PC300 5 400 5 PDF

Time 01 Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
30-70 30-87 0 30-113-2 40- 5 40-36
30-71 30-88 0 30-114 40- 6 40-37
30-72 30-89 0 30-115 40- 7 40-38
30-73 30-90 0 30-115-I 40- 8 40-39
30-74 30-91 0 30-115-2 40- 9 40-40
30-75 30-92 0 30-115-3 40-10 40-41
30-76 30-93 0 30-115-4 40-11 40-42
30-77 30-94 0 30-115-5 40-12 40-43
30-78 30-95 0 30-115-6 40-13 0 40-43-I
30-79 30-96 0 30-116 40-13-I . 40-44
30-80 30-97 30-117 40-13-2 40-45
30-81 30-98 30-118 40-14 40-46
30-82 30-99 30-119 40-15 40-47
30-83 30-100 0 30-119-I 40-16 0 40-48
30-84 30-101 0 30-119-2 40-17 0 40-49
30-85 30-102 30-120 40-18
30-85-I 30-103 30-121 40-19
30-85-2 30-104 30-122 40-20
30-85-3 30-105 30-123 40-22
30-85-4 30-105-I 30-124 40-23
30-85-5 30-105-2 30-125 40-24
30-85-6 0 30-105-3 30-126 40-24-I
30-85-7 0 30-105-4 30-127 40-25
30-85-8 . 30-106 30-128 40-26
30-85-g 30-107 30-129 40-27
30-85-10 . 30-107-I 30-130 40-28
30-85-11 . 30-107-2 30-131 40-29
30-85-12 0 30-107-3 30-132 40-30
30-85-13 0 30-107-4 30-133 40-31
30-85-14 0 30-107-5 30-134 40-32
30-85-15 0 30-107-6 30-135 40-33
30-85-16 0 30-107-7 30-136 0 40-33-I
30-85-17 0 30-107-8 30-137 0 40-33-2
30-85-18 30-108 30-138 0 40-33-3
30-85-19 30-109 30-139 0 40-33-5
30-85-20 30-110 0 40-33-6
30-85-21 30-111 40- 1 0 40-33-7
30-85-22 30-112 40- 2 0 30-33-8
30-85-23 30-113 40- 3 40-34
30-86 0 30-113-I 40. 4 40-35

A IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
The service and repair techniques recommended by Komatsu and described in this
manual are both effective and safe methods of operation. Some of these operations re-
quire the use of tools specially designed by Komatsu for the purpose.
To prevent injury to workers, the symbol A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
A SAFETY
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for
1. Before carrying out any greasing or repairs,
smoking. Never smoke while working.
read all the precautions given on the
decals which are fixed to the machine.
2.When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
l Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
l Always wear safety glasses when
8. Before starting work, lower blade, ripper,
grinding parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, equipment from falling. In addition, be sure
always wear welding gloves, apron, glasses, to lock all the control levers and hang
cap and other clothes suited for welding warning signs on them.
work. 9 When disassembling or assembling, sup-

port the machine with blocks, jacks or
4.When carrying out any operation with two
stands before starting work.
or more workers, always agree on the op-
erating procedure before starting. Always IO Remove all mud and oil from the steps or
inform your fellow workers before starting other places used to get on and off the
any step of the operation. Before starting machine. Always use the handrails, ladders
or steps when getting on or off the
work, hang UNDER REPAIR signs on the
machine. Never jump on or off the machine.
controls in the operator’s compartment.
If it is impossible to use the handrails,
5. Keep all tools in good condition and learn ladders or steps, use a stand to provide safe
the correct way to use them. footing.
00-3
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be
loosen them slowly to prevent the oil from sure that they will not be damaged by
spurting out. contact with other parts when the ma-
Before disconnecting or removing compo- chine is being operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
circuit. sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
13
,,.The water and oil in the circuits are hot
ful when installing tubes for high pressure
when the engine is stopped, so be careful
circuits. Also, check that connecting parts
not to get burned.
are correctly installed.
Wait for the oil and water to cool before car-
rying out any work on the oil or water 21 When assembling or installing parts, always
circuits. use the specified tightening torques. When
13. Before starting work, remove the leads from installing protective parts such as guards, or
the battery. Always remove the lead from parts which vibrate violently or rotate at
the negative (-1 terminal first. high speed, be particularly careful to check
that they are installed correctly.
14. When raising heavy components, use a
hoist or crane. 22. When aligning two holes, never insert your
Check that the wire rope, chains and hooks fingers or hand. Be careful not to get your
are free from damage. fingers caught in a hole.
Always use lifting equipment which has
ample capacity. 23. When measuring hydraulic pressure, check
Install the lifting equipment at the correct that the measuring tool is correctly assem-
places. Use a hoist or crane and operate bled before taking any measurements.
slowly to prevent the component from hit-
24.Take care when removing or installing the
ting any other part. Do not work with any
tracks of track-type machines.
part still raised by the hoist or crane.
When removing the track, the track sepa-
15. When removing covers which are under in- rates suddenly, so never let anyone stand at
ternal pressure or under pressure from a either end of the track.
spring, always leave two bolts in position on
opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not

to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil

from spilling out. If any fuel or oil drips on to
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18.As a general rule, do not use gasoline to

wash parts. In particular, use -only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of
components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Contact your KOMATSU distributor for the
latest information.
I I
00-5
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK (aa@ ..a- )
Shop manuals are issued as a guide to carry- When a manual is revised, an edition mark is
ing out repairs. They are divided as follows: recorded on the bottom outside corner of the
pages.
Chassis volume: Issued for every machine
model
Engine volume: Issued for each engine series
Each issued as
Electrical volume REVISIONS
one volume to
Attachments volume
cover all models Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
These various volumes are designed to avoid
duplicating the same information. Therefore to
deal with all repairs for any model, it is neces-
sary that chassis, engine, electrical and attach-
ment volumes are ready. SYMBOLS
So that the shop manual can be of ample

DISTRIBUTION AND UPDATING
practical use, important places for safety and
Any additions, amendments or other quality are marked with the following symbols.
changes will be sent to KOMATSU distributers.
Get the most up-to-date information before
you start any work.
FILING METHOD
Symbol Item Remarks
1. See the page number on the bottom of the
page. File the pages in correct order. Special safety precautions are
2. Following examples shows how to read the A Safety necessary

the work.
when performing
page number.
Example 1 (Chassis volume): Special technical precautions
or other precautions for
IO-3 Caution preserving standards are
*
necessary when performing
the work.
Item number (IO. Structure
and Function) Weight of parts or systems.
F Consecutive page number for Caution necessary when
r’\
each item. m Weight selecting hoisting wire, or
when working posture is
Example 2 (Engine volume): important, etc.
12-410 Places that require special

Tighten-
attention for the tightening
Unit number (I. Engine) lg torque
torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with
Coat adhesives and lubricants, etc.
Group No. (4. Fuel system)
- Consecutive page No. (Page
Places where oil, water or
IO of Group 4)
“f$
1 Xl, water fuel must be added, and
the capacity.
3. Additional pages: Additional pages are in-
dicated by a hyphen (-1 and number after the Places where oil or water
page number. File as in the example. Drain must be drained, and quantity
Example: to be drained.
1 o-4 12-203
1 o-5 12-204
00-6
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Slinging near the edge of the hook may

Heavy parts (25 kg or more) must be
cause the rope to slip off the hook during
lifted with a hoist etc. In the Disassembly
hoisting, and a serious accident can result.
and Assembly section, every part weigh-
Hooks have maximum strength at the
ing 25 kg or more is indicated clearly with
middle portion.
g
1. If a part cannot be smoothly removed from

the machine by hoisting, the following
checks should be made: L-l u u Ll Ll
Check for removal of all bolts fastening
as%
l
100% 79% 71% 41%
the part to the relative parts.
FSOO64
l Check for existence of another part
causing interference with the part to be 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
removed.
symmetrically wound on to the load.
2. Wire ropes
A Slinging with one rope may cause
turning of the load during hoisting,
1) Use adequate ropes depending on the untwisting of the rope, or slipping of
weight of parts to be hoisted, referring to the rope from its original winding
the table below: position on the load, which can result
in a dangerous accident.
4) Do not sling a heavy load with ropes

Wire ropes
forming a wide hanging angle from the
(Standard “2” or “S” twist ropes
hook.
without galvanizing)
When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter (mm) Allowable load (tons)
will increase with the hanging angles. The
table below shows the variation of
10 1 .o
allowable load (kg) when hoisting is made
11.2 1.4 with two ropes, each of which is allowed
12.5 1.6 to sling up to 1000 kg vertically, at various
hanging angles.
14 2.2
When two ropes sling a load vertically, up
16 2.8 to 2000 kg of total weight can be
18 3.6 suspended. This weight becomes 1000 kg
when two ropes make a 120” hanging
20 4.4
angle. On the other hand, two ropes are
22.4 5.6 subjected to an excessive force as large as
30 10.0 4000 kg if they sling a 2000 kg load at a
lifting angle of 150”.
40 18.0
cy
50 28.0
e kg
60 40.0
A
The allowable load value is estimated to

be one-sixth or one-seventh of the
breaking strength of the rope used.
2) Sling wire ropes from the middle portion

30’ 60” 90” 120” 150”
of the hook.
Lifting angle : a
FSOO65
00-7
STANDARD TIGHTENING TORQUE
mm
1. STANDARD TIGHTENING
STANDARD
TORQUE
The following charts give the standard tightening

TIGHTENING
OF BOLTS AND
torques
NUTS
TORQUE
of bolts and nuts. Exceptions are given in

sections of “Disassembly and Assembly”.
Thread diameter Width

of bolt across flat
(mm) (mm)
kam Nm
6 10 1.35rto.15 13.22 1.4

8 13 3.2~10.3 31.4k2.9
10 17 6.720.7 65.72 6.8
12 19 11.5*1.0 112k9.8
14 22 18.0t2.0 177*19
16 24 28.5-+3 279&29
18 27 39t4 383&39
20 30 56-+6 549*58
22 32 76~~8 745278
24 36 94.5*10 927+98
27 41 135+15 1320? 140

30 46 175r20 172Ok 190
33 50 225+25 2210&240
36 55 280+30 275Ok 290
39 60 335-t35 32802 340
This torque table does not apply to the bolts with which nylon packings or other non-
ferrous metal washers are to be used, or which require tightening to otherwise specified
torque.
t Nm (newton meter): INm + 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Threaot gilneter Width Tightening torque

across flats
(mm) (mm) kgm Nm
10 14 6.7kO.7 65.7t6.8
12 17 11.5kl 1 12a9.8
16 22 28.5*3 279+29
I I I
00-8
STANDARD TIGHTENING TORQUE
Sealing surface
3.TlGHTENlNG TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter
of nut part
Width across flats
of nut part
T Tightening torque
(mm) (mm) kgm Nm
14 19 2.5 kO.5 24.5 24.9

18 24 5f2 49219.6
22 27 822 78.5 -+ 19.6
24 32 1423 137.3k29.4
30 36 1823 176.5 k29.4
33 41 2OI+5 196.1 a49
36 46 25+-5 245.2 +49
42 55 3Ok5 294.2 -+49
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Nomenclature Komatsu code Applications
LT-IA 1 Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-IB Used to apply resin, rubber, metallic and

non-metallic parts when a fast, strong seal is needed.
Adhesives LT-2” Preventing bolts, nuts and plugs from loosening and leaking oil.
LT-3 Provides an airtight, electrically insulating seal.

Used for aluminum surfaces.
LT-4 Used to coat plugs (plate shaped, bowl shaped) and holes, and
mating portion of shaft.
LG-1 Used with gaskets and packings to increase sealing effect.
LG-3 Heat-resistant gasket for precombustion chambers

and exhaust piping.
Sealant gasket
LG-4 Used b itself on mounting surfaces on the final drive and transmission
cases. YThrckness after tightening: 0.07 - 0.08 mm)
LG-5 Used by itself to seal grease fittings, tapered screw fittings and tapered
screw fittings in hydraulic circuits of less than 50 mm in diameter.
LG-6 Silicon base type used in combination with LG-1 and LG-4.
LG-7 Has a shorter curing time than LG-6, and is easier

to peel off.
Antifriction compound
Applied to bearings and taper shafts to facilitate press-fitting and to
(Lubricant including LM-P
molybdenum disulfide) prevent sticking, burning or rusting.
Grease Applied to bearings, sliding parts and oil seals for lubrication, rust
G2-LI
(Lithium grease) prevention and facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion.
‘LT-2 is also called LOCTITE in the shop manuals.
00-9
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Current rating

Nominal Cable O.D.
Applicable circuit
number Number Dia. Tp;ands Cross section (mm) (A)
strands (mm21
0.85 1 11 1 0.32 I 0.88 I 2.4 I 12 1 Starting, lighting, signal etc

