  • Page 1 SEN06722-00 HYDRAULIC PC500LC -10R EXCAVATOR 100001 SERIAL NUMBERS and up...
  • Page 3 00 INDEX AND FOREWORD PC500LC-10R 00-1...

  • Page 4: Table Of Contents

    COMPONENT PARTS OF ENGINE SYSTEM ................10-31 COOLING SYSTEM..........................10-33 LAYOUT DRAWING OF COOLING SYSTEM ................10-33 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH ..............10-35 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH............10-37 COMPONENT PARTS OF COOLING SYSTEM................10-39 00-2 PC500LC-10R...
  • Page 5 CONTENTS ............................20-2 ABBREVIATION LIST ..........................20-3 STANDARD VALUE TABLE FOR ENGINE ..................... 20-9 STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R ............. 20-9 STANDARD VALUE TABLE FOR MACHINE..................20-13 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R............20-13 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......20-27 30 TESTING AND ADJUSTING ........................

  • Page 6: Index

    MAINTENANCE STANDARD OF SPROCKET ................60-17 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING..60-18 UNDERCARRIAGE AND FRAME......................60-20 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION........60-20 MAINTENANCE STANDARD OF IDLER ..................60-22 MAINTENANCE STANDARD OF TRACK ROLLER............... 60-24 00-4 PC500LC-10R...
  • Page 7 CONNECTOR AND WIRING HARNESS CHART (11/15) .............. 90-61 CONNECTOR AND WIRING HARNESS CHART (12/15) .............. 90-63 CONNECTOR AND WIRING HARNESS CHART (13/15) .............. 90-65 CONNECTOR AND WIRING HARNESS CHART (14/15) .............. 90-67 CONNECTOR AND WIRING HARNESS CHART (15/15) .............. 90-69 INDEX..................................1 PC500LC-10R 00-5...
  • Page 8 It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). 00-6 PC500LC-10R...

  • Page 9: 00 Index And Foreword

    (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. PC500LC-10R 00-7...
  • Page 10 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 11 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. PC500LC-10R 00-9...
  • Page 12 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection 00-10 PC500LC-10R...
  • Page 13 00 INDEX AND FOREWORD ABBREVIATION LIST Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission PC500LC-10R 00-11...

  • Page 14: Foreword, Safety, Basic Information

    HOW TO READ THE SHOP MANUAL • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice.
  • Page 15 REMARK Remark This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. PC500LC-10R 00-13...
  • Page 16 Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...
  • Page 17 Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-). PC500LC-10R 00-15...

  • Page 18: Safety Notice For Operation

    • Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic- ular. 00-16 PC500LC-10R...
  • Page 19 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. PC500LC-10R 00-17...
  • Page 20 Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane When raising a heavy component (heavier than 25 kg), use a hoist or crane. 00-18 PC500LC-10R...
  • Page 21 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 318.3 {32.4} PC500LC-10R 00-19...
  • Page 22 When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). 00-20 PC500LC-10R...
  • Page 23 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". PC500LC-10R 00-21...

  • Page 24: Precautions To Prevent Fire

    Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 25 • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual. PC500LC-10R 00-23...

  • Page 26: Actions If Fire Occurs

    Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them. 00-24 PC500LC-10R...

  • Page 27: Precautions For Disposing Of Waste Materials

    Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. PC500LC-10R 00-25...
  • Page 28 Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap- propriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs. 00-26 PC500LC-10R...
  • Page 29 Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine. PC500LC-10R 00-27...

  • Page 30: Precautions For Handling Hydraulic Equipment

    PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. 00-28 PC500LC-10R...

  • Page 31: Precautions For Disconnection And Connection Of Pipings

    Introduction of parts for the disassembly of the face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 PC500LC-10R 00-29...
  • Page 32 Split flange Sleeve head Flange (1) 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032 00-30 PC500LC-10R...
  • Page 33 Introduction of parts for the removal of O-ring boss type joint Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 PC500LC-10R 00-31...
  • Page 34 When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. 00-32 PC500LC-10R...
  • Page 35 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 36 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". 00-34 PC500LC-10R...

  • Page 37: Precautions For Handling Electrical Equipment

    The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage. PC500LC-10R 00-35...
  • Page 38 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. 00-36 PC500LC-10R...

  • Page 39: Precautions For Handling Fuel System Equipment

    If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.

  • Page 40: Precautions For Handling Intake System Equipment

    Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it. 00-38 PC500LC-10R...

  • Page 41: Practical Use Of Komtrax

    To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor. PC500LC-10R 00-39...

  • Page 42: Disconnect And Connect Push-Pull Type Coupler

    Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). 00-40 PC500LC-10R...
  • Page 43 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. PC500LC-10R 00-41...
  • Page 44 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-42 PC500LC-10R...
  • Page 45 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. PC500LC-10R 00-43...

  • Page 46: Precautions For Disconnection And Connection Of Connectors

    Connecting connectors Check the connector visually. • Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion). 00-44 PC500LC-10R...
  • Page 47 If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. PC500LC-10R 00-45...
  • Page 48 After the connector is completely dried, blow the contact restorer, and reassemble them. Handling controller When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point. 00-46 PC500LC-10R...
  • Page 49 When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read- ing does not change. NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit. PC500LC-10R 00-47...

  • Page 50: Method For Disconnecting And Connecting Deutsch Connector

    In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely. 00-48 PC500LC-10R...

  • Page 51: Method For Disconnecting And Connecting Slide Lock Type Connector

    (L2), and then pull out connector (1) to- ward you. Method for connecting slide lock type connector (FRAMATOME-3, FRAMA- TOME-2) Insert it straight until it clicks. Method for disconnecting slide lock type connector (FRAMATOME-24) Slide down lock (red) (L1). PC500LC-10R 00-49...
  • Page 52 TYPE CONNECTOR 00 INDEX AND FOREWORD While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure. Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks. 00-50 PC500LC-10R...

  • Page 53: Method For Disconnecting And Connecting Connector With Lock To Pull

    Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward. Method for connecting connector with lock to pull Insert the connector securely until it "clicks". PC500LC-10R 00-51...

  • Page 54: Method For Disconnecting And Connecting Connector With Lock To Push

    While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the ar- row. Method for connecting connector with lock to push (BOSCH-3) Insert it straight until it clicks. 00-52 PC500LC-10R...
  • Page 55 Method for disconnecting connector with lock to push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow. Method for connecting connector with lock to push (SUMITOMO-4) Insert it straight until it clicks. PC500LC-10R 00-53...

  • Page 56: Method For Disconnecting And Connecting Connector With Housing To Rotate

    REMARK Housing (H1) is left on the wiring harness side. Method for connecting connector with housing to rotate Insert the connector to the end while aligning its groove to the other. Turn housing (H1) clockwise until it clicks. 00-54 PC500LC-10R...

  • Page 57: How To Read Electrical Wire Code

    For mid- to small-size excava- wire for auto- tors CAVS mobile (nominal No. 1.25 and lower) (Type 2) General wiring for extremely Heat-resistant cold weather specification low-voltage Heat-resistant cross- -50 to +110 wire for auto- linked polyethylene Wiring at high-temperature mobile place PC500LC-10R 00-55...
  • Page 58 Standard 10.8 11.4 13.0 13.6 16.0 17.6 Nominal No. 0.5f 0.75f 0.85 1.25f 1.25 Number of strands Diameter of round compres- round compres- round compression strand sion sion Conductor Cross-sec- tional area 0.56 0.88 1.29 ( mm d (approx.) 00-56 PC500LC-10R...
  • Page 59 In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example) GW indicates that the background is "Green" and marking is "White". PC500LC-10R 00-57...
  • Page 60 HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD Types of circuits and color codes Type of wire AVS, AV, CAVS Charge Ground Start Light Instrument Signal Type of circuit Others 00-58 PC500LC-10R...

  • Page 61: Explanation Of Terms For Maintenance Standard

    (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Tolerance Standard dimension Shaft Hole -0.030 +0.046 -0.076 PC500LC-10R 00-59...
  • Page 62 The allowable maximum interference between the hole of a part and the shaft of another part to be assem- bled is called "allowable interference". • The allowable interference shows the repair limit of the part of smaller tolerance. 00-60 PC500LC-10R...
  • Page 63 00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD • The parts whose interferences are out of the allowable interference must be replaced or repaired. PC500LC-10R 00-61...

  • Page 64: Standard Tightening Torque Table

    2890 to 3630 {295 to 370} *1: Split flange bolt *2: Flanged bolt REMARK Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below. 00-62 PC500LC-10R...
  • Page 65 63.7 to 83.4 {6.5 to 8.5} 68.6 {7} -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13} -9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21} PC500LC-10R 00-63...
  • Page 66 382 to 520 {39 to 53} 451 {46} -12UNF -12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61} -12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91} 00-64 PC500LC-10R...
  • Page 67 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75} 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15} 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8} 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3} 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0} PC500LC-10R 00-65...
  • Page 68 25.4 177 to 245 {18.0 to 25.0} 216 {22.0} -12UN 30.2 (10) 177 to 245 {18.0 to 25.0} 216 {22.0} (12) 197 to 294 {20.0 to 30.0} 245 {25.0} (14) 246 to 343 {25.0 to 35.0} 294 {30.0} 00-66 PC500LC-10R...
  • Page 69 Tightening torque table for 102, 107, and 114 series engines (joint bolts) REMARK Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified. PC500LC-10R 00-67...
  • Page 70 In cast iron or steel In aluminum Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} ) 15±2 {1.53±0.20} 5±1 {0.51±0.10} 20±2 {2.04±0.20} 15±2 {1.53±0.20} 25±3 {2.55±0.31} 20±2 {2.04±0.20} 35±4 {3.57±0.41} 25±3 {2.55±0.31} 55±6 {5.61±0.61} 35±4 {3.57±0.41} 75±8 {7.65±0.82} 45±5 {4.59±0.51} 00-68 PC500LC-10R...

  • Page 71: Conversion Table

    0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323 PC500LC-10R 00-69...
  • Page 72 25.625 25.889 26.153  ℓ to  U.K.Gal 1 ℓ = 0.21997 U.K.Gal 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379 00-70 PC500LC-10R...
  • Page 73 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7 PC500LC-10R 00-71...
  • Page 74 -34.4 -22.0 -10.6 55.4 118.4 28.3 181.4 -31.7 -13.0 -10.0 57.2 120.2 28.9 183.2 -28.9 -4.0 -9.4 59.0 10.0 122.0 29.4 185.0 -28.3 -2.2 -8.9 60.8 10.6 123.8 30.0 186.8 -27.8 -0.4 -8.3 62.6 11.1 125.6 30.6 188.6 00-72 PC500LC-10R...
  • Page 75 167.0 65.6 302.0 -14.4 42.8 105.8 24.4 168.8 68.3 311.0 -13.9 44.6 107.6 25.0 170.6 71.1 320.0 -13.3 46.4 109.4 25.6 172.4 73.9 329.0 -12.8 48.2 111.2 26.1 174.2 76.7 338.0 -12.2 50.0 113.0 26.7 176.0 79.4 347.0 PC500LC-10R 00-73...

  • Page 77: 01 Specifications

    01 SPECIFICATIONS PC500LC-10R 01-1...

  • Page 78: Contents

    CONTENTS 01 SPECIFICATIONS CONTENTS ABBREVIATION LIST ............................ 01-3 SPECIFICATIONS ............................01-9 SPECIFICATION DRAWING........................01-9 SPECIFICATION DRAWING: PC500LC-10R ................... 01-9 WORKING RANGE DRAWINGS ......................01-10 WORKING RANGE: PC500LC-10R....................01-10 SPECIFICATIONS ..........................01-11 SPECIFICATIONS: PC500LC-10R ....................01-11 WEIGHT TABLE ........................... 01-14 WEIGHT TABLE: PC500LC-10R....................01-14 TABLE OF FUEL, COOLANT, AND LUBRICANTS ................

  • Page 79: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 01-3...
  • Page 80 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 01-4 PC500LC-10R...
  • Page 81 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 82 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 01-6 PC500LC-10R...
  • Page 83 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 01-7...
  • Page 84 ABBREVIATION LIST 01 SPECIFICATIONS Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 01-8 PC500LC-10R...

  • Page 85: Specifications

    01 SPECIFICATIONS SPECIFICATION DRAWING SPECIFICATIONS SPECIFICATION DRAWING SPECIFICATION DRAWING: PC500LC-10R Item Unit PC500LC-10R Machine weight  kg 49400 Bucket capacity  m Engine model Komatsu SAA6D125E-5 diesel engine Engine rated horsepower Gross (SAE J1995) • 270{362}/1900{1900}  kW  ISO14396 • { HP} / min   270{362}/1900{1900} { rpm} ...

  • Page 86: Working Range Drawings

    WORKING RANGE DRAWINGS 01 SPECIFICATIONS WORKING RANGE DRAWINGS WORKING RANGE: PC500LC-10R Item Unit PC500LC-10R Maximum digging reach  mm 11985 Maximum digging depth  mm 7695 Maximum digging height  mm 10885 Maximum vertical wall digging  mm 6335 depth Maximum dumping height  mm...

  • Page 87: Specifications

    01 SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS: PC500LC-10R Machine model Unit PC500LC-10R Bucket capacity  m Machine weight  kg 49400 Performance Working ranges Maximum digging depth  mm 7695 Maximum vertical wall digging depth  mm 6335 Maximum digging reach  mm 11985 Maximum digging reach at ground level  mm...
  • Page 88 SPECIFICATIONS 01 SPECIFICATIONS Machine model Unit PC500LC-10R Model SAA6D125E-5 4-cycle, water-cooled, in-line, vertical, and direct Type injection type with turbocharger and air-cooled af- tercooler No. of cylinders - bore x stroke  mm 6-125 x 150 Total piston displacement  ℓ { cc}  11.045 {11045}...
  • Page 89 01 SPECIFICATIONS SPECIFICATIONS Machine model Unit PC500LC-10R Operating method Hydraulically operated type Variable displacement piston type x 2 pieces Travel motor (with brake valve and parking brake) Fixed displacement piston type x 1 piece Swing motor (with safety valve and parking brake)

  • Page 90: Weight Table

    WEIGHT TABLE 01 SPECIFICATIONS WEIGHT TABLE WEIGHT TABLE: PC500LC-10R This weight table is provided for your reference for when handling the components or when trans- porting. This weight table shows the dry weight. Unit:  kg Machine model PC500LC-10R Engine assembly 1670...
  • Page 91 01 SPECIFICATIONS WEIGHT TABLE Unit:  kg Machine model PC500LC-10R Bucket link assembly Boom foot pin Boom cylinder bottom pin 25 x 2 Boom cylinder head pin Arm cylinder bottom pin Arm cylinder head pin Boom and arm connecting pin Bucket cylinder bottom pin...

  • Page 92: Table Of Fuel, Coolant, And Lubricants

    DS500 Fuel tank Diesel fuel ASTM D975 No. 1- D S15 ASTM D975 No.2– DS500 KES: Komatsu Engineering Standard Reservoir Specified capacity (Liter) Refill capacity (Liter) Engine oil pan Swing machinery case Final drive case (each of right and left)
  • Page 93 Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4,000 hours.

  • Page 95: 10 Structure And Function

    10 STRUCTURE AND FUNCTION PC500LC-10R 10-1...

  • Page 96: Contents

    MACHINE MONITOR SYSTEM DIAGRAM..................10-43 FUNCTION OF MACHINE MONITOR SYSTEM ................10-43 KOMTRAX SYSTEM..........................10-45 KOMTRAX SYSTEM DIAGRAM ....................10-45 FUNCTION OF KOMTRAX SYSTEM .................... 10-45 COMPONENT PARTS OF CONTROL SYSTEM................... 10-46 MACHINE MONITOR........................10-46 REARVIEW CAMERA........................10-57 KOMTRAX TERMINAL ........................10-58 10-2 PC500LC-10R...
  • Page 97 HYDRAULIC OIL ADDITIONAL FILTER CLOGGING SWITCH.............10-220 SWING SYSTEM ............................10-222 LAYOUT DRAWING OF SWING SYSTEM ..................10-222 SWING CONTROL SYSTEM DIAGRAM .....................10-226 FUNCTION OF SWING CONTROL SYSTEM................10-226 COMPONENT PARTS OF SWING SYSTEM..................10-230 SWING MOTOR ...........................10-230 SWING MACHINERY ........................10-243 SWING CIRCLE..........................10-244 TRAVEL SYSTEM............................10-248 PC500LC-10R 10-3...
  • Page 98 ROPS CAB ............................10-280 STRUCTURE OF ROPS CAB.......................10-280 FUNCTION OF ROPS CAB ......................10-280 CAB MOUNT ............................10-281 STRUCTURE OF CAB MOUNT....................10-281 FUNCTION OF CAB MOUNT .......................10-281 CAB TIPPING STOPPER ........................10-282 STRUCTURE OF CAB TIPPING STOPPER.................10-282 FUNCTION OF CAB TIPPING STOPPER ..................10-282 10-4 PC500LC-10R...

  • Page 99: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 10-5...
  • Page 100 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 10-6 PC500LC-10R...
  • Page 101 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 102 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 10-8 PC500LC-10R...
  • Page 103 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 10-9...
  • Page 104 ABBREVIATION LIST 10 STRUCTURE AND FUNCTION Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 10-10 PC500LC-10R...

  • Page 105: Boot-Up System

    10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF BOOT-UP SYSTEM BOOT-UP SYSTEM LAYOUT DRAWING OF BOOT-UP SYSTEM 1: Engine controller 4: Pump controller 2: KOMTRAX terminal 5: Machine monitor 3: Fuse box 6: Battery 7: Battery disconnect switch PC500LC-10R 10-11...
  • Page 106 LAYOUT DRAWING OF BOOT-UP SYSTEM 10 STRUCTURE AND FUNCTION 8: System operating lamp 9: Fusible link 10-12 PC500LC-10R...

  • Page 107: System Operating Lamp System

    “ON” position once and then turn it to “OFF” position. Lamp goes off in a maximum of. 6 minutes. After system operating lamp goes off, turn the battery disconnect switch immediately to “OFF” position. PC500LC-10R 10-13...

  • Page 108: Battery Disconnect Switch

    KOMTRAX terminal is performing communication, even if the starting switch is set to OFF position. • If battery disconnect switch (1) has been at OFF position for a long period, the machine monitor and the clock of the radio may return to the initial state. Resetting is required in this case. 10-14 PC500LC-10R...

  • Page 109: Engine System

    8: Torsion spring 2: Damper 9: Drive plate 3: Engine oil filter 10: Alternator 4: Rear engine mount 11: Auto-tensioner 5: Engine controller 12: Vibration damper 6: Stopper pin 13: Front engine mount 7: Friction plate 14: Starting motor PC500LC-10R 10-15...
  • Page 110 LAYOUT DRAWING OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION 15: Turbocharger 16: Muffler SPECIFICATIONS OF ENGINE SYSTEM Type of damper: Wet type Oil for damper: TO30 Quantity of damper oil: 1.6 ℓ 10-16 PC500LC-10R...

  • Page 111: Engine Control System

    5: Fuse box 15: Starting motor 6: Starting switch 16: Fuel supply pump 7: Engine shutdown secondary switch 17: Various sensors 8: Engine controller 18: Machine monitor 9: Lock lever 19: KOMTRAX terminal 10: PPC lock switch 20: Pump controller PC500LC-10R 10-17...
  • Page 112 (18). Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting mo- tor (15), thus the engine does not start. Mechanism and function of engine speed control system 10-18 PC500LC-10R...
  • Page 113 When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as when starting switch (6) is turned to OFF position, and the engine stops. PC500LC-10R 10-19...

  • Page 114: Auto-Deceleration System

    • If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control dial. 10-20 PC500LC-10R...
  • Page 115 When the control lever is operated When any control lever is operated while the engine speed is kept at the control speed (approximately 1000 rpm), the engine speed increases in a moment to the speed being set with the fuel control dial. PC500LC-10R 10-21...

  • Page 116: Engine Automatic Warm-Up System

    11: Pump drive secondary switch 18b: Merge-divider valve 12: Fuel control dial 18c: Travel junction valve 13: Fuel supply pump 19: Front pump PC-EPC valve 14: Various sensors 20: Rear pump PC-EPC valve 15: Hydraulic oil temperature sensor 10-22 PC500LC-10R...
  • Page 117 Auto- Coolant temperature: Min. 30 °C matic Warm-up operation time: 10 minutes or opera- → more tion Engine speed: Any Manual Fuel control dial: Held for 3 seconds at Min. opera- 70 % of full speed (Max.) tion PC500LC-10R 10-23...

  • Page 118: Overheat Prevention System

    11: Pump drive secondary switch 18b: Merge-divider valve 12: Fuel control dial 18c: Travel junction valve 13: Fuel supply pump 19: Front pump PC-EPC valve 14: Various sensors 20: Rear pump PC-EPC valve 15: Hydraulic oil temperature sensor 10-24 PC500LC-10R...
  • Page 119 Engine speed: Low idle Fuel control dial: Return to low idle Alarm monitor: Lights up (MIN) position. Hydraulic oil temperature: Alarm buzzer: Sounds Min. 105 °C When above conditions are satisfied, it is restored to the state before oper- ation (manual restoration). PC500LC-10R 10-25...

  • Page 120: Turbocharger Protection System

    11: Pump drive secondary switch 18b: Merge-divider valve 12: Fuel control dial 18c: Travel junction valve 13: Fuel supply pump 19: Front pump PC-EPC valve 14: Various sensors 20: Rear pump PC-EPC valve 15: Hydraulic oil temperature sensor 10-26 PC500LC-10R...
  • Page 121 B: Turbocharger protection time (approximately 0 to 20 sec- onds) C: Modulation time (approximately 1 second) D: : 500 rpm E: : approximately 1000 rpm F: : 1770 rpm (when working mode is P mode) Fuel control dial: High idle (MAX) position, lever is in NEUTRAL position PC500LC-10R 10-27...

  • Page 122: Automatic Idle Stop System

    Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”. (It does not operate when working mode is “L”) • "Normal warm-up" mode of engine automatic warm-up function is not in operation. • Engine coolant temperature is not overheated (less than 102 °C). 10-28 PC500LC-10R...
  • Page 123 Auto Idle Stop Time Fixing (user menu) Setting Contents of setting Auto idle stop function is not actuated. (Default) y minutes It stops the engine in Y minutes (set time at left) after setting the lock lever to “LOCK” position. PC500LC-10R 10-29...
  • Page 124 If the number of occurrence is not reset by using “Reset Number of Abrupt Engine Stop by AIS”, failure code “A900FR” is sent again next time and after. Be sure to perform the reset always after the turbocharger assembly is replaced. 10-30 PC500LC-10R...