2 1 26 / 0.32 1 2.09 I 3.1 I 20 I Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 -1851 0.80 -42.73 1 1.4 135 Starting

~~~ 1 I
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Instrument Signal Other
Code W B B R Y G L
Pri-
1
maw Color White Black Black Red Yellow Green Blue
I I I I I I I I
I 1 Code 1 WR I - BW RW YR GW LW
2
Color White& Red - Black &White Red &White Yellow & Red Green & White Blue &White
I
I Code WB - BY RB YB GR LR
3
-I
Auxi_ Color White& Black - Black &Yellow Red &Black Yellow & Black Green & Red Blue & Red
liary RY GY LY
Code WL BR YG
4
Color White&Blue - Black & Red Red & Yellow Yellow & Green Green &Yellow Blue &Yellow
I I I I I I
I 5
Code 1 WG - - RG I YL (GB) (LB)
Color White &Green - Red & Green Yellow &Blue (Green & Black) (Blue &Black)
Code - - RL YW (GL)
6
Color - - Red & Blue Yellow & White (Green & Blue)
00-l 0
CONVERSION TABLE
CONVERSION TABLE
Method of using the Conversion Table

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
l Method of using the Conversion Table to convert from millimeters to inches
I. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the came procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in

I
/
0 1 2 3 4 5; 6 7 8 9
I
0.039 0.079 0.118 0.157 0.197 j 0.236 0.276 0.315 0.354

0.394 0.433 0.472 0.512 0.551 0.591 I 0.630 0.669 0.709 0.748
0.787 0.827 0.866 0.906 0.945 0.984 j 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
0 i
--1.969 2.008___._ -2.047
-___ -_-_-- _________2.087
-_-_-_- 2.126
--_.. 12.1651 2.205 2.244 2.283 2.323
2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
1 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 1
CONVERSIONTABLE
Millimeters to Inches 1 mm =O.O3937in
0 1 2 3 4 5 6 7 8 9
:
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.20461b
l- 7
Kilogram 0 1 2 3 4 5 6 7 8 9
2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
1 1
00-l 2
CONVERSIONTABLE
Liter to U.S. Gallon 1 !Z= 0.2642 U.S. Gal
l-
10
0
2.642
1
0.264
2.906
2
0.528
3.170
3
0.793
3.434
4
1.057
3.698
5
1.321
3.963
I 6
1.585
4.227
7
1.849
4.491
8
2.113
4.755
9
2.378
5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 i9.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 P = 0.21997 U.K. Gal
10
20
0
2.200
4.399
I 0.220
2.420
4.619
2
0.440
2.640
4.839
3
0.660
2.860
5.059
4
0.880
3.080
5.279
5
1.100
3.300
5.499
6
1.320
3.520
5.719
7
1.540
3.740
5.939
8
1.760
3.950
6.159
9
1.980
4.179
6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
L L L
00-13
CONVERSION TABLE
kgm to ft.lb 1 kg.m = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 1 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-14
CONVERSION TABLE
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2%l5 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-l 5
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion. -A simple way to convert a Fahrenheit temperture reading into a Centigrade
temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees,consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it isdesired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
OC OF "C "F OC OF "C OF
'-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 4.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 3410
00-l 6
WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine Model PC300-5 PC3OOLC-5
Serial Numbers 20001 and up 20001 and up
Engine assembly 986 986
l Engine 700 700
l Damper 14 14
l Hydraulic pump 272 272
Radiator and oil cooler assembly 152 152
Hydraulic tank assembly

224 224
(without hydraulic oil)
Fuel tank (without fuel) 175 175
Revolving frame 2,540 2,540
Operator’s cab 238 238
Operator’s seat 31.7 31.7

z
z
Counterweight 5,420 5,420
z
Swing machinery 440 440
Control valve assembly 236 236
Swing motor assembly 125.5 125.5
Travel motor assembly 239x2 239x2
Center swivel joint 43 43
Track frame assembly 6,700 7,230
l Track frame 3,885 4,312
l Swing circle assembly 430 430
l Idler 166 166
l Idler cushion 257x2 257x2
0 Carrier roller 31 x4 31 x4
l Track roller 52x14 52x16
l Final drive 426x2 426x2
002 8
Unit: kg
Track shoe assembly
Triple shoe (600 mm) 3,500 3,730
Triple shoe (700 mm) 3,840 4,090
Wide triple-shoe (750 mm) 4,010 4,270

Flat shoe (500 mm) 3,160 -
Boom assembly 2,357 2,357
Arm assembly 981 981
Bucket assembly (with side cutter) 1,014 1,014
Boom cylinder assembly 293x2 293x2
Arm cylinder assembly 425 425
Bucket cylinder assembly 263 263
Link assembly I 320

I 320
76 + 15x2 + 76 + 15x2 +
Boom pin
56 + 17 +42 56 + 17 +42
Arm pin 13 + 17 13 + 17
I I
Bucket pin 30x2 30x2

I I
Link pin 27x2 27x2
00619
PC300,3OOLC-5 MIGHTY
Unit: kg
Machine Model PC300-5 MIGHTY PC3OOLC-5 MIGHTY
Engine assembly 986 986
l Engine 700 700
l Damper 14 14

224 224
Swing motor assembly 125.5 125.5
Travel motor assembly 239 x 2 239 x 2
Track frame 3,885 4,312
Swing circle assembly 430 430
Idler 166 166
Idler cushion 257 x 2 257 x 2
Carrier roller 31 x4 31 x4
Track roller 52x14 52x 16
Final drive 426 x 2 426 x 2
Roller guard 143x 2 158x2
00620
Unit: kg
Machine Model PC300-5 MIGHTY PC3OOLC-5 MIGHTY
Track shoe assembly

Triple shoe (600 mm) 3,500 3,730
Arm assembly 1,051 1,051
Boom cylinder assembly 293 x 2 293 x 2

I I
Link assembly I 320 I 320
76+15x2+ 76+15x2+
Boom pin
56+17+42 56+ 17f42
Arm pin 13+ 17 13 + 17
Bucket pin I - 30 x 2 I 30 x 2
Link pin 27 x 2 27 x 2
I I
PC300HD-5
Unit: kg
Machine Model PC300HD-5
Serial Numbers 21401 and up
Engine assembly 986
l Engine 700
l Damper 14
l Hydraulic pump 272
Radiator and oil cooler assembly 152

224
Fuel tank (without fuel) 175
Revolving frame 2,540
Operator’s cab 238
Operator’s seat 31.7
Counterweight 5,420
Swing machinery 440
Control valve assembly 236
Swing motor assembly 125.5
Travel motor assembly 290 x 2
Center swivel joint 43
Track frame assembly 9,414
Center frame 3,270
Track frame (excluding guards) 1,665 x 2
Swing circle assembly 430
Idler 166
Idler cushion 257 x 2
Carrier roller 31 x 4
Track roller 52x 14
Final drive 426 x 2
0022
Unit: kg
Machine Model PC300HD-5

I
Track shoe assembly
Triple shoe (600 mm) 4,490
Triple shoe (700 mm)
Boom assembly I 2,357 I
Arm assembly 981
Bucket assembly (with side cutter) 1,014
Boom cylinder assembly 293 x 2

?
:: Arm cylinder assembly 425
0
I I
Bucket cylinder assembly 263
Link assembly 320
76+15x2+
Boom pin
56 + 17 + 42
Arm pin 13 + 17
Bucket pin 30 x 2
Link pin 27 x 2
I I
Unit: kg

I
Serial Numbers 20001 and up I 20001 and up
Engine ass’y 1,500 1,500
l Engine 1,090 + 110 (mount) 1,090 + 110 (mount)
l Damper 20 20
Radiator and oil cooler assembly I 180 180

290 290
(without hydraulic oil1
Operator’s seat 31.7 31.7 z

0”
Counterweight 8,470 8,470 2
Swing motor assembly 130 130
Travel motor assembly I 290x2 I 290x2
l Idler 235 235
l Idler cushion 365x2 365x2
. Carrier roller 31 x4 31 x4
. Track roller 73x14 73x16
e Final drive 560x2 560x2
00624
Unit: kg
Track shoe assembly
Triple shoe (600 mm) 4,490 4,760
Triple shoe (700 mm) 4,910 5,210
Wide triple-shoe (900 mm) 5,750 6.1 10

I I
Boom cylinder assembly 400x2 400x2

I I
Link assembly 397 397
93 +20x2 + 93 + 20x2 +
Boom pin
73 + 24 + 54 73 + 24 + 54
Arm pin 17 +24 17 +24

I I
Bucket pin 34x2 34x2
Link pin 38x2 38x2

PC400,4OOLC (LOADING SHOVEL)
Unit: kg
Engine ass’y 1,500 1,500
l Damper 20 20

290 290
l Idler 235 235
l Idler cushion 365 x 2 365 x 2
l Carrier roller 31 x4 31 x4
l Track roller 73x 14 73x16
l Final drive 560 x 2 560 x 2
oo--5-1
Unit: ko
Track shoe assembly

Triple shoe (600 mm) 4,490 4,760
Triple shoe (700 mm) 4,910 5,210
Boom assembly 2,425
Bucket assembly 3,408 3,408
Bucket cylinder assembly 248 x 2 248 x 2
Bottom cylinder assembly 104x2 104x2

I I
Link assembly
Boom pin
I I
Arm pin
Bucket pin
Link pin
00-g-2
PC400,4OOLC-5 MIGHTY Unit: .kg
Machine Model PC400-5 MIGHTY PC400LC-5 MIGHTY
Engine assembly 1,500 1,500
l Damper 20 20

290 290
Track frame 6,230 6,600
Swing circle assembly 585 585
Idler 235 235
Idler cushion 365 x 2 365 x 2
Carrier roller 31 x4 31 x4
Track roller 73x 14 73x 16
Final drive 560 x 2 560 x 2
Roller guard 240 x 2 240 x 2
0026
Unit: kg
Machine Model 1 PC400-5 MIGHTY 1 PC4OOLC-5 MIGHTY
Track shoe assembly

Triple shoe (600 mm) 4,490 4,760
Boom assembly I 3,110 ~ 3,110
Arm assembly I 1,343 / 1,343
Link assembly 397 397
Boom pin 93 + 20 x 2 + 93 + 20.x 2 +

73 + 24 + 54 73 + 24 + 54
Arm pin 17f24 17 + 24
Bucket pin 34 x 2 34 x 2
Link pin 38 x 2 38 x 2
0027
PC400HD-5
Unit: kg
Machine Model PC400H D-5
Engine ass’y 1,500
l Engine 1,090 + 110 (mount)
l Damper 20
l Hydraulic pump 280
Radiator and oil cooler assembly 180

290
Revolving frame 3,090
Operator’s cab 238
Operator’s seat 31.7
Counterweight 8,470
Swing machinery 620
Swing motor assembly 130
Travel motor assembly 290 x 2
Track frame assembly 10,650
Center frame 3,270
Track frame (excluding guards) 1,782 x 2
Swing circle assembly 585
Idler 235
Idler cushion 365 x 2
Carrier roller 31 x4
Track roller 73x 14
Final drive 560 x 2
00628
Unit: kg
Machine Model I
I
PC400HD-5
/I
Serial Numbers 20603and up
Track shoe assembly
Triple shoe (750 mm)
Semi-double shoe (750 mm1 5,490
Boom assembly 2,990
Arm assembly 1,234
Bucket assembly (with side cutter) 1,300

I I
Boom cylinder assembly 400 x 2

I I
Arm cylinder assembly 580

F
z Link assembly 397
”
Boom pin 93 + 20 x 2 +
73 + 24 + 54
Arm pin 17 + 24
Bucket pin 34 x 2
Link pin 38 x 2
o”629
LIST OF LUBRICANT AND WATER
Pc300,300Lc-5
RESERVOIR
KIND OF
FLUID I 14
AMBIENT
32
TEMPERATURE
50
Engine oil pan
Damper case - . ., I [ 1 ,I_ 1.24

tnglne 011 ‘:.“.‘:.‘:.p.:..:..:‘:‘,~
“:““::: .\... ,:_:::::,::::
:.,.:.
..::“:::
::i:::.::::~::~:~~‘i:i:p
23.0 22.5
Swing machinery case
Final drive case (each) 1 8.0 7.4
Hydrau Iic system 195
Carrier roller (1 piece)

Track roller (1 piece)
Idler (1 piece)
Fuel tank
Cooling system
z ASTM D975 No. 1
NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than O”C, be sure to
tenance hours described in this manual. use engine oil of SAEI OW, SAEI OW-30 and
Change oil according to the following table if SAE15W-40 even though an atmospheric
fuel sulphur contect is above 0.5% temperature goes up to 10°C more or less in
the day time.
(3) Use API classification CD as engine oil and if
Change interval of oil in
Fuel sulphur contect API classification CC, reduce the engine oil
engine oil pan
I
I
change interval to half.
I
0.5 to 1 .O% l/2 of regular interval (4) There is no problem if single grade oil is
II
- mixed with multigrade oil (SAEIOW-30,
Above 1 .O% l/4 of regular interval 15W-40), but be sure to add single oil that
I
matches the temperature in the table on
the left.
ASTM: American Society of Testing and Material
(5) We recommend Komatsu genuine oil which
SAE: Society of Automotive Engineers
has been specifically formulated and ap-
proved for use in engine and hydraulic
work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
0020
PC300HD-5
KIND OF
RESERVOIR
FLUID
Engine oil pan
Damper case
Swing machinery case Engine oil
Final drive case (each)
Hydraulic system
Carrier roller (1 piece)

Track roller (1 piece) Gear oil
Idler (1 piece)
Fuel tank Diesel fuel
::
Cooling system Water I Add antifreeze I 30 I -
Z
2 % ASTM D975 No. 1
NOTE:
(1) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
tenance hours described in this manual. use engine oil of SAEl OW, SAEI OW-30 and
Change oil according to the following table if SAE15W-40 even though an atmospheric
the day time.
Change interval of oil in API classification CC, reduce the engine oil
Fuel sulphur contect
engine oil pan
I change interval to half.
(4) There is no problem if single grade oil is
mixed with multigrade oil (SAEIOW-30,
15W-40), but be sure to add single oil that
the left.
00631
Pc400,400Lc-5
PC400HD-5
RESERVOIR
Engine oil pan
Swing machinery case
Hydraulic system
Fuel tank
% ASTM D975 No. 1
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
tenance hours described in this manual. use engine oil of SAEI OW, SAEl OW-30 and
Change oil according to the following table if SAEl5W-40 even though an atmospheric
the day time.
Change interval of oil in
Fuel sulphur contect API classification CC, reduce the engine oil
engine oil pan
I change interval to half.
(4) There is no problem if single grade oil is
mixed with multigrade oil (SAEIOW-30,
15W-40), but be sure to add single oil that
the left.
00632
10 STRUCTURE AND FUNCTION
Powertrain .......................... IO- 2

Final drive ........................... IO- 4
Swing circle......................... IO- 6
Swing machinery .................... IO- 8
Track frame and recoil spring .......... 1 O-l 0
Idler ................................ IO-12
Track roller, carrier roller .............. 1 O-l 4
Trackshoe .......................... IO-15
Hydraulic piping ..................... 1 O-l 9
Hydraulic circuit diagram .............. 1 O-20
Hydraulic tank ....................... 1 O-23
OLSS (Open center
Load Sensing System) .............. 10-24-I
Hydraulic pump ...................... 1 O-25
.........................
Line oil filter 1 O-44
Control valve ........................ 1 O-46
Swing motor ........................ 1 O-58
Center swivel joint ................... 1 O-6 1
Travel motor ........................ 1 O-62
Valve control ........................ 1 O-7 1
PPC valve ........................... 1 O-72
Accumulator, safety lock valve ........ 1 O-78
Solenoid valve assembly .............. 1 O-79
Shuttle valve ........................ 1 O-83
Boom holding valve .................. 1 O-84
Hydraulic cylinder .................... 1 O-87
Work equipment ..................... 1 O-90
Electrical wiring diagram .............. 1 O-92
Electrical circuit diagram .............. 1 O-96
Engine control system ............... 1 O-l 00
PEMC system ............................ 10-111
EMACC ............................ IO-138
POWER TRAIN
\
112 205FO5008
1. Idler 7. Hydraulic pump

2. Center swivel joint 8. Swing brake solenoid valve
3. Control valve assembly 9. Travel speed solenoid valve
4. Final drive 10. Swing motor
5. Travel motor 11. Swing machinery
6. Engine 12. Swing circle
1o-2
FINAL DRIVE
Pc300,300Lc-5
1. Level plug
2. Drain plug
3. No. 1 sun gear (13 teeth)
4. No. 2 sun gerar (I 9 teeth)
5. Cover
6. No. 2 plant gear (30 teeth)
7. No. 2 ring gear (80 teeth)
8. Spacer
9. No. 1 ring gear (80 teeth)
10. No. 1 planet gear (33 teeth)
11. Sprocket
12. Floating seal
13. Travel motor
14. Hub
15. Retainer
16. No. 1 planetary carrier
SPECIFICATIONS
Reduction ratio:
_ (80+ 13
13 ‘x(
7 8 9 10 11 12
- 36.275
5
/13
17 16 15 14
Section A - A 207FO5008
PC300HD-5
Pc400,400Lc-5
PC400HD-5
1. Level plug
2. Drain plug
4. No. 1 sun gear (I 7 teeth)
7. Cover
9. Retainer
10. Sprocket
1 1. Floating seal
12. Travel motor
13. Hub
16. Spacer
SPECIFICATIONS
Reduction ratio:
_ (81 + 12 83:7’7)+ 1 =
12 ‘xl
-44.588
SWING CIRCLE
Pc300,300Lc-5
PC300HD-5
Detail P
___
3
I
Section A - #
207i=o5009
1. Swing circle outer race SPECIFICATIONS

2. Ball bearing
Reduction ratio- 90 = 6.923
3. Swing circle inner race (90 teeth) . 13
Grease volume: 35 R (G2-LI)
a. Outer race soft zone “S”
b. Inner race soft zone “S”
Pc400,400LC-5
PC400,400LC-5 MIGHTY
PC400HD-5
a b
Section A - A
208FO5009
1. Swing circle outer race SPECIFICATIONS

2. Ball bearing 84
Reduction ratio: 13 = 6.462
3. Swing circle inner race (84 teeth)
Grease volume: 35 Q(G2-LI)
a. Outer race soft zone “S”
b. Inner race soft zone “S”
SWING MACHINERY
Pc300,300Lc-5
PC300HD-5 \\\ \
1. Swing pinion (13 teeth)

2. Cover
3. Case
4. Planetary carrier
5. Ring gear (79 teeth)
6. Bearing holder
7. Drive gear (I 7 teeth)
8. Swing motor
9. Bearing holder
IO. Cover
11. Driven gear (63 teeth)
12. Planet gear (32 teeth)
13. Sun gear (I 4 teeth)
14. Drain valve
15. Breather
16. Level gauge
SPECIFICATIONS
Reduction ratio:
s .(7gl+414) = 24.618
16
Section B - B
207FO5010
Pc400,400Lc-5
PC400HD-5
1. Swing pinion (I 3 teeth)

2. Cover
3. Case
4. Planetary carrier
5. Ring gear (84 teeth)
6. Bearing holder
7. Drive gear (I 7 teeth)
8. Swing motor
TA 9. Bearing holder
10. Cover
1 1. Driven gear (86 teeth)
12. Planet gear (34 teeth)
13. Sun gear (I 5 teeth)
14. Drain valve
15. Breather
16. Level gauge
SPECIFICATIONS
Reduction ratio:
g x (841+515) = 35.475
7
10
8
11
5
12
4
13
3
14
Section B - B
TRACK FRAME AND RECOIL SPRING
Pc300,300Lc-5
207FO5011
1. Idler Depending on the model, the dimensions and

2. Track frame number of track rollers and center guards are
3. Carrier roller different, but the basic structure is the same.
4. Final drive (The diagram shows PC3001
5. Track roller * Number of track rollers
6. Track shoe PC300: 7 (each side)
7. Center guard PC3OOLC: 8 (each side)
8. Recoil spring * Number of center guards
9. Front guard PC300: 2 (each side)
PC3OOLC: 3 (each side)
PC300HD-5
ro 9 8 7 6
F207K5001
1. Idler
2. Center frame
3. Carrier roller
4. Track frame
5. Final drive
6. Track roller
7. Track shoe
8. Center guard
9. Recoil spring
10. Front guard
Pc400,400LC-5
\ \
Q 7 5
208FO5011

4. Final drive (The diagram shows PC4001
5. Track roller * Number of track rollers
7. Center guard
8. Recoil spring
or Number of center guards
9. Front guard
PC400: 2 (each side)
Pc400,400Lc-5
VARIABLE GAUGE
1 2 3 4
8
F20805101

4. Final drive (The diagram shows PC4OOLC)
5. Track roller + Number of track rollers
7. Center guard PC4OOLC: 8 (each side)
8. Recoil spring
* Number of center guards
9. Front guard
PC400: 2 (each side)
PC400LC: 3 (each side)
‘O-F2
PC400HD-5
F207K5002
1. Idler
2. Center frame
3. Carrier roller
4. Track frame
5. Final drive
6. Track roller
7. Track shoe
8. Guard
9. Recoil spring
10. Front guard
IDLER
Pc300,300LC-5
- _I
207FO5012
1. Lubricating plug
2. support
3. Idler
4. Floating seal
5. Idler shaft
6. Bushing
PC300HD-5
Pc400,400Lc-5
PC400H D-5
208FO5012
1. Lubricating plug
2. Support
3. Idler
4. Floating seal
5. Idler shaft
6. Bushing
TRACK ROLLER
1 2 3 4 5 6
1. Lubricating plug
2. Collar
3. Floating seal
4. Track roller
r_ 5.
6.
Bushing
Shaft
I! / I /L--
i
-A-L__
k-------i i
- - - -
i
L.--_ - - -1
208FO5013
CARRIER ROLLER
1. Shaft
1 2 3 4 5 6 2. Collar
3. Floating seal
4. Carrier roller
5. Ring
6. Cover
7. Lubricating plug
208FO5014
10-14
TRACK SHOE
Pc300,300Lc-5
\ \ \ \
4 5 6 7
8 9 10
207FO5013
1.Shoe STANDARD SHOE SPECIFICATIONS

2. Regular pin PC300: 600 mm triple-shoe
3. Regular dust seal Link pitch: 203 mm
4. Regular bushing Number of shoe: 94
5. Master pin
6. Master dust seal PC300LC: 700 mm triple-shoe
7. Master bushing Link pitch: 203 mm
8. Link Number of shoe: 100
9. Shoe bolt
10. Shoe nut
PC300HD-5
Pc400,400Lc-5
PC400H D-5
-
I
8
I
9
\
10
208FO5015
1. Shoe STANDARD SHOE SPECIFICATIONS

2. Master bushing PC300H D: 700 mm triple-shoe
3. Master dust seal Link pitch: 216 mm
4. Master pin Number of shoe : 98
5. Regular bushing
6. Regular dust seal PC400: 600 mm triple-shoe
7. Regular pin Link pitch: 216 mm
8. Link Number of shoe: 98
9. Shoe bolt
IO. Shoe nut PC4OOLC: 700 mm triple-shoe
Link pitch: 216 mm
Number of shoe: 104
PC400HD: 750 mm triple-shoe

Link pitch: 216 mm
Number of shoe: 104
SELECTION OF TRACK SHOE
l Select the most suitable track shoe from the following table
PC400-5 PC400-5 MIGHTY PC4OOLC-5 PC4OOLC-5 MIGHTY PC400HD-5

Cate- Cate- Cate- Cate- Cate-
Specification Specification Specification Specification Specification
gory gory gory gory gory
600 mm triple-shoe A 600 mm triple-shoe A 700 mm triple-shoe B 600 mm triple-shoe A 700 mm triple-shoe B
700 mm triple-shoe 1 B 1 - 1 - 1600 mm triple-shoe1 A I _ I - 1750 mm triple-shoe / B
750 mm triple-shoe I B I - I - 1750 mm triple-shoe1 B I _ I - 1750

mmsemi-do&shoe/ B
800 mm triple-shoe I C I - I - 1800 mm triple-shoe1 C I _ l-l - l-

900 mm triple-shoe I C I - I - 1900 mm triple-shoe] c I - l-l - I-
l Category
Cate-
Use Precautions when using
gory
Rocky ground, l Travel in Lo when traveling on rough ground with obstacles
A
normal river soil such as large boulders and fallen trees.
l Cannot be used on rough ground where there are large

obstacles such as boulders and fallen trees.
Normal soil,
l Travel in Hi speed only on flat ground, and when it is
soft land
impossible to avoid traveling over obstacles,
lower the travel speed to approx. half of Lo. speed.
l Use only for ground where “A” and “B” sink and
are impossible to use.
l Cannot be used on rough ground where there are large
Extremely short
obstacles such as boulders and fallen trees.
ground
l Travel in Hi speed only on flat ground, and when
(swampy ground)
it is impossible to avoid traveling over
obstacles, lower the travel speed to approx.
half of Lo speed.
Paved surface l The shoe are flat, so they have low gradeability.
* Categories “B” and “C” are wide shoe, so * When selecting the shoe width, select the
there are restrictions on their use. Therefore, narrowest shoe possible within the range
before using, check the restrictions and con- that will give no problem with flotation and
sider carefully the conditions of use before ground pressure.
recommending a suitable shoe width. If If a wider shoe than necessary is used, there
necessary, give the customer guidance in will be a large load on the shoe, and this
their use. may, lead to bending of the shoe, cracking
of the links, breakage of the pins, loosening
of the shoe bolts, or other problems.
‘O&l7
HYDRAULIC PIPING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Accumulator
6. R.H. travel motor
7. Control valve
8. Oil cooler
9. Hydraulic filter
(PC300: 1, PC400: 2)
10. Hydraulic tank
1 1. Hydraulic pump
12 12. Line oil filter
13. L.H. travel motor
14. Solenoid valve assembly
15. Arm shuttle valve
16. Swing shuttle valve
17. Boom l bucket shuttle valve
18. Arm half flow solenoid valve
19. Safety lock valve
20. Travel shuttle valve
2 1. L.H. PPC valve
22. Travel PPC valve
23. R.H. PPC valve
24. Center swivel joint
25. Boom holding valve
207FO5015
10-19
HYDRAULIC CIRCUIT DIAGRAM
PC300,3OOLC-5 Serial No: 20001 - 21400
PC400,4OOLC-5 Serial No: 20001 - 20602
)I( )I(
I I
I I
I !
-------------*---1
Ta iN GIL ‘Ncs~
! -- f
;+_+------
I
--------- I, t-g-
//
1 I
l---------j
R.H. travel motor
PC300: HMVPSOADT 175/280cc/rev
PC400: HMV355ADT 191/355cc/rev
3
I
:
ZL I.
/I
[(
I ,
t’ _ ~
2L
Ilr - -“-----.’ f
I
L
Regulator
pressure:
switching
8 kg/cm2
)
(
:=
A
t
i;:.
IP
T -
!Ii -FP
Wok equipment
-swing oil /(Forward)
pressure switch L----_A_ _--
Check
valve
Swing motor
Cracking
KMF160AB-2 160.7 cc/rev T
pressure:
4.3 kg/cm’ MB[
et prer 0 4 f 0 07 @/Cm: ri1 ( I 1 1 I
I IIIII I
IlUll I
t Iilil I
.l
I
I
I
I
I
I I
/
______--------- iI
L--______ 207F5016A
PC300,3OOLC-5 Serial No: 21401.and up PC400,4OOLC-5 Serial No: 20603 and up
PC300,3OOLC-5 MIGHTY PC400,4OOLC-5 MIGHTY
PC300HD-5 PC400HD-5
Arm half flow’

solenoid valve’
I R.H. travel motor

I PC300,3OOLC: HMV28OADT 175/280cc/rev
PC300HD: HMV355ADT 191/355cc/rev
I PC400,4OOLC: HMV355ADT 191/355cc/rev
I
I PC400HD: HMV355ADT 191/355cclrev
is
6 I
I
8 I
I
J
i;r
, I
4 r.-_-J
1 pressure: 8 kg/cm?
jli’l /
I’llI -----------=$ ____~ \
I($ t
1111’ I I
l/II’ \
II/l/ ‘t
I
I
i i’lli I
I I’ll1
, I’ll1 i
l IIIII
l IIIII
I IIIII
, IIIII
ii/ , I i_____________-____i I
I
i IIIII
IIlII
Ill!’
-._
14.3 kg/cm21
w
--ct+t”-h
___I
205FO5958
LOADING SHOVEL
.14
1. Bottom dump cylinder

2. Bucket cylinder
3. Arm cylinder
4. Boom cylinder
5. Bottom dump solenoid valve
6. Swing motor
7. Accumulator
8. R.H. travel motor
9. Control valve
10. Oil cooler
11. Hydraulic filter
12. Hydraulic tank
13. Hydraulic pump
14. Line oil filter
15. L.H. travel motor
16. Solenoid valve assembly
17. Arm shuttle valve
18. Swing shuttle valve
19. Boom - bucket shuttle valve
21. Safety lock valve
22. Travel shuttle valve
23. L.H. PPC valve
24. Travel PPC valve
25. R.H. PPC valve
26. Center swivel joint
27. Boom holding valve
205FO5.308
LOADING SHOVEL ‘
Pc400,400Lc-5 ~_----------- ---- - ---- ----_-___________

- - -----__I===__________:, _ _ _ _
! ,~~______~~_~~~~~~~~~~~~~~~~~____~~~~~~~~__~~-~~~~~~~-~---
Shuttle valve I
i--“--’ Bottom dump cyl
Control
valve in iN CAL1Nc.s~
;--;--_+-_____-
! Iill
ii-i----------l
i Boom /
holding valve
R.H travel motor
HMV355AbT 191/355cc/rev
____s~mgmor6i___________-__;
KMF160AB-2 160.7 cc/rev T, I

MBr^- (AHswing) m I
-1-j
“II
; ~ ~~~~i_______~;_____________r_____>
I, Ii____ -- ---- ---___-_________ _-----
: CCIIl. I(
r K----x
,
iiiif I , ,___________-_-L__-~~_ZZZZ___~~-_~~-~~I_-~~~~~’ ;’
Y P T \ j L____--__---------______--
l_____--___--------__ --------- __---,,,I J III ,I
,I
III’i_________““‘“__i: _,_-__ _____-_________ ,___&_____--_----------_____===z== -zI-~~~~=~~==~=,~t,___--__--________________
j, LL_-------_-----+---- t__7______------------- -.-___ ____ ------------___
L}-_~~_z~r~_-l~~~rz_-_-” _ ---------_____
~ -_ -_ -_ -_ l---------------
q= = = = = q = = q _ ~z__r_~~eq___--_z-~ = = = = =:= = --_= t 5 f ~~~~~~ _y~~~~~_=..=l~~f~~=y
L---______-_________---____---___--____________ f’
’o-$2-2
Pc300,300Lc-5
PC300HD-5
5 6
Section B - B
Section A - A
1. Bypass valve SPECIFICATIONS

2. Bypass filter Tank capacity: 3 15 Q
3. Filter element Oil amount: 195 Q
4. Check valve Breather
5. Breather Relief set pressure: 0.4 + 0.07 kg/cm2
6. Cap Suction set pressure: 0.04 + 0.01 kg/cm2
7. Hydraulic tank Bypass valve set pressure: 1.05 * 0.2 kg/cm2
8. Hydraulic oil level sensor Check valve set pressure: 1.75 kg/cm2
9. Suction strainer
10. Sight gauge
1 1. Filter case
Pc400,400Lc-5
PC400HD-5
Section B - B
Section A - A
10
208FO5016
1. Bypass valve SPECIFICATIONS

2. Bypass filter Tank capacity: 358 II
3. Filter element Oil amount: 255 R
4. Check valve Breather
5. Breather Relief set pressure: 0.4 * 0.07 kg/cm2
6. Cap Suction set pressure: 0.04 f 0.01 kg/cm2
7. Hydraulic oil level sensor Bypass valve set pressure: 1.05 +- 0.2 kg/cm2
8. Suction strainer Check valve set pressure: 2.50 kg/cm2
9. Hydraulic tank
IO. Sight gauge
1 1. Filter case
OLSS (Open center Load Sensing System)
Cylinder
F205C5006-1
OLSS (Open center Load Sensing System) is

an energy-saved system to reduce the fuel
consumption by means of controlling the
swash plate angle (delivery) of the variable-
displacement swash-plate type piston pump.
Therefore this system acts to reduce the hy-
draulic loss during operation, to increase the
fine control and to control the pump delivery.
’0-i4-’
Main pump delivery
1. EFFECTIVE USE OF ENGINE
HORSEPOWER P
E
The set spped of the engine and the actual 2 H
speed of the engine are always detected. 2 s H.O.
ti G.O. L.0 + L.
As a result, even if the load changes during 1
2 F.0 + L
operation, the discharge amount (swash 2
plate angle) of the pump is controlled so 4
that the load on the engine (engine speed) :
I? III!!!&
is always maintained constant, thus ensur- Pump delivery volume Q
ing effective use of the engine horsepower.
205FO5121A
(Engine speed, oil pressure sensing control)
(Note) H.0: Heavv duty operation mode,
G.0: Geneial operkion mode.
F.0: Finishing operation mode,
L.0: Lifting operation mode
2. CUT-OFF CONTROL
l The cut-off control is a function to re-
Loss when there is no cut-off
duce relief loss during operations.
If the load increases, the discharge
pressure of the main pump is in-
creased; if the load comes close to
the relief pressure, the discharge vo-
lume is decreased.
l This function is carried out with the
CO valve.
For details of the operation of the CO
valve, see HYDRAULIC PUMP. Pump discharge volume @/min.)
F205C5008
3. FLOW CONTROL
PNC (pump neutral control)
l When the control levers are at neu-
tral, the pump discharge volume is
kept to the minimum to reduce the
wasteful flow of oil when the control
valve is at neutral.
PFC (pump fine control)
l When the lever is operated, the ne-
cesary flow is ordered to the pump
based on the flow command that
corresponds with the lever travel.
This reduces the wasteful flow of oil
Lever travel (mm)
that occurs during fine control.
205FO5 145
l At the same time, by increasing the
pump discharge pressure to the opti-
mum value according to the lever tra-
vel, the fine control performance is
improved.
l This function is carried out with the
NC valve and jet sensor.
For details of the operation of the NC
valve and jet sensor, see HYDRAULIC
PUMP.
’o-i4-2
HYDRAULIC PUMP
L-.
View Z
i
9
207FO5018
a. Jet sensor output pressure Pd IN port 1. TVC valve

b. CO cancel pressure PsolN port 2. Front CO NC valve
l
c. Jet setnsor output pressure Pt IN port 3. Front servo valve

d. Jet sensor output pressure Pd IN port 4. Rear CO NC valve
l
e. CO cancel pressure PsolN port 5. Rear servo valve

f. Jet sensor output pressure Pt IN port 6. Rear main pump
7. Charging pump,
8. Front main pump
9. Charging pump relief valve
1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPV 160 + 160)
b C d
a
View Z
e i
I m n
\ I I
View X View Y
207FO5019
a. Suction PS port i. Front main pump output pressure PPI port)

b. Front main pump drain Pdl port j. Charging pump pressure PCI port
Charging pump pressure PC IN port k. Servo valve output pressure PciB port
:: Rear main pump drain Pd2 port I. Servo valve output pressure Pc2B port
Front main pump discharge Ppl port m. Charging pump pressure Pc2 port
f”.’ Rear main pump discharge Pp2 port n. Rear main pump output pressure Pp2 port
9. Servo valve output pressure PciA port 0. Servo valve output pressure Pc2A port
h. Rear main pump output pressure Pp2 port
1O&26
Section C - C
Section A - A
Section B - B
207FO5020
1. Drive gear (6 1 teeth) 9. Front piston 17. Rear cylinder

2. Driven gear (42 teeth) 10. Front cylinder 18. Rear piston
3. Shaft 1 1. Front valve plate 19. Rear rocker cam
4. Coupling 12. Front end cap 20. Rear pump case
5. Front drive shaft .I 3. Impeller pump 2 1. Rear cradle
6. Front cradle 14. Coupling 22. Rear drive shaft
7. Front pump case 15. Rear end cap 23. Servo piston
8. Front rocker cam 16. Rear valve plate
lo-27
2. SERVO VALVE + The drawing shows the servo valve for
front main pump
a d
Section A - A
Section B - B Section C - C
, Section D - D Section E - E Section F - F Section G - G

205FO5020
a. Servo actuator port h. CO * NC valve drain Pdr IN port

b. Servo actuator port i. CO - NC valve output pressure Pin IN port
c. Servo actuator port i. Charging pump pressure Ppo OUT port
d. NC valve output pressure Pi pick-up port k. Rear main pump output pressure Pp2 OUT port
Servo valve drain Pdr OUT port I. Front main pump output pressure Ppl OUT
Y.’ Rear main pump output pressure Pp2 IN port port
g. Front main pump output pressure PPI IN
Port
/ I i \ \ I \
19 18 16 15 14 13 12
Section A - A
205FO5021
I. Lock nut 8. Pin 15. Guide spool

2. Cover 9. Control piston 16. Spring
3. Plug 10. Lock nut 17. Plug
4. Spring 1 1. Plug 18. Cover
5. Body 12. Lock nut 19. Lock nut
6. Spring 13. Cover
7. Arm 14. Sleeve
FUNCTION
Discharge volumes Ql and Q2 of main pumps
PPI and PP~ are controlled individually by
their own servo valve.
The relationship between pump discharge vo-
lume Q and input signal Pi sent to the
servo valve is as shown in the graph on the
right. Q changes in proportion to Pi.
(cc/rev) ,,/’
CO. NC valve output pressure Pi (kg/cm*)
205FO5022
1Ok29
OPERATION
I) Operation for increasing pump discharges (rocker cam angle changes to the large)
NC valve
i 1COvalve
205F05023A
Charging pump pressure PC is sent to port The movement of guide spool (15) closes
a. port a and port d, and connects port d with
Signal pressure Pi from the NC valve is drain chamber e. As a result, servo piston
sent from port b to chamber c. chamber f is also connected to chamber e
As signal pressure Pi rises, the pressure in through port g and port d.
chamber C .pushes control piston (9) to At the same time, port a and port h are
the left in the direction of the arrow. The connected, and the flow passes through
piston stops in a position where it is port i to servo piston chamber j to push
balanced with the force of springs (4) and servo piston (20) to the left in the direction
(6). of the arrow. The rocker cam angle of the
At the same time, arm (7) uses servo piston main piston pump becomes larger, and the
(20) as a fulcrum, moves to the left in the pump discharge volume increases.
same way as control piston (9), and whi!Je Because of the movement of servo piston
fluctuating, moves guide spool (15) to the (20), arm (7) rotates clockwise around pin
left. (B), moves guide spool (15) to the right, and
closes port a, port d, and port h, so the
discharge volume increases only by an
amount corresponding to signal pressure
Pi.
2) Operation for decreasing pump discharges (rocker cam angle changes to the small)
NC valve
I TVC valve
I
::
w
0
PC
205FO50124A
l When signal pressure Pi drops, control At the same time, port a and port d are
piston (9) moves to the right in the direction connected, and the flow passes through
of the arrow to a point where the hydraulic port g to servo piston chamber f to push
pressure of chamber c is in balance with the servo piston (20) to the right in the
force of springs (4) and (6). direction of the arrow. The rocker cam
At the same time, arm (7) uses servo piston angle of the main piston pump becomes
(20) as a fulcrum, moves to the right in the smaller, and the pump discharge volume
same way as control piston (91, and while decreases.
fluctuating, moves guide spool (15) to the l Because of the movement of servo piston
right. (201, arm (7) rotates counterclockwise
l The movement of guide spool (15) closes around pin (8). moves guide spool (I 5) to
port a and port h, and connects port h with the left, and closes port a, port d, and port
drain chamber e. As a result, servo piston h, so the discharge volume decreases only
chamber j is also connected to chamber e by an amount corresponding to signal
through port i and port h. pressure Pi.
1021
3. TVC VALVE a
\
e d
C--l B-4
1 2 34567 8
IpF
Section B - B
Section A - A
D-4
Section C - C Section D - D Section E - E Section F - F
205FO5025
a. Charging pump pressure Ppo IN port 1. Spring 5. Sleeve

b. Front main pump output pressure Ppl IN 2. Spool 6. Piston
port 3. Piston 7. Body
c. Rear main pump output pressure Pp2 IN 4. Piston 8. Solenoid
port
d. TVC valve drain Pdr OUT port
d. TVC valve output pressure Pe OUT port
FUNCTION AND OPERATION
I) When command current from pump controller is small (when pump controller is normal)
TVC valve
K PC
2
Discharge
Resistor
205FO5026A
FUNCTION OPERATION
l When the pump controller is normal, the l Because of the command current sent from
main pump discharge volume can be the controller, solenoid push pin (9) moves,
controlled as desired over a wide range and piston (2) also moves. It stops at a
according to the command current from the point where the sum of the force of spring
pump controller to carry out the power (1) and the force of push pin (9) and the
mode function. force of n/C output pressure Pt2 acting on
l When the pump controller is abnormal, piston (3) is in balance. When this happens,
hydraulic sensing is carried out to control the command current is small, so piston (2)
the main pump discharge volume according balances at the bottom.
to the load (pump discharge pressure) to As a result, port a and port b are almost
carry out the constant torque control completely open, and almost all the
function (prolix function.) pressurized oil from the charging pump is
* For details, see PEMC SYSTEM. output as TVC output pressure Pt2. Be-
cause of this, the pump discharge volume
is m.aximum.
1o-33
0
2) When command current from pump controller is large (when pump controller is normal)
TVC valve
l-
i:~li:~i:i:i:~i:~:i:#:i:i:i8i:i8iii:i(: pi NC co
:z:.
:.:.:
::::: valve valve
:;:i:
z;i
:.:.:
.:.:.:
;:3;
.:.:.
:.:.:
.:.:.
:.:.:
i.:.
>:.
.:.:..
::.:.
.:(.:
L_
:;:;:s
Decrease -
R Servo valve
Servo piston
u
Discharge
Increase
Resistor
205F05027A
l Because of the command current sent from

the controller, solenoid push pin (9) moves,
and the piston (21 also moves. It stops at
the point where it is balanced with the force
of spring (I). When this happens, the com-
mand current is large, so piston (2) is bal-
anced at the top. As a result, the flow of oil
sent from the charging pump is throttled at
port a and port b, and the area of the open-
ing at port b and port c (drain port) becomes
larger. Because of this, TVC valve output
pressure Pt2 drops and the pump discharge
volume is reduced.
3) Main pump under light load (pump controller abnormal and TVC prolix switch ON)
TVC valve
Pi
l-
NC CO
vak
-L
valve
Dee ease
Discharge
I
TVC prolix switch
Resistor
l Main pump discharge pressures PPI and

PP~ are low, so spool (2) is pushed down
by spring (1). As a result, charging pump
discharge pressure PC and lVC valve out-
put pressure Pt2 are equal.
When this happens, n/C valve output
pressure Pt2 is maximum and the main
pump discharge volume is also maximum.
1o-35
0
4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON)
TVC valve
Discharge
1 . .
Resistor
205F05029A
l When main pump discharge pressure PPI

(or PP~) increases, spool (2) is moved up
by piston (4) or piston (6). As a result,
the flow at port a and port b is throttled
by the notch in the spool, and the area
of the opening at port b and port c (drain
port) becomes larger. Because of this,
TVC valve output pressure Pt2 drops and
the main pump discharge volume is
reduced.
lo-36
0
4. CO . NC VALVE + The diagram shows the CO l NC valve for
the front pump.
a
d g
i
e h
b
Section A - A
205FO5030
a. Charging pump pressure PRO OUT port co VALVE NC VALVE

b. Main pump output pressure Ppl (Pp2) OUT 1. Plug 7. Plug
Port 2. Piston 8. Sleeve
c. Main pump output pressure Pp2 (Ppl) OUT 3. Spring 9. Piston
Port 4. Spool 10. Spool
d. WC valve output pressure Pt2lN port 5. Piston 11. Spring
e. TVC valve drain Pdr port 6. Plug 12. Plug
f. CO cancel pressure Pet (Per) IN port
g. TVC valve output pressure Pt2 F-R * ( I: For rear servo valve
connection port
h. Jet sensor output pressure Pd IN port
i. Jet sensor output pressure Pt IN port
FUNCTION AND OPERATION OF CO VALVE
1) When main pump discharge pressure is below relief pressure
PP
Discharge
205F05031A
FUNCTION OPERATION
o If the load increases during operation, and 0 Spool (4) is pushed down by spring (3).
the main pump discharge pressure in- As a result, port a and port b are com-
creases, when it becomes nearly the relief pletely open, and TVC valve output pres-
pressure, the CO valve carries out the cut- sure Pi are equal.
off function to reduce the discharge Because of this, CO valve output pressure
amount of the pump and reduce the relief Pi becomes maximum, and the discharge
loss. volume of the main pump is also maxi-
l At the same time, the pilot pressure of the mum.
CO function cancel solenoid valve also has
the function of canceling the cut-off.
l The CO valve is controlled by balancing
the spring with the sum of main pump
discharge pressure Pp and CO valve out-
put pressure Pi.
2) When the main pump discharge pressure is higher than the main relief pressure
JJ 7 ,,, pi
::::
:::’
solenoid valve @]
valve .
7
Servo piston
Decrease
i - Increase
Discharge
I”i >c/-
205F05032A
0 When main pump discharge pressure PP

comes close to the relief pressure owing
to an increase in the load, piston (5) is
pushed by main pump discharge pressure
PP and at the same time piston (5) is
pushed by CO valve output pressure PCO.
When the force of spring (3) is overcome
by the pressing force of the pistons,
spool (4) moves upward.
As a result, the spool land restricts the oil
flow from port a to port b and at the same
time the opening areas of port b and port c
(drain port) are made larger.
With angle reduced by the operation of the
servo valve, the main pump discharge is
reduced.
3) When cut-off function is canceled by CO cancel solenoid valve
20 cancel
solenoid valve
NC
valve
Servo valve
Servo piston
I 1
Decrease v - Increase
Discharge
205F05033A
0 When the CO cancel solenoid valve is

switched, pilot pressure is taken to port
Pso and piston (2) is pushed down.
As a result, the setting of spring (3) be-
comes larger, so even when main pump
discharge pressure PP rises and reaches
the relief pressure, spool (4) is not actuat-
ed and CO valve output pressure Pco re-
mains at the maximum.
FUNCTION AND OPERATION OF NC VALVE
1 I Control valve at neutral
m Jet sensor
Control valve
NC valve
205F05034B
FUNCTION OPERATION
The NC valve controls the main pump dis- a The differential pressure (Pt - Pd) of the
charge volume according to the amount of jet sensor reaches the maximum and jet
operation of the control valve spool, and sensor output pressure Pt acting on piston
carries out the function of controlling the oil (IO) becomes greater than the sum of the
flow to reduce the neutral loss and fine con- force of spring (I 2) and jet sensor output
trol loss. pressure Pd acting on the lower end of
The NC valve is controlled by balancing the spool (I 31.
sum of jet sensor output pressure Pt and As a result, spool (I I) is pushed downward,
NC valve output pressure Pi with the causing a restriction of the oil flow between
sum of the force of NC valve spring (12) port c and port b and in turn opening port b
and jet sensor output pressure Pd. and port a (drain port).
The jet sensor detects the flow of return oil Output pressure Pt of the NC valve is then
passing through the control valve and re- reduced to the minimum and the main
turning to the tank, and takes it as NC valve pump discharge is also reduced to the mini-
Pt and Pd. mum with the swash plate angle minimized
through the operation of the servo valve.
2) When the control valve is operated
nsor
I
Control valve
NC valve
PP.
l With the jet sensor differential pressure (Pt

- Pd) reduced according to the operation
of the control valve, spool (I 1) is pushed
upward, fully opening port c and port b.
Thus, the NC valve output pressure in-
creases. Together with the increase in the
main pump swash plate angle through the
servo valve operation, the main pump dis-
charge is also increased. That is to say, the
pump discharge increases as the stroke of
the lever increases.
’o642
5. CHARGING PUMP
Suction
0
Discharge
3 4 5
Section A - A
207FO5021
1. Filter SPECIFICATIONS
2. Relief valve Theoretical delivery: 32.3 cc/rev
3. Collar Operating pressure: 30 kg/cm2
4. Body
5. Housing
6. Drive gear
7. Driven gear
1o-43
LINE OIL FILTER
From pump _
-c To control valve
207FO5022
1. Bracket
2. Cartridge
3. Element
4. Drain plug
1o-44
CONTROL VALVE
1 2 3
b\
-C
a/
X Y
,
ek cib dc db a‘a
9% hh
ff, ii
-00
kk .PP
jj ‘WI
207FO5023
1 O-46
1. Travel shuttle valve OUTLINE
2. 4-spool valve (Built-in straight-travel valve, l This control valve consists of a 4-spool
arm throttle valve) valve and a 5-spool valve. In addition, it also
3. 5-spool valve (Built-in swing priority valve) has a travel shuttle valve.
It has a built-in straight-travel valve, arm
a. P3 port (From arm PPC shuttle valve) throttle valve and swing priority valve.
b. PL port (From rear main pump)
l The 4-spool valve and 5-spool valve are
C. PR port (From front main pump)
connected by bolts to form one unit. The oil
d. B~L port (To bucket cylinder bottom side) flow merges inside the valve, so the valve is
e. B~L port (To boom cylinder head side)
compact and provides excellent ease of
f. BIL port (To L.H. travel motor PA port)
maintenance.
g. P5 port (From swing PPC shuttle valve)
h. P4 port (From boom * bucket PPC shuttle valve)
i. P6 port (To work equipment * swing oil
pressure switch)
j. AIL port (To L.H. travel motor PB port)
k. AWL port (To boom cylinder bottom side)
I. A3L port (To bucke cylinder head side)
m. P4AL port (From arm PPC valve)
n. PBAL port (From bucket PPC valve)
0. P2AL port (From boom PPC valve)
P. PI AL port (From L.H. travel PPC valve)
q. PRL port (From 2-stage relief solenoid valve)
t:
r. PRR port (From 2-stage relief solenoid valve)
G
nl S. PI AR port (From swing PPC valve)
0
t. PBAR port (Service)
U. P4AR port (From arm PPC valve)
V. P5AR pot-t (From R.H. travel PPC valve)
w. A3R port (Service)
X. Al R port (To swing motor MA port)
Y. Bl R port (To swing motor port MB)
2. B3R port (Service)
aa. B4R port (To arm cylinder bottom side)

bb. B5R port (To R.H. travel motor PB port)
cc. T port (To tank)
dd. A5R port (To R.H. travel moor PA port)
ee. A4R port (To arm cylinder head side)
ff. PtL port (To rear NC valve)
99. PdL port (To rear NC valve)
hh. PtR port (To front NC valve)
ii. PdR port (To front NC valve)
jj. Pl BL pot-t (From L.H. travel PPC valve)
kk. PZBL port (From boom PPC valve)
II. P3BL port (From bucket PPC valve)
mm. Ts port (To tank)
nn. P5BR port (From R.H. travel PPC valve)
00. P4BR port (From arm PPC valve)
PP. PBBR port (Service)
qq. Pl BR port (From swing PPC valve)
/
7 6
Section A - A
Section B - B
207FO5024
1. Spool return spring 6. Jet sensor orifice

2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (Boom-Lo) 8. Main relief valve
4. Spool (Bucket) 9. Spool (Straight-travel)
5. Spool (Arm-Hi) IO. Spool (Arm throttle valve)
1 O-48
8 i
Section C - C
Section D - D
207FO5025
1. Spool return spring 6. Spool RH. travel)

2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Service) 9. Main relief valve (5-spool)
5. Spool (Arm-Lo) 10. Spool (Swing priority)
1o-49
Section E - E
Section F - F
Section G - G li Section H - H
207FO5026
1. Check valve 7. Suction valve

2. Check valve spring 8. Spool (Boom-Lo)
3. Spool (L.H. travel) 9. Check valve
4. Spool (Straight-travel) 10. Spool (Boom-Hi)
5. Spool (Swing priority) 11. Safety-suction valve.
6. Spool (Swing)
1O-50
Section J - J
Section K - K
Section L - L
207FO5027
1. Safety-suction valve 6. Check valve

2. Spool (Bucket) 7. Spool (Arm-Lo)
3. Spool (Arm throttle) 8. Safety-suction valve
4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) 10. Spool (R.H. travel)
10-51
PC 400,4OOLC-5 (LOADING SHOVEL)
I
d ’ ’
bb aa
=\
ff’
-00
'PP
‘WI
205FO58 I9
1. Travel shuttle valve OUTLINE
2. 4-spool valve (Built-in straight-travel valve, 0 This control valve consists of a 4-spool
arm throttle valve) valve and a 5-spool valve. In addition, it also
3. 5-spool valve (Built-in swing priority valve) has a travel shuttle valve.
It has a built-in straight-travel valve, arm
a. P3 port (From arm PPC shuttle valve)
throttle valve and swing priority valve.
b. PL port (From rear main pump)
0 The 4-spool valve and 5-spool valve are
c. PR port (From front main pump)
connected by bolts to form one unit. The oil
d. B~L port (To bucket cylinder bottom side)
flow merges inside the valve, so the valve is
e. B~L port (To boom cylinder head side)
compact and provides excellent ease of
f. BlL port (To L.H. travel motor PA port)
maintenance.
P5 port (From swing PPC shuttle valve)
E: P4 port (From boom - bucket PPC shuttle valve)
i. P6 port (To work equipment - swing oil
pressure switch)
i. AIL port (To L.H. travel motor PB port)
k. AWL port (To boom cylinder bottom side)
I. A3L port (To bucke cylinder head side)
m. P4AL port (From arm PPC valve)
n. P3AL port (From bucket PPC valve)
0. P2AL port (From boom PPC valve)
P. Pl AL port (From L.H. travel PPC valve)
9. PRL port (From 2-stage relief solenoid valve)
z
r. PRR port (From 2-stage relief solenoid valve)
E
hl S. PEAR port (From swing PPC valve)
0
t. PBAR port (From bottom dump solenoid valve)
U. P4AR port (From arm PPC valve)
V. PBAR port (From R.H. travel PPC valve)
w. A3R port (To bottom dump cylinder head side)
X. Al R port (To swing motor MA port)
Y. Bl R port (To swing motor port MB)
2. B3R port (To bottom dump cylinder bottom side)
aa. B4R port (To arm cylinder bottom side)

bb. B5R port (To R.H. travel motor PB port)
CC. T port (To tank)
dd. A5R port (To R.H. travel moor PA port)
ee. A4R port (To arm cylinder head side)
ff. NCAL port (To rear NC valve)
99. NCBL port (To rear NC valve)
hh. NCAR port (To front NC valve)
ii. NCBR port (To front NC valve)
jj. PI BL port (From L.H. travel PPC valve)

kk. PZBL port (From boom PPC valve)
II. P3BL port (From bucket PPC valve)
mm. Ts port (To tank)
nn. P5BR port (From R.H. travel PPC valve)
00. P4BR port (From arm PPC valve)
PP. PBBR port (From bottom dump solenoid valve)
qq. PI BR port (From swing PPC valve)
Section A - A
Section B- B
205FO5820
1. Spool return spring 6. Jet sensor orifice

2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (Boom-Lo) 8. Main relief valve
4. Spool (Bucket) 9. Spool (Straight-travel)
5. Spool (Arm-Hi) 10. Spool (Arm throttle valve)
1o-2’-3
-3
-4
‘6
8 i
Section C - C
10’
Section D - D
205FO582 I
1. Spool return spring 6. Spool (R.H. travel)

2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Bottom dump) 9. Main relief valve
5. Spool (Arm-Lo) 10. Spool (Swing priority)
Section E- E
Section F- F
Section G - G Ii Section H - H
207FO5026
1. Check valve 7. Suction valve

2. Check valve spring 8. Spool (Boom-Lo)
3. Spool (L.H. travel) 9. Check valve
4. Spool (Straight-travel) 10. Spool (Boom-Hi)
5. Spool (Swing priority) 11. Safety-suction valve
6. Spool (Swing)
Section J - J
Section K - K
Section L - L 205FO5822
1. Safety-suction valve 7. Check valve

2. Spool (Bucket) 8. Spool (Arm-Lo)
3. Spool (Arm throttle) 9. Safety-suction valve
4. Spool (Bottom dump) IO. Check valve
5. Safety-suction valve I 1. Spool (R.H. travel)
6. Spool (Arm-Hi)
TRAVEL SHUTTLE VALVE a
/ d \
b i C
i j
Section A - A
Section C - C Section D - D
Section B - B 207FO5028
a. Ps port (Work equipment l f. P5a port (TO swing priority valve) 1. Cover
swing switch) g. PT port (To tank) 2. Spool return spring
b. P4 port (From boom l bucket h. PO port (To straight-travel valve) 3. Body
shuttle valve) i. PI port (From L.H. travel control 4. Spool
c. P5 port (From swing shuttle valve) valve)
d. P3 port (From arm shuttle valve) j. P2 port (From L.H. travel control
e. P4a port (To arm throttle valve) valve)
1o-52
TRAVEL SHUTTLE VALVE
FUNCTIONS
o The travel shuttle valve is installed to the
top of the 4-spool valve control valve. It
takes the PPC valve pressures from the left
travel, work equipment, and swing, and
sends pilot pressure to the straight-travel
valve when the travel and work equipment
or swing are operated at the same time.
OPERATION
Travel lever at “FORWARD” (other levers at
“NEUTRAL”)
From L.H. trave
l Pilot pressure oil flows to Pl port from the
left travel circuit and pushes the spool to To arm
the right. c$ throttle valve
Therefore, ports P3, P4, P5 and PO are con-
nected through the groove in the spool, and
are also connected to the straight-travel
valve. However, there is no flow of pilot
pressure oil from the shuttle valves of the
PPC valves, so the straight-travel valve is
not actuated.
(When operating in “REVERSE”, pressure
oil is sent to port P2, and pushes the spool
of arm PPC valve valve of boom From shuttle
to the left.) bucket PPC valve of swing
valve PPC valve
205F2032-2
During simultaneous operation

When the arm and travel FORWARD are
operated at the same time, pilot pressure oil
flows from the left travel circuit to port PI
and pushes the spool to the right.
At the same ti.me, when the arm is
operated, pilot pressure oil flows to port P3
from the shuttle valve of the arm PPC valve.
From
This passes through the groove in the spool FORWARD circuit travel vcalve REVERSE circuit
and port PO, and then flows to the ;;
straight-travel valve. oil e throttle valve
l The pilot pressure oil from the shuttle valve SW
of the swing PPC valve flows port P5b
port PO-straight-travel valve, and the
pilot pressure oil from the shuttle valve of
the boom and bucket PPC valves flows port
P4*port PO-straight-travel valve.
From shuttle valve of From shuttle

arm PPC valve valve of From shuttle valve of
boom, bucket swing PPC valve
PPC valve
205F2033-2
1o-53
STRAIGHT-TRAVEL VALVE
FUNCTION
While operating the swing, boom, arm, or
bucket when traveling, the pressure oil
flowing to the R.H. and L.H. travel circuit
branches into the swing, boom, arm, or
bucket circuit.
Since the supply of pressure oil in a
branched travel circuit is less than that in
the circuit before the branch, the motor
naturally slows down, resulting in a turn.
When the straight-travel valve is switched
over to establish continuity between the
R.H. and L.H. travel circuits, this undesired
turning is prevented by equalizing the
supply of pressure oil to the R.H. and L.H.
travel motors so that they rotate at the
same speed.
OPERATION
When traveling only
Since no pilot hydraulic oil flows from the
shuttle valve in the PPC valve, no hydraulic
oil flows from the travel shuttle valve to the
straight-travel valve.
Therefore, the circuit between port PR (R.H.
travel circuit) and port PL(L.H. travel circuit)
remains closed and both circuits remain
independent.
205FO5042
While operating the swing, boom, arm, or

bucket when traveling
l Spool (1) of the straight-travel valve is
pushed to the right by the pilot pressure
from the travel shuttle valve.
l Port PR and port PL then become connect-
ed to each other and an equal amount of
pressure oil is supplied to the R.H. and L.H.
travel motors, allowing both motors to
rotate at the same speed. The machine trav-
els thus in a straight line.
205FO5043
1o-54
SWING PRIORITY VALVE
FUNCTION
When operating the swing and arm at the
same time, most of the oil flows to the arm,
which has less load. The flow of oil to the
swing circuit is reduced so the arm speed is
faster than the swing speed. This makes
combined operations difficult.
To prevent this, the swing priority valve is
switched to restrict the flow of pressure oil
to the arm-Lo control valve. This restricts
the arm speed and makes it easier to
operate the arm and swing at the same time.
OPERATION
When swing is at neutral
l No pilot pressure oil flows from the travel
shuttle valve, so the swing priority valve is
not switched. Because of this, the pressure
oil from the front main pump passes
through port PR and all the oil flows to the
arm-lo control valve.
205FO5044
When swing is operated

l When the swing is operated, spool (I) of
the swing priority valve is pushed to the left
by the pilot pressure from the travel shuttle
valve.
Because of this, the pressurized oil flowing
from front main pump - port PR to the
arm-Lo control valve is throttled, and the
arm speed is controlled, so the simultaneous
operation performance is improved.
205FO5045
1o-55
ARM THROTTLE VALVE
FUNCTION
l When the arm control lever and boom l The arm is actuated by the merged oil flow
control lever are operated at the same time, from two pumps, and the bucket is
most of the pressure oil flows to the arm actuated by the flow from one pump.
circuit, where the load is less. The amount For this reason, when the arm and bucket
of oil flowing to the boom circuit drops, so are operated together, the flow of oil to the
the arm speed is faster than boom speed. arm circuit is greater, so the arm moves
This makes combined operations difficult. much faster than the bucket. This makes
(particularly when using “ARM OUT” and combined operations difficult. (Particularly
“BOOM RAISE” at the same time.) when using “ARM OUT” and “BUCKET
When this happens, the arm throttle valve is CURL” at the same time.)
switched and the flow of oil to the arm-Hi When this happens, the arm throttle valve is
control valve is restricted. This regulates the switched and the flow of oil to the arm-Hi
arm speed and makes combined operations control valve is restricted. This regulates the
easier. arm speed and makes combined operations
easier.
OPERATION
When arm is operated independently
0 The pilot pressure does not flow- from the
travel shuttle valve, so the arm throttle
valve is not actuated and the pressure oil
from the rear pump passes through port PL
and all flows to the arm Hi control valve.
205FO5046
Simulataneous operation
l When the arm is operated together with the I Arm-Hi I
boom or bucket, the pilot pressure from the
travel shuttle valve pushes spool (I) of the
arm throttle valve to the left. When this hap-
pens, the flow of pressure oil from the rear
pump to the arm Hi control valve is throttled,
and the arm speed is controlled to improve
the ease of simultaneous operation.
valve
205FO5047
1O-56
SWING MOTOR
View 2 \
e
207FO5029
SPECIFICATIONS
a. T2 port (To tank) Type: KMFI 60AB-2
b. Sport Theoretical delivery: 160.7 cc/rev
c. MA port (From control valve) Safety valve set pressure:
d. MB port (From control valve)
275 ‘z kg/cm* at 244 Urnin
e. C port (From swing brake solenoid valve)
(PC300)
260 “8 kg/cm* at 300 Umin
(PC400)
Rated speed: 1,560 rpm (PC3001
1,925 rpm (PC4001
Brake releasing pressure: 16.5 * 2 kg/cm2
LLU LLL.
Section A - A
17 16
Section B - B
Section C - C
1. Safety valve 10. Cylinder

2. End cover 11. Center spring
3. Brake spring 12. Piston
4. Brake piston 13. Plug
5. Plate 14. Valve plate
6. Disc 15. Center shaft
7. Housing 16. Check valve spring
8. Cover 17. Check valve
9. Drive shaft
1o-59
SWING HOLDING BRAKE
OPERATION
11 When swing brake solenoid valve is
deactivated
When the swing brake solenoid valve is
deactivated, the pressurized oil from the
charging pump is shut off and port B is con-
nected to the tank circuit.
Because of this, brake piston (4) is pushed
down in the direction of the arrow by brake
spring (31, so disc (6) and plate (5) are
pushed together and the brake is applied.
205F05050K
s
&
N
0
2) When swing brake solenoid valve is

excited
When the swing brake solenoid valve is ex-
cited, the valve is switched, and the pressu-
rized oil from the charging pump enters
port 6 and flows to brake chamber a.
The pressurized oil entering chamber a
overcomes the force of brake spring (31,
and brake piston (4) is pushed up in the di-
rection of the arrow. Because of this, disc
(6) and plate (5) separate, and the brake is
released.
205FO5051 K
1O-60
CENTER SWIVEL JOINT
3
AI
B1
C!
4
Dl
Fl
Section A - A
T2 DP
\ /
View 2
B2 A2 c2
207FO503 1
1. Cover Al : From control valve AIR port D 1: From control valve AI L port
2. Body A2: To R.H. travel motor PB port D2: To L.H. travel motor PA port
3. Slipper seal Bl : From control valve PI L port F 1: From travel speed solenoid valve
4. Oil seal B2: To R.H. travel motor PB port F2: To L.H. and R.H. travel motor P port
5. Shaft C 1: From control valve BBR port Tl: To tank
C2: To R.H. travel motor PA port T2: From L.H. and R.H. travel motor T port
1O-61
TRAVEL MOTOR
Pc300,300Lc-5
207FO5032
a. T2 port (To tank) SPECIFICATIONS

b. PB port (From control valve) Type: HMV280ADT
C. P port (From travel speed solenoid valve) Theoretical delivery: Min. 175.1 cc/rev
d. PA port (From control valve) Max. 280.0 cc/rev
e. TI port (To tank) Rated pressure: 325 kg/cm2
Rated speed: Min. 1,430 rpm
Max. 895 rpm
Brake releasing pressure: 13 + 3 kg/cm2
Hi-Lo switching pressure: 8 “_41kg/cm2

Section C - C
I i
20 19 18 17 16 15
\
26
Section A - A
27
/
Section D - D
Section B - B 207FO5033
10. Check valve 19. Regulator piston

1. Output shaft
11. Check valve spring 20. Spring
2. Motor case
12. Regulator valve 2 1. Check valve spring
3. Regulator piston
13. Spring 22. Check valve
4. Cradle
14. Air bleeder 23. Counterbalance valve
5. Rocker cam
15. Brake spring 24. Spool return spring
6. Piston
16. Brake piston 25. Piston
7. Cylinder
17. Plate 26. Safety valve
8. Valve plate
18. Disc 27. Check valve
9. End cover
1 O-63
PC300HD-5
Pd400,4ooLc-5
PC400H D-5
L!cP
View 2
208FO5017
a. T2 port (To tank) SPECIFICATIONS

b. PB port (From control valve) Type: HMV355ADT
c. P port (From travel speed solenoid valve) Theoretical delivery: Min. 19 1.3 cc/rev
d. PA port (From control valve) Max. 355.4 cc/rev
e. TI port (To tank) Rated pressure: 355 kg/cm2
Rated speed: Min. 1620 rpm
Max. 870 rpm
Brake releasing pressure: 13 f 3 kg/cm2
Hi-Lo switching pressure: 8 “!, kg/cm2

! 5 6
Section C - C 2\6
li 1’6
Section A - A
Section D - D
Section B - B
208FO5018
1. Output shaft IO. Check valve 19. Regulator piston

2. Motor case 11. Check valve spring 20. Spring
3. Regulator piston 12. Regulator valve 21. Check valve spring
4. Cradle 13. Spring 22. Check valve
5. Rocker cam 14. Air bleeder 23. Counterbalance valve
6. Piston 15. Brake spring 24. Spool return spring
7. Cylinder 16. Brake piston 25. Piston
8. Valve plate 17. Plate 26. Safety valve
9. End cover 18. Disc 27. Check valve
1O-65
MOTOR
OPERATION
I) At Lo speed (motor rocker cam angle at maximum)
3a
\
205F05059K
l The solenoid valve is deactivated, so the l A.t the same time, the .pressurized oil at
pilot pressure oil from the charging pump regulator piston (3b) at the bottom passes
does not flow to port P. through orifice b in regulator valve (9) and
For this reason, regulator valve (12) is is drained to the motor case.
pushed to the right in the direction of the l As a result, rocker cam (5) moves in the
arrow by spring (I 3). maximum rocker cam angle direction, the
l Because of this, it pushes check valve (27). motor capacity becomes maximum, and the
and the main pressure oil from the control system is set to Lo speed.
valve to end cover (9) passes through
passage a in regulator valve (121, enters
regulator piston (3a) at the top, and pushes
regulator piston (3a) to the right in the direc-
tion of the arrow.
1O-66
2) At Hi speed (motor rocker cam angle at minimum)
Y-r Traveling speed

solenoid valve
205F05060K
l The solenoid valve is excited, so the pilot l At the same time, the pressurized oil at
pressure oil from the charging pump flows regulator piston (3a) at the top passes
to port P, and pushes regulator valve (I 2) is through orifice d in regulator valve (I 2) and
pushed to the left in the direction of the is drained to the motor case.
arrow. l As a result, rocker cam (5) moves in the
l Because of this, the main pressure oil from minimum rocker cam angle direction, the
the control valve passes through passage c motor capacity becomes minimum, and the
in regulator valve (I 2). enters regulator system is set to Hi speed.
piston (3b) at the bottom, and pushes
regulator piston (3b) to the right in the di-
rection of the arrow.
1O-67
PARKING BRAKE
OPERATION
1 I When starting to travel 18 17
When the travel lever is operated, the 18
, 15
l
,
pressurized oil from the pump actuates
counterbalance valve spool (23), the circuit
to the parking brake is opened, and the oil
flows into chamber a of brake piston (16),
overcomes the force of spring (15), and
pushes piston (16) to the right in the direc-
tion of the arrow.
When this happens, the force pushing plate
(17) and disc (18) together is lost, so plate
(17) and disc (18) separate and the brake is
released.
205FO5061 K
2) When stopping travel

When the travel lever is placed in neutral,
18 17
counterbalance valve spool (23) returns to
the neutral position and the circuit to the
parking brake is closed. The pressurized oil
in chamber a of brake piston (16) is drained
to the case from the orifice in the brake
piston, and brake piston (16) is pushed to
the left in the direction of the arrow by
spring (I 5).
As a result, plate (17) and disc (I 8) are
pushed together, and the brake is applied.
1 O-68
Control valve
BRAKE VALVE
l The brake valve consists of a check valve,

counterbalance valve, and safety valve in a
circuit as shown in the diagram on the right.
(Fig. I)
l The function and operation of each compo-
nent is as given below.
Motor
(Fig. 1) 205FO5063
I) Counterbalance valve, check valve

Control valve
Function
l When traveling down a slope, the weight of
the machine makes it try to travel faster
:: than the speed of the motor.
G As a result, if the machine travels with the
2 engine at low speed, the motor will rotate
without load and will run away, which is ex-
tremely dangerous.
To prevent this, these valves act to make
the machine travel according to the engine
speed (pump discharge volume).
Operation when pressure is supplied
l When the travel lever is operated, the
pressurized oil from the control valve is sup-
plied to port PA. It pushes open check valve ($2 205F05064A
(22a) and flows from motor inlet port MA
to motor outlet port MB. However, the
motor outlet port is closed by check valve
(22b) and spool (231, so the pressure at the
supply side rises. (Fig. 2)
l The pressurized oil at the supply side flows
from orifice El in spool (23) to chamber
Sl, and when the pressure in chamber Sl
El.
goes above the spool switching pressure,
spool (23) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
s,-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
(Fig. 31 205FO5065
1 O-69
Operation of brake when traveling downhill
l If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop, and the pressure in chamber SI
through orifice El will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(23) is returned to the left in the direction of
the arrow by spring (241, and outlet port
MB is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents run-
ning away.
In other words, the spool is moved to a posi-
tion where the pressure at outlet port MB
(Fig. 4) 205FO5066
balances the pressure at the inlet port and
the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the speed according to the dis-
charge volume of the pump. (Fig. 4)
2) Safety valve
Function
l When travel is stopped (or when traveling
downhill), the circuit at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the oulet port of
the motor will become abnormally high and
damage the motor or piping. The safety
valve acts to release this abnormal pressure
and sed It to the inlet port side of the motor
to prevent damage to the equipment.
Operation
When stopping travel (or when traveling
downhill), chamber E in the outlet port cir-
cuit is closed by the check valve of the (Fig. 5) 205F2044
counterbalance valve, but the pressure at

the outlet port rises because of inertia. (Fig.
5)
If the pressure goes above the set pressure,
the force produced by the difference in area
between Dl and D2 [7r/4(Dq - 0%) x pres-
sure] overcomes the force of the spring and
moves the poppet to the right, so the oil
flows to chamber F in the circuit on the
opposite side. (Fig. 6)
(Fig. 6) 205F2045
1O-70
VALVE CONTROL
Boom raise
Bucket dump .-
1'
207FO5035
1. L.H. travel control lever 9. Arm shuttle valve

2. R.H. travel control lever 10. Swing shuttle valve
3. R.H. PPC valve 1 1. Boom l bucket shuttle valve
4. R.H. work equipment control lever 12. Travel shuttle valve
5. Accumulator 13. Safety lock valve
6. Control valve 14. L.H. work equipment control lever
7. Hydraulic pump 15. L.H. PPC valve
8. Arm half flow solenoid valve 16. Travel PPC valve
10-71
PC400,4OOLC-5 (LOADING SHOVEL)
Bottom open
au,_ketU\ Boom raise
i7
205FO5825
1. L.H. travel control lever IO. Arm shuttle valve

2. R.H. travel control lever 11. Swing shuttle valve
3. R.H. PPC valve 12. Boom - bucket shuttle valve
4. R.H. work equipment control lever 13. Travel shuttle valve
5. Accumulator 14. Safety lock valve
6. Bottom dump solenoid valve 15. L.H. work equipment control lever
7. Control valve 16. L.H. PPC valve
8. Hydraulic pump 17. Travel PPC valve
PPC VALVE
FOR WORK EQUIPMENT AND SWING
C d
View 2
205FO5068
a. P port (From charging pump)

b. T port (To tank)
c. P3 port (L.H.: arm in/R.H.: bucket dump)
d. P2 port (L.H.: R.H. swing/R.H.: boom lower)
e. P4 (L.H.: arm out/R.H.: bucket curl)
f. PI (L.H.: L.H. swing/R.H.: boom raise)
1 O-72
Section A - A Section B - B
Section D - D
Section C - C
205FO5069
1. Spool 7. Disc
2. Metering spring 8. Lever
3. Centering spring 9. Joint
4. Pilot piston 10. Plate
5. Pilot spring 11. Collar
6. Piston 12. Body
1o-73
FOR TRAVEL
\
a
207FO5036
a. P port (From charging pump)

b. T port (To tank)
c. P2 port (L.H. reverse)
d. P4 port (R.H. reverse)
e. PI port (L.H. forward)
f. P3 port (R.H. forward)
1o-74
1/ Section A - A Section B - B
Section D - D
1. Spool 5. Bolt
2. Metering spring 6. Plate
3. Centering spring 7. Collar
4. Piston 8. Body
1o-75
OPERATION * The operation depends on the work
1) At neutral equipment and swing PPC valve.
Ports PI and P2 of the PPC valves in circuits
A and B of the control valve are connected
to drain chamber D through fine control
hole f in spool (1). (Fig. I)
21 Control lever operated slightly (fine

control)
When piston (4) starts to be pushed by disc
(2). retainer (7) is pushed. Valve (10) is also
pushed by spring (9) and moves down.
When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time it is connected to pump pres-
(Fig. 1) 205FO5072
sure chamber Pp, and the pilot pressure of
the control valve is sent through fine control
hole f to port Pl . When the pressure at port
PI rises, valve (10) is pushed back. Fine
control hole f is shut off from pump pres- 7
sure chamber Pp. At almost the same time &IL
\
it is connected to drain chamber D, so the
pressure at port Pl escapes to drain cham-
ber D.
Valve (10) moves up and down until the
force of spring (9) is balanced with the pres-
sure of port P 1.
The relationship of the positions of spool
(1) and body (12) (fine control hole f is in
the middle between drain hole D and pump
pressure chamber Pp), does not change
until damper piston (4) contacts piston (6).
Therefore, spring (2) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port PI also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a posi-
tion where the pressure of port A (same as
pressure at port PI) and the force of the
return spring of the control valve are bal-
anced. (Fig. 2) (Fig. 2) 205FO5073
31 During fine control (control lever
returned)
When disc (7) starts to be returned, spool
(I) is pushed up by the force of centering
spring (3) and the pressure at port PI.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil at port PI is released.
If the pressure at port PI drops too much,
spool (1) is pushed down by metering spr-
ing (2), so fine control hole f is shut off
from drain chamber D. At almost the same
time it is connected to pump pressure
chamber Pp, so the pressure at port PI
supplies the pump pessure until the pres-
sure recovers to a pressure equivalent to
the position of the lever.
When the control valve spool returns, oil in
drain chamber D from fine control hole f’ of
the valve on the side that is not moving
flows through port P2 and goes to chamber
B, so the oil is charged. (Fig. 3)
(Fig. 3)
205FO5074
4) At full stroke
Disc (7) pushes down piston (61, but
damper piston (4) also follows this and
pushes down spool (I 1. Fine control hole f is
shut off from drain chamber D, and is con-
nected to pump pressure chamber Pp.
Therefore, the pilot pressure oil. from the
charging pump passes through fine control
hole f and flows to chamber A from port PI
to push the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f’ and
flows to drain chamber D.
With damper piston (4) that was following
piston (61, the pressurized oil in the spring
chamber flows out from orifice a, and
damper piston (4) and spool (I) are pushed
back by the force of metering spring (2) and
the hydraulic pressure at port PI.
The time lag when the lever is suddenly
operated is prevented by damper piston (4).
(During fine control, damper piston (4) does
not follow piston (6). so the fine control per-
formance is maintained.) (Fig. 4)
(Fig. 4) 205FO5075
ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATION
Gas capacity: 300 cc (PC300)
500 cc (PC400)
205FO5076
SAFETY LOCK VALVE
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
/ i
2 3 4 5
207FO5038
SOLENOID VALVE ASSEMBLY
FOR 2-STAGE RELIEF, CO CANCEL, SWING BRAKE AND TRAVEL SPEED
d
?
0
cv
0
3
205FO5078
a. T port (To tank) 1. CO cancel solenoid valve

b. P port (From charging pump) 2. 2-stage relief solenoid valve
c. To front and rear NC valve 3. Travel speed solenoid valve
d. To main relief valve 4. Swing brake solenoid valve
e. To L.H. and R.H. travel motor
f. To swing motor
1o-79
1) FOR 2-STAGE RELIEF, CO CANCEL AND TRAVEL SPEED
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spool
6. Spring
7. Bracket
205FO5079
OPERATION
Solenoid deactivated
l No signal current flows from the controller,
so solenoid is deactivated.
Because of this, port A is closed, and the
pressurized oil from the charging pump
does not flow to the actuator.
At the same time, the oil from the actuator
flows from port B to port C and is drained
to the tank.
205FO5080-1
Solenoid excited
l When the signal current flows from the
controller to solenoid, solenoid is excited.
As a result, the pressurized oil from the
charging pump flows from port A to port B,
and to the actuator.
At the same time, port C is closed, and the
does not flow to the tank.
205FO5081-1
2) FOR SWING BRAKE
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5082
OPERATION
0 No signal current flows from the controll-
er, so coil is deactivated.
Because of this, port P is closed, and the
z does not flow to the swing motor.
z At the same time, the oil from the swing
2 motor flows from port A to port T and is
drained to the tank.
205FO5083-1
Solenoid excited
0 When the signal current flows from the
controller, coil is excited.
Because of this, port P and port A are inter-
connected, and the pressurized oil from the
charging pump flows to the swing motor.
At the same time, port T is closed, so the oil
does not flow to the tank.
205FO5084-1
FOR ARM HALF FLOW
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5085
OPERATION
0 No signal current flows from the controll-
er, so coil is deactivated.
Because of this, port P and port S are in-
terconnected, so the pressurized oil from
the PPC valve flows to the control valve.
205FO5086-1
Solenoid excited
0 When the signal current flows from the
controller, coil is excited.
Because of this, port P is closed, and the
pressurized oil from the PPC valve does not
flow to the control valve.
At the same time, port S and Port T are in- Exe:i
terconnected, so the pressurized oil from
the control valve is drained to the tank.
205FO5087-1
SHUTTLE VALVE
FOR BOOM -BUCKET AND TRAVEL
a b 1. Plug
2. Ball
3. Body
4. Plug
a. Pin port (Bucket dump)

[R.H. reverse]
b. P3n port (Bucket curl)
[R.H. forward1
c. PEA port (Boom raise)
I h
[L.H. forward]
I 2 3
d. PEA port (Boom lower)
[L.H. reverse]
e. P5 port (Travel shuttle valve)
[Travel oil pressure switch]
f. P313 port (Bucket curl)
[R.H. forward1
9. PI B port (Bucket dump)
[R.H. reverse]
h. PZB port (Boom lower)
Section A - A Section B - B
[L.H. reverse1
207FO5039 i. PUB port (Boom raise)
[L.H. forward1
( 1: For boom l bucket,
[ I : For travel
FOR ARM AND SWING
a b c
1. Ball
2. Body
3. Plug
a. Pin port (Arm out) [L.H. swing]

b. P3 port (Travel shuttle valve)
A
[Blind plug]
3
c. PZA port (Arm in) [R.H. swing]
d. PIB port (Arm out) [L.H. swing1
e. PZB port (Arm in) [R.H. swing]
( I: For arm, [ I: For swing
\ A
Section A - A
e
207FO5040
1 O-83
BOOM HOLDING VALVE
Section A - A
207FO5041
a. T port (To tank) 1. Safety-suction valve

b. Pi port (From boom PPC valve) 2. Pilot spring
c. Cy port (To boom cylinder) 3. Pilot spool
d. V port (From boom control valve) 4. Poppet spring
5. Poppet
1 O-84
OPERATION
1) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes up poppet (5)
in the direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
205FO5091
21 Boom lever at NEUTRAL

When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of
the boom cylinder is closed by poppet (5) in
the direction of the arrow.
Because of this, the main pressure oi from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
1 O-85
3) Boom LOWER
When the boom is lowered, the pilot pres-
sure from the PPC valve pushes pilot spool
(3) and the pressurized oil in chamber b
inside the poppet is drained.
When the pressure at port Cy rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered be-
cause of orifice a.
If the pressure in chamber b drops below
the pressure at port V, poppet (5) opens,
the pressurized oil flows from port Cy to
port V, and then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve (I 1 is actuated.
205FO5093
?l
s
$
1 O-86
HYDRAULIC CYLINDER
1. BOOM CYLINDER
Pc300,300Lc-5
PC300HD-5
12 3 4 5 6 7 8 9 10 11 12 13 14 15
207FO5042
Pc400,400Lc-5
PC400HD-5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
208FO5019
2. ARM CYLINDER
Pc300,300Lc-5
PC300HD-5
12 3 4 5 6 7 8 9 10 11 12 13 17 14 15
I
IJ
207FO5043
10687
Pc400,400Lc-5
PC400HD-5
208FO5020
3. BUCKET CYLINDER
Pc300,300Lc-5
PC300HD-5
207FO5044
Pc400,400Lc-5
PC400HD-5
208FO5021
1. Rod side bushing 8. Head side cushion plunger 15. Bottom side bushing
2. Piston rod 9. Piston 16. Head side tube
3. Cylinder head 10. Piston ring 17. Spacer
4. Rod packing 1 1. Wear ring 18. Bottom side cushion plunger
5. Buffer ring 12. Ring 19. Ball
6. Wear ring 13. Spacer
7. Cylinder 14. Bottom side tube
SPECIFICATIONS
Unit: mm
Arm Bucket
Cylinder inside diameter 140 160 160 185 140 160
:: Rod outside diameter 100 110 110 120 100 110
z
: Stroke 1,480 1,570 1,685 1,820 1,285 1,270
Maximum length 3,610 3,830 4,080 4,410 3,275 3,265
Minimum length 2,130 2,260 2,395 2,590 1,990 1,995

1. BOOM CYLINDER
205FO5833
2. ARM CYLINDER
205FO5834
3. BUCKET CYLINDER
205FO5835
4. BOTTOM DUMP CYLINDER
205FO5836
1. Rod side bushing 7. Cylinder 13. Spacer

z 2. Piston rod 8. Head side cushion plunger 14. Bottom side tube
6 3. Cylinder head 9. Piston 15. Bottom side bushing
g
4. Rod packing 10. Piston ring 16. Bottom side cushion plunger
5. Buffer ring 11. Wear ring 17. Ball
6. Bushing 12. Ring 18. Head side tube
SPECIFICATIONS
Unit: mm
Bottom dump
Rod outside diameter 110 120 95 90
Cylinder inside diameter 160 185 135 130
Stroke 1,338 1,292 1,287 284
Maximum length 3,837 3,615 3,322 1,091
Minimum length 2,499 2,323 2,035 807

ELECTRICAL WIRING DIAGRAM
PC%kC-5 Serial No:K20001 and UP
22'
View Z
205F05603A
1. Motor panel 12. Pump controller

2. Swing lock switch 13. Engine throttle controller
3. Horn switch 14. TVC prolix resistor
4. Starting switch 15. Heater
5. Fuel control dial 16. Power maximizing switch
6. Cigarette lighter 17. Wiper relay