  • Page 125: Component Parts Of Engine System

    1: Blower housing 7: Blower impeller 2: V-band 8: Insert 3: Center housing (diffuser portion) 9: Thrust bearing 4: Center housing (water-cooled center housing) 10: Journal bearing 5: Heat shield 11: Seal ring 6: Turbine housing 12: Turbine rotor PC500LC-10R 10-31...
  • Page 126 COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION SPECIFICATIONS OF TURBOCHARGER Model: Komatsu KTR90 (Water-cooled type) Overall length: 268 mm Overall width: 247 mm Overall height: 227 mm Weight: 16 kg BLOWBY PRESSURE SENSOR STRUCTURE OF BLOWBY PRESSURE SENSOR 1: Connector 3: O-ring 2: Sensor FUNCTION OF BLOWBY PRESSURE SENSOR This sensor is installed to the blowby outlet side.

  • Page 127: Cooling System

    9: Oil cooler 3: Air conditioner condenser 10: Radiator cap 4: Aftercooler outlet hose 11: Radiator inlet hose 5: Oil cooler outlet hose 12: Fan guard 6: Oil cooler inlet hose 13: Shroud 7: Aftercooler 14: Radiator outlet hose PC500LC-10R 10-33...
  • Page 128 Fin pitch: 3.5/2 mm Heat dissipation area: 70.48 m Pressure valve cracking pressure: 0.09 MPa {0.9 kg/cm }  Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kg/cm }  Oil cooler Core type: CFA5 Fin pitch: 3.5/2 mm Heat dissipation area: 46.32 m Aftercooler Core type: Aluminum wave, 4 lines Fin pitch: 4.0/2 mm Heat dissipation area: 22.50 m 10-34 PC500LC-10R...

  • Page 129: Fan Speed Control System Of Fan Clutch

    CAN signal (air conditioner fresh air temperature gine speed sensor signal) sensor signal, air conditioner compressor signal) c: Cooling fan speed sensor signal 1: Engine controller 3: Engine speed sensor 2: Coolant temperature sensor 4: Hydraulic oil temperature sensor PC500LC-10R 10-35...
  • Page 130 Fan speed is controlled also by outside air temperature and information of air conditioner control (air condi- tioner compressor signal) while air conditioner is operated. • Excess noise and fuel consumption are reduced by decreasing the fan speed when these temperatures are low. 10-36 PC500LC-10R...

  • Page 131: Engine Output Control System Of Fan Clutch

    FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH When it is normally operated The pump controller calculates the horsepower the fan consumes. It controls the engine output curve (A1), (B1) by fan speed so that the excess fuel consumption is restricted. PC500LC-10R 10-37...
  • Page 132 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 10 STRUCTURE AND FUNCTION Image of engine output (when fan speed varies) 10-38 PC500LC-10R...

  • Page 133: Component Parts Of Cooling System

    4: Shaft (Engine mounting portion) SPECIFICATIONS OF FAN CLUTCH Type: Fluid coupling FUNCTION OF FAN CLUTCH Fan speed which is transmitted from the engine to the shaft is decreased by built-in fluid coupling to achieve the target speed. PC500LC-10R 10-39...

  • Page 134: Control System

    LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION CONTROL SYSTEM LAYOUT DRAWING OF CONTROL SYSTEM 1: Rearview camera (*1) *1: Indicates machine with rearview camera. 10-40 PC500LC-10R...
  • Page 135 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM 2: CAN terminating resistor 3: Engine controller PC500LC-10R 10-41...
  • Page 136 LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION 4: Machine monitor 7: Pump controller 5: Communication antenna 8: Resistor for PC-EPC valve 6: GPS antenna 9: KOMTRAX terminal 10-42 PC500LC-10R...

  • Page 137: Machine Monitor System

    The information displayed on the machine monitor falls into the following types: • Alarm when the machine has trouble • Machine state display (coolant temperature, power train oil temperature, hydraulic oil temperature, fuel level, etc.) PC500LC-10R 10-43...
  • Page 138 MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION • Display of camera image (machine with camera) • The switches on the machine monitor also have the functions to control the machine. 10-44 PC500LC-10R...

  • Page 139: Komtrax System

    Positional information • Working information • Alarm and failure information • Fuel consumption information • Maintenance information • Machine working condition information and others. NOTICE Radio station for KOMTRAX needs to be established separately to supply the service. PC500LC-10R 10-45...

  • Page 140: Component Parts Of Control System

    • Alarm when the machine has trouble • Machine state display (engine coolant temperature, hydraulic oil temperature, fuel level, etc.) • Display of camera image • The switches on the machine monitor have functions to control the machine. 10-46 PC500LC-10R...
  • Page 141 Charge level (alternator terminal R) Input (*1) (*1) *1: Never connect these pins. Malfunctions or failures may occur. 070-12P “CM02” Pin No. Signal name Input/output signal Seat belt alarm switch Input Engine oil level sensor Input Radiator coolant level sensor Input PC500LC-10R 10-47...
  • Page 142 (*1) (*1) (*1) (*1) *1: Never connect these pins. Malfunctions or failures may occur. 070-8P “CM04” Pin No. Signal name Input/output signal Power supply for camera (8 V) Output Camera NTSC signal 1 Input Camera NTSC signal 2 Input 10-48 PC500LC-10R...
  • Page 143 100 °C Blue temperature components. gauge 85 °C Blue 40 °C Blue 20 °C White Monitor back- Indicates corresponding remaining Range Quantity (%) ground level. 504.9 ℓ Blue 373.1 ℓ Blue (*1) 295.9 ℓ Blue Fuel gauge 149.7 ℓ Blue 116.5 ℓ Blue 79.8 ℓ PC500LC-10R 10-49...
  • Page 144 If monitor background color is 20 °C, higher Lit (white) white, warm up the hydraulic than 105 °C components. Lower than Background color of monitor 79.8 ℓ, higher Lit (red) changes according to the remaining Fuel level than 20 °C amount. Min. 79.8 ℓ Lit (blue) 10-50 PC500LC-10R...
  • Page 145 L04, L03 an abnormality is detected in detected machine system. State of sys- • Alarm buzzer sounds when When action lev- the background color of the el L01 is detect- Lit (yellow) L01 (*3) caution lamp is red. PC500LC-10R 10-51...
  • Page 146 When action lev- el L02 is detect- Lit (red) Action level When action lev- el L01 is detect- Lit (yellow) When action lev- el L01 is detect- Lit (yellow) When action lev- el L01 is detect- Lit (yellow) L01 (*3) 10-52 PC500LC-10R...
  • Page 147 40 seconds Not lit or longer One-touch Display of the state of one-touch power maxi- Monitor display power maximizing function mizing switch One-touch pow- er maximizing (Goes out approximately 8.5 seconds after, if held down) Not lit PC500LC-10R 10-53...
  • Page 148 E0, E1, E2, or E3 is dis- played at the right top of stand- ATT-E: 2-way attachment operation with low ard screen. fuel consumption Displays the set mode of travel Lo: Low-speed travel speed. Travel speed Mi: Middle-speed travel Hi: High-speed travel 10-54 PC500LC-10R...
  • Page 149 Items available in the operator mode are as follows. Display order (*2) Category Item (*1) KOMATSU logo display Password input display Service person identification state display Operator ID input screen display Breaker mode check display Check before starting display...
  • Page 150 Z: When any item is detected as the maintenance due time is over REMARK • For how to operate the operator mode functions, see Operation and Maintenance Manual. • For the operating method of the engine start lock function, see Password setting and canceling manual. 10-56 PC500LC-10R...
  • Page 151 Pump Absorption Torque (R) Travel Lo Speed Setting Att Flow Adjust in Combined Ope Fan Speed Mode Select KomVision Adjustment No-Injection Cranking KOMTRAX Settings Terminal Status GPS & Communication State Modem Information Service Message REARVIEW CAMERA (Machine with rearview camera) PC500LC-10R 10-57...
  • Page 152 *1: Never connect these pins, otherwise it may cause malfunctions and failures. KOMTRAX TERMINAL STRUCTURE OF KOMTRAX TERMINAL General view Model: TC630/TC635/TC330/TC730 1: GPS antenna connection port 3: Machine wiring harness connection port (070-12P) 2: Machine wiring harness connection port (070-18P) 4: Communication antenna connection port 10-58 PC500LC-10R...
  • Page 153 REMARK • When commencing the operation of the KOMTRAX system or changing the country in which the system is used, you must give notice to Komatsu Ltd. • TC630, TC635, TC330, and TC730 can be used in different countries. • When operating TC330 in Japan, it is required to install a TC330 terminal for exclusive use in Japan.
  • Page 154 Input and output signals Starting switch (ACC) Input Alternator (R) Input (*1) Power supply Input Power supply Input (*1) (*1) (*1) Starting switch (C) Input (*1) *1: Never connect these pins, otherwise it may cause malfunction or failures. 10-60 PC500LC-10R...

  • Page 155: Pump Controller

    Continuous power supply (24 V) Input Continuous power supply return Input Window washer Output Continuous power supply (24 V) Input Continuous power supply return Input Potentiometer power supply (5 V) Output Input and out- CAN (R)_H Service oil pressure sensor Input PC500LC-10R 10-61...
  • Page 156 Fan speed sensor Input Swing parking brake cancel switch Input Model selection 2 Input PPC lock solenoid valve monitor signal Input One-touch power maximizing switch Input Starting switch ACC signal Input Pulse signal return Input and out- CAN (C)_H 10-62 PC500LC-10R...
  • Page 157 Cab front window open limit switch Input Model selection 4 Input PPC lock switch (solenoid side) Input PPC lock switch (starting motor side) Input Starting switch ACC signal Input (*1) *1: Never connect these pins, otherwise it may cause malfunctions or failures. PC500LC-10R 10-63...
  • Page 158 Output 2-stage relief solenoid valve Output (*1) ATT1 variable relief pressure EPC (*3) Merge-divider EPC valve (main) Output Variable back pressure solenoid valve Output Wiper motor (-) Output GND (solenoid) Input Solenoid power supply Input GND (solenoid) Input 10-64 PC500LC-10R...

  • Page 159: Resistor For Pc-Epc Valve

    It allows a proper current to flow to EPC valve, according to the condition, when the pump drive secondary switch is turned to “ON” position. REMARK No current flows normally. CAN TERMINATING RESISTOR Abbreviation for Controller Area Network PC500LC-10R 10-65...

  • Page 160: Engine Controller

    CAN communication signals sent and received between each terminals. REMARK If the CAN terminating resistor is not installed, CAN communication errors occur and the operator cannot oper- ate the machine. ENGINE CONTROLLER STRUCTURE OF ENGINE CONTROLLER 10-66 PC500LC-10R...
  • Page 161 NC (*) Common rail pressure sensor Output Bkup sensor (+) Output NE sensor (+) Output NC (*) NC (*) Fuel temperature sensor Output NC (*) NC (*) Sensor 5 V power supply Power supply NC (*) NC (*) NC (*) PC500LC-10R 10-67...
  • Page 162 Input and output signals NC (*) Input NC (*) Input NC (*) Input NC (*) Input NC (*) Input NC (*) Input NC (*) Input NC (*) Input Fuel control dial (+) Input NC (*) Communication NC (*) Input 10-68 PC500LC-10R...
  • Page 163 Intake air heater relay drive Output NC (*) Output Intake air heater relay return Ground/Shield/Return NC (*) Output NC (*) Output NC (*) CAN (+) Communication CAN (-) Communication NC (*) Output PWM OUTPUT (Power train relay output) Output NC (*) Output PC500LC-10R 10-69...

  • Page 164: Fuel Control Dial

    *1: Never connect these pins, otherwise it may cause malfunctions or failures. FUEL CONTROL DIAL STRUCTURE OF FUEL CONTROL DIAL The fuel control dial is installed to R.H. console box. General view, sectional view 1: Potentiometer 3: Knob 2: Spring 10-70 PC500LC-10R...
  • Page 165 (1) varies according to this rotation, and throttle signals are sent to the controller. REMARK The hatched area in the following graph is the abnormality de- tection area. When the throttle voltage is in this area, the en- gine speed is set to low idle. PC500LC-10R 10-71...

  • Page 166: Fuel Feed Pump

    B: Fuel outlet 1: Body 2: Connector FUNCTION OF FUEL FEED PUMP The fuel feed pump is controlled and driven by monitor operation in the following cases. • Bleed air from fuel passage (engine side) (Control by monitor operation) 10-72 PC500LC-10R...

  • Page 167: Hydraulic System

    10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM HYDRAULIC SYSTEM LAYOUT DRAWING OF HYDRAULIC SYSTEM 1: Control valve 4: Main pump 2: Fuel supply pump 5: Hydraulic tank 3: Engine controller 6: Solenoid valve PC500LC-10R 10-73...
  • Page 168 12: Rear pump oil pressure sensor 9: Merge-divider EPC valve (for main spool) 13: Front pump oil pressure sensor 10: Merge-divider EPC valve (for LS spool) 14: LS-EPC valve 16: Front pump PC-EPC valve 15: Rear pump PC-EPC valve 17: Bucket CURL sensor 10-74 PC500LC-10R...
  • Page 169 22: Boom RAISE sensor 19: Swing RIGHT sensor 23: Swing LEFT sensor 20: Arm IN sensor 24: Arm OUT sensor 21: Bucket DUMP sensor 1: Machine monitor 3: Pump controller 2: Fuel control dial 4: Resistor for PC-EPC valve PC500LC-10R 10-75...
  • Page 170 5: One-touch power maximizing switch 8: Left travel REVERSE pressure sensor 6: Right travel FORWARD pressure sensor 9: Right travel REVERSE pressure sensor 7: Left travel FORWARD pressure sensor 10: Service pressure switch 11: Pump secondary drive switch 10-76 PC500LC-10R...

  • Page 171: Clss

    Valve for control of swash plate angle PC valve (Power Constant) It prevents the engine from stopping by the large load on the engine. LS Valve (Load Sensing) It controls the pump flow rate in accordance with the travel of control lever. PC500LC-10R 10-77...
  • Page 172 It returns the minimum discharged volume from the pump to the tank at neutral. (although the flow amount is little, there is no place for this oil to go) Operating the lever causes the LS pressure which closes the valve. 10-78 PC500LC-10R...

  • Page 173: Operation Of Unload Valve And Ls Pressure

    When lever is operated, spool opens and cylinder is acti- vated. LS pressure (PLS) is transmitted to the spring chamber of unload valve (2), and it is closed by LS pres- sure + set pressure {spring force (F)}. 13MPa 15MPa 3.9MPa 13MPa A4P15703 PC500LC-10R 10-79...

  • Page 174: Pump Swash Plate Angle (Oil Flow) Control

    LS valve (when the actuator load pressure is high). • The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher than the set pressure (when the actuator load pressure is low). 10-80 PC500LC-10R...
  • Page 175 10 STRUCTURE AND FUNCTION CLSS OPERATION OF PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL When lever is in NEUTRAL 1: PPC valve 2: Hydraulic cylinder PC500LC-10R 10-81...
  • Page 176 4: Spool 11: PC valve 5: 2-stage relief valve 12: PC-EPC valve 6: Unload valve 13: LS-EPC valve 7: LS bypass valve 14: Controller 8: Main pump 15: Self-pressure reducing valve 9: Seavo piston 16: 2-stage relief solenoid valve 10-82 PC500LC-10R...
  • Page 177 10 STRUCTURE AND FUNCTION CLSS When balanced PC500LC-10R 10-83...
  • Page 178 CLSS 10 STRUCTURE AND FUNCTION When lever is returned to fine control state 10-84 PC500LC-10R...
  • Page 179 10 STRUCTURE AND FUNCTION CLSS When lever is pulled at a stroke PC500LC-10R 10-85...
  • Page 180 CLSS 10 STRUCTURE AND FUNCTION When lever is in stroke end 10-86 PC500LC-10R...
  • Page 181 LS valve increases and decreases the flow rate until the differential pressure becomes to the set pressure, and returns to the balanced position. • LS valve controls the pump discharged volume to keep the LS differential pressure at constant. • Pump discharged volume is controlled so be in proportion to travel of lever. PC500LC-10R 10-87...
  • Page 182 PC valve to the right against spring. This function enables the pump absorbs 100 % of engine horsepower. • Pump controller controls the PC-EPC current to keep the engine speed at constant by the signal of engine speed sensor. 10-88 PC500LC-10R...
  • Page 183 Pump (1) swash plate angle becomes maximum and flow rate becomes maximum. Range A in P-Q diagram Service piston (2) and follow up link (3) are mechanically connected. As the swash plate angle decreases, follow up link (3) pushes back PC valve spool (4) to the center. PC500LC-10R 10-89...
  • Page 184 PC valve spool (4) moves to the right, and pump pressure is transmitted to the large diameter side of piston (2). Range B in P-Q diagram As the pump pressure increases further and compressed spring (6) reaches to the stroke end, only spring (5) is applied. 10-90 PC500LC-10R...
  • Page 185 If PC valve (4) fails, the engine stops due to the excessive pump absorption horsepower. Controller (7) changes the command current in order to shift the working mode to P, E, B or L. PC500LC-10R 10-91...
  • Page 186 When the one-touch power maximizing function is not activated and the average of front pump and rear pump oil pressure sensor values is 27.9 MPa {285 kg/cm }  or higher. It does not operate when machine is traveling or swing lock switch is “ON”. 10-92 PC500LC-10R...

  • Page 187: Pressure Compensation Control

    If the pressure compensation valve is not installed, ••• CLSS is a parallel circuit, so light load side (B) actuates earlier than heavy load side (A). As a result, performance of the simultaneous operation becomes worse. LS BYPASS PLUG Abbreviation for Load Sensing PC500LC-10R 10-93...
  • Page 188 The effective LS differential pressure decreases, and the dynamic stability of the actuator is improved. A4P15728 LS SELECT VALVE Abbreviation for Load Sensing FUNCTION OF LS SELECT VALVE The illustration shows the state of simultaneous operation of swing and travel RIGHT. (It shows the state when pilot pressure (BP) is supplied) 10-94 PC500LC-10R...
  • Page 189 When piston (3) moves to the right, valve (1) disconnect port (A) from port (B). Since port (A) is disconnected from port (B), swing LS pressure (P1) does not flow to LS shuttle valve. Even swing LS pressure (P1) increases, it does not affect other LS circuits. PC500LC-10R 10-95...

  • Page 190: Engine And Pump Combined Control System

    Various sensor signals 1: Battery disconnect switch 6: Resistor for PC-EPC valve 2: Battery 7: Pump controller 3: Battery relay 8: Engine controller 4: Fusible link 9: Machine monitor 5: Fuse box 10: Pump secondary drive switch 10-96 PC500LC-10R...

  • Page 191: Function Of Engine And Pump Combined Control System

    It controls the pump so that the engine speed is kept around the matching point set in each mode even when the heavy load is applied. • When the engine speed decreases, the pump absorption torque is reduced to prevent engine from being stopped. PC500LC-10R 10-97...
  • Page 192 The controller increases pump absorption upper limit tor- que (PT) to keep the engine speed at around the matching point. (Graph (5)) Control method in mode B and L Working mode Partial output 81 % 62 % Working mode Matching point 195 kW/1660 rpm {261 HP/1660 rpm} 150 kW/1550 rpm {202 HP/1550 rpm} 10-98 PC500LC-10R...
  • Page 193 ENGINE AND PUMP COMBINED CONTROL SYSTEM • In B mode or L mode, engine output is kept constant. • The controller controls pump absorption upper limit torque (PT) so that the engine torque is kept constant along the equal engine horsepower curve. PC500LC-10R 10-99...
  • Page 194 PC-EPC valve at this time. REMARK The pump secondary drive switch (1) is an alternative type. Action level L03 appears on the display if the ma- chine is operated with this switch at emergency (a) position while the machine is normal. 10-100 PC500LC-10R...
  • Page 195 10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM a: Emergency (when abnormal) b: Normal (when normal) PC500LC-10R 10-101...

  • Page 196: Pump And Valve Control System

    9: Machine monitor 3: Battery relay 10: Pump secondary drive switch 4: Fusible link 11: Fuel control dial 5: Fuse box 12: Fuel supply pump 6: Resistor for PC-EPC valve 13: Various sensors 7: Pump controller 14: Front pump 10-102 PC500LC-10R...

  • Page 197: Function Of Pump And Valve Control System

    However, it does not operate in P mode or E mode and when swing lock switch is ON. A: PC-EPC power supply when cut-off function operates 2-stage relief function The relief pressure during work increases when the operating conditions of 2-stage relief function are satisfied. PC500LC-10R 10-103...
  • Page 198 Variable back pressure function is a function that changes the set pressure of the back pressure valve according to the operating state of the machine. Operating condition Setting of back pressure valve During swinging or travel High-pressure set During state other than swinging or travel Low-pressure set 10-104 PC500LC-10R...

  • Page 199: Component Parts Of Hydraulic System

    10: Suction strainer SPECIFICATIONS OF HYDRAULIC TANK Hydraulic tank refill capacity: 377 ℓ Hydraulic tank refill capacity: 279 ℓ Bypass valve set pressure: 0.3±0.05 MPa {3.0±0.5 kg/cm }  HYDRAULIC TANK OIL FILLER CAP STRUCTURE OF HYDRAULIC TANK OIL FILLER CAP Sectional view 1: Bottom plate 2: Gasket PC500LC-10R 10-105...
  • Page 200 (Set pressure of intake valve: 2 ± 0.3 kPa {0.02 ± 0.003 kg/cm } ) BYPASS VALVE STROKE SENSOR OF HYDRAULIC TANK STRUCTURE OF BYPASS VALVE STROKE SENSOR OF HYDRAULIC TANK General view 10-106 PC500LC-10R...
  • Page 201 Bypass valve is opened when the pressure loss is increased and it is lost more than the bypass set pressure, and the voltage is output corresponding to the valve open- ing. PC500LC-10R 10-107...

  • Page 202: Main Pump

    COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION MAIN PUMP STRUCTURE OF MAIN PUMP General view 10-108 PC500LC-10R...
  • Page 203 1: Front pump 6: Rear pump PC valve 2: LS-EPC valve 7: Rear pump LS valve 3: Front pump PC-EPC valve 8: Front pump LS valve 4: Rear pump PC-EPC valve 9: Front pump PC valve 5: Rear pump PC500LC-10R 10-109...
  • Page 204 1: Front shaft 8: Valve plate 2: Cradle 9: End cap 3: Front case 10: Rear shaft 4: Rocker cam 11: Rear case 5: Shoe 12: PC valve 6: Piston 13: Servo piston 7: Cylinder block 14: Slider 10-110 PC500LC-10R...
  • Page 205 The tip of piston (6) is shaped as a concave sphere and is crimped with the shoe (5). • Piston (6) and shoe (5) form a spherical bearing. • Rocker cam (4) has flat surface (A), and the shoe (5) is always pressed against this surface while sliding in a circular pattern. PC500LC-10R 10-111...
  • Page 206 The impeller (18) is connected to the shaft (1) through the bevel gear (17). As they rotate together with the shaft (1), the sucked pressurized oil is sent into the cylinder block (7) by centrifugal force to help suction. FUNCTION OF MAIN PUMP 10-112 PC500LC-10R...
  • Page 207 (7) (the swash plate an- gle is zero). The suction and discharge of pressurized oil is not per- formed. The pumping action is not performed. (Angle of swash plate does not become zero actually) PC500LC-10R 10-113...
  • Page 208 (PP) and the large diameter side (PEN) and by the ra- tio of the area receiving the pressure between the small di- ameter piston and the large diameter piston. MAIN PUMP LS VALVE Abbreviation for Load Sensing 10-114 PC500LC-10R...
  • Page 209 LS-EPC valve as shown in the figure. • When (ISIG) varies from 0A to 1A, the set pressure of the spring changes, and the selector point for pump dis- charged volume changes as shown in the figure below. PC500LC-10R 10-115...
  • Page 210 Spool (6) is pushed to the right, and port (C) and port (D) are connected. Pump discharged pressure (PP) is sent from the port (K) to A4P21604 the large diameter side of piston. The same pump discharged pressure (PP) is sent to the small diameter side of piston. 10-116 PC500LC-10R...
  • Page 211 If piston (7) is pushed to the right, the set force of spring (4) is reduced, and LS differential pressure (∆PLS) “difference between oil pressures (PLS) and (PP)” changes when port (D) and port (E) of spool (6) are con- nected. PC500LC-10R 10-117...
  • Page 212 (12) is pushed to the right by the area difference between the large diameter side and small diameter side of servo piston (12). As a result, the pump swash plate angle decreases. When LS set select pressure (PSIG) enters port (G), the set force of spring (4) is decreased. 10-118 PC500LC-10R...
  • Page 213 When (PSIG) [“output pressure of LS-EPC valve, 0 to 2.9 MPa 30 kg/cm ”] is applied to port (G), the bal- anced position changes in the range of (PP) - (PLS) = 2.65 MPa {27 kg/cm }  to 1.18 MPa {12 kg/cm }  in proportion to pressure (PSIG). MAIN PUMP PC VALVE Abbreviation for Pressure Compensation PC500LC-10R 10-119...
  • Page 214 PC-EPC valve solenoid increases according to the de- crease of the engine speed, and the pump inclination an- gle decreases. • The controller counts the actual engine r.p.m. 10-120 PC500LC-10R...
  • Page 215 The other pump pressure means the pressure of the pump on the opposite side. The other pump pressure for the front pump is the rear pump pressure, and that for the rear pump is the front pump pressure. PC500LC-10R 10-121...
  • Page 216 The port (C) is connected to port (D), and the pressure entering LS valve is to be drain pressure (PT). 10. When port (E) and port (G) of LS valve are connected, the pressure entering from port (J) to large diameter piston side becomes drain pressure (PT), and servo piston (9) moves to the left. 10-122 PC500LC-10R...
  • Page 217 When spool (3) moves to the left, the opening of ports (C) and (D) expands. The pressure (= J) in port (C) decreases and the servo piston (9) stops moving to the right. PC500LC-10R 10-123...
  • Page 218 (3), the relationship between average of pump pressures (PP1+ PP2)/ 2 and pump discharged volume (Q) is translated from (A) to (B) as command current (X) in- creases. 10-124 PC500LC-10R...
  • Page 219 The port (C) is connect to the drain pressure in port (D). The large diameter piston side of servo piston (9) is also set to the drain pressure (PT) through LS valve. The pressure on the small diameter piston side is high, and servo piston (9) moves in the direction to in- crease the discharged volume. PC500LC-10R 10-125...
  • Page 220 The curves of pump discharged pressure (PP) and discharged volume (Q) are determined corresponding to the current value supplied to PC-EPC valve solenoid through the resistor when the pump secondary drive switch is turned on as shown in the figure. 10-126 PC500LC-10R...
  • Page 221 (B) is further to the left than that of when the pump controller is normal (A). MAIN PUMP LS-EPC VALVE Abbreviation for Load Sensing Abbreviation for Electromagnetic Proportional Control STRUCTURE OF MAIN PUMP LS-EPC VALVE LS-EPC valve generates EPC output pressure and outputs it to LS valve. PC500LC-10R 10-127...
  • Page 222 COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION General view, sectional view C: To LS valve T: To hydraulic tank P: From self-pressure reducing valve 1: Connector 5: Spool 2: Coil 6: Rod 3: Body 7: Plunger 4: Spring 10-128 PC500LC-10R...
  • Page 223 Port (P) is closed, and the pressurized oil from the self- pressure reducing valve does not flow to the LS valve. The pressurized oil from the LS valve is drained to the tank through port (C) and then port (T). PC500LC-10R 10-129...
  • Page 224 EPC valve and LS valve is maximized. The pressurized oil does not flow to the tank since the port (T) is closed. MAIN PUMP PC-EPC VALVE Abbreviation for Pressure Compensation 10-130 PC500LC-10R...
  • Page 225 PC-EPC valve generates EPC output pressure and outputs it to PC valve. General view and sectional view C: To PC valve T: To hydraulic tank P: From self-pressure reducing valve 1: Connector 5: Spool 2: Coil 6: Rod 3: Body 7: Plunger 4: Spring PC500LC-10R 10-131...
  • Page 226 Spool (5) is pushed to the left by spring (4). Port (P) is closed, and the pressurized oil from the self- pressure reducing valve does not flow to PC valve. The pressurized oil from PC valve is drained to the tank through port (C) and port (T). 10-132 PC500LC-10R...
  • Page 227 The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between the EPC valve and PC valve is maximized. The pressurized oil does not flow to the tank since the port (T) is closed. PC500LC-10R 10-133...
  • Page 228 Since these valves are formed in one unit with connecting bolts and the passages are connected inside, the control valve is compact and serviced very easily. The structure of this control valve is simple with actuator-to-spool type. The structure of the 8-spool valve (6-spool valve with Hi-valve and service valve) is explained below. 10-134 PC500LC-10R...
  • Page 229 A6: To arm cylinder head A2: To left travel motor A-1: To boom cylinder bottom A3: To boom cylinder bottom A-2: To attachment A4: To swing motor B1: To bucket cylinder head A5: To right travel motor B2: To left travel motor PC500LC-10R 10-135...
  • Page 230 10: Cover A 4: Merge-divider EPC valve (for main spool) 11: Service valve 5: Arm check valve 12: Arm quick return valve 6: Boom hydraulic drift prevention valve 13: Cover B 7: Boom Hi-valve, arm Hi-valve 14: Merge-divider valve 10-136 PC500LC-10R...
  • Page 231 5: Pressure compensation valve (left travel RE- 12: Pressure compensation valve (boom LOWER) VERSE) 13: Pressure compensation valve (swing RIGHT) 6: Pressure compensation valve (bucket CURL) 14: Pressure compensation valve (right travel FOR- 7: Pressure compensation valve (boom Hi RAISE) WARD) PC500LC-10R 10-137...
  • Page 232 26: Spool (arm) 20: Spool (arm Hi) 27: Spool (boom Hi) 21: Spool (bucket) Sectional views (C-C, D-D, AE-AE) 1: Suction valve(arm OUT) 3: Suction valve (boom RAISE) 2: Suction valve (right travel REVERSE) 4: Suction valve (left travel REVERSE) 10-138 PC500LC-10R...
  • Page 233 19: LS shuttle valve (bucket) 11: Suction 2-stage safety valve (boom LOWER) 20: LS shuttle valve (service) 12: Suction valve (right travel FORWARD) 21: LS check valve 13: Suction safety valve (arm IN) Sectional views (E-E, F-F, G-G, H-H) PC500LC-10R 10-139...
  • Page 234 19: LS select valve 8: Spool 20: Pressure compensation valve (right) 9: Suction safety valve (digging) 21: Spool 10: Check valve for regeneration circuit 22: Pressure compensation valve (left) 11: Suction valve (dump) 12: Pressure compensation valve (DUMP) 10-140 PC500LC-10R...
  • Page 235 5: Merge-divider valve (main) 13: Suction valve (RAISE) 6: Return spring 14: Pressure compensation valve (RAISE) Boom valve Left travel valve 7: Boom hydraulic drift prevention valve 15: Merge-divider valve (travel junction valve) 8: LS shuttle valve 16: Return spring PC500LC-10R 10-141...
  • Page 236 22: Pressure compensation valve (REVERSE) 28: Pressure compensation valve (digging) Bucket valve Sectional views (N-N, AA-AA, AB-AB, AD-AD, BB-BB) Boom Hi-valve, arm Hi-valve 2: Arm quick return valve 1: Boom Hi check valve 3: Pressure compensation valve (arm Hi IN) 10-142 PC500LC-10R...
  • Page 237 7: Suction valve (boom Hi RAISE) 14: Pressure compensation valve 8: Pressure compensation valve (boom Hi RAISE) 15: Unload valve Service valve 16: Main relief valve 9: LS shuttle valve 17: LS bypass plug 10: Pressure compensation valve PC500LC-10R 10-143...
  • Page 238 COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF VALVES 1: Arm valve 2: Right travel valve 10-144 PC500LC-10R...
  • Page 239 PRESSURE COMPENSATION VALVE OF CONTROL VALVE FUNCTION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE In this machine, the built-in pressure compensation type valve is employed for the travel valve, bucket valve (cylinder bottom), swing valve, arm Hi-valve (cylinder bottom), and service valve. PC500LC-10R 10-145...
  • Page 240 (example: when the breaker is used), valve (2) collides with valve chamber seat (C), and high pressure can occur. To prevent this, the pressure compensation valve having valve (2) and piston (4) as one unit in it is used. 10-146 PC500LC-10R...
  • Page 241 Since the spool meter-in upstream pressure at port (A) is the pump pressure, the spool meter-in differential pressure “Upstream pressure (Port (A) pressure) - Downstream pressure (Port (B))” is the same in all the spools in operation. • The pump discharged volume is divided at the meter-in opening area ratio. PC500LC-10R 10-147...
  • Page 242 Piston (4) and valve (2) move in the closing direction (right side) with the LS circuit pressure from other work equipment of port (F). The valve upstream pressure (= spool meter-in downstream pressure) at port (B) is controlled by LS pres- sure. 10-148 PC500LC-10R...
  • Page 243 • When the surface area ratio is smaller than 1, the spool meter-in downstream pressure is lower than the maximum load pressure, and the oil flow is divided more than the surface area ratio. PC500LC-10R 10-149...
  • Page 244 STRUCTURE OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF CONTROL VALVE When traveling 1: Main pump 5: Pressure compensation valve Pressure compensation valve (5) without shuttle valve is employed since no holding pressure is applied to port (A) of the travel circuit. 10-150 PC500LC-10R...
  • Page 245 The holding pressure in port (A) is sent to spring chamber (B) and presses piston (4) to the left so that pis- ton (4) and valve (2) do not separate from each other. INTRODUCTION OF LS PRESSURE IN CONTROL VALVE Abbreviation for Load Sensing PC500LC-10R 10-151...
  • Page 246 Introduction hole (a) in main spool (2) is small in diameter and used as an orifice. • LS pressure is used as source pressure for closing the unload valve and as operating pressure when the pressure compensation valve is compensated. 10-152 PC500LC-10R...
  • Page 247 When the main spool (2) is operated, the pump pressure enters introduction port (a), and it is introduced to LS circuit. When the pump pressure reaches the load pressure on port (B), the check valve (5) opens and the pressur- ized oil flows. LS BYPASS PLUG OF CONTROL VALVE Abbreviation for Load Sensing PC500LC-10R 10-153...
  • Page 248 COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION STRUCTURE OF LS BYPASS PLUG OF CONTROL VALVE 1: Main pump 4: LS shuttle valve 2: Main spool 5: LS bypass plug 3: Pressure compensation valve 6: LS circuit 10-154 PC500LC-10R...
  • Page 249 (c) of main spool (2) to LS shuttle valve (4). • The LS bypass plug of control valve lowers the differential pressure of the effective LS circuit in order to improve the dynamic stability of actuator. PC500LC-10R 10-155...
  • Page 250 Hi-valve looks as if it has only 1 spool, but it actually has divided 2 spools. The left side is the boom Hi-spool, and the right side is the arm Hi-spool. The arm Hi-spool moves to both right and left, and the 2 spools are inde- pendently controlled. A4P15733 A: From boom Lo valve B: From arm Lo valve 10-156 PC500LC-10R...
  • Page 251 FUNCTION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE When the cylinder head pressure is lower than the bottom pressure (when hy- draulic drift, etc.) 1: Main pump 3: Pressure compensation valve 2: Boom valve spool 4: Suction safety valve PC500LC-10R 10-157...
  • Page 252 When the cylinder head pressure is higher than the bottom pressure (when dig- ging, etc.) Check valve (6) installed to regeneration circuit (C) closes to stop the oil flow from the cylinder bottom to the cylinder head. 10-158 PC500LC-10R...
  • Page 253 (B) from the notch of boom spool (2). The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom through circuit (D). The flows from regeneration circuit (C) and main pump (1) merge in circuit (E). PC500LC-10R 10-159...
  • Page 254 7: LS shuttle valve 4: Suction safety valve Cylinder speed is increased by the regeneration circuit from cylinder head to cylinder bottom during arm IN op- eration, since the cylinder flow rate becomes pump discharged volume plus regenerated volume. 10-160 PC500LC-10R...
  • Page 255 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM When cylinder head pressure is lower than bottom pressure Check valve (6) installed to regeneration circuit (C) closes to cut the oil flow from the cylinder head to the cylin- der bottom. PC500LC-10R 10-161...
  • Page 256 (B) through the notch of arm spool (2). The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder bottom through circuit (D). The flows from regeneration circuit (C) and main pump (1) merge in circuit (E). 10-162 PC500LC-10R...
  • Page 257 10: Merge-divider EPC valve (for selecting LS spool) • This valve merges the pressurized oil (P1) and (P2) discharged from two pumps, or divides them (to each control valve groups). • This valve merges or divides the LS circuit pressure. PC500LC-10R 10-163...
  • Page 258 LS spool (3) is pushed to the right by the spring (4) since EPC valve drive signal (IS2) is not given. Port (A) and port (D) are connected. Port (B) and (C) are connected. LS pressure which is led from the control valve spools to LS circuits (5), (6), (7), and (8) is sent to all pres- sure compensation valves. 10-164 PC500LC-10R...
  • Page 259 LS SEPARATION VALVE OF CONTROL VALVE Abbreviation for Load Sensing FUNCTION OF LS SELECT VALVE OF CONTROL VALVE The illustration shows the state of simultaneous operation of swing and travel RIGHT. “When pilot pressure (BP) is supplied” PC500LC-10R 10-165...
  • Page 260 Swing LS pressure (P1) pushes valve (1) to the left, and port (A) is connected to port (B). Swing LS pressure (P1) flows from port (A) through port (B) to LS shuttle valve (8). AEP21620 u ON v Swing AEP21619 10-166 PC500LC-10R...
  • Page 261 AEP21619 SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE FUNCTION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE This valve reduces the discharged pressure of the main pump and supplies it as control pressure to the solenoid valves, EPC valves, etc. PC500LC-10R 10-167...
  • Page 262 Since valve (14) is pressed to the left by spring (13), the circuit between port (P2) and port (TS) is closed. Since valve (7) is pressed to the left by spring (8), the cir- cuit between port (P2) and port (A2) is closed. AEP21622 10-168 PC500LC-10R...
  • Page 263 (P2) and port (PR). Pressure (P2) is reduced and kept constant (at set pres- sure) according to the area of the opening at this time, and it is supplied as pressure (PR). AEP21624 PC500LC-10R 10-169...
  • Page 264 When the travel lever is operated for steering, the travel junction valve receives pilot pressure (PST) from the travel junction solenoid valve, and accordingly R.H. and L.H. travel circuits are disconnected, and inde- pendent oils are supplied individually to R.H. and L.H. travel motors to keep the steering performance. 10-170 PC500LC-10R...
  • Page 265 (2) to the port on the low pres- sure side to compensate for the differential pressure, and oil is supplied to R.H. and L.H. motors evenly. PC500LC-10R 10-171...
  • Page 266 (1) and moves to the right, and port (PTL) and port (PTR) are disconnected. Independent oil flows are supplied to R.H. and L.H. travel motors. TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE Abbreviation for Proportional Pressure Control 10-172 PC500LC-10R...
  • Page 267 The oil in stroke limit signal chamber (a) flows through orifices (5) and (6) of pistons (3) and (4) in the travel spring case, and flows through travel PPC valve and then drained. When the arm is moved IN, spool (1) moves to the left until it touches the end surface of spring case (2) (st0). PC500LC-10R 10-173...
  • Page 268 (6) of piston (4) to the left end surface of piston (8) to push piston (8) to the right side. When the arm is moved IN, spool (1) moves to the left. Maximum stroke of spool is reduced by the moving amount of piston (8) to the right side (st2), and be- comes (st1). 10-174 PC500LC-10R...
  • Page 269 AEP21629 When the boom is not operated with the R.H. work equipment control lever, this function is used to prevent the pressurized oil in the boom cylinder bottom from leaking through spool (1) and causing boom hydraulic drift. PC500LC-10R 10-175...
  • Page 270 The force acting leftward on area (S) pushes and compresses spring (4) and moves poppet (5) to the left. The oil from the control valve flows through the opening of poppet (5) to the bottom side of the boom cylin- der. 10-176 PC500LC-10R...
  • Page 271 The combined force of the force acting rightward on area (S) and the reaction force of spring (4) moves poppet (5) to the right. The circuit from the control valve to he boom cylinder bottom is shut off, and the oil pressure on the boom cylinder side is hold. PC500LC-10R 10-177...
  • Page 272 When the pressure in chamber (b) decreases below the pressure in port (B), poppet (5) opens. When poppet (5) opens, the pressurized oil from port (B) flows to port (A), and then flows to the control valve. ARM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE (Machine with arm hydraulic drift prevention valve) 10-178 PC500LC-10R...
  • Page 273 A E P 2 1 6 0 7 When the arm is not operated with the L.H. work equipment control lever, this function is used to prevent the pressurized oil in the arm cylinder head from leaking through spool (1) and causing arm hydraulic drift. PC500LC-10R 10-179...
  • Page 274 (d2). The force acting leftward on area (S) compresses spring (4) and moves poppet (5) to the left. The pressurized oil from the control valve flows through the opening of poppet (5) to the arm cylinder head. 10-180 PC500LC-10R...
  • Page 275 The combined force of the force acting rightward on area (S) and the reaction force of spring (4) moves poppet (5) to the right. The circuit from the control valve to the arm cylinder head is shut off, and the oil pressure on the arm cylin- der head side is hold. PC500LC-10R 10-181...
  • Page 276 Chamber (b) in the poppet is connected to drain port (T), and the pressure in chamber (b) decreases. When the pressure in chamber (b) decreases below the pressure in port (B), poppet (5) opens. When poppet (5) opens, the pressurized oil from port (B) flows to port (A), and then flows to the control valve. 10-182 PC500LC-10R...
  • Page 277 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM SUCTION SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE OPERATION OF SUCTION SAFETY VALVE FOR HYDRAULIC DRIFT PREVEN- TION VALVE OF CONTROL VALVE When the abnormally high pressure occurs AEP21610 PC500LC-10R 10-183...
  • Page 278 The pressurized oil in the chamber (b) inside the valve is drained through the orifice (c). The pressurized oil in the arm cylinder bottom flows to drain port (T) through orifice (a), chamber (b), and orifice (c). Chamber (b) is connected to drain port (T), and the pressure in chamber (b) decreases. 10-184 PC500LC-10R...
  • Page 279 (S2) of valve (2) and area (S1). The combined force of the force acting rightward on the area of the ring and the reaction force of spring (3) moves valve (2) to the right, and port (A) and port (B) are disconnected. PC500LC-10R 10-185...
  • Page 280 "d" x Pressure (PR) + Reaction force of spring (5) ) / Area of diameter "d1" The oil flow from drain circuit (A) of the control valve to port (T) is adjusted to the set pressure of variable back A EP2 16 1 4 pressure valve (4). 10-186 PC500LC-10R...
  • Page 281 (T) is adjusted to the set pressure of variable back pressure valve (4). A EP2 16 1 5 MAIN RELIEF VALVE OF CONTROL VALVE STRUCTURE OF MAIN RELIEF VALVE OF CONTROL VALVE Sectional view 1: Spring 2: Poppet PC500LC-10R 10-187...
  • Page 282 1st stage changes. OPERATION OF MAIN RELIEF VALVE OF CONTROL VALVE When pilot pressure (P) is cut off (low pressure setting) The set pressure is determined by the installed load of spring (1). 10-188 PC500LC-10R...
  • Page 283 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE STRUCTURE OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE Sectional view “Port (B) of boom valve and port (B) of service valve” 1: Spring 3: Spring 2: Piston 4: Holder PC500LC-10R 10-189...
  • Page 284 Set pressure decreases since the tension of spring (1) is lowered and the load at installed height decreases. AEP21 632 Pressurized oil caused by the stroke of piston (2) is drained through the passage (C) and the chamber (D). 10-190 PC500LC-10R...

  • Page 285: Work Equipment System

    LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM Chassis part 1: Bucket cylinder 5: Accumulator 2: Arm cylinder 6: Hydraulic oil additional filter (with clogging switch) 3: Boom cylinder 7: Fuel supply pump 4: Attachment selector valve 8: Engine controller PC500LC-10R 10-191...
  • Page 286 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION 8: Main pump 10: Front pump PC-EPC valve 9: Rear pump PC-EPC valve 10-192 PC500LC-10R...
  • Page 287 12: Control valve 16: Machine push-up solenoid valve 13: Solenoid valve 17: PPC lock solenoid valve 14: 2-stage relief solenoid valve 18: Rear pump oil pressure sensor Around cab and floor 1: Machine monitor 2: R.H. work equipment PPC valve PC500LC-10R 10-193...
  • Page 288 14: Left travel FORWARD pressure sensor 8: One-touch power maximizing 15: Left travel REVERSE pressure sensor 9: Service pressure switch 16: Right travel REVERSE pressure sensor 17: Pump controller 19: Resistor for PC-EPC valve 18: Emergency pump drive switch 10-194 PC500LC-10R...

  • Page 289: One-Touch Power Maximizing System

    13: Various sensors 19d: Main relief valve 14: One-touch power maximizing switch 20: Front pump PC-EPC valve 15: Front pump oil pressure sensor 21: Rear pump PC-EPC valve 16: Rear pump oil pressure sensor 22: 2-stage relief solenoid valve PC500LC-10R 10-195...
  • Page 290 }  Cutoff function Cancel The one-touch power maximizing system keeps increasing the power while one-touch power maximizing switch (1) is pressed. Even if the switch is kept pressed, this function is canceled au- tomatically in approximately 8.5 seconds. 10-196 PC500LC-10R...