7. Buzzer 18. Heater Lo relay
8. Service meter 19. Heater.Hi relay
9. Radio 20. Speaker
10. Swing lock prolix switch 21. Light relay
1 1. TVC prolix switch 22. Fuse box
1 o-91 -1
23. W.orking lamp
24. Head lamp
25. Battery
26. Battery relay
27. Fuel level sensor
28. Horn (Low tone)
29. Horn (High tone)
30. Room lamp
3 1. Front pump pressure sensor
32. Rear pump pressure sensor
33. Work equipment l swing oil pressure
.44 switch
34. Alternator
35. Coolant level sensor
36. Coolant temperature sensor
37. Heater relay
38. Glow plug
39. Engine oil level sensor
40. Starting motor
41. Engine oil pressure switch
42. Governor motor
43. TVC valve
44. Engine speed sensor
45. Hydraulic oil level sensor
47. Swing brake solenoid valve
48. Travel speed solenoid valve
49. 2-stage relief solenoid valve
50. CO cancel solenoid valve
5 1. Travel oil pressure switch
52. Wiper motor
207FO5046
1 o-91 -2
ELECTRICAL CIRCUIT DIAGRAM
PC3OOLC-5 Serial No:K20001 and up
iiadio
CN-M26tKES4)
CN-Ml2(KES3)
To (2i21
Heater Heater
Light relay Wiper relay
Hi relay LO relay 207F&49
ALPHABETICAL INDEX
NO. PARTS NAME ADDRESS

84 CN-Sl c7
85 CN-SlO c7
86 CN-S2 c7
0-l ,-%l_rrl ^_
Governor motor
--
Working lamp (Boom)
13 CN-C2 18
14 CN-C3 G8
L.H. head lamp 15 CN-C4 L8
Y7 !Isensor R5
858 Battery relay perature sensor R3
1 mbly P2
stnn -it,+
R5
M7
Engine
03
L6
Glow
plug
To (l/2)
140 1R.H. head lam-
CN-PJ(XI) Engine oil level
~N_p7(X2) Coolant temperature
68 1 CN-M7 1 M4
69 ) CN-M8 1 M9
7rI I CN.MQ I Mg
71 / CN-Pl 1 Hl
72 / CN-PlO 1 A5
77 I I-M-P, 1 Fl
,_ , _#., _
75 1 CN-P5 / Q4
76 1 CN-P6 / N2
77 I #-h1.P7 I 03
79 [ CN-P9 1K8
*A I r-hl_Q)‘l I F7
81 1CN-R2 1Dl ._. I
82 1CN-R3 1Dl 165 1Work equipment. swing oil pressure switch 1
166 1Workinq lamp (boom) 1 M9
1 o-91-4
ELECTRICAL WIRING DIAGRAM
Pc300,300Lc-5
PC300HD-5
9
? i 10
/’
_.I’
I
I /’ ’
I““.+ ’ /”
View Z
205F05603A
I. Motor panel 12. Pump controller

8. Service meter 19. Heater Hi relay
I 0. Swing lock prolix switch 2 1. Light relay
1 1. TVC prolix switch 22. Fuse box
1 o-92
8
23. Working lamp
24. Head lamp
25. Battery
26. Battery relay
28. Horn (Low tone)
30. Room lamp
33. Work equipment l swing oil pressure
switch
34. Alternator
37. Heater relay
38. Glow plug
39: Engine oil level sensor
40. Starting motor
42. Governor motor
43. TVC valve
49.2-stage relief solenoid valve
5 1. Travel oil pressure switch
52. Wiper motor
207FO5046
1o-93
Pc400,400Lc-5
PC400HD-5
View Z
205F05603A
1. Motor panel 12. Pump controller

8. Service meter 19. Heater Hi relay
2 1. Light relay
10. Swing lock prolix switch
22. Fuse box
11. TVC prolix switch
1024
23. Working lamp
24. Head lamp
25. Battery
26. Horn (Low tone)
27. Battery relay
30. Room lamp
34. Heater relay
35. Alternator
38. Electrical intake air heater
39. Starting motor
40: Work equipment l swing oil pressure
switch
42. TVC valve
43. Engine oil level sensor
44. Governor motor
49.2-stage relief solenoid valve
51. Travel oil pressure switch
52. Wiper motor
208FO5022
1o-95
_J CN-FI (M4)
CN-D9
Z-stage relief
solenoid valve
Arm half flow

solenoid valve
co cancel
solenoid valve
Travel speed
solenoid valve
Swing brake
solenoid valve
Pump controller
TVC prolix
res,stor
TVC solenoid
valve
020705
ALPHABETICAL INDEX
NO. 1 PARTS NAME 1ADDRESS

Rd I CN-s,
Governor motor
/ --
Working lamp (Boom)
1 95 1 CO cancel solenoid valve 1E9 J

96 1 Condenser 1 N2
w
97 1 Condenser relay I RI
L.H. head lamp
II Alternator
.__ ..__._. ._._,

123 1Horn (High. 390 Hz)
124 1Horn (Low. 330 Hz) I 02
125 1Horn switch 184
126 I Hydraulic oil level sensor 1K9
127 L.H. head lamp M8
128 Light relay Cl
129 Magnetic clutch of compressor R4
::::::::
3%;
&
.A.. . .
To (l/2)
-
CN-M7(L2)
r_ll,D
To ,112,); ;, I
.:.>:.:
:+::::
::....::
:.*.:.
.:...:.:
$,
$3
c~-p7(~2) Coolant temperature E
3; 1-1 ,
148 I Starting motor

;$g
.:....:
z:::::::
149 Starting switch
150 Swing brake solenoid valve , Ii
‘4% 1K9._
i:;:;:; 151 Swing lock prolix switch
69 1 CN-M8 1M9 152 Swing lock switch
70 1CN-MS 1 M9 ‘I&7 C..,i”” _:I .._^^^ .._^ ^,.I :+..I.
7,
I
I ,-F.-D,
, ,A”-1
I u,
72 1CN-PlO
Travel oil pressure switch
Travel speed solenoid valve
._ _-....__.._, ._
163 Wiper motor A4
164 Wiper relay El
165 Work equipment. swing oil pressure switch D8
166 Working lamp (boom) M9
207FO5050
..%..........
..%................
~~ilii~:~~~:i~~~M~~~~~::~:~~~~~~ N .......................
:.:.: .......‘oi~~sl~~~:~~~~
........................................
...........
...:.>:.:.:.:.:.:
.: 1 P ,...............
Ci%in%~~d~~~~~~.~~~~~~~~~:~~~:~
.......................................... R
1o-97
0
PC300,3OOLC-5 Serial No: 21401 and up
PC300HD-5
Monitor panel switch output
Heater fan
Power set
Travel speed
Light
Radio
CN-M26(KES4)
To (2/Z)
ALPHABETICAL INDEX
NO. 1 PARTS NAME 1ADDRESS

84 1 CN-Sl 1 c7
RE. I CN-C’Ill I r7
Governor mote,
CN-EZ(SI2)
Working lamp (Boom)
L.H. head lamp
I”, I
110I Floor frame 03

1111Front pump press. sensor L6
1121Fuel control dial rn
II Alternator
ewce
Magnetic clutch of compressor R9
‘over max. switch 66
‘PC Hyd. monitor (low press.) D8
CN-P5(XI) Engine oil level
CN-P7(X2) Coolant temperature
lenoid valve
Overload warning device
F20705477
PC400,4OOLC-5 Serial No: 20001 - 20602
Working mode Heater fan Fuse box connecting table
Auto-deceleration
Power set
Travel speed
Light Wiper
___ --
Radio
-
Wamng buzzer
20X-05025
‘8
ALPHABETICAL INDEX
NO. PARTS NAME ADDRESS NO. [ PARTS NAME 1 ADDRESS

1 2-stage relief solenoid valve D9 84 1 CN-RI I .-,
2 Air conditioner N2 ii CN-Sl ;;
3 Air conditioner relay Rl 86 CN-SIO c7
4 Alternator R6 87 CN-SP
Ft. H. Head lamp motor
Governor c7
5 Arm half flow solenoid valve E9 88 CN-M c7
1 __ -.. -_
-.-_
6 Batterv R7 R9 CN-S!i n?
, “I
I ;I E%nerv relav I FM ._ I 1 9” I CN-S9 I

I
D-3 I
iI 1 Blower motor I cl2 9; /
CN-VI I FL
Working lamp (Boom) 9 - _ _ ____
I Mower w4Stnr I P:, _..._
99 1 TN-“? I m
I
10 1 Blower switch 9; 1CN-V4 1 E3
11 1 Cigarette lighter 94 I CN-V5 [/ E8
._ _..-.
17 I CN-Cl __ _.. . .
qc, I CN-“7 _n
13 CN-C2 18 96 CO cancel solenoid valve ::

w 14 CN-C3 G8 97 Condenser N2
L.H. head lamp 15 CN-C4 L8 98 Condenser relay Rl
16 CN-C5 K7 rnntrn, ,,ill\,P
858 Battery relay 17 rN-l-6 IR
CN-MII(L2)
858 + 868 24 CN-D3 Al
(I IIll 25 CN-D4 83
Battery 26 CN-D5 E8
Engl
27 CN-D6 E8
II Alternator I
_ _
1 CN-Ml4
45 1 CN-Ml4 1 M3
46 CN-Ml6 02
47 CN-Ml7 P2
48 CN-Ml8 K8
49 CN-M2 07
50
6,
;;
CN-M20
_.. . _
CN-M31
1 CN-M26
F6
A.7
135
._._
I Overload warning device
Potf=ntiomat*r
To (l/2)); I
3 C+p7(X2)cOdant temperature
208FO5026
..... .....(,~.:.yy
./...
‘:.z.:“::“p;“:~~;;;:
~~~~~
. I.......
..... N ..:.:.:.:.:.:.:...:.>~:.~
~~~~~~~~:~~~~~~~
,.,. P ~:.~:~~::i:::ip:~,~~
....-...-...:...:
::::::::.:.:.:.:
.,........ ”
I.,.,.,.........,.
.: R
:‘:‘:y’:‘:‘:‘:‘:y:‘:::;::::‘:‘:‘:
PC400H D-5
Working mode Heater fan

r---
Auto-deceleration
Power set
Travel speed
Light
Radio
CN-M26(KES4)
To (212)
-_ -- I
ALPHABETICAL INDEX
R. H. Head lamp Governor motor
Working lamp (Boom)
i--
I
I
I
I
r-- I! 14 / CN-C3 1G8
15 1 CN-C4 I L8
‘1c I r-hl_CC I Y7
Engir
rame j 03
r,v,,,pump press.
SenSclr 1L6
114 1 Fuel control dial 1D3
115 1Fuel level sensor 1N2
___ _-.. _-... __. ? .__ _
118 Fusible link

119 Governor motor
170
Engine
ground ;
CN-M7(L2)
59 1 CN-M34 I E6
60 1 CN-M35 I a4
61 j CN-M36 I K6
,_%, , “_, “llr -,, r”d’y,’ * ..,. “,, L I38

149 I Starting motor R7
‘1E0
I.,”
I Ct3.+inn
r,.,i+rk
YLo’Lllly ~““l,Lll E4
151 Swing brake solenoid valve E9
_I
152 Swing lock prolix switch K9
70 1CN-M8 j M9 153 Swing lock switch H6
71 1CN-MS ( M9 154 Swing oil pressure switch C8
72 / CN-Pl / Hl 155 Switch 1 A2
I ^.
ststor
vitch
162 Warning buzzer A4

163 Window washer A3
164 Wiper motor A4
165 Wiper relay El
166 Work equipment. swing oil pressure switch D8
167 Workinq lamp (boom) M9
F20705479
To chassis Bonom dump Bottom dump

horn power source switch (Open) switch (Close)
l-
Horn switch
Relay 7 Relay 2
CN-FI(M4)
CN-FZ
1
To swing flasher
CN%lO
To service 1
205FO5850
1O-89-3
ENGINE CONTROL SYSTEM
Pc300,300Lc-5
PC300HD-5
207FO5051
1. Battery relay OUTLINE

2. Battery l The engine can be started and stopped
3. Fuel control dial simply by using the starting switch.
4. Starting switch l The engine speed can be controlled using a
5. Starting motor dial control system for the fuel control.
6. Engine throttle controller l The engine throttle controller also controls
7. Fuel injection pump the engine speed at the same time using
8. Governor motor signals from the pump controller.
* For detail, see PEMC SYSTEM.
Pc400,400Lc-5
PC400HD-5
1 View 2
208FO5027
1. Battery relay
2. Battery
3. Fuel control dial
4. Starting switch
5. Starting motor
6. Engine throttle controller
7. Fuel injection pump
8. Governor motor
GOVERNOR MOTOR LINKAGE
PC300
F20705342
1. Governor motor
2. Yoke
3. Locknut
4. Spring assembly
PC400 5. Engine governor
277.5 (at used center hole)

I
Angle origin
(Position of stopper) T
( -J-P,
F20705: 143
1. Governor motor
2. Yoke
3. Locknut
4. Spring assembly
5. Engine governor
10-101-1
0
1. OPERATION OF SYSTEM
Starting engine
l When the starting switch is turned to the
START position, the start signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle con-
troller checks the signal voltage from the
fuel control dial and sets the engine speed
to the set speed.
205FO5105
Engine speed control

Starting
l The fuel control dial sends a signal voltage
to the engine throttle controller according
to the position of the dial.
The engine throttle controller calculates the
angle of the governor motor according to
this signal voltage, and drives the governor
motor so that it is set to that position.
When this happens, it detects the operating
angle of the governor motor using a poten-
tiometer and observes the governor motor.
205FO5106
Stopping engine
l When the engine throttle controller detects Starting
that the starting switch is at the STOP posi-

tion, it drives the governor motor to set it to
the NO INJECTION position, and stops the
engine.
When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller
itself drives the battery relay.
205FO5107
10-102
2. COMPONENT EQUIPMENT OF SYSTEM
1) ENGINE THROTTLE CONTROLLER
+
Z CN-El
I, “El
1
\
View Z j 1. Self-diagnostic display LEDs 205FO5108
’0-Ao3
Control function of controller
(Input signal) (Output signal)
0 The engine throttle controller receives the
Pump controller
input signals shown in the diagram on the IStarttng stop signal) IThrottle signal)
right, processes these internally and sends Fuel control dial

output signals to the pump controller, (Throttle signal)
governor motor, and battery relay.
(Potentiometer slgnall
205FO5 109
1) Engine speed set function using fuel con- Controller output

trol dial characteristics
An output signal that matches input voltage
a corresponding to the position of the fuel
control dial is sent so that the governor
motor is set to turning angle b.
Turning angle b is fed back to the controller
by the potentiometer signal, and the opera-
output
tion of the governor motor is always
observed.
output
205FO5 110
2) Engine speed control by No. 2 throttle

signal from pump controller
The pump controller controls the engine
speed directly using the No. 2 throttle signal
in order to carry out the PEMC system.
The engine throttle controller controls the
engine using the lower signal (higher vol-
tage) of the throttle signal from the fuel
control dial and the No. 2 throttle signal
from the pump controller.
Example:
Even if the fuel control dial is set to the
MAX. position, if [finishing operation mode
and S mqdel is selected for the working
mode and power mode, the engine speed
will automatically be set to partial speed.
J, For details, see PEMC SYSTEM.
1O-&O4
3) Auto-deceleration function using auto-
deceleration signal from pump controller
When the pump controller detects that all
levers are at neutral, it sends the auto-
deceleration signal to the engine throttle
controller. When this signal is received, the
engine throttle controller reduces the
engine speed to the deceleration position.
Sr For details, see PEMC SYSTEM.
4) Automatic warming-up function using

warming-up signal from monitor
After the engine is started, if the engine
water temperature is low, the monitor sends
the warming-up signal to the engine throttle
controller.
When this signal is received, the engine
throttle controller raises the engine speed
to carry out warming up.
Sr For details, see PEMC SYSTEM.
5) Engine stop function using starting

z
switch signal Starting switch .x1 oFF
G
When the starting switch is turned OFF, the I
$ Operation of
engine throttle controller detects this and governor motor --A
drives the battery relay to maintain the elec-
tric power. At the same time, it drives the
governor motor to pull back the fuel injec-
tion pump lever to the STOP position.
2.5 set
205F05111A
6) Self-diagnostic function
Three LEDs (red, green, red) light up and go
out to indicate that the machine is normal, Voltage between connector CN-El (13) - (12).
or to indicate the location of any failure (Battery relay drive signal)
when any abnormality occurs.

Signal Voltage(V)
Ir For details, see the TROUBLE-
SHOOTING. ON-l 20 - 30
I ON-2 I 18-28 1
I OFF I -15--30 1
Internal structure of controller
0 The inside of the controller consists of the -
input circuit, microcomputer, and drive cir- - B
aY
cuit shown in the diagram on the right, and G 5 C i
0) .=
-0
these have the various functions described -err -z 2 3
5
.E E .L-
5 c- -0 E
below. 8
b s F z
E tQ 2 ‘Z E
L .o n
1) Input circuits $ 2 ?
These receive the signals from the fuel con- G
-
trol dial (throttle signal), pump controller
(No. 2 throttle signal, auto-deceleration 205FO5 112
signal), monitor (warming-up signal), and
starting switch (start signal), and send them
to the microcomputer. In this portion, the
noise in the signal is removed and the wave
pattern of the signal is regulated.
In addition, it makes the power source
(approx. 34 for the governor motor poten-
tiometer and fuel control dial.
2) Microcomputer
The angle of the governor motor is calculat-
ed from the input signals sent from the
input circuits, and the pulse signal to drive
the governor motor is sent to the drive
circuit.
3) Drive circuit
The pulse signal sent from the micro-
computer is used to switch the direction of
1the current flowing to the governor motor
to rotate the motor clockwise or
counterclockwise.
lo-106
2) FUEL CONTROL DIAL
MAX. A---l
1. Knob
2. Dial
3. Spring
Machine 4. Ball
forward
5. Potentiometer
6. Connector
MIN.
A-4
6
Section A - A
205FO5 113
FUNCTION
l This is installed under the monitor panel. A
potentiometer is installed under the knob,
and when the knob is turned, it rotates the
potentiometer shaft.
This rotation changes the resistance of the
variable resistor inside the potentiometer,
and sends the desired throttle signal to the
engine throttle controller. The shaded area
in the graph on the right shows the abnor- 0 0.25 1 4 4.75 5
Throttle voltage
mal detection area, and the engine speed is
characteristics (VI
set to low idling. 205FO5 114
l There are detents at ten places on the knob

of the fuel control dial, but the knob can be
set at nay desired position.
’O-P7
3) GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
Section A - A
@ (i-j-
@ @p---
Composition of circuit
205FO5115
FUNCTION OPERATION
The motor is rotated and the governor lever Motor stationary
of the fuel injection pump is controlled by l Current is passing through both the
the drive signal from the engine throttle A-phase coil and B-phase coil of the motor.
controller. Motor rotating
A stepping motor is used for the motor l A pulse current is applied to the A phase
which provides the motive power. and B phase by the engine throttle controller
In addition, a potentiometer to give feed- to give synchronous rotation with the pulse.
back is installed to allow observation of the
operation of the motor.
The rotation of the motor is transmitted to
the potentiometer through a gear.
’O-Lo8
OUTLINE OF OPERATION OF STEPPING
MOTOR
Fig. 1 shows a diagram of the stepping mo-

tor expanded in the direction of the circum-
ference.
It shows the relative positions of the teeth of
the rotor and stator, and the condition corre-
sponds to current drive pattern 1 in Table 1.
If the motor is changed from this condition
into current drive pattern 2, the relative posi-
tions of the stator and rotor will become as
shown by the dotted line in Fig. 1 (the stator
is fixed, so the rotor moves to the left).
When switched in the pattern 2 + 3 -L 4 -1
.... the rotor also moves to the left in the
same way. If the current drive pattern is
changed 4 + 3 -. 2 + 1 + 4 . ... the
rotor moves to the right.
Fig. 1 Expanded diagram of stepping motor
Rotor (permanent magnet)
N S N S N S N S N S N
‘-1 --1 -7 -7
N S S I N
I
I i I I I
I I
I I I
nn
I
-1 .-J --I nn --I,
+i Stator -i
t’ (
c (
& “b
A phase B phase
F20505392
Table 1
Current drive pattern Pattern I’ Pattern 2 Pattern 3 Pattern 4
A-phase current +i +i -i -i
B-phase current -i +i +i -i
10-109
a
4) LOOSE SPRING
PC300,3OOLC-5 Serial No: 20001 - 24100
PC400,4OOLC-5 Serial No: 20001 - 20602
1 2 3 4 5 1. Yoke
2. Pipe
3. Spring
4. Spring
5. Rod
205FO5852
PC300,3OOLC-5 Serial No: 21401 and up PC400,400LC-5 Serial No: 20603 and up
PC300HD-5 PC400HD-5
1 2 3 4 5 1. Rod
2. Spring
3. Pipe
4. Spring
5. Joint
205FO596 I
PEMC SYSTEM
Working mode selection function
Power set selection function
r Pump flow control (PFC, PNC) function
-Cut-off (CO) function

Pump control system
-Cut-off cancel function
-Half flow function
Power maximizing system 1
Auto-deceleration system
I
Engine automatic warming-up function

Engine automatic warming-up and
Engine overheat prevention function
Swing lock function

Swing control system
Swing holding brake function
Automatic Hi-Lo travel speed shift

function
Self-diagnostic function
I
205FO5116
PEMC system: Pump and Engine Mutual Control System

l The PEMC system is a system of total control to give a high level of both power and fuel econo-
my by controlling both the pump and engine.
PC300,3OOLC-5 Serial No: 20001 - 21400
PC400,4OOLC-5 Serial No: 20001 - 20602
Travel motor
i--d
IArm curl)
1Arm throttle 1
[Straight travel p
Swing p ( L.H. travel 1 1 / II I

I
._--$ i i
Koo1ant temperat”re
I 1 signal) Engine
Swing
hargin lock
‘“Iv switch
II -1:
Fuel control dial
(
Swing
Power max. lock
switch prolix
switch
1 ~(Drwesignall
, I I I 4444
IRearoil prei+re sensor signal1 ,, I
(Front oil pressure sensors~gnal),,
(Switch signal)
iDrivesigMI[,
Controller (Drive signal);, I
(Drive signal),,
(Drive signal)
I
(Work equipment.swing lever signal)
(Travel lever signal)
(Drive signal!,
(Swing lock switch slgnall
(Kerosene mode signal)
(Swing lockswltch signal)
207FO5052
‘-’
‘O-ii
PC300,300LC-5 Serial No: 21401 and up PC400,4OOLC-5 Serial No: 20603 and up
PC300HD-5 PC400H D-5
Travel motor
..gj$ i g.... sw@ brake

~____~~:_~~~~_~~
I L ___----A+-
IL____-~---------___-.+--
L
.-
r
pres.
switch
1R.H. travel 1
- c
9
Swing
ChargInS lock
pump switch
Power ma: zk
switch rolix
&itch
controller 1
205FO5755
1. PUMP AND ENGINE MUTUAL CONTROL SYSTEM (WORKING MODE SEL .ECTION
AND POWER SET SELECTION)
Engine
Travel control lever
PPC shuttle valve
Fuel control dial
ItSwitch s$nal) [g]
205FO5 118A
OUTLINE
l The changes in the engine speed caused by 0 The combination of the 4-level working
the pump load are detected by the engine mode and 3-level power set makes it possi-
speed sensor and fuel control dial output ble to choose a pump absorption torque
signal. The pump controller calculates these corresponding to the nature of the work, so
signals, and sends the results to the TVC it is possible to use the engine more effec-
valve as a signal to control the pump dis- tively while also reducing fuel consumption.
charge volume. In this way, it can always 0 Normally, the combination of the working
give the optimum matching of the engine mode and power mode takes the working
torque and pump absorption torque. mode as the basic mode, and the power
mode is automatically set according to the
selection of the working mode.
Engine torque Engine horsepower Main pump delivery

L.O + L G.0, F.0, L.0 + S
/(yyzfy ~~~~~Si
Engine speed N 205F051~9A Engine speed N

205FO5120A
Pump delivery volume Q
Note) H.0: Heavy duty operation mode, G.0: General operation mode, 205F05121A
F.0: Finishing operation mode, L.0: Lifting operation mode
10-112
CONTROL OF H MODE l Engine torque
When using H.O. G.O. F.0 or L.0 mode and H
mode
Working mode: Same for any mode
Power set: H
CO function: Actuated
Pump absorption At rated output
horsepower: point
PC300 PC400
207 HP/l ,950 rpm 276.1 HP/2,000 rpm

Engine speed N
205FO5 122
When the pump controller receives the

power set [HI signal from the monitor, it l Engine horsepower
sends out an electric command for the H
mode output setting to the engine throttle
controller.
The engine throttle controller receives this
and uses the governor motor to set the
engine governor lever to the FULL position.
If the pump load becomes too high and the
engine speed drops, the engine speed sens-
ing reduces the pump discharge amount,
and momentarily resets the engine speed to
the rated point. In this way, the engine Engine speed N
205FO5 123
torque and pump absorption torque are
always matched at the rated point, and the
l Main pump delivery
engine horsepower can be used to the
maximum.
The CO (Cut-off) function is actuated, and
when it reaches near the relief pressure, the
pump discharge amount is reduced to
reduce hydraulic loss and power loss.
Pump delivery volume Cl

205FO5 124
CONTROL OF S MODE
When using H.0 mode and S mode Engine torque l Engine horsepower
b
Working mode: H.0
Power set: S
Pump absorption At 80% partial
horsepower: output point
PC300 PC400
Engine speed N Engine speed N
Lu
177.5 HP/l ,950 rpm 236.6 HP/2,000 rpm 205FO5125 205FO5126

Main pump delivery
working mode LH.01 and power set [Sl
signal from the monitor, it sends out an
electric command for the S mode output
setting to the engine throttle controller.
governor lever to the FULL position.
0 The pump absorption horsepower and
engine speed are different, but the control
is basically the same as for [HI mode
(engine speed sensing at the matching
205FO5133
point).
When using G.O. F.0 or L.0 mode and S mode

l Working mode: G.O. F.0 or L.0 l Engine torque 8 Engine horsepower
0 Power set: S
0 CO function: Actuated
l Pump absorption At 80% partial
PC300 PC400
Engine speed N
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm w
205FO5128 205FO5129
l When the pump controller receives the

working mode IG.01 (or iF.01 [L.Ol) and l Main pump delivery
power set, IS1 signal from the monitor, it
sends out an electric command for the S
mode output setting to the engine throttle
controller.
governor lever to the partial position.
l The pump absorption horsepower and
205FO5 136
point).
CONTROL OF L MODE
When using H-0 mode and L mode Engine torque l Engine horsepower
Working mode: H.0 n
I
Power set: L G
3
E
Pump absorption At 68% partial z
horsepower: output point _c
z
PC300 PC400 \ E
._
Engine speed N F
Lu
Engine speed N
147.9 HP/l ,950 rpm 192.3 HP/2,000 rpm 205FO5131 205FO5 132

Main pump delivery
working mode IH.01 and power set [Ll
signal from the monitor, it sends out an a I
electric command for the L mode output
governor lever to the FULL position.
0 The pump absorption horsepower and
0” point). 205FO5127
5
0
When using G.0, F.0 or L.0 mode and L mode

Engine torque l Engine horsepower
Working mode: G.0 or F.0
Power set: L
PC300 PC400
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm

205FO5134 L” 205FO5135

working mode iG.01 (or iF.01) and power Main pump delivery
set IL] signal from the monitor, it sends out
an electric command for the L mode output
governor lever to the partial position.
The pump absorption horsepower and -7
I
engine speed are different, but the control I
/
is basically the same as for [HI mode I
I
(engine speed sensing at the matching Pump delivery volume 0

point). 205FO5 130
When using L.0 mode and L mode l Engine torque
Working mode: L.0
Power set: L
PC300 PC400
128.2 HP/l ,400 rpm 172.5 HP/l ,400 rpm

i
1 \
Engine speed N
When the pump controller receives the 205FO5137
working mode iL.01 and power set [Ll signal
from the monitor, it sends out an electric l Engine horsepower
command for the L mode output setting to
the engine throttle controller.
and sets the governor lever to the partial
position.
The pump absorption horsepower and
point).
The area around the matching point is a Engine speed N
205FO5138
highly efficient area for engine fuel con-
sumption, so the fuel reduction effect is ex-
tremely large. l Main pump delivery
At the same time, by throttling the pump
output, it is possible to obtain a high level of
fine control performance to match fine con-
trol operation.

205FO5 139
‘O-P
CONTROL OF POWER MAXIMIZING FUN- l Engine torque
CTION
l When the power max. switch is OFF
l Working mode: H.0 orG.0

0 Power set: Same for any mode
0 CO function: Actuated
l Pump absorption Depends on the
horsepower: setting for working
mode and power set
\
Engine speed N
0 205FO5122
a When power maximizing switch ON
l Engine horsepower
l Working mode: H.0
0 Power set: H
0 CO function: Cancel
l Pump absorption At rated output point
horsepower:
0 Operation time: Even if the switch is
kept ON, it is auto-
matically canceled
after 8.5 seconds.
::
&
z l When the working mode switch is at IH.01 Engine speed N
or LG.01, and the power max. switch is 205FO5123
pushed ON, the following functions are ac-
tuated while the switch is being pressed.
Main pump delivery
I) If either of the working modes and any
of the power sets is selected, the
system will switch to LH.01and [HI.
21 The CO (cut-off) function is canceled,
and the flow at near relief pressure is
increased.
* For details, see PUMP CONTROL
SYSTEM.
* Even if the switch is kept pressed, the
above function is automatically canceled
after 8.5 seconds, and the system is
reset to the condition before the switch 205FO5 140
was pressed.
* This function does not work when the
working mode switch is at IF.01 or tL.01.
10-117
CONTROL FUNCTIONS WHEN TRAVELING l Engine torque
l When the travel is operated, even if any
working mode or power set is selected, the
working mode and engine speed will stay as
they are, and only the power set is switched
to the equivalent of H mode (Pump con-
trol by engine speed sensing) to increase
the pump absorption torque.
Engine speed N
205FO5141
l Engine horsepower
0”
s
Engine speed N 2
207FO5053
CONTROL FUNCTION WHEN TVC PROLIX l Main Dump delivery

SWITCH IS ON
l If any abnormality occurs in the controller or
sensors, a constant current flows from the
battery to the TVC valve so that the function
can be maintained through a pump absorp-
tion torque more or less equivalent to S
mode.
In this condition, only hydraulic sensing
using the TVC valve is used.

207FO5079
2. PUMP CONTROL SYSTEM
‘“‘;““-‘L&J v ,_ ,, :Tczxm..
..___:_~_
-.m.,-,-. . .. ... . .. .
1 (Switch signal)
f I I
r_ (Drive signal)
(Switch signal)
- Pump y(Drive signal):, I
controller ‘ItDrive signal)‘,
I (Travel lever signal)
205FO5144
OUTLINE
l By controlling the main pump discharge
volume according to the stroke of the con-
trol lever, it is possible to reduce the neutral
loss and fine control loss.
l The half flow mode function that is auto-
matically set by the working mode provides
excellent fine control performance.
l The cut-off function and cut-off cancel
function, together with the 2-stage relief
function provide both reduction of relief
loss and increase of digging power.
10-121
I) FLOW CONTROL FUNCTION
PNC (Pump Neutral Control)
l When the control levers are at neutral,
the pump discharge volume is controlled
to the minimum to reduce the wasted
oil flow that occurs when the control
valve is at neutral.
PFC (Pump Fine Control)
l When the lever is operated, the control
for the necessary oil flow is sent to the
pump based on the flow command cor-
responding to the stroke of the lever. In I
this way, the wasted oil flow that Lever stroke L
occurs during fine control is reduced. 205FO5145
l At the same time, by increasing the
pump discharge volume by a suitable
amount to correspond to the stroke of
the lever, the fine control performance
is improved.
+ For detail, see HYDRAULIC PUMP.
2) CUT-OFF (CO) FUNCTION

l When the load increases during opera-
tions and the main pump discharge
pressure rises, it reduces the pump dis-
charge volume when the pressure is
near the relief pressure, and acts to
reduce relief loss.
+ For details, see HYDRAULIC PUMP.
3) CUT-OFF CANCEL FUNCTION

l When the load increases during opera- Pump discharge volume Q
tions and the main pump discharge 205FO5 146
pressure rises, the pump discharge
volume is not cut-off even when the
pressure is near the relief pressure. This Pump discharge volume is
ensures the flow of oil and prevents any not cut-off.
drop in speed.
l Actuation and cancelation of the cut-off
function is automatically determined by
the position of the power max. switch,
travel lever and swing lock switch.
l Operation of switches and cut-off

function
I\i]
Pump discharge volume 0

COfunction Canceled Actuated Canceled Actuated Canceled Actuated
205FO5147
Note I) This is only effective when the

working mode switch is at
IH.01 or LG.01.
1o-1 22
* Quick warming up of hydraulic oil
when swing lock switch is ON
When the swing lock switch is turned
ON, the CO function is canceled.
In this condition, if the work equipment
is rekeved, the hydraulic oil temperature
can be raised quickly to reduce the time
taken for warming up.
4) HALF FLOW MODE FUNCTION

When lF.01 or IL.01 is selected with the
working mode switch, the operation of the
control valve for the arm Hi (acceleration) is
stopped. The pumps actuating the boom
and arm are separated, so the digging
(finishing) operation is not affected by the
load on the other circuit. This improves the
fine control and finishing precision.
l Relationship between working mode
and pump discharge volume (during in-
dependent operation)
%
::
E Boom Arm Travel
C-l Bucket Swing
0 Raise Lower In out L.H. R.H.
H.0
200 100 200 200 100 100 100 100
G.0
F.0
200 100 100 200 100 100 100 100
L.0
I I I I I I I I I I
* The portion for one pump is taken as

100%.
+ When the arm OUT and bucket are
operated simultaneously, the half flow
mode does not function.
5) 2-STAGE RELIEF FUNCTION

When the power max. switch is pushed ON
(Note I), the 2-stage relief solenoid valve
pilot pressure raises the set pressure of the
main relief valve from 325 kg/cm2 to 350
kg/cm2 to increase the digging power.
Note 1) This is only effective wtien the
working mode switch is at LH.01
or LG.01.
lo-123
3. POWER MAXIMIZING FUNCTION
Control valve
-1
Engine
Fuel Governor
injection motor
t (Switch signal) , M
t _ 1(Engine speed signal)

c (Drive signal)
Engine throttle (Throttle signal) t
- Pump controller (Drive signal)
controller (No. 2 thtottle signal)
r-
I t
I
205FO5148
OUTLINE
l By pressing the switch on the left work
equipment lever knob, the maximum digging
power is increased to give superior
production.
lo-124
l When the working mode is switched to
IH.O1 or IG.O1, and the power max. switch is
switched ON, the following functions are
actuated.
Power set H
CO function Canceled
350 kg/cm2
Even when pressed

Length of
continuously, it is
operation
canceled after 8.5 sec.
0
t This function does not work if the working
mode switch is at LF.01or iL.01.
1O-125
4. AUTO DECELERATION SYSTEM
Engine
Fuel control dial

Hi Governor
Fuel injection
motor
(Throttle signal)
L.H. control R.H. control

lever lever f Travel control lever
Oil pres.
switch L (Work equipment -
Pump controller
*(Switch signar j[s]
I (Travel lever signal)
207FO5054
OUTLINE
l This is a fully electronic control type, and , Fuel control dial setting rpm
when all the work equipment, swing and
rpm
travel levers are at neutral, and the pump
controller receives the signal, it sends a
command to the engine throttle controller.
When this is received, the engine throttle
controller drives the governor motor to
reduce the engine speed, thereby reducing 4 set
fuel consumption and noise.
Control lever Neutral Control lever Operation
205FO5150
1O-l 26
OPERATION
When auto-deceleration switch ON
1. If the fuel control dial is set at a position
higher than 1500 rpm, and all control levers
are at neutral, the pump controller receives
the neutral signal and sends the auto-
deceleration signal to the engine throttle
controller.
When the engine throttle controller receives
the signal, it sends the drive signal to the
governor motor to drive the governor motor
and pull back the injection pump governor
lever to the No. 1 deceleration position. It
holds it at this position for approximately 4
seconds. When this happens, the engine
speed is lowered by about 100 rpm from
the dial setting. FO20705001
2. After the levers have been at neutral for

more than 4 seconds, the drive signal is
again sent from the engine throttle control-
ler to the governor motor, and the governor
lever is pulled back and held in the No. 2
deceleration position.
The engine speed in this position is approx.
1400 rpm.
I I
FO20705002
3. In the deceleration condition, if any control

lever is operated, the pump controller re-
ceives the signal and cancels the auto-
deceleration signal sent to the engine throt-
tle controller. When this happens, the
engine throttle controller sends a drive
signal to the governor motor to return the
governor lever to its original setting.
When auto-deceleration switch is OFF

l The engine speed can be set as desired
using the fuel control dial, and even if all the
levers are at neutral, the engine speed is not
reduced.
1O-l 27
5. ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION
Fuel control dial

5 bServo
valve
:;:;::
>:.:.
.:.:..
Servo
valve
$j
.i...
c )_ Engine throttle
(Warming-up signal)
controller
f I
Q)=
I
% zg
za&
g .F
‘5
: 5”g5
F (v
,: (Coolant temp. 102°C signal) -

s 8
,: _ (Coolant temp. 107°C signal) c (Drive signal)

, (Working mode signal) Pump controller
)_
(Power set signal)
-
205FO5 154
OUTLINE
l After the engine is started, this raises the engine
speed automatically to warm up the engine. (Au-
tomatic warming-up function)
In addition, to protect the engine, if the coolant
temperature rises too high, it lowers the pump
load and engine speed to prevent overheating of
the engine. ‘(overheat prevention function)
1O-l 28
I) AUTOMATIC WARMING-UP FUNCTION
l Actuation table
Conditions Action
Coolant temperature: Less than 30°C

Fuel control dial: Below set speed
[set speed: 1,250 rpml
Engine speed: 1,250 rpm
* If all the above conditions are satisfied,
the automatic warming-up function
is actuated.
Coolant temperature: Above 30°C

Fuel control dial: Held above 70% of high idling
for more than 3 sec.
Engine speed: As desired
Warming up time: At least 10 minutes
* If any of the above conditions is applicable, the
automatic warming-up function is canceled.
2) OVERHEAT PREVENTION FUNCTION

l Actuation table
PC300,3OOLC-5 Serial No: 20001 - 21400

PC400,4OOLC-5 Serial No: 20001 - 20602
r T Conditions Action
Power set:
Selected mode Action mode
1 H.0andH.S mode 1 H.0 and Lmode 1

Coolant temperature: 102” - 107°C
(Coolant temperature gauge: G.0 and H,S mode G.L and L mode
Red range)
( F.OandH,Smode 1 F.OandLmode 1
1 L.OandH,Smode 1 L.OandLmode 1
Engine speed: Default mode speed
Coolant temperature: Above 107°C Power set: L mode (same as No. 1 setting)
(Coolant temperature gauge: Engine speed: Low idlig
Red range Warning lamp, buzzer: ON
Coolant temperature: Under 102°C

(Coolant temperature gauge: Power set: Default mode
Green rage) Engine speed: Default mode speed
+ Automatic reset
When coolant temperature is less

Power set: Default mode
than 102”C, return fuel control
Engine speed: Fuel control dial set speed
dial to low idling position.
(as desired)
* Manual reset
’o-A29
PC300,300LC-5 Serial No: 21401 and up PC400,4OOLC-5 Serial No: 20603 and up
PC300HD-5 PC4OOHD-5
Conditions Action
Power set:
Selected mode Action mode

? H.0 and H,S mode H.0 and L mode
‘E
z Coolant temperature: 102” - 105°C
a (Coolant temperature gauge: G.0 and H,S mode G.L and L mode
2 ‘. Red range)
0 F.0 and H,S mode F.0 and L mode
5 z
L.0 and H,S mode L.0 and L mode
2
Engine speed: Default mode speed
~ ? Coolant temperature: Above 105°C Power set: L mode (same as No. 1 setting)
6% (Coolant temperature gauge: Engine speed: Low idling
Z% Red range) Warning lamp, buzzer: ON
O) Coolant temperature: Under 102°C

y.5 (Coolant temperature gauge: Power set: Default mode
u-l
Green range) Engine speed: Default mode speed
z %
* Automatic reset
x
Z
2 %
?I m When coolant temperature is less
Power set: Default mode
hl.g than 102”C, return fuel control dial
Engine speed: Fuel control dial speed
$E to low idling position.
(as desired)
* Manual reset
’o-!!z9-1
6. SWING CONTROL SYSTEM
L.H. control lever

Swing motor h
I Swing brake
solenoid valve
I,
1
es.
h
1
Swing lock
I Monitor panel
I
OFF
0
switch
ON
I, N’ Swing lock
15
I prolix switc
c-‘= I
z cd
.EJ sl
In ‘Z
22 a
0 .z
-’ ,& /
(Swing lock signal) 5’
t / N 0
Pump controller
(Swing lever signal)
,,
,, //
205FO5155B
OUTLINE
0 The swing is controlled comprehensively
both when stopping and when operating
the swing or work equipment, by the swing
lock, swing holding brake, and swing
priority function.
’O-A30
SWING LOCK AND AUTOMATIC SWING l Relationship between swing lock lamp and
HOLDING BRAKE SYSTEM the brake
The swing lock (manual) and swing holding
brake (automatic) are employed to lock the Lock lamp Actuation
swing in the desired position and to prevent
hydraulic drift after stopping the swing. The swing brake is applied
approx. 4 seconds after the
swing or work equipment
control lever is placed at
OFF (switch OFF)
neutral.
(Swing holding
When the swing or work
brake applied)
equipment control lever is
operated, the swing brake is
released and the upper
structure can swing freely.
The upper structure is held in

place by the swing brake, and
even if the swing or work
3N (switch ON)
* Swing lock prolix switch function equipment control lever is
iswing lock applied)
When the pump controller is abnormal operated, the swing brake is
not canceled, so the upper
and the swing holding brake function
structure does not swing.
does not work normally, the swing lock
prolix switch cancels the swing brake
and operates the swing.
* Even when the swing lock prolix switch
Actuation table
is turned ON, the swing lock switch
stays ON and the swing brake is not
canceled.
* When the swing brake is canceled, the
swing has only a hydraulic brake operat-
ed by the safety valve, so if the swing is
stopped on a slope, there may be hy-
draulic drift.
HYDRAULIC OIL QUICK WARM-UP

FUNCTION WHEN SWING LbCK
SWITCH IS ON
+ For details, see PUMP CONTROL
SYSTEM.
10-131
7. TRAVEL CONTROL SYSTEM

Travel motor
g
RBg”lwn
p
:;:i
..:.....i.....- :,:&
_:.:.:: .7x
:,,.yy.&:“._*J
.T.
.....:.:
!....
!z!
,Tv,.,~..~
..,..:
_.........,
R*gY,ator
. ...
!iii(
.’
ES
\ Throttlesignal) 2 ,”
‘Lo HI
90
TRAVEL
SPEED La, -
Pump controller (Drive signal)
(Swing signal) JTravel lever signa I)
4
205FO5156
OUTLINE
l This increases the pump absorption torque
and drawbar pull when traveling.
l The travel performance is improved by
switching the travel speed manually or
automatically.
lo-132
1) PUMP CONTROL FUNCTION WHEN
TRAVELING
When traveling, the following functions are
actuated.
l If any of the working mode and power
set are selected, the working mode and
engine speed stay as they are and the
power set only is switched to the
equivalent of H mode.
* For details, see ENGINE AND PUMP
MUTUAL CONTROL SYSTEM.
2) TRAVEL SPEED SWITCHING FUNCTION
The switching of the travel speed can be
carried out manually or automatically, and
has the following functions.
When the travel speed switch is
switched, the solenoid valve is
switched. The action of the pilot pres-
sure then changes the motor rocker
cam angle and changes the travel speed.
If the speed setting of the fuel control
dial is set to less than approx. 1200
rpm :
l When traveling in Lo, even if it is
switched to Hi, the transmission is
not shifted.
l When traveling in Hi, the transmis-
sion is automatically shifted to Lo.
Automatic switching between Hi and Lo
according to pump discharge pressure
When traveling with the travel speed High speed
Uphill slope
switch at Hi, if the machine travels up a travel
I I
slope and the pressure in the travel cir- (Travel speed (Travel pressure
cuit goes above 310 kg/cm2 for more switch at Hi) continues at
than 1.0 (PC3001, 2.0 (PC4001 second, more than 3 10
the solenoid valve is deactivated kg/cm2 for
(closed) and the travel speed is more than 1 .O
switched to Lo. If the machine continues (PC3001, 2.0
to travel at Lo (with the travel speed (PC400) seconds)
switch still at Hi) and it comes again to
flat ground or travels downhill, and the
pressure
below 210
in the
kg/cm2
travel
for more
circuit
than
drops
1 .O 1EZZri~la~~pe I+ kZYipeed 1
second, the solenoid is excited (opened) (Travel pressure (Travel speed
and the speed is switched again to high continues at switch at Hi)
speed. less than 2 10
* Detection of the pressure in the kg/cm2 for
more than 1 .O
travel circuit when only the travel is
seconds)
being operated is made by sensing
the pressure for both the front
pump and the rear pump, and taking
the higher value; for compound op-
erations, only the sensor for the rear
pump pressure is used.
1o-1 33
8. SYSTEM COMPONENT EQUIPMENT
1) PUMP CONTROLLER
CN-C3 CN-C2 CN-Cl
1. Self-diagnostic
display window
1
\ t--A
\
P h
I
---- --+L!\___=__i’_e&sL
A
===I===
Section A- A
205FO5157
2) ENGINE SPEED SENSOR
i
\
_--
F9
Ii
5
b 0
0.75fG ,
43 0.75fE
2
205FO5158B
1. Magnet FUNCTION
2. Terminal a The engine speed sensor is installed to the
3. Case ring gear of the engine flywheel, and acts to
4. Boot count electrically the number of gear teeth
5. Connector that pass in front of the sonsor. This detec-
tion is carried out magnetically, and the
sensor contains a magnet and detection coil.
3) ENGINE THROlTLE CONTROLLER, FUEL

CONTROL DIAL AND GOVERNOR
MOTOR
* For detail see ENGINE CONTROL
SYSTEM.
4) MONITOR PANEL
+r For detail, see EMACC.
5) TVC VALVE
* For detail, see HYDRAULIC PUMP.
6) Z-STAGE RELIEF1 SOLENOID VALVE
CO CANCEL SOLENOID VALVE
TRAVEL SPEED SOLENOID VALVE
ARM HALF FLOW SOLENOID VALVE
+ For detail, see SOLENOID VALVE
ASSEMBLY.
10-135
7) PUMP PRESSURE SENSOR
Amplifier
Cord
Connector
Flange
Detect module of oil pressure
‘6 6. Introduction pipe of oil pressure
Amplifier
-
205FO5 159A
OUTLINE
l The pump discharge pressure is converted OPERATION
to a voltage, and the signal is sent to the
pump controller. Isolation
To amplifier seam
FUNCTION
l The voltage output is proportional to the
pressure.
t
Oil pressure 205FO5160
When the pressurized oil entering from

pressure introduction pipe (6) is pressurized
by the diaphragm of pressure sensor
module (51, the diaphragm shape changes.
0 100
A bridge is formed on the opposite face of
200 300 400 500
this diaphragm by a strain gauge, and the
Oil pressure P (kg/cm21
deflection of the diaphragm is converted
205FO5161
from a resistance value of the strain gauge
l Relationship between output voltage V (v) to the bridge output voltage and is sent to
and pressure P (kg/cm2). the voltage amplifier (amp).
V = 0.008 x P + 1 .O The voltage is further amplified by the
amplifier, and is output to the controller.
lo-136
8) WORK EQUIPMENT-SWING OIL PRESSURE SWITCH, TRAVEL OIL PRESSURE SWITCH
202FO5 I65
1. Plug SPECIFICATIONS
2. Diaghragm Actuation pressure: 5.0 f 1 .O kg/cm2
3. Back up spring Reset pressure: 3.0 * 0.5 kg/cm2
4. Pin
5. Guide pin
6. Movable contacts
7. Connector
1o-1 37
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)
Monitor panel Relay Electrical parts
Sensor signal Engine throttle controller
Warming-up signal
/
I=
Pump controller
Sensor Power
source Buzzer signal
L:.
Switch signal
1
Coolant temp. signal
Buzzer
Battery
205FO5162
l The electronic monitor and control console l Various modes selector switches are built
(EMACC) observes the condition of the ma- into the monitor panel, and it acts as the
chine through the sensors installed to vari- control portion of the machine control
ous parts of the machine, and processes system.
this information quickly. The system informs
the operator of the condition of the machine
by displaying the condition on the panel.
The content of the panel displays can be
broadly divided into the following.
1. Monitor portion that gives warnings
when any abnormality occurs in the
machine.
2. The gauge portion (coolant temperature,
fuel level) that always informs the condi-
tion of the machine.
lo-138
1. MONITOR PANEL
WORKING MODE
205FO5 163
CdPl CN!PZ
OUTLINE
l The monitor panel has the switch functions
for the electrical parts, mode selection, and
monitor display functions.
It has a built-in CPU (Central Processing
Unit), and processes the data and outputs
the display.
The monitor display uses a liquid crystal dis-
play (LCD). The switches are flat sheet
switches.
MONITOR
PC300,300LC-5 Serial No: 20001 - 21400
PC400,4OOLC-5 Serial No: 20001 - 20602
1. Coolant temperature gauge

2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
\
205FO5164
Classifi-
cation 01
indicatior
Symbol item
I Condition for displaying
abnormalities I
Description
Coolant level Below low level Indicates when placing the starting
switch to ON before starting the
engine.
& Engine oil level Below low level
If it is normal, the lamp goes off.
If it is an abnormalitv. , the lamo
flashes.
Hydraulic oil level Below low level
G L Engine oil pressure 0.5 kg/cm2 max. Indicates while the engine is tunning
and the starting switch is set to ON.
Coolant level Below low level If it is normal, the lamp goes off.
8
If it is an abnormality, the lamp
91 Coolant temperature 107°C min.

flashes and the buzzer sounds.
Indicates when the engine is running

a Charge level When charging system fails. and the starting switch is set to ON.
If it is normal, the lamp goes off.
@I /
Fuel level
I
Below low level
I
If it is an abnormality, the lamp
flashes.
aii6
67 76 83 90 97 102 107T
I:‘.:I
52 Coolant temperature
0-10
1::
:::
OD:;: 0
Appropriate
lights up.
place (one place)
C H
All light up below appropriate

Fuel level
level
When the starting switch is turned to

HEAT position, this pilot lights for 30
Preheat When preheating seconds, then flashes (for 10
m
seconds) to indicate the preheating
is finished.
pC300,300LC-5 Serial No: 21401 and up pc400,40OLC-5 Serial No: 20603 and UP
PC300,3OOLC-5 MIGHTY ~C400,40OLC-5 MIGHTY

PC300HD-5 PC400HD-5
1 2 3 4 5
\ ~lL-L__ I. Coolant temperature

2. Engine oil level caution lamp
3. Coolant level lamp
gauge
4. Coolant temperature caution lamp

5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Engine preheat pilot lamp
10. Hydraulic oil level caution lamp
11. Fuel level guage
li lil ri i 205FO5164
Classifi- Condition for displaying

cation of Symbol Item Description
abnormalities
indication
E Coolant level Below low level Indicates when placing the starting
O!Z switch to ON before starting the
ILL -
engine.
Liz 0 Engine oil level Below low level If it is normal, the lamp goes off.
?% ?-=, If it is an abnormality, the lamp
flashes.
Hydraulic oil level Below low level
a b Engine oil pressure 0.5 kg/cm” max. Indicates while the engine is tunning
and the starting switch is set to ON.
Coolant level Below low level If it is normal, the lamp goes off.
8
z If it is an abnormality, the lamp
OL 102°C (Flash) flashes and the buzzer sounds.
s=
0 Coolant temperature
$ 105°C (Buzzer)
FG Indicates when the engine is running
m Charge level When charging system fails. and the starting switch is set to ON.
/ If it is normal, the lamp goes off.
I @I Fuel level Below low level

If it is an abnormality,
flashes.
the lamp
67 76 83 90 97 102 107°C
\\\I I//
Appropriate place (one place)
Coolant temperature
/ hbddfdQ / lightsup.
All light up below appropriate

Fuel level
level
When the starting switch is turned to

HEAT position, this pilot lights for 30
5 m Preheat When preheating seconds, then flashes (for 10
L seconds) to indicate the preheating
is finished.
’O-it4’
SWITCH
3. Working mode selection switch
i i i 205FO5165
l The switches consist of four mode selector Switch actuation table

switches and four electrical component
switches; every time the switch is pressed, Item Action
the condition of the machine changes. The Working mode G.0 - H.0 - L.0 - F.0
present condition is displayed by the light-
ing up of the LED above the switch. Power set S -H-L
Auto decel ON -OFF
Travel speed Lo -Hi
Fan OFF-Lo-Hi
Wiper OFF -Lo -Hi
Lamp OFF-l -2
Buzzer cancel OFF -ON
* The bold letters indicate the default values

when the starting switch is truned ON.
2. SENSOR
0 The signals from the sensors are input
directly to the monitor panel.
One of the contact points of the sensors
with contacts is always connected to the
chassis GND.
Classification
Type of sensor Sensing type Normal Abnormal
of indication
Coolant level Contact type ON (close) OFF (open)
CHECK
MONITOR Engine oil level Contact type ON (close) OFF (open)
GROUP
Hydraulic oil level Contact type ON (close) OFF (open)
CAUTION Engine oil pressure Contact type QFF (open) ON (close)
Coolant temperatrue Resistance type - -

GAUGE GROUP
Fuel level Resistance type - -
1) COOLANT LEVEL SENSOR
1. Sub-tank
2. Float
3. Sensor
4. Connector
205FO5166
ENGINE OIL LEVEL SENSOR
HYDRAULIC OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
A
205F05167A
ENGINE OIL PRESSURE SENSOR
2 3 4 5 6
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
205FO5169
5) COOLANT TEMPERATURE SENSOR
1. Connector
2. Plug
3. Thermister
w
205F05170A
’o-ih44
6) FUEL LEVEL SENSOR
1. Float
2. Connector
3. Cover
% 4. Variable resistance
/ \
Section A- A
205FO5171
1O-&45
20 TESTING AND ADJUSTING
Table of judgement standard ......................

value .. 20- 2
Standard value table for electrical system ................ 20-27
Tools for testing, adjusting, and troubleshooting .......... . . . 20-39
Adjusting valve clearance ............................... . 20-40
Measuring compression pressure ........................ . 20-42
Testing and adjusting fuel injection timing ................ 20-43
Testing and adjusting travel of governor motor lever ....... 20-45
Adjusting engine speed sensor .......................... . 20-46
Testing and adjusting hydraulic pressure in
work equipment, swing, travel circuit ................. . 20-47
Testing and adjusting charging pump pressure _ . . . 20-50
z Testing and adjusting main pump control pressure ........ . . 20-52
z Testing and adjusting ....................
travel deviation . 20-59
: Measuring stroke of servo piston ........................ .. 20-62
Measuring output pressure of PPC valve .................. . 20-63
Adjusting work equipment, swing PPC valve . . _ . 20-64
Testing PPC shuttle valve ............................... .. 20-65
Measuring solenoid valve outiet port pressure ............. .. 20-67
Testing locations causing hydraulic drift of work equipment .. 20-68
Bleedingair ............................................ .. . 20-69
Releasing remaining pressure in hydraulic circuit .......... 20-7 1
Handling connectors ................................... . 20-72
Troubleshooting . . . . . .._...._..._____.______________________________................... 20-73
ABefore performing inspection, adjustment or faultfinding, park the machine on level ground and
check the safety pin and chock.
A When performing joint work, make appropriate signals and allow only authorized personnel near
the machine.
A When checking the water level, allow the engine to cool down before removing the radiator cap to
prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
A Take great care to avoid getting caught in rotating parts such as the fan, etc.
TABLE OF JUDGEMENT STANDARD VALUE
. FOR ENGINE
Machine model PC300 PC400
Engine SAGD108-1 S6D125-1
Item Measurement conditions Unit

i’;
i
High idling wm
Engine speed Low idling rpm 650 +I 4o

-50
Rated speed rm 1,950

I _
Bosch
At sudden acceleration Max. 8.5 10.2 Max. 5.0 7.0
index
Exhaust gas color
Bosch
At high idling Max. 1.5 / 2.5
index
I
lnta ke valve mm 0.34 -
Valve clearance
(normal temperature)
Exhaust valve mm 0.66 -
Compression pressure
(SAE 30 oil)
Oil temperature:40
(Engine speed)
- 60” 1
C kg/cm z
(rpm)
Min. 28
(250 - 300) (250 “_” 3001
Min. 32
(200 - 250) (200 2_”250)
(Coolant temperature:
Blowby pressure
Operating range) mmH,O Max. 150 300 Max. 80 1 160 i
(SAE oil)
At high idling
(Coolant temperature:
Operating range)
At high ldllng (SAE30) kg/cm 2 3.0 - 5.0 3.0 - 5.0 3.0 - 5.0 2.1
Oil pressure
(SAE~ owl kg/cm2 Min. 1.2 0.8 Min. 1.5 0.7
At low ldllng (SAE30) kg/cm’ 2.5 - 4.5 2.5 - 4.5 2.5 - 4.5 1.8
(SAEl OW) kg/cm* Min. 1.O 0.7 Min. 1 .O 0.7
“C go- 110 120 80- 110 120

)
I
1
0
24 zt 1 -
I I
Between fan -
Deflection 11 - 12
-I
and alternato r
when pressed
Belt tension with finger
force of Between fan ---t-----
approx. 6 kg. and water
pump
5--7 AL-
l FOR CHASSIS (PC300,3OOLC-5, PC300,300LC-5 MIGHTY, PC300HD-5)
* The standard values and permissible values shown in this table are all values for H.0 (heavy-duty
operation) and H mode.
Machine model
T PC300
Classifi
Item Measurement conditions Unit Standard value Permissible value
cation
Hydraulic oil temperature: 45 - 55°C

At l-pump relief Engine oil pressure:
Within operating range
. Coolant temperature: 2,100 * 100 _
At 2-pump relief 1 -pump relief: Bucket relief
. 2-pump relief: Arm relief
Speed when auto-
. Fuel control dial at MAX.
deceleration is 1.400~120 1,400i 120
actuated
. Control lever at neutral
Boom-Lo control
valve
I
P a b Q
a
mm 11 It 0.E I1 + 0.51 11 * 0.5
Bucket control valve
Swingconlrolvalvel
’ 202F2302
Travel control valve
ci 1;,a,
;;;~,;;t~~~~,av
Read max. value to end of travel
65*10
65110
Max. 75
Min. 55
Max. 75
Min. 55
Max. 75
Bucket control lever 65210
Min. 55
mm
Max. 75
Swing control lever 65?10
Min. 55
Max. 121
Travel control lever 110*11
Min. 99
Play of travel lever Max. 15 Max. 20

I
Boom control lever Engine at high idling 2.3tO.3 Max. 3.1
Oil temperature: 45-55°C
‘. Fit push-pull scale to center of
1.8t0.3 Max. 2.6
1.8tO.3 Max. 2.6
Swing control lever 2.3iO.4 Max. 3.1
Lever 3.0 * 0.75 Max. 4.8

Pedal a.4 * 2.1 Max. 13.4
Machine model PC300
Classi
Item Measurement conditions Unii Standard value Permissible value
catior
Boom . Oil temperature: 45 - 55°C

Relief pressure with engine at
high idling
(Relieve only circuit to be Max. 345
325 f 10
Arm measured) Min. 315
H.0 and H mode
. ( ) : When using power
maximizing (reference) (350:;:)
Bucket
At outlet of pump
* Oil pressure when travel is
relieved on one side.
+I5 Max. 310
Swing 285 -5 Min. 280
120 Max. 370

Trave I 340 o
Min. 340
Max. 38
Charging pump 32 ‘06
Min. 30
. Oil temperature Control lever at

Max 18
45-55°c neutral
. Engine at high
idling 1 -pump relief
. H.0 and
TVC valve output H mode [2pump average
pressure oil pressure1
PI +p* =,,I)-,180 Max. 20
2 kg/cm’ 19f 1
Min. 17
g/cm
. Oil temperature: Control lever
45 - 55’c 3t neural
. Engine at high CO valve not Max. 5 Max. 5.5
idling actuated, NC
. H.0 and H mode : valve actuated
. Measure at NC
valve outlet port Travel lever at full,
track rotating freely
I
CO. NC valve CO valve, NC Min. 18 Min. 18
output pressure
. valve both not
. actuated
‘ump relief
-CO valve actuated
Max. 5 Max. 5.5
NC valve not
.actuated
Lever at Oil temperature: 45 - 55°C

Max. 24
neutral Engine at high idling 21 *3
Min. 18
Control lever at neutral
t sensor
Fferentiai
eaure
Oil temperature: 45 - 55°C
Lever at end Engine at high idling
of travel Control lever at end of travel Max. 2.5 Max. 2.5
(Pump discharge pressure as
desired)
Machine modal PC300
Classi
cati or Measurement conditions Unit Standard value Permissible value
Working equipment Max. reach
202F232 Deg.
Swing brake angle Engine at high idling Max. 78 Max. 88
(mm)
. Hydraulic oii temperature: 45 - 55’1
. Stop after swinging one turn
and measure distance that swing
circle moves
( ): Distance of movement on
outside circumference of
swing circle
Nork equipment Max. reach 1
90” 3.4 * 0.3 Max. 4.0
Time taken to start sec.

swing Engine at high idling
Hydraulic oil temperature:
45 - 55°C
H.0 and H mode 180’ 5.0 * 0.5 Max. 6.0
Time taken from starting
position to swing 90” and
180”
.-P
c?J Work equipment Max. reach
posture
Time taken to swing sec. 30 + 2 Max. 36
. Engine at high idling 202F2323

. Hydrau lit oil temperature:
45-555Oc
H.0 and H mode
Swing one turn, and measure time
taken to swing next 5 turns
Hydraulic drift of
Engine stopped
swing mm 0 0
45 - 55°C
Set machine on 15’ slope, and set
upper structure at 90’ to the side.
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart after 5 minutes.
Engine at high idling

Leakage from swing Hydraulic oil temperature:
45 - 55°C !/min Max. 5 Max. 10
motor
* Swing lock switch ON
Relieve swing circuit.
Machine model
T PC300
Classifi-
cations
I
PC300 PC3OOLC PCBOOHD PC300 PC3OOLC PCBOOHD
--
LO
0.6 + 3 53.8 k : 76,, * 3 Max. 56.6 Max. 59.8 82.1
Min. 47.6 Min. 50.8
Travel speed (1)

sec.
. Hydraulic oil temperature:
45 - WC
. H.0 and H mode Hi
Max. 35.3 Max. 37.3
1.3 i 2 33.3 k 2 43.3 ?I 2 Min. 29.3 Min. 31.3
Max. 47.3
Min. 41.3
. Raise track on one side
at a time, rotate one turn,
then measure time taken
for next 5 turns.
- 4
25.2 Max. 25.2 Max. 31.0

Lo 1.2 * 2 !I.2 + 2 29.0 * : Max.
Min. 19.2 Min. 19.2 Min. 27.0
2MF2409
Travel speed (2) sec.

s
. Engine at high idling
6
. Hydraulic oil temperature: z
45 - 55°C
Hi Max. 17.1 Max. 17.1 Max. 20.4
H.0 and H mode 3.1 +2 13.1 k 2 16.4 + 2
Min. 11.1, Min. 11.1 Min. 14.4
. Run up for at least 10 m,
and measure time taken to
travel next 20 m on flat
ground.
205F2409

45-55°c
Travel deviation Run up for at leats lOm, and mm Max. 200 Max. 220
measure deviation when travel-
ing next 20 m on flat ground.
l Use a hard horizontal surface
I 20 m
+z-& 205F2402
l Measure dimension x
Machine model PC300
Class?
Measurement conditiom Unit Standard value Permissible value
catiol
-
Hydraulic drift of
mm
travel
Engine stopped
45- 55°C
‘Stop machine on 12” slope
with sprocket facing straight
up the slope.
Measure the distance the
machine moves in 5 minutes.
-
Leakage of travel Lock/pin !/mir Max. 20 Max. 40

motor F207K?cc*

* Hydraulic oil temperature:
45-55°C
. Lock shoes and relieve travel
circuit.
Work equipment posture

Total work equip-
ment (hydraulic
drift at tip of Max. 450 Max. 675
bucket teeth)
Boom cylinder
(amount of
retraction of Max. 25 Max. 38
cylinder)
. Place in above posture and
measure extension or retraction
of cylinder and downward
mm
movement at tip of bucket teeth.
. Bucket: Rated load
Arm cylinder . Horizontal, flat ground
(amount of . Levers at neutral Max. 135 Max. 203
extension of . Engine stopped
cylinder) . Hydraulic oil temperature:
45-5!9c
. Start measuring immediately
after setting.
. Measure hydraulic drift for each
Bucket cylinder 5 minutes, and judge from results
(amount of for 15 minutes.
retraction of Max. 20 Max. 30
cylinder)
Machine model PC300
Classifi
cation
Item
T Measurement conditions Unit Standard value Permissible value
Boom
Bucket teeth in 3.5 rt 0.4 Max. 4.3
contact with
ground
C
cylinder fully . Engine at high idling
3.1 * 0.3 Max. 3.7
extended . Hydraulic oil temperature:
45-555°c
. H.0 and H mode .-
Arm 4.1 i 0.4 Max. 4.9

Cylinder fully
retracted
5
205F2422
fully extended . Engine at high idling
3.1 * 0.3 Max. 3.8
45-55Oc
. H.0 and H mode
4.8 f 0.5 Max. 5.8

But ket z
Cylinder fully
retracted z
Sec.
2
5 205FZb23
fully extended . Engine at high idling

2.8 i 0.3 Max. 3.4
45 - 5&c
. H.0 and H mode
Boom Max. 3.0
Lower bucket to ground and

measure time taken for chassis
to rise from ground
. Engine: Low idling
45-55Oc
Arm
Max. 3.0 -
. Amount of time when arm stops

for a moment.
45-55°c
Machine model PC300
Classifi
Item Measurement conditions Unit Stand value Permissible value
cations
Bucket Sec. Max. 3.0 -
. Amount of time when bucket

stops for a moment.
45-55°c
Cylinders Max. 4.5 Max. 20

45-55OC clmir
Relieve circuit to be measured
Center swivel
Max. 10 Max. 50
joint

45-55°C
* Use a hard horizontal surface.
20 m
Travel deviation
mm Max. 400 Max. 440
(travel and work
equipment)
205F2402

45-55Oc
. Measure with engine running at
Charging pump rated speed. Min. 82
Min. 90
. At relief valve set pressure
2lmin
(32 kg/cm* )
Piston pump See next page See next page

Classifi-
cation Discharge volume of PC300 main piston pump (H mode)
I
3
0
I 100 200
Pl + P2
Pump discharge pressure = 2
300
(kg/cm’ )
400
205FO5644A
Pump rated speed: 1,950 rpm
Discharge pressure Discharge pressure AveragePressure Standard value Judgement standard

for discharge
Check point of test pump of other pump
amount
) (kg/cm*)
(kg/cm’ 1 (kg/cm’
I I I I I
P, + P, See graph
As desired P, P, See graph (Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these ponts.
+ When measuring with the pump mounted on the machine, if it is not possible to set the engine
to the specified speed with the fuel control dial, use the engine speed and pump discharge
amount as a base to calculate the pump discharge amount at the specified speed.
Clanifi-
cation
Discharge volume of PC300 main piston pump 6 mode)
Pl + P2
Pump discharge pressure = - (kg/cm2 1
2
Discharge pressure Discharge pressure Average Pressure Standard value Judgement standard
of test pump of other pump for discharge value
Check point
amount
1kg/cm’) kg/cm*) (kg/cm’ ) 0 (Q/min) 0 (Q/min)
pl+p2 See graph

As desired PI P, See graph
2 (Lower limit)
when measuring.
+ When measuring with the pump mounted on the machine, if it is not possible to set the engine
Classifi-
cation Discharge volume of PC300 main piston pump (L mode)
Pl + P2
Pump discharge pressure = - (kg/cm2)
2 205F05742A
Standard value Judgement stand=d

Discharge pressure Discharge pressure Average Pressure
for discharge value
Check point of test pump of other pump
amount
(kg/cm* 1 (kg/cm’) (kg/cm’ ) Q (Qlmin) Q’(Q/min)
As desired PI + P, See graph

PI P, See graph
2 (Lower limit)
* Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
* When measuring with the pump mounted on the machine, if it is not possible to set the engine
2022
TABLE OF SPEEDS FOR S, L MODES
f The values in this table are reference values for the speed of the work equipment, swing, and travel
when switching from H.0 and H mode to other modes
Classifi
Measurement condition Unit PC300-5 PC3OOLG5
cation
s.o+s I=.o +s L.0 +I ;.o+s F.O+S L.o+L

mode mode mods mode mode mode
Boom
. Measure full stroke for each 3.8 3.8 4.6 3.8 3.8 4.6
(Bucket teeth in
* 0.4 * 0.4 f 0.8 f 0.4 * 0.4 * 0.5
contact with cylinder (for boom only,
ground *cylinder measure time taken to lower
fully extended) to the ground)
Set the machine on a flat 3.2 3.2 3.4 3.2 3.2 3.4
horizontal surface. rl: 0.3 f 0.3 It 0.3 f 0.3 * 0.3 * 0.3
. No load in bucket
. Hydraulic oil temperature: 4.5 8.0 10.0 4.5 8.0 10.0
Arm 45 - 55°C f 0.5 kO.8 fl.O f 0.5 f 0.8 * 1.0
SX.
(Cylinder fully . When measuring boom: arm,
retracted cf fully bucket cylinders fully retracted
extended) . When measuring arm: top 3.4 3.4 3.7 3.4 3.4 3.7
surface of boom horizontal * 0.3 * 0.3 f 0.4 f 0.3 f 0.3 * 0.4
bucket cylinder fully
reta rat ted
. When measuring bucket: top 4.9 4.9 6.2 4.9 4.9 6.2
Bucket surface of boom horizontal, * 0.5 rt 0.5 f 0.6 f 0.5 f 0.5 rt 0.6
(Cylinder fully arm cylinder fully retracted
I
retracted h
fully extended) 2.9 2.9 3.0 2.9 2.9
* 0.3 * 0.3 It 0.3 * 0.3 f 0.3
No load in bucket
Time taken to . Swing one turn, then measure 13.3 13.3 16.7 13.3 13.3 16.7
Sec.
swing time taken to swing next * 0.7 jz 0.7 i 0.8 * 0.7 f 0.7 * 0.8
two turns.

22.2 22.2 27.5 23.6 23.6
k 1.1 fl.l il.4 * 1.2 * 1.2
45 - 55Oc
Travel speed Raise track on one side at a time, sec.
rotate one turn, then measure
14.0 14.0 17.6 14.9 14.9
time taken to rotate the next
t 0.7 * 0.7 * 0.9 It 0.7 * 0.7
two turns.
. Amount of deviation when

traveling 20 m as shown below
l Us a hard horizontal surface.

Travel deviation
205F2402
* Measure dimension x
20613
l FOR CHASSIS (PC400, 400LC-5, PC400, 4OOLC-5 MIGHTY, PC400HD-5)
+ The standard values and permissible values shown in this table are all values for i-l.0
(heavy-duty
operation) and H mode.
Machine model
T PC400
Classifi
cation
. Hydraulic oil temperature: 45 - 55°C

At l-pump relief Engine oil pressure:
. . Coolant temperature: 2,100 f 100 _
At 2-pump relief . l-pump relief: Bucket relief mm
. Z-pump relief: Arm relief
Speed when auto-
deceleration is
. Fuel control dial at MAX.
. Control lever at neutral 1,400t120 1.400~120
actuated
Boom-Lo control
valve !? a b -J-JY--
I
7
Boom-Hi control
valve
Arm-Lo control valve
Arm-Hi control valve mm ILtC 1.5 1 1 * 0.5 - 11 f 0.5 11 i 0.5
Bucket control valve
202F2302
Swing control valve
k2 Travel control valve

5 -
0
=I ;p,;~;;;~;~~,c,,
Max. 75
65tlO Min. 55
Read max. value to end of travel
Max. 75
65*10
Min. 55
Max. 75
65ilO
Min. 55
mm
Max. 75
65rlO
Min. 55
Max. 131
120t11
Min. 109
Max. 15 Max. 20
Boom control lever Engine at high idling 2.3 f 0.6 Max. 3.8
Oil temperature: 45-55°C
Fit push-pull scale to center of
Arm control lever control lever knob to measure 1.8 + 0.5 Max. 3.0
Measure max. value to end of
travel
Bucket control lever 1.8 * 0.5 Max. 3.0
Swing control lever 2.3 f 0.6 Max. 3.8
Lever 3.0 Max. 4.8

Pedal 8.4 * 2.1 Max. 13.4
Machine model PC400
Classi
item Measurement conditions Unit Standard value Permissible value
catior
Boom . Oil temperature: 45 - 55’C

. Relief pressure with engine at
high idling
(Relieve only circuit to be Max. 345
325 f 10
Arm measured) Min. 315
. H.0 and H mode
. ( ) : When using power
maximizing (reference) (358f:00)
Bucket
. At outlet of pump
* Oil pressure when travel is
relieved on one side.
Swing Max. 300
275 +I5
-5 Min. 270
Max. 370
Travel 340 I;;
Min. 330
Max. 38
Charging pump 32 +6
0 Min. 30
. Oil temperature:
45 - 55°C Control lever at 27 + 1 Max. 18
neutral
. Engine at high
idling l-pump relief
H.0 and
TVC valve output H mode
pressure
Max. 21
20 * 1
Min. 18
. Oil temperature: Control lever at

45 - 55°C neutral
Max. 5 Max. 5.5
. Engine at high CO valve not
idling actuated, NC
. H.0 and H mode valve actuated
. Measure at NC
valve outlet port Travel lever at full,
track rotating freeb
CO . NC va Ive Min. 18 Min. 18
output pressure
Pump relief
CO valve
actuated, NC Max. 5 Max. 5.5
valve not
actuated
. Oil temperature: 45 - 55’C

Max. 24
. Engine at high idling 21 * 3
Min. 18
. Control lever at neutral
Oil temperature: 45 - 55’ C

Lever at end Engine at high idling
Control lever at end of travel Max. 2.5 Max. 2.5
(Pump discharge pressure as
desired)
Machine model PC400
Classi Standard value Permissible value

Measurement conditions
ficatio
‘osture of work equipment: Max. reach

BACK HOE
202F2323
LOADING SHOVEL
iwing brake angle Max. 90 Max. 120

(degree)
2lNF01201
Engine speed: High idling

Oil temp.: 45 - 55°C
Put match marks on the swing circle outer race and
the track frame. Swing the upper structure 360”, then
stop it. Measure the distance between the match
marks after the upper structure comes to a stop.
Distance between match marks (mm)
‘osture of work equipment: Max. reach

BACK HOE
90 3.6 s 0.4 Max. 4.4
LOADING SHOVEL
Yme taken to
itart swing (sec.)
. Engine speed: High idling

180 5.3 * 0.5 Max. 6.3
l Oil-temp.: 45 - 5s”C
l H.0 and H mode
l Measure the time required for the upper
structure to swing from its starting position
past the 90” and 180” points.
Posture of work equipment: Max. reach

l BACK SHOE
202F2323
. LOADING SHOVEL
Normal swing speed 32 i 2 Max. 38
(sec.)
l Engine speed: High idling

l Oil temp.: 45 - 55°C
l H.0 and H mode
l Measure time taken to swing for 5 turns, after
swinging one turn as an approach swing.
2027
Machine model PC400
Class
Measurement conditions Standard value Permissible value
ficatic
Posture of work equipment: Max. reach

l BACK HOE
2lNF01202
l LOADING SHOVEL
Hydraulic drift
of swing 0 0
(mm)
2INF01203
) Engine: Stopped
m Oil temp.: 45 - 55°C
) With the tracks facing uphill on a 15” slope, turn the
upper structure to 90’ angle.
l Put match marks on the swing circle outer race and
the track frame. Wait 5 minutes, then measure the
distance between the match marks.
Swing parking brake switch: ON

Leakage of swing
motor Max. 5 Max.10
l Relieve oil in swing circuit
(Urnin.)
l Measure leakage from swinq motor with measuring
cylinder.
Travel posture PC4OOLC PC4OOLC

PC400 PC400
l BACK HOE PC400HD PC400HD
Low
Max. 67.5 Max. 71.2
61.5 + 3 65.2 i 3
Min. 58.5 Min. 62.2
205F2427
l LOADING SHOVEL
Travel speed (I)
(sec.)
Max. 38.6 Max. 40.8

High 34.6 + 2 36.8 + 2
l Engine speed: High idling Min. 32.6 Min. 34.8
l Oil temp.: 45 - 55’C
l H.0 and H mode
* Raise one track off the ground, let it spin one

revolution, then measure the time required for
it to spin 5 revolutions.
Repeat this procedure for the other track.
2061 8
Machine model PC400
Classi Permissible value

Item
ficatia
Travel posture PC4OOLC PC4OOLC

PC400 PC400
m BACK HOE ‘C400HD PC400HD
LOW
Jax. 27.2 Max. 27.2
23.2 + 2 23.2 i 2
Win. 21.2 Min. 21.2
205F2409
. LOADING SHOVEL
Travel speed (2)
(sec.)
a ‘, ,.. : ,, .; .r.5’ )’
2lNFOl205 High 13.1 j, 2

rr/lax.
17.1
IMin. 11.1
Max. 17.1
Min. 11.1

l H.0 and H mode
. On a flat surface, make an approach run of

at least 10 r-n, then measure the time
required for the machine to travel 20 m.
Travel posture
. SACK HOE
205F2409
. LOADING SHOVEL
Travel deviation Max. 200 Max. 220

lmm)
) Engine speed: High idling

b Oil temp.: 45 - 55°C
B On a flat surface, make an approach run of at least
10 m, then travel another 20 m. Measure the travel
deviation.
20 m
I- -I
I
205F2402
* Measure dimension P.
Machine model PC400
Class
Item Measurement conditions Standard value Permissible value
ficatic
Hydraulic drift of
travel 0
F20703007
(mm)
l Engine: Stopped
l On a slope of 12”. stop the machine with the sprocket
sections on the upper side of the slope.
l Wait 5 minutes, then measure the distance the
machine moves.
Leakage of travel
motor Max. 20 Max. 40
@/min.)
Lock pin
F20703008
l Engine oG;---d: High idling

* Oil temp.: 45 - 55°C
l Relieve oil in travel circuit with lock track shoe.
Machine model PC400
Classi
IT
ficatio n
Measurement conditions t Standard value
T Permissible value
Posture of BACK HOE BACK LOADING BACK LOADING

HOE SHOVEL HOE SHOVEL
Entire work equipment

(Hydraulic drift at the
tip of bucket teeth)
(mm) Max. 600 Max. 600 900 900
Posture of LOADING SHOVEL
Boom cylinder
(Retraction of
Max. 25 Max. 25 38 38
cylinder)
(mm)
2DDF1002
l In the posture shown above, measure the

extension and retraction of each cylinder as well
as the hydraulic drift at the tip of the bucket teeth.
Arm cylinder l Work equipment rated load:
BACK HOE: 6,840 kg
(mm)
LOADING SHOVEL: 9,900 kg
:BACK HOE:
l Flat level surface Max. 85 Max. 85 128 128
Extension)
:LOADING SHOVEL: l Control levers in neutral
Retraction) l Engine: Stopped
l Start measuring immediately after setting.
l Measure the hydraulic drift every 5 minutes,
and make judgement after 15 minutes.
( ): Unloaded
3ucket cylinder
Retraction of
Max. 30 Max. 30 45 45
:ylinder)
(mm)
‘osture of work equipment

b BACK HOE
3.8 + 0.4 4.7 It 0.5 4.6 5.7
3ucket teeth on the

ground
l LOADING SHOVEL
t
Cylinder fully
extended
(sec.)
4.3 i 0.4 3.7 5.2

l H.0 and H mode
Machine model PC400
‘osture of work equipment BACK OADING BACK .OADING

’ BACK HOE HOE SHOVEL HOE SHOVEL
i.8 !c 0.5 3.9 i 0.4 5.8 4.7
Cylinder fully retracted

205F2422
) LOADING SHOVEL
r
Cylinder fully extended

(sec.)
!.8 3t 0.3 4.7 3.4

2lNF01207
1 Engine speed: High idling

1Oil temp.: 45 - 55’C
1H.0 and H mode
‘o-ture of work equipment
’ BAG !“?E
::
6
I.8 k 0.5 3.5 j, 0.7 5.8 7.9 2
Noload { c /
3ucket %.,‘::=z&&“*.~:~
.;...._?.. ..X‘b.r?6)F
205F2423
3ylinder fully retracted ’ LOADING SHOVEL

(sec.)
3.5 4.0
No load 3
.; .- ., .,
* Oil temp.: 45 - 55’C 2lNF0120.3
l H.0 and H mode
Posture of work equipment

l LOADING SHOVEL
1.8 i 0.2 _ 2.2
Bottom dump
Cylinder fully retracted

\ /
(sec.)
21NF01209
- 2.1 _+0.2 - 2.5
Engine speed: High idling
1
l
* Oil temp.: 45 - 55’C

l H.0 and H mode
-
20-g -1
Machine model PC400
Classi-
ficatior t Standard value
BACK OADING
r Permissible value
BACK .OADING
HOE ;HOVEL HOE SHOVEL
) BACK HOE
205F2424
1 LOADING SHOVEL
Boom
(sec.) Vlax. 3.0 Wax. 3.0 flax. 3.0 -
-_ .‘.. ,. ,’ ; “.‘., ._ .‘i.,.
2l’NFOl210
) Engine speed: Low idling

1Oil temp.: 45 - 55°C
1 Measure the time it takes for the front of the
machine to be lifted off the ground, starting
from the time the bucket contacts the ground.

1 BACK HOE
205F2422
) LOADING SHOVEL
Arm (sec.) Vlax. 3.0 IVlax. 3.0 Wax. 3.0
; ‘_
2lNFOl2l I
l Engine speed: Low idling

l Time required to momentarily stop the arm.
Machine model PC400
Classi,
T
ficatiol n
l
BACK HOE
BACK
HOE
.OADING
SHOVEL
BACK
HOE T
L.OADING
SHOVEL
l LOADING SHOVEL
Bucket
(sec.) Max. 3.0 Max. 3.0 Aax. 3.0 -
‘\ /
I ._ . ->c.,
,” ,’ 1 __ I .
2jNF01212

l Time required to momentarily stop the bucket.
Bottom dump (sec.)

- Max. 3.0
_ -

l Time taken for bottom dump to move again when
operated from max. bottom open position and
stopped temporarily.
Fach cylinder
Max. 4.5 Max. 20
(cc/min.)
l Oil temperature: 45 - 55°C
l Oil pressure: 31.4 :::A, MPa
t10
(320 -5 kg/cm2)
Swivel joint
Max. 10 Max. 50
(cc/min.)
Machine model PC400
Classi-
Standard value Permissible value
ficatiol

l Drive the machine while operating the work
equipment. Make an approach run of at least
10 m, then travel 20 m on a flat surface.
Travel deviation when

operating the work
&if*
equipment while Max. 400 440
traveling
(mm)
205F2402
l Measure dimension P.
l Engine speed: Rated speed

Charging pump discharge
l Hydraulic oil temperature: 45 - 55°C Min. 90 82
(Urnin.)
l Relief pressure is 3.14 MPa (32 kg/cm2)
20-g-4
Classifi-
cation
Discharge volume of PC400 main piston pump (H mode)
“‘j’ ‘.
I I.!.
‘.
:..
Pump discharge Pressure = v (kg/cm’)

205F05646A
I I I I /
p, + p, See graph
As desired PI P2 See graph (Lower limit)
when measuring.
Ciassifi-
cation
Discharge volume of PC400 main piston pump 6 mode)
3oc
c
b
1:
200
1
:.:....
::
I::
-----xi
:
..
.’
::
:‘:
.... .
;’
:,::
:‘.
100
Pump discharge pressure = v (kg/cm’)

205F05647A
I I I I
p, See graph
As desired P, P* See graph
2 (Lower limit)
when measuring.
Clanifi-
cation
Discharge volume of PC400 main piston pump (L mode)
I-
3
1
Pl + P2
Pump discharge pressure = - (kg/cm’)
2 205F05648A
Standard value Judgement standard

Discharge pressure Discharge pressure Average Pressure for discharge value
Check point of test pump of other pump amount
a’ (Q/min)
(kg/cm*) (kg/cm2 ) (kg/cm’ ) Q (Qlmin)
I I I I I
p1+p, See graph

As desired PI P* See graph (Lower limit)
2
when measuring.
to the specified speedswith the fuel control dial, use the engine speed and pump discharge
TABLE OF SPEEDS FOR S, L MODES
* The values in this table are reference values for the speed of the work equipment, swing, and travel
when switching from H.0 and H mode to other modes
Classifi-
Measurement condition Unit PC400-5 PC4OOLC-5
cation
z.o+z ; F:.o+s _.OiL

mode Inode mode
Boom
4.2 4.2
(Bucket teeth in . Measure full stroke for each
+ 0.4 i: 0.4
contact with cylinder (for boom only,
ground *cylinder measure time taken to lower
fully extended) to the ground)
. Setthe machine on a flat 3.2 3.4 3.2 3.2 3.4
horizontal surface. * 0.3 * 0.4 * 0.3 * 0.3 f 0.4
No load in bucket
Hydraulic oil temperature: 12.7
Arm 45-55°c & 1.3
SW.
(Cylinder fully When measuring boom: arm,
retracted * fully bucket cylinders fully retracted
extended) . When measuring arm: top 4.1 4.4
surface of boom horizontal f 0.4 k 0.4
bucket cylinder fully
retaracted
When measuring bucket: top 5.0 6.4
Bucket surface of boom horizontal, It 0.5 * 0.6
(Cylinder fully arm cylinder fully retracted
retracted *
fully extended) 3.1 I 3.1 I 3.7 3.1 3.7
f 0.3 * 0.3 i 0.4 * 0.3 i 0.4
. No load in bucket
.-P Time taken to . Swing one turn, then measure Sec. 14.6 14.6 18.4 14.6 14.6
3 swing time taken to swing next + 0.7 * 0.7
03 * 0.7 * 0.7 f 0.9
two turns.

30.0 36.8
* 1.5 j, 1.8
45-555OC
Travel speed . Raise track on one side at a time, sec.
rotate one turn, then measure
16.2 16.2 20.2
time taken to rotate the next
* 0.8 * 0.8 * 1.0
two turns.
. Amount of deviation when

traveling 20 m as shown below
l Us a hard horizontal surface.

Travel deviation
205F2402
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
*Note 1: (Male) and (Female) in the Connector No. column indicates the mating at the terminal
(pin). (For details, see CONNECTION TABLE FOR CONNECTORS).
2: The figure in ( ) in the Judgement table column indicates the pin number.
Classif:i. Measurement
Component Connector No. Judgement table
cation S conditions
If the condition is as shown in the 1) Turn starting

table below, it is normal switch OFF.
2) Disconnect
Between (1) - (2) I 0.25 - 7kCZ connector.
Fuel control dial E6 (Male)
Between (2) - (3) 0.25 - 7 kR
I
Between (1) - (3) 4-6162

2) Disconnect
Between (1) - (2) 0.25 - 7k.Q
connector.
Potentiometer E4 (Male)
Between (2) - (3) 0.25 - 7k.D
Between (1) - (3) I 4-6162

table below, it is normal switch OFF
2) Disconnect
Between (1) - (2) I 4-952 I
connector
Between (3) - (4) 4-9D

I I
Motor E5 (Male)
Between (1) - (3) I No continuity i
I (1) - chassis
I
No continuity
(3) - chassis No continuity
T Power source
voltage
If the condition is as shown in the