  • Page 291: Machine Push-Up System

    4: Fusible link 12: Fuel supply pump 5: Fuse box 13: Various sensors 6: Resistor for PC-EPC valve 14: Machine push-up switch 7: Pump controller 15: Front pump oil pressure sensor 8: Engine controller 16: Rear pump oil pressure sensor PC500LC-10R 10-197...
  • Page 292 This function is used to increase the push force of the boom for ditching or excavating hard ground. Function Setting Boom cylinder head Safety valve set pressure 14.7 MPa {150 kg/cm }  Boom cylinder head Safety valve set pressure 28.4 MPa {290 kg/cm }  10-198 PC500LC-10R...

  • Page 293: Ppc Lock System

    • When PPC lock switch is turned OFF, the current flowing into PPC lock solenoid valve is cut out, and the work equipment and machine body do not move even if any control lever or pedal is operated. PC500LC-10R 10-199...

  • Page 294: Work Equipment And Travel Automatic Lock System

    This function automatically sets the lock lever in the same state as when it is locked to prevent the work equip- ment or the machine continues its operation when the lock lever is unlocked while the work equipment control lever or the travel lever is operated. 10-200 PC500LC-10R...
  • Page 295 The following failure codes are recorded when this switch is “ON”. Action level Failure code Failure (displayed on screen) DDNS00 Lock Lever Auto Lock Release SW On PC500LC-10R 10-201...

  • Page 296: Oil Flow Adjuster System For Attachment

    9: Machine monitor 3: Battery relay 10: Pump secondary drive switch 4: Fusible link 11: Fuel control dial 5: Fuse box 12: Fuel supply pump 6: Resistor for PC-EPC valve 13: Various sensors 7: Pump controller 14: Oil pressure switch 10-202 PC500LC-10R...
  • Page 297 When the attachment control pedal is depressed fully, the oil flow to the attachment is controlled by setting the working mode and oil flow with the machine monitor. The operation of the attachment changes as shown in the table below, depending on the working mode. Working mode Operation of attachment ATT/P, ATT/E Double-acting Single-acting PC500LC-10R 10-203...

  • Page 298: Component Parts Of Work Equipment System

    COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM WORK EQUIPMENT AND SWING PPC VALVE Abbreviation for Proportional Pressure Control STRUCTURE OF WORK EQUIPMENT AND SWING PPC VALVE General view 10-204 PC500LC-10R...
  • Page 299 R.H. work equipment control lever P: From self-pressure reducing valve P1: To control valve (boom LOWER port) P2: To control valve (boom RAISE port) P3: To control valve (bucket CURL port) P4: To control valve (bucket DUMP port) T: To hydraulic tank PC500LC-10R 10-205...
  • Page 300 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION Sectional view 1: Spool 3: Disc 2: Piston 4: Nut (for connecting lever) 10-206 PC500LC-10R...
  • Page 301 The control valve spool moves to a position where the pressure in the port (A) which is “equal to the pres- sure in the port (P1)” is balanced with the reaction force of the return spring of the control valve spool. PC500LC-10R 10-207...
  • Page 302 (f') to the drain chamber (D). 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) Abbreviation for Proportional Pressure Control Abbreviation for Electromagnetic Proportional Control STRUCTURE OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) (Machines ready for installation of attachment) 10-208 PC500LC-10R...
  • Page 303 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM General view and sectional view P: From self-pressure reducing valve P2: To control valve (service valve 1 port) P1: To control valve (service valve 1 port) T: To hydraulic tank PC500LC-10R 10-209...
  • Page 304 For explanation of operation of PPC valve, see “Operation of work equipment and swing PPC valve”. EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE Abbreviation for Proportional Pressure Control Abbreviation for Electromagnetic Proportional Control STRUCTURE OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE (Machines ready for installation of attachment) 10-210 PC500LC-10R...
  • Page 305 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM General view and sectional view P: From self-pressure reducing valve T: To hydraulic tank C: To PPC valve (R.H. attachment) 1: Body 5: Plunger 2: Spool 6: Push pin 3: Spring 7: Connector 4: Coil PC500LC-10R 10-211...
  • Page 306 OPERATION OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE When signal current is zero (coil is de-energized) AEP2 1 6 3 6 When the signal current from the controller does not flow into coil (4), coil (4) is de-energized. 10-212 PC500LC-10R...
  • Page 307 Spool (2) moves up and down so that the thrust force of plunger (5) is balanced with the total of the pres- sure in port (C) and load of spring (3). The circuit pressure between EPC valve and control valve is controlled in proportion to the signal current. PC500LC-10R 10-213...
  • Page 308 The maximum rate of the pressurized oil flows from port (P) to port (C), and the circuit pressure between EPC valve and control valve becomes the maximum. The port (T) closes and no pressurized oil flows into the hydraulic tank. 10-214 PC500LC-10R...
  • Page 309 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM SOLENOID VALVE STRUCTURE OF SOLENOID VALVE General view and sectional view PC500LC-10R 10-215...
  • Page 310 The circuit between port (P) and port (A) opens and pilot pressure flows from port (A) to the actuator. At the same time, port (T) closes and oil from the actuator does not flow to the hydraulic tank. AE P2 16 3 5 10-216 PC500LC-10R...
  • Page 311 When the engine is running, the pilot pressure in port (P) pushes plunger (1) to the right, and port (P) and port (ACC) are interconnected. ATTACHMENT CIRCUIT SELECTOR VALVE (Machine with attachment) STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE General view and sectional view P1: From attachment selector solenoid valve V: To control valve attachment 1 port PC500LC-10R 10-217...
  • Page 312 Spool (1) is pressed to the left by the force of spring (2). Port (ATT) is connected to port (V), and port (ATT) is dis- connected from port (T), and the attachment is connected to the control valve. 10-218 PC500LC-10R...
  • Page 313 (T) without passing through the control valve. PILOT CIRCUIT ACCUMULATOR STRUCTURE OF PILOT CIRCUIT ACCUMULATOR General view and sectional view 1: Gas plug 2: Shell 3: Poppet 4: Holder 5: Bladder 6: Oil port PC500LC-10R 10-219...
  • Page 314 }  HYDRAULIC OIL ADDITIONAL FILTER CLOGGING SWITCH FUNCTION OF HYDRAULIC OIL ADDITIONAL FILTER CLOGGING SWITCH If the hydraulic oil additional filter is clogged, the pressure difference between the upstream side and down- stream side of the filter increases. 10-220 PC500LC-10R...
  • Page 315 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM If the pressure difference between the upstream side and downstream side exceeds the operation pressure of clogging switch of hydraulic oil additional filter, the hydraulic oil addition- al filter caution lamp lights up on the machine monitor. PC500LC-10R 10-221...

  • Page 316: Swing System

    LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION SWING SYSTEM LAYOUT DRAWING OF SWING SYSTEM Chassis part 1: Swing circle 4: Swing motor 2: Center swivel joint 5: Control valve 3: Swing machinery 6: Main pump 10-222 PC500LC-10R...
  • Page 317 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM 7: Right swing oil pressure sensor 8: Left swing oil pressure sensor PC500LC-10R 10-223...
  • Page 318 LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION 9: Swing parking brake solenoid valve 10: 2-stage swing relief solenoid valve Around cab and floor 10-224 PC500LC-10R...
  • Page 319 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM 1: Machine monitor 4: L.H. work equipment PPC valve 2. R.H. work equipment PPC valve 5: Attachment PPC valve 3: Swing lock switch 6: Swing parking brake cancel switch 7: Pump controller PC500LC-10R 10-225...

  • Page 320: Swing Control System Diagram

    • To reduce the load on the swing device during digging work, the swing parking brake is canceled simultaneously with operations of R.H. and L.H. work equipment control levers and attachment control pedal. 10-226 PC500LC-10R...
  • Page 321 • Even if swing parking brake cancel switch (2) is set to CANCEL position (a), the swing parking brake is not canceled while the swing lock switch is enabled. • The swing parking brake cancel switch (2) is an alternate type. When it is set to CANCEL (a) position, the swing lock monitor on the machine monitor flashes. PC500LC-10R 10-227...
  • Page 322 (except repeating an abrupt swing) 100 ℓ/min Relationship between set pressure and flow rate A: When pilot pressure is blocked (low-pressure setting) B: When pilot pressure is supplied (high-pressure setting) P: 27.9 MPa {285 kg/cm }  Q1: 260 ℓ/min Q2: 100 ℓ/min Characteristics of 2-stage swing relief valve 10-228 PC500LC-10R...
  • Page 323 10 STRUCTURE AND FUNCTION SWING CONTROL SYSTEM DIAGRAM A: Flow rate when low pressure is set B: Flow rate when high pressure is set C: Flow rate necessary to swing Z: Loss reduction (fuel efficiency improvement) range during relief PC500LC-10R 10-229...

  • Page 324: Component Parts Of Swing System

    S: From control valve (variable back pressure valve) MB: From control valve (swing LEFT port) T: To hydraulic tank B: From swing parking brake solenoid valve PU: 2-stage swing relief solenoid valve 1: Reverse prevention valve 2: 2-stage swing relief valve 10-230 PC500LC-10R...
  • Page 325 Sectional view 1: Brake spring 8: Housing 2: Drive shaft 9: Piston 3: Oil seal 10: Cylinder block 4: Case 11: Valve plate 5: Disc 12: Center shaft 6: Plate 13: Center spring 7: Brake piston 14: Check valve PC500LC-10R 10-231...
  • Page 326 The disc (5) and plate (6) are pressed. Accordingly, the swing parking brake is applied. When solenoid valve is energized (swing parking brake is canceled) The valve is switched when the swing parking brake solenoid valve is energized. 10-232 PC500LC-10R...
  • Page 327 (a) through port (B). The pressurized oil in chamber (a) compresses brake spring (1), and the brake piston (7) is moved upward. The disc (5) and plate (6) are separated. Accordingly, the swing parking brake is canceled. PC500LC-10R 10-233...
  • Page 328 • If the motor outlet circuit pressure increases abnormally, it may damage the motor. • Abnormally high pressure is released from the motor outlet (high-pressure side) to port (S) to prevent damage to the motor. 10-234 PC500LC-10R...
  • Page 329 During swing acceleration, the pilot pressure from the 2- stage swing relief solenoid valve is added to port (PU), and the relief rate is limited. The pressurized oil from the motor outlet returns to the tank through port (MB) and control valve (6). PC500LC-10R 10-235...
  • Page 330 While 2-stage swing relief valve (1) is in operation, the re- lieved pressurized oil and the pressurized oil from port (S) are supplied to port (MA) through check valve (3). Cavitation in port (MA) is prevented. AEP20509 10-236 PC500LC-10R...
  • Page 331 • The set pressure depends on the load at installed height of spring (4). • During swing acceleration, the relief rate (drain rate) is reduced by receiving pilot pressure (PU) from the 2- stage swing relief solenoid valve. PC500LC-10R 10-237...
  • Page 332 P: 27.9 MPa {286 kg/cm }  Q1:260 ℓ/min Q2:100 ℓ/min OPERATION OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR When the pilot pressure (PU) is not supplied (low pressure setting) The set pressure depends on the load at installed height of the spring (4). 10-238 PC500LC-10R...
  • Page 333 The spring (4) is compressed and its installed load increases, and the pump discharged volume is reduced by the controller and the passage between valve (2) and valve seat (1) is choked. By the above operation, the relief rate is reduced when the relief pressure is kept constant. PC500LC-10R 10-239...
  • Page 334 COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION SWING MOTOR REVERSE PREVENTION VALVE STRUCTURE OF SWING MOTOR REVERSE PREVENTION VALVE General view and sectional view 10-240 PC500LC-10R...
  • Page 335 This valve can reduce such movement. • The valve contributes in preventing spill of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, and enables to proceed to the next work quicker). PC500LC-10R 10-241...
  • Page 336 Port (MA) and chamber (b) are connected. The oil flows through drilled hole (h) of spool (5) and port (b) and port (f) are connected. The reverse pressure of port (MA) is bypassed to port (T) to prevent the second re- verse rotation. 10-242 PC500LC-10R...
  • Page 337 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM SWING MACHINERY STRUCTURE OF SWING MACHINERY General view and sectional view PC500LC-10R 10-243...
  • Page 338 Swing reduction ratio: 26.053 x (84/13)=168.340 Swing speed: 9.1 rpm FUNCTION OF SWING MACHINERY The swing machinery reduces the swing motor speed, increases the swing force, and reduces the swing speed to proper speed. SWING CIRCLE STRUCTURE OF SWING CIRCLE Machine with tube 10-244 PC500LC-10R...
  • Page 339 General view and sectional view a: Position of outer race soft zone b: Position of inner race soft zone mark (S) 1: Greasing port of swing circle pinion 4: Outer race 2: Inner race (quantity of teeth: 84) 5: Seal 3: Ball PC500LC-10R 10-245...
  • Page 340 Position of inner race soft zone mark (S) 1: Greasing port of swing circle pinion 4: Outer race 2: Inner race (quantity of teeth: 84) 5: Seal 3: Ball SPECIFICATIONS OF SWING CIRCLE Reduction ratio: -84/13 = -6.462 Grease: G2-LI Quantity of grease: 33.0 ℓ 10-246 PC500LC-10R...
  • Page 341 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM FUNCTION OF SWING CIRCLE The swing circle connects the upper structure and carrier unit. PC500LC-10R 10-247...

  • Page 342: Travel System

    LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION TRAVEL SYSTEM LAYOUT DRAWING OF TRAVEL SYSTEM 1: Control valve 4: Main pump 2: Fuel supply pump 5: LS-EPC valve 3: Engine controller 6: Travel alarm 10-248 PC500LC-10R...
  • Page 343 12: Right travel FORWARD pressure sensor 8: Machine monitor 13: Travel PPC valve 9: Fuel control dial 14: Left travel FORWARD pressure sensor 10: Pump controller 15: Left travel REVERSE pressure sensor 11: Right travel REVERSE pressure sensor PC500LC-10R 10-249...
  • Page 344 LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION 16: Control valve 19: Rear pump oil pressure sensor 17: Travel speed increase solenoid valve 20: Front pump oil pressure sensor 18: Travel junction solenoid valve 10-250 PC500LC-10R...
  • Page 345 10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM 21: Center swivel joint 22: Travel motor PC500LC-10R 10-251...

  • Page 346: Travel Control System Diagram

    14: Travel motor 11: Front pump 15: Travel speed increase solenoid valve 11a: Servo 16: Travel junction solenoid valve 11b: LS valve 17: LS-EPC valve FUNCTION OF TRAVEL CONTROL SYSTEM Travel speed selector function Manual gear shift of travel speed 10-252 PC500LC-10R...
  • Page 347 • In the steering operation, signals to the travel junction solenoid valve are blocked to set the flow rates to the right and left travel motors independently to improve the travel performance during steering. PC500LC-10R 10-253...

  • Page 348: Component Parts Of Travel System

    B: Brake pressure pickup port R.H. travel motor MA: Port (MA) pressure pickup port PA: From control valve (right travel FORWARD port) MB: Port (MB) pressure pickup port PB: From control valve (right travel REVERSE port) 1: Bleeder 10-254 PC500LC-10R...
  • Page 349 8. Quick return valve 2: Motor case 9: Regulator piston 3: Piston 10: Plate 4. Cylinder block 11: Disc 5: Valve plate 12: Check valve spring 6: End cover 13: Check valve 7: Slow return valve 14: Counterbalance valve spool PC500LC-10R 10-255...
  • Page 350 Rated speed (at Min. delivery): 2650 rpm Rated speed (at Max. delivery): 1550 rpm Brake canceling pressure: 0.98 MPa 10 kg/cm Travel speed selector pressure: 0.78 MPa {8.0 kg/cm }  FUNCTION OF TRAVEL MOTOR The travel motor converts the fluid energy of hydraulic oil into rotational mechanical energy, and travels the ma- chine. 10-256 PC500LC-10R...
  • Page 351 Regulator valve (17) is pressed down by spring (18). The pressurized oil from control valve pushes the check valve (21), flows to the end cover (6), and via regu- lator valve (17) to the chamber (b). A downward force is generated in regulator piston (9). PC500LC-10R 10-257...
  • Page 352 (21), flows to the end cover (6), and via regulator valve (17) to the chamber (a). An upward force is generated in regulator piston (9). The valve plate (5) and cylinder block (4) move to the direction of minimum tilt angle. The motor capacity becomes the minimum and machine travels at high speed. 10-258 PC500LC-10R...
  • Page 353 The pressurized oil flows into the chamber (e) of brake piston (20). The spring (19) is compressed, and the piston (20) is pushed to the right. The press force to plate (10) and disc (11) is lost, and plate (10) and the disc (11) separate from each other to release the brake. PC500LC-10R 10-259...
  • Page 354 When the counterbalance valve spool (14) returns to the neutral position, the oil is drained from the throttle (f) of brake piston (20) into the case. The brake piston (20) is pushed to the left by spring (19). The plate (10) and disc (11) are pressed, and the brake is applied. 10-260 PC500LC-10R...
  • Page 355 This is very dangerous. • The counterbalance valve and check valve of the travel motor are valves that prevent the motor from running away and makes it travel in accordance with the engine speed (pump discharged volume). PC500LC-10R 10-261...
  • Page 356 (14) is pushed to the right. The motor outlet port (MB) and port (PB) are connected to the outlet passage. The motor outlet side opens, and the motor is operated. AEP20518 10-262 PC500LC-10R...
  • Page 357 The safety valve releases this abnormal pressure into the motor inlet side to protect the devices from damage. PC500LC-10R 10-263...
  • Page 358 The check valve of the counterbalance valve closes cham- ber (MA) in the outlet circuit when the machine stops trav- eling (or travels downhill). The pressure on the outlet (MA) side increases since the motor continues rotation because of inertial force. AEP20523 10-264 PC500LC-10R...
  • Page 359 (J) through chamber (G) and passage (H). It pushes the piston (3) to the right, compresses the spring (2), and increases the set load. The safety valve is set to high pressure, and large traction force is obtained. AEP20525 PC500LC-10R 10-265...
  • Page 360 (PA) through passage (H) and chamber (G), until spool (14) returns to the neutral position. Piston (3) moves to the left and reduces the set load. The safety valve is set to low pressure, and reduces the shocks during deceleration. AEP20526 10-266 PC500LC-10R...
  • Page 361 10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM FINAL DRIVE STRUCTURE OF FINAL DRIVE General view and sectional view PC500LC-10R 10-267...
  • Page 362 FUNCTION OF FINAL DRIVE The travel motor is high in speed but low in torque. Accordingly, the final drive reduces the speed, increases the driving force, and transmits it to the sprocket. TRAVEL PPC VALVE Abbreviation for Proportional Pressure Control 10-268 PC500LC-10R...
  • Page 363 P: From self-pressure reducing valve P3: To control valve (right travel REVERSE port) P1: To control valve (left travel REVERSE port) P4: To control valve (right travel FORWARD port) P2: To control valve (left travel FORWARD port) T: To hydraulic tank PC500LC-10R 10-269...
  • Page 364 10 STRUCTURE AND FUNCTION Sectional view A - A C - C D - D B - B A 4 P 1 4 8 8 2 1: Plate 4: Seal 2: Case 5: Spool 3: Piston 6: Damper 10-270 PC500LC-10R...
  • Page 365 (PP)” does not change until retainer (9) touches spool (1). The metering spring (2) is compressed in proportion to the travel of control levers. The pressure in the port (P1) increases in proportion to the travel of control levers. PC500LC-10R 10-271...
  • Page 366 (A) through fine control hole (f) and port (P1), and it pushes the control valve spool. The oil returning from the port (B) flows from port (P2) through the fine control hole (f') to the drain chamber (D). 10-272 PC500LC-10R...
  • Page 367 DR1: From R.H. and L.H travel motors (port T) C2: From control valve (port A5) DR2: To hydraulic tank 1: Cover 5: Oil seal 2: Rotor 6: Cover 3: Slipper seal 7: Shaft 4: Dust seal 8: O-ring PC500LC-10R 10-273...
  • Page 368 Center swivel joint sends the oil from main pump installed to the the upper structure to travel motor installed to the lower structure while rotating. Center swivel joint would not be twisted unlike hoses or tubes which would be twisted if they are installed, for the upper structure rotating relative to the lower structure. 10-274 PC500LC-10R...

  • Page 369: Undercarriage And Frame

    3: Carrier roller 8: Front guard 4: Final drive 9: Idler cushion 5: Track roller SPECIFICATIONS OF UNDERCARRIAGE Number of track rollers (one side) 8 pieces Standard shoe Shoe width: 600 mm Link pitch: 228.6 mm Number of shoes (each side): 49 pieces PC500LC-10R 10-275...

  • Page 370: Work Equipment

    STRUCTURE OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION WORK EQUIPMENT STRUCTURE OF WORK EQUIPMENT General view 1: Bucket 5: Arm cylinder 2: Bucket link 6: Boom 3: Bucket cylinder 7: Boom cylinder 4: Arm 10-276 PC500LC-10R...

  • Page 371: Function Of Work Equipment

    The boom is operated by the boom cylinder, and moves the whole work equipment up and down. • The arm is operated by the arm cylinder, and pulls in or pushes out the bucket. • The bucket is operated by the bucket cylinder. • The bucket link increases the moving range of the bucket. PC500LC-10R 10-277...

  • Page 372: Work Equipment Clearance Adjustment Shim

    The purpose of the steel shim is to reduce the clearance in the right and left direction. Depending on the amount of clearance adjustment, you may not have to insert the shim on the other side if you insert the shim on the left or right. 10-278 PC500LC-10R...

  • Page 373: Bucket Clearance Adjustment Shim

    Split-type steel shims are used for the joint of the arm and bucket. You can adjust the clearance in the joint by changing the num- ber of the shims. You can reduce the large clearance by reduc- ing the shims. PC500LC-10R 10-279...

  • Page 374: Cab And Its Attachments

    5: KOMTRAX GPS antenna 2: Windshield wiper 6: Radio antenna 3: Headlamp 7: Door 4: Ceiling window 8: Mirror FUNCTION OF ROPS CAB ROPS cab protects the operator wearing seat belt from being crushed when the machine rolls over. 10-280 PC500LC-10R...

  • Page 375: Cab Mount

    Identification seal color Front left Made Front right Made Rear left None Green Rear right None Green FUNCTION OF CAB MOUNT Sealed and lubricated type damper absorbs vibration of machine in order to reduce the vibration transmitted to an operator. PC500LC-10R 10-281...

  • Page 376: Cab Tipping Stopper

    1: Bolt 3: Lock plate for fixing 2: Lock plate bolt for fixing FUNCTION OF CAB TIPPING STOPPER Cab tipping stopper is installed at 1 place in the rear part to secure the cab when the machine tips over. 10-282 PC500LC-10R...

  • Page 377: 20 Standard Value Table

    20 STANDARD VALUE TABLE PC500LC-10R 20-1...
  • Page 378 CONTENTS ABBREVIATION LIST ............................ 20-3 STANDARD VALUE TABLE FOR ENGINE ....................20-9 STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R ..............20-9 STANDARD VALUE TABLE FOR MACHINE....................20-13 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R..............20-13 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ........ 20-27...

  • Page 379: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 20-3...
  • Page 380 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 20-4 PC500LC-10R...
  • Page 381 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 382 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 20-6 PC500LC-10R...
  • Page 383 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 20-7...
  • Page 384 ABBREVIATION LIST 20 STANDARD VALUE TABLE Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 20-8 PC500LC-10R...

  • Page 385: Standard Value Table For Engine

    20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R STANDARD VALUE TABLE FOR ENGINE STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R Performance Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Engine coolant temperature: 60 to 100 °C •...
  • Page 386 STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R 20 STANDARD VALUE TABLE Air intake and exhaust system Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Engine coolant tempera- • Gauge pres- Min. 140　{Min. 113 {850}...
  • Page 387 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R Main body Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Engine oil temperature 40 to 60 °C •  MPa Compression Min. 2.9 {Min. 30} 2.0 {20}...
  • Page 388 STANDARD VALUE TABLE FOR ENGINE: PC500LC-10R 20 STANDARD VALUE TABLE Lubrication system Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Engine coolant tempera- • Fuel control di- 0.29 to 0.69 al: MAX (High 0.18 {1.8}...

  • Page 389: Standard Value Table For Machine

    20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R STANDARD VALUE TABLE FOR MACHINE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Engine speed Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Engine coolant temperature: 60 to •...
  • Page 390 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Control valve spool stroke Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Boom control ℓ ℓ valve Arm control Engine: Stopped •...
  • Page 391 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Operating effort of control lever and pedal Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine 15.7±3.9 24.5 or less Boom control lever {1.6±0.4}...
  • Page 392 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Hydraulic oil 34.8 (+1.47/-1.18) • 33.2 to 36.8 tempera- {353 (+15/-12)} {338 to 375}...
  • Page 393 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Hydraulic oil tempera- Front pump • 36.12 to 38.77 35.6 to 39.2 discharged ture: 45 to 55 °C...
  • Page 394 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Machine model PC500LC-10R Engine SAA6D125E-5 Standard value Item Measurement condition Unit Repair limit for new machine Hydraulic oil tempera- Travel speed: • Approx. 2.9 {30} Approx. 2.9 {30} ture: 45 to 55 °C Fuel control dial: MAX •...
  • Page 395 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temper- 90 ° 3.9±0.4 4.8 or less • ature: 45 to 55 °C Fuel control dial: •...
  • Page 396 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Traveling Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temper- • 67.3±13.5 45.0 to 84.5 ature: 45 to 55 °C 48.1±7.2 34.0 to 58.0...
  • Page 397 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temperature: 45 to • 55 °C Engine: Stopped • Place the machine on a slope of •...
  • Page 398 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Work equipment speed Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temper- • ature: 45 to 55 °C Fuel control dial: •...
  • Page 399 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temper- Bucket CURL 3.5±0.4 4.3 or less • ature: 45 to 55 °C Fuel control dial: •...
  • Page 400 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temperature: 45 to • 55 °C Fuel control dial: MIN (Low idle) po- •...
  • Page 401 20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R Pump performance Machine model PC500LC-10R Engine SAA6D125E-5 Standard value for Item Measurement condition Unit Repair limit new machine Hydraulic oil temperature: 45 to • 55 °C Fuel control dial: MAX (High idle) •...
  • Page 402 STANDARD VALUE TABLE FOR MACHINE: PC500LC-10R 20 STANDARD VALUE TABLE REMARK • Adjust the pump discharged pressures P1 and P2 as close to the average pressure as possible when meas- uring. • Avoid performing the test where the lines of the flow lower limit and the flow upper limit begin to drop sharp- ly, as the margin of error increases.

  • Page 403: Machine Posture And Procedure For Measuring Performance

    MACHINE POSTURE AND PROCEDURE FOR MEASURING PER- 20 STANDARD VALUE TABLE FORMANCE MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM- ANCE Fig. 1 Fig. 2 Fig. 3 Fig. 4 PC500LC-10R 20-27...
  • Page 404 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER- FORMANCE 20 STANDARD VALUE TABLE Fig. 5 Fig. 6 Fig. 7 Fig. 8 20-28 PC500LC-10R...
  • Page 405 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER- 20 STANDARD VALUE TABLE FORMANCE Fig. 9 Fig. 10 Fig. 11 Fig. 12 PC500LC-10R 20-29...
  • Page 406 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER- FORMANCE 20 STANDARD VALUE TABLE Fig. 13 Fig. 14 Fig. 15 20-30 PC500LC-10R...

  • Page 407: 30 Testing And Adjusting

    30 TESTING AND ADJUSTING PC500LC-10R 30-1...
  • Page 408 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............ 30-60 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK ..... 30-60 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT ..30-60 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT... 30-62 30-2 PC500LC-10R...
  • Page 409 SET AND OPERATE MACHINE MONITOR..................30-112 OPERATOR MODE ........................30-115 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN ......30-115 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN .........30-115 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) ..........30-116 CHECKING FUNCTION OF SERVICE METER ................30-117 PC500LC-10R 30-3...
  • Page 410 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ..............30-181 HANDLE BATTERY DISCONNECT SWITCH ..................30-182 TEST DIODES .............................30-183 METHOD FOR TESTING DIODE USING DIGITAL TESTER ............30-183 METHOD FOR TESTING DIODE USING ANALOG TESTER............30-183 Pm CLINIC..............................30-184 Pm CLINIC SERVICE ..........................30-184 Pm CLINIC CHECK SHEET: PC500LC-10R .................30-185 30-4 PC500LC-10R...

  • Page 411: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 30-5...
  • Page 412 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 30-6 PC500LC-10R...
  • Page 413 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 414 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 30-8 PC500LC-10R...
  • Page 415 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 30-9...
  • Page 416 ABBREVIATION LIST 30 TESTING AND ADJUSTING Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 30-10 PC500LC-10R...

  • Page 417: Related Information On Testing And Adjusting

    Part name Q'ty Remarks 795–799–1132 Gear Commercially Feeler gauge available Tools for testing compression pressure Symbol Part No. Part name Q'ty Remarks 795–502–1590 Gauge assembly Pressure range: 0 to 7 MPa 795–471–1420 Adapter 6217–71–6112 Gasket Commercially Hose Hose inside diameter: 14 mm available PC500LC-10R 30-11...
  • Page 418 Commercially Measuring cylinder available Commercially Stopwatch available Commercially Oil container Approx. 20 ℓ available 07376-70315 Plug Tools for testing leakage in fuel system Symbol Part No. Part name Q'ty Remarks Commercially Developer for dye penetrant (color available checker) 30-12 PC500LC-10R...
  • Page 419 Tools for testing and adjusting oil pressure in control circuit Symbol Part No. Part name Q'ty Remarks 799–101–5002 Hydraulic tester 799-101-5130 Gauge Pressure range: 6 MPa 790-261-1205 Digital hydraulic tester Pressure range: 70 MPa 799–101–5220 Nipple Size: M10 x 1.25 mm 07002–11023 O-ring PC500LC-10R 30-13...
  • Page 420 Tools for testing PPC valve outlet pressure Symbol Part No. Part name Q'ty Remarks 799–101–5002 Hydraulic tester 799-101-5130 Gauge Pressure range: 6 MPa 799–101–5160 Nipple Size: R1/8 790-261-1205 Digital hydraulic tester Pressure range: 70 MPa 790-301-1730 Joint Size: PF1/4 x Rc1/8 07000-12011 O-ring 30-14 PC500LC-10R...
  • Page 421 TOOLS FOR TESTING AND ADJUSTING Tools for testing oil leakage Symbol Part No. Part name Q'ty Remarks Commercially Measuring cylinder available 07379-01044 Flange Size: 10 07376-70522 Plug Size: 4 Commercially Plate Size: 250x260x32 available Commercially Size: φ 200x80 available PC500LC-10R 30-15...

  • Page 422: Sketch Of Tools For Testing And Adjusting

    SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. Sensor adapter Nipple 30-16 PC500LC-10R...
  • Page 423 30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING Socket Plug PC500LC-10R 30-17...

  • Page 424: Engine And Cooling System

    Check the engine speed when all control levers and con- trol pedals are in NEUTRAL position. For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. Engine speed when the oil pressure of 2-pumps are relieved Start the engine. 30-18 PC500LC-10R...
  • Page 425 Set the working mode to P (“Power Mode”). Turn on the auto-deceleration. Turn the fuel control dial to MAX (High idle) position. Check the engine speed when auto-decelerator is operated after setting all control levers and control ped- als in NEUTRAL position. PC500LC-10R 30-19...
  • Page 426 If all control levers and control pedals remain NEUTRAL for more than 4 seconds, the engine speed de- creases to the speed at auto deceleration. Check the engine speed at this time. (For details, see STRUC- TURE AND FUNCTION, “ENGINE SYSTEM”.) For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. 30-20 PC500LC-10R...

  • Page 427: Test Boost Pressure

    Test the boost pressure when the oil pressure is relieved in arm IN circuit + one-touch power maximizing is ON by op- erating the work equipment control lever. For standard values, see the absolute pressure in STAND- ARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. PC500LC-10R 30-21...

  • Page 428: Method For Testing Boost Pressure

    Set the engine coolant temperature and the hydraulic oil temperature so that it is within the testing condition range. Set the working mode to P (“Power Mode”). 10. Turn off the auto-deceleration. 11. Turn the swing lock switch to ON position. 30-22 PC500LC-10R...
  • Page 429 • The relationship between the absolute pressure and the gauge pressure is as follows. Gauge pressure = Absolute pressure - Ambient pressure Remove the testing tools and restore the machine after the test is finished. Boost pressure pickup plug (1):  2.0±3.9 Nm {0.2±0.4 kgm}  Boost pressure pickup plug (1):  Liquid adhesive (LS-2) PC500LC-10R 30-23...

  • Page 430: Test Exhaust Gas Temperature

    • Hydraulic oil temperature: 45 to 55 °C For testing of exhaust gas color to perform troubleshooting, refer to this section. METHOD FOR TESTING EXHAUST GAS TEMPERATURE Open the engine hood (19). Remove the exhaust gas temperature pickup plug (1). 30-24 PC500LC-10R...
  • Page 431 For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR EN- GINE”. Remove the testing tools and restore the machine after the test is finished. Plug (1):  Seizure prevention compound (LC-G) Plug (1):  3.9 to 6.9 Nm {0.4 to 0.7 kgm}  PC500LC-10R 30-25...

  • Page 432: Test Exhaust Gas Color

    Remove the filter paper and compare it with the attached scale for judgment. For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. 30-26 PC500LC-10R...

  • Page 433: Method For Testing Exhaust Gas Color By Smoke Meter

    Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. PC500LC-10R 30-27...

  • Page 434: Test And Adjust Valve Clearance

    Open the engine hood (19). Remove the cylinder head cover (1) to be checked. See DISASSEMBLY AND ASSEMBLY, “REMOVE AND IN- STALL INJECTOR ASSEMBLY”. Remove the undercovers (2) and (3). Remove the undercover (2) to check the timing mark. 30-28 PC500LC-10R...
  • Page 435 No. 1 cylinder is at the compression top dead center. You may check the valve clearance of each cylinder in the fir- ing order by turning the crankshaft in the normal direction by 120 ° at a time. Firing order: 1-5-3-6-2-4 PC500LC-10R 30-29...

  • Page 436: Method For Adjusting Valve Clearance

    ARD VALUE TABLE FOR ENGINE”. Tighten lock nut (7) with adjustment screw (6) fixed. Locknut (7):  58.8 to 73.5 Nm {6.0 to 7.5 kgm}  Tighten lock nut (7), and check the valve clearance again. After finishing the adjustment, restore the machine. 30-30 PC500LC-10R...

  • Page 437: Test Compression Pressure

    Check that both of the intake rocker arm and exhaust rock- er arm at the compression top dead center are movable the same amount of valve clearance by hand. Remove the common rail cover (1) and remove fuel high- pressure tube (2) to be tested. PC500LC-10R 30-31...
  • Page 438 14. Test the compression pressure when the engine is cranked by the starting motor. REMARK Read the compression pressure when the pointer of gauge is stabilized. For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. 30-32 PC500LC-10R...
  • Page 439 Tighten the clamping bolt of the fuel piping. Clamp bolt:  11.8 to 14.7 Nm {1.2 to 1.5 kgm}  Rocker arm assembly mounting bolt:  58.8 to 73.5 Nm {6.0 to 7.5 kgm}  Adjust the valve clearance by referring to the “TEST AND ADJUST VALVE CLEARANCE”. Cylinder head cover mounting bolt:  9.8±1 Nm {1.0±0.1 kgm}  PC500LC-10R 30-33...

  • Page 440: Test Blowby Pressure

    Test the blowby pressure when the pressure is relieved at arm IN and one-touch power maximizing is ap- plied. Read the blowby pressure when the pointer of the gauge is stabilized. For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. 30-34 PC500LC-10R...

  • Page 441: Method For Testing Blowby Pressure By Testing Tool

    10. Turn the fuel control dial to MAX (High idle) position. 11. Test the blowby pressure when the pressure is relieved at arm IN and one-touch power maximizing is ap- plied. Read the blowby pressure when the pointer of the gauge is stabilized. PC500LC-10R 30-35...
  • Page 442 TEST BLOWBY PRESSURE 30 TESTING AND ADJUSTING For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. 30-36 PC500LC-10R...

  • Page 443: Test Engine Oil Pressure

    “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL Open the cover (1) on the left side of the machine. PC500LC-10R 30-37...
  • Page 444 “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. Engine oil pressure pickup plug (2):  2.0 to 3.9 Nm {0.2 to 0.4 kgm}  Engine oil pressure pickup plug (2):  Thread locking fluid (LT-2A) 30-38 PC500LC-10R...

  • Page 445: Test Fuel Pressure

    For testing the fuel pressure to perform troubleshooting, refer to this section. METHOD FOR TESTING FUEL PRESSURE Open the cover (1) on the left side of the machine. Remove the fuel pressure pickup plug (2) (inlet side) of the fuel filter head. PC500LC-10R 30-39...
  • Page 446 For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. Fuel pressure pickup plug (2):  2.0 to 3.9 Nm {0.2 to 0.4 kgm}  Fuel pressure pickup plug (2):  Thread locking fluid (LT-2A) 30-40 PC500LC-10R...

  • Page 447: Test Fuel Return Rate And Leakage

    Since the fuel flows out during measurement, prepare oil pan G to receive it. For testing of fuel return rate and leakage to perform troubleshooting, refer to this section. METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE Testing leakage from pressure limiter Open the engine hood (19). Remove the undercover (5). PC500LC-10R 30-41...
  • Page 448 Bind the connecting part of test hose D with a wire, etc. to prevent it from coming off. Adjust the route of the test hose D so that it does not slack. Insert its end to the measuring cylinder E. 30-42 PC500LC-10R...
  • Page 449 “STANDARD VALUE TABLE FOR ENGINE”. Remove the testing tools and restore the machine after the test is finished. Joint bolt on the block side:  24.5 to 34.3 Nm {2.5 to 3.5 kgm}  Joint bolt on the common rail side:  17.7 to 22.6 Nm {1.8 to 2.3 kgm}  PC500LC-10R 30-43...

  • Page 450: Bleed Air From Fuel System

    When starting the engine for the first time after the fuel piping or supply pump was replaced. Refill the fuel tank with fuel until the fuel level monitor indicates in blue. Turn the starting switch to ON position. 30-44 PC500LC-10R...
  • Page 451 F6: Enters the selected item. NOTICE • Electric fuel primer pump does not start operation in some cases when the warning lamp is lit. • Cancel the warning lamp if “Elec. fuel primer pump does not operate.” screen is shown. PC500LC-10R 30-45...
  • Page 452 After approximately 5 minutes passed, stop the engine again, and start the engine as it is usually done. NOTICE • Do not operate the starting motor continuously for 20 seconds or more. • If it is not started, try starting again after approximately 2 minutes. 30-46 PC500LC-10R...

  • Page 453: Test Fuel Circuit For Leakage

    Stop the engine and check the fuel piping and component for fuel leakage. • Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is sprayed. • If any fuel leakage is detected, repair it and perform the checks from step 1 again. PC500LC-10R 30-47...
  • Page 454 Stop the engine and check the fuel piping and component for fuel leakage. • Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is sprayed. • If any fuel leakage is detected, repair it and perform the checks from step 1 again. 30-48 PC500LC-10R...

  • Page 455: Handle Cylinder Cut-Out Mode Operation

    Common rail fuel injection system individually controls the injector of each cylinder electronically , so the cylinder cutout test can be performed easily by the simple operations of the switches compared with the mechanical fuel injection system. So, the defective cylinder can be found out easily. PC500LC-10R 30-49...

  • Page 456: Handle No-Injection Cranking Operation

    The purpose and effect of this operation are as follows. No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed before the engine is started after the machine or engine has been stored for a long period. 30-50 PC500LC-10R...

  • Page 457: Test Fan Belt

    In that case, the newly replaced fan belt may be damaged on early stage because of the continuous use of the pulley. Replacement of the fan belt and the auto-ten- sioner are recommended. PC500LC-10R 30-51...

  • Page 458: Test Alternator Belt

    Replace the alternator belt (3) in the following cases. • There is a horizontal abrasion (a) crossed with a vertical abrasion (b). • The alternator belt is partly frayed (c). Replacement is not required if there are only horizon- tal scratches. 30-52 PC500LC-10R...
  • Page 459 If the belt is visibly worn, the auto-tensioner may be worn as well, and the pulley may have a rough surface. In that case, the newly replaced alternator belt may be damaged on early stage because of the continuous use of the pulley. Replacement of the Alternator belt and the auto-tensioner are rec- ommended. PC500LC-10R 30-53...

  • Page 460: Test Automatic Tensioner

    Replace the fan belt (2) if the arm stopping portion (c) of the auto-tensioner (5) comes in contact with the spring case stopping portion (d) or (e). REMARK Replace the fan belt (2). See DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL FAN BELT”. Method for testing automatic tensioner for alternator Remove the undercover (1). 30-54 PC500LC-10R...
  • Page 461 (d) or (e). REMARK Remove the alternator belt (2). See DISASSEMBLY AND ASSEMBLY “REMOVE AND INSTALL ALTERNA- TOR BELT”. Remove the testing tools and restore the machine after the test is finished. PC500LC-10R 30-55...

  • Page 462: Test Cooling Fan Speed

    After testing, select the normal control mode on “Fan Speed Mode Select” by referring to “SET AND OPER- ATE MACHINE MONITOR”. REMARK If you turn the starting switch to OFF position, the cooling fan speed is set in the normal control mode when the engine is started again. 30-56 PC500LC-10R...

  • Page 463: Power Train

    The value indicated by dial gauge A is the clearance of the bearing. Return the machine to the state in step 2, and check that dial gauge A indicates 0 point again. If the dial gauge does not indicate 0 point, repeat steps 3 through 5. PC500LC-10R 30-57...

  • Page 464: Undercarriage And Frame

    0 mm. If the tension is still loose, the wear of pins and bushings is large. In such a case, the pins and bush- ings need to be turned 180 deg. or replaced. 30-58 PC500LC-10R...
  • Page 465 MIN (low idle) position, and move the machine slowly forward by length of track on ground, then stop the machine. Check that the tension is correct according to the above procedure after finishing adjustment. PC500LC-10R 30-59...

  • Page 466: Hydraulic System

    5 seconds to increase the pressure in the accumulator. Repeat above Step 2. and Step 3. for a couple of times. Lower the work equipment to the ground and release the remaining pressure in the hydraulic tank. See “METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”. 30-60 PC500LC-10R...
  • Page 467 • However, use the bleeder (5) which is attached to the plug for releasing the remaining pressure in the arm cylinder circuit, bucket cylinder circuit, and each cylinder. PC500LC-10R 30-61...

  • Page 468: Method For Releasing Remaining Pressure From Swing Motor Circuit

    “METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”. Lower the work equipment to the ground in a stable posture, and stop the engine. Loosen the oil filler cap (1) of the hydraulic tank gradually to release the air in the tank. 30-62 PC500LC-10R...
  • Page 469 When the pressure in swing circuit or travel circuit is relieved singly, the oil flows from the pumps are divided. The actuators in the following table are arranged in the order that the control valves are viewed from the front of the machine. ("Service" of "Actuator" is for when 1 attachment is installed) PC500LC-10R 30-63...

  • Page 470: Method For Testing Oil Pressure In Work Equipment, Swing, And Travel Circuits

    See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. METHOD FOR TESTING UNLOAD PRESSURE BY TESTING TOOLS Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. Open the cover on the left side of the machine. 30-64 PC500LC-10R...
  • Page 471 Operate the cylinders to be checked to the stroke end. REMARK Turn the secondary work equipment actuation switch to OFF position when oil pressure in boom circuit is relieved. Turn the fuel control dial to MAX (High idle) position. PC500LC-10R 30-65...
  • Page 472 See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. Remove the testing tools and restore the machine after the test is finished. METHOD FOR TESTING SWING RELIEF PRESSURE BY MACHINE MONITOR Start the engine. 30-66 PC500LC-10R...
  • Page 473 See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. METHOD FOR TESTING SWING RELIEF PRESSURE BY TESTING TOOLS Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. Open the cover on the left side of the machine. PC500LC-10R 30-67...
  • Page 474 Remove the testing tools and restore the machine after the test is finished. METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY MACHINE MONITOR Start the engine. Insert the pin E and the plate F between the sprocket and the track frame to securely lock the track. 30-68 PC500LC-10R...
  • Page 475 See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY TESTING TOOLS Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. Open the cover on the left side of the machine. PC500LC-10R 30-69...
  • Page 476 The machine monitor displays the pressure when the main relief valve is relieved. The travel circuit is al- ways relieved at high pressure. See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. Remove the testing tools and restore the machine after the test is finished. 30-70 PC500LC-10R...

  • Page 477: Method For Adjusting Oil Pressure In Work Equipment, Swing, And Travel Circuits

    }  Tighten the lock nut (7) with the holder (6) fixed. Lock nut (7):  49 to 58.8 Nm {5 to 6 kgm}  Connect the pilot hose (5). After the adjustment, recheck the oil pressure according to the testing procedure previously described. PC500LC-10R 30-71...
  • Page 478 (8) for boom LOWER according to the following procedure. • The machine push-up switch is turned off. The pilot pres- sure acts on the selector port. Disconnect the pilot hose (9). 30-72 PC500LC-10R...
  • Page 479 }  Tighten the lock nut (17) with the holder (16) fixed. Lock nut (17):  93.1 to 122.5 Nm {9.5 to 12.5 kgm}  Connect the pilot hose (15). After the adjustment, recheck the oil pressure according to the testing procedure previously described. PC500LC-10R 30-73...