table below, it is normal
Between (1) - (12)

1) Turn starting
switch ON.
2) Insert
T-adapter.
Between (2) - (12)
1) Turn starting
switch ON.
2) Insert
Fuel control dial T-adapter.
(Throttle signal)
El

table below, it. is normal switch ON.
2) insert
T-adapter.
Governor ii
Potentiometer
Between (6) - (16) 4.75 - 5.25V

Classi, Measurement
cation
Component Connector No. Judgment table
conditions

tabe below, it is normal switch ON.
No. 2 throttle
signal 2) Insert
Between (9) - (19) 0.25 - 4.75v
T-adapter
If the condition is as shown in 1 I Turn starting

the table below, it is normal switch ON.
I I I I
Warming-up 2) Insert
Between
1 When warming up 1 Max. 1V ) T-adapter.
signal
(21) - (12)
When canceled a-12v

table below, it is normal switch ON.
Auto-deceleration 2) Insert
signal T-adapter.
If thecondition is as shown in 1) Turn starting

the table below, it is normal. switch ON.
El 2) Insert
Governor motor Between (3) - (14) 2.8 - 6.3V Tdapter
Between (4) - 115) 2.8 - 6.3V
If the condition is as shown in the 1) Turn starting ::

table below, it is normal switch ON.
z
21 Insert rJ
Between (13) - (12) 20 - 3ov 0
1 T-adapter
Battery relay
*This is only for 2.5 seconds after

turning the starting switch ON -+ OFF,
At other times, it is 0 V.
If the condition is as shown in the I ) Turn starting

Model selection 2) Disconnect

connector
Inspec-
Classifi, Measurement
cation Component Connector No. tion Judgment table
conditions
method

Throttle signal E 0 table below, it is normal. switch ON.
(engine throttle c2 ag
controller) z5 Between (20) - (10) 0.25 - 4.75 2) Insert
I>
T-adapter
If the condition is as shown in the 1 j Turn starting

table below, it is normal. switch OFF.
2) Disconnect
Between (I) - (2) 500 - 1 ,OOOC
connector.
Between (2) - chassis Min. 1 MO
Measure at AC range 1) Start engine

Engine speed sensor E7 f$ 2) Insert T-
s: adapter.
H >
Between (1) - (2) 0.5 - 3.ov
1) Screw in speed sensor until it contacts

ring gear, then turn back one turn.
5
3 2) Work normally after carrying out above
a adjustment.
If the condition is as shown in the 1 j Start engine.

table below, it is normal (Charge
accumulator)
For boom, arm, bucket and swing control levers
2) Disconnect
connector.
Work equipment .
swing oil pressure Sl (Male)
switch
Between (I), (2) - chassis Min. IMQ

I

table below, it is normal. (Charge accumu-
For travel control l&er later).
2) Disconnect
connector.
Travel oil pressure
swicth S4 (Male)
Between (1 j, (2) - chassis Min. 1 MR I

table below, it is normal.
2) Fuel control
dial at MAX.
Between (1) - (2)
3) Insert
T-adapter.
Pump pressure sensor C7 (Rear)
C8 (Front)
ARM IN relief 3.1 - 4.5v
20-29
Classifi
cation3 I Component bdgment table
Measurement
conditions
If the condition is as shown in the 1) Turn start-

table below, it is normal. ing switch
OFF.
Swing lock switch Switch OFF Min. 1 Ma 2) Disconnect
Between (8) - (4) connector
Switch ON Max. 1 n c2.
1) Turn TVC
If the condition is as shown in the
prolix switch
table below, it is normal
OFF.
2) Turn start-
TVC solenoid valve Between (1) - (2) IO-22L-z
ing switch
OFF.
Between (2) - chassis Min. 1 M&l 3) Disconnect
connector C4.
z If the condition is as shown in the 1) Turn start-

E
.II
OFF.
Swing brake E 2) Disconnect
solenoid valve
Vl (Male) Between (1) - (2) 10 - 350
E connector
2 Vl.
Between (2) - chassis Min. 1 M.fl
5

E
m table below, it is normal ing switch
.-t: OFF.
Travel speed
solenoid valve
V2 (Male) ? Between (1) - (2) 50 - loon 2) Disconnect
connector
f
I Between (2) - chassis Min. 1 MO v2.
z
2 h
b
CJ
8 If the condition is as shown in the 1) Turn start- 0
5 table below, it is normal. ing switch
.-z
OFF.
CO cancel
V4 (Male) E Between (1) - (2) 50 - looa 2) Disconnect
solenoid valve
E connector
2 Min. 1 Ma v4.
Between (2) -chassis
E
8 If the condition is as shown in the II Turn start-

6 table below, it is normal. ing switch
;;
‘Z -.
OFF
2-stage relief 2) Disconnect
solenoid valve
V7 (Male) F
a,
Between (I) - (2) 50 - 1009
connector
;
Between (2) - chassis v7
Min. 1MR
! I I
I I I f I ’ I
z If the condition is as shown in the 1) Turn start-

z% table below, it is normal. ing switch
z
Arm half flow ‘sr OFF.
V5 (Male) z Between (1) - (2) lo-335a 2) Disconnect
solenoid valve
2 connector
2 v5.
Between (2) - chassis Min.1 M.Q
20630
1Inspec-
Classif Measurement
cation!
Component Connector No. ion I
conditions
netho<

Power source OFF.
Cl IBetween (12), (13)-(3). (411 2) Insert
voltage 20 - 3ov
I T-adapter.

ON.
2) lnsart
T-adapter.
Working mode
switch c2
Between (8) - (14) o-1v

F.0 mode
Between (8) - (15) 10 - 13V
Between (8) - (14) o-1v

L.0 mode
Between (8) - (15) o-1v
L ,
If the condition is as shown in the 1 ) Turn start-

ON.
Between (8) - (5) 10 - 13V 2) Insert
tl mode T-adapter.
Between (8) - (6) IO - 13V
Between (8) - (5) o-1v

Power set switch
S mode
Between (8) - (6) 10 - 13V
Between (8) - (5) * 0 - 1V

L mode
Between (8) - (6) o-1v
* 10 - 13V when workino mode is L.0 mode

ON.
Autodeceleration 2) Insert
switch c2 T-dadapter

I I I I ON.
Travel speed 2) Insert
c2 Between
switch T-adapter.
(8) - (3)

ON.
Power maximizing 2) Insert
c2 Switch OFF 20 - 28V
switch Between T-adapter.
(8) - (12)
Switch ON O-IV
nspec
Classi Measurement
cati or Component Connector No ion bdgnent table
conditions
If the condition is es shown in the I) Turn start-

ON.
2) insert
T-adapter.
Coolant temperatu
signal c2
(102”C, 107Oc

Model I I I ! ON.
c2 2) Insert
selection
T-adapter.
If the condition is as shown in the I) Turn start-

ON.
Kerosene mode c2 2) Insert
> T-adapter.
::
z
:
If the condition is as shown in the I) Start engine.
table below, it is normal. 2) Insert
Autodeceleration T-adapter.
output signal c2 3) All levers
at neutral
If the condition is as shown in the I) Turn start-

Between ON.
(21)-(11) PC300 PC400 [Coolant
I I temperature
H.0 mode gauge is with-
0.75 - I .ov 0.75 - I .ov
or H mode in green range]
\lo. 2 throttle signa 2) Insert
c2
1 G.O.F.O. L.0 1 I I Tadapter.
and S mobe, I .23 - 1.53V 1.35 - 1.65V
G.O. F.0 and
temperature is 4.0 - 4.25V 4.0 - 4.25V

above 107°C
If the condition is as shown in the I Start engine.

table below, it is normal. !) Turn swing
lock switch
OFF.
Swing brake 9 Turn swing
Cl
solenoid lock prolix
switch OFF.
.) Insert
T-adapter.
2022
Classifi Measurement
Connector No. Judgment table
cations conditions
If the condition is as shown in the 1) Start engine.

table below, it is normal. 2) Insert
T-adapter.
3) Fuel control
Travel speed dial at MAX.
solenoid Cl 4) Travel on
flat ground

ON.
2) Insert
2-stage relief T-adapter.
Cl
solenoid 3) H.0 or
G.0 mode

I I I 1 ON.
2) Insert
CO cancel Tadaoter.
Cl
solenoid

ON.
I I I I 2) Insert
Arm half flow Tadapter.
Cl
solenoid
F.O. L.0 mode o-3v

Classifi Pvleasurement
cation
Component cionnector No. tion Judgment table
conditions
method
CHECK, CAUTION If the condition is as shown in Table 1, Table 2, and Table 3, the monitor 1) Start engine
group Psrnel is normal. 2) Insert T-adapter
Buzzer signal Ti sble 1 (CHECK, CAUTION group)
7
The voltage for H and Monitor auxiliary signal input
L in the table are as
follows.
I
%I. Engine oil I
pressure signal
H: 3.5 - 30V
L: Approx. OV
(3001ant level
I‘1 (17)
-
*2. Starting signal
H: 7 - 30V I!ngine oil
Engine oil pressure signal
H Flashing
Ieve1 L
L: Approx. OV L or starting signal L
I‘1 (18) L OFF
The starting signal is I

H once, but after that I
it becomes L. How- I
ever, until the starting
switch is turned OFF. I
the starting signal is I
held in the memory
inside the monitor
I
panel as H.
I
f3. Alternator
signal ,
H: 20 - 30V 1
L: Max. 5V I
%4. Sensor signal IFuel level

H:3.5-30V IPl (5)
L: Approx. OV
,
I
3
Overload H Flashing
warning H
IPl 120) L OFF
IPPC oil H Flashing

I
Ipressure H
IPl (19) L OFF
T ‘able 2 (Buzzer signal)
Pl (4) Open (no connecting wiring)

P2 (l), (2), (14), I15)
PI (1) - (3) Starting switch ON

(+24V input) 20 - 3ov
Starting switch OFF

ov
Pl (11) (Alarm buzzer output) - (3) Remove connector, and

Disconnect PB (coolant level sensor) buzzer sounds, or the follow-
ing cycle is repeated.
$
Connect short connector to P8 Over 20V: 0.8 set
3V: 0.8 set
When short connector is

connected, buzzer stops or
voltage is OV.
20634
Inspec-
Classifi- Measurement
Component Connection No. tion Judgemen table
cation conditions
method
GAUGE group Table 3 (GAUGE group) 1) Turn starting

switch OFF,
Position of Display level resistance (kR) insert dummy
gauge display (Monitor panel input resistance) resistance, or
measure resist-
Starting switch
Starting switch OFF ance (kS2)
ON
(Monitor panel
Min. - Max. input resistance)
2) Turn starting
Right 0 - 0.7 switch ON, and
side check display
0.5 - 3.245 3) Connect socket.
t 3.015 - 3.665
Measure resist-
ance between Dis- 3.419 - 4.222
coolant tempera- play
ture gauge Pl posi- 3.946 - 5.092
(female) tion 4.764 - 6.248
(6) - (3)
1 5.844 - 7.713
Left I 7.086 - 10.17 ~ 1

side I 9.455 - Disconnection I
Right
side
F 10
a
I
I
I
0 - 14.24
11.23 - 20.87
I
I
I
l-l
17.51 - 27.32
t
7 I 23.52 - 34.07 I
29.98- 39.55
Measure
resistance be- Dis- I I
tween fuel level
gauge PI (female)
play
posi-
I 35.15 - 44.38 I
(5) - (3) tion 39.70 - 49.45
44.47 - 61.60
1 55.89 - 79.36
72.52 - 691.63
Left
side 611.82 - Disconnection
PC300, 300LC-5 Serial No: 20001 - 21400 1) Turn starting

PC400, 4OOLC-5 Serial No: 20001 - 20602 switch ON.
If the condition is as shown in the table below, 2) Insert T-adapter.
it is normal.
Coolant Between (12) - (16) IO-13v

temperature
below 102’C Between(13)-(16) IlO-13V
Coolant temperature
P2
signal PC300, 3OOLC-5 Serial No: 21401 and up
PC300,3OOLC-5 MlGHT’f PC300HD-5
PC400,4OOLC-5 MIGHP/ PC400HD-5
If the condition is as shown in the table below,
it is normal.
Coolant Between (12) - (16) lo-13v

temperature
below 102°C Between(13)-(16) [IO-13V
Measurement
Connector No. Judgment table
conditions
If the condition is as shown in the table below, 1) Trun starting

it is normal. switch ON.
2) InsertT-adapter.
Coolant temperature Max. 1 v
Warming-up signal P2
below 10°C Between
Coolant temperature (11 j-116)
8-12V
above 50°C
If the condition is as shown in the table below. I) Turn starting

switch ON.
2) Insert T-adapter.
H.0 mode -1
Working mode
P2
switch
L.0 mode -3
If the condition is as shown in the table below, 1) Turn starting
Between (5) - (16) lo-13v

H mode
Between (61 - (16) 10 - 13v
Power set switch P2 Between 15) - 116) 0 - 1v

S mode
Between (6) - (I 6) 10 - 13v
Between (51 - (16) *o--1v

L mode
Between (61 - (16) O-IV
L
* 10 - 13V when working mode is L.0 mode
If the condition isas shown in the table below, 1) Turn starting

Auto-deceleration
P2
switch
If the condition is as shown in the table below, I ) Turn starting

Travel speed switch P2
If the condition is as shown in the table below, I ) Turn starting

it is normal. switch OFF.
?) Disconnect
connector P8.
Coolant level sensor P8 (Male) Coolant level normal Continuity I
Coolant level abnormal No. continuity
Inspec-
Classif i- Measurement
component Connector No. tion Judgment table
cation conditions
method
r
If the condition isas shown in the table below, 1) Turn starting
2) Disconnect
Engine oil level sensor P5 (Male) Engine oil level~normal Continuity connector P5.
Engine oil level abnormal No continuity
If the condition is as shown in the table below, I) Turn starting

2) Disconnect
connector P9.
Hydraulic oil level sensor P9 (Male)
1) Turn starting
switch OFF
2) Disconnect
Coolant temperature connector P7.
sensor P7 (Male)
E
t; If the condition is as shown in the table below, 1) Start engine.
t 2) Disconnect
z
C
wiring.
6 Engine oil pressure

zz sensor
If the condition is as shown in the table below, 1) Turn starting

switch OFF.
2) Disconnect
Fuel level sensor P6 (Male) ] connector P6.
& When engine is running (l/2 throttle or above): I) Start engine.

z 27.6 - 29.5U
9 * If the battery is old, or after starting in cold
E areas, the voltage may not rise for some time.
2
20637
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or
iymbol Part No. Part Name Remarks
measurement item
L. 60 - 2,OOOrpm
Engine speed A 799-203-8000 Multi-tachometer Digital display,,‘16O _ , 9 999rDm
Water and oil

B
Degital temperature _50 _ , 2oooc
799-l 01-6000
temoeratures aauae
- -
Pressure gauge
799-101-5001 Hydraulic tester
25, 60,400,600 kg/cm2
1
Digital hydraulic
790-261-I 201 Pressure gauge 700kg/cm2
tester
-
Hydraulic pressure C .790-261-1310
-
0 - 70 kg/cm2
1 795-502-1590 Compression gauge Kit Part No, 7g5_502_, 205
Compression pressure D -
For PC300
2 Adapter
For PC400
- -
Blow-by pressure E 799-201-I 504 Blow-by checker 0 - 500 mmH,O
Commercially
Valve clearance F Feeler gauge
available I
Handy smoke Discoloration 0 - 70%
799-201-9000
checker (with standard color)
Exhaust color G
Commercially (Discoloration % x I/ 10
Smoke meter
available = Bosch index)
Operating force 79A-264-0020 Push-pull scale -
Stroke, hydraulic Commercially -

Scale
drift available I
Commercially
Work equipment speed Stop watch
available I
Pump performance 790-303-I 002 Flowmeter kit

I
1 799-601-2600 T-adapter box
799-601-7000 Adapter Ass’y

Troubleshooting of l Kit Part No.
wiring harnesses and
sensors
Throubleshooting of
voltage and resistance 79A-264-0210 Tester
values
Engine oil pressure 799-401-2320 Hydraulic gauge 10 kg/cm2
20639
ADJUSTING VALVE CLEARANCE
Pc300,300Lc-5
PCSOOHD-5
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction to
align pointer (2) with 1.6 TOP line (I 1 on the
crankshaft pulley. When rotating, check the
movement of the intake valve of No. 6 cylinder.
3. When No. 1 cylinder is at top dead center,
adjust the valves marked l. Next, rotate the
crankshaft one turn (360”) in the normal direc-
tion and adjust the valve clearance of the re-
maining valves marked o.
* Valve arrangement
4. To adjust the valve clearance, loosen locknut

(61, then insert feeler gauge F between rocker
arm (3) and valve stem (41, and turn adjustment
screw (5) until the clearance is a sliding fit.
I ’ 205FO5211
Then tighten locknut (6) to hold the adjustment
screw in position.
w Locknut: 4.5 f 0.5 kgm
* After adjusting No. 1 cylinder at top dead
center, it is also possible to turn the crankshaft
120” each time and adjust the valve clearance
of each cylinder according to the firing order.
l Firing order: 1 - 5 - 3 - 6 - 2 - 4
l After tightening the locknut, check the clear-
ance again.
*Og40
PC400HD-5
1. Remove the cylinder head cover.
align pointer (2) with “1.6 TOP” line (I 1 on the
crankshaft pulley. When rotating, check the
movement of the valves.
3. When No. 1 cylinder is at compression top dead
center, adjust the valves marked . . Next, rotate
the crankshaft one turn (360”) in the normal di-
rection and adjust the valve clearance of the re-
maining valves marked o.
* Valve arrangement
Winder , 2 3 4 5 6
No.
8.
=Intake0 0 0 0
valve
l l
Exhaust 0 0 l 0 l 0
valve
4. To adjust the valve clearance, loosen locknut

(61, then insert feeler gauge F between rocker
lever (3) and crosshead (41, and turn adjustment
screw (5) until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment
screw in position.
4 3 5 6
m Locknut: 6.75 + 0.75 kgm
* After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120” each time and adjust the valve
clearance of each cylinder according to the
firing order.
l Firing order: 1 -5 - 3 -6 - 2 - 4
* After tightening the locknut, check the valve
clearance again.
6 I5OF20 I
PC300
A When measuring the compression pressure,
be careful not to touch the exhaust mainfold
or muffler, or to get your clothes caught in
the fan, fan belt or other rotating parts.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE
CLEARANCE.
2. Warm up the engine to make the oil temperature
40 - 60°C.
3. Remove the nozzle holder assembly from the
cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle PC400
holder, then connect compression gauge Dl.
D2
5. Set tachometer A in position.
6. Disconnect the fuel control rod, place the gover-
nor lever of the injection pump in the NO INJEC-
TION position, then crank the engine with the
starting motor and measure the compression
pressure.
Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
After measuring the compression pressure, in-
stall the nozzle holder assembly.
FO20705005
20642
TESTING AND ADJUSTING FUEL INJECTION TIMING
Pc300,300Lc-5
PC300HD-5
align pointer (2) with “16”” line (I) on the
crankshaft pulley.
2.Disconnect fuel injection pipe (3) of No. 1
cylinder.
3. Remove delivery valve holder (41, take out deliv-
ery valve (5) and spring (61, then install delivery
valve holder (4) again.
4. Place the governor lever at the FULL position.
5.Loosen the nuts in the oblong hole of the
mounting flange of the fuel injection pump,
then loosen injection pump mounting bolt (7).
6. Move the fuel injection pump towards the out-
side, then move the injection pump towards the
cylinder block a little at a time while operating
the priming pump, and stop the point where the
fuel stops flowing from the delivery valve
holder.
+ If the fuel does not stop whichever way the
injection pump is moved, rotate the crank-
shaft one more turn.
* Adjust the fuel injection timing by moving
the fuel injection pump as follows.
To RETARD timing, move towards OUTSIDE
To ADVANCE timing, move towards CYLIN-
DER BLOCK
7. Tighten injection pump mounting bolt (7).
&Tighten the nuts in turn in the oblong hole of
the mounting flange of the fuel injection pump.
9.Remove delivery valve holder (41, assemble
delivery valve (5) and spring (61, then install
delivery valve holder (4) again.
W Delivery valve holder: 9 * 1 kgm

10. Connect fuel injection pipe (3).
m Sleeve nut: 2.25 f 0.25 kgm
205FO5216
205FO5655
2023
Pc400,400LC-5
PC400HD-5
align pointer (2) with “24”” line (I) on the
crankshaft pulley.
2. Disconnect fuel injection pipe (3) of No. 1
cylinder. ‘\
3. Remove delivery valve holder (41, take out deliv-
ery valves and springs, then install delivery
valve holder (4) again.
4. Place the governor lever at the FULL position.
5. Loosen bolt (7) in the oblong hole of the mount-
ing flange of the fuel injection pump, then move 2/
’ II 205FO5650
the injection pump a little at a time while operat-
ing the priming pump, and stop at the point
where the fuel stops flowing from the delivery
valve holder.
* If the fuel does not stop whichever way the
injection pump is moved, rotate the crank-
shaft one more turn.
* Adjust the fuel injection timing by moving
the fuel injection pump as follows.
To RETARD timing, move towards OUTSIDE
To ADVANCE timing, move towards CYLIN-
DER BLOCK
6. Tighten bolt (7) in the oblong hole of the
mounting flange of the fuel injection pump.
7. Remove delivery valve holder (41, assemble
delivery valve (5) and spring (61, then install
delivery valve holder (4) again.
B Delivery valve holder: 9 * 1 kgm
6. Connect fuel injection pipe (3).
B Sleeve nut: 3 f 1 kgm
205FO52 16
-
2024
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR
LEVER
* The positions for the governor motor and injec-

tion pump are opposite on the PC300-5 and
PC400-5, but the procedure is the same. (The
diagram shows the PC300-5)
1. Testing
I) Set the switches in the following position.
* Condition Starting switch: ON
Working mode: H.0
Power set: H
Auto-deceleration: OFF
2) Set the
the following
i) Measure
fuel control
measurements.
clearance
dial to MAX
a between
and take
governor
I- 205FO5657
lever (2) and injection pump FULL stop-

per bolt (I 1.
* Clearance a: Max. 0.4 mm
ii) Measure extension b of spring rod (3).
* Extension b: Max. 1 .O mm
3) Turn the fuel control dial to MIN, turn the
starting switch OFF and take the following
measurements.
After the starting switch is turned OFF,
the governor motor continues to push
governor lever (2) to the stop position
205FC 15658
for approx. 4 seconds, and after this, it
is returned to the low idling position, so
take the measurement in this 4 seconds
interval.
i) Measure clearance c between governor
lever (2) and injection pump STOP stop-
per bolt (4).
Sr Clearancec: 0
ii) Measure contraction b of spring rod (3).
* Contraction b: Max. 24 mm .
2. Adjusting
I) Turn the starting switch OFF.
2) Pull out pin (51, and disconnect spring rod
(3) from governor motor lever (6).
3) Set governor motor lever (6) and governor
lever (2) in the position where they contact
FULL stopper bolt (I 1, adjust the length of
spring rod (31, and connect it again
temporarily.
4) After temporarily assembling, tighten yoke
(7) 1.5 turns and fix it in position with lock-
nut (8).
* After completion of adjustment, carry out
the inspection in Item 1 again.
205FO5659
ADJUSTING ENGINE SPEED SENSOR
PC300
1. Screw in so that the tip of sensor (I) contacts
gear (2).
2. When sensor (I) contacts gear (21, turn it back
one turn. Engine speed
3. Tighten locknut (3). sensor
* When connecting the wiring, be careful to
prevent any excessive force from bearing
on the wiring of the sensor.
* Be careful not to scratch the top of the
sensor or to get any metal powder stuck to
. it.
205FO5660
PC400
205FO5661
I /; Clearance
205FO5222
2026
INSPECTION OF SWING CIRCLE
BEARING CLEARANCE
Method of inspecting swing circle bearing clear-

ance on machine
Re
1. Fix a dial gauge equipped with a magnet to
the outer ring (or inner ring) of the swing cir-
cle, and put the probe in contact with the
end face of the inner ring (or outer ring).
Set the dial gauge at the front or rear.
me
F20705344
2. Set the work equipment to the maximum

reach with the tip of the bucket at the height
of the bottom surface of the frame.
In this condition, the front of the upper struc-
ture will go down, and the rear will go up.
3. Set the dial gauge to the 0 point.
ul
0
“0
8
4. Set the arm at 90” perpendicular to the

ground surface, then lower the boom until
the front of the track comes off the ground.
The front of the upper structure will go up,
and the rear will go down.
5. With the machine in this condition, read the
value on the dial gauge.
This reading of the dial gauge is the clear-
F2.0705346
ance of the swing circle bearing.
AWhen carrying out the measurement, do
not put your hands or feet under the un-
dercarriage.
6. Return the machine to the condition in Step
2, and check that the dial gauge has returned
to the 0 point. If the dial gauge has not re-
turned to the 0 point, repeat Steps 2 - 5.
*O-P’
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
EQUIPMENT, SWING, TRAVEL CIRCUIT
1. Measuring
* Oil temperature when measuring:
45 - 55°C
Y Y
‘! Lower
and stop
the work
the
equipment
engine. Operate
to the ground
the control
levers several times to release the remaining
pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
Put the safety lock lever in the LOCK
- Y 705FO5662
position.
I) Remove pressure pick-up plug (I) or (2)
(Thread dia. = 1 Omm, Pitch = 1.25mm)
from the circuit to be measured, then install
oil pressure gauge Cl (600 kg/cm2).
2) Start the engine, set to the H.0 and H mode,
and measure the main relief pressure with
the engine at high ilding.
. Condition of actuator to be measured
i) For the work equipment, set each
cylinder to the end its stroke.
ii) For swing, turn the swing lock
switch ON.
iii) For travel, fit block @ under the
track shoe grouser. Or fit block @
between the sprocket and frame to
lock the track shoe. Measure one
side at a time.
Table 1
Plug Pump Actuator controlled
. Arm cylinder
l Boom cylinder
I I 1 Front pump
l
.
Swing motor %
R.H. travel motor 205F0522E FO20705006
l Arm cylinder
l Boom cylinder %
2 Rear pump
l Bucket cylinder
l L.H. travel motor
+xThe set pressure of the safety valve for the

boom head end and swing motor is lower
than the set pressure of the main relief valve,
so be careful.
2027
2. Adjusting
Main relief valve For front pump For rear pump
I) Adjusting high set pressure
/ \ /
i) Loosen locknut (3) and turn holder (4)

to adjust.
* Adjust the holder as follows.
l To INCREASE pressure, turn
CLOCKWISE
l To DECREASE pressure, turn
COUNTERCLOCKWISE
m Locknut: 11.5 f 1 .O kgm

205FO5663
+ When the high set pressure is ad-
justed, the low set pressure also
changes so always adjust the low
set pressure also.
2) Adjusting low set pressure
3 4 PR 5 6
i) Loosen locknut (5).
* Check that elbow (6) moves.
ii) Loosen locknut (7) and turn holder (8)
to adjust.
CLOCKWISE
COUNTERCLOCKWISE
205FO5664
* Amount of adjustment for one turn
of holder: 128 kg/cm2
B Locknut: 4.5 k 0.5 kgm R.H. swing L.H. swing
* Normally, the pressure applied to port PR is
approx. 13 kg/cm2 or less, and at high set
pressure, is approx. 30 kg/cm2.
Swing motor safety valve

1) Loosen locknut (9) and turn adjustment
screw (I 0) to adjust.
* Adjust the adjustment screw as follows.
CLOCKWISE
0 To DECREASE pressure, turn
COUNTERCLOCKWISE
* Amount of adjustment for one turn of
adjustment screw: 48.6 kg/cm2
m Locknut: 4 * 1 kgm
* After adjusting, repeat the procedure in
Step 1 to check again.
* Adjustment of the safety valve set pressure
is only for the swing motor. Do not try to
adjust the safety valve set pressure for any
other part.
I 205FO5666
2028
Precautions when measuring hydraulic pressure
1) Measuring hydraulic pressure under normal
operation
Relieve the boom, arm, and bucket cylinders
when measuring.
* Do not operate the power max. switch.
2) Measuring hydraulic pressure when 2-stage
relief is actuated
Push the power max. switch when measuring.
* If the power max. switch is pressed, the
2-stage relief solenoid valve and CO cancel
solenoid valve are actuated.
* When the CO valve is canceled, the relief
pressure is different when one side is
relieved and when both sides are relieved.
2029
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
1. Measuring
Sr Oil temperature when measuring: 45 -
55°C
I) Remove pressure pick-up plug (I) (Thread
dia: 14 mm, Pitch: 1.5 mm), and install hy-
draulic pressure gauge Cl (60 kg/cm*).
2) Start the engine and measure with the
engine running at high idling.
+ When measuring for internal leakage from
equipment in the charging circuit, use the
parts given below to shut off the following
205FO566i
parts of the circuit when measuring the
relief pressure.
\lo. Selection of hydraulic Equipment that

circuit shut off can be inspected
Piston pump
1 Piston pump
inlet port
2 Charging pump
Charging pump
outlet port
3 Solenoid valve
Solenoid valve
inlet port
4 Travel PPC valve

Travel PPC valve
Inlet port
5 L.H. PPC valve

L.H. PPC valve Sleeve
Inlet port
6 R.H. PPC valve Plug

R.H. PPC valve r
Inlet port
k Items No. 2 and below can be checked

if the equipment in the previous number
is normal.
f Use the parts given below to shut off
the circuit. u 205FO5669
l For elbow
Travel PPC valve
Sleeve nut: Solenoid valve
0722 I-2031 5, 07221-20422
07221-20520
Plug: pump
07222-50325, 07222-00414
07222-005 15
l For hose valve L.H. PPC valve
Plug:
07376-50315, 07376-50422
07376-50522
205FO5234
20650
2. Adjusting
II Loosen locknut (2) and turn adjustment
screw (31 to adjust.
CLOCKWISE
COUNTERCLOCKWISE
adjustment screw: 5.4 kg/cm*
m Locknut: 6.5 & 1 .O kgm
205FO5235
* After completion of adjustment, repeat
the procedure in Step 1 to check the set
pressure again.
2021
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
1. TVC valve output pressure

Measuring
45 - 55°C
* Measure the relief pressure of the charging
pump first, and check that it is normal.
* The TVC valve output pressure varies ac-
cording to the average pressure for the
PI + P2
pump discharge pressure ( =
2
average pressure), so before measuring,
205FO5670
always adjust the main relief pressure to the
specified pressure.
I) Remove pressure pick-up plug (I) (Thread
dia. = 1 Omm, Pitch = 1.25mm), and install
oil pressure gauge Cl (60 kg/cm2).
2) Set to H.0 and H mode, run the engine at
high idling, and measure the hydraulic pres-
sure with the control lever at neutral and at
pump relief.
[Reference]
a) The average
approx.
sure
kg/cm2
of
175
the
pressure
kg/cm2
pump
and the discharge
at one pump relief is
(The discharge
being relieved
pressure
pres-
is 325
of the
I-
pump not being relieved is approx. 20 Graph 1
kg/cm2.)
b) For the relationship between the change in
the TVC valve output pressure and the
pump discharge amount, see graphs 1 and
2.
Pump discharge pressure 9 = Average pressure (kg/cm*)
205F0523E
Graph 2
I
3
> TVC valve control area
H
When CO function is canceled
NC valve
Control area co valve
control area
/ ‘-lb0 260 3bO
Pump discharge pressure v = Average pressure (kg/cm*)
205FO5239
20652
Adjusting
* If the results of the measurement show that the
hydraulic pressure is not within the standard,
adjust as follows.
1) Loosen locknut (2).
2) Turn adjustment screw (3) to adjust.
* If the adjustment screw is stiff, do not use
excessive force. If excessive force is used
to turn the screw, the tip may break.
3) Adjust the adjustment screw as follows.
l To INCREASE pressure, turn CLOCKWISE TVC valve
l To DECREASE pressure, turn COUNTER- 205FO5671
CLOCKWISE
* Amount of adjustment for one turn of ad-
justment screw: Approx. 3.5 kg/cm2
* After adjusting with the adjustment screw,
repeat the procedure in measuring to check the
3.
output pressure.
* If the adjustment screw is stiff and excessive
force is used to turn it, the tip may break, so in
this case, remove the TVC valve assembly,
remove the cover assembly, and put lubricant
on the screw before trying to move it.
205FO5241
20653
2. Output pressure of CO valve and NC valve
[Reference]
The output pressure of the NC valve controls
the discharge amount of the piston pump flow-
ing to the servo valve.
The oil flows TVC valve - CO valve - NC
valve - servo valve, and the output pressure
changes as follows according to the movement
of the control lever of work equipment.
* Control levers at neutral
The NC valve is actuated by the differential
pressure of the jet sensor, and the output
pressure drops below 5.5 kg/cm2.
(The pump discharge amount is the minimum)
* When hydraulic cylinder is relieved
The CO valve is actuated, and lowers the
pressure of the oil entering the NC valve to
below 5.5 kg/cm2. The NC valve supplied
this pressure as it is to the servo valve.
(The pump discharge amount in this case is
the minimum)
* Work equipment, swing, travel actuated
The output pressure of the TVC valve is not
affected by the CO valve and NC valve, and
is supplied as it is to the servo valve.
(The discharge amount of the pump varies
between the maximum and the point where
the CO valve is actuated.)
Measuring
* Olil temperature when measuring:
45 - 55°C
l Remove pressure pick-up plug (4) (Thread
dia. = 1 Omm, Pitch = 1.25 mm), and install
oil pressure gauge Cl (60 kg/cm?.
* This is at the body side of the servo
\
valve. 20705008
I) Pressure when NC valve is actuated
Set to H.0 and H mode, run the engine at
high idling, and measure the pressure when
all control levers are at netural.
* Turn the auto-deceleration switch OFF.
* If the output pressure is more than 5.5
kg/cm2, measure the differential pres-
sure of the jet sensor.
20654
2) Pressure when CO valve is actuated
Run the engine at high idling and measure
the hydraulic pressure when any of the
boom (except LOWER), arm, or bucket are
relieved.
3) Pressure when work equipment or swing
are actuated.
A The work equipment is actuated

when the pressure is measured, so
be careful of the surrounding area.
Measure the hydraulic pressure when reliev-
ing the swing (F pump) and when rotating
the track under no load (F, R pump) at the
same time as measuring the output pressure
of the TVC valve.
* If there is a big difference from the TVC
valve output pressure, the operation of
the CO valve or NC valve is probably
defective.
t The CO valve is canceled when the
travel is operated.
Adjusting
II CO valve
* If the set pressure of the CO valve is high,
the discharge amount is not reduced when
the circuit is relieved, so the relief pressure
becomes high. For this reason, always
adjust the pressure to the specified
pressure.
i) Loosen locknut (5) and turn adjustment
screw (6) to adjust.
+ Adjust the adjustment screw as follows. I CO valve
205FO5673
CLOCKWISE
a To DECREASE pressure, turn
COUNTERCLOCKWISE
adjustment screw: 41.25 kg/cm2.
* If the hydraulic pressure does not drop
even when the adjustment screw is ad-
justed, there is probably a defect inside
the CO valve.
ii) After adjusting, repeat the procedure in
measuring to check the set pressure again.
205FO5246
20555
2) NC valve
* The NC valve is actuated by the dif- NCnvalve,
ferential pressure of the jet sensor, so
when adjusting it, always check first
that the differential pressure of the jet
sensor is correct.
i) Loosen locknut (7) and turn adjustment
screw (8) to adjust.
* Adjust the adjustment screw as
follows.
205FO5674
CLOCKWISE
CLOCKWISE
* Amount of adjustment for one turn
LJ
of holder: Approx. 4.3 kg/cm2. 63
00
d=h
205FO5248
2026
3. Defferential pressure of jet sensor
[Reference] Relationship between travel of
control lever and differential
High pressure and low pressure (high pressure pressure of jet sensor
- low pressure = differential pressure) is
formed at the outlet port of the control valve,
and this differential pressure controls the NC
valve.
The differential pressure is at its maximum
when the control levers are at neutral, and is at
its minimum when the control levers are operat- _L
ed to the end of their travel. ’ Control lever travel (mm)
205F0524E
Measuring
SF Loosen the oil filler cap slowly to

release the pressure inside the hydraulic
tank.
45 - 55°C
1) Remove pressure pick-up plugs (9) (high
pressure side) and (IO) (low pressure side)
(PT l/8).
z * For both front

farthest from
and rear sides, the plug
the engine is the high-
5
0 pressure side.
7
205FO5675
2) Install oil pressure gauge Cl (60 kg/cm2 at

high pressure side, 25 kg/cm2 at low pres-
sure side).
3) Set to H.0 and H mode, run the engine at
high idling, and measure the differential
pressure with the control levers at neutral.
* High pressure (Pt) - low pressure (Pd)
= Differential pressure
4) Using the work equipment, raise the track
frame on one side, and measure the dif-
ferential pressure with the track rotating
freely (control lever operated to the end of
its travel).
* Any actuator can be measured, but it is
easiest to measure the free rotation of
the track because the measurement
time can be chosen as desire.
* The differential pressure is the minimum
(below 2.5 kg/cm*).
2027
Adjusting
* If the results of the measurement show that
the differential pressure is not within the
standard value, adjust as follows.
I) Loosen locknut (I I) and turn adjustment
screw (I 2) to adjust.
l To INCREASE pressure, turn Jet sensor relief valves
CLOCKWISE
COUNTERCLOCKWISE
205FO5676
adjustment screw: Approx. 16.6 kg/cm2
m Locknut: 7.0 2 1 .O kgm
sr After adjusting the adjustment screw,
repeat the procedure in measuring to check
the differential pressure again.
F20505398
TESTING AND ADJUSTING TRAVEL DEVIATION
* When traveling on flat ground

Travel posture
1. Measuring when traveling
1) Set the machine in the travel posture.
* When setting the machine in the travel
posture, extend the bucket and arm cyl-
inder rod fully, and hold the boom at 45”.
2) Travel for IO m, then measure the deviation
when traveling for the next 20 m.
t Set to the H.0 and H mode, and measure
with the engine at high idling.
202F2322
20 m 0 Travel for 10 m
I
Travel straight _
through without
stopping
\ Make a mark -Make a mark at ‘Make a mark

the 10 m midpoint
;IrI~,n;<A;~Mark
Mark
this deviation 202F5258
*Ok60
2. Adjusting
If the result of the measurement shows that
the value is not within the standard value, adjust
as follows.
* Measurement procedure
If the travel deviation is still not within the PJ 205FO5876/!
standard value even after carrying out this

adjustment, see TROUBLESHOOTING,
Travel deviation is excessive.
1) Loosen 4 bolts (1).
* The shims are split shims, so do not
remove the cap.
2) Add shim (2) of a thickness that matches
the amount of deviation, then tighten bolts
(1).
* Add maximum of 0.3 mm of shim.
m Mounting bolt: 6.75 f 0.75 kgm
\
* Amount of travel deviation and thick- 1 205FO5877
ness of shim to add.
PC300
20 400
P
E
2 15 300
z
E 10 200
a,
g
: 5 100
u-o-
Y
0.1 0.2 0.3 0.4 0.5 0.6

Amount of shim to add (mm)
205FO5878
PC400
20 400 z
z 5
E
2 15 300 g
% ,::
E 10 200 -2 3
_z g
E
ng 5 100 $4
$ .k
ii 2%
i-u
0 0.1 0.2 0.3 0.4 0.5 0.6
Amount of shim to add (mm)
205FO5879
20G61
MEASURING STROKE OF SERVO PISTON
* If the output pressure of the NC valve is normal,

and it is considered that the pump performance
is defective, inspect as follows to determine if
the servo valve is defective or not.
1. Prepare the tool

Make up gauge @ from the following parts.
1) Servo piston cap (side which has spring)
2) Dump truck brake wear measurement
gauge (566-98-41120)
3) Tap PT l/4 threads in the center of the cap,
205FO5254
and install the gauge.
2, Measuring
I) Remove the cap (with the spring) from the +--Stroke
side to be measured.
2) Fit the shims that were removed, and install
gauge 0.
* Do not let the shims catch on the
threaded portion of the bolt.
3) Stop the engine, push the rod in fully, then
measure the dimension of the rod.
4) Raise the track shoe on the side where the
gauge is installed, and measure the dimen-
205FO5677
sion of the rod when the engine is run at
high idling and the track is rotated freely.
* Standard stroke:
PC300: Approx. 8.9 mm
PC400: Approx. 11.2 mm
* When the track shoe is rotated freely,
push the rod by hand, and check at the
same time that the rod moves smothly
in accordance with the travel of the con-
trol lever.
2022
MEASURING OUTPUT PRESSURE OF PPC VALVE

45 - 55°C
1. Disconnect the hose (see diagram below) from
the circuit to be measured.
2. Install adapter C2 between the hose and elbow.
3. Install oil pressure gauge Cl (60 kg/cm21 to
adapter C2.
4. Run the engine at high idling, operate the con-
trol lever for the circuit to be measured, and
measure the hydraulic pressure.
Travel PPC valve
Travel shuttle valve
Swing shuttle valve 1
L.H. PPC valve
I,6 I
=:
205F05685A
k Color code
B: Black, Br: Brown, W: White, Y: Yellow
Bu: Blue, G: Green, R: Red
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
* If there is excessive play in the work equipment

or swing lever, adjust as follows.
9 Y
Lower the work equipment to the ground
‘!
and stop the engine. Operate the control
levers several times to release the remaining
pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the
Set the safety lock lever to the LOCK PO-
sition.
1. Remove the boot, loosen the lever mounting

bolt, then remove the lever.
2. Hold down disc (I), and loosen locknut (2).
3. Turn disc (I 1 and adjust the clearance.
* Adjust the clearance with the disc as
follows.
l To DECREASE clearance, turn
CLOCKWISE
l To INCREASE clearance, turn
COUNTERCLOCKWISE
i) When adjusting the clearance, adjust four
pistons (3) separately. (Two pistons in the
front-to-rear direction (A - a) and two pis-
tons in the left-to-right direction (B - b)).
ii) Set disc (I) so that it contacts one of the
0.3 - 0.5 mm
pistons in the front-to-rear direction (A - 1
a), then adjust the clearance between disc
(1) and piston (3) on the opposite side to
3
0.3 - 0.5 mm.
iii) After adjusting in the front-to-rear direction,
adjust in the left-to-right direction (B - b).
iv) If the clearance exceeds 0.5 mm, change
the position of disc (I) or change the
mounting position of piston (31, then check
again.
QZ4 Locknut: 11.5 * 1.5 kgm

* If no clearance is made, even when the lever
is at neutral, the work equipment will move,
or the hydraulic drift will increase, so
always provide a clearance.
205FO5257
TESTING PPC SHUTTLE VALVE
* If the auto-deceleration does not work, the

swing brake is not canceled, the travel lacks
power, or if there is any other problem, and the
pressure switch is normal, check the operation
of the PPC shuttle valve as follows. (Check first
that the electrical system is normal.)
* Oil temperature when testing: 45 - 55’C
1. Remove the pressure switch from the circuit to

be tested.
I) Work equipment *swing pressure switch (I 1
2) Travel pressure switch (2) I i 205FO5258
2. Install pressure gauge Cl (60 kg/cm2).

3. Run the engine at high idling, operate the fol-
lowing control lever, and measure the hydraulic
pressure.
In the case of switch (1). operate the work
equipment or swing lever.
In the case of switch (21, operate the travel
lever.
i 205FO5686
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
Measure each solenoid valve at the following

places.
ho.1 Solenoid Measurement location
Solenoid valve
outlet port
205FO5687
1. Disconnect the hose, and install adapter C2 be-

tween the measurement point and the hose.
* Adapter
205FO5688
2. Install oil pressure gauge Cl (60 kg/cm21 to the

adapter.
3. Run the engine at high idling and measure the
hydraulic pressure under the following
conditions.
1) Arm half flow solenoid valve
If the working mode switch is set to heavy-
duty or general mode, and the arm is operat-
ed, the PPC valve output pressure is sup-
plied; if the working mode switch is set to
finishing or lifting mode, the pressure
should be 0 kg/cm2.
2) Swing brake soleoid valve
Operate the swing.
3) Travel speed solenoid valve
Set the travel speed switch to Hi.
4) CO cancel solenoid valve
Turn the swing lock switch ON.
5) 2-stage relief solenoid valve
Push the power max. switch ON.
205FO5263
20-$6
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF
WORK EQUIPMENT
* If there is any hydraulic drift in the work equip-

ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking for defective cylinder packing

I) Checking boom and bucket cylinders
i) Set in the same posture as when
PC300: 2,160 kg
measuring hydrau’lic drift, and stop the
engine.
ii) Operate the boom control lever to
RAISE or the bucket control lever to 205FO5264
CURL.
l If the lowering speed increases, the
packing is defective.
l If there is no change, the holding
valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the arm control lever to IN.
l If the lowering speed increases, the
z
packing is defective.
z 205FO5265
2 l If there is no change, the control
valve is defective.
* If the pressure in the accumulator has been
lost, run the engine for approx. 10 seconds
to charge the accumulator again before
operating.
[Reference]
If the cause of the hydraulic drift is in the
packing, and the above operation is carried
out, the downward movement becomes
faster because of the following reasons.
I) If the work equipment is set to the above When the pressure is balanced, the down-
posture (holding pressure applied to the ward movement becomes slower. If the
bottom end), the oil at the bottom end leaks lever is then operated according to the
to the head end. However, the volume at the procedure given above, the circuit of the
head end is smaller than the volume at the head end is opened to the drain circuit (the
bottom end by the volume of the rod, so the bottom end is closed by the check valve),
internal pressure at the head end increases so the oil at the head end flows to the drain
because of the oil flowing in from the circuit and the downward movement be-
bottom end. comes faster.
2) When the internal pressure at the head end
increaes, the balance is maintained by a cer-
tain pressure (this differes according to the
amount of leakage) in proportion to it.
2. Checking boom holding valve
SF Set the work equipment at the maximum

reach, and the top of the boom horizon-
tal, then stop the engine.
Lock the work equipment control levers
and release the pressure inside the hy-
draulic tank.
1) Disconnect pilot hose (I 1 of the boom hold-
ing valve, and install a blind plug in the hose.
Ir Blind plug: 07376-50315 ,,
205FO5691
Ir Leave the holding valve end open.
2) Start the engine, charge the accumulator,
then stop the engine.
3) Operate the boom control lever to the
LOWER position.
Sr If any oil leaks from the port that is left
open, the holding valve is defective.
3. Checking PPC valve

If the hydraulic drift differs when the safety
lock lever is in the LOCK or FREE position,
(engine running), the PPC valve is defective.
2028
BLEEDING AIR
Order for operations and procedure for bleeding air
Air bleeding item Air bleeding procedure
1 2 3 4 5 6
Bleed air from Bleed air from Bleed air from

travel mOtor Start operation
Nature of work
. Replace hydraulic oil

0
. Clean strainer 7 ’ 7 ’ 7 %oteT ?NoteT ’
. Replace return filter element 0
. Replace, repair pump

. Replace, clean line filter element o-o-o ) 0
. Remove suction piping
. Replace, repair control valve 0 - 0 * 0
. Replace cylinder
5 0
0 - 0
. Remove cylinder piping
. Replace swing motor w w

0
. Remove swing motor piping
I O I I O
I I I
I O I,I
. Replace travel motor, swivel
. Remove travel motor, swivel piping 0 0
I I I
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor
case has been drained.
1. Bleeding air from pump

I) Loosen bleeder (I 1, and check that oil oozes
out from the bleeder.
2) When oil oozes out, tighten bleeder (I 1.
m Bleeder: 0.9 + 0.1 kgm
*
3)
If no oil oozes out from the bleeder:
Leave bleeder (I 1 loosened and remove plug
c
(2).
4) Pour in oil through the plug hole until oil
oozes out from the bleeder.
5) Tighten plug (2). 205FO5691
m Plug: 7.0. + 1 .O kgm
6) Tighten bleeder (I 1.
* Precautions when starting the engine
After completing the above procedure and
starting the engine, run the engine at low
idling for 10 minutes.
* If the coolant temperature is low and au-
tomatic warming up is carried out, cancel it
by using the fuel control dial after starting
the engine.
2. Bleeding air from hydraulic cylinders
1) Start the engine and run at low idling for
approx. 5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
* Operate the piston rod to approx. 100
mm before the end of its stroke.
Do not relieve the circuit under any
circumstances.
3) Run the engine at high idling and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the end
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
* If the hydraulic cylinder has been re-
placed, it is better to bleed the air be-
fore connecting the work equipment
again.
(In particular, for the LOWER end of
the boom cylinder, if it contacts the
boom, the cylinder cannot be operat-
ed to the end of its stroke.)
205FO5692
3. Bleeding air from swing motor
1) Run the engine at low idling, loosen air
bleed plug (31, and check that oil oozes out.
* If no oil oozes out from the air bleed plug:
2) Stop the engine, and pour oil into the motor
case from plug (3).
3) Tighten air bleed plug (3).
m Plug: 14.0 * 2.0 kgm
4. Bleeding air from travel motor

I) Run the engine at low idling, loosen air
bleeder (41, when oil oozes out, tighten
again.
m Bleeder: 0.9 5 0.1 kgm
20-70
0
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
* If the piping between the hydraulic cylinder and

the control valve is disconnected, remove the
remaining pressure from the circuit as follows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the

pressure inside the tank.
2. Operate the control levers.
* When the levers are operated 2 - 3 times,
the pressure stored in the accumulator is
removed.
3. Start engine, run at low idling for approx. 5 mi-
nutes, then stop the engine and operate the
control levers.
* Repeat the above operation 2 - 3 times to
release all the remaining pressure.
TROUBLESHOOTING
Points to remember when troubleshooting ................................... ....... 20- 74

Sequence of events in troubleshooting ...................................... ....... 20- 75
Precautions when carrying out maintenance ................................. ....... 20- 76
Checks before troubleshooting ............................................. ....... 20- 83
Electrical circuit diagram ................................................... ....... 20- 84
Position of connectors for troubleshooting .................................. ....... 20- 88
Connection table for connector ............................................. ....... 20- 92
Explanation of functions of control mechanism of electrical system ............ ....... 20-100
Display method for monitor panel, pump controller and engine throttle controller ....... 20- 103
Action of self-diagnostic function and symptoms on machine ................. ....... 20- 107
Method of using judgement table ........................................... ....... 20-I 10
Method of using troubleshooting charts ..................................... ....... 20-I 12
Troubleshooting of engine throttle controller system ...................

(E mode) ....... 20-I 15
Troubleshooting of pump controller system ..........................
(C mode) ....... 20-I 41
Troubleshooting of pump controller input signal system (F mode) ................ ....... 20-I 71
Troubleshooting of hydraulic and mechanical system (H mode) .................. ....... 20-I 81
Troubleshooting of monitor system (P mode) ................................... ....... 20-213
20673
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A* Stop the machine
securely fitted.
in a level place, and check that the safety pin, blocks, and parking brake are
0 When carrying out the operation with two or more workers, keep strickly to the agreed signals,
and do no allow any unauthorized person to come near.
0 Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
0 When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
Y &
9’ When removing the plug from a location

release the internal pressure first. When
which is under pressure from oil, water, or air, always
installing measuring equipment, be sure to connect it
properly.
0 The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs
swiftly, and to prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the struc-
ture and function. However, a short cut to effective troubleshooting is to ask the operator vari-
ous questions to form some idea of possible cases of the failure that would produce the report-
ed symptoms.
1. When carrying out troubleshooting, do not 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve
If components are disassembled immediate- spool.
ly any failure occurs: 5) Other maintenance items can be
0 Parts that have no connection with the checked externally, so check any item
failure or other unnecessary parts will that is considered to be necessary.
be disassembled. 4. Confirming failure
0 It will become impossible to find the l Confirm the extent of the failure your-
cause of the failure. self, and judge whether to handle it as a
It will also cause a waste of manhours, real failure or as a problem with the 0”
parts, or oil or grease, and at the same time, method of operation, etc. &
N
will also lose the confidence of the user or + When operating the machine to re- 0
operator. enact the torubleshooting symp-
For this reason, when carrying out trou- toms, do not carry out any investiga-
bleshooting, it is necessary to carry out tion or measurement that may make
thorough prior investigation and to carry the problem worse.
out troubleshooting in accordance with the 5. Troubleshooting
fixed procedure. o Use the results of the investigation and
2. Points to ask user or operator inspection in Items 2 - 4 to narrow
I) Have any other problems occured apart down the causes of failure, then use the
from the problem that has been troubleshooting flowchart to locate the
reported? position of the failure exactly.
2) Was there anything strange about the * The basic procedure for troublesh-
machine before the failure occurred? ooting is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points.
there problems with the machine condi- 2) Start from the most likely points.
tion before this? 3) Investigate other related parts or
4) Under what conditions did the failure information.
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before l Even if the failure is repaired, if the root
the failure? cause of the failure is not repaired, the
When were these repairs carried out? same failure will occur again.
6) Has the same kind of failure occurred To prevent this, always investigate why
before? the problem occurred. Then, remove the
3. Check before troubleshooting root cause.
1) Check the oil level.
2) Check for any external leakage of oil
from the piping or hydraulic equipment.
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Jobsite
\
Step 1
[Examination, confirmation of symptoms
1 ) When a request for repairs is received. Ring! Ring!

first ask the followng points. /l_--------
. Name of customer _--- -- - -
3
* Type. serial number of machine
* Details of jobsite. etc.
21 Ask questions to gain an outline of the
problem.
* Condition of failure
. Work being carried out at the time
of the failure
* Operating environment
. Past history, details of rnalntenance,
etc.
Step 2
DetermIning probable location of cause
1) Look at the troubleshooting section of the

shop manual to find locations of possible
causes
step 3
1Preparation of troubleshooting tools]
1) Look at the table of troubleshooting tools

in the shop manual and prepare the
necessary tools.
- T-adapter
. Hydraulic pressure gauge kit, etc. troubleshooting)
2) Look in the parts book and prepare the * Decide action to take
necessary replacement parts
1) Before starting troubleshooting, locate and
repair simple fallures.
I * Check before starting items
. Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshooting
flowchart that matches thesymptoms. and
carry out troubleshooting.
Step 6
1Re-enacting fallurel
* Drive and operate the machine to confirm

the condition and judge if there is really a
c failure.
I step5
\ 1Askoperator questions to confirmdetails of ] _
* Was there anything strange about the

machme before the failure occurred?
Did the fallure occur suddenly,
Had any repairs been carried out before the
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct opera-
tion, maintenance and inspection, troubleshoot-
ing, and repairs must be carried out. This section
deals particularly with correct repair procedures
for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sec-
tions on “Handling elecric equipment” and
“Handling hydraulic equipment” (particlularly
hydraulic oil).
1. PRECAUTIONS WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and

connectors
Wiring harnesses consist of wiring connect-
ing one component to another component,
connectors used for connecting and discon-
necting one wire from another wire, and
protector or tubes used for protecting the
wiring. Compared with other electrical
components fitted in boxes or cases, wiring
harnesses are more likely to be affected by
the direct effects of rain, water, heat, or vi-
bration. Furthermore, during inspection and
repair operations they are frequently re-
moved and installed again, so they are likely
to suffer deformation or damage. For this
reason, it is necessary to be extremely care-
ful when handling wiring harnesses. F20505201
Main failures occurring in wiring harness

(11 Defective contact of connectors
(defective contact between male and
female)
Problems with defective contact are Improper insertion
likely to occur because the male connec-
tor is not properly inserted into the
female connector, or because one or
both of the connectors is deformed or
the position is not correctly aligned, or
because there is corrosion or oxidization
of the contact surfaces. F20505202
(2) Defective compression or soldering of
Improper compressio
connectors
The pins of the male and female
connectors are in contact at the
compressed terminal or soldered
portion, but there is excessive force on
F56103079
the wiring, and the plating peels to
cause improper correction or breakage.
(3) Disconnections in wiring

If the wiring is held and the connectors
are pulled apart, or components are
lifted with a crane with the wiring still
connected, or a heavy object hits the
wiring, the compression of the
connector may be lost, or the soldering
may be damaged, or the wiring may be
broken.
(4) High pressure water entering connector F20505204

The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector,
water may enter the connector depend-
ing on the direction of the water jet.
The connector is designed to prevent
water from entering, but at the same
time, if the water does enter, it is diffi-
cult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry F20505205
the connector or take other appropriate
action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connec-
tor and an oil film is formed on the
mating surface between the male and
female pins, the oil will not let the elec-
tricity pass, so there will be defective
contact.
If there is oil or grease or dirt stuck to
the connector, wipe it off with a dry
cloth or blow dry with air, and spray it
with a contact restorer.
J, When wiping the mating portion of
the connector, be careful not to use
excessive force or deform the pins. ~20505206
* If there is water or oil in the air, it
will increase the contamination of
the points, so clean with air from
which all the water and oil has been
removed.
2) Removing, installing, and drying connec-

tors and wiring harnesses
Disconnecting connectors
(1) Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors and not the wires. Lock
For connctors held by a screw, loosen
the screw fully, then hold the male and
female connectors in each hand and pull
F20505207
apart. For connectors which have a lock
stopper, press down the stopper with
your thumb and pull the connectors
apart.
(2) Action to take after removing

connectors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
F20505208
Connecting connectors
(I 1 Check the connector visually.
a. Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
b. Check that there is no deformation,
defective contact, corrosion, or
damage to the connector pins.
C. Check that there is no damage or
breakage to the outside of the
connector.
Ir If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
* If there is any damage or breakage,
replace the connector.
(2) Fix the connector securely.
Align the position of the connector cor-
rectly, then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper
clicks into position. .Cliks into position
F20505209
(3) Correct any protrusion of the boot and
any misalignment of the wiring hanress
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
Jr When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean
with air from which all the water
and oil has been removed.
F20505210
Drying wiring harness
If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
(I) Disconnect the connector and wipe off
the water with a dry cloth.
t If the connector is blown dry with
F20505211
air, there is the risk that oil in the air
may cause defective contact, so
avoid blowing with air.
(2) Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
f Hot air from the dryer can be used,
but be careful not to make the
connector or related parts too hot,
as this will cause deformation or
damage to the connector.
F20505212
(3) Carry out a continuity test on the
connector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
* After completely drying the connec-
T-adapter
tor, blow it with contact restorer
and reassemble.
hh F20505213
3) Handling control box

(I) The control box contains a micro-
computer and electronic control circuits.
These control all of the electronic cir-
cuits on the machine, so be extremely
careful when handling the control box.
(21 Do not open the cover of the control
box unless necessary.
(31 Do not place objects on top of the con-
trol box.
F20505214
(4) Cover the control connectors with tape
or a vinyl bag.
(5) During rainy weather, do not leave the
control box in a place where it is ex-
posed to rain.
(6) Do not place the control box on oil,
water, or soil, or in any hot place, even
for a short time. (Place it on a suitable
dry stand)
(7) Precautions when carrying out arc
welding
When carrying out arc welding on the
body, disconnect all wiring harness F205052 :15
connectors connected to the control
box. Fit an arc welding ground close to
the welding point.
F20505216
20680
2. POINTS TO REMEMBER WHEN
HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydrau-
lic cirucit. When adding hydraulic oil, or when
disassembling or assembling hydraulic equip-
ment, it is necessary to be particularly careful.
II Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
21 Disassembly and maintenance work in

the field
If disassembly or maintenance work is car-
ried out on hydraulic equipment in the field,
there is danger of dust entering the equip-
ment. It is also difficult to confirm the per-
formance after repairs, so it is desirable to
use unit exchange. Disassembly and mainte-
g
nance of hydraulic equipment should be car-
5 ried out in a specially prepared dustproof
0
workshop, and the performance should be
confirmed with special test equipment.
F20505217
3) Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surrounding
area being made dirty by leaking oil so
never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose
of it, or take it back with you for disposal. F20505218
4) Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil con-
tainers. If an oil cleaning device is used, it is
possible to filter out the dirt that has collect-
ed during storage, so this is an even more
effective method. F20505219
20681
5) Change hydraulic oil when the tempera-
ture is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit togeth-
er with the oil, so it is best to change the oil
when it is still warm. When changing the oil,
as much as possible of the old hydraulic oil
must be drained out. (Do not drain the oil
from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants
and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri-
mary flushing is carried out with flushing
oil, and secondary flushing is carried out
with the specified hydraulic oil.
F20505220
71 Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to
remove the ultrafine (about 3~) particles
that the filter built into the hydraulic equip-
ment cannot remove, so it is an extremely
effective device.
F20505221
2022
HANDLING CONNECTORS
1. When removing the connectors from the

clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left
and right or up and down, the housing
may break.
205FO5609
205FO5610
2. When disconnecting
connectors, release the
male
lock
and
and
female
pull in
1
parallel with both hands.
jr Never try to pull out with one hand.
205FO5611
3. When the wiring harness clamp of the

connector has been removed, always return
it to its original condition and check that
there is no looseness of the clamp.
205FO5612
*O-k*-’
CHECKS BEFORE TROUBLESHOOTING
(1. Checks before starting, 2. Other check items)
T Item
Judgement
standard
Remedy
1. Check fuel level - Add fuel
2. Check for dirt or water in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydraulic oil strainer Clean, drain
5. Check swing machinery oil level Add oil
6. Check engine oil level (Level of oil in oil pan) Add oil
7. Check cooling water level - Add water
8. Check condition of dust indicator - Clean or replace
S. Check for loose or corroded battery - fighten or replace

terminals
,O. Check for loose or corroded alternator
righten or replace
terminals
1,. Check for loose or corroded starting motor

righten or replace
terminals
12. Check for abnormal noise or smell - Repair
13. Check for oil leakage Repair
14. Bleed air from system - Bleed air
15. Check battery voltage (engine stopped) 20 - 3OV Replace
16. Check level of battery electrolyte Add or replace
17. Check for discolored, burnt, or bare wiring Replace
Check for missing wiring clamps, hanging -

18. Repair
wires
Checks for water leaking onto wiring Disconnect

19. (check carefully water leakage at connector: connector and
and terminals) dry connection
20. Check for broken or corroded fuses Replace
2, _ Check alternator voltage

27.5 - 29.6V Replace
(engine running at over half throttle)
22_ Noise when battery relay is operated
Replace
(switch starting switch from on to off)
ELECTRICAL CIRCUIT DIAGRAM
ENGINE THROTTLE CONTROLLER SYSTEM

Pc300,400-5
Starting switch
Fuse
, 0.85GY mi
0.85WR IOA
9 5WR
I I-‘- I
I 1
Starting motor Alternator
Batteryrelay I
Ml4LS8)
I
I I I
clovernor motor
- 1
7Motor
E6W3) Fuel control dial
‘PC300 only
connector
205FO5697
20684
PUMP CONTROLLER SYSTEM
Pc300,400-5
Work equipment
Swing lock . swing oil
prolix switch pressure switch
-
TVC prolix switch i;i

X
G
v,
FirI
TVC prolix TVC
resistor solenoic
I-]
,CI(MICl7) ,I ,,
1 solenoid valve
_I ISTiP
-1 &!hl Swing brake
I I I I I 0
--
solenoid valve
Engine throttle controller

r-1
Engine
speed
sensor
205FO5703
MONITOR SYSTEM
PC3004
Service meter Fuse
I Glow plug
I
Engine oil level sensor
Overload
warning device Coolant temperature sensor
Fuel level sensor
-_I
L--III Engine throttle controller
r-1
Hydr
Startina switch I
Window washer
1-1
I Engine loom lamp 1
lamp
R.H. head lamp
205FO5707
PC400-5
Service meter Fuse
Wipermotor (KFSO) MO(KFSOI M5IMO) r
D3
Glowplug
R3 I II I I
3JLR
Heater
P5tx,) Engine oil levl sensor
Hi relay ( e/f4
R2
11 Overload
warning device
P7tx2) Coolant temperature sensor
--a
Heater
Lo relay I ------ r-1
:
tIfYJ
_i
ure switch
Wiper
relay
/IllI I II
vei sensor
!#I
Fuel level sensor
P6(XI)
fh
Pump controller
I-1
P4VA2) Swing lock switch
Startina switch
Window wash er
r----
1
J
Boom lamp
- R.H. head lamp
205FO5709
POSITION OF CONNECTORS FOR TROUBLESHOOTING
Pc300,300Lc-5
PC300HB5
r
(:N NojELECTRICAL COMPONENT 1Type ( “,“i,“’ IL;;;-1
Cl ( Pump controller ( MIC ( 17 ( F6

C2 I Pump controller IMIC( 21 1~6
C3 I Pumocontroller 1 MIC 1 9 1 F5 1
C4 ) TVC valve I x I 2 IN61
c5 TVC prolix switch M 6 F5
C6 TVC prolix resistor M 2 F4
Rear pump oil pressure
c7
sensor IX 1 3 I4
E4 Governor potentiometer X 3 N7
E5 Governor motor 1 x 1 4 1~8
E6 Fuel control dial M 3 B6
E7 Engine speed sensor X 2 N6
E8 Intermediate connector 8kVP 14 N5
El 1 Heater relay L 2 L9
PI Monitor panel AMP 20 A5
P2 Monitor panel AMP 16 A5
P4 Warning buzzer M 2 C6
P6 1 Fuel level sensor
I
Ix I
I
I 1~81
/
Coolant temperature
P7 X 2 M8
sensor
P8 Coolant level sensor X 2 L9
P9 Hydraulic oil level sensor X 1 M4
V4 I CO calcel solenoid valve X 2

Arm half flow solenoid
V5 X 2 N5
valve
2-stage relief
v7 X 2 K3
solenoid valve
20688
M8
E6 \ \ \ \ 1.
Ml \ \ \
PI
P9
Mi7 Mllj2
s4
205FO5711
M6 \ M25
Ml4
ii R4
R3
View Z
205FO5617
Pc400,400Lc-5
PC400HD-5
No. of Loca-
CN No. ELECTRICAL COMPONENT Type
pin tion
Ml Starting switch M 4 A6
M2 Starting motor X 2 M8
Rear pump oil pressure

c7 X 3 L9
sensor
M9 Working light M 1 G8
M 10 Intermediate connector KES 2 J9
Ml 1 Fusible link L 2 I8
Ml 2 Heater KES 3 E2
M 13 Speaker KES 2 A3
Ml 4 Intermediate connector S 8 c2
E5 Governor motor X 4 N6
Ml 6 Horn (High tone) KES 1 H4
E6 Fuel control dial M 3 B6
E7 Engine speed sensor X 2 N8
E8 Intermediate connector SWP 14 N6

PI Monitor panel AMP 20 A5
P2 Monitor panel AMP 16 A5
P4 Warning buzzer M 2 C6
P5 Engine oil level sensor X 1 N8
P6 Fuel level sensor X 1 J8
Coolant temperature
I M26
I
Power source
air conditioner
for cooler or
1KES / 4 1 F2
* swing
I Sl I
L
Work equipment
oil pressure switch
Swing oil pressure switch
I
2 K3
s2 X
s4 Travel oil pressure switch X 2 L4
RI Wioer relay 6 A3
R2 Heater Lo relay 6 A3
R3 Heater Hi relay 6 Dl
R4 Light relay 6 Dl
Fl Intermediate connector M 4 F6
2O-JO
M35
c7 I P7
Ml0
P6 ..--I
M3
M21 E2
PI0
El
P4 /
Pl-
Rl
205FO5712
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g;?
R3 ):$
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205FO5617 $)
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.:.:-:.
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2069 1
CONNECTION TABLE FOR CONNECTOR
* Display of male and female connectors

All the displays of male and female show the mating portion at the terminal (pin) end. Therefore,
the diagram does not always match the male and female at the housing mating end.
In the circuit diagrams, the pointed side (the part inside the pointed line) as shown in the diagram
below is the male side.
Female side of terminal Male side of terminal
2 Governor potentiometer
3
S
F20505399
No. cIf T N-SLC CONNECTOR

pins Female connector Male connector
423F349 423F350
423F351 423F352
423F353 423F354
2022
No. a M TYPE CONNECTOR
pins
Male connector Female connector
205FO5318
i
205FO5319 205FO5320
i i
205FO5321 205FO5322
13
EI
2 4
205FO5323 205FO5324
No. o’ FI M TYPE CONNECTOR
pins Male connector Female connector
1 4
\ I
/ \
3 6
205FO5325 205FO5326
20694
No. c S TYPE CONNECTOR
pins
4 8
205FO5327 205FO5328
16 6 1
10
5 10
205FO5329
6 1
12
6 i
205FO5331 205FO5332
16 7
16
8 1 16 7
205FO5333 205FO5334
No. cIf AMP040 TYPE CONNECTOR
pin:
8 16 16 8
\ /
16
i 9 1
205F0533E 205FO5336
i
205FO5337 205FO5338
F
No. oiF SVyP TYPE CONNECTOR
pins Male connector Female connector
6
E@ 0
205FO5339 205FO5340
1 5 5 1
4 8 8 4
205FO5341 205FO5342
20697
No. o fl MIC CONNECTOR
pins Female connector Male connector
1 5
205FO5343 205FO5344
17
142F414 142F415
21
I I
142F416 142F417
20698
No. ( X TYPE CONNECTOR
pin:
205F0530E 205FO5310
1
I
205FO5311 205FO5312
205FO5313 205FO5314
205FO5315 205FO5316
20-99
0
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM
OF ELECTRICAL SYSTEM
This section gives the functions and details of checks for the monitor panel, pump controller, and
engine throttle controller needed to carry out troubleshooting of the electrical system.
1. Explanation of functions
The control mechanism for the electrical system consists of the monitor panel, pump controller,
and engine throttle controller. It carries out control by changing the absorption torque of the pump
(power set1 or by changing the output of the engine (working mode).
Monitor panel and both the controllers i) each input the necessary signals, and ii) combined with
the signals selected by the monitor panel, the controllers input and output the necessary signals to
control the absorption torque of the pump and theengine output.
l Input and output signal system of monitor pane! and both controllers (Fig. 1)
Monitor panel
Power set switch signal
Auto-deceleration switch SIgnal Engine speed sensor

L
Work equipment. I
swing oil @-I
AII Travel speed swttch slgnal

Pump k
pressure switch
@o
Coolant temperature Travel 011
102°C signal
controller pressure switch
Coolant temperature
107YY105’C signal (Note)
Pump
pressure sensor
H
r-l
I
Power Inax
watch sIgnal
205FO5714
Note, 107°C: PC300, 3OOLC-5 Serial No: 20001 - 21400

PC400,4OOLC-5 Serial No: 20001 - 20602
105°C: PC300, 3OOLC-5 Serial No: 21401 and up

PC300HD-5
PC400HD-5
2o-Aoo
The pump controller and engine throttle controller have a self-diagnostic display function and if any
electrical abnormality (disconnection, contact with ground, internal short circuit, or short circuit be-
tween wires) occurs in the output signals (input signal for the receiving controller) for numbers 0 -
@ in Fig. 1, the content of the abnormality is displayed.
l If 01 - 09, or 25 are displayed (if a short circuit or other fault causes a current above the
specified level to flow to the controller, the controller stops the operation of that system).
l If 1 1 - 28 are displayed, there is a disconnection (the operation of that system stops) or there
is contact of the No. 2 pin of the solenoid with the ground (the solenoid continues to operate).
Even if there is any abnormality in the input signal system for @ - 0, the abnormality is not displayed
in the display area, but the pump controller has a built-in monitor function to check the input signals.
The controller starts to work only when there is an input signal, and it gives a display on the display
panel.
Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical
system in the case of “There is no abnormality display on the display panel, but there is an abnormality
in the movement of the unit”, the first step when carrying out troubleshooting is to use the method of
checking the operation of the electrical systm in Item 2 to check if the necessary signal is being output
to the pump controller correctly.
2. Checking operation of electrical system
When the set of operations given below is carried out in the order given, and the action of the
monitor panel, pump controller, and engine throttle controller are as given in the table, the monitor
panel (EMACCI and both the controllers are normal.
The IH.l.j and other displays given in the table are the monitor displays given by the controller if
the input and output signals are normal.
The monitor display of the pump controller is displayed for 1.5 seconds after the signal is
input, and after that the operaton mode is displayed.
For items @, 0, and 0, the system automatically enters the auto-deceleration mode, so set
the auto-deceleration switch on the monitor panel OFF.
Operation procedure and condition of Items for confirmation (when normal) 1

machine
Monitor panel Pump controller Engine throttle controller
I I I
*
*
Turn starting switch OFF.
Turn fuel control dial to MIN. H All lamps OFF All lamps OFF All lamps OFF
Display lamps light up is displayed

Dc3ca)B
3 Turn starting switch ON. k ;;;pa”e S mode is m is disPlaYed (model displayed
‘Ouw)~ for 5 set)
Start engine
If coolant temperature is below 3O’C. After 5 sec. normal display
3 --c
carry out automatic warning up and m is displayed
[Operating model
increase engine speed.
Decimal point flashes
* Turn fuel control dial to MAX.

Raise engine speed in FULL speed of Engine speed rises (fuel
G.0 mode. control dial, governor

I-i
Set auto-deceleration switch OFF. potentiometer systems normal1
Engine speed rise (No. 2

Raise engine speed from FULL speed of
throttle signal system
G.0 mode to FULL speed of H.0 mode.
normal)
H~fp~~fe~
mode
isj:_.‘-:/
Set auto-deceleration switch OFF.
I
* Set working mode to L.0 mode Engine speed drops (No. 2
Lower engine speed from FULL speed is displayed throttle signal system
B
of H.0 mode to FULL speed of L.0 mode. normal)
l Set working mode to GO mode

Engine speed rises again (No
Raise engine speed from FULL speed of
9 -) ~‘~i~~~~e~de m isdisplayed 2 throttle signal system
L.0 mode to FULL speed of G.0 mode.
normal)
* Set auto-deceleration switch OFF.
3 Press power maximizing switch _) j ;; dyyc]
Travel speed Hi - Lo
a Switch travel speed switch between Hi and Lo -) mz:_.ol
is displayed
11 - 1.5 secl
Operate work equipment or swing

IQ Cancel deceleration and raise engine 4
speed.
H
Switch auto-deceleration switch ON.
Deceleration is is displayed
3 Engine speed drops to deceleration
displayed Ix.,-:l[, - ,.5sec]
speed after a few seconds.
I I
- Swing lock lamp OFF

3 Switch swing lock switch ON and OFF.
_ and ON is displayed
$ Operate travel lever slightly.
Return fuel control dial to MIN. Engine speed drops (fuel

9 Engine speed drops to low idling.
-
control dial system normal)
+ Engine stops
Turn starting switch OFF.
(battery relay system normal)
20-Lko2
DISPLAY METHOD FOR MONITOR PANEL, PUMP
CONTROLLER AND ENGINE THROTTLE CONTROLLER
1. MONITOR PANEL
Approximately 2 seconds after the starting l Model code display
switch is turned ON, all monitor and gau’ge
lamps light up and the buzzer sounds for Model LEDs (Light Emitting Diodes)
I
approximately 1 second. This is the
self-diagnostic function of the monitor
panel. After this, the display returns to
normal.
Red Green Red
PC400 0 0 0
2. ENGINE THROTTLE CONTROLLER OFF ON OFF I
Model code display function (normal
display)
When the starting switch is turned ON,
u
the model code is displayed for approxi- Red Green Red
mately 5 seconds on the controller dis- Normal display 0 0 0
OFF ON OFF
play panel.
* After 5 seconds, the model code
display changes to the normal
display or the abnormal display
(self-diagnostic display).
* The display for the wrist control
type is the opposite (left becomes
right) of the display for the long
lever control type.
Self-diagnostic display (abnormal l Self-diagnostic display

display)
The abnormal display
consists of 3 Order of LEDs
Abnormal system
LEDs, and the ON/OFF combination priority (Light Emitting Diodes)
of these displays the type of

Red Green Red
Power source system
abnormality (abnormal system). 1 0 0 0
or controller sytem
If two or more abnormalityes occur OFF OFF OFF
at the same time, the abnormalities

Red Green Red Short circuit in
are displayed in the order of priority 2 0 0 0 governor motor
shown in the table on the right. ON OFF ON system
Once the starting switch is turned

Red Green Red
OFF, the self-diagnostic display is Short circuit in
3 0 0 0
battery relay system
reset. OFF OFF ON
Check the abnormal display with

the starting switch ON.
When the abnormality is removed,
the display is automatically reset, so
nor motor potentiomete
if the abnormality occurs intermit- 0 0 0 sytem, or motor is
tently, the abnormal display and OFF ON ON steo out
I I
normal display will appear alternate- Red Green Red

Abnormality In fuel
ly, and the display may appear to be 6 0 0 0
control dial system
flashing. ON ON ON
Red Green Red

Abnormaltiy in No. 2
7 0 0 0
throttle signal system
ON ON OFF
20-A03
3. PUMP CONTROLLER
1) Model code display function (normal l Model code display
display)
When the starting switch is turned ON,
the model code is displayed for approxi- m
mately 0.5 seconds on the controller
display panel.
2) Operation mode display function

l Operation mode display
(normal display)
The operation mode is displayed unless Power mode
selection system Working mode selection system
there is any change or abnormality in