  • Page 480: Test Oil Pressure Of Control Circuit

    Turn the fuel control dial to MAX (High idle) position. 10. Check the oil pressure when all control levers and control pedals are in NEUTRAL position. See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. 30-74 PC500LC-10R...
  • Page 481 Do not adjust the relief valve for the control circuit oil pressure. REMARK Control circuit oil pressure can be tested with the nipple C at- tached to the pressure pickup port (PEPB). PEPB: EPC source pressure pickup port PC500LC-10R 30-75...

  • Page 482: Test And Adjust Oil Pressure In Pump Pc Control Circuit

    (PRC): Rear pump discharge pressure pickup port (PENF): Front PC valve outlet pressure pickup port (PENR): Rear PC valve outlet pressure pickup port Install the nipple C to the oil pressure pickup plugs (PFC), (PRC), (PENF), and (PENR). 30-76 PC500LC-10R...

  • Page 483: Test Pc-Epc Valve Outlet Pressure

    Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. Open the cover on the left side of the machine. Remove the oil pressure pickup plugs (PMF) and (PMR). (PMF): Front PC mode selector pressure pickup port (PMR): Rear PC mode selector pressure pickup port PC500LC-10R 30-77...

  • Page 484: Method For Adjusting Oil Pressure In Pump Pc Control Circuit

    (This is for the adjustment screw to return to the original position for the time when turning it in reverse) Loosen the lock nut (9). Rotate adjustment screw (10) clockwise or counterclock- wise to adjust it. 30-78 PC500LC-10R...
  • Page 485 Tighten the lock nut (9). Lock nut (9):  27 to 34 Nm {2.8 to 3.5 kgm}  After the adjustment, see “METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)” to check that PC valve outlet pressure (servo piston inlet pressure) is normal. PC500LC-10R 30-79...

  • Page 486: Test And Adjust Oil Pressure In Pump Ls Control Circuit

    METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR Open the cover on the left side of the machine. Remove the oil pressure pickup plugs (PLSFC) and (PLSRC). (PLSFC): Front load pressure pickup port (PLSRC): Rear load pressure pickup port 30-80 PC500LC-10R...
  • Page 487 12. Turn the fuel control dial to MAX (High idle) position. 13. Check the pump discharge pressure and the LS pressure (actuator load pressure) simultaneously when all the con- trol levers and pedals are in NEUTRAL position, and the travel lever is at half stroke. PC500LC-10R 30-81...

  • Page 488: Method For Testing Ls Differential Pressure

    TRAL position, and set the lock lever in OFF position. Start the engine. Select and display “Pre-defined Monitoring” (01/11) by referring to “SET AND OPERATE MACHINE MONI- TOR”. Adjust the hydraulic oil temperature so that it is within the specified range. 30-82 PC500LC-10R...
  • Page 489 Remove the oil pressure pickup plugs (PFC), (PRC), (PENF), and (PENR) (PFC): Front pump discharge pressure pickup port (PRC): Rear pump discharge pressure pickup port (PENF): Front LS valve outlet pressure pickup port (PENR): Rear LS valve outlet pressure pickup port PC500LC-10R 30-83...

  • Page 490: Method For Testing Ls-Epc Valve Outlet Pressure

    BLE FOR MACHINE” for standard values. Remove the testing tools and restore the machine after the test is finished. METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. 30-84 PC500LC-10R...

  • Page 491: Method For Adjusting Ls Valve

    Tighten the lock nut (11) with the adjustment screw (10) fixed. Lock nut (11):  49 to 68.6 Nm {5 to 7 kgm}  After the adjustment, see “METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)” to check that LS valve outlet pressure (servo piston inlet pressure) is normal. PC500LC-10R 30-85...

  • Page 492: Test Outlet Pressure Of Solenoid Valve

    Start the engine. Select “Monitoring Selection Menu” and display the following monitoring items by referring to “SET AND OPERATE MACHINE MONITOR”. Monitoring code: 04401 “Hydraulic Oil Temperature” Monitoring code: 02300 “Solenoid Valve 1” Monitoring code: 02301 “Solenoid Valve 2” 30-86 PC500LC-10R...

  • Page 493: Operating Condition Of Solenoid Valve

    OFF (de-ener- Other than B gized) Working mode ON (ener- gized) (3) Machine push-up solenoid valve operation table Operating Operating condition of solenoid valve state of sole- noid valve ON (ener- gized) Machine push-up switch OFF (de-ener- gized) PC500LC-10R 30-87...
  • Page 494 F pump pressure is ation of changing ducted lowering and Min. swing direction When the pump flow is divided 25.5 MPa  {260 kg/cm } Min. OFF (de-ener- Other than the above conditions gized) 30-88 PC500LC-10R...
  • Page 495 TEST OUTLET PRESSURE OF SOLENOID VALVE (8) PPC lock solenoid valve operation table Operating Operating condition of solenoid valve state of sole- noid valve OFF (de-ener- LOCK position (Lock) gized) PPC lock lever ON (ener- UNLOCK position (Canceled) gized) PC500LC-10R 30-89...

  • Page 496: Test Ppc Valve Outlet Pressure

    METHOD FOR TESTING PPC VALVE OUTLET PRESSURE Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. Check that the system operating lamp is not lit, and turn the battery disconnect switch to OFF position. Remove the undercover (1). 30-90 PC500LC-10R...
  • Page 497 “SET AND OPERATE MACHINE MONITOR”. Adjust the hydraulic oil temperature so that it is within the specified range. 10. Set the working mode to P (“Power Mode”). 11. Turn the fuel control dial to MAX (High idle) position. PC500LC-10R 30-91...
  • Page 498 See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. Remove the testing tools and restore the machine after the test is finished. 30-92 PC500LC-10R...

  • Page 499: Adjust Work Equipment And Swing Ppc Valves

    Grease (G2-LI) REMARK • Apply 7 to10 mℓ of grease to all periphery (a) of the pin. • Apply 0.2 to 0.4 mℓ of gear oil to sliding portions (b) of joint and pin (4 places). Install the boot (1). PC500LC-10R 30-93...

  • Page 500: Test The Parts Causing Hydraulic Drift In Work Equipment

    No change: The control valve is defective. REMARK • Operate the control lever when the starting switch is turned to ON position. • If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the pres- sure. 30-94 PC500LC-10R...

  • Page 501: Method For Testing The Parts Causing Hydraulic Drift Of Ppc Valve

    In case there is a difference of hydraulic drift between LOCK and FREE positions, the PPC valve is defective (internal defect). REMARK • Operate the control lever when the starting switch is turned to ON position. • If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the pressure. PC500LC-10R 30-95...

  • Page 502: Test Oil Leakage

    METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER Set the arm cylinder at IN stroke end, and stop the engine. Release the remaining pressure from the piping on the arm cylinder head side by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. 30-96 PC500LC-10R...

  • Page 503: Method For Testing Oil Leakage From Bucket Cylinder

    See STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE” for standard values. Restore the machine after finishing the test. METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR Release the remaining pressure in the circuit by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”. PC500LC-10R 30-97...

  • Page 504: Method For Testing Oil Leakage From Travel Motor

    10. Move the motor a little each time and test the oil leakage several times (changing the relative position be- tween the valve plate and cylinder and that between the cylinder and piston). Restore the machine after finishing the test. 30-98 PC500LC-10R...

  • Page 505: Bleed Air From Hydraulic Circuit

    For releasing the air from hydraulic systems to perform troubleshooting, refer to this section. Bleed air in the hydraulic system which marked with ●. Start bleeding air from Step 1. Air in the hydraulic system which marked with “x” does not need to be bled. PC500LC-10R 30-99...
  • Page 506 Replacement • and repair of the swivel joint ● ● Removal of the • swivel joint pip- *1: Bleed air from the swing motor and travel motor only when the oil in the motor case is drained. 30-100 PC500LC-10R...

  • Page 507: Method For Bleeding Air From Hydraulic Circuit

    Be careful to stop the piston rod at approximately 100 mm before each stroke end to avoid relieving. Operate the piston rod to each stroke end to relieve the oil pressure in the circuit. Bleed air from the arm cylinder and bucket cylinder according to Step 2. to Step 4. PC500LC-10R 30-101...
  • Page 508 Raise one track off the ground by using the work equip- ment. Slowly run the raised track off the ground for 2 minutes. Run the track off the ground on the opposite side for 2 mi- nutes in the same manner. 30-102 PC500LC-10R...
  • Page 509 Check the oil level by sight gauge (6) at the rear of the hy- draulic tank. When the oil level is between the lines “H” and “L”, it is correct. When the oil level is below line “L”, it is insufficient. Add more oil. PC500LC-10R 30-103...

  • Page 510: Cab And Its Attachments

    98 to 123 Nm {10 to 12.5 kgm}  Note that the tightening torque for mounting bolt (4) of cab tip- ping stopper (3) is different from that of a common bolt whose thread diameter is 30 mm. Bolt (4):  245 to 309 Nm {25 to 31.5 kgm}  30-104 PC500LC-10R...

  • Page 511: Method For Adjusting Mirrors

    Adjust the mirror with your hand so that the side of the ma- chine is reflected in the mirror as shown in the figure. Check that you can see a person at the rear left end of the machine. PC500LC-10R 30-105...

  • Page 512: Procedure For Adjusting Regular Position Of Machine Left Front Mirror (A)

    The lock lever is in LOCK position. The engine is stopped. When returning the mirror to its regular position, perform the following adjustment. Adjust stay (1). Mounting position (2): 59 mm {2.3 in}  Mounting angle (3): 81 ° Mounting angle (4): 110 ° Adjust mirror (5). 30-106 PC500LC-10R...

  • Page 513: Procedure For Adjusting Machine Right Front Mirror (B)

    Tightening torque of mounting bolt (6): 6.0 to 7.0 Nm {0.61 to 0.71 kgm,4.41 to 5.14 lbft} Mounting position (7): 151 mm {5.9 in}  Install the mirror so that its KOMATSU logo is at the left side of the machine body. NOTICE • Tighten the right and left bolts of each bracket al- ternately so that their right and left clearances (R) and (L) become equal.

  • Page 514: Procedure For Adjusting Regular Position Of Machine Right Front Mirror (B)

    The machine is placed on a level ground. The work equipment is lowered to the ground in secure posture. The lock lever is in LOCK position. The engine is stopped. When returning the mirror to its regular position, perform the following adjustment. 30-108 PC500LC-10R...
  • Page 515 Mounting position (6): 85 mm {3.3 in}  Mounting angle (7): 27 ° Mounting angle (8): 9 ° Install the mirror so that its KOMATSU logo is at the right side of the machine body. NOTICE • Tighten the right and left bolts of each bracket al- ternately so that their right and left clearances (R) and (L) become equal.

  • Page 516: Procedure For Adjusting Machine Right Side Mirror (C)

    Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61 to 0.71 kgm,4.41 to 5.14 lbft} Mounting angle (3): 5 ° Mounting position (4): 44 mm {1.7 in}  Mounting angle (5): 15 ° Install the mirror so that its KOMATSU logo is at the right side of the machine body. 30-110 PC500LC-10R...

  • Page 517: Procedure For Adjusting Machine Rear Counterweight Mirror (D)

    (W): 1 m • The regular position of the mirror is as follows. Adjust the mirror (1). Tightening torque of mounting bolt (2):4.0 to 5.4 Nm {0.41 to 0.55 kgm,2.97 to 3.98 lbft} Mounting angle (3): 60 ° Mounting position (4): 29 mm {1.1 in}  PC500LC-10R 30-111...

  • Page 518: Electrical System

    SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING ELECTRICAL SYSTEM SET AND OPERATE MACHINE MONITOR 30-112 PC500LC-10R...
  • Page 519 (Display and setting of some items need special operation of switches.) For the details, see Operation and Maintenance Manual. Operator mode Display of KOMATSU logo and mark Display of password input screen Display of check of breaker mode Display of check before starting Display of warning after "Check before starting"...
  • Page 520 METHOD FOR OPERATING MAINTENANCE MODE SETTING METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE) METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT) METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT) 30-114 PC500LC-10R...

  • Page 521: Operator Mode

    (maintenance work, etc.) and operating state by operator when the customer controls operating state by operator, fuel con- sumption, machine trouble by using operator ID function. DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN After displaying the technician identification state screen, the operator ID input screen PC500LC-10R 30-115...

  • Page 522: Checking Function By Lcd (Liquid Crystal Display)

    When finishing the operation of the switches, release F2 first. • If there is a display error in the LCD, only that part is indi- cated in black. • To return to the former screen, press any one of the func- tion switches. 30-116 PC500LC-10R...

  • Page 523: Checking Function Of Service Meter

    Switch operation (press the switches in order while press- ing 4): 4 + 5 → 5 → 5 REMARK This switch operation can be used 10 minutes after the starting switch is turned to ON position. PC500LC-10R 30-117...
  • Page 524 On “Usage Limitation New Password Input” screen, input a new password with the numeral input switches and enter it with the function switch. F5: The inputted number is deleted. The screen returns to the standard screen. F6: Enters inputted password 30-118 PC500LC-10R...

  • Page 525: Service Mode

    SERVICE MODE METHOD FOR OPERATING SERVICE MODE Perform the following operation to change the mode of the machine monitor from the operator mode to the serv- ice mode. This operation is always required when you use the service mode. PC500LC-10R 30-119...
  • Page 526 METHOD FOR CHECKING SELF-DEFINE MONITORING Self-define Monitoring INFORMATION Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD ty Record (MECHANICAL SYSTEMS) Abnormality Record Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD Record (ELECTRICAL SYSTEMS) Maintenance Record METHOD FOR CONFIRMING MAINTENANCE RECORD 30-120 PC500LC-10R...
  • Page 527 METHOD FOR CONFIRMING KOMTRAX SETTINGS (TER- Terminal Status MINAL STATUS) KOMTRAX GPS & Communication METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS Settings State AND COMMUNICATION STATUS) METHOD FOR CONFIRMING KOMTRAX SETTINGS (MO- Modem Information DEM STATUS) Service Message METHOD FOR DISPLAYING SERVICE MESSAGE PC500LC-10R 30-121...

  • Page 528: Method For Checking Pre-Defined Monitoring Information

    Self-define Monitoring items (screen Applicable code display) component Metric Imperial 01002 Engine Speed r/min 04107 Coolant Temperature °C °C °F 37200 Engine Oil Pressure Sensor kg/cm 04401 Hydraulic Oil Temperature °C °C °F PUMP 03203 Battery Power Supply 30-122 PC500LC-10R...
  • Page 529 PUMP kg/cm 04401 Hydraulic Oil Temperature °C °C °F PUMP Pre-defined Monitoring (06/11) F pump application Unit Monitoring Self-define Monitoring items (screen Applicable code display) component Metric Imperial 01002 Engine Speed r/min 01100 Front Pump Pressure PUMP kg/cm PC500LC-10R 30-123...
  • Page 530 04401 Hydraulic Oil Temperature °C °C °F PUMP Pre-defined Monitoring (10/11) PPC pressure (3) Unit Monitoring Self-define Monitoring items (screen Applicable code display) component Metric Imperial 01002 Engine Speed r/min 07102 Travel Forward Left PPC Press PUMP kg/cm 30-124 PC500LC-10R...

  • Page 531: Method For Checking Self-Define Monitoring Information

    F5: Clears the input value. The screen returns to " Service Menu" screen. F6: Enters the selected item. • Setting of the monitoring changes to “ENG”→“PUMP”→“MON”→“ENG” in this order when function switch F2 is pressed. (When F1 is pressed, sequential switching takes place in the reverse order.) PC500LC-10R 30-125...
  • Page 532 Hold the monitoring information or cancelling HOLD can be performed with the function switches. F4: Selects HOLD or releasing HOLD. (When HOLD is se- lected, “HOLD” part is hatched.) F5: The screen returns to “Monitoring Selection Menu” screen. 30-126 PC500LC-10R...
  • Page 533 TABLE OF SELF-DEFINE MONITORING Unit (Default: SI Applicable Monitor- Self-define Monitoring items (screen dis- compo- Remarks ing code play) Metric Imperial nent 01002 Engine Speed r/min 04107 Coolant Temperature °C °C °F PC500LC-10R 30-127...
  • Page 534 °F 20400 Engine Controller S/N 01601 2nd Engine Speed Command r/min PUMP 01100 Front Pump Pressure kg/cm2 PUMP 01101 Rear Pump Pressure kg/cm2 PUMP 07400 Boom Raise PPC Pressure kg/cm2 PUMP 07500 Boom Lower PPC Pressure kg/cm2 PUMP 30-128 PC500LC-10R...
  • Page 535 PC-EPC Cal Current 1 (Factory) PUMP 01345 PC-EPC Calibration Torque 1 lbft PUMP 01349 PC-EPC Calibration Current 1 PUMP 42803 Blowby Pressure mmAq PUMP 42804 Blowby Pressure Sensor Volt PUMP 46806 Bypass Valve1 Stroke PUMP 46807 Bypass Valve1 Stroke Sensor Volt PUMP PC500LC-10R 30-129...
  • Page 536 ON/OFF PUMP 02201 SW Input 2 Model Selection 3 ON/OFF ON/OFF ON/OFF PUMP Model Selection 4 ON/OFF ON/OFF ON/OFF PUMP Model Selection 5 ON/OFF ON/OFF ON/OFF PUMP 02202 SW Input 3 Key SW (ACC) ON/OFF ON/OFF ON/OFF PUMP 30-130 PC500LC-10R...
  • Page 537 04501 Monitor Input 2 Engine Oil Level ON/OFF ON/OFF ON/OFF Battery Charge Voltage ON/OFF ON/OFF ON/OFF Swing Parking Brake ON/OFF ON/OFF ON/OFF 04502 Monitor Input 3 Engine Shutdown 2nd ON/OFF ON/OFF ON/OFF Seat Belt SW ON/OFF ON/OFF ON/OFF PC500LC-10R 30-131...
  • Page 538 20260 KOMTRAX Assembly P/N 20418 KOMTRAX S/N 20261 KOMTRAX Program P/N 20273 KOMTRAX Program Version • Listing order in table The items are listed in the same order as the display on Monitoring Selection Menu screen. • Unit 30-132 PC500LC-10R...

  • Page 539: Abnormality Record Menu

    Occurrence order of abnormalities from latest one/ Total number of records b: Failure code c: Detail of failure d: Number of occurrences (displayable range: 0 to 65535 times) e: Service meter reading at the first occurrence PC500LC-10R 30-133...
  • Page 540 Select “Electrical Sys Abnormality Record” with the func- tion switches or numeral input switches on “Abnormality Record” screen. F3: Moves the selection downward. F4: Moves the selection upward. F5: The screen returns to the “Service Menu” screen. F6: Enters the selected item. 30-134 PC500LC-10R...
  • Page 541 • If the message of the failure code is too long, the rest of the message is scrolled. Delete the information about abnormality record by per- forming the following operations with the numeral switches while “Electrical Sys Abnormality Record” screen is dis- played. PC500LC-10R 30-135...
  • Page 542 On “Electrical Systems Abnormality Record Reset” screen, operate the function switches to delete all the records. F5: The screen returns to “Electrical Sys Abnormality Record” (Delete mode) F6: Executes the deletion REMARK • This is the screen when a selected abnormality re- cord is going to be deleted. 30-136 PC500LC-10R...

  • Page 543: Method For Confirming Maintenance Record

    The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and checked by the following operations. If the data are reset in the operator mode when the maintenance is performed, the number of the times of main- tenance is recorded here. PC500LC-10R 30-137...
  • Page 544 Hyd Oil Tank Breather Change Fuel Main Filter Change Hydraulic Oil Filter Change Damper Case Oil Check/Refilling Swing Machinery Case Oil Change Final Drive Case Oil Change Coolant Change Coolant Filter Change Radiator Cap Change Hydraulic Oil Change 30-138 PC500LC-10R...

  • Page 545: Method For Operating Maintenance Mode Setting

    Selectable items on maintenance mode setting screen Code Item Maintenance Mode Change Air Cleaner Cleaning or Change Interval Additional Hydraulic Oil Filter Change Interval Hydraulic Oil Pilot Filter Change Interval Additional Fuel Filter Change Interval Fuel Tank Breather Change Interval PC500LC-10R 30-139...
  • Page 546 Mode Change” screen. F6: Selection is entered. The screen returns to Mainte- nance Mode Change screen. REMARK Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual set- ting. 30-140 PC500LC-10R...
  • Page 547 Maintenance remaining time is reduced at an accelerat- ed rate according to the breaker use remaining time. “OFF”: Disables the function of the individual maintenance item in operator mode. F3: Moves the selection downward. F4: Moves the selection upward. PC500LC-10R 30-141...
  • Page 548 “Maintenance Mode Setting”, and the setting is ena- bled. • If the setting item is changed when the maintenance mode setting is turned “ON” after running the machine more than an hour from the setup, the change is recog- nized as a reset operation. 30-142 PC500LC-10R...

  • Page 549: Method For Operating Phone Number Entry Setting

    Phone number must be registered in order to display the number while in operator mode. Select “Phone Number Entry” from the “Service Menu” screen. REMARK For selecting method, see “Operating method of service mode” in “SERVICE MODE”. PC500LC-10R 30-143...

  • Page 550: Default Menu

    See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “Key-on Mode” with the function switches or numer- al input switches on “Default” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. 30-144 PC500LC-10R...
  • Page 551 See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “Unit” with the function switches or numeral input switches on “Default” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. PC500LC-10R 30-145...
  • Page 552 Select “With attachment” on this screen when attachment is installed. The attachment will not be available in “Working Mode” in operator mode if it is not set on this screen. It results in that the attachment does not function well or a failure may occur in the hydraulic components. 30-146 PC500LC-10R...
  • Page 553 See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “Camera” with the function switches or numeral in- put switches on “Default” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. PC500LC-10R 30-147...
  • Page 554 (mirror images if it is used for rearview monitor). Я: Reverse images (mirror images if it is used for rear view monitor) are displayed. R: Normal images (visual images if it is used for front or side monitor) are displayed. 30-148 PC500LC-10R...
  • Page 555 See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “Auto Idle Stop Time Fixing” with the function switches or numeral input switches on “Default” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. PC500LC-10R 30-149...
  • Page 556 Select “Option” with the function switches or numeral input switches on “Default” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “With/Without Eco mode Easy Setting” on “Option” screen with function switches or numeral input switches. 30-150 PC500LC-10R...
  • Page 557 See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. Select “With/Without Water in Fuel Sensor” with the func- tion switches or numeral input switches on “Option” screen. REMARK See “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE” for selecting method. PC500LC-10R 30-151...

  • Page 558: Diagnostic Tests Menu

    F1: Moves the selected item to the left F2: Moves the selected item rightward F4: Selects HOLD or releasing HOLD. (When HOLD is se- lected, “HOLD” part is hatched.) F5: The screen returns to “Diagnostic Tests” screen F6: Enters the selected item. 30-152 PC500LC-10R...
  • Page 559 Use the testing menu for testing the machine or resetting the settings of the machine monitor. “Reset Number of Abrupt Engine Stop by AIS” function resets the counter of high engine speed which activates the auto idle stop function. Use this function when turbocharger is replaced. PC500LC-10R 30-153...

  • Page 560: Adjustment Menu

    Use the adjustment menu to check the various settings of the machine or to adjust the value. The “Pump Absorption Torque (F)” is a function that finely adjusts the main pump absorb torque. Select “Adjustment” on “Service Menu” screen. REMARK For selecting method, see “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE”. 30-154 PC500LC-10R...
  • Page 561 Use the adjustment menu to check the various settings of the machine or to adjust the value. The “Pump Absorption Torque (R)” is a function that finely adjusts the absorption torque on the rear side of the main pump. PC500LC-10R 30-155...
  • Page 562 Relation between the set value and torque adjustment value Code Set value Torque adjustment value +39.2 Nm {+4 kgm}  +29.4 Nm {+3 kgm}  +19.6 Nm {+2 kgm}  +9.8 Nm {+1 kgm}  0 Nm {0 kgm}  -9.8 Nm {-1 kgm}  -19.6 Nm {-2 kgm}  -29.4 Nm {-3 kgm}  -39.2 Nm {-4 kgm}  METHOD FOR ADJUSTING (Low Speed) Use the adjustment menu to check the various settings of the machine or to adjust the value. 30-156 PC500LC-10R...
  • Page 563 Use the adjustment menu to check the various settings of the machine or to adjust the value. The Attachment Flow Adjustment function is a function that finely adjusts the flow rate supplied to the attach- ment flow in the combined operation. PC500LC-10R 30-157...
  • Page 564 Use the adjustment menu to check the various settings of the machine or to adjust the value. The Fan Rotation Mode Selection is used to select the maximum speed of the cooling fan from the normal con- trol mode, 100 % mode or 70 % mode. 30-158 PC500LC-10R...
  • Page 565 Use the adjustment menu to check the various settings of the machine or to adjust the value. The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief and to set the matching speed of the engine correctly when the pump or pump controller is replaced. PC500LC-10R 30-159...
  • Page 566 Hydraulic oil temperature: 45 to 55 °C Working mode: P (“Power Mode”) Fuel control dial: MAX (High idle) position Air conditioner: OFF Select “Adjustment” on “Service Menu” screen. REMARK For selecting method, see “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE”. 30-160 PC500LC-10R...
  • Page 567 U: User calibration value On the “Matching Speed Check” screen, check the match- ing speed by relieving the arm circuit in digging operation and by using the function switches F1: Starts the matching speed check. F5: Returns to “Pump Calibration” screen PC500LC-10R 30-161...
  • Page 568 IN circuit until the check is finished. REMARK It takes approximately 10 seconds to start the bar graph operation. If the check is normally completed, the result is displayed. Press F6 to go to bucket CURL relief. 30-162 PC500LC-10R...
  • Page 569 During matching speed check, a bar is displayed on the screen. Keep relief operation until the check is finished. 11. If the check is normally completed, the result is displayed. Return to “Pump Calibration” screen by pressing F6. PC500LC-10R 30-163...
  • Page 570 *1: When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the relief pressure to be 0 MPa {0 kg/cm } . Accordingly, perform troubleshooting by referring to the Troubleshooting (Fail- ure codes [DHPAMA] and [DHPBMA]). 30-164 PC500LC-10R...
  • Page 571 F6. REMARK Since this function is required only when the pump is re- placed, the PC valve is adjusted or disassembled, or the pump controller is replaced, it is not displayed in the menu list. PC500LC-10R 30-165...
  • Page 572 Select “Adjustment” on “Service Menu” screen. REMARK For selecting method, see “METHOD FOR OPERATING SERVICE MODE” in “SERVICE MODE”. Enter “40” with numeral input switches after the “Adjust- ment” screen is displayed, and press F6. 30-166 PC500LC-10R...

  • Page 573: Method For Performing No-Injection Cranking

    No-Injection cranking does not function while the engine is run- ning. This function can be selected even when the engine is running. However, if you execute No-Injection cranking, “Engine is run- ning. Please turn the key off once.” is displayed on the screen. PC500LC-10R 30-167...

  • Page 574: Komtrax Settings Menu

    KOMTRAX SETTINGS MENU METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS) On “KOMTRAX setting display” screen, select “Terminal Status” with the function switches or numeral input switches. "“Terminal Status”" is used to check the setting condition of the KOMTRAX terminal. 30-168 PC500LC-10R...
  • Page 575 “GPS & Communication State” is used to check the positioning and communication state of the KOMTRAX ter- minal. Select “KOMTRAX Settings” on “Service Menu” screen. REMARK For selecting method, see “Operating method of service mode” in “SERVICE MODE”. PC500LC-10R 30-169...
  • Page 576 For selecting method, see “Operating method of service mode” in “SERVICE MODE”. On “KOMTRAX Settings”screen, select “Modem Informa- tion” with the function switches or numeral input switches. REMARK For selecting method, see “Operating method of service mode” in “SERVICE MODE”. 30-170 PC500LC-10R...

  • Page 577: Method For Displaying Service Message

    KOM- TRAX base station. F5: Returns the screen to “KOMTRAX Settings” screen F6: Enters and sends the input value. PC500LC-10R 30-171...
  • Page 578 • This message is different from that sent to the operator in the operator mode. • Since this message is special for the technician, the message monitor is not displayed as it is dis- played in the operator mode. 30-172 PC500LC-10R...

  • Page 579: Method For Starting Up Komtrax Terminal

    Check the machine for KOMTRAX Communication Inspection Observe the following when checking if KOMTRAX Communication Inspection is required or not. On “Service Menu” screen, select “KOMTRAX Set- tings” with function switches or numeral input switches. PC500LC-10R 30-173...
  • Page 580 Observe the following when performing KOMTRAX Com- munication Inspection. On “Service Menu” screen, select “KOMTRAX Set- tings” with function switches or numeral input switches. On “KOMTRAX Settings” screen, select “GPS & Com- munication State” with the function switches or numer- al input switches. 30-174 PC500LC-10R...
  • Page 581 “KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is indicated for the item in “KOMTRAX Communication Inspection”. • KOMTRAX Communication Inspection may not be completed when the machine is placed indoor where radio wave from the satellite is blocked. PC500LC-10R 30-175...
  • Page 582 Check for the connection. If the connection is loose, machine side wiring harness, or they are secure it. loose. After troubleshooting, perform 1) in step 2 again. When the problems are not solved, contact your KOMTRAX support center. 30-176 PC500LC-10R...
  • Page 583 30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL PC500LC-10R 30-177...

  • Page 584: Adjust Rearview Camera Angle

    (W) can be seen in the machine monitor at the operator's seat. If the image on the monitor is not aligned correctly, adjust the mounting angle (A) of the rearview camera in the following pro- cedure. Angle (A) can be adjusted within the range from 32 to 53 °. 30-178 PC500LC-10R...
  • Page 585 Loosen the camera mounting bolts (5) (3 places) and ad- just the camera mounting angle (A) so that the corner (D) of mounting bracket (C) is aligned with the horizontal line (E). After adjusting, tighten the bolts (5). PC500LC-10R 30-179...
  • Page 586 ADJUST REARVIEW CAMERA ANGLE 30 TESTING AND ADJUSTING Tightening torque:11.8 to 14.7 Nm {1.2 to 1.5 kgm, 8.68 to 10.8 lbft} REMARK A part of the machine is shown on the monitor screen. 30-180 PC500LC-10R...

  • Page 587: Handle Voltage Circuit Of Engine Controller

    • Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or connected to the connector between the engine controller and engine. REMARK You may turn the starting switch to OFF or ON position but do not turn it to START position. (Do not start the engine). PC500LC-10R 30-181...

  • Page 588: Handle Battery Disconnect Switch

    ON position first, then turn it to OFF position. The lamp goes out in the maximum of six minutes. After the system operating lamp goes out, turn the battery disconnect switch immediately to OFF position. 30-182 PC500LC-10R...

  • Page 589: Test Diodes

    Normal (however, the movement of the pointer (resistance) varies by type Moves Does not move of tester, or selection of measuring range). Moves Moves Defective (internal short circuit) Does not move Does not move Defective (internal open circuit) PC500LC-10R 30-183...

  • Page 590: Pm Clinic

    Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Pm CLINIC Pm CLINIC SERVICE Machine model Serial number Service meter □ PC500LC-10R User name Date of inspection Inspector Specifications Main parts Attachment Shoe width □ Boom, standard □ Breaker □ 600 mm □...

  • Page 591: Pm Clinic Check Sheet: Pc500Lc-10R

    (a) 105 °C 102 °C 100 °C 85 °C Blue 40 °C 20 °C White Pm CLINIC CHECK SHEET: PC500LC-10R PC500LC-10R Perform the checks after warming up the engine sufficiently. Machine model Serial number Service meter User name Date of inspection Inspector PC500LC-10R 30-185...
  • Page 592 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING PC500LC-10R Engine Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine • Engine coolant temperature: 60 to 100 °C • Hydraulic oil temperature: 45 to 55 °C...
  • Page 593 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine • Engine coolant temperature: 60 to 100 °C • Hydraulic oil temperature: 45 to...
  • Page 594 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Engine coolant temperature60 • to 100 °C • Working mode: P (Power Mode) Fuel control dial: MIN (Low •...
  • Page 595 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Work equipment speed Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: 45 to • 55 °C Fuel control dial: MAX (High •...
  • Page 596 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: 45 to • 55 °C • Fuel control dial: MAX (High...
  • Page 597 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Swing speed Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: • 45 to 55 °C 28.0 to 36.3 38 or less Fuel control dial: MAX •...
  • Page 598 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Travel speed Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine • Hydraulic oil tempera- 53.8 to 80.8 45.0 to 84.5 ture: 45 to 55 °C Fuel control dial: MAX •...
  • Page 599 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Hydraulic drift of work equipment Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: 45 to • 55 °C Engine: Stopped •...
  • Page 600 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Hydraulic circuit Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: 45 to • 55 °C Fuel control dial: MAX (High •...
  • Page 601 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil temperature: 45 to • 55 °C Fuel control dial: MAX (High •...
  • Page 602 Pm CLINIC SERVICE 30 TESTING AND ADJUSTING Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil tem- Running • L.H. track perature: 45 to idle off the 2.55 to 2.75...
  • Page 603 30 TESTING AND ADJUSTING Pm CLINIC SERVICE Machine model PC500LC-10R Engine SAA6D125E-5 Standard val- Meas- Item Testing conditions Unit ue for new Repair limit ured val- machine Hydraulic oil tem- Approx. 2.09 Approx. 2.09 • Fuel control {Approx. {Approx. perature: 45 to dial: MIN 21.3}...
  • Page 605 60 MAINTENANCE STANDARD PC500LC-10R 60-1...
  • Page 606 WORK EQUIPMENT............................ 60-63 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE............60-63 DIMENSION OF ARM........................60-68 DIMENSIONS OF BUCKET ......................60-70 MAINTENANCE STANDARD OF BOOM CYLINDER ................60-72 MAINTENANCE STANDARD OF ARM CYLINDER ................60-73 MAINTENANCE STANDARD OF BUCKET CYLINDER................ 60-74 60-2 PC500LC-10R...

  • Page 607: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 60-3...
  • Page 608 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 60-4 PC500LC-10R...
  • Page 609 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 610 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 60-6 PC500LC-10R...
  • Page 611 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 60-7...
  • Page 612 ABBREVIATION LIST 60 MAINTENANCE STANDARD Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 60-8 PC500LC-10R...

  • Page 613: Engine And Cooling System

    MAINTENANCE STANDARD OF ENGINE MOUNT ENGINE AND COOLING SYSTEM MAINTENANCE STANDARD OF ENGINE MOUNT Item Judgment criteria Remedy Tightening torque of the 824 to 1030 Nm {84 to 105 kgm}  bolt Re-tighten Tightening torque of the 245 to 309 Nm {25 to 31.5 kgm}  bolt PC500LC-10R 60-9...

  • Page 614: Maintenance Standard Of Cooling System

    MAINTENANCE STANDARD OF COOLING SYSTEM Item Judgment criteria Remedy Tightening torque of the 10.8 to 11.8 Nm {1.1 to 1.2 kgm}  clamp Tightening torque of the 10.8 to 26.5 Nm {1.1 to 2.7 kgm}  Re-tighten Tightening torque of the 10.8 to 11.8 Nm {1.1 to 1.2 kgm}  clamp 60-10 PC500LC-10R...

  • Page 615: Power Train

    MAINTENANCE STANDARD OF SWING CIRCLE POWER TRAIN MAINTENANCE STANDARD OF SWING CIRCLE Machine with tube Unit: mm Item Judgment criteria Remedy Axial clearance of the bear- Standard clearance Allowable clearance Replace 0.5 to 1.6 (when installed on machine) PC500LC-10R 60-11...
  • Page 616 MAINTENANCE STANDARD OF SWING CIRCLE 60 MAINTENANCE STANDARD Unit: mm Item Judgment criteria Remedy Axial clearance of the bear- Standard clearance Allowable clearance Replace 0.5 to 1.6 (when installed on machine) 60-12 PC500LC-10R...

  • Page 617: Maintenance Standard Of Swing Machinery

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MACHINERY MAINTENANCE STANDARD OF SWING MACHINERY PC500LC-10R 60-13...
  • Page 618 Backlash of swing pinion and 0 to 1.21 2.00 swing circle Standard di- Tolerance Repair limit Repair the hard mensions Outside diameter of oil seal chrome plating or contact surface of spacer replace it -0.100 60-14 PC500LC-10R...

  • Page 619: Maintenance Standard Of Final Drive

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF FINAL DRIVE MAINTENANCE STANDARD OF FINAL DRIVE PC500LC-10R 60-15...
  • Page 620 Backlash between No. 1 planetary carrier and No. 2 0.15 to 0.54 sun gear Wear of sprocket tooth profile Repair limit: 6 Repair by build- Standard dimensions Repair limit up welding or re- Face width of sprocket place 90 ± 2.5 60-16 PC500LC-10R...

  • Page 621: Maintenance Standard Of Sprocket

    Standard dimensions Repair limit Wear of tooth tip Repairing by Thickness of tooth bottom 21.8 15.8 build-up welding or replacing Width of tooth Repair limit: 6 (Use "Full-scale drawing of sprocket profile" Wear of tooth profile for judgment) PC500LC-10R 60-17...

  • Page 622: Maintenance Standard Of Sprocket Tooth Profile Full-Scale Drawing

    SCALE DRAWING 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL- SCALE DRAWING REMARK Make the dimensions of the figure to the full-scale and duplicate the figure onto an OHP sheet, and fit it to sprocket to judge. 60-18 PC500LC-10R...
  • Page 623 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL- 60 MAINTENANCE STANDARD SCALE DRAWING PC500LC-10R 60-19...

  • Page 624: Undercarriage And Frame

    Unit: mm Item Judgment criteria Remedy Standard dimen- Tolerance Repair limit sions Track frame Vertical width of Repairing by idler guard Idler ±0.5 build-up weld- support ing or replacing Track frame Lateral width of idler guide portion Idler support 60-20 PC500LC-10R...
  • Page 625 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSH- 60 MAINTENANCE STANDARD Unit: mm Item Judgment criteria Remedy Standard dimensions Free height x out- Load at installed Recoil spring Installed height Replace side diameter height 845.3 x 262 239.0 kN {24375 kg}  PC500LC-10R 60-21...

  • Page 626: Maintenance Standard Of Idler

    MAINTENANCE STANDARD OF IDLER 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF IDLER 60-22 PC500LC-10R...
  • Page 627 -0.120 +0.360 0.340 to 0.567 -0.207 +0.220 Replace the bushing Standard Tolerance Standard in- Allowable in- dimen- terference terference Shaft Hole Interference between the id- sions ler and bushing +0.087 -0.027 0.064 to 107.6 0.149 +0.037 -0.062 PC500LC-10R 60-23...

  • Page 628: Maintenance Standard Of Track Roller

    59.2 53.2 Rebuild by build- Overall width 291.2 up welding or re- Width of tread 58.2 place Width of flange 37.4 Clearance between bushing and collar 0.45 to 0.98 (sum of both clearances at out side and inside) 60-24 PC500LC-10R...
  • Page 629 Clearance between shaft and bushing -0.250 +0.174 0.279 to 0.524 -0.350 +0.029 Replace bushing Tolerance Allowable Standard Standard in- interfer- dimension terference Shaft Hole Interference between roller ence and bushing +0.087 +0.022 0.015 to 91.6 0.100 +0.037 -0.013 PC500LC-10R 60-25...

  • Page 630: Maintenance Standard Of Carrier Roller

    0.214 to 0.380 -0.280 -0.036 Tolerance Standard Allowable Standard interfer- interfer- dimension Shaft Hole Interference between roller ence ence and bushing +0.117 +0.030 0.057 to 0.117 +0.087 Standard clearance Allowable clearance Axial play of roller 0.5 to 0.7 60-26 PC500LC-10R...

  • Page 631: Maintenance Standard Of Track Shoe

    The link on the bushing press-fit side is shown in P part. Unit: mm Item Judgment criteria Remedy Standard dimensions Repair limit Link pitch 228.9 231.9 Turn 180 deg. or Standard dimensions Repair limit replace Outside diameter of bushing Thickness of bushing 13.3 PC500LC-10R 60-27...
  • Page 632 (Nm {kgm}) (Degree) a. Reg- ular link Triple grouser 588 ± 59 120 ± 10 shoe {60 ± 6} Shoe bolt Re-tighten Tightening tor- Lower limit tor- Retightening angle b. Mas- (degree) (Nm {kgm}) (Nm {kgm}) ter link 60-28 PC500LC-10R...
  • Page 633 Interference between master pin and link +0.03 -0.218 48.75 0.218 to 0.310 -0.280 Tolerance Standard dimen- Standard clear- sions ance Shaft Hole Clearance between master pin and bushing -0.2 +0.914 48.75 0.614 to 1.318 -0.4 +0.414 *: For dry track. PC500LC-10R 60-29...

  • Page 634: Maintenance Standard Of Triple Shoe

    Item Judgment criteria Remedy Standard dimensions Repair limit Overall height of grouser Overall height of shoe Thickness of plate Repair by build- up welding or re- Length of grouser base place 25.5 Length of grouser end 17.5 23.5 60-30 PC500LC-10R...

  • Page 635: Hydraulic System

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF MAIN PUMP HYDRAULIC SYSTEM MAINTENANCE STANDARD OF MAIN PUMP PC500LC-10R 60-31...
  • Page 636 MAINTENANCE STANDARD OF MAIN PUMP 60 MAINTENANCE STANDARD 60-32 PC500LC-10R...

  • Page 637: Maintenance Standard Of Swing Motor

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MOTOR MAINTENANCE STANDARD OF SWING MOTOR PC500LC-10R 60-33...
  • Page 638 MAINTENANCE STANDARD OF SWING MOTOR 60 MAINTENANCE STANDARD 60-34 PC500LC-10R...
  • Page 639 Check valve spring height height Replace spring if ameter height height damaged or de- 6.96 N  5.59 N  formed 66.5 x 25.6 45.0 {0.71 kg}  {0.57 kg}  7.75 N  6.20 N  Shuttle valve spring 24.5 x 11.6 14.5 {0.79 kg}  {0.63 kg}  PC500LC-10R 60-35...

  • Page 640: Maintenance Standard Of Travel Motor

    MAINTENANCE STANDARD OF TRAVEL MOTOR AEP21641 Item Judgment criteria Remedy Tightening torque of bolt 490 to 608 Nm {50 to 62 kgm}  Tightening torque of LS relief 372 to 421 Nm {38 to 43 kgm}  valve Re-tighten Tightening torque of the 27.4 to 35.3 Nm {2.8 to 3.6 kgm}  bleeder 60-36 PC500LC-10R...
  • Page 641 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL MOTOR PC500LC-10R 60-37...
  • Page 642 98.1 N  78.5 N  Regulator piston spring 55.0 x 9.0 50.0 formed {10.0 kg}  {8.0 kg}  3.51 N  2.82 N  Check valve spring 62.5 x 20.0 34.9 {0.36 kg}  {0.29 kg}  427 N  341 N  Spool return spring 62.5 x 32.0 42.0 {43.5 kg}  {34.8 kg}  60-38 PC500LC-10R...

  • Page 643: Maintenance Standard Of Control Valve

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE MAINTENANCE STANDARD OF CONTROL VALVE PC500LC-10R 60-39...
  • Page 644 MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60-40 PC500LC-10R...
  • Page 645 {11.4 kg}  aged or de- formed 94.1 N  75.3 N  Spool return spring 54.2 x 34.8 53.5 {9.6 kg}  {7.7 kg}  33.4 N  26.7 N  Spool return spring 54.9 x 24.2 54.5 {3.4 kg}  {2.7 kg}  248 N  198.4 N  Spool return spring 57.2 x 32.8 53.5 {25.3 kg}  {20.2 kg}  PC500LC-10R 60-41...
  • Page 646 MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60-42 PC500LC-10R...
  • Page 647 Replace the Suction valve spring height length ameter height height spring if dam- aged or de- 5.5 N  4.4 N  46.8 x 7.5 40.6 formed {0.56 kg}  {0.45 kg}  1.47 N  1.2 N  Check valve spring 11.5 x 4.6 {0.15 kg}  {0.12 kg}  PC500LC-10R 60-43...
  • Page 648 MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60-44 PC500LC-10R...
  • Page 649 Check valve spring of hy- 35.3 N  28.2 N  71.1 x 19.3 formed draulic drift prevention valve {3.6 kg}  {2.88 kg}  13.7 N  11 N  Check valve spring 33.8 x 6 {1.4 kg}  {1.12 kg}  Check valve spring for re- 6.2 N  4.71 N  31.5 x 10.3 19.5 generation circuit {0.63 kg}  {0.48 kg}  PC500LC-10R 60-45...
  • Page 650 MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60-46 PC500LC-10R...
  • Page 651 {3.6 kg}  {2.88 kg}  13.7 N  11.0 N  Check valve spring 33.8 x 6.0 29.0 {1.4 kg}  {1.12 kg}  Check valve spring for re- 5.1 N  4.71 N  31.5 x 10.3 generation circuit {0.53 kg}  {0.48 kg}  50.0 N  40.0 N  Travel junction valve spring 30.7 x 20.5 {5.1 kg}  {4.08 kg}  PC500LC-10R 60-47...
  • Page 652 MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD 60-48 PC500LC-10R...
  • Page 653 Replace the Boom Hi check valve spring height length diameter height height spring if dam- aged or de- 35.3 N  29.0 N  71.1 x 19.3 formed {3.6 kg}  {3.0 kg}  35.3 N  28.2 N  Arm quick return valve spring 33 x 12 {3.6 kg}  {2.9 kg}  PC500LC-10R 60-49...