the input or output system for the pump Mode Display Mode Code Display
controller on controller.
H 1-t \
\ \ Heavy-duty 1 \
s \;, -\
General 2
c
L \ -\
\- Finishing 3
3
Lifting 4 \ 1
-\
P/
n-b a-9
.a,03
z
Power source E
Engine speed signal monitor c-4
monitor 0
When engine speed signal is
Lights up when
input
power is ON
Flashes
(At 2,000 rpm, approx.
20 times/l 0 set)
3) Input signal display function (normal l Input signal display

display)
When the input signal to the controller
:::::,11”7:!
is switched, the input signal is displayed
for approx. 1 - 1.5 sec.
* If it’ is not displayed, there is an Auto-deceleration switch OFF - ON Ad !&.I
abnormality in the input signal Swing lock switch OFF- ON
system. Work equipment .
swing oil pressure switch OFF _ ON P2 .‘f‘.2
* After the input signal is displayed
Service oil pressure switch 1, 2 OFF -c ON \-I I)
for 1 - 1.5 set, the display P4 .I- . \
Travel oil pressure switch OFF - ON P6 $-I I-
changes to the operation mode .I- .\3
display. Power max. switch OFF - ON UP \ 1 \-I

.I_(.\_
Free swing FS :--- .‘=\
4) Self-diagnostic display function (abnor-
mal display) Abnormality system
If there is any abnormality in ‘Ihe
controller output signal system and
sensor system, the abnormal display
and operation mode display are
shown alternately.
* If two or more abnormalities
occur at the same time, all of the
abnormality displays and opera-
tion mode display are shown in
turn.
If 01 - 09, 25 are displayed, there
is danger that the controller may be
broken, so the controller automati-
cally stops the output to the system
where the abnormality has occurred.
Once the starting switch is turned
OFF, the abnormal display is reset,
so check with the starting switch solenoid system
ON. Disconnection in swing brake ,4 ‘\A n
Ir If the starting switch is turned solenoid system . 1. \
OFF, re-enact the abnormal dis- Disconnection in travel speed
play as follows. solenoid system
W System Disconnection in CO
Turn the starting switch ON. cancel solenoid system
Cl System Disconnection in TVC solenoid
18 \ \-1 ,
Turn starting switch ON system . \.a
(Engine stopped) and oper-
ate the control lever.
D System
Start the engine and operate
the control lever Front pump pressure sensor
If no signal comes from the engine svstem 1 23 I.?.?/ . /
speed sensor (engine stopped, Rear pump pressure sensor
defective clearance at sensor, etc.), system / 24 /.?.‘-:I n 1
the central decimal point does not Pressure sensor power source
25 .a!;, n
flash. system
Example of display -1 \- n
Engine speed sensor system 26 .I: .I3
a) H.0 and H mode when normal
Auto-deceleration output 7 \-\ n
28 .\: .\z\
system
Overheat system 29 --\ \l .

b) Same as a) but “throttle signal .L . 3
system abnormal”
Controller
flashes in
turn with Power source system All OFF n
20$05
POSITION OF SELF-DIAGNOSTIC DISPLAY FOR EACH CONTROLLER
engine throttle controller
For pump controller F20505400
TROUBLESHOOTING PROCEDURE WHEN ABNORMALITY OCCURS
Remedy
2 YES
Go to troubleshooting for
governor controller system
Engir Does governor
controller give ab- _
normal display?
Problem in engine, mechan

NO c.3 swtem
Go to troubleshooting for
pump cO”trOller system
‘IH
3
Go to troubleshooting for H
Does pump con- mode hydraulic and me-
troller give abnor- chanical system
Hydrauli c mal display?
wste”l
-1
4 5
4
YE! 30 to troubleshooting for
npplicalble item in C mode
Is monitor display
there is abnormality in
of pump Controller
em (2). (3). (51 - (7). (9).
NO input signal
12). (13)
normal?
I I >o to troubleshooting for
* See table for confirmation applicable item in M mode
of operation of electrical
sy.stem.
Note: items (11, (4). (15).
(16) do not apply.
‘there is abnormality in ;O to troubleshooting for
em @L 110). (11). (14). applicable item in F mode
20-io6
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE
l ENGINE THROTTLE CONTROLLER SYSTEM * This table shows how the controller reacts and what symptoms the machine displays if any abnormality should occur in the
Condition when normal Symptoms shown by machine when there is

Display code System with abnormality Details of abnormality Action of controller when abnormality is detected
(voltage; current, resistance values) abnormality
1. Controller power source system

Disconnection in wiring harness between El (1) and fuse (2)
Red Green Red Disconnection in wiring harness between El (2) - M20 (3) - M20 (4) 1. Engine can be started, but remains at low
Power source system 1. Between!?1 (1) - El (12): 20 - 30V
0 0 0 - starting switch Cannot control idling.
or controller 2. BetweenEl (2) - El (12): 20 - 30V
OFF OFF OFF Disconnection in wiring harness between Ml (I 2) and chassis 2. Engine does not stop.
2. Defective controller
3. Defective contact of connector El
El E5 Resistance value
Makes motor drive current 0.
1. Short circuit inside governor motor Between (31 - Cl41 Between (11 - 12l 4- 9u
(Abnormal display disappears when starting
1. During operation
2. Short circuit of wiring harness between El (3) - E2 (3) - E5 (1) with Between (3) - (4) 4-911
I) Speed drops to low idling.
Red Green Red Between (41 - I1 51 switch is turned OFF.) 2) Engine does not stop.
0 0 0
Short circuit in wiring harness between El (14) - E2 (4) - E5 (2)
Between 13) - I41 Between (1) - (3) Min 1MIl * If the failure location is reset during opera- 2. When engine stops
governor motor system 3. Short circuit of wiring harness between El (4) - E2 (10) - E5 (2) with
Min 1 MR
ON OFF ON wiring harness between El (15) - E2 (9) - E5 (4)
Between 114) - I1 51 Between (2) - (4) tion, the display returns to the normal dis- 1)
Engine starts, but stays at low idling.
Between each pin - chassis Min. 1 Mf1 play. (The same applies for other failures 2) Engine does not stop after starting.
4. Wiring harness in Item 2 or 3 in contact with ground
also)
Motor drive current: 0.6 - 0.8A
When excess current fl

* Occurs only when e
Red Green Red 1. Between El (13) and chassis: 20 - 3OV
Short circuit in battery Battery relay drive current is set to 0. Engine does not start.
* Is held for approx. 4 set after starting
switch is turned OFF.
1. Disconnection inside governor motor

Red Green Red 2. Disconnection in wiring harness between El (3) - E2 (3) - E5 (1)
Disconnection in 3. Disconnection in wiring harness between El (4) - E2 (IO) - E5 (3)
Same as short circuit for governor motor system No particular action is taken.
governor motor system 4. Disconnection in wiring harness between El (14) - E2 (4) - E5 (2) phase or B phase,
ON OFF OFF
6. Disconnection in wiring harness between El (15) - E2 (9) - E5 (4) 1)Engine does not stop.
6. Defective contact of connectors El, E2, E5
1. Short circuit in wiring harness between El (5) - (6). (6) - (16). (5) - (16).
2. Short circuit in wiring harness between E2 (1) -
(2). (2) - (7). (1) (7). -
(2). (2) - (3). (1) - (3).
(2). (2) - (3). (11 (3). - Controls by calculating the position of the
5. Short circuit in wiring harness between El (10) - (20). (C20 (10) - (20)).
motor from the voltage value just before oc-
6. Shortcircuit in wiring harness between El (7) - (8). (8) - (18). (7) - (18).
currence of the abnormality.
OFF ON ON
7. Disconnection in wiring harness between El (6) - E2 (1) -
E4 (1).
8. Disconnection in wiring harness between El (5) - E2 (2) - E4 (2).
9. Disconnection in wiring harness between El (16) - E2 (7) - E4 (3).
10. Defective governor potentiometer.
1 1. Defective contact of connectors El, E2, E5
Fuel control dial
Fuel control dial

Abnormality in fuel At MAX: 0.25 - 1 .OV Holds the engine speed at the fuel control dial
control dial system 1. Short circuit in wiring harness between El (7) - (18), (7) - (8). (8) - (18). position just before the abnormality occurs.
At MIN: 4.0 - 4.75\/
(2). (1) -
(3). (2) - (3).
3. Short circuit in wiring harness between El (10) - (20). (C2 (10) - (20)). * PEMC control impossible
4. Disconnection in wiring harness between El (7) - E6 (1).
5. Disconnection in wiring harness between El (8) - E6 (2).
6. Disconnection in wiring harness between El (I 8) - E6 (3).
7. Defective fuel control dial
8. Defective contact of connectors El, E6
1. Contact of wiring between harnesses between El (9) - (19) (C2 (1 1) - 21)). Actuated by the movement of the fuel control
Red Green Red 2. Disconnection in wiring harness between El (9) - C2 (1 1). When power set is set to S or L mode, engine
Abnormality in No. 2 BetweenEl (9) - (19) (C2 (1 1) - (21)): dial.
3. Disconnection in wiring harness between El (19) - C2 (21). speed does not drop.
0 0 0 throttle signal system 0.25 - 4.75u * In the case of Item 2, the pump controller
4. Abnormality in pump controller signal * PEMC control impossible
ON ON OFF also displays.
5. Defective contact of connectors El, C2
20-Ao7
. PUMP CONTROLLER SYSTEM t This table shows how the controller reacts and what symptoms the machine displays if any abnormality should occur in the
sensors or actuators. (For those who have good understanding of mechatronics, troubleshooting can be carried out using this table.)
Display System with Condition when normal
Details of abnormality Action of controller when abnormality is detected Symptoms shown by machine when there is abnormality
code abnormality (voltage, current, resistance values)
2-stage relief Resistance value of solenoid: The relief pressure is not increased when using the power maximiz-
01 ing function, so there is lack of power
solenoid 50- 1000
Arm half flow Resistance value of solenoid: In F.0 mode, the Hi circuit is not cut, so the fine control is poor. (The
03 solenoid IO-350 digging speed is the same as in G.0 mode)
Short circuit inside solenoid or between .

solenoid pins (1) - (2).
Swing brake Resistance value of solenoid: During swing operations, the motor brake is not released, SO the
04 (When resistance inside solenoid is ex-
solenoid IO-35a machine does not swing
tremely low) It makes the current to the solenoid 0.
Excessive current flows However, the abnormality is temporary (momentary short
circuit, etc.), so if the system returns to normal, the drive
Travel speed Resistance value of solenoid: current is output again when all control levers are returned Travel speed does not change (stays in Lo) when travel speed
05
solenoid 50 - 100 n to neutral. switch is operated
* However, the display does not disappear (it disappears
when the power is turned OFF).
* The above automatic reset is repeated up to three times. Action of CO valve does not stop when using the power maximizing
CO cancel Resisistance value of solenoid:
07 function, so the pump discharge amount is minimum. Therefore,
solenoid 50- IOOR
the speed is low in this pressure range.
TVC (+I line in contact with ground

08
(excessive current flows)
Current does not flow to the TVC solenoid. Therefore, when the
Resistance value of solenoid:
TVC solenoid load is high, the engine speed drops excessively, and the engine
IO-22I1
Short circuit or contact with ground may even stall. (All of H, S, and L modes)
09 inside TVC solenoid (excessive current
flows)
1. In cases 1) and 21, current stops flowing to the solenoid,

2-stage relief Resistance value of solenoid: so not particular action is carried out. Therefore, if abnor-
11 1. In cases 1) and 21, it is the same as display 01.
solenoid 50- IOOR mal places are reset by the vibration of the machine, they
become normal again.
* However, the display does not disappear (disappears
when power is turned OFF.) 1. In cases I) and 2), it is the same as display 03.
Arm half flow Resistance value of solenoid:
13 2. In the case of 31, the Hi circuit remains cut, so the speed for
solenoid IO-35R 2. In case 3). electric current continues to flow to the sole-
1) Disconnection inside solenord normal work is low.
noid, but the controller does not carry out any action.
(The resistance inside the solenoid
Therefore, if the abnormal places are reset, they return to
is extremely large) 1. In cases 1) and 21, it is the same as display 04.
normal.
Swing brake 2) Disconnection in wiring harness be- Resistance value of solenoid: 2. In the case of 31, the brake stays released, so the brake has no
14 * However, the display does not disappear (disappears
solenoid tween solenoid pin (2) and controller IO-35n effect even when the lever is returned to neutral. (The upper
when power is turned OFF.) structure will swing on slopes.)
3) Contact with ground at pin (2) of
solenoid
* When the controller sends the command to turn the sole- _
Travel speed
noid current OFF, the voltage at portion @ should be 20 1. In cases I) and 21, it is the same as display 05.
Resistance value of solenoid: - 30V; if there is any disconnection or contact with the 2. In the case of 31, the solenoid continues to be actuated and
15’
solenoid 50- 1000 ground, the voltage at portion @ is low (almost OV), so it stays at Hi.
can be judged that there is an abnormality.
CO cancel Resisistance value of solenoid: 1. In cases I) and 21, it is the same as display 07.
17
solenoid - 100 fi w/sJ+zBv = 1”. 205F05348
Resistance value of solenoid:

IO-22R
I) Disconnection inside solenoid or dis- Value of current 1. In the cases I), it is the same as display 08,09.
connection in wiring harness be-
1. In the case of I),it is the same as Item 1 above. 2. In the cases 2). the same current (approx. 1A) continues to flow
tween controller Cl (9). (17) - &, 2. In the case of 21, current continues to flow (approx. IA) to the TVC solenoid, so the TVC valve output pressure drops
18 TVC solenoid TVC solenoid
to the solenoid and the total speed becomes slower.
2) Contact of wiring harness between
3. Other items are the same as Item 2 above. (There is no change even when the power set is switched be-
controller Cl (17) - TVC solenoid
Engine at high idling, H.0 mode. tween H, S, and L.)
C4 (2) with ground
(Auto-deceleration OFF, levers at
neutral)
1. Voltage between Cl (1 I) and There is an abnormal display, but no particular action is
(12) taken. Therefore, if the places in contact with the ground
Wiring harness between controller C2 Even when the fuel control dial is set to MAX and the auto-
21
No. 2 throttle
(1 I) - engine throttle controller El (9) : 0.8 - 4.2V are reset by the vibration of the machine, the condition re-
deceleration is canceled, the high idling speed of the engine does
signal 2. Resistance value between Cl turns to normal.
in contact with ground not change for H.0 + H mode or G.0 + S mode.
(female) (1 I) and El (9) * However, the display does not disappear (disappears
: Min. 1 M n (Disconnect El) when power is turned OFF.)
20-Ao8
lisplay System with Condition when normal
Details of abnormality Action of controller when abnormality is detected Symptoms shown by machine when there is abnormality
:ode abnormality (voltage, current, resistance values)
I) Disconnection in wiring harness (I).
2) Wiring harness (1) in contact with
ground
3) Disconnection in wiring harness (2).
4) Disconnection in wiring harness (3)
or contact with ground
It acts when the fuel control dial is set to MAX. If it is reset, it 1. In the case of I) or 31,
5) Disconnection in wiring harness (4) 1. Between El (8) and (18) acts again in proportion to the mbvement of the fuel control i) Operates normally when the fuel control dial is set to MAX.
or contact with ground : (MAX) 0.25 - 4.75 v (MINI dial. ii) When the fuel control dial is set to “partial”, the power feels
6) Disconnection in wiring harness (5). 2. Between El (7) and (18)
22 Throttle signal t However, the display does not disappear (disappears less than S mode although it is in H mode.
E6iS161 : 5 * 0.5v
&ON when power is turned OFF.) 2. In case of 2),4), 5). or 6).
COntlOl
dldl 3. Between C2 (IO) and (20) * In the case of 21, 4). 51, and 6). the engine throttle con- The engine speed does not change even when the fuel control
c : (MAX) 0.25 - 4.75 v (MINI troller also shows abnormality. dial is turned.
Pvmp
COntrOlier
205F05349
* In the case of 2). 41, 51, and 6). the
engine throttle controller also show
abnormality.
”
1) Defective pressure sensor
2) Disconnection in wiring harness be-
tween pressure sensor (3) pin and k 205FO5350 1. Cannot carry out PEMC control in S or L mode
controller,.or contact with ground Operate with pressure at 0 kg/cm2. If the abnormal place is
3) Disconnection in wiring harness be- 1. Between C3 (6) a\d (1) (There is a horsepower difference between H, S, and L mode)
23 Pump pressure : 0.5 - 4.5v reset, it operates normally. 2. Travel speed does not change automatically (does not change
tween pressure sensor (I) pin and f However, the display does not disappear (disappears
sensor signal controller
2. Between C7 (1) and (2) from Hi to Lo)
24 when power is turned OFF.)
4) Disconnection in wiring harness be-
: l8-28V * Can be changed manually.
tween pressure sensor (2) pin and 3. Resistance value between C3
(female) (6) and (1). and be-
controller, or contact with ground
tween (6) and chassis
I) Defective pressure sensor : Min. 1 M fi Operates with pressure at 0 kg/cm2. When it detects an ab-
Pump pressure
2) Wiring harness between pressure (Disconnect connector of pres- normality, it turns the output OFF; when all control levers
25 sensor power Same as display 23
sensor (2) pin and controller in con- sure sensor and connector at are returned to neutral, it outputs again.
source Sr This automatic resetting is repeated up to three times.
tact with ground C3 (male))
1. Operates when the engine is at low idling. In other words,
I) Disconnection inside speed sensor it judges that the engine speed is low, so it increases the
(When the resistance inside the current to the TVC solenoid. If it is reset during operation,
Engine speed it returns to normal. The output pressure of the TVC valve drops, so the pump discharge
sensor has become extremely high)
26 Resistance value: 500 - 1000 R * However, the display does not disappear (disappears pressure drops (the engine load becomes lighter), and the total
sensor signal 2) Disconnection in wiring harness be-
when power is turned OFF.) speed becomes slower.
tween speed sensor E7 (11 (2) pin
2. When the sensor function has been lost because of dis-
and controller
connection inside the speed sensor, the speed sensor
monitor on the controller does not flash.
I) Disconnection in wiring harness be-
tween controller C2 (19) and engine 1. Voltage between C2 (19) and When the auto-deceleration switch on the panel is ON
throttle controller El (1 1) chassis I) When the engine speed has dropped to deceleration speed, it be-
It does not carry out any particular action. Therefore, if it is comes FULL speed. Or, if the engine is running at FULL speed,
Auto-deceleration 2) Wiring harness between C2 (14) l During deceleration: 0 - 1V
reset during operation, and all control levers are returned to
28
signal and El (I I) in contact with ground l When canceled: 8 - 12V the engine speed does not drop to deceleration speed even
neutral, the output starts again. when the levers are placed in neutral.
3) When auto-deceleration is canceled, 2. Resistance value between C2
and voltage between C2 (19) and (19) and chassis: Min. 1 fi 2) Even when the levers are operated, deceleration is not canceled.
(2 I) drops below 7V.
1. Voltage between C2 (17) and 1. When 102°C signal is input:
When voltage between controller C2
chassis, and between (I 8) and No. 2 throttle circuit outputs L mode speed command to
(I 7). (I 8) - (8) is below IV (when I. In the case of I), it becomes L mode (controller display also be-
chassis engine thrcttle controller
29 Overheat signal engine is overheating and monitor comes L)
l When normal: IO - 13V 2. When 107°C signal is input:
panel gives coolant temperature 2. In the case of 2). the engine speed becomes low idling.
l When overheat signal is NO. 2 throttle circuit outputs low idling command to
warning)
given: 0 - 2V engine throttle controller.
1. Upper structure does not swing because swing brake is not
released.
1) Power source is not input All functions stop, but when the power source voltage be- 2. Current of TVC solenoid becomes 0.
411off Power source 2) When voltage is more than 38V or Voltage: 20 - 30V comes normal, the functions return to normal. (If the load is high, the drop in engine speed is large, and the
less than 19V. * The display also becomes normal engine may stall)
3. Travel speed is not switched.
4. Engine speed does not go down to deceleration speed.
Except for swing brake circuit, all functions stop.

Self-diagnostic check inside controller Apart from swing brake and TVC solenoid, same as above.
0 Only dot lights up Sr However, TVC solenoid only gives a fixed output of
(cannot be measured from outside)
approx. 0.7A.
20-&O?
METHOD OF USING JUDGEMENT TABLE
This judgement table is a tool to determine if the problem with the machine is caused by an abnormali-
ty in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms
are then used to decide which troubleshooting table (E-c c, C-c c, H-c c) matches the symptoms.
The presence of any self-diagnostic display given in the judgement table indicates which troubleshoot-
ing table to use.
Ir The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of
the vehicle monitor (P-o 01.
(See the contents for troubleshooting of the vehicle monitor system)
1. Judgement table for engine throttle controller, engine related parts

l If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (E-c.1
given on the bottom line of the judgement table.
(There is a l given in the column where the failure mode.and self-diagnostic display, go to the
troubleshooting code (E-c or engine shop manual) given in the column on the right of the
judgement table for that failure mode.
< Example > Failure mode “Engine does not start”
[Procedure]
Check the three LEDs on the side face of the controller to see if their ON/OFF co.mbination gives an ab-
normal display for the self-diagnostic display.
[Judgementl
If there is an abnormal display (for example, F]) on the self-diagnostic display:
Go to troubleshooting E-2 of the electrical system
If there is no abnormal display on the self-diagnostic display:

Go to troubleshooting of
Starting motor rotates: .. . ... . ... .. .. .. . . .. ... .. .. . mechanical system
(see engine shop manual)
l Check that the starting
motor rotates
--II Go to troubleshooting of
Starting motor does not rotate: ............
electrical system Fl , 2, or 6
2. Judgement table for pump controller, hydraulic related parts
l If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (C-c
01 given on the bottom line of the judgement table.
(There is a l given in the column where the failure mode and self-diagnostic display come
together.)
l For any problem where there is no abnormal display given by the self-diagnostic display, check
the chart for the place where the failure mode and input signal display come together (place
marked G).
If the display is normal, go to the troubleshooting code (H-c c) given in the column on the
right of the judgement table.
If the input signal is not displayed, go to the troubleshooting code (F-c c) given on the
bottom line.
<Example > Failure mode “Auto-deceleration does not work”
[Procedure]
Check if an abnormal display is given by the self-diagnostic display, or if the numbers on the side face
of the controller are flashing.
If there is an abnormal display (for example, 28) on the self-diagnostic display:

Go to troubleshooting C-21 of the electrical system.
If there is no abnormal display on the self-diagnostic display, and the auto-deceleration does not work:
Display given: ...................... Go to troubleshooting of

I- hydraulic system H-7
l Check the monitor for the pu.mp
controller input signal
-L No display given: ........ .... .. .. Go to troubleshooting of
electrical system F 1, 2, 3, or 6
*O-A’
’
METHOD OF USING TROUBLESHOOTING CHARTS
1. Category of troubleshooting code number
Troubleshooting
Component
Code No.
Troubleshooting of engine throttle

E-c G
controller system
Troubleshooting of pump controller

c-cc
system
F-G G
1 Troubleshooting
input signal system
Troubleshooting
of pump controller
of hydraulic,
H-cc
mechanical system
P-c c Troubleshooting of monitor system
2. Method of using troubleshooting table

Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the prob-
lem with the machine.
Distinguishing condition
Even with the same problem the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item.
Method of following troubleshooting chart
Check or measure the item inside the box, and according to the answer follow either the
YES line or the NO line to go to the next box. (Note: The number written at the top right
corner of the box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
Below the box there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the box are correct or the answer to the question
inside the box is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item I).
General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top
of the page and marked with *. The precautions marked Ir are not given in the box, but must
always be followed when carrying out the check inside the box.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-A12
Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection table, so when carrying out troubleshooting, see this chart for details of the
connector pin number and location for details of the connector pin number and locations for in-
spection and measurement of wiring connector number o o appearing in the troubleshooting
flow chart.
< Example >
o E_2 PI
[Short circuit in governor motor] is displayed
@ (There are cases where the troubleshooting is divided into Sections a), b) etc.)
* If this happens during operation, because of the force of the spring:
I) Engine speed changes to low idling
2) Engine does not stop
* If the problem occured when the engine was stopped:
1) Engine starts but remains at low idling
2) Engine starts, but does not stop
A Stop the engine (place the fuel lever of the injection pump in the NO INJECTION posi-
tion) before carrying out any checks.
@ Ir Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
0
TROUBLESHOOTING OF ENGINE THROTTLE
CONTROLLER SYSTEM (E MODE)
Engine throttle controller or in engine related parts. _. . . . . . . . . . . . _ . . . . . . . _. . . . . . 20-I 16

Points to remember when carrying out troubleshooting on engine
throttle controller system.. . . . . . . . . . . . . . . . . __ . . . _ . . . . _ . . . . . . . . . . . . . . . . . . . . 20-I 17
Failure mode
Self-diagnostic display
E- 1 -1 [Abnormality in power source system or controller] is
displayed .............................................
(All lamps OFF) 20-I 18
E- 2 vf [Short circuit in governor motor1 is displayed ........................... 20-I 20
E- 3 I=] [Abnormality in battery relay) is displayed .............................. 20-I 21
E- 4 I=0 [Disconnection in wiring harness of governor motor1 is displayed ......... 20-I 22
E- 5 m [Abnormality in governor potentiometer] is displayed .................... 20-I 24
E- 6 m [Abnormality in fuel control dial1 is displayed . . . . 20-126
E- 7 m [Abnormality in No. 2 throttle signal1 is displayed . 20-128
No self-diagnostic display
E- 8 Engine does not start ........... .. ........ ...... 20-I 30
E- 9 Engine rotation is irregular
a) Idling rotation is irregular.. . . . . . . . _. . . . . . . . . . . _ . . . . 20-132
b) There is hunting. . . . . . . . . . . . . . . . . . . . . . . . . _. . . 20-134
E-l 0 Lack of output power (max. engine speed is too low) . . . 20-136
E-l 1 Engine does not stop _ . . . . . . . . . . . _ . . . . . . . . _ . . . 20-138
E-l 2 Automatic warming-up operation is defective . ....... . 20-140
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS
Lack of output power
011level Increases
POINTS TO REMEMBER WHEN CARRYING OUT
TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER
SYSTEM
The engine on the PC300,400 is controlled by an engine throttle controller.

The problems that may arise with this system are as follows.
1. Low idling speed in too high (low)

2. High idling speed is too low
3. Auto-deceleration speed is too high (low)
4. Automatic warming-up speed is too high (low)
5. There is hunting
6. Engine does not stop
If an abnormality occurs and the abnormality is displayed by the self-diagnostic display, use the charts
to go to the applicable troubleshooting flowchart G-l - G-7. However, if there is no self-diagnostic
display, and there is an abnormality in the machine, it is necessary to determine if the problem is in the
mechanical system or in the electrical system.
For example, if there is defective adjustment of the linkage between the governor motor and injection
pump, the above problems 1 - 6 may occur.
Therefore, if any of the above problems 1 - 6 occurs, carry out the following troubleshooting
procedure.
YES Defective adjustment of governor

motor lInKage
SeeTESTING AND ADJUSTING.
Go to troubleshooting of electrical
svstem E-9- E-l 1.
P If the enginedoes
not stop, push the
governor lever to
the STOP position
and check if the
engine stops.
After disconnecting or adjusting the linkage as shown above, go to the troubleshooting flow chart for
the mechanical system or electrical system.
* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
E-1 m] [Abnormality in power source system or controller] is
displayed (All lamps OFF)
PC300,3OOLC-5 Serial No: 20001 - 21400
PC400,4OOLC-5 Serial No: 20001 - 20602
* When fuse 9 is not blown
(If it is blown, check for any short circuit with the ground in the circuit to the starting switch.)
* If battery is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
3 YES
Disconnect connec-
YES tar El and replace
2 - fuse 2. Does it blow
- again?
Repalce fuse 2. . Turn starting NO

, Does it blow again7 - switch ON.
* Turn starting
switch ON.
NO
ES
Does working lamp
- Turn starting
switch ON.
4
\, Is voltage between
El (1) and El 112)
* 20 - 3ov
. Turn start,ng
switch ON.
Is voltage between
battery relay termi-
1
NC
* Turn starting
switch ON.
starting swatch ter-
minal BR and
Chassis normals
* 20 - 3ov
. Turn starting
switch ON.
NO
“al BR and chassis

10 YES
* 20 - 3ov
/SHP
* Turn starting
switch ON. I
n .
* zo-3ov
Turn starting
switch ON.
NO
MZOlM4)
EI(MIC2Il
Ml4(S8)
F20505466
Cause
Short circuit in wiring

harness between fuse 2 and Inspect, repair
Abnormally in engine
ReDlace
throttle controller
Defective enigne throttle

ReDlace
controller
Defective contact, Or
disconnection in wiring
harness between El
(female) (12) - Ml4 (8)
chassis ground
Defective contact, or
harness between El
(female) (2) - D14 - M20
- Ml (2) -starting switch
terminal BR
Defective starting switch Repl.3Ce
Defective contact. Or
Repair or
harness between El
W2pkCe
(female) (1) and fuse 2
Outlet
Defecwe battery relay RZ?.plXe
Defective contact. or
harness between stating Repair or
switch terminal BR - Ml (2) replaCe
- M20 - DlO - M7 (2) -
battery relay terminal BR
Defective starting switch
20219
PC300,3OOLC-5 Serial No: 21401 and up PC400,4OOLC-5 Serial No: 20603 and up
PC300HD-5 PC400H D-5
* When fuse 9 is not blown
(If it is blown, check for any short circuit with the ground in the circuit to the starting switch.)
* If battery is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on to the next step.
3 YES
Disconnect connec-
YES tar El and replace
.
fuse 2. Does it blow
again?
H’
r---4
I I
Repalce fuse 2. Turn starung NO
Does it blow again? switch ON.
*
------I
Turn starting
switch ON.
NO
7 YES
Is there continuity
YES between El
- (female) (12) and -
battery relay termi-
6 nal i-b?
. Turn staning NO
Is voltage between switch OFF.
El (2) and chaws - * Disconnect El.
normal’
fl YES
5 * 20 - 3ov
Is voltage between
* Turn starting
starting switch ter
Isvoltage between switch ON.
-
NO
minal BR and
El (1) and El (12) chassis normal?
* 20 - 3ov NO
* 20 - 3ov . Turn starting
swtch ON.
4 . Turn staning
switch ON.
1
NO
Does working lamp
light up?
I
* Turn staning
YES
switch ON. 9 1
I I
1 20 - 3ov NO
f Turn staeing
watch ON.
F20505467
Cause Remedy
/ Shoe circuit in wiring

harness between fuse 2 and Inspect. repair
controller
Abnormality in engine
thronle controller
Already reset
Defecwe enigne throftle

ReplaCe
Controller
disconnection in Wiring
Repair or
harness between El
reDlace
(female) 112) - Ml4 (81 -
chassis ground
disconnection in wiring Repair or
harness between El repLXf2
(female) (2) - D14 - M2O -
Ml (2) -starting switch
terminal BR
Defective starting switch Replace
Defective cbntact, Or
Repair or
harness between El
reDlace
(female) (1) and fuse 2
Outlet
Defective battery relay RC!DlFJC.9
Defective contact. or
harness between starting Repair or
switch terminal BR - Ml (2) P?plG3
- M20 - DlO - M7 (2) -
battery relay terminal (c)
Defective starting switch RKhX

E-2 f%?!?i [Short circuit in governor motor] is displayed
* If this happens during operation, because of the force of the spring:

1) Engine speed changes to low idling.
* If the problem occured when the engine was stopped:
I) Engine starts but remains at low idling
2) Engine starts, but does not stop
Stop the engine (place the governor lever of the injection pump in the NO INJECTION position)
before carrying out any checks.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
YES ween each pin of

- El (female), and _
Red Green Red each pin - chassis Short circuit in wiring
Is as shown in Table harness for problem
Repair or
tween each pin of pin No. (between El-
replaCe
E5 (male),and ‘_ NO E2-E5)
each pin-chassis
-,‘i ._ ___._.__
srarr,ng
I “rrl
* See Fig. 1
ON OFF ON switch OFF.
as she
l Disconnect El.
I?
1
l Turr 1
startina
~._ Defective go”ernor n__,___
NO motor nqA.dse
switch OFF.”
l Disconnect E5.
Fig. 1
205FO5352-2
20-l 20
0
E-3 I] [Abnormality in battery relay] is displayed
Note: This occurs only when the engine is stopped and the starting switch is turned to the OFF position.
* The engine does not stop.
Astop the engine (place the governor lever of the injection pump in the NO INJECTION position)
-J, Always connect any disconnected connectors before going on to the next step.
. Between El (13)-battery relay BR: Max. Ia harness

. Between wiring harness - chassis: Min. 1 MS1 2) When lamp is
*Turn starting switch OFF. connected
. Disconnect El and battery relay BR.
MI(M4) Fuse
Starting switch
E I (MIC21) M7(L2) Battery relay
F20505356
When ON (approx. 24V)
Voltage from starting 1 To battery re,ay BR

switch (El (2))
OFF
Voltage output from controller when starting
- switch is OFF
When ON
(approx. 24V)
Controller circuit (Note)
To battery relay BR
actuated (El (13)) OFF1
L - Min.: 2.5 set
Drive time Max.: 7 set (when it is impossible to set to NO INJECTION
because of failure of the motor)
205FO5354
Note: When the starting switch is ON, the controller is OFF, but a voltage of 20 - 3OV is always
flowing from the starting switch BR, so if the measurement is made at El (13). the voltage is
20 - 3ov.
2o-A21
E-4 I”,“-\ [Disconnection in wiring harness of governor
motor1 is displayed
* During operation:
1) If there is disconnection simultaneously in the A phase and B phase:
Engine speed changes to low idling
Engine does not stop
2) If there is a disconnection in either A phase or B phase:
The engine speed stays the same as immediately before the problem occured.
* If the problem occurred when th engine was stopped:
I) Engine starts but remains at low idling
AStop the engine (place the governor lever of the injection pump in the NO INJECTION position)
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
Remedy
2 YES Defective engine throttle

Replace
’ 19 resistance controller
k$$e;,each
YES
1 - (fema’e’,and
eacn pin-chassil Short circuit in wiring
Red Green Red Is resisrance 3%IhOW” in harness for problem pin
Table 17 NO Repair or
between each No. (between El - E2
I,eplace
pin of E5 (male), _ . Turn starting switch OFF. -E5)
000 and each pin- * Disconnect El. l See Fig. 1
chassis as shown
ON OFF OFF
in Table 1?
Defective governor
Replace
motor
Table 1
E5 (male) El (female) Resistance value
(1) - (2) (3) - (14) 4--9a-?
(3) - (4) (4) - (15) 4-951
I (1) - (3) I (3) - (4) 1 Min. 1 M.Q 1

(I) - (4) (3) - (15) Min. 1 Ma
Between pins (1). (2) Between pins (3). (4).

Min. 1 Ma
(3). (4) - chassis (14). (15) -chassis
Fig 1
E I (MIC21)
I \\ _I1
205FO5352-2
*O-A**
E-5 r] [Abnormality in governor potentiometer] is
displayed
* If the pump controller displays only “22”. go to troubleshooting C-l 8.

* Always connect any disconnected connectors before going on the next step.
4
Is resistance bet-
YES ween El (female)
.- (6) - (5). (5) - -
(16). (6) - (16) as
_ 3 shown in Table 11
Is resistance
betwBen E4 . Turn starting
_ (male) (1) - (2). switch OFF.
(1) - (3). (2) - - * Disconnect El.
(3) as shown in
Table I?
* Turn starting
* Between wiring
harness and I
chassis: Min. 1 MAI I\
* Turn starting
switch 0 F F.
*Disconnect El and C2.
8 YES
Governormotor
. Turn starting I
switch OFF. NO
- Disconnect E4.
E I (MIC21)
C2(MIC21)
Puma controller
Fuel control dial
Governor potentiometer
E2(Sl2) E4(X3)
F205F05357A
20-A24
F
Cause Remedy
6 YES
r
Defective engine throttle
RW+Xe
Is resistance bet- controller
ween El (female)
YI
- (71 - (B), (8) - -
(18), (7) - (18) as Wiring harness between
shown in Table l? ND El (female) (7) - E6
Repair or
* (female) (1) in contact rePlaCe
* Turn starting switch OFF. with ground, or contact
* Disconnect El. with other wiring harness
Defective fuel
switch 0 F F. control dial
* Disconnect E6.
Wiring harness between

El (female) (6)-E2 (1)
I -E4 (female) (I) in Repair or
NO contact with ground, or reDlace
contact with other
wiring harness.
Defective governor
motor Replace

harness between El
(female) (IO), (20) - qepair or
c2 (female) (10). 120), %vlace
or contact with ground
Defective wiring
harness in system where iepair or
resistance value is ep1ace
defective
Table 1
E4 (male) E6 (male) El (female) El (female) Resistance value (KR)
Between (I) - (3) Between (I) - (3) Between (6) - (16) Between (7) - (18) 4-6
Between (I) - (2) Between (I) - (2) Between (6) - (5) Between (7) - (8) 0.25 - 7.0
Between (2) - (3) Between (2) - (3) Between (5) - (16) Between (8) - (I 8) 0.25 - 7.0
- - Betfhwa;w; (6) (5) (16) Between (7) (8) (18) Min. 1 MA2
_ - chassis
20-125
0
E-6 I”,” [Abnormality in fuel control dial] is displayed
Ir When the relevant abnormality is displayed, “Pump controller abnormality display 22” is also dis-
played at the same time.
GUS5 Ret-“&V
j 13efective engine throttle

Redace
c:ontroller
YE
2 Ilarness between
,Ifemale)
El Repair or
(10). (20) - rewlace
f Min. lOOkS2 NC) ,C2 (female) (10). (20).
ween El (female) - Between wiring ,3r contact with ground
(7) - (81, (7) - harness - chassis:
(181, (8) - (18) as Min. 1 Ma
shown in Table I? * Turn starting
switch OFF.
. Turn starting Defective wiring
* Disconnect El and CZ !
switch OFF. harness in system where
. Disconnect El. resistance value is
defective
A . Turn starting
switch OFF.
Defective fuel control
. Disconnect E6 RePlaCe
dial
Table 1
E6 (male) El (female) Resistance value (Ka;2)
Between (1) - (3) Between (7) - (18) 4-6
Between (1) - (2) Between (7) - (8) 0.25 - 7.0

Between (2) - (3) Between (8) - (18) 0.25 - 7.0
_ Between (7)(8)(18)
Min. 1 Ma
- chassis
Fig. 1
El (MIC21)
I C2(MIC211
I 1 r I 1
Pump controller
E6(M3)
Fuel control dial
F20505358
E-7 E] [Abnormality in No. 2 throttle signal] is displayed
Yl iS
9 r
15 re*istance -1 I . Turn starting
‘:::h:FF, ’ j
NO
* Disconnect El.
1 Red Green Red i Is resistance

switch OFF.
* Disconnect El
and C2.
’ a Turn starting
switch OFF.
* Disconnect El.
Table 1
El (female) - Engine throttle controller Pump controller

El (female) Resistance value
C2 (female)
-
EI(MICZl)
Between (9) - (19) Min. 1 M.Q
Between (9)-chassis _ Min. 1 h0.Q
Between (19) - - Min. 1 M.Q

chassis
- Between (9) - (11) Max. 1 .Q
- Between (19) - (21) Max. 1 n
205FO5358
Table 2 Voltage (V)
Condition when measuring PC300 PC400
(1) when overhearing 4.0 - 4.25 4.0 - 4.25
(2) L.0 and L mode 2.10 - 2.40 2.20 - 2.50
G.O. F.O. L.0 and S mode

(3) - 1.23 - 1.53 1.35 - 1.65
G.O. F.0 and L mode
(4) H.0 mode or H mode 0.75 - 1.0 0.75 - 1 .o
Engine speed (rpm)
*O-i**
CalEe Remedy
Defective engine throttle ReplaCe

controller
Replace
Contact of wiring
harness between El Repair or
(female) (9), (19)- replace
C2 (female) (1 l), (21)
Disconnection in wiring
harness between El Repair or
(female) (9), (19)-C2 replace
(female) (11). (21)
Wiring harness between

El (female) (9). (19)- Repair or
C2 (female) (11). (21) in replace
contact with ground
20-i29
E-8 Engine does not start
Ir When the starting motor does not turn.

Sr Check that fuse 9 is not blown before starting troubleshooting.
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
. Turn starting
’ ,::::. to sTA-G!\e[[
* Turn startina switch to START.

* Approx. 24c
2
Is any noise 9 YES
heard from
1
Y battery relay Is there con-
when starting YES tinuity between
switch is rurned - battery terminal -
El OFF? 8
_ (-) - batrerv
- Turn starting Is resistanceof relay terminal-b?
Switch ON-OFF wiring harness
between starting NO
switch BR-
battery reray BR
normal?
a Between starting NO
switch BR- battery
relay BR: Max. 1 CZ
’ Between wiring harness- chassis: Min. IMQ
. Disconnect at both Starting switch and bartery
relay ends.
- Voltage:
NO
Min. 24V
SDecific
gravity:
- Connect t-1 pole of‘I
Min. 1.26 tester to C-1terminalL
of battery.
NO
. zo-29v
NO
MZ(X2) E86WP8) Ml4681
r m Fysible link
MI(M4)
Mll(L2)
Starting
switch
205FO5721
*O-i30
Cause Remedy
I
Defective starting
ReDlace
motor
wiring harness between

Repair
battery terminal (+I -
starting motor terminal 6
switch terminal C-Ml
replace
(41-M14(1)--S(9)-
M2 (1 J-starting motor
terminal S
Defective starting
switch (between- ReDlaCe
terminals B-C)
Defective battery 3eDlace

WlPf
Defective contact of
battery terminal (-I-
battery relay terminal-b
switch terminal BR - Ml replace
(2)- M7 (2)-battery
relay terminal BR
Defective starting
switch (between Replace
terminal B- BR)
harness between battery Repair or
terminal (+)-Ml1 - M7 ri?DlaCe
(l)-Ml (l)-starting
switch terminal B
(including fusible link)
Charge or
Battery capacity too low
replaCe
E-9 Engine rotation is irregular
a) Idling rotation is irregular

* Before starting troubleshooting, check the model code.
* Always connect any disconnectd connectors before going on to the next step.
Warming-up signal 6 YES
Is voltage
YES between El
Starting signal 5 - (21) -(12) -
position when normal and
Is voltage stable?
connected? YES between El - When warming-up VO
- (2) - (12) Operating: Max. 1V
* Turn starting switch-
Potentiometer 4 normal and
* When warming-up
OFF. 7 stable?
canceled: 8 - 12V
Is voltage
* When operating:
YES between El (5) _ 20-30V
r - (16) normal NO
Fuel control dial
- At low ldllog
’ :fo::: *.9”J I
i
PC400: 2.6 - 3.0V NO
stable?
I
.At MIN.:
4.0 - 4.75v
. At MAX.:-
I
NO
0.25 - l.OV
Fuel control dial
205FO5722
Cause Remedy
Defective adjustment
Adjust
of linkage
Defective injection ;ee Engine she

pump nanual
Defective governor
m*tOr
See E-l 2
Defective contact of wiring

switch BR - Ml (2) - M20 reDlace
(4). (3) - El (female) (2), or
defective starting switch
See E-5
See E-6
b) There is hunting
I PC300 I PC400 I
2 YES
Adjust linkage
between governor
<ES motor and injec-
tion pump. Doer
it become
normal?
r
YES
Starting signal 7
IS voltage
between El
1 YES
(2) - (12)
Deceleration
Is motor lever signal normal and
6
aligned with dial stable?
I s-l--l 1
position
linkaoe
con&ted?
when
is dir-
YES
-
IS voltage
between
(~1) _ (~2)
El
_
* When
running:20-30V
engine ‘I NO
No. 2 throttle
normal and
- Turn starting signal 5 stable?
switch ON.
IS voltage
* Move fuel control
YES betwse” El
. When auto-decele-
dial from MIN. to _ ration operating:
- (9) - (19) NO
MAX. and stop on Max. 1V
Stable and as
the way. Potentiometer 4 . When auto-deceleration
shown in Table 17
canceled: 8 - 12V
IS voltage
Y ; between El Nrl
- (5) - (16)
normal and
stable?
. At low idling:
between El PC300: 2.6 - 2.9V
PC400: 2.6 - 3.OV
normal and . At high idling: NO
Pc300,400: 0.5 - 0.9v
At MIN.:
. When decelerating: PC300, 400: 1.7 - 2.0 V
4.0 - 4.75v
. When warming-up: PC300: 1.8 - 2.2V
PC400: 1.9 - 2.3V
At MAX.:
0.25 - 1 .OV IO
Table 1 Voltaae (VI
(1) When overheating 4.0 - 4.25 4.0 - 4.25
(2) 1L.0 and L mode .2.10- 2.40 2.20 - 2.50
(3) G.O. F.O. L.0 and S mode

1.23 - 1.53 1.35 - 1.65
G.O. F.0 and L mode
(4) H.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
Engine speed (rpm)
205FO5362
2o-A34
CFIlSe Remedy
Defective adjustment Adjust

of linkage
Defective injection See Engine she

pump nanua1
Warming-up signal 8 YES Defective governor

motor Replace
is voltage
between El
- (21) - (12) -
normal and
stable?
I I See E-l 2
. When warming-up NO
operating: Me;. 1 V
* When warming-up Defective contact of
canceled: 8 - 12V wiring harness between
starting switch BR - Ml Repair or
(2) - M20 (4). (31 - repleCe
El (female) (2) -
starting switch, or
See P-l 9
see E-7
See E-5
See E-6
Fuse
Fuel control dial
205F05723A
E-10 Lack of output power (max. engine speed is too low)
YES
YES
Deceleration
YES Is voltage between

No. 2 throttle 7 El (11) - (12)
normal and stable?
signal 5
tion pump in
contact with IS voltage
FULL stopper? between
El - When auto-decele-
YI :, (9) - (19) ration operating: _
Stable and as Max. 1v NO
* Start engine.
Potentiometer 4 *how” in - When auto-deceleration
* Fuel control dial Table-l?
at MAX Canceled: 8- 12V
. Heavy-duty
between El
+H mode
normal and
Fuel control dial 3
YES
Adjust linkage
between governor
motor - injec- I
NO tion pump. Does
it become
“0Vl-lZ3l? NO
l See TESTING AND
ADJUSTING.
; 4.0 -
2
p 3.0 - Table 1 Voltage(VI
Condition when measurina I PCROOI Pr‘lnn 1
.-s
(1) ‘When overheating 4.0 - 4.25 4.0 - 4.25
j 2.0 - (2) 1L.0 and L mode 12.10 - 2 40 1 2.20 - 2.50
2+ G.O. F.O. L.0 and S mode

(3) 1.23 - 1.53 1.35 - 1.65
m G.O. F.0 and L mode
p 1.0 - (4) H.0 mode or H mode 0.75 - 1 .o 0.75 - 1 .o
Engine speed (rpm)
205FO5364
CalWZ I
F
Remedy
1
Defective injection ee Engine sho

Pump 1anual
Warming-up signal 8 YES Defective governor 3ephX

motor
IS voltage
YES between El
Starting signal 7 - (*‘I - (‘*)
normal and
-
IS vo tage stable? NO
between El j See E-12
* When warming-up operating: Max. 1 V
- (2) - (12)
normal and
* When warming-up canceled: 8 - 12V
stable? Defective contact of

* When engine starting switch BR - Ml Repair or
running: 20-30V NO . (2) - M20 (4). I31 - %plaCe
El (female) (2). or
see P-19
See E-7
See E-5
see E-6
Defective adjustment of 4djust

governor motor linkage
See Engine stc

. Defective injection pump
manual
Fuse
Fuel control dial
Pump controller
Monitor panel
205F05723A
2o-A37
E-l 1 Engine does not stop.
Astop the engine (place the governor lever of the injection pump in the NO INJECTION position)
+I Always connect any disconnected connectors before going on to the next step.
YES
1
Has lever of
governor stopped
in contact with
STOP stopper?
2
’ Starting switch Potentiometer 5 YES
ON-OFF . Does engine
return to normal
Y ES
_ when linkage is pH---
NO adjusted? i Relay drive 4
* Is loose spring When srarting
free of twisting? switch is OFF,
I 1 YES does KIltage . When engine is NO
. See TESTING AND between El (13) stopped: 3.8 - 4.3V
Starting signal 3 - (12) change as
ADJUSTING.
1 shown in Table 17
When starting
switch is OFF, is 1
- voltage between - N
Ii ) El (2) - (12)
normal?
. Max. 1V
Table 1
~;k;;e~~;;;;arting ~(pp’o” 24v) To batterY re,ay BR
OFF
(Note) - Voltage Output from controller when starting switch is OFF
---_---_
Controller circuit
To battery relay BR
actuated (El (13))
Min.: 4.0 set
OFF/_
Drive time - Max.: 7 set (when it is impossible to set to NO INJECTION
because of failure of ttie motor)
I
205FO5366
Note: When the starting switch is ON, the controller is OFF, but a voltage of approx. 20 - 30V is
always flowing from the starting switch BR, so if the measurement is made at El (I 31, the vol-
tage is 20 - 30V.
Defective injection See Engine sho
pump nanual

of linkage
Defective governor Replace

motor
See E-5
Defective engine
RepIS?
throttle controller
starting switch BR - Ml Repair or
(2) - M20 (4). (3) - reDlace
El (female) (2). or
M20CM4)
FE ( Fs Governor potentiometer
M7(L2)
I -
1 I I *) 1-u Battery relay
205F05724A
20-139
0
E-l 2 Automatic warming-up operation is defective
* Warming-up is not carried out when the coolant temperature is under 30X, or does not stop when
the coolant temperature goes above 30°C.
(When it is canceled by the fuel control dial, there is no change in the voltage.)
* Conditions for carrying out warming-up:
1) Coolant temperature below 30°C
2) Fuel control dial set at about 50% or below (warming-up signal: Max. 1 VI
-k Conditions for canceling warming-up:
1) Coolant temperature above 30°C
2) Fuel control dial raised to above 70% and kept there for at least 3 seconds in power set switch
H or S mode (see Note I)
Note 1 :When the fuel control dial is turned up to cancel warming-up, warming-up will not start again
unless the starting switch is turned OFF and then turned ON again.
2:When the fuel control dial is turned up to cancel warming-up, the voltage of El (21) does not
change.
Remedy
YES Defective engine throtrle

Replace
(See Note 2) 2 controller
T
Warming-up IS voltage
I operation
canceled
is not - between El (21)
- (12) normal?
A
_
Is resistance bet-
wee” El (female)
3 YES
see P-21
. When canceled: (21) - chasskand _

8-12V N; between (21) C2- Disconnection in wiring
. Fuel control dial (female) (11) as
harness between E 1 Repair or
operarion is “of at MIN. shown in Table I? NO
(female) (21)- P2 replace
canceled, or * Start engine. * Turn starting switch (female) (11). or contact
operarion does OFF. with ground
* Disconnect El and
c2.
4 VES Defective engine throttle
controller
Warming-up
operation does
not start
See P-21
* Warming-up: Max. IV
- Fuel control dial at MIN.
* Start engine.
Table 1 E I (MIC21)
I Wirincl harness I Resistance value I Monitor panel
Between El (ferixale) (21)

Min. 1 MU_
P2(04015)
- chassis
Between El (female) (21)

Max. 1 n
- P2 (female) (11)
205FO5366
TROUBLESHOOTING OF PUMP CONTROLLER
SYSTEM (C MODE)
Chart for distinguishing if failure is in pump controller or in hydraulic related parts ........ . 20-l 43
Failure mode
[OFFI Self-diagnostic display of controller does not light up ............... .... 20- 144
C-l
c-2 [Ollisdisplayed ...................................................... .. .. 20- 145
c-3 [031 is displayed ...................................................... .. 20-I 46

c-4 1041 is displayed ...................................................... .. 20-I 47
c-5 [051 is displayed ...................................................... .. 20-I 48
C-6 [07lisdisplayed ...................................................... ..... 20- 149
c-7 [081isdisplayed ...................................................... .. 20-I 50
C-8 [091 is displayed ...................................................... . . 20-I 51
c-9 [Illisdisplayed ...................................................... . . 20-I 52
C-IO [131isdisplayed ...................................................... .. . 20-I 53
C-II [14]isdisplayed ...................................................... ... . 20-I 54
C-12 [15]isdisplayed ...................................................... . . . 20-I 55
C-13 [17lisdisplayed ...................................................... ... 20-I 56
C-14 [18lisdisplayed ...................................................... ... 20-I 57
C-15 121lisdisplayed ...................................................... .. 20-I 58
C-16 [22]isdisplayed ...................................................... ... . 20-I 59
C-17 [23]isdisplayed ...................................................... ... . 20-I 60
C-18 [24]isdisplayed ...................................................... ... . 20-I 62
C-19 [25]isdisplayed ...................................................... ... . 20-I 64
C-20 [261isdisplayed ...................................................... ... . 20-I 66
:: ... . 20-I 67
C-21 [28lisdisplayed ......................................................
G
C-22 [29]isdisplayed ...................................................... ... 20-l 68
g
C-23 [.O lisdisplayed ...................................................... . 20-I 69
20-A41
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP Note, 107°C: PC300, 3OOLC-5 Serial No: 20001 - 21400 105°C: PC300, PC3OOLC-5 Serial No: 21401 and up PC400,400LC-5 Serial No: 20603 and up
PC400,4OOLC-5 Serial No: 20001 - 20602 PC300,3OOLC-5 MIGHTY PC400, 4OOLC-5 MIGHTY
CONTROLLER OR IN HYDRAULIC RELATED PARTS PC300HD-5 PC40SHD-5
Self-diagnostic display (abnormality display No and system) Input signal display

C-l [$JJ@ [OFF] Self-diagnostic display of controller does not
light up
-k Check if fuse 1 is blown. If the fuse is blown, check if the wiring harness between the fuse 1 - Cl
(3) (4) is in contact with the ground.
Cause Remedy
i-----
Defective pump
controller Replace
OFF 1 I I
IS voltage Defective contact, or dis-
between Cl (3) _ connection in wiring Repair or
YES
harness between fuse I - M2PlSX
zr 2 M20 (Z), (1) - M3 (3) - Cl
(female) (3), (4)
- 20-30V Is voltage at Outlet
- Turn starting Defective contact,
-end of fuse 1
3% or disconnection
switch ON. ND normal? Repair or
in wiring harness
between Ml 1 (female) rep I ace
- Is voltage between (l&M7 (l&fuse1
- 20-30V L Ml1 (1) -chassis -
. Turn starting
No normA? Defective contact, or
switch 0 N.
Repair or
harness between fusible
. 20- 3ov replace
link or Ml 1 (female)
. Turn starting
(2)-battery
switch ON.
M20(M4)
r-u Fusible link
Mll(L2)
Pump controller
Cl (MICl7) M3(Sl6)
205FO5369-1
20-A44
c-2 [.z.:][Short circuit in 2-stage relief solenoid valve
system] is displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then
set the power max. switch to ON, and check that the display is [Oil. (If it is not displayed, the
system has been reset.)
sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
2 YES
Defective pump controller
III
\-\ \ ~
i J-L \
C To A
. Disconnect Cl NO
Contact between wiring

harness of power source
3 YES
and wiring harness between
Cl (female) (15) and V7
(female) (2)
FH_
Defective Z-stage relief

NO solenoid valve
Turn starting
switch OFF
. Disconnect V7
Cl (female) V7 (male) Resistance value

Between (3) (4) and (15) Between (I) and (2) 50-loon
Between (15) and chassis Between (2) and chassis Min. 1 MR
- M20tM4)
(i)@
Pump controller M3ISl6)
Fuse
Cl (MICl7) I
V7tX2)
- 2-stage
205FO5370-1
C-3 [~_z,] [Short circuit in arm half flow solenoid valve
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the working mode switch to F.0 mode, and check that the display is [031. (If it is not displayed, the
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy
2 YES Defective pump

Replace
controller
Interchange with
1 cancel solenoid.
ween Cl (female)
(3), (4) and (6), (6)
and chassis as Turn starting switch ON
Set working mode
switch to F.0 mode
switch OFF - I 1 - ToA

. Disconnect Cl. NO
Contact between wiring

3 YES 7arness of power source ant
Repair or
Niring harness between Cl
replace
Is resistance bet- gmale) (6) and V5 (female)
ween V5 (male) (1)
A :
and (2) as shown in
Table l?
Defective arm half flow
?eplace
. Turn starting NO solenoid valve
switch OFF.
Disconnect V5
Table 1
Cl (female) V5 (lamp) Resistance value

Between (3) (4) and (6) Between (1) and (2) IO-35R
Between (6) and chassis Between (2) and chassis Min. 1M R
v M20(M4)
(T)@
Pump controller M3LSl61
Fuse
Cl (MICl7) I
-3
V7(X2)
1,l---l
1 half flow
solenoid
205FO5726
c-4 [y&q[Short circuit in swing brake solenoid valve
* If the starting switch is turned OFF after the abnormality occurs, start the engine, operate the
swing, and check that the display is [041. (If it is not displayed, the system has been reset.)
Cause Remedy
2 YES Iefective pump Replace

:ontroller
\-\
\
A -1
J-L
\ ~~
. Turn starting
switch OFF -ToA
. Disconnect Cl
:ontact between wiring

5 YE larness of power source am Repair or
Is resistance bet- viring harness between Cl replace
female) (8) - M3 (female) (5
YES ween M3 (female)
(3) and (l), (1) and Contact between wiring
4 - chassis as shown ir larne*s of power source ant
Table 17 viring harness between M3 Repair or
Is resistance bet-
NI female) (1) and VI (female) replace
YE9 ween M3 (male) (1) . Turn starting
2)
andA. (1)or (9) switch OFF.
Defective swing lock
3 and chassis normal? . Disconnect M3. Replace
switch
Is resistance bet- Contact between wiring
. Bezay 1’; - (9): harness of power source
A- ween Vl (male) (1) Repair or
and (2) as shown in NO and wiring harness bet-
. (I) 0$9! ;Dchassis: replace
Table I? ween M3 (male) (1) - lock
switch - M3 (male) (9)
- . Turn starting switch OFF’
. Turn starting . Disconnect M3
switch OFF )efective swing brake
. Disconnect VI NO olenoid valve
Table 1
Cl (female) M3 (female) M3 (male) Vl (male) 1 Resistance value
Between (3) and (I) 1 Between (1) and (9) 1 Between (1) and (21 1 lo-35Q
Between (8) and chassis Between (I) and chassis Between (9) and chassis Between (2) and chassis Min. 1M R
Swing lock prolix switch Swing lock switch
Pump controller
Cl (MIC17)
Fuse
M20H4)
205FO5727
20-A47
C-5 [CL,] [Short circuit in travel speed solenoid valve system] is
displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the fuel control dial to MAX. and the travel speed switch to Hi, and check that the display is 1051.
(If it is not displayed, the system has been reset.1
+ Always connect any disconnected connectors before going on to the next step.
CW.M Remedy
2 YES Defective pump Replace

Interchange with controller
YE wiring of Z-stage
1
. relief solenoid -
valve. Is LO61
Is resistance bet- displayed?
\-1 \-
L--t
NO
wee” Cl (female)
(3) (4) - (16). (16) * Interchange V2 and V3.
J-L 3
- Turn starting switch ON.
- chassis ground as
- Place travel speed switch at Hi.
shown in Table l?
* Turn starting I
switch OFF. -ToA
IO
* Disconnect Cl.
contact between wiring

3 YES harness of power SOUrCe
Repair or
and wiring harness
Is resistance replace
between Cl (female)
between V2 (16)-V2 (female) (2)
A - (male) (1) - (2) -
as shown in
Table l? Defective travel speed Replace
* Turn starting NO solenoid valve
switch OFF.
* Disconnect V2.
Table 1
Cl (female) v2 (male) Resistance value

Between (3) (4) - (16’ Between (1) - (2) 50-loon
Between (16) - chassis Between (2) - chassis Min. 1 MQ
M20(M4)
Pump controller
Fuse
Cl (MICl7)
_ Travel
speed
solenoid
- valve
205FO5373-1
20--48
C-6 [:3.‘-‘,] [Short circuit in CO cancel solenoid valve system]
L-
’ is displayed
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then
set the power max. switch to ON, and check that the display is [07l. (If it is not displayed, the
It is also possible to operate the travel lever with the engine at high idling.
CaUSe Remedy

controller
Interchange with
YES_ wiring of z-stage _
1 relief solenoid.
- Is [07] displayed?
IS resistance bet- ,NO
ween Cl (female) (3) p
_ (4) and (7). (7) and - lnterchaweV4 and V3.
chassis as shown in Turn starting switch ON.
. Set power max. switch to ON.
Table l?
. Turn starting t
switch OFF T
NO
. Disconnect Cl
NO solenoid Valve
. Turn starting
switch OFF
. Disconnect V4
I I
Table 1
Between (3) (4) and (7) 1 Between (1) and (2) 1 50-IOOR
Between (7) and chassis Between (2) and chassis Min. 1 MD
Pump controller
Cl (MICl7)
205FO5374-1
C-7 [ss] [Short circuit in TVC solenoid sysem (1 )I is displayed
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is 1081. (If it is not displayed, the system has been reset.)
* Turn the TVC prolix switch OFF.
C2dUS.S Remedy
YES
Defective pump controller RePlaCe
1
Is resistance
between Cl
\-\ \-\ _ (female) 19) -
chassis, (9) - - 2 YES
(17) as Shown in
.\A. \I\ Table l? Ir-“--A
bewveen C4
* Turn starting _ (male) (1) -
switch OFF. NO chassis, (1) - (2) -
* Disconnect Cl. as show” in
Table 17
Defective TVC solenoid Seplace
- Turn starting NO
switch OFF. Wiring harness between
* Disconnect C4. Cl (female) (9)-c5
(female) (1) in contact
4 YE! with ground, or in contact Sepair or
WI- with GND wiring eplace
* Wirina harness between

C5 (“Yale) (I)-prolix
switch-C5 (male) (3)
in contact with ground, Repair or
Or in contact with GND replace
wiring
. Defective TVC prolix
switch
* Turn starting Wiring harness between Repair or

switch OFF. C5 (female) (3)- C4 replace
* Disconnect C5. (female) (1) in contact
with ground, or in contac
with GND wiring
Table 1
Cl (female) C5 (female) c4 (male) Resistance value
Between (9) - (17) Between (3) - (4) Between (I) - (2) lo-22a
Between (17) -chassis Between (4) -chassis Between (2) - chassis Min. 1 Ma
Between C5 (male) 11) - (3). 12) - (41 Max. 1 52
M20hl4)
TVC prolix switch
T T
i v
: D C
(-1 (t)
205FO5375-1
Pump controller
C-8 [.‘$!!] [Short circuit in TVC solenoid valve system (211 is
displayed
+ Turn the TVC prolix switch OFF.
Cause Remedv
2 YES ReplaCe
Defective pump ContrOlief
15 resktance I I
To A
* Turn starting
switch OFF. Defective TVC solenoid RC3plaCe
* Disconnect C4. -
Wirina harness between

Cl (female) (9)-c5
4 YE! with ground, or in contacl Repair or
with GND wiring replace
Is resistance bet-
YES ween C5 (female)
- Wiring harness between
3 - (1) - (3). (2) - -
C5 (male) (l)- orolix
(4) as shown in
Is resistance switch-C5. (k&e) (3)
, Table l? N in contact with ground,
between C5
A c
(female) (3) - * Turn starting switch or in contact with GND
chassis, (3) - (5) - OFF. wiring
a* shown in * Disconnect C5. * Defective TVC prolix
Table l? switch
. Turn starting switch
Wiring harness between Repair or
OFF.
c5 (male) (3)-c4 (female WplaCe
* Disconnect C5. No
(1) in contact with grounc
or in contact with GND
wiring
Table 1
Cl (female) C5 (female) C4 (male) Resistance value
Between (9) - (17) Between (3) - (4) Between (1) - (2) IO-222R
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1 Ma
Between C5 (male) (1) - (3). (2) - (4) Max. 1 fl
TVC prolix switch

Fs M20tM4)
205FO5375-1
Pump controller
2o-A51
c-9 1.\. :1[Disconnection
c-
in 2-stage relief solenoid valve
’ system] is displayed
sr If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.
If pin (2) of the solenoid is short circuiting with the ground, the solenoid stays actuated.
sr If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is [I 1 I. (If it is not displayed, the system has been reset.)
* If [I 11 is displayed, start the engine, and press the power max. switch. If there is no difference in
the digging force between when the switch is pressed and when it is not pressed, start troublesh-
ooting from Item 4 in the flow chart below.
sr Always connect any disconnected connectors before going on to the next step.
Cause

Reolace
controller
H J
as when measuring
item 1, is [ll]
displayed?
Already reset
21; starting switch NO
. Turn starting
switch ON. Is resistance bet-
. Power max. harness between Cl (female)
switch:
(31. 141, (15) - V7 (female) qepair or
ON: 0 - 3V (1) (2), or wiring harness .eplace
(8.5 set) between Cl (female) (15) -
OFF: 20 - 30V V3 (female) (2) in contact
with ground
IL Defective 2-stage relief

Replace
. Turn starting N( solenoid valve
switch OFF.
. Disconnect V7.
I
Table 1
Cl (female1 I V7 (male) I Resistance value I
Between (31 (4).and (15)’ 1 Between (1) and (2) 1 50-IOOR
Between (15) and chassis 1 Between (2) and chassis 1 Min. 1 MR
205FO5370-1
c-10 1.
.
:.31LDisconnection in arm half flow solenoid valve
Ir If there is a disconnection in the solenoid or wiring harness, the solenoid is ot actuated.
check that the display is [I 41.(If it is not displayed, the system has been reset.)
* Always turn the swing lock prolix switch OFF, and set the swing lock switch at OFF before starting
to check.
* If [I41 is displayed, start the engine, and if the swing brake is not released when the swing is
operated, start troubleshooting from item 4 in the flow chart below.
C.SUSf2 Remedy
Defective pump
controller
YE
I
A read Y reset
ON.
. Turn starting switch ON.

. Finishing, lifting
mode: Max. 3V
. Heavy-duty, general Disconnection in wirina
mode: 20 - 30V harness between Cl -
* Turn starting switch (female) (3)(4)- M3
OFF. (female) (3)(5), or
* Disconnect Cl wiring harness between
Cl (female) (6)-M3
(female) (5) in contact Repair or
6 YE5
with ground replaCe
male) (3) -
5). (5) - chassis H harness between
(male) (3)(5)-~6
M3
Repair or
(male) (7)(6), or wiring
harness between M6 replace
YE lg switch (female) (5)- M6 (male)
(6) in contact with
4
&J
jchassis as shov
- Escon”ect M3. ground
Repair or
harness between M6
OFF. replace
NO (female) (7) (6) - V5
. Disconnect M6. (female) (1) (2). or wiring
harness between M6
(female) (7) - V5 (female
* Turn starting switch (2) in contact with ground
OFF.
Defective arm half ReplaCe
- Disconnect V5. IO flow solenoid valve
Table 1
Cl (female) M3 (male) v5 (male) M6 (female) Resistance value
Between (3) (4) - (6) Bqtween (3) - (5) Between (1) - (2) Between (7) - (6) lo-35a
Between (6) - chassis Between (5) - chassis Between (2) - chassis Between (6) - chassis Min. 1 Ma
205FO5371-1
C-l 1 1. :_q [Disconnection in swing brake solenoid valve system]
is displayed
* If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
* Always turn the swing lock prolix switch OFF, and set the swing lock switch at OFF before starting
to check.
Ir If [I41 is displayed, start the engine, and if the swing brake is not released when the swing is
operated, start troubleshooting from Item 4 in the flow chart below.
Cause Remedy

r I controller
1 In same conditions 11 I
Already reset
. Lever at neutral: Max. 3V

. Lever operated: 20 - 30V
. Turn swing lock switch ween Cl (female)
OFF.
. Turn starting switch ON. To A
shown in Table l?
ween Vl (male) (I)
. Disconnect Cl.
Defective swing brake

Replace
. Turn startina NC solenoid valve
switch OFF.-
. Disconnect VI Disconnection in wiring
harness between Cl (female)
(8) - M3 (female) (9). or
6 YES qepair or
:ontact with ground
.eplace
Defective swing lock
switch
. Disconnection in wiring
harnes between M3 (male)
(1) - lock switch - M3 ?epair or
g;al$dd(9), or contact with .eplace
Iisconnection in wiring
larness between M3 (female)
. Turn starting 1) (3) - VI (female) (1) (2) or lepair or
switch OFF. wiring harness between M3 ,eplace
. Disconnect M3. female) (1) and Vl (female)
2) in contact with ground
Table 1
Cl (female) M3 (female) M3 (male) VI (male) Resistance value

Between (3) (4) and (8) Between (3) and )I) Between (I) and (9) Between (1) and (2) 10 - 35 R
Between (8) and chassis Between (I) and chassis Between (9) and chassis Between (2) and chassis Min. 1 MR
Swing lock Swing lock

prollx Switch switch
Swing brake
solenoid
valve
205FO5727
20254
c-12 1.
.
:.q [Disconnection in travel speed solenoid valve system]
is displayed
If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set
the travel speed switch to Lo, and check that the display is 1151. (If it is not displayed, the system
has been reset.)
If [I 51 is displayed, start the engine, and if the speed does not become Hi when the travel speed
switch is set to Hi and the engine is at high idling, start troubleshooting from “A” in the flow chart
below.
Remedy

controller
In same condition c
YES as when measuring
c Item 1, is [151
displayed?
1 NO r Al ready reset
\
* Turn starting switch
Is voltage between ON.
\ \-
. , . =, - ;,b;,“,\- chassis -
3 YES
* At Lo: 20-30V 15 reli*fanCe

* At Hi: Max. 3V between Cl
(female) (3) (4)
* Switch travel
speed switch. NO - 116). (16) - -
chassis as show”
. Turn starting switch in Table 1’ NO
ON. F ToA
OFF. 3isconnection in wiring
. Disconnect Cl. ,arness between Cl
female) (3) (4) (16) -
4 YE ti2 (female) (1) (2). or
Niring harness between
--#zFJ[ El (female)
:female)
,vith ground
Defective
116) - V2
(2) in contact
travel speed
* Turn starting switch solenoid valve
OFF.
. Disconnect V2.
Table 1
Cl (female) v2 (male) Resistance value
Between (3) (4) - (16) Between (1) - (2) 50 - lOOJ-2
Between (16) - chassis Between (2) - chassis Min. 1 Mn
v M20M4)
(i)@
Pump controller Fuse
I
g V2(X2)
Travel
4
I ’” Travel
speed
solenoid
speed 16 valve
solenoid
205FO5373-1
c-13 1. \\-\. 1 [Disconnection in CO cancel solenoid valve system]
L
’ is displayed
sr If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then
turn the swing lock switch ON, and check that the display is [I 71.(If it is not displayed, the system
has been reset.)
* If [I 71 is displayed, start the engine, and if there is no difference in the digging force between when
the swing lock switch is ON and when the swing lock switch is OFF, start troubleshooting from
“A” in the flow chart below.
Remedy

controller
Y FHi
1 Already reset
. Turn starting
Is voltage between switch ON
\ \-\ Cl (7) and chassis
.
__t 1. \
. Turn starting
switch ON. ween Cl (female)
. Swing lock (3) (4) and (7L (7)
switch I and chassis as
ON: Max. 3V shown in Table I?
OFF: 20 - 30V ToA
. Turn startina
switch OFF -
. Disconnect Cl Disconnection in wiring
harness between Cl (female
4 YF (3) (41, (7) - V4 (female) (1) Repair or
(2). or wiring harness bet- replace
Is resistance between Cl (female) (7) and V4
ween V4 (male) (1) (female) (2) in contact with
A and (2). (2) and ground
chassis as shown in
---i Table 17 Defective CO cancel Replace
solenoid valve
. Turn starting
switch OFF
. Disconnect V4
Table 1
.__._
Between (3) (4) and (7) Between (1) and (2) 50 - IOOR
Betwee’n 171and chassis Between (2) arid chassis Min. 1MR
205FO5374-1
c-14 [. \\.,3]
\-\ [Disconnection in TVC solenoid valve system] is
displayed
* If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not ac-
tuated. If pin (2) of the solenoid is short circuiting with the ground, the current (approx. IA1 con-
tinues to flow to the solenoid.
Sr If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
check that the display is [I 81. (If it is not displayed, the system has been reset.)
* Turn the TVC prolix switch OFF.
Remedy
YES Defective pump

I) l- ReplaCe
controller
To A
harness between C5
(female) (3), (4)-c4
(female) (l), (2). or Repair or
wiring harness between reDlaCe
C5 (female) (4)-C4
OFF.
e Turn starting switc - Disconnect C5.
with ground
OFF.
* Disconnect C4.
Defective TVC solenoid Replace
NO
harness between C5
(female) (1). (2kCl
4 YEC (female) (9). (17). or Repair or
wiring harness between rePlaCe
c5 (female) (2)-Cl
A_F[
with ground
Defective TVC prolix Repair or

* Turn starting switch switch, or defective replace
OFF. wiring harness between
* Disconnect C5. switch-C5
Table 1
Resistance value
Cl (female) c5 (female) c4 (male)
Csz)
Between (9) - (17) Between (3) - (41 ‘Between (1) - (2) 10-22
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1 M.I-l
Between C5 (male) (I) - (3). (2) - (4) Max. 1
NC prolix switch
I I 205FO5375-1
Pump controller
c-15 [.z. :] [Abnormality in No. 2 throttle signal system] is
displayed
check that the display is [211. (If it is not displayed, the system has been reset.)
CWXS! Remedy
3 YE
Already reset -
Defective pump
ReplaCe
controller
ON.
- (12) es shown
3efective engine
:hrottle controller -
See E-7)
1
Is resistance bet-
ween c2 (female)
Table l?
(11) - (21). (11) - Iefective pump controller
\- \ - zri;,;hassis * Turn startina switch
.-. ON.
- Switch working
* Min. 1Mfi mode switch.
. iFo”“ect C2 and . Disconnect El.
a Turn starting switch

Xsconnection in wiring har-
OFF.
less between C2 (female) Repair or
NO 11). (21) - El (female) (9). replaCe
19). or contact with ground
Pump controller Engine throttle controller

C2IMIC21) E I (MIC21)
205F05383-K
Table 1 Voltage IV)
(1) When overheating 4.0 - 4.25 4.0 - 4.25
(2) L.0 end L mode 2.10 - 2.40 2.20 - 2.50
G.0, F.O. L.0 and S mode

(3) . 1.23 - 1.53 1.35 - 1.65
G.O. F.0 and L mode
(4) H.0 mode or H mode 0.75 - 1 .o 0.75 - 1.0
Engine speed (rpm)
*O-i5*
C-l 6 [_z_$ [Abnormality in throttle signal system] is displayed
* If an abnormality is displayed for the engine throttle controller, go first to troubleshooting E-6.
Cause Remedy

Replace
controller
In same condition
- Item 1, is [221 -
NO
Already reset
Disconnection in wirina
- (20) normal? harness between C2 (fgmale
3 YES (10). (20) - El (female) (10). Repair or
(20). or wiring harness bet- replaCe
* 0.25- 4.75V
ween C2 (female) (10) - El
* Turn starting switch ON. Is voltage (female) (10) in contact with
. Fuel control dial N; between El (10) - ground
MIN.-MAX. - (20) normal?
See E-6
. 0.25-4.75V NO
- Turn starting switch
ON.
* Fuel control dial
MIN. -MAX.
C2(MlCl7) EI(MIC21)
205F05385A
c-17 [2.L .z,l [ Abnormality in front pump pressure sensor signal
c
1
5 YES
-\ -\ IS voltage
YES IS voltage
\- -\ - beyye,“o,c,3a/;’ -
4 - between C8 (3) -
.a.- - (1) normal?
. 0.5-4.5v
* Start engine. YES IS voltage
. 0.5-4.5v NO
(High idling) - between C8 (2) -
* Start engine.(High idling)
- (1) normal?
+ 3 +
* Repeat bucket
Is resistance P * Repeat bucket
relief.
between C3
* 18-28V relief.
- [female) (5) _ _ - ;;.n starting switch NO
No (1). (6) -
chassis normal?
. Min. 1Ma
- Turn starting
switch OFF. NO
* Disconnect C3
and C8.
Pump controller
C3IMICS) C8(X3)
pressure sensor
205FO5386-1
Call%? Remedy
t- Defective pump Replace

controller
Already reset
disconnection in Repair or
wiring harness between replace
C3 (female) (l)-C8
(female) (1)
Defective front pump Rk?PlKZ

pressure sensor
Repair or
harness between C3
lepke
(female) (3)-C8 (female)
(2)
Short circuit in wirina

harness between C3 -
Repair or
(female) (61, (l)-C7. C8
replace
(female) (31, (1),or
contact with ground
20-21
C-l 8 [.z.‘-:] [Abnormality in rear pump pressure sensor signal
It If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, and
, 21 YES
I
1In same conditions1 1
V ES as when measuring
item 1, is [241
displayed?
NO
ON.
1
5 YES
normal?H
III
YI Isvoltage
between C7 (3)
- Start engine. YES

4 Is voltage between
- (1)
-----k------
* 0.5-4.5v
(High idling) I- c7 (2) - (1) * Start engine.
+ normal?
. Repeat arm relief.
3 (High idling)
Is resistance a -
. 18-28V * Repeat arm relief.
between C3
- (female) (7) _ . Turn starting switch\
JO
I\10 ON.
- w. (7) - ?
chassis normal’
z
- Min. ‘I Ma
. Turn starting 2
switch OFF. NO
- Disconnect C3
and C7.
Pump controller
C3(MIC9) C8(X3)
pressure sensor
Rear pump
pressure sensor
205FO5386-1
disconnection in Repair or
- wiring harness between replaCe
z C3 (female) (3)- C7
(female) (2)
z
CII Short circuit in wiring
0 Repair or
harness between C3
replaCe
Ifemale) (7). (2) -
C7 C8 (female) (3).
(1). or contact with
ground
c-19 3 .\i,]
1.L [Abnormality in pressure sensor power source
YES
2
Is same conditi-
YESI- ons as when
measuring
Item 1, is [251
displayed?
I
I
NO
ES
* 18-28V
- Turn starting switc:h
ON.
YES
- (1) normal?
DisconnectC7.
. Disconnect C8. Is voltage YES
. 18-28V - between C3 (3) - 5
. Turn starting switch - (2) normal7 Is resistance
ON. - between C3
. Disconnect C7. _ [female) (3) -
- ‘IS-28V NO (I ). (3) - (21, (31
* Turn starting switch - chassis normal’
ON.
* Min. 1MR
- ;u;Fn.starting switch NO
* Disconnect C3, C7.

and C8.
Pump controller
C3IMIC9) C8(X3)
(F) Pressure sensor
(R) Pressure sensor( -) pressure sensor
(F)pressure
sensor(S 1G) pressure sensor
205FO5386-1
20-24
Defective pump RePlaCe
- controller
- Already reset
Defective front pump

Replace
- pres*ure sensor
Defective rear pump

- pressure sensor
Defective pump
Replace
- controller
harness or contact with
ground between
.C3 (female) (1) and
c C8 (female) (1)
C7, C8 (female) (2)
C7 (female) (1)
*O-P5
c-20 [.&] [Abnormality in engine speed sensor system1 is
displayed
check that the display is [261.(If it is not displayed, the system has been reset.)
Note: If the decimal point on the pump controller self-diagnostic monitor display does not flash when
the engine is started, go to troubleshooting F-8.
I Call% I Remedy

controller
YES When engine is
2 r started, is [261 -
_ displayed?
IS resistance Already reset

YES_ between C3 * Start engine. NO (see Note)
(female) (8) - -
Note 1 (4) normal? Disconnection in wiring
J harness between C3
Is resistance * 500-l ooon (female) (8). (41 - M3
NO Repair or
-\ \- _ between E7 - Turn starting switch (121, (4) - E2 (1 1). replace
(male) (1) - - OFF. (121 - E7 (female) (2).
(2) normal? . Disconnect C3. (1). or contact with
.\I .\i\
ground
- 500-l ooon
- Turn starting switch Defective engine speecj Replace
OFF. NO SfZ”SOr
- Disconnect E7.
Pump controller
C3(MIC9) M3(Sl6) E2(Sl2) E7(X2)
3 . Engine
soeed
a---
sensor
205FO5389-1
c-21 r.a.B]
L
[Abnormality in auto-deceleration signal output
* When the auto-deceleration switch is ON.

* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn
the auto-deceleration switch ON, then operate the control lever (Neutral - operated), and check
that the display is [281. (If it is not displayed, the system has been reset.)
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
t Always connect any disconnected connectors before going on to the next step.
&US2 Remedy
2 YES Defective pump ReplaCe

controller
In same conditions I
- Item 1, is [281 -
displayed?
1 ~o-f- already reset
IS voltage ON.
between C2 (19)
- chassis as
shown in
YES
Table l?
3
. Turn starting
switch ON. Disconnect C2.
Is voltage between
NO El (11) - (12)
normal? Defective engine
throttle controlle,
* Turn starting switch c2 (female, ,19)--E,
(female) (11).and
ON.
- C2 disconnected: Disconnection in
8-12V wiring harness between
C2 (female) (19)-El
* Turn starting switch (female) (I I), or
OFF. contact with ground
- EF,co”nect C2 and
Table 1