  • Page 654: Maintenance Standard Of Work Equipment And Swing Ppc Valve

    MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60-50 PC500LC-10R...
  • Page 655 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING 60 MAINTENANCE STANDARD PPC VALVE PC500LC-10R 60-51...
  • Page 656 Replace spring if 17.7 N  14.1 N  42.5 x 15.5 34.0 damaged or de- {1.80 kg}  {1.44 kg}  formed Centering spring (for P1, P2 29.4 N  23.5 N  44.5 x 15.5 34.0 port) {3.0 kg}  {2.40 kg}  16.7 N  13.3 N  Metering spring 26.5 x 8.15 24.9 {1.70 kg}  {1.36 kg}  60-52 PC500LC-10R...

  • Page 657: Maintenance Standard Of Travel Ppc Valve

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL PPC VALVE MAINTENANCE STANDARD OF TRAVEL PPC VALVE Item Judgment criteria Remedy Tightening torque of bolt 27 to 34 Nm {2.8 to 3.5 kgm}  Re-tighten Tightening torque of bolt 0.441 to 0.588 Nm {0.045 to 0.06 kgm}  PC500LC-10R 60-53...
  • Page 658 MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60 MAINTENANCE STANDARD 60-54 PC500LC-10R...
  • Page 659 48.57 x 108 N  86.3 N  32.5 formed 15.5 {11 kg}  {8.8 kg}  26.53 x 16.7 N  13.3 N  Metering spring 24.9 8.15 {1.7 kg}  {1.36 kg}  Tightening torque of bolt 25 to 31 Nm {2.5 to 3.2 kgm}  Re-tighten Tightening torque of the 34 to 44 Nm {3.5 to 4.5 kgm}  plug PC500LC-10R 60-55...

  • Page 660: Maintenance Standard Of 1St-Line Attachment Ppc Valve (With Epc Valve)

    MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) (Machines with attachment) 60-56 PC500LC-10R...
  • Page 661 125 N  100 N  33.9 x 15.3 28.4 formed {12.7 kg}  {10.2 kg}  16.7 N  13.3 N  Metering spring 22.7 x 8.10 22.0 {1.70 kg}  {1.36 kg}  Tightening torque of the 11.76 to 14.7 Nm {1.2 to 1.5 kgm}  Re-tighten bolt PC500LC-10R 60-57...

  • Page 662: Maintenance Standard Of Epc Valve Of 1St-Line Attachment Ppc Valve

    Repair limit Free height Load at in- Load at in- Replace EPC Installed x outside stalled Free height stalled valve assembly Metering spring height diameter height height if damaged or deformed 3.2 N  2.6 N  9.5 x 11.4 {0.33 kg}  {0.26 kg}  60-58 PC500LC-10R...
  • Page 663 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE 60 MAINTENANCE STANDARD (WITH EPC VALVE) Unit:  mm Item Judgment criteria Remedy Tightening torque of the 9.8 to 12.7 Nm {1.0 to 1.3 kgm}  bolt Re-tighten Tightening torque of the fil- 8.8 to 11.8 Nm {0.9 to 1.2 kgm}  PC500LC-10R 60-59...

  • Page 664: Maintenance Standard Of Solenoid Valve

    MAINTENANCE STANDARD OF SOLENOID VALVE 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SOLENOID VALVE REMARK The figure is for the machines ready for installation of attachment. 60-60 PC500LC-10R...

  • Page 665: Maintenance Standard Of Attachment Circuit Selector Valve

    Installed Free Replace spring stalled stalled Spool return spring outside di- height height if damaged or height height ameter deformed 834 N  667 N  132 x 29 114.5 {85.0 kg}  {68.0 kg}  Tightening torque of bolt 59 to 74 Nm {6 to 7.5 kgm}  Retighten PC500LC-10R 60-61...

  • Page 666: Maintenance Standard Of Center Swivel Joint

    Item Judgment criteria Remedy Standard dimen- Standard clear- Allowable clear- Clearance between the rotor sions ance ance Replace and shaft 0.050 to 0.110 0.111 Tightening torque of the bolt 31.4±2.9 Nm {3.2±0.3 kgm}  Re-tighten Tightening torque of the plug 33.3±3.9 Nm {3.4±0.4 kgm}  Re-tighten 60-62 PC500LC-10R...

  • Page 667: Work Equipment

    60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE WORK EQUIPMENT MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE PC500LC-10R 60-63...
  • Page 668 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD 60-64 PC500LC-10R...
  • Page 669 Clearance between mount- -0.036 +0.329 0.295 to ing pin and bushing of link 0.419 -0.090 +0.259 Replace the pin and bucket and bushing -0.036 +0.329 Clearance between mount- 0.295 to ing pin and bushing of links 0.419 -0.090 +0.259 PC500LC-10R 60-65...
  • Page 670 R16: Insert shim whose thickness is 1.5 mm (1). +1.5 ±1.2 119.3 2.1 to 6.0 The joint of arm Clearance is and bucket cylin- L17: - Max. 1.0 mm. (*2) R17: Adjust by combining shims whose thickness is 0.8 mm 100 hours (1) and 1.5 mm (3). 60-66 PC500LC-10R...
  • Page 671 The quantity in ( ) after each shim thickness indicates the quantity of shim to be prepared. *1: The criteria are for the R.H. boom cylinder. The shim adjustment position of the L.H. boom cylinder is re- verse to R.H. *2: Use steel (non-flanged) shims. *3: Use split-type steel shims. PC500LC-10R 60-67...

  • Page 672: Dimension Of Arm

    60 MAINTENANCE STANDARD DIMENSION OF ARM Unit: mm Tolerance Measuring point Standard dimensions Shaft Hole -0.036 +0.1 -0.090 +1.5 Arm side 129.3 Cylinder head side ±1.2 +0.5 Boom side -0.3 Arm side -0.8 -0.043 +0.1 -0.106 647.7 ±1 60-68 PC500LC-10R...
  • Page 673 ±3 3419.2 ±1 506.8 ±1 ±0.2 ±0.5 574.8 1804 -0.036 +0.1 -0.090 Bucket side Link side ±0.5 -0.036 +0.2 -0.090 -0.036 +0.144 -0.090 +0.074 Arm as a bare unit -0.5 With the bushing press-fitted Minimum 2210 Maximum 3660 PC500LC-10R 60-69...

  • Page 674: Dimensions Of Bucket

    MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD DIMENSIONS OF BUCKET 60-70 PC500LC-10R...
  • Page 675 60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE Unit: mm Measuring point Standard dimensions Tolerance ±0.5 125.3 ±0.5 102°35′ 574.8 1786 52°35′ +0.1 +0.063 +0.1 +0.5 613.5 -2.5 147.5 PC500LC-10R 60-71...

  • Page 676: Maintenance Standard Of Boom Cylinder

    0.300 -0.090 +0.075 bushing Tightening torque of the cyl- 892±137 Nm {91±14 kgm}  inder head bolt Tightening torque of the cyl- 294±29.4 Nm {30.0±3.0 kgm}  Re-tighten inder piston Tightening torque of the cyl- 58.9 to 73.6 Nm {6.0 to 7.5 kgm}  inder piston fixed screw 60-72 PC500LC-10R...

  • Page 677: Maintenance Standard Of Arm Cylinder

    0.547 -0.090 +0.370 bushing Tightening torque of the cyl- 892±137 Nm {91.0±14 kgm}  inder head bolt Tightening torque of the cyl- 294±29.4 Nm {30.0±3.0 kgm}  Re-tighten inder piston Tightening torque of the cyl- 58.9 to 73.6 Nm {6.0 to 7.5 kgm}  inder piston fixed screw PC500LC-10R 60-73...

  • Page 678: Maintenance Standard Of Bucket Cylinder

    0.547 -0.090 +0.370 bushing Tightening torque of the cyl- 530±78.5 Nm {54.0±8.0 kgm}  inder head bolt Tightening torque of the cyl- 294±29.4 Nm {30.0±3.0 kgm}  Re-tighten inder piston Tightening torque of the cyl- 58.9 to 73.6 Nm {6.0 to 7.5 kgm}  inder piston fixed screw 60-74 PC500LC-10R...
  • Page 679 90 CIRCUIT DIAGRAMS PC500LC-10R 90-1...
  • Page 680 CONNECTOR AND WIRING HARNESS CHART (11/15) ..............90-61 CONNECTOR AND WIRING HARNESS CHART (12/15) ..............90-63 CONNECTOR AND WIRING HARNESS CHART (13/15) ..............90-65 CONNECTOR AND WIRING HARNESS CHART (14/15) ..............90-67 CONNECTOR AND WIRING HARNESS CHART (15/15) ..............90-69 90-2 PC500LC-10R...

  • Page 681: Abbreviation List

    It is written as CDR valve and is not Regulator used independently. This is a system that can actuate multiple actua- Closed-center Load CLSS Hydraulic system tors simultaneously regardless of the load (pro- Sensing System vides better combined operation than OLSS). PC500LC-10R 90-3...
  • Page 682 (D Series) combination of hydraulic motor and bevel shaft. Transmission Hydraulic transmission system that uses a com- Hydro Static Transmis- bination of hydraulic pump and hydraulic motor sion (D, WA) without using gears for stepless gear shifting. 90-4 PC500LC-10R...
  • Page 683 Inlet Metering Valve Engine pump combustion discharged volume. (Same as IMA) This is a mechanism that burns the blowby gas Komatsu Closed Crank- again by separating oil from blowby gas and re- KCCV Engine case Ventilation turning it to the intake side. It primarily consists of filters.
  • Page 684 This is an actuator that consists of a solenoid and Solenoid Electrical system an iron core that is operated by the magnetic force when the solenoid is energized. 90-6 PC500LC-10R...
  • Page 685 Abbreviation Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection PC500LC-10R 90-7...
  • Page 686 ABBREVIATION LIST 90 CIRCUIT DIAGRAMS Abbreviation Actual word spelled out Steering STRG Signal Solenoid Standard Option PRESS Pressure SPEC Specification Switch TEMP Temperature Torque Converter Transmission 90-8 PC500LC-10R...

  • Page 687: Hydraulic Circuit Diagram

    SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM Symbol Content Main piping route Pilot and drain route Flexible piping such as hose Crossing of disconnected route Connected route Flow of fluid Throttle Variable Electric Spring Pickup port Pickup port and pressure gauge PC500LC-10R 90-9...
  • Page 688 Reference: ▲ in the figure shows outlet Variable displacement hydraulic pump Hydraulic motor Reference: ▲ and ▼ in the figure show the direction of oil flow into hydraulic motor, and as direction changes, the rotation of motor is reversed. Servo piston PPC valve 90-10 PC500LC-10R...
  • Page 689 Hydraulic 2-stage pilot valve Lock valve Drain valve Pressure regulating valve, safety valve, relief valve Pressure regulating valve, safety valve, relief valve (when the oil pressure is discharged to the low-pressure side) Bypass valve Accumulator Cylinder Cylinder with piston valve PC500LC-10R 90-11...
  • Page 690 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 CIRCUIT DIAGRAMS Symbol Content Unit 90-12 PC500LC-10R...
  • Page 691 HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED) PC500LC-10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas. 90-13 PC500LC-10R...
  • Page 693 HYDRAULIC CIRCUIT DIAGRAM (WHEN UPPER STRUCTURE IS SWING TO LEFT) PC500LC-10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas. 90-15 PC500LC-10R...

  • Page 695: Hydraulic Circuit Diagram (When Boom Is Raised And Upper Structure Is Swung To Left)

    HYDRAULIC CIRCUIT DIAGRAM (WHEN BOOM IS RAISED AND UPPER STRUCTURE IS SWUNG TO LEFT) PC500LC-10R REMARK This figure includes the equipment and device that are unavailable as optional items in some areas. 90-17 PC500LC-10R...

  • Page 697: Hydraulic Circuit Diagram (2/2)

    HYDRAULIC CIRCUIT DIAGRAM (1/2) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-19 PC500LC-10R...
  • Page 699 HYDRAULIC CIRCUIT DIAGRAM (2/2) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-21 PC500LC-10R...
  • Page 701 Grounding by chassis ground Grounding by terminal Contact, switch Push button switch (N.O. type) N.O.: Normally Open Push button switch (N.C. type) N.C.: Normally Closed Push button switch (N.O. type) N.O.: Normally Open Push button switch (N.O. type) N.C.: Normally Closed PC500LC-10R 90-23...
  • Page 702 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM Symbol Content Variable Resistor Variable resistor Diode Light emitting diode (LED) Photo diode Low-voltage diode (Zener diode) Transistor (PNP type) Transistor (NPN type) Electromagnetic coil Battery Fuse 90-24 PC500LC-10R...
  • Page 703 Plug type connector (left: male, right: female) REMARK Figure shows the connected state. Solenoid Motor Lamp Pressure switch (N.O. type) N.O.: Normally Open Pressure switch (N.C. type) N.C.: Normally Closed Potentiometer, fuel control dial Temperature sensor Starting switch Backup alarm Horn PC500LC-10R 90-25...
  • Page 704 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM Symbol Content Buzzer Antenna 90-26 PC500LC-10R...

  • Page 705: Electrical Circuit Diagram

    ELECTRICAL CIRCUIT DIAGRAM (1/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-27 PC500LC-10R...

  • Page 707: Electrical Circuit Diagram (1/7)

    ELECTRICAL CIRCUIT DIAGRAM (2/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-29 PC500LC-10R...

  • Page 709: Electrical Circuit Diagram (2/7)

    ELECTRICAL CIRCUIT DIAGRAM (3/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-31 PC500LC-10R...

  • Page 711: Electrical Circuit Diagram (3/7)

    ELECTRICAL CIRCUIT DIAGRAM (4/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-33 PC500LC-10R...

  • Page 713: Electrical Circuit Diagram (4/7)

    ELECTRICAL CIRCUIT DIAGRAM (5/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-35 PC500LC-10R...

  • Page 715: Electrical Circuit Diagram (5/7)

    ELECTRICAL CIRCUIT DIAGRAM (6/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-37 PC500LC-10R...

  • Page 717: Electrical Circuit Diagram (6/7)

    ELECTRICAL CIRCUIT DIAGRAM (7/7) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 90-39 PC500LC-10R...

  • Page 719: Connector And Wiring Harness Chart (1/15)

    CONNECTOR AND WIRING HARNESS CHART (1/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. 0.85LR 0.85W 9 10 DIODE 1349 1401 S25-7 S25-1 K01-2 11 12 13 14 15 16 17 18 19 20 0.85GR...

  • Page 721: Connector And Wiring Harness Chart (2/15)

    CONNECTOR AND WIRING HARNESS CHART (2/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. WHITE TAPE F01-2 H14-1 J01-19 AC95-8 H09-2 M05-5 AC01-1 AC95-11 CM02-9 N08-10 CP01-64 0.5RY 1.25L 0.5L 1.25L...

  • Page 723: Connector And Wiring Harness Chart (3/15)

    CONNECTOR AND WIRING HARNESS CHART (3/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. (FROM 2/15) SUNSHINE SENSOR J05-12 1.25RL CN-P31 1237 WIPER MOTOR (050) CN-M05 R07-2 J01-20 AC01-10 AC01-9 0.5BR...

  • Page 725: Connector And Wiring Harness Chart (4/15)

    CONNECTOR AND WIRING HARNESS CHART (4/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. TRAVEL RIGHT FORWARD PRESSURE SENSOR (FROM 3/15) CN-P11 (AMP) TRAVEL RIGHT REAR CP01-72 0.85B 0.85WR 0.85WB...

  • Page 727: Connector And Wiring Harness Chart (5/15)

    CONNECTOR AND WIRING HARNESS CHART (5/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. JUNCTION CONNECTOR(PINK) JUNCTION CONNECTOR(ORANGE) ROOM LAMP CN-J02(J) CN-J03(J) CN-L03 CP01-1 CP01-4 CM01-1 CM01-2 AC95-1 AC95-2 N08-1...

  • Page 729: Connector And Wiring Harness Chart (6/15)

    CONNECTOR AND WIRING HARNESS CHART (6/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. HUSIBLE LINK CN-F04 HUSIBLE LINK CN-F05 1426 1427 L02-1 A13-1 R05-5 1428 1621 1000 1006 L02-2...

  • Page 731: Connector And Wiring Harness Chart (7/15)

    CONNECTOR AND WIRING HARNESS CHART (7/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. (FROM 3/15) HYDRAULIC RETURN FILTER CLOGGING SENSOR *0.85B BP67 CP01-74 0.85LB CN-P67 CP67 *0.85WB (DT) 3901 WATER IN FUEL SENSOR *0.85G...

  • Page 733: Connector And Wiring Harness Chart (8/15)

    CONNECTOR AND WIRING HARNESS CHART (8/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. F PUMP PRESS SENSOR CP01-11 0.85B 0.85GR 0.85WB CN-P25 1738 1264 1739 (AMP) (FROM 7/15) 0.85WB...

  • Page 735: Connector And Wiring Harness Chart (9/15)

    CONNECTOR AND WIRING HARNESS CHART (9/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. CONTROLLER H15-14 R18-2 CM850 *0.85WB *0.85B 3814 3816 CN-CE03 H15-16 (DTP) *0.85B *0.85B 16H15 3803 3804...
  • Page 737 CONNECTOR AND WIRING HARNESS CHART (10/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. REAR BEACON L05A-2 A15-2 CN-L05A 0.85B (GRO) 1625 1003 1046 (DT) BACK CAMERA 1 A40-4 (TO 15/15) CM04-2 0.5B...
  • Page 739 CONNECTOR AND WIRING HARNESS CHART (11/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. A/C AMBIENT AIR TEMP SENSOR CN-P18 (YAZAKI) AC01-8 AC01-7 0.85RW 0.85BrR 1011 1010 WASHER MOTOR CN-M06...
  • Page 741 CONNECTOR AND WIRING HARNESS CHART (12/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. ENGINE SHUTDOWN SECONDARY SWITCH CN-S18 (SWP) 0.5LR 0.5LW 1628 1629 0.5LR 0.5LW 1630 1631 S18-4 S18-1...
  • Page 743 CONNECTOR AND WIRING HARNESS CHART (13/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. HOUSING : SUMITOMO 1 2 3 PFUEL 1 2 3 HOUSING :AMP J1939 SEGR TWTR JM03...
  • Page 745 CONNECTOR AND WIRING HARNESS CHART (14/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. DIRECTION OF LEVER DIRECTION OF LEVER DIRECTION OF LEVER DOWN SIDE(NORMAL) UPPER SIDE DOWN SIDE(NORMAL) UPPER SIDE...
  • Page 747 CONNECTOR AND WIRING HARNESS CHART (15/15) PC500LC-10R REMARK This figure covers the equipment and devices that are unavailable as optional items in some areas. KOMTRAX < )(OPT)> CN-CK02 (FROM 1/15) KOMTRAX (070) WORKING LAMP (REAR) CN-CK01 (070) AC95-3 AC95-4 AC95-5 AC95-8 1.25B...
  • Page 749 INDEX INDEX Symbols Arm quick return valve of control valve - Operation................10-184 1st-line attachment PPC valve (with EPC valve)..Arm regeneration circuit of control valve...10-160 ..............10-208 Arm regeneration circuit of control valve - Function..1st-line attachment PPC valve (with EPC valve) - ..............10-160 Maintenance standard.........
  • Page 750 INDEX Bucket clearance adjustment shim....10-279 Connector and wiring harness chart (7/15)..90-53 Bucket clearance adjustment shim - Function.. 10-279 Connector and wiring harness chart (8/15)..90-55 Bucket cylinder - Maintenance standard.....60-74 Connector and wiring harness chart (9/15)..90-57 Bucket cylinder - Test oil leakage......30-97 Connector with housing to rotate - Disconnect/ Bypass valve stroke sensor of hydraulic tank...
  • Page 751 INDEX Diodes - Test............. 30-183 Display function of operator identification input screen Fan belt - Test............. 30-51 ..............30-115 Fan clutch............10-39 Fan clutch - Function.......... 10-39 Fan clutch - Specification........10-39 Electric circuit diagram symbol list...... 90-23 Fan clutch - Structure..........10-39 Electrical circuit diagram........
  • Page 752 INDEX Hydraulic circuit diagram (when swinging to left)90-15 Hydraulic circuit diagram symbol list.....90-9 Left front mirror - Adjust........30-105 Hydraulic circuit diagrams of control valve and names Left front mirror (A) - Adjust to the regular position..of valves.............10-144 ..............30-106 Hydraulic cylinder circuit - Release remaining pres- LS bypass plug...........
  • Page 753 Main relief valve of control valve - Structure..10-187 tion............... 00-29 Maintenance mode - Set........30-139 Pm Clinic............30-184 Maintenance record - Confirm......30-137 Pm clinic check sheet - PC500LC-10R.....30-185 Maintenance standard of carrier roller....60-26 Pm Clinic service..........30-184 Maintenance standard of solenoid valve.....60-60 Power train system........30-57,60-11 Maintenance standard of swing motor....
  • Page 754 Test swing relief pressure - By machine monitor 30-66 Standard tightening torque table......00-62 Test swing relief pressure - By testing tools..30-67 Standard value for engine - PC500LC-10R..20-9 Test travel relief pressure - By testing tools..30-69 Standard value table for machine - PC500LC-10R..
  • Page 755 Travel motor - Maintenance standard....60-36 Travel motor - Specifications......10-256 Travel motor - Structure........10-254 Weight table............01-14 Travel motor - Test oil leakage......30-98 Weight table - PC500LC-10R......01-14 Travel motor circuit - Release remaining pressure..Work equipment........10-276,60-63 ..............30-62 Work equipment - Function.......10-277 Travel motor motor part - Operation....10-257...
  • Page 756 INDEX Work equipment, swing, and travel circuits - Test/ Adjust oil pressure........30-63 Work equipment, swing, and travel circuits oil pres- sure - Test............ 30-64 Work equipment/Travel - Adjust relief pressure.. 30-71 Work range drawing - PC500LC-10R....01-10 Working range.............01-10...
  • Page 758 PC500LC-10R HYDRAULIC EXCAVATOR Form No. SEN06722-00 ©2018 KOMATSU All Rights Reserved Printed in Japan 11-2018...

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