Operation Voltage between C2 (female) (19) - chassis
Auto-deceleration switch ON, lever at neutral O-l v
Auto-deceleration switch OFF, lever at neutral 8- 12V
Table 2
CO”“eCtOr Resistance value
Between C2 (female) (19) - El (female) (I 1) Max. ls2
Between C2 (female) (19) - chassis Min. 1 Ma
C2(MIC21)
205F05390A
20-467
c-22 I.2.q [Abnormality in overheat signal system] is displayed
* If 1291 is displayed again when engine is restarted.

. Turn startinq
switch ON. _ Is voltage be1Nveen
.._4 r, 177, ,,*I
. ._!-(8)
N” ;;&$,:i 3 YES Defective mOnitOr
ReDlace
Is resistance bet- pall4
- ween P2 (female)
. When normal:
- (12). (13) - (IS), -
lo-13v Disconnection in wiring
ND (12) (13) -
. When overheated: harness between C2
chassis normal? Repair or
o-1v (female) (17), (18)-
- Start engine NO P2 (female) (12). (13). replace
- Min. 1Ma
* Disconnect C2 and or contact with ground
P2.
Pump controller Monitor panel

C2IMIC21) P2(04016)
GND
205FO5391-1
C-23 [z!$zL] [Controller abnormal system] is displayed
TROUBLESHOOTING OF PUMP CONTROLLER
INPUT SIGNAL SYSTEM
(F MODE)
Failure mode
F-l Pump controller monitor does not display [P2l . .... .. 20-I 72
F-2 Pump controller monitor does not display IP61 . ..... . 20-I 73
F-3 Pump controller monitor does not display [b5] . . . . . . . . 20-I 74
F-4 Pump controller monitor does not display [Hi or Lo1 . . . . 20-I 75
F-5 Pump controller monitor does not display [Ad1 . . . . . . . . 20-I 76
F-6 Pump controller monitor does not display [UPI .... 20-I 77
F-7 Pump controller monitor does not display L0 . 1 . ...... 20-I 78
F-8 Pump controller working mode display does not switch . 20-I 79
F-9 Pump controller power set display does not switch . . . . .. 20-I 80
20-J17’
F-l Pump controller monitor does not display [P_z] work
equipment Swing oil pressure switch]
l
j, After starting the engine, and operating the work equipment lever or swing lever, it is displayed for
approx. 1 sec.
A Before operating the swing lever, turn the swing lock switch ON.
Cause Remedy
YES
Already reset
C3 (5) and chassis Repair or

reolace
H I
:3 (female) contact with ground
lal and is Defective contact,
. Lever operated resistance bet- 1 from chassis? 1 NO - Repair or
3817Sl (male) (1) llYl111_” YI<.Vl
replace
. Start engine. anId (2) normal and . Between Sl and C3: Max. 1R (5) and Sl (fen _ _, ~_,, _
‘I is circuit insulated
NO . Between wiring harness and chassi.s: contact with ground
,m chassis?
. Disconnect Sl and C3. Min’ ‘lMR Defective oil pressure switch
. Lever operated: % If the condition does
Max. IQ not return to normal
. Lever at neutral: when the switch is
Min. 1MQ replaced, go to H-7.
. Start engine
. Disconnect Sl
Ifis also possible to fit a short connector to make judgement.
In this case, proceed as follows after checking the voltage between C3 (5) and the
chassis in Step 1.
If voltage is 20 - 3OV. ansver YES and go to Item 2.
If voltage is 1V or below, answer NO and go to Item 3.
Work equipment.
Pump controller swing oil pressure switch
Cl (MIC17)
205FO5728
20-ii72
F-2 Pump controller monitor does not display [ _‘? .‘&I [Travel oil
pressure switch]
* After starting the engine, and operating the travel lever, it is displayed for approx. 1 sec.
Sr Always connect any disconnected connectors before going on to the next step.
A Before operating the travel lever, check that the surrounding area is safe.
* If it is not displayed when operating the travel lever on one side, the PPC shuttle valve is defective.
CaLI%? Remedy
2 YES Already reset

In same conditi-
YE ons as when
measuring Item 1,
is [P6] displayed?
Defective pump
ReDlace
Controller
1
- Start engine.
. operate travel
Defective contact,
lever
Is voltagebetween harness between S4
C2 (1) - chassis (female) (I) - Cl
(female) (12). (131, or
contact with ground
. Lever at neutral:
20 - 3ov Defective contact.
* Travel lever disconmection in wiring
Qpair or
operated: Max. 1L harness between C2
XplaCe
* Start engine. (female) (1) - M3 (13)
h - S4 (female) (21. Or
contact with ground
- Lever operated: Defective travel oil

Max. 1.Q pressure switch
NO
* Lever at neutrai: l If the condition does
Min. 1 Ma not become normal
- Start engine. even when the switch
- Disconnect S4. is replaced, go to H-7.
It is aIs0 possible to fit a short c~nnecf~r W make judgement.
In this case, proceed as follows after checking the voltage between C2 (1) and the
chassis in Step 1.
If voltage is 20 - 3OV. answer YES and go to Item 2.
If v&age is ‘IV or below, answer NO and go 70 Item 3
Travel oil
Pump controller
pressure switch
Cl (MICl7)
GND
205FO5394-1
F-3 r;np;lontroller monitor does not display [ !,=,.“_,] [Swing lock
.
Sr After starting the engine, and turning the swing lock switch ON, it is displayed for approx. 1 sec.
Sr If the panel display is normal (if the swing lock lamp on the panel lights up, go to P-22.)
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
Remedy
2 YES
Already reset
In same conditions
YE as when measuring
Item 1, is [b5]
displayed?
1 Defective pump Replace
. Turn swing lock NO controller
I -7
Is voltage
W&J;;”
between
(8)
. Swing lock switch:

ON: Max. IV
OFF: 18 - 28V
switch ON - OFF.
Is there continuity
~ _ between C2 (female)
3 YES
. Defective
switch
. Disconnection
swing lock
in wiring
harness between C2
(female) (8) and swing
lock swith (21, or contact
Repair or
replace
(4) and swing lock - with ground

. Turn starting switch (l)?
switch ON Disconnection in wiring Repair or
harness between C2
. Turn starting NO (female) (4) and lock
replace
switch OFF switch (I)
’ Disconnect C2
Swing brake VI(X2)

solenoid valve
@:-
I- M20h44)
Fuse
PUlnp controller CI(MICI~PI M3(
@ L
+
1
=I!
4 3
J
Swing brake @ 9
12
GND 13 o\- Swing lock

I 2 switch ON (lock)
I
Pump controller C2(MlC2l) Swing lock
prolix switch
205FO5730
F-4 Pump controller monitor does not display [.k\. ,] or [J,_.,-,] [Travel
speed switch]
* After starting the engine, and switching the travel speed switch to Hi or Lo, it is displayed for
approx. 1 sec.
-k If the monitor panel display is normal (if the panel display is not normal, go to P-20).
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
CC%.Se Remedy
2 YES
Already reset
In same conditi-
Yl 3 ons as when
measuring Item 1, -
is [Hi] or [Lo1
I
displayed?
Defective pump
ReplaCe
NO Controller
Isvoltage between
C2 (3) - (8) as
shown in table 17
3 YES Defective monitor Repair or
* Turn starting Disconnect P2. Is PWd replace
switch ON. voltage between
a Travel speed switct P2(female) (4) - - Defective contact,
Hi -Lo I\ JO (16)asshown disconnection in
below? NO wiring harness Repair or
between C2 (female) rePlaCe
(3) - P2 (female)
ON.
(4), or contact with
- P2 disconnected:
ground
lo- 13v
Table 1
Travel speed switch Lo 10 - 13V
Travel speed switch Hi 1 Max. 1V

C2(MIC21) P2 (04016)
205FO5396
F-5 Pump controller monitor does not display [.R&
[Auto-deceleration switch]
* After starting the engine, and set auto-deceleration switch to ON, it is displayed for approx. 1 sec.
* If the monitor panel display is normal (if the auto-deceleration display on the panel does not
change, go to P- 19).
CaLI%? Remedy
2 YES
Already reset
In same conditi-
YES ens as when
measuring Item 1.
is [Ad1 displayed?
1 Defective pump Replace
* Auto-deceleration NO controller
Is Voltage between switch ON -OFF
c2 (7) - (8) as -
shown in Table 1?
3 YES Defective monitor
* Turn starting Replace
Disconnect P2. Panel
switch ON. Is voltage between
- Auto-deceleration - ~2 (female) (7) _ _
switch ON -OFF ND (16) as shown Defective contact, or
below? disconnection in wiring
harness between C2 Repair or
* Turn starting NO (female) (7) - P2 KSplXe
switch ON. (female) (7)
’ P2 disconnected:
10 - 13v
I I
Auto-deceleration switch ON Max. 1V

Auto-deceleration switch OFF 10 - 13v
C2(MIC21) P2 (04016)
205FO5397
c
\ \ \-\1 [Power
F-6 Pump controller monitor does not display
maximizing switch]
! J .u.\-
* After starting the engine, and pressing the power maximizing switch, it is displayed for approx. 1
sec.
2 YES
Already reset
In same conditi-
YES ons as when
F measuring Item 1, -
is [UPI
1 displayed? NO Defective Pump
ReplaCe
* Engine at high idling Controller
Is voltage between * Push switch.

c2 (12) - (8)
Defective contact,
I- I 3 YES
or disconnection
wiring
in
harness between
Repair
replaCe
or
. When switch is c2 (female) (12), (8)

Is resistance
not pressed: -switch
_ between switch _
20 - 3ov
. When switch is
pressed : Max. 1 V
I 1 L Defective power
Replace
* When switch is not NO maximizing switch
pressed: Min. 1 Ma
. When switch is
pressed: Max. lS?.
Pump controller
C2(MIC21)
205FO5398
F-7 Pump controller monitor does not display [~~~U~~~~]
[decimal
point of [Engine speed sensor]
* The display flashes when the engine is started.

Cause Remedy
Defective adjustment of
Replace
engine speed sensor
Adjust speed
Defective pump
Replace
Controller
I I I Defective engine speed Replace

* Measure with NO sensor
AC range.
. 0.5 - 3v Defective contact,
. Start engine. disconnection in wiring
h 4 YES harness between C3
(female) (8). (4) - M3
Is resistance between
(121. (41 - E2 (1 1). (12)
E7 (male) (1) - (21. - E7 (female) (2). 11).
ig (2) - chassis normal - or contact with ground
and is circuit insulated
from chassis) NO
Defective weed sensor 3 eDlace
. Between (I) and (2):
500 - 1 oooL2
- Between (1) and
chassis: Min. 1 M0.
OFF.
. Disconnect E7.
Pump controller
C3(MIC9) M3(Sl6) E2 (Sl2) E7(X2)
Engine
speed
sensor
205FO5389-1
F-8 Pump controller working mode display does not switch
1\ -\ 1
\ \:
7 \ \
3 -\
t The working mode is displayed approx. 1 set after the starting switch is turned ON.
* If the monitor panel display is normal and the working mode does not switch, go to
Troubleshooting P-l 7.
J, Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES
Already reset
Under same con-
d,ilOns ar when
YES mUar”rlng Irem
_ 1, does wOkring -
InOde ma”lTor
d,Splay
IWItCh
1 "ormallv' Defective pump
ReplaCe
controller
r Is voltage bet- . Switch working NO
ween c2 (14) mode on
(15) and (8) as - monitor Panel
sh_own in Table
n .._-
IT El Ykb
I Defective monitor panel Replace
. Turn starting When P2 19dIs-
switch ON. connecred. iQ
“Ollage berween
. Switch working -
PZ (female) (8) -
Defective contact or
mode on NO (9) and (161 ar disconnection in wiring
monitor panel show” below? harness between C2
Repair or
(female) (14) - P2
. Turn starting NO (female) (8). and
reDlaCe
switch ON. between C2 (female)
. When P2 is (15) - P2 (female) (9).
disconnected:
10 - 13v
Table 1
Between C2 Between C2
C2 (MIC21) P2 (04016)
WorkingmodeIal
205FO5627
2o-A79
F-9 IPump controller power set display does not switch
1‘4 ‘3- t I
The power set is displayed approx. 1 set after the starting switch is turned ON.
If the monitor panel display is normal and the power set does not switch, go to Troubleshooting
P-18.
However, if the coolant temperature gauge on the monitor panel is showing the red range (over
102”C), the pump controller displays L mode.
Cause Remedy
Already reset
Defective pump
controller
17
3 YES
Defective monitor panel
. Turn starting When P2 IL dir-
switch ON. connecred, is
vo,rage between
. Switch power - P2 (fetiale) (5) -
mode on NO disconnection in
(6) and (16, ar
monitor panel. Shownb4DW7 wiring harness between
c2 (female) (51 - P2
. Turn starting NO (female) (5). and bet-
switch ON. ween c2 (female) (6)
* When P2 is - P2 (female) (6).
disconnected:
10 - 13v
Table 1
-1
C2 (MIC211 P2 (04016)
1 Hmode 1 lo-13V / lo-13V 1
* 10 - 13V when working mode is

L.0 mode
205FO5628
20;80
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
Failure mode
Work equipment, travel, swing system
H- 1 Speeds of work equipment, travel, swing are all slow .................. 20-182
H- 2 There is excessive drop in engine speed, or engine stalls ............... . 20-184
H- 3 Work equipment, travel, swing do not move, or speed is extremely slow .. . 20-186
H- 4 Work equipment, travel, swing ............................
lack power . 20-188
H- 5 Power set selection system ..........................
does not switch .. . 20-188
H- 6 Abnormal noise generated (from around pump) ....................... . 20-189
H- 7 Auto-deceleration does not work .................................... 20-189
Work equipment system
H- 8 Boom, arm speed is extremely slow .._ . ... ... .... .. .. . . 20-190
H- 9 Work equipment (boom, arm, bucket) speed is slow . .. ... ... 20-192
H-l 0 When boom and arm are operated simultaneously, boom is slow .... . 20-194
H-l 1 Work equipment (boom, arm, bucket) lacks power ... ...... . . . 20-194
H-l 2 Excessive hydraulic drift.. . _ ... ..... ... . . ..... . ... 20-194
H-13 Excessivetimelag . . . . . . . . . . .._......._.................._. ... 20-196
H-14 Does not enter F.0 mode . . . . _. . . . . . . . . . . .......... .. . 20-196
H-l 5 When arm and swing are operated simultaneously, arm is slow . 20-196
Travel system
H-16 When machine is traveling, it deviates naturally to one side
a) Deviates in same direction both in forward and reverse .. . . . 20-198
b) Deviates in different direction in forward and reverse _ . . 20-200
H-17 Excessive deviation during .
compound operations ... . . . 20-201
H-18 Excessive deviation when . . . ..
starting .. ... . . . 20-202
H-19 Travel lacks power or speed is slow.. . ... .. ... . . . .. 20-204
H-20 Travel speed does not switch .. . . .. .. . .. . .. 20-204
H-21 Machine does not move (one side only) .. ... ... . 20-205
Swing system
H-22 Doesnotswing .......................................... .. . 20-206
H-23 Swing speed is slow or acceleration ................
is poor. . 20-208
H-24 Excessive overrun when stopping swing ................... . . 20-209
H-25 Excessive shock when stopping swing ..................... .. 20-209
H-26 Excessive abnormal noise when stopping swing ............ .. 20-210
H-27 Excessive hydraulic drift of swing ......................... . .. 20-210
H-28 When operated simultaneously with arm, swing speed is slow . .. 20-210
TABLE OF FAILURE MODES AND CAUSES ........................... . . 20-211
H-1 Speeds of work equipment, travel, swing are all slow
* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-l 6.
8 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated.
+x2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.
4 YES
Is engine speed . When normal relieved:

YES normal when 2100 + 100 rpm
- pump is relieved -
with CO canceled?
3
* When CO canceled: NO
PC300: 1980 & 100 rpm PC400: 1970 * 100 rpm
IS set pressure
YES
- at TVCvalve -
* H.0 + H mode
“Orf-“al?
* Engine at high idling
. Arm relieved 5 YES
PC300: 17 - 20 kg/cm’
Does condition
2_ . PC+OO: 18 - 21 kg/cm:
H.O+HmOde N_ become “~rmal _
0 when TVC valve
Is relief pressure * l-pump relief is adjusted?
Yf * Engine at high
- of F, R pump -
idling NO
“O”llal?
. At normal relief
315 - 345 kg/cm’
1 . At 2.stage relief 6 YES
340 - 380 kg/cm’
Does condition
Is relief pressure . H.0 and H mode _ become “Orma _
at charging pump . Engine at high NO when main relief
normal? idling valve is adjusted?
12
* Engine at hlgtl NO
idling
30 - 38 kg/cm’
?%I
*Oii**
Cause Remedy
Leakage inside Replace pump

Pump assembly
See Engine shop manual -

of TVC valve
Defective TVC valve Replace

of main relief valve
Defective main relief ReplaCe

:: valve
z
r4
0
(Go to H-3, Item 3)
20-A83
H-2 There is excessive drop in engine speed, or’ engine stalls
ES
. -I
2
When pump is
* Output pres-
sure becomes
relieved, is normal
‘T
output pressure of Problem does
CO valve normal? not change
r-l
1 J
* At normal relief: output pres-
*
Max. 5.5 kg/cm’
When CO canceled:
Same pressure at h
s” re becomes
normal
Condition
becomes
also
1-
1 TVC pressure
* Engine at high normal
El
IS set pressure of
* H.0 + H mode Output pres-
TVC valve
sure does not -
normal?
become i
1 normal J
. PC3OO: 17 -20 kg/cm2 . Set pressure
PC400: 18 - 21 kg/cm2 becomes
- l-pump relief normal
- H.0 + H mode
. Problem does
not change
* Engine at high
idling . Setpressure
when TVC valve
. Condition also
Remedy
See Engine shop manual
Defective adjustment Of Adjust

co valve
Defective CO valve ReplaCe
Defective adjustment of
Adjust
TVC valve
Defective TVC valve ReplWe
20-185
H-3 Work equipment, travel, swing do not move, or speed
is extremely slow
* When there is a big difference from the permissible value.

* Auto-deceleration is normal.
* Mode selection is H.0 and H mode.
YES
3 r
Block circuit (I 1-
YES(6) in Fig. 1. Is
- charging pump .
relief pressure 4 YES
normal?
2
- 30 - 38 kg/cm?
Does oil come out Engine at high /-HP
idling R
YES when main pump
[ Donotmove J pressure pick-up -
plug is removed?
NO
._I Crank with startino

I motor.
- Disconnect
governor motor
DO not move, or connector, and set NO
speed is extremely governor lever
slow? to NO INJECTION.
‘ES
__e To Item 3 above
:
NO 6 YES
Does condition
I become normal
. PC300: 0”
when TVC valve
17 - 20 kg/cm2 NO
is adjusted?
. PC400: z
18 - 21 kg/cm2 z
NO
. H.0 + H mode
l-pumprelief
Fig. 1 Control circuit
Travel PPC valve
Solenoid valve
Piston pump-
ttlb+
I
R.H. PPC valve
Charging pump
Safety lock valv, e
L.H. PPC valve
9
6
205FO5300
Replace relief
valve
Adjust
20-187
H-4 Work equipment, travel, swing lack power
Remedy
3 YE!
Defective CO valve
pressure at
YES Outlet port of
- CO cancel
Defective CO cancel
ReplaCe
- See conditions for NC solenoid valve
Is main relief
When digging pressure normal Item 4 below.
force is
Does
- ;=;iziggiw
maximized
maximized? 41 IEI 1rop in set prB*SUw Of
340 - 380 kg/cm? IS hydraulic nain relief valve
Engine at high idling pressure at
1
1 ouflef port of
-
NO 2-stage relief _
the problem solenoid valve
occ”r when
digging force is
normal?
IE Mfective 2-stage
RS?plaCe
When digging fbrce NC elief solenoid valve
maximized, or is maximized:
during normal 27 - 35 kg/cm2
ooeration?
. During normal
operation: 0 kg/cm2
valve
outlet
If is also possible to hold the solenoid
1
hose by hand to judge.
During normal )rop in set pressure Adjust or
operation ,f main relief valve rePlace
C
H-5 Power set selection system does not switch
Remedy
Defective TVC valve Replace
selection switch is
operated with con-
nectar stillconne-
cted, does spool Defective TVC solenoid ReplaCe
1’
of solenoid move?
1) Turn starting
switch ON.
20-ih88
H-6 Abnormal noise generated (from around pump)
Cause Remedy
Clogged strainer 3lean
Y ES
1
Loose piping clamp Tighten
4 YES
3efective pump
Is oil level in
hydraulic tank
Operate for a time Inspect again

and watch any :Depending on
NC changes in symptoms changes
in symptoms)
Add hydraulic
Lack of oil
NO oil
H-7 Auto-deceleration does not work
Remedy
1 YES Defective travel shuttle

valve
Is hydraulic
pressure at inlet
port of travel -
shuttle valve
normal? II Defective
valve
PPC shuttle Repair
replace
or
‘27 - 35 kg/cm2 NO
20-A89
H-8 Boom, arm speed is extremely slow
l Mode selection is H.0 and H mode.

+ When the travel, swing, and bucket speeds are normal.
1 YES Defective operation Repair or

of straight-travel valve replaCe
Does travel shuttle

valve spool move -
smoothly?
Defective operation Of Repair or
travel shuttle valve replaCe
*valve on top of NO
control valve
20-A90
H-Q Work equipment (boom, arm, bucket) speed is slow
* When the travel and swing speeds are normal

(However, if there is any travel deviation and the bucket or boom speed is slow when operated indi-
vidually, go first to “H-l 4 When machine is traveling, it deviates naturally to one side”.)
3 YES
I II
Is operation of
( Boom Onl’f ] - boom holding -
valve normal?
NO
* Check movement of
valve with Your hand.
i
4 YES
Is hydraulic
YES pressure at outlet
--I: Arm onlv ] - port of arm half -
flow solenoid
valve normal? NO
2 *Finishing or lifting mode: 0 kg/cm2
* Normal operation: 27 - 35 kg/cm2
YES Is output pressure l It is also possible to hold the solenoid valve outlet
- at PPC valve hose by hand to judge.
normal?
-[ Bucketonly ]
. 30 - 38 kg/cm2
Engine at high
1 idling
Is hydraulic drift NO
of slow cylinder _
y;;t.L; standard
PC300
Does hydraulic
drift become
YES
Does condition
become normal
changed?
. For details of the
type of safety
* When relieved
valve, see ‘4NO 7 YES
Table 1.
r---lr-----
H
I [
L Boom only Is boom holding
valve normal?
i I
- Check mc,“ement NO
of valve with your
hand.
Table 1 Table of locations and types of safety valves used for

each cylinder
( ): set pressure
Cylinder Bottom end (kg/cm’) Head end (kg/cm’)

Boom Safety-suction valve (365) Safety - suction valve (290)
Arm Safety - suction valve (365) Safety valve (365)
Bucket Safety - suction valve (365) Safety - suction valve (365)
CatIS Remedy
Repair or
Defective operation Of replaG3
control valve spool control valve
(boom) assembly
Defective operation Repair or

of boom holding valve replace
Repair or
Defective operation of
WPl?lC2
control valve spool (arm)
control valve
assembly
Defective arm half flow RePlaCe

solenoid valve
Repair or
Defective operation Of replaCe
control valve spool control valve
(bucket) assembly
Defective PPC valve RePlace
Defective cylinder piston ReplaCe

packing
Defective safety (suction) ReplaCe

valve
Defective oil-tightness
Replace
of control vaive spool
Oefective boom holding

ReplaCe
valve
2o-A93
H-IO When boom and arm are operated simultaneously,
boom is slow.
l When usual operation is normal.
Defective arm throttle Repair or

valve replace
H-l 1 Work equipment (boom, arm, bucket) lacks power.
* When the travel and swing speeds are normal.

2 YES
l-l pressure
normal
IS main relief
r
YES
When digging
force is
1 maximized j
when digging
340 - 380 kg/cm2 NO

occur when digging

force is maximized, 4 YES
or during normal
Both ends _jKl_
1
NO
During
operation
normal head end and
bottom end, or
. See Table 1. NO
Table 1 NO
One end only
3
PC300 mm PC400 mm
BOOIT Max. 38 BOOlTl Max. 38
Arm Max. 203 Arm Max. 128
Bucket Max. 30 Bucket Max. 45
H- 12 Excessive hydraulic drift
* Go to H-9. Item 5.
20-ih94
Cause Remedy
- CO cancel solenoid ReplaCe
valve
Defective Operation Of
p-stagerelief solenoid Replace
valve
(Go to H-9, Item 2)
(Go to H-9, Item 5)
_ Defective safetv
Replace
(suction) valve
20-A95
H-13 Excessive time lag
* If the work equipment speed is normal (if the speed is slow, go first to H-9. Item 2).
Cause Remedy
Defective operation
ReplC2
of suction valve
Time lag set
H-l 4 Does not enter F.0 mode (Half flow functiuon)
Cause Remedy
Defective operation
of arm half flow Replace
solenoid valve
H-15 When arm and swing are operated simultaneously, arm

is slow
* If the operation of the auto-deceleration is normal (if the auto-deceleration is defective, go first to
H-7).
Remedy
Defective OperatiOn Of Repair or

swing priority valve replaCe
20-A96
H-16 When machine is traveling, it deviates naturally to one
side
* When the travel speed is normal.

a) Deviates in same direction both in forward and reverse

v ES
5 YES
YES Is servo piston

stroke normal?
Direction of
4-_
deviation
changes
* For details, see NO
TESTING AND
ADJUSTING.
. For details, see
TESTING AND
ADJUSTING.
ted freely or during

normal travel, Is differential
pressure of jet
11
sensor normal?
the TVC o”tput
pressure.
I\IO
. iever at neutral:
18 - 24 kg/cm2
Max. 5.5 kg/cm’ NO
. Engine at high idling * See Note.
At travel relief:
PC300: 340 - 370 kg/c,+
PC400: 330 - 370 kg/cm2
At work equipment
relief:
PC300: 315 - 345 kg/cm2
PCOOO: 315 - 345 kg/cm’
Engine at high idling 0 E!
YES
10
Are metal particles
found in oil
YES
drained from final _ YES
drive on side
which deviates? 11 -
Doesdirecrio"
Of
deviafion
changewhen
_ leftend
righthoses
NO beNYee"CO":rO,
valve
s
andswivel
ioinf
are
inrerchangsd'
NO
lirection of
eviation does
ot change
I
30 - 38 kg/cm2
Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the
output pressure of the TVC valve, both the jet sensor and NC valve are normal.
20-ii98
See TESTING
ADJUSTING
Replace
Defective operation Adjust or

of NC valve replace
I
? YES Drop in set pressure
Adjust
Does condition of jet sensor relief valve
become norma,
when relief valve
of jet sensor is
interchanged or
adiurted? Defective jet sensor Clean or
orifice replace
. Lever operated: NO
Max. 2.5 kg/cm2
Drop in set PreSSUre Of Adjust or

main relief valve replace
Repair or
replace
ReplaCe
12 YES Defective swivel Replace

Does directi 0f joint
deviafio” change
when lefi 0”d
righf tlorer tar *wiYeI
joini ou*,el wrt are
i”Wcha”g.Z*? Replace motor
Defective travel
NO lTlot0r assembly
Defective operation Of
Replace
control valve SPOOI
Replace
20-A99
b) Deviates in different direction in forward and reverse (See Fig. I)
CaUSe Remedy
2 YES Defective swivel

I I I joint packing
Defective PPC valve
,~
Drop in set pressure

of travel motor safety
valve
Location of defective swivel

Fig. 1 joint packing and direction
of deviation in travel
Right reverse and

left forward
Right forward and

left reverse
Left reverse only = 1 left:,, 1
I I
H-l 7 Excessive deviation during compound operations
* If individual travel is normal.
CElUSe Remedy
Defective operation Repair or

of straight-travel valve replWX
I valve move
smoothly?
I Defective operation Of Repair or

Is oil pressure at
replace
inlet port of wave NO travel shuttle valve
p.hm;“‘“’
. 27 - 35 kg/cm’ Defective operation of

N PPC shuttle valve
z
z J, If the pressure in Item 1 is lost, the auto-deceleration also will not work.
z
H-l 8 Excessive deviation when starting
* When the travel speed is normal

* If there is also deviation during normal travel, go to “H-l 6 When machine is traveling, it deviates
naturally to one side.”
For deviation during simultaneous operations with the work equipment, go first to “H-l 7 Excessive
deviation during compound operations.”
* Bleed all air completely from the circuit.
r-l
I
.
Does machine
deviate
during
control?
220mm/20m
at lever
full stroke,
fine
or
1
YES
r
IS output
pressure at NC
valve at fast end
6
_
NO
YES
II
NO
Machine
regardless
deviates
when starting,
fine control,
of N-
N - Full stroke
or
-
Is differential
pressure of jet
se”so~ at fast
side (outside
turn) normal?
Of
-
- Control
neutral:
- Track
lever at
Max.5.5
rotating
freely:
7
NO
kg/cm*
Min.
YES
18 kg/cm’
. ml; leverat When relief valves

of jet *enSor are
18 - 24 kg/cm2 - interchanged or -
. Control lever at No adjusted. is
full stroke problem reversed?
Max. 2.5 kg/cm’
NO
Remedy
Defective operation ReplaCe

Of servo valve
Defective control ReplaCe

valve
Repair or
Defective swivel joint reDlace
Redace
.-I Defective travel motor
Replace
Servo valve
Defective adjustment Of
NC valve
Defective jet SenSO!’ Repair or

relief valve ~~Pl.3C~
Replace
20203
H-19 Travel lacks power (or speed is slow)
* The mode selected is H.0 mode (the power set is automatically set to HI
Sr When there is not travel deviation.
Sr If the main relief pressure has dropped, there is also lack of power for normal operations using the
work equipment.
If there are problems in the CO cancel system, there is lack of power when using the power max.
switch.
Cause Remedy
YES
Defective CO valve Replace
Defective CO cancel
Replace
solenoid valve
Drop in set pressure of Adjust or replace

main relief valve
~~400: 330 - 370 kg/cm2 No It is also possible to hold the
. Engine at high idling solenoid valve outlet hose by
hand to judge.
H-20 Travel speed does not switch
* When the travel speed is normal at Hi or Lo.
Defective travel motor

1 YES
. Speed change servo Replace motor
Is hydraulic valve ass’y
pressure at
outlet port of -
travel speed
solenoid normal? Defective travel speed
solenoid valve
. At Hi: NO
27 - 35 kg/cm’
At Lo: 0 kg/cm2
H-21 Machine does not move (one side only)
G3llS.e Remedy
.
2 YES
Defective final drive
Is any foreign
YES material found in _
1 oil drained
final drive?
from
’ 1 Travel
dragging
motor brake Replace
asrem b I y
motor
Is main relief
pressure at motor -
relief normal?
3 YES Defective travel Replace safety
At travel relief: motor safety valve Valve
15 hydraulic pressure
PC300: 340 - 370 kg/cm’
normal at motor
PC400: 330 - 370 kg/cm’ _ relief when safety -
Engine at high idling NO valves are
interchanged?
Defective travel Replace motor
. For standard value, NO motor assembly
see Item 1.
H-22 Does not swing
l When other work equipment and travel speeds are normal

* Turn swing lock switch OFF.
YES
4
Is any foreign
material found in
oil drained from
5 YES
swing machinery? 1
Does control
NC valvespool move -
smoothly?
[
NO
Does not swing

in either
direction
normal?
. Lever operated:
I
27 - 35 kg/cm2
. Lever at neutral: NO
either direction, Or 0 kg/cm2
in one direction l It is also possible to hold the solenoid valve outlet hose by hand to judge.
judge.
PC300: 280 - 310 kg/cm’
PC400: 270 - 300 kg/cm’
I Cause Remedy
Repair or
~replace
Replace motar
assembly
Replace motor
.~I Defective swing motor assembly
Defective operation Of
swing brake solenoid ReplaCe
valve
Defective safety valve ReDlace

::
2
Defective PPC valve Repl.Xe
20-207
0
H-23 Swing speed is slow or acceleration is poor
* When other work equipment and travel speeds are normal. (If there is also deviation (to right)
during normal travel, go first to “H-l 6 When machine is traveling, it deviates naturally to one side”.)
CaUSe Remedy
Excessive leakage inside

3 YE:
swing motor, or brake
Replace motor
dragging assembly
*H
Defective operation of Replace contrc

NC control valve spool ilalVe
c
Both
right
left and of co valve
swing relief
normal?
at
Drop in set pressure of

Adjust
.Must be the same a co valve
TVC valve output Does condition
pressure become normal
- At relief:
Max. 5.5 kg/cm’
. Measure at NC valve.
co valve
Replace
. For standard value, NC
both left and
see Item 2.
right, or in one
6 YEE Drop in set pressure of

. Time taken to start
safety valve
Adjust
swing (sac) (90”):
Does condition
PC300: Max. 4.0
YES_ become Norman
PC400: Max. 4.4
when safety valve
. Time taken for
-
5
is adjusted?
swing (sac) (5 turns) When left and
Defective safetv valve +??PlXX
PC300: Max. 36 right safety
PC400: Max. 38
One direction
- valves are inter- -
* For standard value, NC
only see Item 5.
. Engine at high idling ) 1 changed, is
problem reversed?’
* Is also possible ra measure NO

Defective PPC valve ?eplace
the hydraulicpressurefo
judge.
PC300:280 - 310 kg,cm’
PC400:270 - 300 kg,cm’
H-24 Excessive overrun when stopping swing
* If the speed is slow or the acceleration is poor, go first to H-23.
C.WSe Remedy
Both left and Replace motor

Leakage inside motor sssem blv
right
excessive to both
left and right, or
in one direction
One direction Replace or
Defective safety valve
Only adiust
. Overturn
when
stopping swing:
. PC300: Max. 88
. PC400: Max. 120
5
0
H-25 Excessive shock when stopping swing
Sr When the swing speed is normal.
Defective swing Repair

machinery
~ Defective swing motor ReDlace

Both left and brake
right
Is shock excessive . Lever operated: 27 - 35 kg/cm’ NO Defective swing brake Replace

on both left and Ll . Lever at neutral: 0 kqlcm’ __._.
qnlenoid valve
When the swing is operated and the lever
is returned to neutral, the hydraulic
pressure becomes 0 after approx. 4 sec. I
Replace
A[ ~~,~direcfion ] 11 Defective safety valve
20-$09
H-26 Excessive abnormal noise when stopping swing
* When the swing speed is normal.
CaUSe Remedy
2 YES Defective swing

Repair
machinery
r
YES Both left and
right +j$$GHP
Defective lift check ReDlace

NO valve
IS abnormal noise
on both left and
right, or in one
direction only?
3 YES
Defective safety valve Replace
O$direction
_lEHP
NO
3efective suction valve Replace

NO
H-27 Excessive hydraulic drift of swing
CALlSI? Remedy
t-
1 YES Defective swing motor Replace motor
brake assembly
Is hydraulic
pressure at swing
brake solenoid -
valve Outlet port
normal? Defective swing brake
Replace
. never et neutral: NO solenoid valve
0 kg/cm=
* Lever operated:
27 - 35 kg/cm2
H-28 When operated simultaneously with arm, swing speed

is slow
l When the usual swing speed is normal.
cause Remedy
Defectite operation of Repair or

swing priority valve replace
020705
TROUBLESHOOTING OF MONITOR SYSTEM
(P MODE)
Failure mode
P- 1 Monitor panel lamps do not light up for 3 seconds when starting
SwitchisturnedON ...................................................... . .. 20-2 14
a) No monitor panel lamps light up ........................................ 20-214
b) Some monitor panel lamps do not light up .............................. 20-2 14
P- 2 Monitor panel lamps all light up when starting switch is turned ON,
butdonotgoout ........................................................ . . 20-215
P- 3 When starting switch is turned ON (engine stopped), CHECK items flash ....... . . 20-216
a) Coolant level flashes .................................................. . . 20-2 16
b) Engineoillevelflashes ................................................ . . 20-2 17
c) Hydraulic oil level flashes .............................................. . .. 20-218
P- 4 Preheating is not being used, but preheating display lights up ................. .. 20-219
P- 5 When starting switch is turned ON and engine is started, CHECK items flash ... . 20-22 1
a) Alternatorsystem .................................................... .. 20-22 1
b) Engine oil pressure system ............................................ 20-22 1
P- 6 When starting switch is turned ON (engine stopped), CAUTION items flash .... 20-222
P- 7 When starting switch is turned ON and engine is started, CAUTION items flash . 20-223
a) Engine oil pressure flashes ............................................ 20-223
b) Coolant level flashes .................................................. 20-223
c) Coolant temperature flashes ........................................... 20-224
d) Chargeflashes ....................................................... 20-224
e) Fuellevelflashes ..................................................... 20-225
P- 8
a) When starting switch is turned ON (engine stopped),
buzzer does not sound for 1 second ................................ . 20-226
CAUTION item is flashing but buzzer does not sound ..................... . .. 20-226
b) There is no abnormality display on the monitor, but the buzzer sounds ..... . . 20-226
P- 9 Panel lighting of monitor panel does not light up ............................ 20-227
P-l 0 Coolant temperature shows abnormally low temperature. .................... . .. 20-228
P-l 1 Coolant temperature gauge gives no display ................................ .. 20-228
P-l 2 Fuel gauge always displays FULL .......................................... 20-229
P- 13 Fuel gauge gives no display ..... _ ......................................... 20-229
P-14
a) Lampsdonotlightup ................................................. . 20-230
b) Lamps light up even when lamp switch is not operated ................... 20-230
P-15
a) Wipers do not work ................................................... 20-232
b) Wipers work even when wiper switch is not operated .................... 20-232
P-16
a) Fandoesnotwork .................................................... .. 20-234
b) Fan works even when fan switch is not operated ......................... .. 20-234
P- 17 Working mode does not switch ........................................... 20-236
P-l 8 Power set does not switch ................................................ 20-237
P- 19 Auto-deceleration does not switch
(Does not enter auto-deceleration; auto-deceleration is not canceled) ...... 20-238
P-20 Travel speed does not switch between Hi and Lo ............................ 20-239
P-21 Warming-up operation is not carried out below 3O”C, or warming-up
operation is not canceled even when temperature goes above 30°C ....... . .. 20-240
P-22 Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up ...................... 20-241
P-l Monitor panel lamps do not light up for 3 seconds
when starting switch is turned ON
a) No monitor panel lamps light up
CElUSe Remedy
2 YES
Defective monitor panel l3epkCe
YES IS VOltage between

- Pl (female) (1) - -
_1
(3) normal? 5iscon”ection in wiring Clean
,arness between fuse 3 - (defective
Is voltage between contact) or
- Voltage 20 - 30V NO Pl (female) (1) or Pl
terminals of fuse reDlace
- a Turn starting switch (female) (3) - M6 (9) -
3 - chassis ground
ON. chassis ground
normal?
* Voltage 20 - 30v NO leplace after

* Turn starting switch Disconnection in fuse lspecting cau*e
ON. f disconnection
Monitor panel
PI (040201
\dy Fuse
205FO5300
b) Some monitor panel lamps do not light up
Defective monitor panel F?qIlace
20-214
0
P-2 Monitor panel lamps all light up when starting switch is
turned ON, but do not go out
CaLIS? Remedy
I Defective monitor panel ReplaCe
20-215
0
P-3 When starting switch is turned ON (engine stopped), CHECK
items flash (Levels for CHECK items are as specified)
a) 9 (Coolant level) flashes

1
* Check that the coolant is at the specified level before carrying out the troubleshooting.
Remedy
Y
_
Ii
1
Does display go 3 YES
off when short r I I I Defective monitor panel leplace
connector is Is continuity bet-
connected? YES_ ween Pl (female) _
2 (17) and (3) as Defective contact, or
. Connect short - shown in table? disconnection in wiring Iean (defective
connector to P8 Is there continuity harness between P8 (female :ontact) or
(female) between P8 (female) _ . Connect and dis- NO (I) - E8 (2) - M6 (1) - PI eplace
. Turn starting r40 (2) and chassis connect short conne- (female) (17)
switch ON. ground? ctor to P8 (female).
p *Turn starting switch Defective contact, or
.
Turn starting OFF. disconnection in wiring :lean (defectiv
switch OFF. harness between P8 (female ontact) or
NO
(2) and chassis ground splace
Pl(O4020) E 8GWPl4) P8(X2)

Coolant level sensor
205FO5731
bl $ (Engine oil level) flashes
rl
* Use the dipstick to check that the engine oil is at the specified level before carrying out the
troubleshooting.
I Cause I Remedy
Defective engine 011 level

YES
sensor SYstem
1 (See P-25)
Does display gooff

when P5 (female)
(1)is connected to NO 2 YES
chassis ground? Defective monitor panel ReplaE!
- Is continuity be-
- connect P5 (female) _ tween Pl (female) _
to chassis ground. (18) - (3) as Defective contact, or
* Turn starting switch shown in table? disconnection in wiring Clean (defectk
ON. NO harness between P5 contact) or
. Connect and disconnect (female) (1) - E8 (5) reDlace
P5 (female) to chassis G;14 (5) - Pl (female)
ground.
Table
Chassis around 1Continuitv 1
Pl(O4020) Ml4681 E 86WP8) P5(Xl) Engine oil

level aenaor
Monitor panel
205FO5732
(Hydraulic oil level) flashes
CalSe Remedy
YES Defective hydraulic oil level _

1 sensor system (See P-27)
Does display go off

when P9 (female)
(1) is connected to - 2 YES
chassis ground? 1 Defective monitor panel Replace
- Is continuity bet-
Turn starting _ ween Pl (female) _
switch ON. NO (10) and (3) as Defective contact, or
shown in table? disconnection in wiring Clean (defective
- harness between P9 (female) contact) or
Connect T-adapter NO (1) - M3 (7) - PI replace
to Pl (female) (female) (10)
Table
E
Pl(O4020) M3EY6) P9(XI) Hydraulic oil
2
level sen*or
205FO5733
20-218
0
P-4 Preheating is not being used, but preheating display
lights up
Pc300,300Lc-5
PC300H D-5
YES
2 v Defective monitor panel Replace
YES Is voltage between Wiring harness between

r Pl (9) and chassis - heater relay - El 1 (1) - E8
ground normal?
3 YES
(1) - Ml4 (4) - PI (female)
After insepectior
repair or replace
(9) in contact with +24V, or
1 - Is voltage between
- .ov defective heater relay
Is voltage between . Ml4 (3). (4) -
Turn starting NO chassis ground
starting switch switch ON.
terminal Rl wiring - normal? Wiring harness between Ml4
After inspection,
and chassis ground (male) (3) - Ml (3) - starting
repair or replace
ov NO switch in contact with +24V.
normal?
. p;.n starting switch
. ov Defective starting switch
Turn starting (contact of terminal between
switch ON. Band RI), or wiring harness
After inspection,
between heater relay - El 1
NO repair or replace
(1) - E8 (1) - Ml4 (3) - Ml
(3) - starting switch Cerminal
RI in contact with +24V
Pl(O4020)
Glow Plug
205FO5734
Pc400,400LC-5
PC400H D-5
I Cause Remedy
YES
Defective monitor panel Replace
2 I
After inspection,
repair or replace
^I.^^^:^ __^.._rl
-0v -...._.._,.. 1Defective starting switch I I

. Turn starting (contact of terminal between
switch ON. B and Rl), or wiring harness After inspection,
between heater relay - E8 (1 repair or replace
NO - Ml4 (3) - Ml (3) - startin!
switch terminal Rl in contact
with +24V
Pl(O40201
Monitor panel
tyll468)
Starting switch
Glow
Plug
205FO5735
20-220
@
P-5 When starting switch is turned ON and engine is started,
CHECK items flash
* Check both the alternator system and engine oil pressure system.
Cause Remedy
a) Alternator system
2 YES
Is voltage between
YE Pl (female) (7) -
1 chassls ground Defective contact, or dis-
normal? connection in wiring ,3lean (defective
tween alternator . 26 -30V
harness between alternator ,:ontactl or
terminal R - E8 (8) - Ml4 Ireplace
terminal R - * Start engine, and (2) - Pl (female) (7)
chassis ground run et half
throttle or above.
. 26 -30V Replace
Defective alternator
- Start engine, and
JO
run et half
throttle or above.
C:heck that
t erminal is not
clefective (con-
b) Engine oil pressure system t act, insertion),
c heck operation
Sr When the engine oil pressure is normal.
c,f sensor ac-
c ordinc! to
5Xandard Value:
YES Defective engine oil 1-able for elect-
1 pressure sensor r ical
c ompo”e”ts,
Does display go off
when wiring t hen replace
harness terminal _ Contact of wiring harness
Jetween engine oil
of engine oil NO 2 YES Ftfter inspection
prenure sensor is xessure sensor - E8 (71
rlepair or replace
_
removed?
Is there conti- -Ml4 (7) - Pl (female)
* Remove wiring nuity between :16) with chassis ground
harness terminal of _ Pl (female) (16) -
engine oil pressure - chassis ground?
sensor. NO
Iefective monitor panel RW.lECe
* turn starting switch * Remove wiring harness
ON. terminal of engine oil
pressure se”sor.
PI (040201 Ml4(S8) E8CSWPl4)
0 Alternator R terminal
panel
Engine oil
pressure sensor
G+?
205FO5736
P-6 When starting switch is turned ON (engine stopped),
CAUTION items flash
* When the engine oil pressure is normal.
Defective alternator ReplaCe
Wiring harness be-

.
tween a,rernaror
terminal R - E8 (8) - After inspection,
Ml4 (2) - Pl (female) repair or replace
(7) in contact with
+24V
I I * Remove alfernaior
1 * Turn starting switch terminal R wiring.
Clean (defective
ON.
Defective contact, or dis- contact),repair
Is there continuity connection in wiring harness or replace
between Ml4 NO between E8 (male) (7) - Ml4
(female) (7) - - (7) - PI (female) (16)
chassis ground?
* :;,n starting switch NO

Defective engine oil
Is there continuity ’ YES pres*ure sensor
between Ml4
- (female) (7) - engine- ~_ _.
replace
oil pressure sensor Disconnection in wiring
harness terminal? NO harness between Ml4
(female) (7) - E8 (7) - Repair or
. Connect T-adapter to replaCe
engine oil pressure sensor
Ml4 (male).
I I I
PI (04020) Ml4C38) E8CSWPl4)
0 Alternator R terminal
Monitor panel
Engine oil
pressure sensor
205FO5736
P-7 When starting switch is turned ON and engine is started,
CAUTION items flash
(When there is no abnormality in CHECK items or engine)
a) +& (Engine oil pressure) flashes

D
I Cause Remedy
YES Defective engine oil

1 pressure sensor
Does display go
off when wiring
harness of engine -
2 YES ground with wiring
oil pressure After inspection
harness between E8
sensor is removed? _ repair or
Is there (male) (7) -Ml4 (7)
replace
- Remove wiring continuity - Pl (female) (16)
- between Pl
~fa~n~~n~~~‘“a’ NO (female) (16) -
chassis ground? NO
pressure sensor. Defective monitor panel Replace
* Start engine. . Turn starting switch
OFF.
PI (040201 Ml4(S8) E86WPl4)
-3
d7
205FO5737
(Coolant level) flashes
I
See P-3
(Coolant temperature) flashes
CaUSe Remedy
2 YES Defective coolant tempe-

rature sensor system -
Does display go (See P-24)
; off when short
- connector is
connected to P7
(female)? NO
. Connect short co”-
nectar to P7.
* Start engine.
- Start enwine, and

I3efective monitor panel =ZpbXe
Pl(O4020) M14(S8) E8(SWPl4) P7(X2)

Coolant temperature sensor
Monitor panel @
205FO5738
d) /m I (Charge) flashes
C.%Se RemedY
2 YES
Is voltage be-
YES tween PI
- (female) (7) - -
1 chassis ground
normal?
1s voltage be- :lean (defectiv
harness between
tween alternator .20 - 3ov NO alternator terminal R :ontact) or
terminal R - - wace
- Start engine. - E8 (8) - Ml4 (2) - Pl
chassis ground
(female) (7)
“OTllZJ?
- 20 ---3ov
. Start engine, and NO Defective alternator
“_I” at half throttle
Pl(O4020) Ml4G8) E8c3WP8)

1
Monitor panel 0 Alternator R terminal
205FO5739
20224
e) @ (Fuel level) flashes
L-.
+ Check that there is fuel before carrying out troubleshooting
CaLBe Remedv
Defective fuel level

2 YES *ensor SyStem
(See P-23)
YES Does displw 90
off when P6 is -
removed?
Defective monitor Panel

or above.
PI (040201 M6 P6tXI)
Fuel level sensor
Monitor panel @ .4 I
205FO5309
P-8 (a) When starting switch is turned ON (engine stopped),
buzzer does not sound for 1 second
CAUTION item is flashing but buzzer does not sound.
Sr Of the CAUTION item, the buzzer does not sound if there is any abnormality in the charge or fuel
level.
Remedv
1 YES Defective monitor panel ReplaCe
Does buzzer sound

when Pl (female)
(11) and chassis - Disconnection in wiring
ground are con- harness between P1
nected? NO (female) (I 1) - P4 (2) RePlace
- buzzer f-j, or between
. turn starting switch
+24V - P4 (1) - buzzer
ON.
(+), or defective buzzer
P-8 (b) There is no abnormality display on the monitor, but

the buzzer sounds
Cause Remedy
Contact of chassis ground fter inspectior

1 YES with wiring harness 3pair or
between Pl (female) ?place
(11) -buzzer (-)
Does buzzer
sound when Pl is -
removed?
Defective monitor panel ;eplXe

- Remove Pl. NO
* turn starting switch
ON.
r +24V
205FO5310
P-9 Panel lighting of monitor panel does not light up (liquid
crystal display is normal)
C.WSC? Remedy
Seplace bulb, o
1 YES Bulb broken or defective :lean (defective
contact :ontact)
Is bulb broken or
is there defective -
contact?
Defective monitor panel R@WZ2
- Remove bulb. NO
- Check condition of
bulb visually.
20-227
0
P-IO Coolant temperature shows abnormally low
temperature
Sr If the coolant temperature actually remains low, check the engine system
CZlU%2 Remedy
Defective coolant
YES -
, 3 temperature Sensor SYstern
(See P-24)
Does display of all

gauge levels go -
off? 2 YES
k Defective monitor panel Replace
- Is there continuity
. Connect short
_ between Pl
connector Defective contact, or dis-
NO (female) (6) - connection in wiring
to P7 (male)
chassis ground? Clean (defective
- Turn starting switch NO harness between Pl
(female) (6) - Ml4 (6) - contact) or
ON. . Connect short connector
ES (5) - P7 (female) (1) replaCe
to P7 (male).
or P7 (female) (2) - ES
- Turn starting switch OFF. (6) - chassis ground
P-l 1 Coolant temperature gauge gives no display (during

operation, no level of gauge is displayed)
Defective coolant tempe-

rature sensor *ystern
(See P-24)
Contact of chassis ground

perature gauge with wirina harness bet-
appear when P7 After inspection
ween P7 &male) (1) -
repair,or replace
Is there continuity ES (5) - Ml4 (6) - Pl
. Remove P7 between Pl (6) - (female) (6)
(female). - chassis ground -
* Turn starting switch when P7 is
ON. removed?
* Remove P7. NO
OFF.
P-l 0, 11 Related electrical circuit diagram
PI (04020) Ml468) E86WPl4) P7(X2)
Monitor panel @
205FO5738
P-12 Fuel gauge always displays FULL
* Check first if the fuel tank is actually full before carrying out troubleshooting.
CZ3US3 Remedy

sensor SYstem -
(See P-23)

with wiring harness be- fter inspection
tween P6 (female) (1) - !pair, or
M6 (4) - Pl (female) (5) !place
* Wait for approx. 2

Defective monitor panel ep,lace
. P6 is removed? NO
OFF.
. The surface of the fuel varies, so there is a delay built intO

the display for the fuel level.
P-l 3 Fuel gauge gives no display
Sr Check if there is any fuel before carrying out troubleshooting.
CaUSe Remedy

YES
sensclr system _
dDoes display appear
(See P-23)
when P6 (female)
2 YES
?eplaCe
between PI (female,
. Connect P6 (5) -Chaws wound
(female) (1) and - when P6 ,female) -
NO 1,) and chassis Defective contact, or
chassis ground.
grwnd are CO”- disconnection in wiring :lean (defectiv
- Turn starting switch “KWd? NO
-.. harness between P6 ontact) or
ON.
. Connect short connector (female) (1) - M6 (4) - epke
to P6 (female). Pl (female) (5)
OFF.
P-l 2, 13 Related electrical circuit diagram
Pl(O4020) M6(SIO) P6(XI)

Fuel level sensor
Monitor peflel @
205FO5309-1
P-14 (a) Lamps do not light up
YES
Defective monitor panel ReplaCe
2’
Does lamp light up
YES when Pl (female)
Clean (defective
- (14) and chassis - Disconnection, defective contact) or
ground are con- NO 3 YES
_______ contact in lamp repI%?
netted?
1p Is there any dis- Defective contact, or dis-
- . Connect Pl (female) connection or connection in wiring
(14) and chassis defective contact harness between Pl
Do LEDs on
ground. in lamp? (female) (14) - lamp
monitor
light up?
panel - * Turn starting switch ( relay R4 (2). between Clean (defective
contact) or
ON. * Check visually. NO lamp relay R4 (1) - fuse
replace
(5). between lamp relay
* Turn Starting switch R4 (5) - M6 (3) - M8
ON. cl), or between M6 (3)
* Turn lamp switch - Ml0 (1) - M9 (1)
ON.
NO Defective monitor panel Replace
P-14 (b) Lamps light up even when lamp switch is not

operated
Cause Remedy

with wiring harness bet-
3 YES After inspec-
ween Pl (female) (14) - tion, repair or
Is there lamp relay R4 (2). or replace
YES continuity defective lamp relay
2 - between Pl
_ (female) (14) - Wiring harness between
chassis ground? M6 (female) (3) - M8 After inspec-
NO
Does lamp light (female) (1) or M6 (male) tion, repair or
YES up when Pl . Turn starting switch
(3) - Ml0 (1) - MS replace
r (female) is - OFF.
1 removed? . Disconnect PI.
with +24V
* Remove Pl(female).
Are LEDs on
mOnifOr panel _ . 21.n starting switch NO Defective monitor panel Replace
out?
- 2d.n starting switch(

* Turn lamp switch NO
OFF
20-230
0
+24V
M6c30) M8(MI)
Lamp relay (R4)
A7
MI0
M9tMIl
Boom head lamp
205FO5313-1
20-23.1
0
P-15 (a) Wipers do not work
Remedy
YES
Does wiper work

when Pl (female) / Replace
ES Defective wiper motor
(15) and chassis IS there
ground are con- continuity
YES
NO 3_ r betwee”
(female) M4
(2) - Defective contact, or dis-
chassis ground? h connection in wirino Clean (defectiv
(15) and chassis t Is voltage between / - harness between MC :ontact) or
ground. * Turn starting switch
I _ M4 (female) (1) _ (female) (2) - M5 (2) -2PlWX
Do LEDs on
* Turn starting switch _ chassis ground OFF. - chassis ground
ON. * Disconnect M4.
monitor panel normal? Defective wiper relay,
or defective contact,
* Turn starting switch or disconnection in Clean (defectiv
ON. wiring harness between :ontact) repair
* Turn starting switcl 4 NO
* Turn wiper switch wiper relay Rl (3) - 3r replace
ON. ON. M5 (1) - M4 (female)
* Turn wiper switch
(1)
ON.
! Defective monitor Panel qeplace
N0
P-15 (b) Wipers work even when wiper switch is not

operated
CF3tE.e Remedy

with wiring harness ,fter inspectior
3 YES
zpair or
between Pl (female) (15)
Is there --yiper relay Rl (female) ?place
YES continuity
2 - between Pl
_ (female) (15) - Wiring harness between
wiper relay Rl (3) - .fter inspectior
chassis ground?
M5 (1) - M4 (1) in ?pair or
YES Does wiper work NO
- Disconnect Pl. contact with +24V, Or zplace
- when Pl (female) -
- Turn starting switch defective wiper relay
is removed?
1 OFF.
* Remove Pl(female). NO
Are LEDs on
monitor panel -
* Turn starting switch Defective monitor Panel replace
ON.
out?
-+hi
Iefective monitor panel lEplZVZ3

- ‘,“I;: wiper switch ND
*O-i3*
+24V M 5tM41 ML+(KES4) (KESI)
-4 -4
3 \_w -3 -3 -
Wiper
3 g) motor
Monitor
I I
205FO5314
P-l 6 (a) Fan does not work
Cause Remedy
YES
I
Is there con- S Defective heater 7ep1ace

tinuity between
R2 (female) (3) Defective contyt! or dis-
:s connection in wlrlng
r (2). or between harness between
(female)
Pl
(12) - heater
R3 (female) (3) :lean (defectiv
relay R2 (2). between Pl
(female) (131 - heater ontact) or
- connect PI 3 relay R3 (2). between Ml: epl&X
(12) (or (13)) and (female) (2) - heater
chassis ground. (LO side) or R3 a Turn starting switch
(female) (3) (Hi relay R2 (3). or between
side) - chassis
OFF.
Ml2 (female) (3) heater
ON. relay R3 (3)
Do LEDs on 5
monitor panel Defective heater relay 3eplace
‘O-1v
H
* Turn starting
-1 Does heater work

switch ON. Disconnection in wiring
normally?
- Turn fan switch Or\ Ilarness between R2
ON.
* Turn fan switch
II! 01 (female)
(female),
(2) - Pl (12)
or between R3
- Interchange lamp rela) ’
ON. (female) (2) -PI (13)
and heater relay.
(female)
ON.
. Turn heater switch Oh I.
P-16 (b) Fan works even when fan switch is not operated
I CaUSe I Remedy
I

with wiring harness
between Pl (female) (12) After inspec-
heater relay R2 (2), or tion, repair or
&tween Pl (female) (13) replace
- heater relay R3 (2)
2 - (female) (12) ior - Contact of chassis

(13)) -chassis ground with wiring
ground? harness between heater After inspec-
NO
--M
-_ ;_,
12 (2) (or (3)) - __ 1 tion,
i rmn,>p~
repair or 1
.,_._,n heater relav nz (3) or ~3 I
1 Lis removed? , OFF. I(3). or defective heater 1 ‘“r’---
relay R2 or R3
Are LEDs on
. Remove Pl(female).
- -fyn starting swtch NO Defective monitor panel Replace
monitor panel -
Out?

ON.
- Turn fan switch ~0
OFF.
I
+ 24V M 12
Heater Lo
205FO5315
P-17 Working mode does not switch
Cause Remedy
a) Even when monitor panel switch is pressed, mode

display (LED) above switch does not change.
. Defective monitor panel ReplaCe
b) When monitor panel switch is pressed, mode

display (LED) above switch changes.
YES See troubleshooting of

1 pump Controller SVSffxTl
Is voltage between
C2 (14) - (8) and Oisconnection in wiring
between (I 5) - - harness between C2
(8) as shown in 2 YES (14) - P2 (8) or correct or
Table I? between C2 (15) - P2 replace
Is voltage between
(9), or short circuit
* Turn starting switch with GND
ON.
Replace
Table 1
Working mode Between (14) - (8) Between (15) - (8)
H.0 1 12V (Note) Max. 1V
I G-0 1
I
12V (Note) II 12” (Note) /
F.0 Max. 1V 12V (Note)
L.0 Max. 1V Max. ‘IV
Table 2
~.
Note: If the voltage is not 12V and is unstable, take the answer
as YES.
C2 (MIC21) P2 (04016)
Workingmode(a)
205FO5627
20-236
0
P-18 Power set does not switch
Cause Remedy
a) Even when monitor panel switch is pressed, mode

display (LED) above switch does not change.
I Defective monitor panel ReplaCe
bl When monitor panel switch is pressed, mode display (LED)

above switch changes.
YES See troubleshooting of

1 I pump controller system

ON.
Table 1 Table 2
Between (6) - (8)
Note: If the voltage is not 12V and is unstable,

take the answer as YES.
C2 (MIC21) P2 (04016)
205FO5628
20-237
0
P-19 Auto-deceleration does not switch (Does not enter
auto-deceleration; auto-deceleration is not canceled)
a) Even when monitor panel switch is pressed, ON-OFF display

(LED) above( switch does not change.
t-=7=
I Defective monitor panel Replace
b) When monitor panel switch is pressed, ON-OFF display

(LED) above switch changes.
See troubleshooting of
YES
. pump Controller
1 system
Is voltagebetween Disconnection in wiring

C2 (7) - (8) as harness between C2
2 YES correct or
shown in Table l? . (7) - P2 (7), or
replace
contact with chassis
18 voltage between ground
- Turn starting switcl
- P2 (7) - (16) as -
ON. k ) shown in Table 17
NO Defective monitor panel ReplaCe
ON.
Table 1
-1
Note: If the voltage is “or 72V and

is unstable, take the answer as
YES.
C2(MIC21) P2 (04016)
~--y$fq
205FO5397
20-238
0
P-20 Travel speed does not switch between Hi and Lo
I CXlSe Remedy
1
a) Even when monitor panel switch is pressed, Lo - Hi display
(LED) above switch does not change.
Defective monitor panel F7eplWX
b) When monitor panel switch is pressed, Lo - Hi display

(LED) above switch changes.
YES See troubleshl: 30ting of

1 pump control ler wstenl
Is voltage between
Disconnectior I in wiring
c2 (3) - (8) as -
harness befwe en c2 (3)
- P2 (4). or c ontact
with chassis g\round
* T_... _._. ....= _...._..
ON.
H I
Replace
wcJJi Defective monitor panel
Note: If the voltage is not 12V

and is unstable, take the
answer as YES.

C2(MIC211 P2 (04016)
,205FO5396
20-i39
P-21 Warming-up operation is not carried out below 30°C,
or warming-up operation is not canceled even when
temperature goes above 30°C
* Carry out troubleshooting first for E-l 2 Automatic warming-up is defective
Cause Remedy
YES -
See E-12
YES Defective coolant tempe-

(See P-24)
Is voltage between Warming-up
P2 (11) and (16) as operation Wiring harness between Pl
shown in Table l? cannot be ifemale) (61 - Ml4 (61 - E8
carried out i5) - Pi ifkmale) cli in Repair or
contact with chassis ground replace
Turn starting
switch ON. or other GND wiring
-I- Defective monitor panel Replace

. Remove P7. N(
Y ES
Defective coolant tempe-
2 (See P-24)
I
I I
Warming-up
operation is Defective contact, or dis-
not canceled 3 YE! connection in wiring harness
between Pl (female) (6) - Repair or
Ml4 (6) - E8 15) - P7 replace
Is there conti-
nuity between Pl (female) (1)
connector to P7 ,40 (female) (6) and
(female) chassis ground?
. Start engine. Defective monitor panel
f Connect short
connector to P7
(female)
Table 1
W]
Note: If the voltage is not 12V and is

unstable, take the anser as YES.
PI (04020) Ml4(!38) E8BWPl4) P7(X2)
Monitor panel 6
205FO5738
20-240
0
P-22 Even when swing lock switch is turned ON (LOCK),
swing lock lamp on monitor panel does not light up
* Only carry out this troubleshooting if the swing lock is actually applied.
1 YES Defective monitor pane!
Is voltage between
P2 (3) - (16) as -
shown in Table l?
. harness between swing
- Turn starting switch lock switch (1) - P2 (3)
ON.
Swing lock switch OFF
Swing lock switch
P2(04016)
I
Monitor panel
205FO5741
P-23 Fuel level sensor system defective
Note 1: Difference between fuel level and gauge display

If the gauge display position is “lo”, the fuel level display is 78% or 100%; if it is “1”,
the fuel level display is less than 14.5%. If the machine is on a slope, the display and
actual fuel level will be different. Therefore, when checking, always stop the machine on
level ground and wait for at least two minutes before reading the gauge. (The fluid level
changes when the machine is moving, so a time delay is provided to give a stable display.)
* Remove the fuel level sensor when carrying out this troubleshootlng.
CaUSe Remedy
Interference with sensor (Note 21

mslde tank
Defecwe contact of connector Clean connector

or replace
Defective sensor (Note 2) ReplaG

NO
reSlSrance between
COnnector (1) and
flange as shown I”
4 YES Dsconnect~on I” wring Repau w,r,ng
harness or
IS wlrlng of w,r,ng n harness (Note 3)
(Defectwe clamp) replace sensor
harness broken? Is
resistance between
, connector (1) and
senwr terrmnat
below 1 SI? Replace
- NO
F20205053
Note 2: There is probably interference with the sensor inside the tank, or defective installation.
Install carefully when replacing.
Note 3: Check for any vibration at the connector mount, and take the necessary action if the vibration
is excessive.
P-24 Coolant temperature sensor system defective
C3W.e Remedy
YES Defective contact of co”nector Clean COnnectOr

1 (Note 1) or replace sensor
I Is resstance 1
between
fempera”re *enSOr 2
connector (male) (1) -
YES
and (2) as show” I” Is wring of wlrfng
Table 1) harness broken? IS
res~.ta”ce between
NC ;;;nector(“Iale) -
narness ,l”OE L,
(Defectwe clamp)
Table 1
Normal tern-
Approx. 37 - 50kR
perature (25°C
100°C APPTOX. 3.5--4.Okn
Connector Sensor
F20205054
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so replace the connector (harness) at the chassis end.
is excesive.
20-243
0
P-25 Engine oil level sensor system defective
Note 1: Variations in oil level

The oil level changes according to the angle of the machine, the engine speed, and oil
temperature, so if any display is given, stop the machine on flat ground and check the
oil level before carrying out the check again.
+ Remove the engine level sensor when carrying out this troubleshooting
CWJSe Remedy
2 YES
Excessive contamination of oil
Replace filter
element. change
oil
YES Is any dirt or dust
1
r stuck in movable part
Of float?
-
Defective contact of connector Clean connectof 01

Move the float up and II NO (Note 2) replace Sensor
down is the resistance
between connector (1) -
and flange as shown
r
3
in Table l? YES
Is wiring of wiring Disconnection in wiring harness Repair wiring
-
harness broken? Is (Note 3) (Defective clamp) harness or replace
resistance between Sensor
NO Co”“%tCX (male) and -
sensor terminal below
I’“’ I ‘NO Defective sensor
Table 1
1 Float UP 1 Max. la 1
Float DOWN Min. 1Mfl
F20205055
is excessive.
20-244
0
P-26 Coolant level sensor system defective
Note 1: Variations in coolant level
The coolant level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the coolant level
before carrying out the check again.
* Remove the coolant level sensor when carrying out this troubleshooting.
Remedy
YES Defective mO”eme”t of float Clean

because of dirt
YE ISanydirt or dust
stuck in float? -
3 YES Resonance of mount (Note 2) Replace sensor
- Is float badly
_ cracked, chipped, or -
NO damaged?
Clean connector
NO or replace
Table 1 ?
I
D,sconnect~on I” w!il”g RepaIr wlrlng
YES
Is wnng of wlrlng harness (Note 31 harness or
harness broken? Is
resistance between
I (Defectwe clamp) replace Sensor
hJO
i
cclnnector (1). (2)
a$e”sor below
1
NO
Defecttve sensor R&%X
Table 1
F20205056
Note 2: There is a strong possibility that the mount is resonating, so check the mount of the sub-
tank.
is excessive.
20-245
a
P-27 Hydraulic oil level sensor system defective
Note 1: Variations in hydraulic oil level

The oil level changes according to the angle of the machine, the engine speed, and oil
temperature, so if any display is given, stop the machine on flat ground and check the
oil level before carrying out the check again.
* Remove the engine level sensor when carrying out this troubleshooting.
I Cause
I Remedy
I
2 YES Excessive contamination

Replace filter
element, change
of oil
oil
YI Is any dirt or dust
- stuck in movable -
part of float?
Clean connector
or replace
NO connector (Note 2)
sensor
resistance between
wnnectcr (1) and
flange as show” I” 3
Table 1) - YES Asconnection in wiring Repair wiring
Is wiring of wiring r harness (Note 3) harness or
harness broken? Is (Defective clamp) replace sensor
_ resistance between _
3 connector (male)
and sensor terminal
below 1 Q Defective sensor Replace
NO
Table 1
1 Float UP / Max ln 1
Float DOWN Min. 1M.Q
F20205055
is excessive.
20-246
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ........... 30- 3 ENGINE, HYDRAULIC PUMP

PRECAUTIONS WHEN CARRYING OUT Removal and Installation (PC300) .... 30-46
OPERATION ........................... 30- 4 Removal (PC400) ...................... 30-48
SPECIAL TOOL LIST ...................... 30- 6 Installation (PC400) ................... 30-50
WEIGHT TABLE ........................... 30-I 1 DAMPER
TIGHTENING TORQUES AND Removal and Installation ............. 30-50
STANDARD VALUES TABLE ......... 30-I 4 CENTER SWIVEL JOINT
LUBRICANT AND COOLANT TABLE ..... 30-16 Removal and Installation ............. 30-52
STARTING MOTOR Disassembly and Assembly .......... 30-52
Removal and Installation ............. 30-18 FINAL DRIVE
ALTERNATOR Removal and Installation ............. 30-54
Removal and Installation ............. 30-I 8 Disassembly ........................... 30-54
ENGINE OIL COOLER Assembly .............................. 30-58
Removal and Installation ............. 30-20 TRAVEL MOTOR
FUEL INJECTION PUMP Disassembly ........................ 30-61-I
Removal and Installation ............. 30-22 Assembly ........................... 30-61-6
WATER PUMP SPROCKET
Removal and Installation ............. 30-24 Removal and Installation ............. 30-62
NOZZLE HOLDER SWING MOTOR
TURBOCHARGER Disassembly ........................ 30-63-I
Removal and Installation ............. 30-28 Assembly ........................... 30-63-4
THERMOSTAT SWING MACHINERY
ENGINE FRONT OIL SEAL Disassembly ........................... 30-66
Removal and Installation ............. 30-30 Assembly .............................. 30-68
ENGINE REAR OIL SEAL REVOLVING FRAME
GOVERNOR MOTOR SWING CIRCLE
CYLINDER HEAD IDLER, RECOIL SPRING
Removal and Installation (PC300) .... 30-36 Removal and Installation ............. 30-76
Removal and Installation (PC400) .... 30-38 RECOIL SPRING
AFTERCOOLER CORE Disassembly and Assembly .......... 30-78
Removal and Installation (PC300) .... 30-40 TRACK ROLLER
HYDRAULIC COOLER Removal and Installation ............. 30-80
Removal and Installation ............. 30-42 CARRIER ROLLER
RADIATOR, HYDRAULIC OIL COOLER Removal and Installation ............. 30-80
Removal and Installation ............. 30-44
TRACK SHOE BOOM CYLINDER
Removal and Installation ............. 30-82 Removal and Installation . . . . . . . . 30-105-I
CHARGING PUMP ARM CYLINDER
Removal and Installation ............. 30-82 Removal and Installation . . . . . . . . . . . . 30-I 06
HYDRAULIC PUMP BUCKET CYLINDER
Removal and Installation ............. 30-84 Removal and Installation . . . . . . . . 30-I 07-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 30-85-I BOTTOM DUMP CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85-8 Removal and Installation . . . . . . . . . 30-I 07-7
HYDRAULIC PUMP INPUT SHAFT HYDRAULIC CYLINDER
OIL SEAL Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 30-I 08
Removal and Installation ............ 30- 86 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-I 10
CONTROL VALVE WORK EQUIPMENT
Removal and Installation ............ 30- 88 Removal and Installation . . . . . . . . . . . 30-I 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 90 BUCKET
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 92 Removal and Installation . . . . . . . . . . . 30-I 14
MAIN RELIEF VALVE ARM
Removal and Installation ....... ... 30- 94 Removal and Installation . . . . . . . 30-I 15-3
Disassembly and Assembly . . . . . . . . . 30- 94 ARM, BUCKET
TVC VALVE Removal and Installation . . . . . . . . . . . 30-I 16
Removal and Installation ....... .... 30- 96 BOOM
CO NC VALVE Removal and Installation . . . . . . . . . 30-I 18
Removal and Installation .... 30- 96 OPERATOR’S CAB
SERVO VALVE Removal and Installation . . . . . . . . . . . 30-120
Removal and Installation .... 30- 96 COUNTERWEIGHT
HYDRAULIC PPC VALVE Removal and Installation _. . . . . . . . . . 30-120
Removal and Installation .... 30- 98 ENGINE THROTTLE CONTROLLER
WORK EQUIPMENT PPC VALVE Removal and Installation . . . . . . . . . . . 30-I 22
Disassembly and Assembly . . . .. 30- 98 PUMP CONTROLLER
TRAVEL PPC VALVE Removal and Installation . . . . . . . . . . 30-I 22
Removal and Installation ....... .. 30-I 00 MONITOR PANEL
Disassembly and Assembly . . . . .. 30-I 00 Removal and Installation . . . . . . . . . . . 30-I 22
BOOM HOLDING VALVE PROCEDURE FOR FLUSHING
Removal and Installation ...... .. 30-I 02 HYDRAULIC CIRCUIT
Disassembly and Assembly . . . . .. 30-I 02 PC300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-I 24
PPC SHUTTLE VALVE PC400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . 30-I 32
Removal and Installation ....... .. 30-I 04
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are markedm, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 00 0 ASSEMBLY. _ . . . Tilte of operation
A . .... ... .... . . .. . . . _ . . . Precautions related to safety when carrying out the
operation
1. XXXX (I 1 . . . . . _. . . . . . . . . . _ . . Step in operation
* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to remember when
removing XXXX (I 1.
2. A A A (2):. . . . . . . . . . . _. . . ... m Indicates that a technique is listed for use
during installation
3. 0 Cl IJ 0 assembly (3)
:
u . . . . . . _ . . . . . . . . . . . . . _ . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 OASSEMBLY . . . Title of operation

. Carry out installation in the reverse order to removal.
m . . .._.............._....... T ec h’q
nr ue used during installation
+ ........ .... .... ._ . . . Technique or important point to remember when in-
stalling A A A (2).
. Adding water, oil . . . . . . . . . _ . . Step in operation
+ . _ . . . . . . . . _ . . . . . . . . . . . . . _ . Point to remember when adding water or oil
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(I) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. Listing of tightening torque, weight, refill amount for oil and water
(I) If symbols such as w , & , or Q appear in the operation procedure, See TIGHTENING
TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHT
TABLE, and LUBRICANT AND COOLANT TABLE for details of the values.
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.

. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws alternately.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end)
Plug (nut end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 107376-50315 107221-20315 (Nut), 07222-00312 (Plug1

04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug1
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)

10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 / 07376-51234 ) 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal Sleeve head

Flange (hose end) Split flange
number (tube end)
04 1 07379-00400 1 07378-10400 1 07371-30400
/ I I
05 07379-00500 07378-10500 0737 I-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number Part number
D d c
06 07049~00608 6 5 8
08 07049-008 11 8 6.5 11 t
10 07049-01012 10 8.5 12
12 )07049-012151 12 I 10 I 15
/
14 107049-014181 14 1 11.5 1 18 I I I I
I
I t
16 07049-01620 16 13.5 20
18 /07049-018221 18 / 15 1 22 I I I
202F2001
2. Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
. When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-PI.
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations
l If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
l If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
l If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re-
moved for repair, always bleed the air from the system after reassembling the parts.
Sr For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equpment related
parts.
SPECIAL TOOL LIST
Pc300,300Lc-5
Nature of work Symbol Part No. Part Name
Disassembly, 1 791-580-1510 Installer

assembly of final A
drive assembly Adjustment of
2 796-570-I 110 Plate 1
clearance of bearing
791-600-2001 Compressor A 1
or
791-685-8003 Compressor B 1
Disassembly,
assembly of recoil B 791-635-3160 Extension 1
spring assembly
790-101-1600 Cylinder (70 t)
790-101-1102 Pump
Disassembly,
assembly of track
shoe assembly
C
k !
791-630-3000
790-101-1300
790-101-1102
Remover & installer
Cylinder (100 t)
Pump
d
1
1
Removal, press fitting
of master pin
1
l Removal,
installation of
charging pump
assembly
l Removal, D 796-760-I 310 Oil stopper 1
installation of
main pump
assembly
Expansion of
1 790-720-1000 Expander 1
Disassembly, , piston ring
assembly of I I
1
-!
E 796-720-1680 Ring
hydraulic cylinder All Compression of
assembly 2
cylinders piston ring
07281-01589 Clamp 1
I I
l Removal,
796-760-I 800 Remover
installation of
boom assembly
l Removal,
Pulling out
F 790-101-3800 Puller (50 t) boom foot pin
installation of
work equipment /
assembly 790-101-1102 Pump
PC300HD-5
Nature of work Symbol Part No. Part Name Q’ty Remarks
Installation of floating
Disassembly, 1 796-672-l 020 Installer 1
seal
assembly of final A
2 796-627-l 010 Plate
F
__-
or
791-685-8003 Compressor B
Disassembly,
assembly of recoil B 791-635-3160 Extension
spring assembly
790-101-1600 Cylinder (70 t) 1
790-101-1102 Pump 1
791-630-3000 Remover 84 installer 1
Disassembly,
assembly of track 790-101-1300 Cylinder (100 t) of master pin
shoe assembly
790-101-1102 Pump
l Removal,
installation of
charging pump
assembly
l Removal, 796-760-1310 Oil stopper
installation of
main pump
assembly
Expansion of
1 790-720-I 000 Expander
piston ring
Disassembly,
assembly of
I/
E 796-720-1680 Ring
hydraulic cylinder 411 Compression of
assembly 2 C:ylinders piston ring
07281-01589 Clamp 1
L
l Removal,
796-760-1800 Remover 1
installation of
boom assembly
Pulling out
l Removal, F 790-101-3800 Puller (50 t) 1
installation of boom foot pin
work equipment
assembly 790-101-1102 Pump
Nature of work Part Name Qw Remarks
4
Repair stand 1
Bracket 1
Plate 1
Oil leak tester 1 ~ Removal of brake piston
796-765-l 140 Bolt
Nut Removal, installation

of spring of cylinder
Washer block
Washer
I---
Press fitting of
Disassembly, 790-201-2720 Push tool 1 bearing inner race
assembly of travel G
motor assembly
Press fitting of bearing

5 796-765-l 120 Push tool 1
inner race
1 Press fitting of bearing

6 796-765-l 110 Push tool
outer race
8
790-I 01-5201 Push tool kit 1
6
7 790-I 01-5311 f Plate 1
Press fitting of 8
oil seal
790-I 01-5221 * Grip 1
0101 O-51 225 * Bolt 1
Press fitting of
796-765-l 130 Push tool 1
dowel pin
-
-I
Repair stand 1
Bracket 1
Plate 1
796-730-2120 Screwdriver
Removal, installation of
2
retainer mounting screw
796-720-2220 Socket
Disassembly,
assembly of swing H
Press fitting of
motor assembly 3 790-201-2840 Push tool 1
bearing inner race
4 796-766-l 110 Guide 1 1 Assembly of drive shaft
Press fitting of
5 790-201-2860 Push tool 1
bearing outer race
Wrench
4 laxi;rement of rotating
Torque wrench set
Nature of work Symbol Part No. Part Name Q’w Remarks
- -
790-501-5000
Repair stand 1
790-5oor-5200
790-901-2110 Bracket 1
1
790-901-I 450 Plate 1
790-901-I 460 Spacer 1
790-767-I 120 Plate 1

-
2 796-720-2270 Screwdriver 1 gear plate mounting screw
796-720-2250 Screwdriver 1 Removal, installation of

impeller mounting screw,
3 shoe retainer mounting
screw and cam plate
796-720-2220 Socket 1 mounting screw
4 796-767-l 140 Wrench 1
Disassembly, strainer of charging pump
assembly of
J
hydraulic pump
assembly
796-730-2120 Screwdriver 1
5
cam stopper mounting screw
796-720-2220 Socket 1
Measurement of shoe
6 791-746-2770 Hook 1
clearance
796-767-l 100 Gauge 1 Adjustment of stroke of

servo piston
7 796-767-l 110 . Plate 1
796-720-4640 Pin 1 (Max. angle side)
790-445-2921 Bar 1
796-720-4681 Gauge 1 Adjustment of stroke of

servo piston
8 796-720-4691 Plate 1
796-720-4640 Pin 1 (Min. angle side)
790-445-2921 Bar 1
796-730-2300 Wrench 1
Measurement of rotating
9
torque
795-630-I 803 Torque wrench set 1
- -
Pc400,400LC-5
PC400HD-5
Nature of work Symbol Part No. Part Name Q’ty Remarks
Installation of floating
k
Disassembly, 1 796-627-l 020 Installer 1
seal
assembly of final A
2 796-627-1010 Plate 1
or
Disassembly,
assembly of recoil B 791-635-3160 Extension 1
spring assembly
790-101-1600 Cylinder (70 t) 1
790-101-1102 Pump 1
791-630-3000 Remover & installer 1

Disassembly,
assembly of track C 790-101-1300 Cylinder (100 t) 1 of master pin
shoe assembly
790-101-1102 Pump 1
l Removal,
installation of
charging pump
assembly
l Removal, D 796-760-1310 Oil stopper 1
installation of
main pump
assembly
Expansion of
790-720-I 000 Expander 1
piston ring
796-720-1680 Ring 1 Boom

Disassembly, and arm
assembly of E 07281-01589 Clamp 1 cylinders
hydraulic cylinder Compression of
assembly piston ring
796-720-I 690 Ring 1
Arm
cylinder
07281-02169 Clamp 1
L
l Removal, 796-760-I 800 Remover 1

installation of
boom assembly
Removal, Pulling out
l
F 790-101-3800 Puller (50 t) 1
installation of boom foot pin
work equipment
assembly 790-101-1102 Pump 1
302 0
-
Nature of work
T
Symbol Part No.
790-501-5000
Part Name o’tr
-
Remarks
Repair stand 1
790-5001-5200
1 -
790-901-2110 Bracket 1
-
796-660-I 010 Plate 1
- -
2 799-301-I 600 Oil leak tester 1 Removal of brake piston
-
796-765-l 140 Bolt 1
-
01580-03024 Nut 1 Removal, installation
3 - of spring of cylinder
01643-33380 Washer 1 block
-
796-765-l 150 Washer 1
-
Press fitting of
Disassembly, 4 790-201-2720 Push tool 1
bearing inner race
assembly of travel G
motor assembly - -
Press fitting of bearing
5 796-765-l 120 Push tool 1 inner race
-
6 796-765-l 110 Push tool 1 Press fitting of bearing

outer race
- -
790-I 01-5201 Push tool kit 1

Press fitting of
7 790-I 01-5311 . Plate 1
oil seal
790-101-5221 * Grip 1
01010-51225 . Bolt 1
-
Press fitting of
8 796-765-l 130 Push tool 1
dowel pin
-
790-501-5000
Repair stand 1
790~504F-5200
1 -
790-901-2110 Bracket 1
-
790-901-1470 Plate 1
- -
2 - Removal, installation of
retainer mounting screw
796-720-2220 Socket 1
Disassembly, -
assembly of swing H
Press fitting of main
motor assembly 3 790-201-2840 Push tool 1
bearing and sub-bearing
-
4 796-766-l 110 Guide 1 Assembly of drive shaft
-
Press fitting of sub-

5 790-201-2860 Push tool 1
bearing outer race
-
796-720-3800 Wrench 1
6 - Measurement of rotating
torque
L -
30-ho-1
Nature of work Symbol Part No. Part Name O’tY Remarks
-
790-501-5000
790-5001-5200 Repair stand 1
790-901-21 IO Bracket 1
1
790-901-I 450 Plate 1
790-901-1460 Spacer 1
790-767-I 120 Plate 1
Screwdriver Removal, installation of

2 796-720-2270 1
gear plate mounting screw
796-720-2250 Screwdriver 1 Removal, installation of

impeller mounting screw,
3 - shoe retainer mounting
screw and cam plate
796-720-2220 Socket 1 mounting screw
140 Wrench Removal, installation of

4 796-767-l 1
Disassembly, strainer of charging pump
assembly of
J
hydraulic pump
assembly _ Removal, installation of
5 screw
796-720-2220 Socket cam stopper mounting
1
Measurement of shoe
6 791-746-2770 Hook 1
clearance
I I
796-660-I 100 Gauge 1

Adjustment of stroke of
servo piston
7 790-445-2950 Plate 1
790-720-4640 Pin 1
(Max. angle side)
790-445-2921 Bar 1
I I I
796-720-4681 Gauge 1
Adjustment of stroke of
8 796-720-4691 Plate servo piston
1
796-720-4640 . Pin 1
790-445-2921 . Bar 1 (Min. angle side)
796-730-2300 Wrench 1
Measurement of rotating
9 torque
-
3o-&o-2
WEIGHT TABLE
Pc300,300Lc-5
Unit: kg
Machine model PC300-5 PC3OOLC-5
Serial No. 20001 and up 20001 and up
Cylinder head assembly 65 65
Hydraulic cooler assembly 70 70
Engine Radiator, hydraulic cooler assembly 160 160
Air cleaner assembly (with bracket) 40 40
Engine, hydraulic pump assembly 1,200 1,200
Center swivel joint assembly 45 45
Final drive assembly 430 430
Power train Sprocket 50 50
Swing machinery assembly 440 440
Revolving frame assembly 7,850 7,950
Idler, recoil spring assembly 430 430
Undercarriage Recoil spring assembly 260 260
Idler assembly 170 170
Hydraulic pump assembly 315 315

g
6 Hydraulic Systerr I I Boom cylinder assembly 300 300
2
Work equipment assembly 5,600 5,600

Arm, bucket assembly 2,700 2,700
Work Equipment, Boom assembly 2,900 2,900
External Parts Operator’s cab assembly 240 240
Operator’s seat assembly 30 30
Engine hood 110 110
Final drive cover 50 50
Battery upper cover 90 90
3021
Unit: kg
Machine model PC300-5 MIGHTY PC300LC-5 MIGHTY

Serial No. 20401 and up 20401 and up
Cylinder head assembly 65 65
Engine Radiator, hydraulic cooler assemt 160 160
Air cleaner assembly (with bracke 40 40
Engine,hvdraulic puma assemblv 1,200 1,200

_
Hydraulic pump assembly 315 315
Hydraulic System Boom cylinder assembly 300 300
Work Equipment, Boom assembly 2,990 2,990
External Parts Operator’s cab assembly 240 240
Operator’s seat assembly 30 30
Engine hood 110 110
3022
PC300HD-5
Unit: kg
T
Machine model PC300HD-5
Serial No. 20401 and up
Cylinder head assembly 65
Hydraulic cooler assembly 70
Engine Radiator, hydraulic cooler assembly 160
Air cleaner assembly (with bracket) 40
Engine, hydraulic pump assembly 1,200
Center swivel joint assembly 45
Final drive assembly 560
Power train Sprocket 75
Swing machinery assembly 440
Revolving frame assembly 7,850
Idler, recoil spring assembly 430
Undercarriage Recoil spring assembly 260
Idler assembly 170
Hydraulic pump assembly 315
Hydraulic System Boom cylinder assembly 300
Arm cylinder assembly 430
Work equipment assembly 5,600
Bucket assembly 1,050
Arm assembly 1,300
Arm, bucket assembly 2,700
Work Equipment, Boom assembly 2,900
External Parts Operator’s cab assembly 240
Operator’s seat assembly 30
Counterweight 5,450
Engine hood 110
Final drive cover 50
Battery upper cover 90
3023
Pc400,400Lc-5
PC400HD-5
Unit: kg
Machine model PC400-5
Serial No. 20001 and up !z%$z&
Radiator, hydraulic cooler assembly 180 180
Engine Air cleaner assembly (with bracket) 30 30
Exhaust muffler 30 30
Turbochager, exhaust manifold 35 35
Final drive assembly 560
Power train Sprocket 75
Swing machinery assembly 620
Idler assernbrv 230 230
---I--
Hydraulic pump-assembly 320 320
Hydraulic System Boom cylinder assembly 400 (408) 400 (408)
Arm cylinder assembly 580 (492) 580 (492)
Bucket cylinder assembly 350 (248) 350 (248)
Work equipment assembly 7,650 (9,300) 7,650 (9,300)
Bucket assembly 1,300 (3,540) 1,300 (3,540)
Arm assembly 1,650 (1,770) 1,650 (1,770)
Boom assembly 3,750 (2,780) 3,750 (2,780)

Work Equipment, Operator’s cab assembly 240 240
External Parts Operator’s seat assembly 30 30
Engine hood I 150 150
Side cover (hydraulic pump side)

I 35 35
( ) LOADING SHOVEL
3o-A3-’
Unit: kg
Machine model PC400-5 MIGHTY PC400LC-5 MIGHTY
Serial No. I 20603 and up 20603 and up
Radiator, hydraulic cooler assembly 180 180
Engine Air cleaner assembly (with bracket) 30 30
Exhaust muffler 30 30
Turbochager, exhaust manifold 35 35
z Hydraulic pump assembly 320 320

6 Control valve assembly 240 240
z Hydraulic System Boom cylinder assembly 400 400
Work Equipment, Operator’s cab assembly 240 240
External Parts Operator’s seat assembly 30 30
Engine hood 150 150
Side cover (hydraulic pump side) 35 35
30-A3-2
TIGHTENING TORQUES AND STANDARD VALUES TABLE
Pc300,300Lc-5 Pc400,400Lc-5
item Unit PC300,3OOLC-5 MIGHTY PC400,4OOLC-5 MIGHTY
PC300HD-5 PC400HD-5
Fuel injection tube sleeve nut ~a~lh,~r’$ 3 f 0.5 3fl
Coupling lock bolt - 6.25 + 0.25
Nozzle holder mounting bolt 4.5 f 0.5 2.2 i 0.3
Turbocharger assembly mounting bolt 3.75 AZ0.75 6.75 + 0.75
Vibration damper mounting bolt - 11.25 k 1.25

14mmP--1.5: l6f2
Crankshaft pulley mounting bolt 46 f 3
16mmP- 1.5: 28.25 * 3.25
Head cover mounting bolt 0.9 + 0.1 1 + 0.1
Intake manifold mounting bolt 2.5 + 1

kgm
Exhaust manifold mounting bolt - 6.75 + 0.75
Rocker arm assembly mounting bolt, nut 2.5 k 0.5 6.75 k 0.75
Locknut for rocker arm adjustment screw 4.5 f 0.5 6.75 + 0.75
Locknut for crosshead adjustment screw - 6.75 + 0.75
Engine Rocker arm housing mounting bolt - 6.75 f 0.75
Cylinder head mountinq bolt

1st pass IOi 1 lo* 1
[Note] PC400,4OOLC-5
See Fig. 1 Tightening 2nd g
pass 15 * 0.5 14 * 0.5
torques. g
LY
3rd pass a 90 +3; 90 +30 0
0
Rear seal assembly

1) Flywheel mounting bolt 1 st pass kgm 9*3 15+3
2nd pass 19+1 29.5 + 2
2) Flywheel Face runout Max. 0.2 Max. 0.2

mm
Radial runout Max. 0.15 Max. 0.15
Engine, hydraulic pump mounting bolt

Front 39.25 k 4.25 94.5 * 10.5
kgm
Rear 94.25 k 10.25 94.5 f 10.5
Damper assembly mounting bolt 7.25 + 0.75 11.25 + 1.25
Final drive assembly mounting bolt 56 k 6.0 56 AI 6.0
o Mounting bolt
Final drive assembly (See Fig. 2)
Power @ Mounting bolt 39.25 + 4.25 76 + 8.5

train
@ Mounting bolt 6.75 + 0.75 11.25 i 1.25
@ Mounting bolt Initial tightening torque 10.0 11.0
A&d$ional tightening 0 120 +;o 120 +;o

g
0 Mounting bolt kgm 6.75 k 0.75 11.25 i 1.25
8 Starting force kg Max. 50 Max. 68
30614
l Cylinder head
m 6.75k0.75kgm
205FO55 IO
Fig. 1 PC400, 400LC-5
l Final drive
205FO5512
Fig. 2
3oi 5
PC300, 3OOLC-5 Pc400,400Lc-5
Componenl Item Unit PC300,3OOLC-5 MIGHTY PC400,4OOLC-5 MIGHTY
PC300HD-5 PC400HD-5
4 Travel motor assembly

28.25 + 3.25 28.25 i 3.25
1) Cladle mounting bolt
2) End cover assembly (See Fig.3)

5.4 i 0.6 5.4 + 0.6
0 Plug
1 0 Plug 6.5 * 1.0 6.5 i 1.0
@ Bleeder 0.9 * 0.1 0.9 io.l
@ @ @ Plug 2.4 YIZ0.4 2.4 k 0.4
! 0 11 Plug 11.25 -c 1.25 11.25 2 1.25
8 End cover assembly mounting bolt 58 * 5 58 I 5
0 Safety valve assembly 26 + 3 26 + 3
@ Mounting plug of counterbalance valve 66.5 zt~7.5 66.5 +_ 7.5
8 Plug of check valve 42.75 k 4.75 42.75 i 4.75
3) Plug of regulator piston 37 * 4 37 +_ 4
Power train 5 Sprocket mounting bolt kgm 65 k 5 65 + 5

I
6 Swing motor assembly
1) Retainer mounting screw 1 st step 0.5 + 0.1 0.5 + 0.1
2nd stop 1.35 * 1.5 1.35 f 1.5
2) Plug of check valve 56 i 6 56 + 6
3) Relief valve 35 *5 35 + 5
4) Valve case mounting bolt 36 i 2 36i 2
7 Swing machinery assembly mounting bolt 94.5 + 10.5 94.6 f 10.5
8 Swing machinery assemly (See Fig. 4)

0 Carrier pin mounting bolt 18+2 28.25 i 3.25
0 Carrier assembly plate mounting bolt 39.25 i 4.25 39.25 + 4.25
0 Bearing cage mounting bolt 6.75 k 0.75 6.75+ 0.75
9 Revolving frame assembly mounting bolt 94.5 i 10.5 94.5 + 10.5
10 Swing circle mounting bolt 94.5 i 10.5 94.5+ 10.5
1 Recoil spring assembly

kg 17,680 24,735
1) Installed load of spring I I I
2) Free length of spring 795 857
Undercar-
riage 3) Installed length of spring mm 648 707
2 Amount of slack for track 331 * 20 358 + 20
3 Track roller assembly mounting bolt kgm 67 + 7 91.5 + 8.5
1 Hydraulic pump assembly (See Fig. 5)

0 Plate mounting bolt I I 6.7 + 0.7 I 6.7 k 0.7
Hydraulic
system km
@ Mounting bolt for hydraulic pump
3.2 * 0.3 3.2 i 0.3
input shat housing assembly
l End cover
F2.0705360
Fig. 3
l Swing machinery
205FO5513
Fig. 4
l Main pump n
205FO5515
Fig. 5
3027
PC300, 3OOLC-5 Pc400,400Lc-5
Componen Item Unit PC300,3OOLC-5 MIGHTY PC400,4ooLC-5 MIGHTY
PC300HD-5 PC400HD-5
I I
2 Hydraulic pump assembly
1) Rocker cam stopper mounting screw
I 3.2 + 0.3
I
3.2 i 0.3
2) Plate mounting screw
3) Bearing reainer mounting screw
4) Rear pump mounting bolt
5) Pump sub-assembly mounting bolt 18* 2 18+ 2
6) Charging pump driven gear

(Charging pump end) I 11.5 * 1.0
I
11.5 * 1.0
(Main shaft end)
7) End cap mounting bolt
8) Impeller mounting screw I 1.35 * 0.15 I 1.35 f 0.15
9) Servo piston cap mounting bolt 6.7 + 0.7 6.7 ? 0.7
IO) Servo valve assembly mounting bolt 3.2 f 0.3 3.2 +_ 0.3
11) TVC valve mounting bolt I 3.2 + 0.3 I 3.2 ?z 0.3
12) CO * NC valve mounting bolt 3.2 k 0.3 3.2 +_ 0.3
13) Plug of strainer assembly 7+1 7+1
14) Sleeve nut of house (CO . NC valve)

I 5+2 5+2
Hydraulic
(Charging pump)
km
I 23 + 3
I 23 + 3
0
system
c 15) End cap mounting nut and bolt 48 f 4 48 k 4
-
3 Control valve assembly (See Fig. 5)
20 f 2 20* 1
@ Plug for check valve mount
0 Safety-suction valve 1911 19+ 1
0 Jet sensor relief valve 5.5 + 0.5 5.5 + 0.5
0 Main relief valve 19+ 1 19+ 1

-
Work equipment PPC valve assembly
4
(See Fig. 6) 11.25 + 1.25 11.25 & 1.25
0 Joint
0 Nut 11.5 + 1.5 11.5 k 1.5

-
5 Boom lock valve assembly (See Fig. 7)
19+ 1 19* 1
0 Safety valve
0 Spool mounting plug 4 * 0.5 4 + 0.5
@ Check valve body mounting bolt 11.25 f 1.25 11.25 + 1.25

-
3 Hydraulic cylinder assembly
38 + 5.5 54 + 8
1) Bucket cylinder Head mounting bolt
2) Arm cylinder Head mounting bolt 54 i 8 91 *I4
Screw 6.75 + 0.75 16+2
3) Boom cylinder Head mounting bolt 38 + 5 54 + 8

-
7 Counterweight mounting bolt 185+10 390 I 40
30-&7-l
0 Control valve
205FO55 I6 205FO55 I7
205FO55 I8
205FO55 I9
Fig. 5
l Work equipment PPC valve l Boom holding valve
205FO552 I
205FO5520
Fig. 7
Fig. 6
30-&7-2
REMOVAL OF STARTING REMOVAL OF ALTERNATOR
MOTOR ASSEMBLY ASSEMBLY
Pc300,300Lc-5 Pc300,300Lc-5
A Disconnect the cable from the negative 6) A Disconnect the cable from the negative (-1
terminal of the battery. terminal of the battery.
1. Disconnect wiring connector (I). (See Fl) 1. Disconnect wiring (1). (See F3)
2. Disconnect wiring (2). (See Fl) 2. Remove adjustment bolt (2). (See F3)
3. Remove starting motor assembly (3). (See * Loosen mounting bolts and nuts (3). (See
Fl) F3)
3. Remove fan belt (4). (See F3) m
4. Remove mounting bolts and nuts (3). (See
F3)
5. Remove alternator assembly (5). (See F3)
INSTALLATION OF STARTING
MOTOR ASSEMBLY INSTALLATION OF
PC300, 3OOLG5 ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to
removal.
removal.
m
. Adjust the fan belt tension. For details,
see TESTING AND ADJUSTING.
REMOVAL OF STARTING
MOTOR ASSEMBLY
PC400, 4OOLC-5
REMOVAL OF ALTERNATOR
ASSEMBLY
A Disconnect the cable from the negative (-1
terminal of the battery. PC400, 4OOLG5
1. Disconnect
A
wiring connector (I). (See F2)
Disconnect the cable from the negative 6)
2. Disconnect wiring (2). (See F2)
terminal of the battery.
3. Remove starting motor assembly (3). (See
1. Disconnect wiring (I).
F2)
2. Remove adjustment bolt (2).
* Loosen mounting bolts and nuts (3).
3. Remove fan belt (4). m
4. Remove mounting bolts and nuts (3).
5. Remove alternator assembly (5).
INSTALLATION OF STARTING
MOTOR ASSEMBLY INSTALLATION OF
PC400, 4OOG5 ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to PC400, 4OOLC-5
removal.
removal.
. Adjust the fan belt tension. For details,

Fl
I F3
I i20705301 ;I
F20705303
F2
F4
I
F20507304
REMOVAL OF ENGINE OIL REMOVAL OF ENGINE OIL
COOLER ASSEMBLY COOLER ASSEMBLY
PC300, 3OOLC-5
1. Remove fuel injection pump assembly. 1. Drain cooling water.

. For details, see REMOVAL OF FUEL 2. Remove bracket (I). (See F3)
INJECTION PUMP ASSEMBLY. 3. Disconnect tube (2). (See F4)
2. Drain cooling water. 4. Remove oil cooler assembly (3). (See F4)
3. Disconnect wiring (I). Gee Fl)
4. Remove oil filter assembly (2). (See Fl)
5. Disconnect hose (3). (See Fl)
6. Disconnect tube (4). (See Fl)
INSTALLATION OF ENGINE OIL
7. Remove oil cooler assembly (5). (See Fl) COOLER ASSEMBLY
m
PC400, 4OOLC-5
INSTALLATION OF ENGINE OIL removal.

. Refilling with water
COOLER ASSEMBLY Ir Add water to the specified level, and run
Pc300,300LC-5 the engine to circulate the water through
the system. Then check the water level
. Carry out installation in the reverse order to again.
removal.
* Add water to the specified level, and run
the engine to circulate the water through
again.
m
. The dimensions of the mounting bolts
differ according to the mounting position,
so refer to the table below when
installing. (See F2)
Unit: I im
Bolt diameter Bolt length
(under head)
A 8 25
B 8 20
C 8 85
D 8 60
E 10 30
F IO 20
G 8 35
H 8 25
Others 8 30
Fl F3
\
i207Oi305 F20705307
r------
I
I
/
I/
F
c
F4
I
.. - -VI-
F20705306 F20705308
REMOVAL OF FUEL INJECTION REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY PUMP ASSEMBLY
Pc300,300Lc-5 Pc400,400Lc-5
1. Remove control rod (I ). (See Fl) 1. Remove control rod (I). (See F3)
* Mark the mounting hole of the pin. Ir Mark the mounting hole of the pin.
2. Disconnect fuel hose (2). (See Fl) 2. Disconnect fuel hose (2). (See F3)
3. Disconnect spill hose (3). (See Fl) 3. Disconnect spill tube (3). (See F3)
4. Disconnect fuel injection tube (4). (See Fl) 4. Disconnect fuel injection tube (4). (See F3)
piJ m
5. Disconnect lubrication tube (5). (See Fl) 5. Disconnect lubrication tube (5). (See F3)
6. Remove bracket (6). (See Fl) 6. Remove coupling lock bolt (6). (See F3)
7. Remove fuel injection pump assembly (7). a
(See Fl) m 7. Remove fuel injection pump assembly (7).

(See F3). m
* Keep the coupling key in a safe place and
INSTALLATION OF FUEL be careful not to lose it.
INJECTION PUMP ASSEMBLY

Pc300,300Lc-5 INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal. Pc400,400Lc-5
m
w Sleeve nut:
removal.
See Tightening Torques and
m
Standard Values Table
m m Sleeve nut :
. See Tightening Torques and
Install the injection pump as follows.
1) Set No. 1 cylindertocompression top
m
dead center.
w Coupling lock bolt :
Ir Rotatethecrankshaftinthenormal
direction to align the pointer with
the Id16”” TOP mark on the
m
crankshaft pulley. When rotating,
. Adjust the fuel injection timing and bleed
check the movement of the intake
the air from the fuel system. For details,
valve of No. 1 cylinder.
2) Align the wide teeth of the coupling
inside the drive case with the wide
teeth of the drive shaft spline for the
injection pump, and install.
3) Align line “a” on the injection pump
flange with line “b” on the drive case,
and tighten the mounting nuts. (See
F2)
Sr If there is no line on the injection
pump flange, adjust the injection
timing. For details, see TESTING
AND ADJUSTING.
* After completing the operation, bleed
the air from the fuel system.
30&22
r------
=\
E
b
>
L
L.A 205FO5523
L
REMOVAL OF WATER PUMP REMOVAL OF WATER PUMP
ASSEMBLY ASSEMBLY
Pc300,300Lc-5
1. Drain cooling water. 1. Drain cooling water.

2. Disconnect hose (1). (See Fl) 2. Disconnect hose (I). (See F3)
3. Disconnect wiring connector (2). (See Fl) * Move the hose upwards.
4. Remove sub-tank (3). (See Fl) 3. Disconnect connector (2). (See F3)
* Remove the sub-tank together with the 4. Remove water pump assembly (3). (See F3).
bracket. -)r Remove 3 mounting bolts, then remove
5. Disconnect hose (4). (See F2) the water pump assembly.
6. Disconnect tube (5). (See F2)
7. Remove elbows (6) and (7). (See F2)
8. Remove belt (8). (See F2) m
Jr Loosen the lock bolts and adjustment bolts, INSTALLATION OF WATER
and remove the belt from the pulley. PUMP ASSEMBLY
9. Remove water pump assembly (9). (See F2)
Pc400,400Lc-5
removal.
INSTALLATION OF WATER . Refilling with water
PUMP ASSEMBLY k Add water to the specified level, and run
Pc300,300Lc-5
. Carry out installation in the reverse order to again.
removal.
m
* Adjust the belt tension. For details, see
TESTING AND ADJUSTING.
again.
Fl
705311
8
6
8
REMOVAL OF NOZZLE HOLDER REMOVAL OF NOZZLE HOLDER
ASSEMBLY ASSEMBLY
Pc300,300Lc-5
1. Disconnect wiring connector (1). (See Fl) 1. Disconnect fuel injection tube (1). (See F4)
2. Disconnect lead (2). (See F2) m
3. Disconnect fuel injection tube (3). (See F2) 2. Disconnect spill tube (2). (See F4)
a 3. Remove nozzle holder assembly (3). (See F4)
4. Disconnect spill hose (4). (See F2)
5. Remove holder (5). (See F3) a When removing the nozzle holder assem-
6. Remove nozzle holder assembly (6). (See F3) bly,becarefuInottoletanydirtordustget
m into the nozzle mount.
* When removing No. 2 and No. 3 nozzle Screw a bolt into the tip of the nozzle
holder assemblies, remove the intake holder, then use lever 0 to pull it out. (See
connector. F5)
Ir When removing the nozzle holder assem- When removing No. 4 nozzle holder
bly, be careful not to let any dirt or dust get assembly, remove the intake connector.
into the nozzle mount.
INSTALLATION OF NOZZLE INSTALLATION OF NOZZLE

HOLDER ASSEMBLY HOLDER ASSEMBLY
Pc300,300Lc-5 Pc400,400Lc-5
. Carry out installation in the reverse order to . Carry out installation in the reverse order to
removal. removal.
m m
m Sleeve nut : B Sleeve nut :
See Tightening Torques and See Tightening Torques and
Standard Values Table Standard Values Table
a m
m Mounting bolt : m Nozzle holder mounting bolt :

See Tightening Torques and See Tightening Torques and
Standard Values Table Standard Values Table
m * When installing the nozzle holder assem-
* When installing the nozzle holder assembly, check and clean the nozzle holder
bly, check and clean the nozzle holder mount before installing.
mount before installing.
Fl F4
F2070531:
F3
-
u
F20705314
30627
REMOVAL OF TURBOCHARGER REMOVAL OF THERMOSTAT
ASSEMBLY ASSEMBLY
Pc300,300Lc-5 Pc300,300Lc-5
1. Disconnect tube (1). (See Fl) 1. Drain cooling water.

2. Disconnect hose (2). (See Fl) 2. Disconnect hose (1). (See F3)
3. Disconnect tube (3). (See Fl) 3. Disconnect wiring connector (2). (See F3)
4. Remove turbocharger assembly (4). (See Fl) 4. Remove sub-tank (3). (See F3)
m * Remove the sub-tank together with the
bracket.
INSTALLATION OF 6. Remove elbow (5). (See F4)
TURBOCHARGER ASSEMBLY 7. Remove thermostat assembly (6). (See F4)
/%?iJ

INSTALLATION OF
removal.
m
THERMOSTAT ASSEMBLY
m Nut: Pc300,300Lc-5
removal.
a
Ir Assemble with the TOP mark at the top.
REMOVAL OF TURBOCHARGER . Refilling with water
ASSEMBLY + Add water to the specified level, and run

Pc400,400Lc-5
1. Disconnect muffler drain tube (1). (See F2) again.
2. Remove muffler and tube (2). (See F2)
Jr Remove the clamp, and move the muffler
REMOVAL OF THERMOSTAT
and tube as one unit towards front.
3. Remove intake connector (3). (See F2) ASSEMBLY
4. Disconnect hose (4). (See F2) Pc400,400Lc-5 .
1. Drain cooling water.
6. Remove turbocharger assembly (6). (See F2)
2. Disconnect hose (1). (See F5)
m
3. Disconnect connector (2). (See F5)
4. Remove thermostat assembly (3). (See F5)
INSTALLATION OF INSTALLATION OF
TURBOCHARGER ASSEMBLY THERMOSTAT ASSEMBLY
Pc400,400Lc-5
removal. removal.
m . Refilling with water
m Nut: * Add water to the specified level, and run
See Tightening Torques and the engine to circulate the water through
Standard Values Table the system. Then check the water level
again.
30-28
0
F4
F2 F5
5
REMOVAL OF ENGINE FRONT REMOVAL OF ENGINE FRONT
OIL SEAL OIL SEAL
Pc300,300Lc-5 Pc400,400Lc-5
1. Radiator, hydraulic cooler assembly 1. Radiator, hydraulic cooler assembly

. Remove radiator and hydraulic cooler . Remove radiator and hydraulic cooler
assembly. assembly.
For details, see REMOVAL OF RADIATOR, For details, see REMOVAL OF RADIATOR,
HYDRAULIC COOLER ASSEMBLY. HYDRAULIC COOLER ASSEMBLY.
2. Remove fan. (See Fl) 2. Remove fan (I). (See F4)
3. Remove vibration damper (1). (See Fl) 3. Remove vibration damper (2). (See F4) m
4. Remove fan belt (2). (See Fl) m 4. Remove fan belt (3). (See F4) m
5. Remove pulley (3). (See F2) m * Loosen the mounting bolts and nuts of the
% Using puller 0, remove the pulley, then alternator assembly, then remove the
remove the collar. adjustment bolts, and move the alternator
6. Remove front oil seal (4). (See F3) m assembly towards the block.
5. Remove pulley (4). (See F4) m
6. Remove front oil seal (5). (See F5) m
INSTALLATION OF ENGINE INSTALLATION OF ENGINE

FRONT OIL SEAL FRONT OIL SEAL
Pc300,300LG5 Pc400,400Lc-5
removal. removal.
m m
. Adjust the fan belt tension. W Mounting bolt:
For details, see Standard Value Table for For details, see Tightening
Engine. Torques and Standard Values
m Table.
W Mounting bolt: m
For details, see Tightening . Adjust the fan belt tension.
Torques and Standard Values For details, see Standard Value Table for
Table. Engine.
m m
4 Lip of oil seal: Grease (G2-LI) B Mounting bolt:
Jr Pressfitthefrontsealsothatitislevelwith For details, see Tightening
the surface of the front cover. Torques and Standard Values
Table.
m
& Lip of oil seal: Grease (G2-LI)
* Press fit the oil seal until the distance from
the front end of the cover is 1 I+J mm.
F-1 F-4
3,
1
Z-
4
205FO5525 :05528
F:2 F:5
205FO5526 VI 205F05529
F3
205F05527
205FO553C
REMOVAL OF ENGINE REAR REMOVAL OF ENGINE REAR
OIL SEAL OIL SEAL
Pc300,300Lc-5 PC400, 4OOLC-5
1. Damper assembly 1. Damper assembly

. Remove damper assembly. . Remove damper assembly.
For details, see REMOVAL OF DAMPER For details, see REMOVAL OF DAMPER
ASSEMBLY. ASSEMBLY.
2. Remove air cleaner assembly (1). (See Fl) 2. Remove air cleaner assembly (I). (See F6)
3. Disconnect tube (2). (See Fl) * Sling the air cleaner assembly, and
4. Remove muffler assembly (3). (See Fl) remove together with the bracket.
* Sling the muffler assembly, and remove kg
&?I See Weight Table
together with the bracket. 3. Remove flywheel (2). (See F7) m
& kg See Weight Table * Using eyebolts, sling the flywheel,
5. Remove flywheel (4). (See F2) [_11 remove the mounting bolts, then remove.
* Using eyebolts, sling the flywheel, re- fi kg See Weight Table
move the mounting bolts, then remove. 4. Remove rear seal (3). (See F7) m
kg
&?I See Weight Table
6. Remove rear oil seal (5). (See F2) a
INSTALLATION OF ENGINE
REAR OIL SEAL
REAR OIL SEAL
removal.
removal.
m
m
* Tightening order of mounting bolts (See
* Tightening order of mounting bolts (See
F9)
F4)
& Mounting bolt: Engine oil SAE30
&?I& Mounting bolt: Engine oil SAE30
w Mounting bolt:
w Mounting bolt:
For details, see Tightening
For details, see Tightening
Torques and Standard Values
Torques and Standard Values
Table.
Table. . Use dial gauge @ to measure the face
. Use dial gauge @ to measure the face runout and radial runout of the flywheel.
runout and radial runout of the flywheel.
(See F8)
(See F3) For details, see Tightening Torques and
For details, see Tightening Torques and Standard Values Table.
Standard Values Table.
m
m
* Set the seal with side without the flange
Ir Press-fit the seal so that the TOP mark
facing straight down, then press fit until
faces upward.
the flange contacts the end face of the
* When assembling, check the wear groove
housing.
of the seal lip contact portion of the
crankshaft, and If necessary, move the
seal approx. 3 mm (change a from 23
mm to 20 mm) towards the flywheel
before assembling. (See F5)
30-32
0
Fl
205FO5534
F7
205FO5404 205FO5404
6 I40F267A 6 I40F267A
F4 F5
I
205FO5532 205F05535
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
Pc300,300Lc-5
A Disconnect the cable from the negative (4

1. Remove control rod (1). (See Fl)
* Remove the pin at governor motor end.
2. Disconnect wiring connector (2). (See Fl)
3. Remove governor motor assembly (3). (See
Fl)
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
Pc300,300Lc-5
removal.
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
Pc400,400Lc-5
A Disconnect the cable from the negative (4

1. Remove control rod (I). (See F2)
Ir Remove the pin at governor motor end.
2. Disconnect wiring connector (2). (See F2)
3. Remove governor motor assembly (3). (See
F2)
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
PC400, 4OOLC-5
removal.
3024
Fl
-
F20705321)
30-35
0
REMOVAL OF CYLINDER HEAD p%J
m Sleeve nut :
ASSEMBLY
PC300. 3OOLC-5 See Tightening Torques and
1. Remove turbocharger assembly. Standard Values Table
2. Drain cooling water. m
3. Disconnect radiator inlet hose (1). (See Fl) m Mounting bolt :
4. Disconnect intake connector (2). (See Fl) See Tightening Torques and
5. Disconnect spill hose (3). (See Fl) Standard Values Table
6. Remove bolt (4).(See Fl) jl
7. Remove heater switch (5). (See F2) sr Tighten the mounting bolts and nuts
* Remove together with the bracket. starting from the center and working in
8. Remove fuel filter assembly (6). (See F2) order to the outside. (See F7)
9. Disconnect tube (7). (See F2) * Check that the ball of the adjustment
10. Remove corrosion resistor assembly (8). (See screw is fitted properly into the socket of
F2) the push rod.
11. Disconnect wiring (9). (See F2) . Adjust the valve clearance.
12. Disconnect tube (10). (See F2) For details, see TESTING AND
13. Disconnect connectors (11) and (12). (See F2) ADJUSTING, Adjusting valve clearance.
14. Remove intake manifold assembly (13). (See m Mounting bolt, nut :
F3). m See Tightening Torques and
* Remove the fuel injection pipes No. 5 Standard Values Table
and No. 6 as one unit. w Locknut :
* Using eyebolts, sling the intake manifold See Tightening Torques and
assembly and remove the mounting Standard Values Table
bolts. m
15. Disconnect fuel injection pipes (14). (See F4) * If any rust of more than 5 mm square is
m found on the shaft or thread of any head
16. Disconnect lead (15). (See F4) bolt, replace the head bolt with a new
17. Remove glow plug (16). (See F4) bolt.
18. Remove nozzle holder assembly (17). (See * Check that there is no dirt or dust on the
F4) cylinder head mounting surface or inside
* Remove 6 nozzle holder assemblies the cylinder.
together with the spill hoses. * Check that the grommet does not come
19. Disconnect hose (18). (See F4) out when installing the gasket.
20. Remove head cover (19). (See F4) m * Screw in the cylinder head mounting
21. Remove rocker arm assembly (20). (See F5) bolts 2 - 3 turns by hand, then tighten
m
as shown in the diagram.
* Loosen the locknut, then loosen the
& Mounting bolt :
adjustment screw 2 - 3 turns.
Anti-friction compound (LM-P)
22. Remove push rod (21). (See F5)
w Mounting bolt :
23. Remove cylinder head assembly (22). (See
F6) m
lE?lSee Weight Table
* After tightening, make one punch mark on
INS;ALLATION OF CYLINDER the bolt head to indicate the number of times
HEAD ASSEMBLY that the bolt has been used.
Pc300,300Lc-5 . If any bolt has 5 punch marks, do not
. Carry out installation in the reverse order to reuse it. Replace it with a new bolt.
removal. . Refilling with water
m * Add water to the specified level, and
w Intake manifold mounting bolt : run the engine to circulate the water
See Tightening Torques and through the system. Then check the
Standard Values Table water level again.
Fl F
I II 205FO5536 1 205FO5540
205FO5537 II I’ 205FO55 41
F:3 F7
Intake side
Exhaust side
L 205FO5542
F4
18
19
,
205FO5539
REMOVAL OF CYLINDER HEAD INSTALLATION OF CYLINDER
ASSEMBLY HEAD ASSEMBLY
Pc400,400Lc-5 PC400, 4OOLcs
1. Drain cooling water. . Carry out installation in the reverse order to

2. Remove heater switch (1). (See Fl) removal.
* Remove together with the bracket. m
3. Disconnect tube (2). (See Fl) m Sleeve nut :
4. Remove intake connector (3). (See Fl) See Tightening Torques and
5. Remove bracket (4). (See Fl) Standard Values Table
6. Remove fuel filter assembly (5). (See Fl) m
7. Remove corrosion resistor assembly (6). (See m Exhaust manifold mounting bolt :
Fl) See Tightening Torques and
8. Remove intake manifold and injection tube Standard Values Table
assembly (7). (See Fl) m m
+ Remove the intake manifold together w Mounting bolt :
with the injection tube. See Tightening Torques and
9. Disconnect muffler drain tube (8). (See F2) Standard Values Table
10. Remove muffler and tube (9). (See F2) m
* Remove the clamp, then move the w Mounting bolt :
muffler and tube together towards the See Tightening Torques and
front, and remove. Standard Values Table
See Weight Table a
&
11. Rekkove intake connector (IO). (See F2) * Clean the oil hole of the mounting bolt,
12. Disconnect tube (I 1). (See F2) then install.
13. Remove turbocharger and exhaust manifold * Check that ball of the adjustment screw
assembly (12). (See F3). m is fitted properly into the socket of the
See Weight Table push rod.
&
14. di::onnect wiring connector (13). (See F3) . Adjust the valve clearance. For details,
15. Disconnect hose (14). (See F3) see TESTING AND ADJUSTING, Adjust-
16. Remove water manifold (15). (See F3) ing valve clearance.
17. Disconnect spill tube (16). (See F4) m Mounting bolt :
18. Remove nozzle holder assembly (17). (See See Tightening Torques and
F4) m Standard Values Table
* Screw a bolt into the tip of the nozzle w Locknut :
holder, then use a lever to pull it out. See Tightening Torques and
19. Remove head cover (18). (See F4) 114j Standard Values Table
20. Remove rocker arm assembly (19). (See F5) m
m + Adjust the crosshead as follows.
* Loosen the locknut, then loosen the I) Press down lightly with a finger on
adjustment screw 2 - 3 turns. the top of the crosshead, screw in
21. Remove crosshead (20). (See F6) m the adjustment screw until it contacts
22. Remove push rod (21). (See F6) the valve stem, then tighten it a
23. Remove rocker arm housing (22). (See F6) further 20”.
a 2) Hold the adjustment screw, and
24. Remove cylinder head assembly (23). (See tighten the locknut.
F7) m m Locknut :
30-38
0
19
---A/---L /
205FO5547
F2
205FO5544 205FO5548
E F3 F7
r
/ II-/?,?I ’ ’
205FO5545 205FO5549
F4
I 16 18
205FO5546
30-39
0
REMOVAL OF AFTERCOOLER
CORE ASSEMBLY
m Mounting bolt: Pc300,300LC-5
See Tightening Torques and 1. Drain cooling water.
Standard Values Table 2. Remove intake connector (1). (See F2)
m 3. Remove heater switch (2). (See F2)
* If any rust more than 5 mm square is + Remove together with the bracket.
found on the shaft or thread of any head 4. Disconnect spill hose (3). (See F2)
bolt, replace the head bolt with a new 5. Remove fuel filter assembly (4). (See F2)
bolt. 6. Remove corrosion resistor assembly (5). (See
* Check that there is no dirt or dust on the F2)
cylinder head mounting surface or inside 7. Disconnect tube (6). (See F2)
the cylinder. 6. Disconnect connectors (7) and (8). (See F2)
Ir Check that grommet does not come out 9. Remove cover (9). (See F3)
when installing the gasket. 10. Remove aftercooler core assembly (10). (See
* Screw in the cylinder head mounting F3) m
bolts 2 - 3 turns by hand, then tighten
as shown in the diagram. (See Fl)
6 Mounting bolt :
Anti-friction compound (LM-P) INSTALLATION OF
w Mounting bolt :
AFTERCOOLER CORE
ASSEMBLY
Ir After tightening, make one punch mark
on the bolt head to indicate the number
of times that the bolt has been used.
removal.
. If any bolt has 5 punch marks, do
m
not reuse it. Replace it with a new
m Mounting bolt :
bolt.
. Refilling with water.
Sr Add water to the specified level, and run
again.
again.
3020
F2
1 I
I I " 'FiO70532,
615OF316
F3
F2070532!
30641
REMOVAL OF HYDRAULIC REMOVAL OF HYDRAULIC
COOLER ASSEMBLY COOLER ASSEMBLY
PC300, 3OOLC-5 PC400, 4OOLG5
Y Y
A+ Lower the work equipment to the ground and *.lower the work equipment to the ground and
stop the engine. Then loosen the oil filler stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside the cap slowly to release the pressure inside the
hydraulic tank. hydraulic tank.
1. Disconnect hose (I). (See Fl) 1. Remove hood.
2. Remove net (2). (See Fl) *‘,&Be careful when removing the hood,
* Loosen the mounting bolts and pull the ’ because it is under tension from the
net up to remove. spring.
3. Remove hydraulic oil cooler assembly (3). & kg See Weight Table
(See F2) 2. Disconnect hose (I). (See Fl)
* Sling the hydraulic oil cooler assembly, 3. Remove net (2). (See Fl)
then remove the mounting bolts and -k Loosen the mounting bolts and pull the
bracket, and pull the hydraulic oil cooler net up to remove.
assembly out from below. 4. Remove hydraulic oil cooler assembly (3).
* The bolts marked % are the mounting (See F2)
bolts for the radiator and hydraulic * Sling the hydraulic oil cooler assembly,
oil cooler assembly, so do not then remove the mounting bolts and
remove them. (See F3) bracket, and pull the hydraulic oil cooler
& ks See Weight Table assembly out from below.

+ The bolts marked u are the mounting
bolts for the radiator and hydraulic oil
cooler assembly, so do not remove them.
(See F3)
INSTALLATION OF HYDRAULIC See Weight Table
&I kg
COOLER ASSEMBLY

removal. INSTALLATION OF HYDRAULIC
. Refilling with oil COOLER ASSEMBLY
* Add engine oil to the specified level, and
run the engine to circulate the oil through
the system. Then check the oil level . Carry out installation in the reverse order to
again. removal.
. Refilling with oil.
* Add engine oil to the specified level, and
run the engine to circulate the oil through
the system. Then check the oil level
again.
Fl
I F207053261
F2
I
F20705327
F3
30643
REMOVAL OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY
YA A?
+ Lower the work equipment to the ground and
stop the engine. Then loosen the oil filler
cap slowly to release the pressure inside the
hydraulic tank.
2. Remove hood (1). (See Fl)
*yBe careful when removing the hood,
because it is under tension from the
spring.
See Weight Table
E?l
3. Rekmove hoses (2) and (3). (See F2)
4. Remove fan guard (4). (See F2)
5. Remove hoses (5). (See F3)
6. Remove radiator and hydraulic cooler
assembly (6). (See F4)
Jr Sling the radiator and hydraulic oil cooler
assembly, remove the upper mount
bracket and lower mount bolts, then
remove the radiator and hydraulic cooler
assembly.
&I kg See Weight Table
INSTALLATION OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY
removal.
. Refilling with oil
j, Add oil to the specified level, and run
the engine to circulate the oil through
the system. Then check the oil level
again.
. Refilling witli water
again.
30&44
Fl
I
F2
F3
205FO5552
F4
205FO5553
REMOVAL OF ENGINE,
HYDRAULIC PUMP ASSEMBLY
16. Remove hoses (15) and (16). (See F6)
P~300,300Lc-5 17. Disconnect hoses (17). (See F6)
* Disconnect 5 pilot hoses.
A Disconnsct the cable from the negative (-1 18. Disconnect tubes (18). (See F6)
terminal of the battery. 19. Disconnect wiring connector (19). (See F6)
*&Lower the work equipment to the ground and 20. Remove engine and hydraulic pump assem-
4
stop the engine. Then loosen the oil filler bly (20). (See F7) a
cap slowly to release the pressure inside the t When removing the engine and hydraulic
hydraulic tank. pump assembly,check that all the piping
. Remove hydraulic tank strainer, and use tool and wiring has been removed, then
D to stop the oil. (See Fl) remove the assembly, taking care that
. When not using tool D, remove drain , there is no interference.
plug and drain the oil from hydraulic tank m See Weight Table
, and piping.
& See Lubricant and Coolant Table
* After removing the piping, mark with tags to INSTALLATION OF ENGINE,
prevent mistakes when installing.
2. Remove hoses (I). (See F2) Pc300,300Lc-5
4. Remove sub-tank (3). (See F2)
removal.
Sr Remove the sub-tank together with the
@?$
bracket.
m Mounting bolt :
6. Remove air cleaner assembly (5). (See F2)
7. Disconnect wiring (6). (See F 3) . Refilling with oil and water
* Fill with oil and water to the specified
9. Disconnect hoses (8). (See F4)
levels.
10. Disconnect fuel hoses (9). (See F4)
Q See Lubricant and Coolant Table.
11. Disconnect wiring connectors (IO). (See F4) . Bleeding air
12. Disconnect ground connection (II). (See F4)
* Bleed the air from the fuel system.
13. Remove fan guard (12). (See F4)
-rt Bleed the air from the hydraulic pump.
14. Remove fan (13). (See F4)
For details, see TESTING AND ADJUST-
15. Remove side cover (14). (See F5)
ING, Bleeding air from all parts.
* Sling the side cover together with the
* After bleeding the air from the hydraulic
frame,remove the mounting bolts, then
_I .* pump, check the hydraulic tank level and
remove me srae cover.
radiator (sub-tank) level.
See Weight Table
&zIkg
30646
F1
\
FI 1229 205FO5557
F2 6
205FO5558
F3
I
i
205FO5555
l-
I ” 205Fb555S
30647
REMOVAL OF ENGINE,
11. Remove side cover (IO). (See F5)
Pc400,400Lc-5 * Sling the side cover together with the
A Disconnect the cable from the negative (-) frame,

remove.
remove the mounting bolts, then
*?Lower the work equipment to the ground and See Weight Table
&I
stop the engine. Then loosen the oil filler 12. RLove frame (I 1). (See F5)
cap slowly to release the pressure inside the
hydraulic tank.
. Remove hydraulic tank strainer, and use tool
D to stop the oil. (See Fl)
l When not using tool D, remove drain the
oil from hydraulic tank and piping.
13. Remove cover (12). (See F6)

_ : See Lubricant and Coolant Table
14. Disconnect starting motor wiring (13). (See
* After removing the piping, mark with tags to
F6)
prevent mistakes when installing.
15. Disconnect ground connection (14). (See F6)
16. Disconnect muffler drain tube (15). (See F6)

2. Disconnect hose (I). (See F2)
4. Remove frame (4). (See F2)
j, Remove the frame together with the sub-
tank.
5. Remove alternator assembly. 17. Disconnect hoses (16) and (17). (See F7)
6. Remove hoses (4) and (5). (See F3) 18. Disconnect hoses (18). (See F7)
7. Remove fan guard (6). (See F3) * Disconnect 5 pilot hoses.
8. Remove fan (7). (See F3) 19. Disconnect tube (19). (See F7)
9. Disconnect fuel hoses (8). (See F4) 21. Remove engine and hydraulic pump assem-
10. Disconnect wiring connector (9). (See F4) bly (21). (See F8) m
Ir When removing the engine and hydraulic
pump assembly, check that all the piping
and wiring has been removed, then
remove the assembly, taking care that
there is no interference.
See Weight Table
PI kg
F5
1 FI 1229 205FO5563
F2 F6
r 1 2 3
205FO5560 205FO5564
Ei
E
0 F:3
205FO5562
L 205F05566
30&49
INSTALLATION OF ENGINE, REMOVAL OF DAMPER
HYDRAULIC PUMP ASSEMBLY ASSEMBLY
PC400, 4OOLG5 1. Hydraulic pump assembly
. Remove hydraulic pump assembly.
For details, see REMOVAL OF
removal.
HYDRAULIC PUMP ASSEMBLY.
m
2. Remove damper assembly (I). (See Fl) m
W Mounting bolt :
. Refilling with oil and water
INSTALLATION OF DAMPER
* Fill with oil and water to the specified
levels. ASSEMBLY
%3 See Lubricant and Coolant Table. . Carry out installation in the reverse order to
. Bleeding air removal.
Bleed the air from the fuel system.
m
Bleed the air from the hydraulic pump. xI1, Damper spline:
For details, see TESTING AND Anti-friction compound (LM-G)
ADJUSTING, Bleeding air from all parts. w Mounting bolt:
After bleeding the air from the hydraulic See Tightening Torques and
pump, check the hydraulic tank level and Standard Values Table
radiator (sub-tank) level.
30650
F1
k 1 205FO54 I6
I.0
x
0
s:
30-&u
REMOVAL OF CENTER SWIVEL DISASSEMBLY OF CENTER
JOINT ASSEMBLY SWIVEL JOINT ASSEMBLY
*A&
4
Lower the work equipment to the ground and 1. Remove cover (I). (See F4)
release the remaining pressure in the circuit. 2. Remove snap ring (2). (See F4)
For details, see TESTING AND ADJUSTING, 3. Using push-puller 0, pull out swivel rotor
Releasing pressure in hydraulic circuit for (4) and ring (3) from swivel shaft (5). (See
machines with PPC valve. F4, F5)
1. Disconnect hoses (I), (2), (3). (See Fl) 4. Remove snap ring (6), then remove oil seal
2. Remove elbow (4). (See Fl) (7) and slipper seal (8). (See F4)
4. Disconnect link (6). (See F2)
5. Remove center swivel assembly (3). (See F4)
el kg See Weight Table

ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
1. Assemble slipper seal (8) to swivel rotor (4).
(See F4)
INSTALLATION OF CENTER
2. Using push tool@, press fit oil seal (7) to
SWIVEL JOINT ASSEMBLY swivel rotor (4), and install snap ring (6). (See
. Carry out installation in the reverse order to F4, F6)
removal. & Lip of oil seal: Grease (G2-LI)
. Refilling with oil 3. Set swivel shaft (5) on block, then using push
* Run the engine to circulate the oil tool, tap swivel rotor (4) with a plastic
through the system. Then check the oil hammer and install. (See F4)
level again. Ir When installing the rotor, be extremely
careful not to damage the lips of the
slipper seal and the oil seal.
4. Install ring (3), and secure with snap ring (2).
(See F4)
5. Fit O-ring and install cover (4). (See F4)
Fl
. ’ ‘4 205FO5567
--5
A
205FO5568 205FO5420
205FO5569 205FO542 I
F6
205FO5422
REMOVAL OF FINAL DRIVE DISASSEMBLY OF FINAL
ASSEMBLY DRIVE ASSEMBLY
1. Sprocket
1. Draining oil
Remove sprocket.
‘a
*+YLoosen the oil filler cap slowly to release
Remove drain plug and drain oil from final
drive case.
the pressure inside the hydraulic tank.
2. Remove cover (I). (See Fl)
_ : Final drive case:
* Using eyebolts, sling the cover, and
See Lubricant and Coolant Table
remove the mounting bolts.
q
L. Cover
See Weight Table
6 kg Using forcing screws and eyebolts 0,
remove cover (I). (SeeF4)
4. Remove final drive assembly (3). (See F3)
m
* Sling the final drive assembly, then
remove the mounting bolts, and lift off 3. Thrust washer
the final drive assembly. Remove thrust washer (2). (See F5)
See Weight Table 4. No. 2 sun gear shaft
ks
II?!?!
Remove sun gear shaft (3). (See F5)
5. No. 2 carrier assembly
1) Remove carrier assembly (4). (See F5)
INSTALLATION OF FINAL
DRIVE ASSEMBLY
removal.
m
& Mounting bolt: Thread tightener
2) Disassembly of carrier assembly
( LT-2)
i) Remove mounting bolts (51, then
Qz Mounting bolt:
remove holder. (See F6)
ii) Set carrier assembly (4) in press, then
using push tool 0, pull out pin (6),
. Bleeding air
and remove gear assembly (7). (See
* Bleed the air from the motor.
F7)
ING, Bleeding air from travel motor.
* After bleeding the air from the motor,
check the level of the hydraulic tank.
iii) Remove bearing (9) and spacer (IO)

from gear (8). (See F8)
iv) Remove outer race (II). (See F8)
30654
1 4
ii 1
1.
205FO5425
F
n
15
I 205FO557 I 205FO5426
F3 6 F7
kh
205FOE.424 205FO5427 205FO5428
F8
I 205FO5429
30655
6. Ring gear 13. Hub assembly
1) Remove ring gear (12). (See Fl) 1) Using eyebolts@, remove hub assmbly
2) Remove ring (13). (See Fl) (27) from travel motor. (See F8)
7. No. 1 sun gear
Remove sun gear (14). (See Fl)
8. Thrust washer
Remove thrust washer (15). (See F2)
9. No. 2 carrier assembly
I) Remove carrier assembly (16). (See F2)
2) Disassembly of carrier assembly 2) Remove floating seal (28). (See F9)

i) Remove mounting bolts (171, then 3) Remove cage (29), then remove floating
remove holder. (See F3) seal (30). (See FIO)
ii) Set carrier assembly (16) in press, 4) Remove bearings (31) and (32). (See FIO)
then using push tool 0, pull out pin
(18), and remove gear assembly (19).
(See F4)
iii) Remove bearing (21) and spacer (22)

from gear (20). (See F5)
iv) Remove outer race (23). (See F5)
IO. No. 1 ring gear

Remove ring gear (24). (See F6)
11. Gear coupling
Remove mounting bolts, then remove gear
coupling (25). (See F6)
12. Spacer
Remove spacer (26). (See F7)
Fl F2
15 16
,
205FO5572 205FO5573 I 205FO5437
F9 F 10
J
205FO5432 205FO5433 205F0543E 205FO5575
F5
J&Lk--
Q 21
22
e-
Y
23 21
205FO5434
F6 F7
I 205FO5574
I_
205FO5436
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
4) Using a depth micrometer, measure
stepped difference a between end face
1. Hub assembly
of shaft and inner race. (See F6)
1) Using push tool, press fit bearings (32)
* Measure two places and take the
and (31). (See Fl)
average value.
2) Using tool A,, install floating seal (30) to
5) Select a spacer to give a value of
cage, then install cage (29). (See Fl)
-0.1
EZ& Cage mounting surface:
a -0.15 mm*
Gasket sealant (LG-6) It Select the suitable thickness of spacer
W Mounting bolt: from the 7 types of spacer.
6) Install the selected spacer (26). (See F7)
3) Using tool A,, install floating seal (28). 3. Gear coupling

(See F2, F3) 1) Fit gear coupling (25), and tighten with
k When installing the floating seals, mounting bolts. (See F8)
remove all oil and grease from the & Mounting bolt:
O-ring and O-ring contact surface, Thread tightener (LT-2)
and dry completely before installing. B Mounting bolt:
+r After installing the floating seals, coat See Tightening Torques and
the sliding surfaces thinly with engine Standard Values Table
oil.
4) Using eyebolts@, set hub assembly (27) 2) Check adjustment of bearing clearance
on travel motor, then using push tool, again. Hook spring balance@ in the tap
tap to press fit bearing. (See F4) hole for the sprocket mounting bolt, pull
to rotate the hub on the shaft and
measure the starting force. (See F9)
Ir Starting force:
* If the starting force is higher than the
standard value, there is a preload on
the bearing, so adjust again.
2. Adjusting bearing clearance 4. No. 1 ring gear

1) Using tool A,, hold bearing, and tempo- Fit ring gear (24). (See F8)
rarily tighten 2 bolts. (See F5) & Ring gear mounting surface:
2) Rotate hub 2 - 3 turns to settle bearing. Gasket sealant (LG-6)
3) Loosen bolts of tool AZ, and then tighten * Coat thread tighter only on ring gear
again to a torque of 2.0 kgm to 3.0 kgm. upper surface.
(See F5)
Fl F2 F6
Inner
205FO5575 205FO5438 I 205FO5578
'3 7 8
L 205FO5509 205FO5436 205FO5574
:4 F9
27
0
I 205FO5437
F5
205FO5577
3029
5. No. 1 carrier assembly 9. No. 2 carrier assembly
1) Assembly of carrier assembly 1) Assembly of carrier assembly
* The inner race, outer race, and spacer + The inner race, outer race, and spacer
form one set for the taper roller form one set for the taper roller
bearing, so assemble the sets with bearing, so assemble the sets with
the same marks. the same marks.
i) Using push tool, press fit outer race i) Using push tool, press fit outer race
(23) in gear (20). (See Fl) (11) in gear (8). (See F6)
ii) Assemble spacer (22) and bearing ii) Assemble spacer (IO) and bearing (9).
(21). (See Fl) (See F6)
iii) Set carrier assembly (4) in press,
assemble gear assembly (7), then
using push tool @ , press fit pin (6).
iii) Set carrier assembly (16) in press, (See F7)
assemble gear assembly (19), then t When press fitting the pin, be
using push tool 0, press fit pin (18). extremely careful of the angle of
(See F2) the pin, and rotate the gear while
* When press fitting the pin, be press fitting.
extremely careful of the angle of iv) Fit holder and tighten with mounting
the pin, and rotate the gear while bolts (5). (See F8)
press fitting. #J?Y= Mounting bolt :
iv) Fit holder and tighten with mounting Thread tightener (LT-2)
bolts (17). (See F3) w Mounting bolt :
& Mounting bolt :
Thread tightener (LT-2)
w Mounting bolt :
2) Align with teeth surface of ring gear, and
install carrier assembly (4). (See F9)
10. No. 2 sun gear shaft
2) Install carrier assembly (16). (See F4)
Assemble sun gear shaft (3). (See F9)
6. Thrust washer
11. Thrust washer
Assemble thrust washer (15). (See F4)
Assemble thrust washer (2). (See F9)
12. Cover
Using eyebolts@), install cover (I). (See FIO)
KYI& Cover mounting surface :
Gasket sealant (LG-6)
7. No. 1 sun gear

Assemble sun gear (14). (See F5)
8. No. 2 ring gear
1) Install ring (13). (See F5)
P=E& Mounting surface of ring :
2) Align with teeth surface of carrier, and
install ring gear (12). (See F5)
& Ring gear mounting surface :
3029-l
Fl
205FO5429
F2 F3
1
I
205FO544 I 205FO5432 205FO5442 11 205FO5427
4 F:9
15 16
205FO5573 2OSFO5426
F5 FIO
205FO5579 205FO5425
30-29-2
. Procedure for tightening cover mounting
bolts
1) Tighten bolts to specified initial torque.
m Mounting bolt:
Standard Values table
2) Set angle of hexagonal head of bolt to
standard, then make start marks on cover
and socket. (See Fl)
3) Make end mark at specified angle from
start mark. (See Fl)
+ Make the end mark only on the cover.
m Bolt tightening angle:
4) Tighten until start mark on socket is
aligned with end mark on cover. (See Fl)
* When disassembling or assembling the
final drive on the following machines, re-
place cover mounting bolt @ with bolt @ ,
and tighten according to the above proce-
dure. (See F2)
PC300,3OOLC-5 Serial No: 20001 - 21400
PC400,4OOLC-5 Serial No: 20001 - 20602
13. Refilling with oil

Tighten drain plug and add engine oil
through oil filler to the specified level.
%z Final drive case:
* Carry out the final check of the oil level
after installing the final drive assembly
to the machine. Check the level again
at the specified position.
30-$0
Fl
Start mark
on cover
1 Start mark 1
Mounting bolt Start mark

on socket
F2
Bolt @ Bolt @
DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT)
(HMV355ADT)
1. Motor assembly
Remove motor assembly from final drive as-
sembly.
* For details, see DISASSEMBLY OF FINAL
DRIVE ASSEMBLY.
2. Spring, pistons
Remove springs (1) and pistons (2).
* Mark match marks on the case, the pis-
tons and the springs.
F20705361 F20705362
3. Set motor assembly (3) in tool Gl.
4. End cover assembly, valve plate

I) Loosen plug (4) of check valve and
mounting plug (5) of counterbalance
valve.
+ If the end cover is an individual part,
the tightening torque is too large and
it is difficult ot remove.
2) Remove safety valve assembly (6), then

remove end cover assembly (7).
5 r F20705363
* Lift off using the mounting plug por-
A
tion of the counterbalance
so be careful when
valve.
The part to fit the lifting tool is small,

lifting the
r---
assembly.
( e F20705364
3) Remove valve plate (8).

* If the valve plate is to be used again,
keep it in a safe place and be careful
not to damage the cylinder block
mounting surface.
F20705365
30-&l
-’
4) Disassemble end cover as follows.
i) Remove bearing (9).
ii) Remove plug (4), then remove spring

(10) and valve (11).
iii) Remove plug (12), then remove spring
(13) and valve (14).
iv) Remove plug (15), then remove ball
(16).
v) Remove bleeder (17) and plug (18),
then remove spring (19) and spool
(20).
vi) Remove plug (21), then remove piston
(22).
vii) Remove plug (5), then remove spring
(23), ring (24) and spool (25).
viii)Remove dowel pin (26).
F20705367
5. Spring
Remove parking brake spring (27).
6. Piston assembly
1) Set tool G2 to hole of brake piston.
Tool setting position F2070536S
2) Taking care that air does not leak from

brake piston hole, blow in air and remove
brake piston (28).
* If the air is blown in at high pressure, ,28
the brake piston may fly out.
F2020525E
r-
7. Disc, plate
Remove plate (29), disc (30), and plate (31)
in order.
8. Cylinder block, piston assembly

1) Remove cylinder block (32) and piston
assembly (33).
F2070537:
30-g-3
2) Disassemble cylinder block as follows.
i) Using tool G3, compress spring (34).
ii) Remove snap ring (35).
iii) Loosen nut of tool 63 gradually and
extend spring until tension is
removed.
iv) Remove seat (36), spring (34), seat
(37) and pin (38).
* Align the notched portion of the
washer (tool part number: 796-765-
1150) with the head of the snap I
ring. 36 3; F2070537:
3) Disassembly of piston assembly.

i) Remove retainer guide (39).
ii) Remove piston (41) from shoe retainer
(40).
40’
F20705374
9. Rocker cam
Remove rocker cam (42).
\ F20205264
10. Cradle
Remove 8 bolts (43) from final drive end,
then remove cradle (44).
11. Oil seal
1) Remove snap ring (45).
2) Using forcing screw (Dia. = 6 mm, Pitch
= 1 .O), remove cage (46).
3) Using push tool, remove oil seal (47).
46
F20705377 F20705378
12. Shaft assembly

1) Remove shaft assembly (48).
2) Remove outer race (49) and spacer (50)
from shaft.
3) Disassemble shaft assembly as follows.

0 Remove snap ring (51).
ii) Remove ring (52).
iii) Using bearing puller, remove main
bearing (53).
iv) Using bearing puller, remove inner
race (54).
F20705380
4) Outer race
Using push tool, remove outer race (55).
55 F20705381
30-g-5
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV 280ADT)
(HMV 355ADT)
Precautions when assembling

1) Clean all parts, check for dirt or damage,
and repair any burrs.
2) Coat the rotating and sliding surfaces of all
parts with engine oil (EOIO-CD) before in-
stalling.
* Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
iii) Main bearing and spacer
1. Set motor case (56) to tool Gl.
2. Outer race
Using push tool, press fit outer race (55) to
case.
I F20705381
3. Shaft assembly
1) Assemble shaft assembly as follows.
G4
i) Using tool 64, press fit inner race
/
(54) to shaft.
* Press fit until it is in tight contact
with the end face of the shaft.
I F20705382
ii) Using tool 65, press fit main bearing

(53). Front side Rear side
* Align the match marks on the t ,Spacer
main bearing, and assemble. Outer race
* Press fit until the end face of the Inner race

main bearing inner race is in tight
contact with the shaft.
y Mach marks
F20705383
iii) Install ring (52).
iv) install snap ring (51).
2) Install spacer (50), and outer race (49) to

shaft assembly.
3) Using tool G6, press fit shaft assembly
(48) in case.
F2070538f
A I
49
-ttJq2 \
50
L i G6 FL20705385 F20705379
4. Oil seal
1) Using tool G7, press fit oil seal (47) in
case.
* Use your fingertip to coat the circum-
ference of the lip portion with one
drop of grease at four places, then
spread the grease uniformly around
the whole oil lip with your fingertip.
& Lip of oil seal: Grease (G2-LI-S)
G7 46
F20705386 F20705378
2) Install case (46) to motor.

3) Secure with snap ring (45).
F20705377
30-g-7
5. Cradle
II Align with dowel pin, set cradle (44) in
position, then tighten with 8 mounting
bolts (43).
w Mounting bolt:
See Tightening Torques and Stan-
dard Values Table
2) Fit dial gauge @ to motor case, move

shaft in axial direction, and measure
amount of movement (end play) of shaft
in axial direction.
* End play: 0.05 - 0.30 mm
* If the end play is not within the stan-
dard value, check the mounting condi-
tion of the bearing in Step 2 and the
mounting condition of the cradle in
Step 4-l).
F20705387
6. Rocker cam
Install rocker cam (42).
* Install the flange of the rocker cam (thin
side) facing the small port *hole side
(angle change piston side).
* After installing the rocker cam, check that
the rocker cam moves smoothly by hand.
w \ F20205264
7. Cylinder block, piston assembly

1) Assemble piston assembly as follows.
i) Assemble piston (41) to shoe retainer
(40).
* The variation between the thick-
ness of the shoe lips must be
within 0.01 mm.
(Spare parts are supplied in a kit
within these dimensions.)
ii) Assemble retainer guide (39).

F20705374
30-$1-8
2) Assemble cylinder block as follows.
- 134
i) Assemble pin (38), seat (37), spring
(34) and seat (36).
ii) Using tool G3, compress spring (34). 35
iii) Secure with snap ring (35).
G3
36
3kl 3j F20705373
3) Assemble cylinder block (32) and piston

assembly (33), align with shaft spline,
then install.
F20205262
32
\ rm
F20705371
8. Disc, plate
Install plate (31), disc (30), and plate (29) in
order.
30-g-9
The space between the cut teeth for the
spline on the disc is uneven, so match
and fit on top when assembling.
6 plates and 5 discs.
F20705388
9. Piston assembly
Assemble O-ring and backup ring, then in-
stall brake piston assembly (28).
+ Assemble so that the groove of the brake

piston is aligned with- the end cover
dowel pin.
F20705389
* Assemble the backup ring in the direction

shown in the diagram.
I
Backup ring
O-rings
Backup ring
F20205298
10. Spring
Install parking brake spring (27).
* Assemble the spring so that the outside
circumference is facing in the “closed”
direction.
11. End cover assembly * valve plate
1) Assemble end cover assembly as follows.
* Precautions when installing plug Valve plate End cover
Remove all grease from the plug, then Groove +
apply two drops of adhesive to the
thread (thread tightener: Loctite No.
638).
i) Using tool G8, install dowel pin (26).
* Install the dowel pin grooved side fac-
ing the valve plate.
F2070539C
ii) Assemble spool (25), ring (24), and
spring (23) in order, then fit O-ring
and tighten plug (5) temporarily.
iii) Assemble piston (22) and fii O-ring, apply (2)

drops Loctite 638 or 648 to plug (21),
then tighten.
m Plug:
iv) Assemble spool (20) and spring (19),

fit O-ring, then tighten plug (18) and
install bleeder (17).
D Plug:
m Bleeder:
v) Assemble ball (16) and ffi O-ring, apply (2) drop

Loctite 638 or 648 to plug (15), then tighten.
m Plug:
See Tigtening Torques and
Standard Values Table FvO705367
vi) Assemble valve (14) and spring (13),

then fit O-ring and tighten plug (12).
Qz Plug:
vii) Assemble valve (11) and spring (IO),

then fit O-ring and tighten plug (4)
temporarily.
viii)lnstall bearing (9).

F2070536E
3o-t!-11
2) Install end cover assembly as follows.
i) Install valve plate (8).
ii) Fit O-ring, then adjust val\ie plate so

that it matches dowel pin, then align
dowel pin with brake piston groove,
and install end cover assembly (7).
Mounting bolt:
iii) Install safety valve assembly (6).
w Safety valve assembly:

iv) Tighten mounting plug (5) of counter-

balance valve and plug. (4) of check
valve. (use Loctite 638 or 648)
m Mounting plug of Counter-
balance valve:
Plug of check valve:
12. Spring * Piston

Align marks, assemble piston (2) and spring (l),
fit O-ring, apply Loctite 638 or 648 and tighten plug.
m Plug: See Tightening Torques and
0 When storing or transporting the motor

assembly, use your finger to coat the lip
surface of the oil seal thinly with engine
oil (EO-IO).
F20705362 F20705361 /
30-g-12
CHECKING CONTACT BETWEEN CYLINDER
BLOCK AND VALVE PLATE, AND ROCKER CAM
AND CRADLE
1. Checking contact between cylinder block Cylinder block Centering tool
and valve plate \ /

1) Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft
material such as plastic or bakelite.
2) Remove grease from the parts to be
checked.
* Do not wipe with a cloth.
31 Set the tool in position, and coat the
cylinder block side with inspection paint.
* Apply the paint thinly.
4) Put the valve plate on top, push with a
force of 4 - 5 kg, and rotate 2 - 3
times.
5) Remove the valve plate, transfer the con-
tact surface to tape, and check the
contact surface.
LD
* The standards for the contact surface are I=20703037
x
as follows.
%
a. Seal Min. 80%
Valve plate
b. land Min. 60%
a. Seal Min. 80%

Cylinder block
b. land Min. 60%
Valve plate Cylinder block
F20705391
3o-%
-13
2. Checking contact between rocker cam and
cradle
II Remove grease from the parts to be
checked.
2) Set the tool in position, and coat the
cradle side with inspection paint.
3) Put the rocker cam on top, push with a
force of 4 - 5 kg, and move 2 - 3 time
from the stopper contact position to the
maximum angle.
4) Remove the rocker cam, transfer the con-
tact surface to tape, and check the con-
tact surface.
* The standard for the contact surface shall

be as shown in the diagram below.
+ If there is no contact at the center but

only at the outside, the contact is no
good.
Contact less
than 50%
/Contact 50% -
Y Co;;;;,ore
. Oo
70---1105
Contact 50% -
L-77--
‘I y;;;;;;ss
0
I+
I - Cradle
F20205290
Reference:
If the contact is not within the contact stan-
dard value, when carrying, always lap both
parts together.
t Parts with scratches canot be reused.
-14
3o-%
REMOVAL OF SPROCKET REMOVAL OF SWING MOTOR
ASSEMBLY
1. Track shoe assembly
. Remove track shoe assembly. *fi Lower the work equipment to the ground and
4
For details, see REMOVAL OF TRACK release the remaining pressure inside the
SHOE ASSEMBLY. circuit. For details, see TESTING AND
2. Jacking up machine ADJUSTING, Releasing remaining pressure
* Swing the work equipment 90” to jack in hydraulic circuit for machines with PPC
up the machine, then set block 0 valve.
between the track frame and the track 1. Disconnect hose (I). (See F2)
shoe. (See Fl) 2. Remove swing motor assembly (2). (See F3)
3. Remove sprocket (I). (See Fl) * Using eyebolts, sling the swing motor
Ir Sling the sprocket, then remove the assembly, then remove the mounting
mounting bolts, and lift off the sprocket. bolts, and remove the swing motor
kg See Weight Table assembly.
&?I
See Weight Table
6 kg
INSTALLATION OF SPROCKET INSTALLATION OF SWING

MOTOR ASSEMBLY
removal. . Carry out installation in the reverse order to
m removal.
a Mounting bolt: . Bleeding air
Thread tightener (LT-2) Ir Bleed the air from the swing motor.
m Mounting bolt: For details, see TESTING AND
See Tightening Torques and ADJUSTING, Bleeding air from all
Standard Values Table parts.
-k After bleeding the air from the swing

motor, check the level in the hydrau-
lic tank.
30;62
Fl F2
-_,- ,.l’Fzy-z-T. = =F205053 15 F20705329
'3
F2070533C
OF SWING MOTOR ASSEMBLY (KMF160)
1. Motor assembly r-
Set swing motor assembly (1) on tool HI.
2. Valve case assembly

1) Remove mounting bolts (2) of valve case.
L
2) Using eyebolts 0 (Thread dia. = 12 mm,
Pitch = 1.75 mm), lift off valve case (3).
3
3. Relief valve
Remove relief valve assembly (4).
4. Check valve
Remove plug (5), then remove spring (6) and
valve (7).
5
g
6
:= F20703013 z
5. Belleville spring
Remove belleville spring (8).
1 d F20705394
6. Valve plate
Remove valve plate (9).
7. Cylinder block
Remove cylinder block (IO).
jz5$$L&Az
F20705395 F20705396
30-$3-l
8. Spring
Remove spring (11) and center ring (12).
9. Retainer
Using tool H2, remove 7 mounting screws,
then remove retainer (13).
10. Shaft, piston

Remove center shaft (14) and 7 pistons (15).
11. Brake piston r

1) Remove brake piston (16).
* Using an oil leak tester, supply air
under pressure through the oil port
and remove the brake piston.
* If the air pressure is too high, the pis-
ton will fly out, so raise the air press-
ure slowly.
2) Remove O-ring (17) and backup ring (18)

from piston.
12. Plate, disc

1) Remove plate (19) and disc (20).
2) Remove plate (21).
I F20703014
13. Cover
1) Remove case assembly from tool Hl and
turn over.
2) Remove snap ring (22), then remove
cover (23).
14. Shaft assembly

1) Remove snap ring (24), then remove
spacer (25).
L-
30-$3-2
2) Set case assembly in press, then remove
shaft assembly (26) from case (27).
3) Remove bearing (28A) and (28B) from
shaft (29).
15. Bearing, spacer, belleville spring

r
1) Remove bearing and outer race (30). 32 31
2) Remove spacer (31) and belleville sprig
(32).
i t-7
F20705405 F20705406
16. Outer race

Remove outer race (33A).
27
r7070540:
30-&3-3
ASSEMBLY OF SWING MOTOR ASSEMBLY (KMF160)
Precautions when assembling

* Clean all parts, and check for dirt or dam-
age. Coat the sliding surfaces of all parts
with engine oil before installing.
* Always use all the parts supplied in the kit.

Do not reuse the retainer mounting screw.
1. Shaft assembly
1) Install bearing outer race (33A). (Outside
diameter: 140 mm) to brake case (27).
127
l---i V/’
F20705607
2) Using tool H3, press fit bearing (28B)

(Inside diameter: 65 mm) to shaft (29).
* Press fit until the end face of the H3
bearing inner race is in tight contact
with the shaft.
3) Install outer race (33B) and spacers (34)
and (35).
4) Using tool H3, press fit bearing (28A)
(Inside diameter: 65 mm).
+ Do not use any bearing if it is uncer-
tain which set it belongs to.
F20705408
5) To prevent the drive shaft from being at

an angle, set tool H4 in position, and
install shaft (29) to brake case (27).
* Push in the outer race with a plastic
bar from groove 0. (Do not use a
metal bar; this will damage the outer H4-
race.) 27
- F2070540t
30-z3-4
6) Assemble spring (33) and spacer (32),
then using tool H5, install outer race (30).
(Outside diameter: 120 mm).
* Align the inside diameter (shaft end)
to install the spring. (With the outside
diameter open) 32
I
r
F20705410
7) Support shaft (26) at both ends, then use

tool H3 to press fit bearing (28) (inside
diameter: 65 mm).
+ The press-fitting force is 400 - 2035
kg, but up to 2200 kg is possible
(when coated with engine oil).
* If the press-fitting force is less than
2200 kg, always push in at 2200 kg
after press fitting.
* Press fit until the spacer is in tight 8
contact. 6
F20705411
I 8
8) Select thickness of 2 spacers (25) using

procedure and table below.
i) Measure dimension @I between seat
portion 0 of shaft and end face of
inner race of bearing (28), then select
2 spacers from table below.
F2070541:
Spacer selection table Unit: mm
(possibleas thickness of
Spacerpartnumber 706-77-42440 706-77-42450 706-77-42460

9)Assemble spacer (25), then install snap
ring (24).
* Check that the snap ring is fitted
securely in the groove.
F20705413
10) Support motor case, push end face of 1

shaft (26) at 500 - 2200 kg in direction
of arrow, and check that movement when
doing this is 0.1 - 0.4 mm.
* When doing this, check that the 500- 2200 kg
a
spacer (25) cannot be moved by
hand.
* If the movement of the shaft is not
within the standard value, adjust the
spacer so that it comes within the
standard value.
F20705414
11) Rotate shaft at a speed of 1 turn every
approx. 5 seconds and measure the rotat-
ing torque.
* Rotating torque: 0.15 - 0.5 kgm
* Supply the bearing with ample oil
when measuring.
f- If the rotating torque is not within the
standard value, replace the bearing
with a new bearing.
2. Cover
1) Press fit oil seal and fit O-ring, then
install cover (23). F2070541E
2) Install snap ring (22).
3. Plate, disc
1) Set case assembly on tool Hl.
2) Install plate (21).
3) Install disc (20) and plate (19).
F20703014
30-$3-6
4. Brake piston
1) Install O-ring (17) and backup ring (18) to
piston.
* See illustration for ,direction of installa-
tion of O-ring and backup ring.
e
F20705400 F20205298
2) Install brake piston (16).

\ , H2
5. Piston, shaft
1) Set 7 pistons (15) and center shaft (14).
2) Install retainer (13) and using tool H2,
tighten 7 mounting screws.
& Mounting screw: Adhesive (LT-2)
QEI Mounting screw:
Direction of installation may be clock- F20705399 ]/ u F20705391
wise or counter-clockwise.
After installing, check that the pistons Play
move smoothly and can fall under its
own weight. If the movement is not
smooth, loosen, then tighten again.
The screws must not be used again.
3) After installing mounting screws, measure

clearance of piston ball.
i) Set dial gauge @ on ball.
ii) Pull piston in axial direction of pump
sub-assembly, and measure clearance
F20703011 IL F20703012
between ball and retainer.
* Ball clearance: Max. 0.25 mm
6. Spring
Fit center ring (12) and install spring (11).
7. Cylinder block
Install cylinder block (10).
F20705396
30-$3-7
8. Valve plate
Install valve plate (9).
9. Belleville spring
Set belleville spring (8).
* See illustration for direction of installation
of belleville spring.
F20705416
IO. Check valve

Fit valve (7) and spring (6), fit O-ring, then
install plug (5).
11. Relief valve

Fit O-ring and install relief valve assembly (4).
In m Relief valve: SeeTightening Torques and

E Standard Values Table
F20703013 5
%
12. Valve case assembly
1) Fit O-ring and using eyebolts @ (Thread
dia. = 12 mm, Pitch = 1.75 mm), set
valve case (3).
* Correctly match dowel pin and valve
plate.
2) Tighten mounting bolts (2).
w Mounting bolt:
2
F2070541’ 7
13. Inspection of rotating torque of drive shaft

1) From C port, apply more than 25 t- 5
kg/cm* pressure, then re.lease brake.
2) Set tool H6 and rotate drive shaft at a
speed of 1 turn every approx. 5 seconds
and measure the rotating torque.
+ Check that there is no uneven rotatin
in rotating torque.
Uneven width: Within 0.15 kgm
Rotating torque: 0.6 - 15.5 kgm range
* If the uneven width is more, reas-
F2070541E
semble.
30-ii3-8
REMOVAL OF SWING REMOVAL OF SWING
MACHINERY ASSEMBLY MACHINERY ASSEMBLY
Pc300,300LG5 PC400,4OOLG5
1. Swing motor assembly 1. Swing motor assembly

. Remove swing motor assembly. . Remove swing motor assembly.
For details, see REMOVAL OF SWING For details, see REMOVAL OF SWING
MOTOR ASSEMBLY MOTOR ASSEMBLY
2. Remove swing machinery assembly (1). (See 2. Disconnect hoses (1) and (2). (See F2)
Fl)m 3. Remove bracket (3). (See F2)
* Sling the swing machinery assembly, 4. Remove clamp (4). (See F2)
then using forcing screws, and remove 5. Remove swing machinery assembly (5). (See
the swing machinery assembly. F3) m
* Sling the swing machinery assembly,
& kg See Weight Table then using forcing screws, and remove
the swing machinery assembly.
See Weight Table

&I kg
INSTALLATION OF SiIVlNG
MACHINERY ASSEMBLY INSTALLATION OF SWING
MACHINERY ASSEMBLY
. Carry out installation in the reverse order to PC400,4OOLG5
removal.
m
removal.
m Mounting bolt:
. Reflling with oil
* Run the engine to circulate the oil
. through the system. Then check the oil
Refilling with oil
level again.
* Run the engine to circulate the oil
@7.J
through the system. Then check the oil
m Mounting bolt:
level again.
See Tightening ‘Torques and
Fl
I
I
_i
FO5. 443
F3
30-65
a
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
vi) Remove inner races (12) and (13)
1. Draining oil from case (II). (See F9)
Remove drain plug and drain oil from swing
machinery case.
_ : Swing machinery case:

2. Cover assembly
I) Remove mounting bolts, then using
eyebolts @ , remove cover assembly (I).
(See Fl)
* There are 9 mounting bolts at the
top and 3 mounting bolts at the
3. Shaft
bottom.
Remove shaft (14). (See FIO)
2) Disassembly of cover assembly
4. Ring gear
Remove cages (2) and (3). (See F2)
Remove ring gear (15). (See FIO)
* Check the number and thickness
of the shims, and keep in a safe
place.
Remove outer races (4) and (5) from
cage. (See F3, F4)
iii) Remove mounting bolts, then re- 5. Carrier assembly

move cover (6). (See F5) I) Remove mounting bolts, then remove
iv) Remove gear assemblies (7) and (8). carrier assembly (16). (See Fll)
(See F6) 2) Disassembly of carrier assembly
i) Remove mounting bolts (17), then
remove holder. (See F12)
v) Remove bearings (9) and (IO) from ii) Set carrier assembly (16) in press,
gear. (See F7, F8) and using push tool @ , remove pin
(18), then remove gear assembly (19).
(See F12, F13)
iii) Remove holder (20). (See F13)
:2 F-9
LI L_l
205FO5444 205F0544E 205FO5452
F3 FlO
205FO5446 205FO5447 205FO5453

J
b
E F5 F6 :I1 I-
:12
18 17
205FO5448 205FO5449 205FO5454 205FO5455
F13
205FO5450
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
iv) Remove bearing (22) and spacer (23)
form gear (21). (See Fl)
1. Case assembly
v) Remove inner race (24). (See Fl)
1) Using push tool, press fit bearing (33).
(See F8)
2) Assemble spacer (29). (See F9)
3) Using push tool, press fit bearing (30).
(See F9)
6. Shaft assembly 2. Shaft assembly

I) Loosen mounting bolts (25). (See F2) 1) Assembly of shaft assembly
2) Set shaft and case assembly (26) in press, i) Using push tool 0, press fit oil seal
and using push tool 0, remove shaft (32). (See FIO, Fll)
& Outer circumference of oil seal:
Adhesive (LG-6)
3) Disassembly of shaft assembly ii) Assemble cover (31) to shaft (28).

i) Remove spacer (29) from shaft (28). (See F12)
(See F4) & Lip of oil seal:
ii) Remove bearing (30). (See F4) Grease (LG-6)
iii) Remove cover (31). (See F5)
iii) Set case assembly in press, and press
fit shaft assembly (27). (See F13)
iv) Tighten mounting bolts (25). (See
F13)
a Cover mounting surface:
Adhesive (LG-6)
iv) Remove oil seal (32) from cover. (See 3. Carrier assembly
F6) 1) Disassembly of carrier assembly
7. Case assembly i) Using push tool, press fit inner race
Remove bearing (33). (See F7) (24). (See F14)
ii) Assemble spacer (23) and bearing
(22) to gear (21). (See F14)
'1 F9
205FO5457 205FO546: 205FO5464
F2 13 10 '11
32
205FO5458 205FO5459 205FO5465 205FO5462

ks
i
6
8 I12 F13
28
205FO5460 11 205FO5461 205FO5461 11 - 20w4b.E
F6 F:7 '14
21
2i
22-
205FO5462 205FO5463 205FO5457
iii) Assemble holder (20). (See Fl) ii) Using push tool 8, press fit bearing
iv) Set carrier assembly (16) in press, (IO) in gear. (See F7)
then assemble gear assembly (19), iii) Using push tool 0, press fit bearing
and using push tool 0, press fit pin (9) in gear. (See F8)
(18). (See F2)
* Be careful to keep the pin
straight, and rotate the gear when
press fitting the pin.
Ir After press fitting the pin, check
that the gear rotates smoothly.
v) Fit hoder and tighten with mounting iv) Install gear assemblies (8) and (7).
bolts (17). (See F3) (See F9)
PC& Mounting bolt: v) Fit cover (6) and tighen with
Thread tightener (LT-2) mounting bolts. (See FIO)
m Mounting bolt: & Cover mounting surface:
See Tightening Torques Adhesive (LG-6)
and Standard Values
Table
2) Fit carrier asseembly (16), and tighten

with mounting bolts. (See F4)
PCY= Mounting bolt:
m Mounting bolt: vi) Using push tool, press fit outer races
See Tightening Torques (5) and (4) in cage. (See Fll, F12)
and Standard Values
Table
4. Ring gear
Install ring gear (15). (See F5)
& Ring gear mounting surface:
Thread tightener (LG-6)
5. Shaft
Assemble shaft (14). (See F5)
6. Cover assembly 7. Adjusting preload of bearing

I) Assembly of cover assembly I) Remove O-ring, and install cages (3) and
i) Using push tool, press fit inner races (2). (See F13)
(13) and (12) in case (II). (See F6) * Install 2 bolts each at a and b.
jr Rotate the spline shaft for the motor
mount 5 - 6 turns, then tighten the
bolts to the specified torque.
m Bolt:
See Tightening Torques
and Standard Values
Table
30-70
0
F2
205FO5467 205FO5468
F4 F:9 FIO
18 17
205FO5455 205FO5454 205FO5449 205FO544t

I-
:!i :I1 F12
205FO5453 205FO5447 205F0544E
:6 :I3
;
205FO5452 205FO5471
2) Selecting shims
Measure points “c” and “d” with a feeler
gauge, then select shims from the table
below.
mm
Clearance Above 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
at c, d Below 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6
Shim thickness 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
* Types of shims:
t = 0.4, t = 0.5, t = 0.6
t = 0.7, t = 0.8
3) Remove cages (3) and (2). (See Fl)
4) Fit O-rings and install cages (3) and (2).
(See Fl)
m Mounting bolt:
Standard Value Table
* Check that the spline shaft for the
motor mount rotates smoothly by
hand.
5) Using eyebolts 0, install cover assembly
(I). (See Fl)
& Cover assembly mounting surface:
Adhesive (LG-6)
8. Refilling with oil
Tighten drain plug and add engine oil
through oil filler. i
Swing mat tJnery case:
%b
30;72
Fl
c d
205FO5472
F2
205FO5444
3og3
REMOVAL OF REVOLVING
FRAME ASSEMBLY
13. Remove revolving frame assembly (9). (See
1. Remove boom cylinder assembly. F5) m
. For details, see REMOVAL OF BOOM * For the mounting bolts marked l, move
CYLINDER ASSEMBLY. the control box assembly, remove the
2. Remove work equipment assembly. grommets, then remove the mounting
. For details, see REMOVAL OF WORK bolts. (See F6)
EQUIPMENT ASSEMBLY. * Leave 2 bolts each at the front and rear,
3. Remove counterweight. then use a lever block to adjust the
4. Remove cab. balance of the revolving frame assembly
. For details, see REMOVAL OF CAB to the front, rear, left, and right, then
ASSEMBLY. remove the remaining bolts, and remove.
5. Remove hood (1). (See Fl) * When removing the revolving frame
*yBe careful when removing the hood, assembly, be careful not to hit it against
because it is under tension from the the center swivel joint assembly.
spring.
& kg See Weight Table el kg See Weight Table

8. Remove frame (4). (See F2)
* Remove the frame together with the sub-
tank.
9. Disconnect wiring connector (5). (See F3) INSTALLATION OF REVOLVING

10. Remove cover (6). (See F3)
FRAME ASSEMBLY
b kg See Weight Table . Carry out installation in the reverse order to
removal.
+ The length of the mounting bolts differs
according to the mounting position, so
refer to the diagram when installing. (See
F7)
Length of mounting bolts marked %
PC300,3OOLC-5: 155mm
PC400, 4OOLC-5: 175mm
Length of other mounting bolts
11. Disconnect hoses (7). (See F4) PC300,3OOLC-5: 140mm
12. Remove link (8). (See F4) PC400, 400LC-5: 165mm
& Swing circle mating surface:
6 Mounting bolt:
m Mounting bolt:
30674
205FO5474
F2 F6
205FO5582
F3
\ %
c 205FO5584 205FO5586
F4
I 205FO5585
REMOVAL OF SWING CIRCLE REMOVAL OF IDLER, RECOIL
ASSEMBLY SPRING ASSEMBLY
1. Remove revolving frame assembly. 1. Track shoe assembly
For details, see REMOVAL OF REVOLVING . Remove track shoe assembly.
FRAME ASSEMBLY. For details, see REMOVAL OF TRACK
2. Remove swing circle assembly (I). (See Fl) SHOE ASSEMBLY.
* Remove 36 mounting bolts. 2. Remove idler and recoil spring assembly (1).
(See F3)
el kg See Weight Table Ir Sling

assembly,
the
and
idler and recoil
pull out to the front
spring
to
remove.
& kg See Weight Table

3. Disconnection of idler and recoil spring
INSTALLATION OF SWING
assembly
CIRCLE ASSEMBLY Secure recoil spring with block 0, then sling
. Carry out installation in the reverse order to idler assembly, remove mounting bolts, and
removal. disconnect idler assembly (2)’ and recoil
+ Align the positions of the (S) mark of the spring assembly (3). (See F4) m
inner circle soft zone and the outer circle Ir Make match marks on the matching
soft zone (plug) when installing the swing surface of the idler and the recoil spring.
circle assembly. (See F2)
4 Mounting bolt:
m Mounting bolt:
INSTALLATION OF IDLER,
6 Circle teeth surface : RECOIL SPRING ASSEMBLY
Grease (G2-LI)
6 Amount of grease :
removal.
27Q (PC300, 3OOLC-5)
35Q (PC400, 4OOLC-5) m
Ir Install recoil spring assembly (3) to

idler assembly (2) so that the mud re-
moval hole in the yoke is at the bot-
tom. (See F5)
Fl F3
-k-x
F20505318 205FO5477
i
F4
I I F20705331 205FO5478
Mud re’moval hole
a=20705473
DISASSEMBLY OF RECOIL ASSEMBLY OF RECOIL SPRING
SPRING ASSEMBLY ASSEMBLY
1. Remove piston assembly (2) from recoil 1. Assembly of piston assembly
spring assembly (I). (See Fl) 1) Assemble ring (14) and U-packing (13) to
2. Disassembly of recoil spring assembly piston (9), and secure with snap ring (12).
1) Set recoil spring assembly (1) to tool B. (See Fl)
(See F2) 2) Fit valve (II) and secure with lock plate
$*‘The spring is under large installed (IO). (See Fl)
load, so be sure to set the tool prop- 2. Assembly of recoil spring assembly
erly. Failure to do this is dangerous. 1) Assemble dust seal (8) to cylinder (7).
* Spring installed load: (See Fl)
See Tightening Torques and &I= Lip of dust seal: Grease (G2-LI)
Standard Values Table 2) Assemble cylinder (7) and yoke (6) to
2) Apply hydraulic pressure slowly to spring (51, and set in tool C. (See Fl)
compress spring, then remove lock plate 3) Apply hydraulic pressure slowly to com-
(3), and remove nut (4). (See Fl) press spring, tighten nut (4) so that in-
* Compress the spring to a point where stalled length of spring is dimension “a”,
the nut becomes loose. then secure with lock plate (3). (See F3)
-k Release the hydraulic pressure slowly * Installed length of spring:
and release the tension of the spring. See Tightening Torques and
* Free length of spring: Standard Values Table
See Tightening Torques and 4) Remove recoil spring assembly (1) from
Standard Values Table tool B. (See F2)
3) Remove yoke (6), cylinder (7), and dust 3. Install recoil spring assembly (1) to piston
seal (8) from spring (5). (See Fl) assembly (2) as follows.
3. Disassembly of piston assembly 1) Set flange portion of cylinder (7) at top
1) Remove lock plate (IO) from piston (9), and stand cylinder upright, then fill in-
then remove valve (I 1). (See Fl) side of cylinder with at least 300 cc of
2) Remove snap ring (12), then remove U- grease. (See F4)
packing (13) and ring (14). (See Fl) Cylinder: Grease (G2-LI)
2) Insert piston (9) slowly into cylinder (7).
* Insert the piston so that the valve
mount is at the side. (See F5)
3) Insert piston fully and push out grease
together with all air mixed with grease.
(See F5)
Fl
1
205FO5479
1
F2 F3
205FO5480 205FO5587
L
F4
Flange
Cylinder
Fill bottom with min.
300 cc of grease
.’
, IF
F20705474
F5
Piston
. Push
‘d F2070547E
REMOVAL OF TRACK ROLLER REMOVAL OF CARRIER
ASSEMBLY ROLLER ASSEMBLY
1. Loosen Lubricator (I). (See Fl) 1. Track shoe assembly
or Loosen the lubricator, and loosen the Jr Using hydraulic jack 3 , push up the
~~ track sh.oe tension. track to a position where the carrier roller
The adjustment cylinder is under ex- assembly can be removed. (See Fl)
tremely high pressure. Never loosen the 2. Remove carrier roller assembly (I). (See F3)
lubricator more than one turn. If the track w
tension is not relieved, move the machine
I5 kg See Weight Table
backwards and forwards.
2. Remove track roller assembly (2). (See F2)
@??J
* Remove the mounting bolts of the track
INSTALLATION OF CARRIER
roller, then swing the work equipment
90”, jack up the machine, and remove ROLLER ASSEMBLY
the track roller assembly. . Carry out installation in the reverse order to
6 kg See Weight Table removal.

m
AYz.= Mounting bolt:
INSTALLATION OF TRACK
ROLLER ASSEMBLY
removal.
D
Ir Set the track roller assembly to the
mounting position, then operate the
control levers to lower the machine
slowly, and tighten the mounting bolts
temporarily.
a Mounting bolt:
Ir Operate the control levers to lower the
machine completely to the ground, then
tighten the mounting bolts fully.
30-80
0
F2050532C F20505322
F2
F2050532 1
30-81
0
REMOVAL OF TRACK SHOE REMOVAL OF CHARGING
ASSEMBLY PUMP ASSEMBLY
1. Positioning track wq Lower the work equipment to the ground and
* Stop the machine in a position where stop the engine. Operate the control levers
the track can be laid out to the front and several times to release the remaining
rear when the master pin is pulled, then pressure in the hydraulic piping. Then loosen
loosen lubricator (I) to relieve the track the oil filler cap slowly to release the pressure
~~ tension.. (See Fl) inside the hydraulic tank.
The adjustment cylinder is under ex- . Remove hydraulic tank strainer, and use tool
tremely high pressure. Never loosen the D to stop the oil. (See F5)
lubricator more than one turn. If the track Ir When not using tool D, remove drain
tension is not relieved, move the machine plug and drain the oil from hydraulic tank
backwards and forwards. and piping.
2. Remove master pin (2) m : See Lubricant and Coolant Table
or Using tool C, pull out the master pin. 1. Disconnect hoses (I). (See F6)
(See F2) 2. Disconnect tube (2). (See F6)
3. Remove track shoe assembly (3) @??! 3. Remove charging pump assembly (3). (See
* Move the machine forward so that the F6)
position of the temporary pin is at the
front of the idler, then put block 0 in
contact with the grouser, pull out tem-
porary pin 0, and remove the dust seal.
(See F3) INSTALLATION OF CHARGING
* Drive the machine in reverse to lay out PUMP ASSEMBLY
the track
removal.
INSTALLATION OF TRACK Ir Refill to the specified level, and run the

engine to circulate the oil through the
SHOE ASSEMBLY
system. Then check the oil level again.
removal. %b See Lubricant and Coolant Table
m
* Using tool C, press fit the master pin.
* Deflection of track a (See F4):

30-82
0
Fl
F20505320 , FI 1225
L
2 F6
F20505323
F4
I
Track frame
/
‘Track shoe
F9883
REMOVAL OF HYDRAULIC REMOVAL OF HYDRAULIC
PUMP ASSEMBLY PUMP ASSEMBLY
Pc300,300LC-5 PC400, 4OOLC-5
Y Y
A4I Lower the work equipment to the ground and QY Lower the work equipment to the ground and
4
stop the engine. Operate the control levers stop the engine. Operate the control levers
several times to release the remaining several times to release the remaining
pressure in the hydraulic piping. Then loosen pressure in the hydraulic piping. Then loosen
the oil filler cap slowly to release the pressure the oil filler cap slowly to release the pressure
inside the hydraulic tank. inside the hydraulic tank.
. Remove hydraulic tank strainer, and use tool . Remove hydraulic tank strainer, and use tool
D to stop the oil. (See Fl) D to stop the oil. (See F5)
* When not using tool D, remove drain Ir When not using tool D, remove drain
plug and drain the oil from hydraulic tank plug and drain the oil from hydraulic tank
and piping. and piping.
:
u See Lubricant and Coolant Table
.
_ : See Lubricant and Coolant Table
Draining oil from damper chamber
. Draining oil from damper chamber
& See Lubricant and Coolant Table
1. Remove side cover (I). (See F2) :

_ See Lubricant and Coolant Table
* Sling the side cover and the frame as 1. Remove side cover (I). (See F6)
one unit, remove the mounting bolts, * Sling the side cover and the frame as
then remove. one unit, remove the mounting bolts,
See Weight Table then remove.
&
2. Remokvgetube (2). (See F3) See Weight Table
&
3. Disconnect hoses (3), (4), (5), and (6). (See 2. Rzove frame (2). (See F6)
F3) * Disconnect 5 hoses (6). 3. Disconnect tube (3). (See F7)
4. Disconnect wiring connector (7). (See F3) 4. Disconnect hoses (41, (5), (6), and (7). (See
5. Remove bracket (8). (See F3) F7)
6. Remove hydraulic pump assembly (9). (See * Disconnect 5 hoses (7).
F4) 5. Disconnect wiring connector (8). (See F7)
el See Weight Table 6. Remove hydraulic pump assembly (9). (See
IN&LLATION OF HYDRAULIC F8)

See Weight Table
PUMP ASSEMBLY & kg
Pc300,300Lc-5 INSTALLATION OF HYDRAULIC

. Carry out installation in the reverse order to PUMP ASSEMBLY
removal.
PC400, 4OOLC-5
* Refill to the specified level, and run the . Carry out installation in the reverse order to
engine to circulate the oil through the removal.
system. Then check the oil level again. . Refilling with oil
* Add oil to the damper chamber to the t Add oil to the damper chamber to the
specified level. specified level.
Q See Lubricant and Coolant Table Q See Lubricant and Coolant Table
. Bleeding air . Bleeding air
* Bleed the air from the hydraulic pump. Ir Bleed the air from the hydraulic pump.
For, details, see TESTING AND For details, see TESTING AND
ADJUSTING, Bleeding air from all parts. ADJUSTING, Bleeding air from all parts.
* After bleeding the air from the hydraulic Ir After bleeding the air from the hydraulic
pump, check the hydraulic tank level. pump, check the hydraulic tank level.
30-84
0
Fl F5
I
FI 1229 FI 1229
2 -6
z 205FO5589 pawa 205FO5592
z
0 F3
I
F4
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPVI 60 + 160)
Note) The procedure for disassembly is basi-

cally the same for both front and rear
pumps, so this section describes the dis-
assembly of the front pump only. When
there are differences, however, they will
be noted at the appropriate place in the
description.
1. Rear pump assembly

1) Set pump assembly (1) in tool Jl.
2) Remove hoses (2) and (3).
‘\
3) Remove 4 nuts (4) of front pump end,

then lift off rear pump assembly (5).
* Separate end cap at center:
* Loosen 4 rear pump end ca mount-
ing bolts (Width across fa+ s = 30
mm).
2. TVC, CO - NC valve assembly

Remove TVC valve (6) and CO * NC valve
assembly (7) as a set.
* TVC valve installed only front pump.
3. Servo valve assembly

Remove servo valve assembly (8).
F20705421
3o-F
4. Charging pump drive gear (Front pump only)
1) Remove charging pump drive gear as fol-
lows.
i) Remove cover (9).
ii) Using tool 52, remove screw (IO),
then remove plate (11).
F20705422 1t -F207054231
iii) Using puller 0, remove gear (12).
I
\\ 0 J F20705424
2) Remove charging pump driven gear as

follows.
i) Stop gear from turning, and remove
bolt (13) and plate (14).
ii) Using puller 0, remove gear (15).
F20705425 F2070542E
5. End cap
1) Using puller 0, push shaft (16) to end
cap side, then hold tension of spring in-
side cylinder block.
F20705427
30-85-2
Ir For the rear pump, remove cover (17),
bolt (18), and plate (19), then use the
mounting holes of plate (19) and the
cover to set puller @ in position.
F20705421 3
F20705A79
2) Remove coupling (20).

3) Using tool 53, remove 4 screws (21).
4) Remove impeller (22).
F2070543C 1 F20705431
5) Remove snap rings (23).

6) Remove spacers (24) and (25).
7) Remove thrust bearings (26).
* Impeller not installed on rear pump,
so remove plate (27), then remove
end cap.
j” 26
21 @’
F20705432 @
30-g-3
8) Loosen 7. bolts gradually, and when
spring in cylinder block is fully extended,
remove end cap (28).
* Before removing end cap (28), remove
the puller @ installed in Step 5-l).
9) Remove bearing (29) from end cap (28).

IO) Remove valve plate (30). .
* When removing valve plate, be careful
not to damage valve plate and cylin-
der block because valve plate adheres
to cylinder block.
8
6
s: F207054341 F20705435
6. Pump sub-assembly
1) Remove cradle mounting bolts.
2) Support shaft on front and rear, and
remove pump sub-assembly (31) from
case.
F20705436
7. Charging pump assembly

1) Remove charging pump assembly (32).
2) Remove plug (33A), then using tool J4, J4 338
remove strainer (33B).
F20705437 F20705438
8. Charging p.ump drive shaft assemblv ,
(front pumfonly)
?I Remove housing (34).
2) Using push tool, remove oil seal (35)
from housing (34).
F20705439 F2070544C
3) Remove drive shaft assembly (36) by

knocking out from charging pump end.
4) Disassemble drive shaft assembly as
follows.
i) Remove key, then use push tool to
remove collar (38), bearing (39), collar
(40), and bearing (41) from shaft (37).
ii) Remove pin (42), then remove coup-
ling (43) from shaft (37).
iii) Remove snap ring (45) from case.
F20705441 F20705442
9. Servo Ipiston assembly

1) Remove caps (46) and (47), and shims
(48) and (49) by using forcing screw.
2) Remove spring (50).
3) Remove servo piston (51).
F20705443
30-:5-5
DISASSEMBLY OF PUMP SUB-ASSEMBLY
1. Cylinder, shaft
1) Set pump sub-assembly in a vice.
* Be careful not to damage the flange
surface of the cradle.
2) Remove slider (53) and cylinder block

(54).
3) Disassembly of cylinder block

Remove snap ring (55), then remove re-
tainer (56), spring (57) and washer (58)
F20205329 F20705444
from cylinder block (54).
4) Using forcing screw, remove housing

(59).
* Check the number and thickness of
shims and keep in a safe plate.
5) Using push tool, remove oil seal (60)

from housing (59).
F20705445 F20705446
6) Remove shaft assembly (61).
7) Disassembly of shaft
Using puller 0, remove cola1 r (63) and
inner race (64) from shaft (62).
* Remove only the inner race for the
rear pump.
F20705447 F20703036
2. Piston
1) Using tool J3, remove 4 screws (65), 69
then remove bearing retainer (66), shoe
retainer (67), spacer (68) and piston (69). 67 66
65
68
%
F20703022-1 F2070544E
30-!5-6
2) Using tool 53, remove screws (70), then
remove plate (71).
3) Remove rocker cam (72).
4) Using tool 55, remove screws (73), then
7
remove rocker cam stopper (74).
F20705449 11 F20705450
L70 F20705451
3. Cradle
Using push tool, remove bearing (76) from
cradle (75).
30-$5-7
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
(HPV160 + 160)
0 Precautions when assembling.

yl
Always use all parts supplied in thekit. In
addition, always use the following parts as
an assembly.
1) Cradle and rocker cam.
2) Cylinder block and valve plate.
Preparatory work
0 Clean all parts, and check for dirt or dam-
age. Coat the sliding surfaces of all parts
with engine oil (EOIO-CD, new oil) before
installing.
ASSEMBLY OF PUMP SUB-ASSEMBLY
1. Cradle and piston assembly

1) Install bearing (76) (Outside diameter: 110
mm) in cradle (75).
& Mounting surface of bearing:
Grease (G2-LI)
75 FZOi '05452
2) Select shims to hold bearing as follows.

i) Measure distance 0 between bearing
(76) and end face of cradle.
ii) Measure distance @ of housing (59).
* Measure distance @ of cover.
(Rear pump)
iii) Select shim thickness as follows..

Shim thickness = 0 - @ - (0 to 0.1
mm)
* There are 3 kinds of shim (thick-
F20205351
ness = 0.15, 0.1 and 0.05 mm).
3) Fit dowel pin, and using tool 55, install

rocker cam stopper (74) with screws (73).
a Stopper screw: Thread tightener
(LT-2)
(Loctite #262)
W Stopper screw:
d-71
&7ll F20705451
304&5-8
4) Fit dowel pin to cradle, set rocker cam
(72) in position, then using tool 53 install
plate (71) with screws (70).
* Install the grooved side of the rocker
arm facing the cradle oil hole.
RC& Plate screw: Thread tightener
(LT-2)
(Loctite # 262)
m Plate screw:
Standard Values Table F2070545C
* After tightening the bolts, check that

the rocker cam moves smoothly. J3
1
Lf F20705449
5) Select the spacer thickness as follows.

Assemble piston (69) to shoe retainer
(67), put on the level block, then
measure distance 0 to top surface of
shoe retainer.
Select spacer thickness as follows.
Spacer thickness = distance 0 +
(0.03 to 0.07 mm).
I . - Ts
* There are thre types of spacer.
6) Install spacer (68) selected in Step 5)-i)

and ii), then install piston (69), shoe
retainer (67) and bearing retainer (66).
a Bearing retainer screw:
(Loctite #262)
m Bearing retainer screw:
65
7) Using tool 53, install screw (65). F20705448
30-g-9
8) Hold rocker cam in position, using tool Rocker cam
J6, pull piston (69) with a force of 5 - 6
kg, and measure clearance @ between
piston shoe and rocker cam.
Measure the clearance with the rocker .Bearing retainer
cam at position a or b, and measure
for all 9 pistons.
Clearance: 0.03 - 0.07 mm
If clearance @ is not within the stan-
dard range, adjust the spacer again.
F20703021
Pull
F20505442
2. Cylinder block
Align piston and install cylinder block (54).
* Install the spring and washer inside the
cylinder after adjusting the preload of the
bearing.
* Always install the valve plate (which
forms a set with the cylinder) together
with the cylinder,
careful not to m&e anv mistake.
F207054
3. Shaft assembly
1) Using push tool, press fit inner race (64),
O-ring, collar (63) (inside diameter: 60
mm) on shaft (62).
* Be sure to install inner race in correct
directon.
F20705454
* For the rear pump, use a push tool to
install inner race (78) to shaft (77),
then fit plate (19) and tighten with
bolt (18).
Mounting bolt: Thread tightener
(LT-2)
(Loctite #262)
Mounting bolt:
t- F2070302:
a Set cradle and piston assembly (79) in

vice.
* Put a block under the cylinder.
3) Align shaft assembly (61) with cylinder,
and install.
Block
F20705455
4) Install housing as follows.

i) Install oil seal (60) (outside diameter:
95 mm) to housing (59).
ii) Fit shim selected in Step l-2), and
install housing (59) to cradle.
F20705446 F20705445
ASSEMBLY OF PUMP ASSEMBLY
1. Charging pump drive shaft assembly

(front pump only)
1) Sub-assembly of shaft assembly.
i) Knock coupling (43) in shaft (37), then
secure with pin (42).
ii) Using push tool, install bearing (41), 42
collar (40), bearing (39), collar (38)
(inside diameter: 35 mm) to shaft (37).
F20703024 (( F20705456
30-g-11
iii) Using push tool, install snap ring (45)
to case (44).
2) Install drive shaft assembly (36) to case.

* Check that shaft rotates smoothly.
F20705457
3) Using push tool, install oil seal (35) to

housing (34).
* When installing oil seal, be careful not
to deform it.
a Lip of oil seal: Grease (G2-LI)
4) Fit O-ring, install housing (34) to pump.
8
6
(v 34
0 F20705439
2. Servo piston
1) Install servo piston (51) in case.
+ Servo piston is the same for front
pump and rear pump.
$1
F20505440
2) Adjust stroke of servo piston as follows.

i) Align tool 57 with dowel pin and
groove for servo valve arm of servo
piston, and set tool 57 in position.
+ As seen from the rear of the
pump, the right side (the side with
the spring) is the maximum swash
plate angle side. (maximum flow
side)
Note: For the rear pump, use the
same tool turned over.
F20505450
30-8$- 12
ii) Measure distance 0 between servo
piston and case.
iii) Measure distance @ of cap (46).
iv) Select shim thickness as follows.
@ - 0 = 0 + 0.05 mm
* After adjusting the shim, put it in
a set with the cap.
F20205356
Servo valve
mounting
surface
Pump case
Cleara
\
Servopiston Clearance \
Servo piston z
0
Clearance 0 6
F20703026 F20703027 8
* To adjust the minimum swash

plate angle, replace tool 58 with
the tool for the minimum angle,
and repeat the same procedure as
in Steps i) - iv).
Note that the case faces in the
opposite direction from the maxi-
mum swash plate angle side.
3. Pump sub-assembly
II Install slider (53)and O-rings.
* Install O-rings on pilot bore and joint
portion.
21 Install joint to case.
* Install with small hole facing cradle
side.
3) Align slider with servo piston, so support
the shaft and install pump sub-assembly
(31).
* Be careful that O-ring is not caught.
4. Charging pump drivengear
(front pump only)
1) Fit key on shaft, then shrink fit gear (15).
(Charging pump end).
* Shrink-fitting temperature: 100°C for 1
hour.
2) Fit plate (14) and tighten bolt (13).
w Bolt: See Tightening Torques and
F20705458 F20705425
3) Fit key, then shrink fit gear (12). (Main

shaft end)
4) Using tool 52, install split plate (11) with

screw (10).
* Push plate into bottom of groove of
shaft completely, then tighten screws
alternately to prevent plate from mov-
ing.
Mounting bolt: Thread tightener
(LT-2) F20705459 1;' -20705423
(Loctite #262)
Mounting bolt:
5) Select plate (11) as follows.

i) Install gear (12).
+ When shrink fitting gear, install
gear after temperature becomes
low.
ii) Select proper plate from 5 kinds of
plate so that clearance 0 becomes
the smallest.
* a = 0 - 0.1 (Best selection of
plate is to fit in position by knock-
ing plate in slightly.)
F20703029
5. End cap
1) Using push tool, install bearing (29) .(out-
side diameter: 54 mm) and ring (80) to
end cap (28).
2) Coat with grease (G2-LI), align with dowel

pin and ring (80), then install valve plate
(30).
* Check that the suction and discharge
ports of the valve plate are aligned
with the ports in the end cap.
F20705434 F20705460
6. Adjusting end play of front (rear) shaft bearing

1) Install joint to case end.
* Install with the small hole facing the
opposite side from the end cap.
2) Install end cap (28) to case.

W Mounting bolt:
3) Coat grease (G2-LI), and install thrust

bearing (26). Outer race seat
* Install the thrust bearing with the out-

side race (the side with the larger /
inside diameter) surface facing the
end cap. Pay attention also to the 8
24
direction of installation of the ball
(Grooved portion of ball holder). (See \
diagram on right)
26
of ball holder F20705461 F2070546;
4) Install spacers (24) and (25), then install 26

snap ring (23).
\
21
F20705432
5) Select spacer (24)as follows. *---
Of the 5 types of spacer, select the End cap
23
Bearing \
spacer (24)that gives the minimum clear-
ance from the snap ring (23).
24 khaft
F20705463
6) Using tool 53, install impeller (22) with

screws (21).
7) Set dial gauge @ on case and measure

axial play of shaft. r +__ Clearance
* Axial play: 0.1 - 0.4 mm 0.1 - 0.4 mm
* If axial play is not within specified
range, select plate from five kinds of
plate.
F2070303’
8) Install selected plate, measure clearance
between impeller and end cap.
* Clearance: 0.65 & 0.18 mm.
F20705465
In
x
F20705466
%
9) After completing measurements, remove
impeller and end cap.
* On the rear pump, plate (27) is used;

there is no impeller.
7. Washer, spring, snap ring

Assemble washer (59), spring (58) and
retainer (57) to cylinder block, then install
snap ring (56). W”7”GdW
* Be sure to install washer in correct direction.
/
F20705468 /I F20705469 I
3o-%?1
7
8. Impeller
1) Secure shaft (16) with puller 0.
2) Fit O-ring, then install end cap.

* For details see step 5 and 6-l), 2).
3) Coat grease (G2-LI), and install thrust

bearing (26).
* For details see Step 6-3), 4).
4) Install spacers (25) and (24), then install

snap ring (23).
+ When doing this, press the shaft with
a force of 170 - 190 kg from the
case side to the end cap side.
21
5) Align bearing, and install impeller (22).
F20705432
6) Using tool J3, tighten screw (21). I -T-1 n

6 Screw: Adhesive (LT-2)
(Loctite #262)
m Screw: See Tightening Torques
and Standard Values Table
F20705431
7) After tightening screws, remove puller 0.

8) Measure rotating torque of pump.
9 Using tool J9, rotate pump shaft at 1
revolution every 3 - 5 set then
measure rotating torque.
ii) There must be no variation in the ro-
tating torque (Range of variation:
Max. 0.3 kgm) and the rotating torque
must be less than 2.0 kgm. (At mini-
mum swash plate angle)
F20705470
3o-Y*
9. Servo piston cap
Aligning servo piston, install spring (50).
* Install on left side when viewing
pump from rear.
Fit O-ring and shims (49) and (48)

selected in step 2, then install caps (47)
and (46).
B Mounting bolt:
F20705443
10. Servo valve assembly

Fit O-ring and align lever with groove of
servo piston, then install servo valve assem-
bly (8).
m Mounting bolt: See Tightening Torques
and Standard Values
Table
F20705421
11. WC, CO * NC valve assembly

Fit O-ring and install NC valve (6) and
CO . NC valve assembly (7) as a set.
w Mounting bolt: See Tightening Torques
and Standard Values
Table 6
or TVC valve is installed only on front
pump.
kpd”L pJitl/ F20705471
30-g-19
12. Charging pump assembly
1) Using tool J4, install strainer assembly
(34), then install plug.
2) Fit O-ring, then install charging pump

assembly (32).
13. Rear pump assembly

1) Install coupling (20).
‘32 F2070547i
2) Fit O-ring to end cap, and raise rear

pump assembly (5), then tighten 4 nuts
(4).
m End cap mounting nut and bolt:
* Also tighten 4 rear pum’p end
mounting bolts (Width across flats =
30 mm). 5
3) Install hoses (2) and (3).

w Sleeve nut of hose (2):
w Sleeve nut of hose (3):
30-83-20
14. Cover
I
Install cover (9).
F20705422)
30-g-21
CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND
ROCKER CAM AND CRADLE
1. Checking contact between cylinder block

and valve plate
Cylinder block Centering tool
1) Make a centering tool for the cylinder
block and valve plate.
* The tool can be made of a soft
material such as plastic or bakelite.
checked.
cylinder block side with inspection paint.
t Apply the paint thinly.
4) Put the valve plate on top, push with a
force of 4 - 5 kg, and rotate 2 - 3
times.
5) Remove the valve plate, transfer the
cntact surface to tape, and check the
contact surface.
t The standards for the contact surface are

as follows.
Valve plate a Seal ’ Min. 80%
Cylinder block a Seal Min. 80%
a Seal
Valve plate Cylinder block
F20703038
30-g-22
Checking contact between rocker cam and
cradle
checked.
cradle side with inspection paint.
3) Put the rocker cam on top, push with a
force of 4 - 5 kg, and move 2 - 3 times
from the stopper contact position to the
maximum angle.
4) Remove the rocker cam, transfer the con-
tact surface to tape, and check the
contact surface.
* The standards for the contact surface are

as follows.
HPVI 60 70 Min. 90% Mln. 50%
* If there is no contact at the center but

only at the outside, the contact is no
good.
cam
F20703039
(Reference)
If the contact is not within the contact stan-
dard value, when carrying out lapping,
always lap both parts together.
t Parts with scratches cannot be reused.
30-g-23
REMOVAL OF HYDRAULIC
PUMP INPUT SHAFT OIL SEAL
1. Remove hydraulic pump assembly.
. For details, see REMOVAL OF HYDRAU-
LIC PUMP ASSEMBLY.
2. Remove cover (I). (See Fl)
3. Remove plate (2). (See Fl) a
4. Remove drive gear (3). (See Fl)
* Using a puller, remove the drive gear.
5. Remove housing assembly (4). (See F2, F3)
m
* Using eyebolts, remove the housing
assembly and the shim.
6. Remove oil seal (5). (See F3) m
. Remove the oil seal from the housing.
INSTALLATION OF HYDRAULIC
PUMP INPUT SHAFT OIL SEAL
removal.
m
& Mounting bolt :
m Mounting bolt :
m
W Mounting bolt :
m
* Using tool 0, press fit oil seal (5) in
housing (4). (See F4)
a Lip of oil seal : Grease (G2-LI)
30-86
@i
Fl
L
‘3
205FO5595
F2
s 205FO5486
20UF01210-K
F4
4 5
2OUFOl21 I-K
REMOVAL OF CONTROL INSTALLATION OF CONTROL
VALVE ASSEMBLY VALVE ASSEMBLY
YY
Carry out installation in the reverse order to
+ Lower the work equipment to the ground and
release the remaining pressure inside the removal.
circuit. For details, see TESTING AND Bleeding air
ADJUSTING, Releasing remaining pressure * Fill with oil to the specified level, then
in hydraulic circuit for machines with PPC bleed the air. For details, see
valve. TESTING AND ADJUSTING, Bleeding
* After removing the piping, mark with tags air from all parts.
to prevent mistakes when installing. * After bleeding the air, check the
1. Remove frame (I). (See Fl) hydraulic tank level.
. Remove the block between the hydraulic
filters. (PC400, 4OOLC-5)
2. Disconnect wiring connectors (2). (See Fl)
It Disconnect the connectors of the front
and rear pump pressure sensors and
work equipment and swing pressure
switches.
3. Disconnect tubes (3). (See Fl)
Ir Disconnect 2 tubes.
4. Remove bracket (4). (See Fl)
6. Disconnect R.H. control valve hoses
I) Disconnect hoses (6). (See Fl)
* Disconnect 6 hoses.
2) Disconnect PPC hoses (7). (See Fl)
Ir Disconnect 3 hoses at the front, 3
hoses at the rear, and 2 hoses at the
bottom.
7. Disconnect L.H. control valve hoses.
* Disconnect 7 hoses
2) Disconnect PPC hoses (9). (See Fl)
* Disconnect 3 hoses at the front, 5 at
the rear, 3 hoses at the top, and 2
hoses at the bottom.
8. Remove control valve assembly (IO). (See
F2)
Jr When removing the control valve
assembly, check that all the piping
and wiring has been removed, then
remove the assembly, taking care
that there is no interference.
* Sling the control valve assembly,
remove the mounting bolts, then
remove together with the bracket.

F7
30;89
DISASSEMBLY OF CONTROL
VALVE ASSEMBLY
6. Bucket valve
1) Remove case (28), then remove spring
* The set pressure of the safety valve cannot
(29) and retainer (30), and pull out spool
be adjusted when the safety valve is installed
on the machine, so do not disassemble it. (31).
. 2) Remove case (32), then remove spring
The following explanation uses the left
(33) and retainer (34).
control valve as the example.
. This applies to the arm Lo, service (R.H.
1. Main relief valve, jet sensor relief valve
control valve), and arm Hi (L.H. control
Remove main relief valve (1) and jet sensor
valve) spools.
relief valve (2). (See Fl)
. Arm Lo (R.H. control valve)
2. Safety-suction valve
There is a retainer assembled
Remove safety-suction valve (3), (4), and (5).
between case (32) and spring (33).
(See Fl)
. Arm Hi (L.H. control valve)
3. Check valve
Shim (35) is assembled.
Remove plug (6), then remove spring (7) and
7. Straight travel valve
check valve (8). (See Fl)
1) Remove plate (36), then remove spring
4. L.H. travel valve
(37).
I) Remove case (9), remove retainer (IO),
2) Remove plug (38), then pull out spool
shim (1 I), spring (12), retainer (13), spring
(14), and retainer (15), then remove spool (39).
(16).
2) Remove case (17), then remove retainer
(18), shim (19), spring (201, retainer (21),
spring (22), and retainer (23).
. This applies to the swing, R.H. travel,
boom Hi (R.H. control valve), and boom
Lo (L.H. control valve) spools.
. Swing spool (R.H. control valve)
i) Shim (11) and retainer (13) are
not assembled.
ii) Shim (19) and retainer (21) are
not assembled.
. Boom Hi (R.H. control valve)
i) 2 shims (11) are assembled.
ii) There is a plate installed instead
of parts (17) - (23) in Step 2).
. Boom Lo spool (L.H. control valve)
i) Shim (11) is not assembled.

ii) Parts (18) - (21) in step 2) are not
assembled.
5. Arm throttle valve
1) Remove plug (24) and spring (25).
2) Remove plate (26), and pull out spool
(27).
. For the swing priority valve (R.H. control
valve), parts (24), (25), and (26) in steps
1) and 2) are installed in the opposite
way.
Fl
z-
I_@Q
3
205F0590E
38
/
‘b
35
205FO59 I 0
ASSEMBLY OF CONTROL
VALVE ASSEMBLY
. Boom Hi (R.H. control valve)
1. Straight-travel valve i) Assemble 2 shims (II). (See Fl)
I) Assemble spool (39), then fit O-ring and ii) Install a plate instead of parts (17)
install plug (38). (See Fl) - (23) in Step 2). (See Fl)
2) Fit spring (37) and install plate (36). (See . Boom Lo spool (L.H. control valve)
Fl) i) Shim (11) is not assembled. (See
2. Bucket valve Fl)
1) Assemble spool (31), fit retainer (34) and ii) Parts (18) - (21) in step 2 are not
spring (33), then fit O-ring and install case assembled. (See Fl)
(32). (See Fl) 5. Check valve
2) Fit retainer (30) and spring (29), then fit Install check valve (8) and spring (7), then fit
O-ring and install case (28). (See Fl) O-ring and install plug (6). (See Fl)
. This applies to the arm Lo, service (R.H. W Plug:
control valve), and arm Hi (L.H. control See Tighiening Torques and
valve) spools. Standard Values Table
. Arm Lo (R.H. control valve) 6. Safety-suction valve
Assemble retainer between case (32) Install safety-suction valve (5), (4), and (3).
and spring (33). (See Fl) (See Fl)
. Arm Hi (L.H. control valve) m Safety-suction valve:
Assemble shim (35). (See Fl) See Tightening Torques and
3. Arm throttle valve Standard Values Table
1) Assemble spool (27), then fit O-ring and
7. Jet sensor relief valve, main relief valve
install plate (26). (See Fl)
Install jet sensor relief valve (2) and main
2) Fit spring (25), then fit O-ring and install
relief valve (I). (See Fl)
plug (24). (See Fl)
m Jet sensor relief valve:
. For the swing priority valve (R.H. control
valve), parts (24), (25), and (26) in steps
1) and 2) are installed in the opposite
B Main relief valve:
way. (See Fl)
4. L.H. travel valve
1) Assemble spool (16), install retainer (23),
spring (22), retainer (21), spring (20), shim
(19), and retainer (18), then fit O-ring and
install case (17). (See Fl)
2) Fit retainer (15), spring (14), retainer (13),
spring (12), shim (II), and retainer (IO),
then fit O-ring and install case (9). (See
Fl)
. This applies to the swing, R.H. travel,
boom Hi (R.H. control valve), and boom
Lo (L.H. control valve) spools.
. Swing spool (R.H. control valve)
i) Shim (11) and retainer (13) are
not assembled. (See Fl)
ii) Shim (19) and retainer (21) are
not assembled. (See Fl)
?------
2--’
fQ!J
205FO590
36
205FO5S 1c
3023
REMOVAL OF MAIN RELIEF DISASSEMBLY OF MAIN
VALVE ASSEMBLY RELIEF VALVE ASSENBLY
nAkLower the work equipment to the ground and 1. Loosen nut (21, and remove plug (I). (See
4
stop the engine. Operate the control levers F3)
several times to release the remaining t Before loosening the nut, measure
pressure in the hydraulic piping. protrusion dimension a of the plug from
Then loosen the oil filler cap slowly to release the end face of the nut. (See F2)
the pressure inside the hydraulic tank. 2. remove retainer (3). (See F3)
1. Disconnsct hoses (I). (See Fl) 3. Loosen nut (5), and remove holder (4). (See
2. Remove R.H. control valve main relief valve F3)
(2). (See Fl) m Sr Before loosening the nut, measure
3. Remove L.H. control valve main relief valve protrusion dimension b of the holder
(3).(See Fl) m from the end face of the nut. (See F2)
4. Remove spring (6) and poppet (7). (See F3)
5. Remove sleeve (81, then remove seat (91,
backup ring (IO), spring (II), and valve (12).
(See F3)
INSTALLATION OF MAIN 6. Remove plug (14) from sleeve (13). (See F3)
RELIEF VALVE ASSEMBLY 7. Remove backup ring (15) from sleeve (13).
(See F3)
removal.
WI ml
m Main relief valve:
See Tightening Torques and ASSEMBLY OF MAIN RELIEF
8
Standard Values Table VALVE ASSEMBLY 6
. After installing the main relief valve on g
1. Assemble backup ring (151 and O-ring in
the machine, adjust the set pressure.
sleeve (13). (See F3)
For details, see TESTING AND
ADJUSTING, Adjusting main relief valve. 2. Install plug (14) to sleeve (13). (See F3)
3. Assemble backup ring (IO) and O-ring to seat
(91, then install valve (8) to sleeve (13). (See
F3)
4. Assemble poppet (7) and spring (6). (See F3)
5. Assemble nut (5) and O-ring to holder (4),
and install to sleeve (13). (See F3)
* Adjust so that protrusion dimension b of
the holder from the end face of the nut
is the same as when it was disassembled,
then secure with the nut. (See F2)
6. Assemble retainer (3). (See F3)
7. Assemble nut (2) and O-ring to plug (I), and
install to sleeve (13). (See F3)
* Adjust so that protrusion dimension a of
the plug from the end face of the nut is
the same as when it was disassembled,
then secure with the nut. (See F2)
30-94
0
205FO5596
F 3.
’ --.._’-
w
2-g
3-Q
0
4- 8
5-@
0
:2
4
8--8
10-g
11----I
12-B
205FO5598
REMOVAL OF TVC VALVE REMOVAL OF SERVO VALVE
ASSEMBLY ASSEMBLY
1. Disconnect wiring connector (I). (See Fl) 1. Remove CO.NC assembly.
2. Remove TVC valve assembly (2). (See Fl) For details, see REMOVAL OF CO.NC VALVE
ASSEMBLY.
2. Remove servo valve assembly (I). (See F3)
INSTALLATION OF TVC VALVE INSTALLATION OF SERVO

ASSEMBLY VALVE ASSEMBLY
. Carry out installation in the reverse order to l Carry out installation in the reverse order to
removal. removal.
REMOVAL OF CO.NC VALVE

ASSEMBLY
+ Remove the hoses (4 hoses for front
pump, 5 hoses for rear pump).
2. Remove CO.NC valve assembly (2). (See F2)
* Remove the CO.NC valve of the front
pump as an assembly with the TVC valve.
INSTALLATION OF CO.NC
VALVE ASSEMBLY
removal.
\ n
F2
30-97
0
REMOVAL OF WORK ASSEMBLY OF WORK
EQUIPMENT PPC VALVE EQUIPMENT PPC VALVE
ASSEMBLY ASSEMBLY
YA Y
+ Lower the work equipment to the ground and 1. Assembly of valve assembly
stop the engine. Operate the control levers Assemble shim (18), spring (17), and retainer
several times to release the remaining (16) to valve (191, and push down retainer
pressure in the hydraulic piping. Then loosen (16) to install collar (15). (See F2)
the oil filler cap slowly to release the pressure 2. Assemble spring (14) and install valve
inside the hydraulic tank. assembly (13). (See F2)
1. Remove lever assembly (1). (See Fl) 3‘ Assembly of piston assembly
2. Remove bolt (2). (See Fl) Assemble the following parts to piston (6).
3. Remove stand (3). (See Fl) & Piston: Grease (G2-LI)
4. Disconnect hoses (4). (See Fl) 1) Assemble spring (12) and piston (II).
* Disconnect 6 hoses. (See Fl) (See F2)
5. Remove PPC valve assembly (5). (See Fl) 2) Fit seal (IO) to collar (9) and assemble.
(See F2)
3) Fit dust seal (8) to collar (7) and assemble.
(See F2)
INSTALLATION OF WORK
4. Install piston assembly (5). (See F2)
EQUIPMENT PPC VALVE 5. Fit plate (4) and install joint (3). (See F2)
ASSEMBLY m Joint:
removal.
6. Fit disc (2) and install nut (I). (See F2)
. Adjust the clearance between disc (2) and
piston (6). For details, see TESTING AND
DISASSEMBLY OF WORK ADJUSTING, Adjusting PPC valve for
EQUIPMENT PPC VALVE work equipment.
m Nut:
ASSEMBLY
1. Remove nut (I), then remove disc (2). (See Standard Values Table
F2)
2. Remove joint (3), then remove plate (4). (See
F2)
3. Remove piston assembly (5). (See F2)
4. Disassembly of piston assembly
Remove the following parts from piston (6).
(See F2)
1) Remove collar (71, then remove dust seal
(8). (See F2)
2) Remove collar (91, then remove seal (IO).
(See F2)
3) Remove pistion (II), and spring (12). (See
F2)
5. Remove valve assembly (13), then remove
spring (14). (See F2)
6. Disassembly of valve assembly
Push retainer (16) to remove collar (151, then
remove retainer (161, spring (17), and shim
(18) from valve (19). (See F2)
Fl
205FO5492
-14
205FO5493
REMOVAL OF TRAVEL PPC DISASSEMBLY OF TRAVEL PPC
*yLower the work equipment to the ground and 1. Remove plate (I), then remove piston
stop the engine. Operate the control levers assembly (2). (See F2)
several times to release the remaining 2. Disassembly of piston assembly
pressure in the hydraulic piping. Then loosen Remove collar (4) from piston (31, then
the oil filler cap slowly to release the pressure remove seal (5). (See F2)
inside the hydraulic tank. 3. Remove valve assembly (61, then remove
1. Disconnect yokes (I). (See Fl) spring (7). (See F2)
2. Disconnect hose (2). (See Fl) 4. Disassembly of valve assembly
Ir Disconnect 6 hoses. Push retainer (9) to remove collar (8), then
3. Remove travel PPC valve assembly (3). (See remove retainer (9), spring (IO), and shim
Fl) (II) from valve (12). (See F2)
INSTALLATION OF TRAVEL PPC ASSEMBLY OF TRAVEL PPC

. Carry out installation in the reverse order to 1. Assembly of valve assembly
removal. Assemble shim (II), spring (IO), and retainer
(9) in valve (121, then push down retainer (9)
to install collar (8). (See F2)
2. Assemble spring (7), and install valve
3. Assembly of piston assembly
Assemble seal (5) to collar (4), and install to
piston (3). (See F2)
4. Assemble piston assembly (2), and install
plate (I). (See F2)
7
2
, /
205FO5599
205FO5495
30-p
REMOVAL OF BOOM HOLDING DISASSEMBLY OF BOOM
VALVE ASSEMBLY HOLDING VALVE ASSEMBLY
*yLower the work equipment to the ground and * The set pressure of the safety valve cannot
release the remaining pressure in the circiut. be adjusted when the safety valve is installed
For details, see TESTING AND ADJUSTING, on the machine, so do not desassemble it.
Releasing pressure in hydraulic circuit for 1. Remove safety valve assembly (I). (See F2)
machines with PPC valve. 2. Remove plug (2), then remove spacer (3),
1. Disconnect hoses (I ). (See Fl) spring (41, seat (5), and spool (6). (See F2)
2. Disconnect tubes (2). (See Fl) 3. Remove body (71, then remove spring (8) and
3. Remove boom holding valve assembly (3). check valve (9). (See F2)
(See Fl)
INSTALLATION OF BOOM ASSEMBLY OF BOOM

HOLDING VALVE ASSEMBLY HOLDING VALVLE ASSEMBLY
. Carry out installation in the reverse order to 1. Assemble check valve (9) and spring (8), then
removal. fit O-ring and install body (7). (See F2)
. Refilling with oil m Mounting bolt:
+ Refill to the specified level, and run the See Tightening Torques and
engine to circulate the oil through the Standard Values Table
system. Then check the oil level again. 2. Fit seat (5) to spool (6) and insert in body
(71, then install spring (4), spacer (31, plug (2)
and O-ring. (See F2)
m Plug:
3. Fit O-ring and install safety valve (I). (See
F2)
m Safety valve:
30-202
1 F2
0
3 9
205FO5900
1
205FO5497
Lo
0
6
8
30-&03
REMOVAL OF PPC SHUTTLE INSTALLATION OF PPC
VALVE ASSEMBLY SHUTTLE VALVE ASSEMBLY
YA&
+ Lower the work equipment to the ground and ’ Carry out installation in the reverse order to
stop the engine. Operate the control levers removal.
several times to release the remaining
pressure in the hydraulic piping. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Arm PPC shuttle valve assembly
I) Disconnect hoses (I). (See Fl)
* Disconnect 2 hoses at the front, and
3 hoses at the rear.
2) Remove arm PPC shuttle valve assembly
(2). (See Fl)
2. Swing PPC shuttle valve assembly
21 Remove pressure switch (4). (See Fl)
3) Remove swing PPC shuttle valve assem-
bly (5). (See Fl)
3. Boom, bucket PPC shuttle valve assembly
+ Disconnect 4 hoses at the front, and
2) Remove boom, bucket PPC shuttle valve
assembly (7). (See Fl)
4. Travel PPC shuttle valve assembly
2) Remove pressure switch (9). (See Fl)
3) Remove travel PPC shuttle valve assem-
bly (IO). (See Fl)
30-404
Fl
I I
/ 2 3 6 8 205FO590 I
30205
REMOVAL OF BOOM INSTALLATION OF BOOM
CYLINDER ASSEMBLY CYLINDER ASSEMBLY
A Extend the arm and bucket fully, lower the . Carry out installation in the reverse order to
work equipment to the ground, and operate removal.
the control levers 2 or 3 times. m
1. Disconnect hose (1). (See Fl) + Tighten with the locknut so that the
2. Remove lock bolt (2). (See Fl) m clearance between the boom boss and
3. Remove pin (3). (See Fl)mj [=I m] nut is 0.5 - 1.5 mm. (See F4)
* Sling the boom cylinder assembly, and m
remove the pin. A When aligning the position of the pin
A Start the engine, and retract the rod of hole, run the engine at low idling. Never
the boom cylinder, tie the rod with wire insert your fingers in the pin hole.
to prevent it from coming out, then lower /
it onto the block. * Adjust with shims so that the clear-
*yRelease the remaining pressure in the ance between cylinder rod (7) and
circuit. For details, see TESTING AND plate (8) is less than 1 mm. (See F5)
ADJUSTING, Releasing pressure in m
hydraulic circuit for machines with PPC * Adjust with shims so that the clear-
valve. ance between cylinder bottom (9) and
4. Disconnect hose (4). (See F2) bracket (10) is less than 1 mm.
5. Remove pin (5). (See F3) ml [=I (See F6)
* Sling the boom cylinder assembly, then m
&III& Inside surface of bushing: LM-P
use forcing screws 0 to remove the pin.
+ For grease, use LM-G.
6. Remove cylinder assembly (6). (See F3)
. Bleeding air
kg
&?I See Weight Table * Bleed the air from the cylinder.
ADJUSTING, Bleeding air from hydraulic
cylinder.
* After bleeding the air from hydraulic
cylinder, check the level of the oil in the
hydraulic tank.
30-105-l
0
Fl F5
\ i 8
205FO5499 F2070534L I
F2 F6
9 10
Lo F20505332 F20705345
0
I-
% F3
I
F20505333
F4
I
-4--I
0.5 - 1.5 mm
2OSF6065
30-105-2
0
PC4006 (LOADING SHOVEL) PC~OO-5 (LOADING SHOVEL)
A the
Extend the arm and bucket fully, then lower
work equipment completely to the ground
. Carry out installation
removal.
in the reverse order to
and stop the engine.

A Loosen the oil filler cap slowly to release the u
pressure inside the hydraulic tank. * Raise boom cylinder assembly (2), then
start the engine.
* After disconnecting the hoses, fit blind plugs Extend the piston rod, install pin (3) and
to prevent dirt or dust from entering. secure it with the mounting plate.
(See Fl)
1. Disconnect grease hose (1). (See Fl)
2. Sling boom cylinder assembly (2), then using A When aligning the mounting position of
forcing screws (M12), remove pin (3). the pin, never put your fingers in the pin
(see Fl) m ml holes. (See Fl)
3. Start engine and retract piston rod fully. pizJ

* Install the hoses without twisting or inter-
A Tie the piston rod with wire to prevent it ference. (See F2)
from coming out.
m
A Stop the engine and release the pressure * Adjust with shims so that the clearance
from inside the piping. between the revolving frame and the
cylinder bottom is less than 1 mm.
4. Lower boom cylinder assembly on to stand,
and disconnect hose (4) at cylinder end. (See . Bleeding air
F2) m * Bleed the air from the work equipment
circuit.
5. Sling boom cylinder assembly and remove For details, see TESTING AND ADJUST-
plate, using forcing screws (Thread dia. = 20 ING, Bleeding air from hydraulic cylinder
mm), pull out foot pin (5) (See Fl) wl I=/ (work equipment circuit).
6. Remove boom cylinder assembly (2). (See * After bleeding the air, add engine oil to
Fl) the hydraulic tank to the specified level.
kg
&YI Boom cylinder assembly: 408 kg
30-p-3
Fl
/
3 1
F2
I F207C5317
30-1$5-4
REMOVAL OF ARM CYLINDER INSTALLATION OF ARM
ASSEMBLY CYLINDER ASSEMBLY
A Set block @ between the arm and the boom, . Carry out installation in the reverse order to
then extend the arm fully, lower the work removal.
equipment to the guound, and operate the m
*
control levers 2 or 3 times.
Sling the arm cylinder assembly.
A when aligning the position of the pin
hole, run the engine at low idling. Never
1. Remove pin (1). (See Fl) ml 1-1 insert your fingers in the pin hole.
A Start the engine, and retract the rod of m
the arm cylinder, then tie the rod with * Adjust with shims so that the clear-
wire to prevent it from coming out. ance between cylinder bottom (6) and
A Release the remaining pressure in the bracket (7) is less than 1 mm.
circuit. For details, see TESTING AND (See F2)
m
ADJUSTING, Releasing pressure in
hydraulic circuit for machines with PPC a Inside surface of bushing: LM-P
valve. * For grease, use LM-G.
. Bleeding air
3. Disconnect hose (3). (See Fl) + Bleed the air from the cylinder. For
4. Remove pin (4). (See Fl) /I I=1 details, see TESTING AND ADJUSTING,
5. Remove arm cylinder assembly (5). (See Fl) Bleeding air from hydraulic cylinder.
+ After bleeding the air from the cylinder,
check the level of the oil in the hydraulic
tank.
Fl
I
0
F20505334
r Max. 1 mm
‘7
m L- F20705346
0
a
0
REMOVAL OF ARM CYLINDER INSTALLATION OF ARM
ASSEMBLY CYLINDER ASSEMBLY
PC400-5 (LOADING SHOVEL) PC400-5 (LOADING SHOVEL)
A Adjust the boom

cylinder, set the
cylinder, extend the arm
bucket with the bottom
l Carry out installation
removal.
horizontal, then lower the work equipment to

the ground and stop the engine.
Operate the contorol levers several times to * Sling arm cylinder assembly, then run
release the remaining pressure in the hy- engine, extend piston rod, and align rod
draulic piping. pin hole. (See Fl)
A Loosen the oil filler cap slowly to release the

m
pressure inside the hydraulic tank. A the
When aligning the mounting position of
pin, never put your fingers in the pin
* After disconnecting the hoses, fit blind plugs holes. (See Fl)
to prevent dirt or dust from entering.
1. Sling arm cylinder assembly (I), and remove * Install the hoses without twisting or inter-
plate, then pull out pin (2). (See Fl)ml\ml ference. (See F2)
4kg Pin: 24 kg 1141

* Adjust with shims so that the clearance
2. Start engine and retract piston rod fully. between the boom and the arm cylinder
bottom is less than 1 mm.
A Tie the piston rod with wire to prevent it
.
from coming out. Bleeding air
* Bleed the air from the work equipment
A Stop the engine and release the pressure circuit.
from inside the piping. For details, see TESTING AND ADJUST-
For details, see TESTING AND ADJUST- ING, Bleeding air from hydraulic cylinder
ING, Releasing pressure from hydraulic (work equipment circuit).
circuit of PCC valve. * After bleeding the air, add engine oil to
the hydraulic tank to the specified level.
3. Disconnect hose (3). (See F2) m
4. Sling at piston rod end and bottom end, then

remove plate, and pull out pin (4). (See Fl)
mm1
* Pull out the pin until the cylinder bottom
can be disconnected.
4kg Pin: 24 kg
5. Lift off arm cylinder assembly (I) slowly.
4kg Arm cylinder assembly: 492 kg
30-g7-1
Fl
F2
i
i
F207C5319
30-1%c17-
REMOVAL OF BUCKET INSTALLATION OF BUCKET
A Set block @ between the link and the arm, j, Tighten with the locknut so that the
and sling the bucket cylinder assembly. clearance between the link boss and nut
1. Remove lock holt (I). (See Fl) m is 0.5 - 1.5 mm. (See F2)
2. Remove pin (2). (See Fl) m ml ml (
A Start the engine, and retract the rod of A When aligning the position of the pin
the arm cylinder, then tie the rod with hole, run the engine at low idling. Never
wire to prevent it from coming out. insert your fingers in the pin hole.
A Release the remaining pressure in the )
circuit. For details, see TESTING AND * Adjust with shims so that the clear-
ADJUSTING, Releasing pressure in ance between link (6) and link (7) is
hydraulic circuit for machines with PPC less than 1 mm. (See F3)
valve. m
3. Disconnect hose (3). (See Fl) * Adjust with shims so that the clear-
4. Remove pin (4). (See Fl) m1 ml ance between cylinder bottom (8) and
5. Remove bucket cylinder assembly (5). (See bracket (9) is less than 1 mm.
Fl) (See F4)
m
kg
E?!Y See Weight Table
& Inside surface of bushing: LM-P
* For grease, use LM-G.
. Bleeding air
* Bleed the air from the cylinder. For
details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
* After bleeding the air from the cylinder,
check the level of the oil in the hydraulic
tank.
Fl
-20505335
F2
--+--I
0.5 - 1.5 mm
2OSF6065
8
6
8 F3
F4
Max. 1 mm
9 F20705348
30-‘$7-4
PC4006 (LOADING SHOVEL) PC400-5 (LOADING SHOVEL)
A ofExtend the arm cylinder

the bucket horizontal,
fully, set the bottom
then lower the work
. Carry out installation
removal.
equipment completely to the ground and stop

the engine. Operate the control levers several m
times to release the remaining pressure in * Adjust with shims so that the clearance
the hydraulic piping. between the link and the bucket cylinder
bottom is less than 1 mm.
A Loosen the oil filler cap slowly to release

the
m
A When aligning the mounting position of

the pin, never put your fingers in the pin
* After disconnecting the hoses, fit blind plugs
to prevent dirt or dust from entering. holes. (See Fl)
m
1. Sling bucket cylinder assembly, remove 3
mounting bolts (I), then pull out pin (2). (See * Sling bucket cylinder assembly, then run
Fl)m]/nlFl engine, extend piston rod, and align rod
pin holes. (See Fl)
A Link (3) will drop, so
pulling out the pin.
be careful when
m
kg
&ZI Pin: 21 kg ference. (See F2)
m
2. Start engine and retract piston rod fully.
* Adjust with shims so that the clearance
A Tie the piston rod with wire to prevent it between the boom and the bucket cylin-
der bottom is less than 1 mm.
from coming out.
A from
Stop the engine
inside the
and release the pressure
piping.
. Bleeding air
* Bleed the air from the work equipment
For details, see TESTING AND ADJUST- circuit.
ING, Releasing pressure from hydraulic For details, see TESTING AND ADJUST-
circuit of PPC valve. ING, Bleeding air from hydraulic cylinder
(work equipment circuit).
3. Disconnect hose (4) (See F2) m * After bleeding the air, add engine oil to
4. Sling piston rod end and bottom end, then
remove plate, pull out pin (51, and remove
bucket cylinder assembly (6). (See Fl)
VI K51
* Check the number and thickness of the
shims, and keep in a safe place.
6 kg Bucket cylinder assembly: 248 kg
* Be careful not to let the grease piping

attached to the bucket cylinder be crushed
by the weight of the cylinder.
30-u&7-5
Fl
F207C5320 1
F2
F207C532
30-k?7-6
REMOVAL OF BOTTOM DUMP INSTALLATION OF BOTTOM
CYLINDER ASSEMBLY DUMP CYLINDER ASSEMBLY
A Set the bottom of the bucket horizontal, then . Carry out installation in the reverse order to
lower the work equipment completely to the removal.
ground.
* After disconnecting the hoses, fit blind plugs * Sling bottom dump cylinder assembly,
to prevent dirt or dust from entering. then run engine, extend piston rod, and
align rod pin hole. (See Fl)
1. Sling bottom dump cylinder assembly, and
remove cover (1). Then remove mounting m
bolts, and using forcing screws (Thread dia.
= 20 mm, Pitch = 2.5 mm), pull out pin (2) to-
A When aligning the mounting position of
the pin, never put your fingers in the pin
gether with lock plate. (See Fl) RI WI holes. (See Fl)
2. Start engine and retract piston rod fully. m

a Stop the engine and release the pressure ference. (See F2)
from inside the piping.
ING, Releasing pressure from hydraulic . Bleeding air
circuit of PPC valve. * Bleed the air from the work equipment
circuit.
3. Disconnect hose (3). (See F2) m For details, see TESTING AND ADJUST-
ING, Bleeding air from hydraulic cylinder
4. Remove retainer (4), and pull out pin (5). (See (work equipment circuit).
Fl)m * After bleeding the air, add engine oil to
5. Lift off bottom dump cylinder assembly (6).
(See F2)
kg Bottom dump cylinder assembly:

&?I
104 kg.
304427-7
Fl
F207C5322
F2
c
F207C5323
1
30-27-8
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
4. Disassembly of collar assembly
. Disassembly of the collar assembly is for
1. Cylinder assembly
the boom and arm cylinders only.
1) Remove mounting bolts, and disconnect
1) Remove O-ring and backup ring (15). (See
head assembly (1). (See Fl)
F5)
2) Pull out piston rod assembly (2). (See
2) Remove collar (17) and ring (18) from
Fl)
collar (16). (See F5)
+ Put an oil pan or container under the
cylinder to catch the oil.
2. Piston rod assembly 5. Disassembly of cylinder head assembly

1) Remove mounting bolts, then remove 1) Remove O-ring and backup ring (19). (See
spacer (3). (See F2) F6)
2) Remove piston assembly (4). (See F2) 2) Remove snap ring (20), then remove dust
3) Remove plunger (5). (see F2) seal (21). (See F6)
. Plunger (5) is for the boom and arm 3) Remove rod packing (22). (See F6)
cylinders only. 4) Remove buffer ring (23). (See F6)
4) Remove collar assembly (6). (See F2) 5) Remove bushing (24). (See F6)
. Collar assembly (6) is for the boom
and arm cylinders only.
5) Remove head assembly (7). (See F2)
6) Remove screw (81, then take out 11 balls

(91, then remove plunger (IO). (See F3)
. Plunger (IO) is for the arm cylinder
only.
7) Remove O-ring and backup ring (I 1). (See
F3)
3. Disassembly of piston assembly

I) Remove ring (12). (See F4)
2) Remove wear ring (13). (See F4)
3) Remove piston ring (14). (See F4)
F5
16
202F0548 I 1: l8 205FO6904
:3
24
19
23
21
22
7 6 5
202FO5486
F3
r 8
I /
9
ill
205FO5903
I 202FO5465
30-109
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
4. Piston rod assembly
* Be careful not to damage packings, dust seals I) Assemble O-ring and backup ring (11).
or O-rings when installing. (See F6)
Ir Do not try to force the backup ring into 2) Set plunger (IO) to piston rod, and
position. Warm it in warm water (50 - 60°C) assemble 12 balls (9) (11 balls on PC400,
before fitting it. 4OOLC), and tighten screw (8). (See F6)
1. Assembly of head assembly w Screw :
1) Press fit bushing (24). (See Fl) See Tightening Torques and
2) Assemble buffer ring (23). (See Fl) Standard Values Table
3) Assemble rod packing (22). (See Fl) * After tightening the screw to the
4) Assemble dust seal (21), and secure with specified torque, caulk it with center
snap ring (20). (See Fl) punch.
5) Assemble O-ring and backup ring (19). * Check that there is a small amount
(See Fl) of play at the tip of the plunger.
. Plunger (IO) is for the arm cylinder
2. Assembly of collar assembly
I) Assemble ring (18) and collar (17) to only.
collar (16). (See F2) 3) Assemble head assembly (7). (See F7)
2) Assemble O-ring and backup ring (15). 4) Assemble collar assembly (6). (See F7)
. Collar assembly (6) for the boom and
(See F2)
arm cylinders only.
5) Assemble plunger (5). (See F7)
. Plunger (5) is for the boom and arm
cylinders only.
6) Assemble piston (4). (See F7)
7) Fit spacer (3) and tighten with mounting
bolts. (See F7)
3. Assembly of piston assembly
I) Using tool E,, expand piston ring (14). 5. Cylinder assembly
(See F3) I) Assemble piston rod assembly (2). (See
Sr Set the piston ring on tool E, and F9)
turn the handle 8 - 10 times to &IYY= Seal : Grease (G2-LI)
expand the ring. j, Set the end gap of the ring in a
2) Set tool E, in position, and compress horizontal (sideways) position, align
piston ring (14). (See F4) it with the center of the axis of the
cylinder, then insert. (See F8)
* After inserting, check that the rings
are not broken or missing, then insert
fully.
2) Tighten head assembly (I) with mounting
3) Assemble wear ring (13). (See F5)
bolts. (See F9)
4) Assemble ring (12). (See F5) m Mounting bolt :
j, Be careful not to open the end gap
of the ring too far. Standard Values Table
& Ring groove : Grease (G2-LI)
30-20
Fl F5
24
19
23
21
22
/
io
202FO5486 9 205FO5906
F2 6
205FO5905 205FO5907
F3
E2
End gaps’of rings

m
I
202FO5487 202FO5488 205FO5908
F‘4
-
r
12 23
12IDI
E 14
1‘3
202FO5485 202FO548 I
REMOVAL OF WORK INSTALLATION OF WORK
EQUIPMENT ASSEMBLY EQUIPMENT ASSEMBLY
1. Disconnect hose (I). (See Fl) j, When tightening the locknut, tighten so
2. Remove lock bolt (2). (See Fl) m that the clearance between the boss of
3. Remove pin (3). (See Fl) m in] mj the boom and the nut is “0.5 - 1.5 mm”.
Ir Sling the boom cylinder assembly and (See F5)
remove the pin. m
A Start the engine and retract the boom A When aligning the position of the pin
cylinder rod fully, then tie the rod with hole, run the engine at low idling. Never
wire to prevent it from coming out, and insert your fingers in the pin hole.
lower it onto the block. m
* Disconnect the boom cylinder on the * Adjust with shims so that the clear-
opposite side in the same way. ance between cylinder rod (8) and
*!Release the remaining pressure in the plate (9) is less than 1 mm. (See F6)
circuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in * Adjust with shims so that the clear-
hydraulic circuit for machines with ance between boom (IO) and bracket
PPC valve. (11) is less than 1 mm. (See F7)
4. Disconnect hoses (4). (See F2) m
5. Disconnect wiring (5). (See F2) & Inside surface of bushing: LM-P
6. Remove pin (6). (See F3) 1x1 mi * For grease, use LM-G.
* Sling work equipment assembly (7), then . Bleeding air
using tool F, remove the pin. (See F3) * Bleed the air from the cylinder. For
7. Remove work equipment assembly (7). (See details, see TESTING AND ADJUSTING,
F4) Bleeding air from hydraulic cylinder.
j, After bleeding the air from the cylinder,
check the level of the hydraulic tank.
Fl
-++--I
0.5 - 1.5 mm
\ 205FO5499 2OSF6065
F2
8 9
205FO5500 F20705349
F7
Max. 1 mm
/ \
11 10
205FO5501 F20705350
F4
205FO5502
I
30-l 13
0
REMOVAL OF WORK INSTALLATION OF WORK
EQUIPMENT ASSEMBLY EQUIPMENT ASSEMBLY
A Retract the boom cylinder fully, extend the . Carry out installation
removal.
arm cylinder, set the bottom of the bucket
horizontal, then lower the work equipment
completely to the ground and stop the en- m
gine. Operate the control levers several times * For details, see INSTALLATION OF BOOM
to release the remaining pressure in the hy- CYLINDER ASSEMBLY.
draulic piping. Then loosen the oil filler cap
slowly to release the pressure inside the m
hydraulic tank. * Install the hoses without twisting or inter-
ference. (See F2)
* Release the pressure from inside the piping.
m
For details, see TESTING AND ADJUSTING,
Releasing pressure from hydraulic circuit of * Move chassis forward slowly, align boom
PPC valve. foot pin mounting position with revolv-
ing frame, then adjust shim, install boom
1. Disconnect boom cylinder from boom. foot pin (5), and lock with plate. (See F4)
For details, see REMOVAL OF BOOM CYLIN-
DER ASSE.MBLY. m A When
of the
aligning the mounting
revolving
position
frame and the boom
2. Disconnect bottom dump cylinder hose (I), foot pin, never put your fingers in the
bucket cylinder hose (2), and arm cylinder pin holes.
hose (3). (See F2) m
* Oil will spurt out when the hoses are * Set bottom of bucket horizontal, lower
z
disconnected, so loosen the hose flanges work equipment completely to ground, 6
slowly to disconnect. then sling work equipment assembly (4).
* When slinging adjust the boom height
A Fit blind plugs securely into the hoses so that the boom foot is at the height
of the mounting position on the
at the chassis end to prevent oil from
spurting out when the engine is chassis.
started.
. Bleeding air
3. Disconnect front lamp wiring. * Bleed the air from the work equipment
circuit.
4. Set bottom of bucket horizontal, lower work For details, see TESTING AND ADJUST-
equipment completely to the ground, then ING, Bleeding air from hydraulic cylinder
sling work equipment assembly (4). (See F3) (work equipment circuit).
5. Pull out boom foot pin (51, and disconnect * After bleeding the air, add engine oil to
work equipment assembly from chassis. (See the hydraulic tank to the specified level.
F4) m
6. Start engine, move chassis slowly to rear,

then operate crane, and lower boom foot to
ground. m
A When
check
driving the machine in reverse,
that the boom foot is completely
disconnected.
6 kg Work equipment assembly: 9,300 kg

Fl
208F1134
F2
F3
--,
F207C5325
F4
ASSEMBLY ASSEMBLY
A Set the back of the bucket facing down, lower l Carry out installation in the reverse order to
the work equipment to the guound, and removal.
operate the control levers 2 or 3 times. ml ml
1. Remove lock bolt (I). (See Fl) m * Tighten with the locknut so that the
2. Remove plate (2). (See Fl) m clearance between the bucket boss and
3. Remove pin (3). (See Fl) m nut is 0.5 - 1.5 mm. (See F2)
4. Remove lock bolt (4). (See Fl) m m
5. Remove pin (5). (See Fl) ) * Adjust the shim thickness so that the
6. Remove bucket assembly (6). (See Fl) clearance between bucket boss (7) and
* Raise the work equipment and disconnect spacer (8) is 2 mm. (See F3)
the arm from the bucket. m
E?kg See Weight Table * When aligning the position of the pin
insert your fingers in the pin hole.
Inside surface of bushing: LM-P

30-A14
Fl
F20505336
F2
0.5- 1.5mm
2OSF6065
F3
F20505337
ASSEMBLY ASSEMBLY
A Set the bottom of bucket horizontal,

lower the work equipment completely
then
to the
l Carry out installation
removal.
ground and stop the engine. Operate the

control levers several times to release the m
remaining pressure in the hydraulic piping. * Install the hoses without twisting or inter-
ference.
A pressure
Loosen the oil filler cap slowly to release
inside the hydraulic tank.
the
* Raise link (5), align mounting pin hole

* After disconnecting the hoses, fit blind plugs with bucket, knock in pin (4), install holder
to prevent dirt or dust from entering. (31, then tighten 3 mounting bolts (2).
(See F2)
1. Disconnect bottom dump cylinder hose (1)
from cylinder end. (See Fl) m A When aligning the mounting position
of the pins, never put your fingers in
2. Sling bucket cylinder assembly, remove 3 the pin holes.
mounting bolts (2), then remove holder (31,
and pull out pin (4). (See F2) m m
* Run engine and operate control levers to
A Link (5) will drop, so be careful
pulling out the pin. (See F2)
when align arm and bucket pin mounting holes.
Pin: 21 kg
A there
Before starting
are blind
the engine, check that
plugs fitted in the pip-
& kg
ing of the bottom dump cylinder.
3. Sling bucket assembly, remove 3 mounting
bolts (61, then remove holder (7), and pull out
pin (8). (See F3) m
A When aligning the mounting position
of the pins, never put your fingers in
the pin holes.
4. Lift off bucket assembly (9). (See F2) m
E?lkg Bucket assembly: 3,540 kg * Raise bucket (9), set bottom of bucket
horizontal, then lower to ground.
Fl
F207C5331
F2
F207C5332
F3
7 F207C5333
REMOVAL OF ARM ASSEMBLY INSTALLATION OF ARM
1. Bucket assembly ASSEMBLY
. Remove bucket assembly . Carry out installation in the reverse order to
For details, see REMOVAL OF BUCKET
removal.
ASSEMBLY. m
2. Work equipment set
* Secure the bucket cylinder assembly to
A When aligning the position of the pin
the arm, pull in the arm, and lower it
insert your fingers in the pin hole.
onto block 0. (See Fl) ‘m (1
* Sling the arm cylinder assembly, and Adjust with shims so that the clear-
remove the pin. ance between boom (5) and arm (6) is
A Start the engine, and retract the rod of less than 1 mm. (See F2)
the arm cylinder, then tie the rod with
wire to prevent it from coming out. Inside surface of bushing: LM-P
A Release the remaining pressure in the
.
circuit. For details, see TESTING AND Bleeding air
ADJUSTING, Releasing pressure in * Bleed the air from the cylinder. For
hydraulic circuit for machines with PPC details, see TESTING AND ADJUSTING,
valve. Bleeding air.
4. Disconnect hose (2). (See Fl) * After bleeding the air from the cylinder,
5. Remove pin (3). (See Fl) w/ jI check the level of the hydraulic tank.
6. Remove arm assembly (4). (See Fl)
j, Raise the boom and disconnect the boom
from the arm.
ti kg See Weight Table
30-p-3
Fl
F2
Max. 1 mm
30-g 5-4
REMOVAL OF ARM ASSEMBLY INSTALLATION OF ARM
ASSEMBLY
PC400-5 (LOADING SHOVEL)
PC400-5 (LOADING SHOVEL)
1. Remove bucket assembly.
For details, see REMOVAL OF BUCKET . Carry out installation in the reverse order to
ASSEMBLY. m removal.
2. Run engine, and set work equipment so that

bucket cylinder is perpendicular. * For details, see INSTALLATION OF
BUCKET ASSEMBLY.
3. Remove holder (I), then remove pin (2). (See a
Fl) m
* Extend piston rod of bucket cylinder, and
align link (3) with pin hole. (See Fl)
t When pulling out the pin, tie link (3) with
wire to prevent it from falling.
A When
of the
aligning the mounting position
pins, never put your fingers in
4. Disconnect bottom dump cylinder hose (4). the pin holes.
(See F2)
5. Disconnect arm cylinder from arm. * For details, see INSTALATION OF ARM
For details, see REMOVAL OF ARM CYLIN- CYLINDER ASSEMBLY.
DER ASSEMBLY. m
* Secure the arm cylinder assembly to the p?g
boom with a lever block. * Raise arm assembly (7) and set in mount-
ing position on boom, then align pin hole.
6. Sling arm assembly, then remove plate, and
pull out pin (6), (See Fl) m
A When
of the
aligning the mounting position
pins, never put your fingers in
& kg Pin: 30 kg the pin holes.
7. Lift off arm assembly (7).
& kg Arm assembly: 1,770 kg
30-g 5-5
Fl
I
REMOVAL OF ARM, BUCKET INSTALLATION OF ARM,
ASSEMBLY BUCKET ASSEMBLY
1. Remove
+ Set block
pin (1). (See Fl) m
@ between
pX_]
the arm and the
A When aligning the position of the pin
boom, then sling the arm cylinder as- insert your fingers in the pin hole.
sembly, and remove the pin. (See Fl) m
A Start the engine, and retract the rod of * Adjust with shims so that the clear-
the arm cylinder, then tie the rod with ance between boom (5) and arm (6) is
wire to prevent it from coming out. less than 1 mm. (See F3)
A Release the remaining pressure in the m
circuit. For details, see TESTING AND & Inside surface of bushing: LM-P
ADJUSTING, Releasing pressure in * For grease, use LM-G.
hydraulic circuit for machines with PPC . Bleeding air
valve. * Bleed the air from the cylinder.
2. Disconnect hose (2). (See F2) For details, see TESTING AND
3. Remove pin (3). (See F2) /I [cl ADJUSTING, Bleeding air.
+ Sling the arm and bucket assembly, then Sr After bleeding the air from the cylinder,
remove the pin. check the level of the oil in the hydraulic
4. Remove arm and bucket assembly (4). tank.

Fl
F20505339
F2
-
F20505340
F3
Max. 1 mm
6 5 F20705351
30-z7
ASSEMBLY ASSEMBLY
1. Arm and bucket assembly . Carry out installation in the reverse order to
. Remove arm and bucket assembly. removal.
2. Disconnect hose (1). (See Fl) m
3. Remove lock bolt (2). (See Fl) m * Tighten with the locknut so that the
4. Remove pin (3). (See Fl) VI jl /ml clearance between the boom boss and
Jr Sling the boom cylinder assembly, and nut is 0.5 - 1.5 mm. (See F5)
remove the pin. aA
.
J1Stat-t the engine, and retract the rod of A When aligning the position of the pin
the boom cylinder, then tie the rod with hole, run the engine at low idling. Never
wire to prevent it from coming out, then insert your fingers in the pin hole.
lower it onto the block. (n31
Ir Disconnect the boom cylinder assembly * Adjust with shims so that the clear-
on the opposite side in the same way. ance between cylinder rod (8) and
*yRelease the remaining pressure in the plate (9) is less than 1 mm. (See F6)
circuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in * Adjust with shims so that the clear-
hydraulic circuit for machines with PPC ance between boom (10) and bracket
valve. (11) is less than 1 mm (See F7)
5. Disconnect hose (4). (See F2) m
6. Disconnect wiring (5). (See F2) & Inside surface of bushing: LM-P
7. Remove pin (6). (See F3) m] p/ * For grease, use LM-G.
. Bleeding air
Ir Sling the boom assembly, then use tool
* Bleed the air from the cylinder.
F to remove the pin. (See F3)
8. Remove assembly (7). (See F4)
ADJUSTING, Bleeding air from hydraulic
cylinder.
* After bleeding the air from hydraulic
cylinder, check the level of the oil in the
hydraulic tank.
F5
----t--I
0.5 - 1.5 mm
\ 205FO5499 2OSF6065
8 9
205FO5500 F20705349
F7
Max. 1 mm
205FO5501 F20705350
F4
F20505341
ASSEMBLY ASSEMBLY
1. Remove arm assembly. l Carry out installation in the reverse order to

For details, see REMOVAL OF ARM ASSEM- removal.
BLY. m
2. Sling bucket cylinder assembly (I), then * For details, see INSTALLATION OF ARM
remove plate, pull out pin (9), and remove ASSEMBLY.
bucket cylinder assembly. (See Fl)
m
* Check the number and thickness of the * For details, see INSTALLATION OF BOOM
shims, and keep in a safe place. CYLINDER ASSEMBLY.
* Remove the bucket cylinder on the oppo-
m
site side in the same way.
3. Sling boom, and set stand under tip of boom ference. (See F2)
to support boom.
4. Disconnect boom cylinder from boom. m * Raise boom (8) and align mounting posi-
tions of left and right boom foot pins.
For details, see REMOVAL OF BOOM CYLIN-
DER ASSEMBLY. A When aligning the mounting position
* Remove the boom cylinder on the oppo- of the boom foot pins, never put your
site side in the same way fingers. in the pin holes.
5. Disconnect bottom dump cylinder hose (4),

bucket cylinder hose (51, and arm cylinder
hose (6). (See F2) m
* Oil will spurt out when the hoses are

disconnected, so loosen the hose flanges
slowly to disconnect.
6. Disconnect front lamp wiring.
7. Using forcing screws (Thread dia. = 16 mm,

Pitch = 2.0 mm), pull out boom foot pin (71,
and lift off boom assembly (8). (See Fl)
m
ks
L??? Boom assembly: 2,780 kg
30-ll9-1
Fl
F207C5327
F2
F207C5328
REMOVAL OF OPERATOR’S REMOVAL OF
CAB ASSEMBLY COUNTERWEIGHT
1. Remove seat assembly (I). (See Fl) 1. Remove conunterweight (I). (See F4) m
* Sling the counterweight, then remove the
I!+kg See Weight Table
mounting bolts.
2. Disconnect wiper motor wiring (2). (See Fl)
Ir Width across flats of bolt:
3. Disconnect antenna wiring (3). (See F2)
4. 45mm (PC300, 3OOLC-5)
Disconnect room lamp wiring (4). (See F2)
65mm (PC400, 4OOLC-5)
5. Disconnect ground connection (5). (See F2)
6. & kg See Weight Table
Remove instument panel assembly (6). (See
I=21
* Remove the cover, then loosen the
mounting bolts, and move the instument
panel assembly towards the inside.
7. Remove cab assembly (7). (See F3) INSTALLATION OF
6 kg See Weight Table COUNTERWEIGHT
removal.
m
m Mounting bolt:
INSTALLATION OF
OPERATOR’S CAB ASSEMBLY Standard Values Table
. Carry out installation in the re:-rse order to
removal.
30-120
a
G
90LOZO
REMOVAL OF ENGINE
THROTTLE CONTROLLER
1. Disconnect wiring connector (I). (See Fl)
2. Remove engine throttle controller assembly
(2). (See Fl)
THROTTLE CONTROLLER
removal.
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1. Disconnect wiring connector (I). (See F2)
2. Remove engine throttle controller assembly
(2). (See F2)
8
6
INSTALLATION OF PUMP 8
CONTROLLER ASSEMBLY
removal.
REMOVAL OF MONITOR
PANEL ASSEMBLY
1. Remove screws (I). (See F3)
Ir Remove.4 screws, and move the moni-
tor panel assembly upward.
3. Remove monitor panel assembly (3). (See
F3)
INSTALLATION OF MONITOR
PANEL ASSEMBLY
removal.
30-A22
Fl
I 205FO5506
:2
205FO5507
F3
30- 123
0
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
j, When carrying out flushing to remove the dirt in the hydraulic circuit, use the following procedure.
Select one of the patterns below to match the level of contamination in the hydraulic circuit.
Flushing
No. Contamination level
oattern I
Hydraulic equipment is broken; there are
1 A
metal particles in the circuit
Parts in the circuit have been disassembled
2 and assembled
B
(there are no metal particles in the circuit)
3 Periodic flushing
4 After assembly at jobsite following C
disassembly and transportation I
1. Parts to prepare
Ir The figures in the table below show the number of parts required.
Part Name
5 Main valve blind plug 07222-00312 5 5 -

and sleeve nut 07221-20315
6 Extension hose for 07102-20340 5 5 -

PPC circuit
7 Extension nipple for 21T-04-11580 5 5 -

PPC circuit
. In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
+ For details, see “Installation of filter element”.
30-224
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of the
filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
I) Short-circuiting the piping
Using the piping short-circuiting flange, short-circuit the following piping.
Method for short-circuiting piping

Hose
Position Attachmen Part No. The whole hydraulic circuit, including the
connections
hoses and tubes, is flushed, so short-circuit
W and F) the supply and return pipes in the circuit.

07377-01018 2
(G) and (l-l) I I
(C) and ID) 07377-01018 1
(A) and (B) 07377-01018 1
4 Swing (I) and (J) 07377-01018 1
Travel
(K) and (L)
5 07377-01018 2
(2 places) I I
F20705337
30$25
2) Installation of filter element
Plate
Spring
AJ
Relief valve
Small drainer4
0
R
Flashing element
(Install)
O-ring -0
-----u
u
/
Strainer (Clean)
F20705338
* When removing the element from the return

filter, use the stopper to prevent the dirt
inside the filter case from entering the tank.
. Inside diameter of hole: 53 mm
* When parts have been removed for shor-t- Element
circuiting, clean the individual parts and blow

with air, then mask with tape to prevent dirt
from entering, and store in a safe place until
mm
assembling again.
* When replacing the pilot filter, always use
the special tool. For details, see TESTING
AND ADJUSTING.
u F20705339
3) Cleaning cylinder
Jr Disassemble all cylinders and clean
Cylinder Rod Head
them.
i) Remove cylinder head, then pull out
piston rod.
F20505382
ii) Fix cylinder at an angle, then use a

pump to clean with flushing fluid.
Cylinder
* If no pump is available, use a
crane, collect the flushing fluid
at the bottom end, shake well,
then drain the flushing fluid, and
blow with air.
F20505383
iii) Apply flushing fluid to the cylinder

head and piston and brush well with
a nylon brush, then blow with air.
* Dirt is likely to collect particularly
in the insert portions, so clean
these parts well.
iv) Check inside of cylinder for damage.

. Any vertical scratches in cylinder
. Any breakage or seizure of wear
rings, piston rings, or guard ring
. Scratches on piston
Jr If there is any scuffing of the
piston or cylinder, replace the
assembly.
* If only the wear ring, piston ring,
or guard ring are damaged,
replace the damaged part with a
new part, and use again. F20705340
30-127
0
4) Flushing PPC circuit
Disconnect PPC hose from

It is not necessary to remove main valve, then fit
noses for port P and port T. nd plug in main valve
Use nipple to connect hose
Replace element and clean

Using extension hose,
small strainer
return PPC circuit hose
directly to hydraulic filter case I
0
3
F20505386
i) Disconnect PPC circuit hose from ii) Run the engine at high idling, operate
main valve, and return directly to the control lever in each direction and
hydraulic tank filter case. hold it for 2 minutes in each position.
* The ARM IN PPC circuit hoses are iii) Repeat the procedure in Step ii) at
connected to both the 4-spool least 5 times.
and 5-spool main valves, so dis- iv) Carry out the procedure in Steps i),
connect from both main valves, ii), and iii) for each PPC circuit.
and return to the hydraulic tank.
Ir Carry out the operation for one
PPC valve.
30-l 28
0
3. Flushing pattern [Al
1) Disassembly, cleaning, reassemble iii) Run the engine at high idling and
i) Failed parts carry out the following operation.
* If any part is badly damaged, . Operating pattern
replace it. Boom RAISE -+ Boom LOWER +
ii) Hydraulic tank Arm IN + Arm OUT + Bucket
iii) Suction strainer CURL + Bucket DUMP + Right
iv) Oil cooler swing + Left swing -+ Left travel
* If excessive amounts of dirt and + Right travel
dust are stuck in the core, . Operating time
replace. Hold the lever in each position
VI Cylinder for 2 minutes.
* For details, see “Cleaning . Number of times of operation
cylinder”. Repeat the above pattern at least
vi) Other hydraulic equipment 5 times.
2) Preparatory work for flushing 4) Restoring cylinder circuit, swing motor
i) Install the flushing element, clean the circuit
small strainer, then install it again. i) Restore the cylinder circuit and swing
Replace the pilot filter with a new motor circuit to the standard circuit.
part. * Keep the travel motor circuit
* For details, see “Installing filter short-circuited.
element”. ii) Add hydraulic oil to the specified
ii) Short-circuit the cylinder circuit, level.
swing motor circuit, and travel motor iii) Bleed the air from the main pump,
circuit. cylinders, and swing motor.
J, For details, see “Short-circuiting 5) Flushing center swivel joint
the piping”. i) Run the engine at high idling and
iii) Add hydraulic oil to the specified carry out the following operation.
level. . Operating pattern
iv) Bleed the air from the main pump. Left and right FORWARD + 90”
3) Flushing cylinder circuit, swing motor swing
circuit, travel motor circuit Left and right REVERSE + 90”
i) Run the engine at low idling for 30 swing
minutes. * Swing 90” to either the left
Ir The control levers must not be or right, but swing in the
moved during this time. same direction each time.
ii) Run the engine at midrange speed . Operating time
for 30 minutes. Hold the lever in each position
sr The control levers must not be for 2 minutes.
moved during this time. . Number of times of operation
* If the oil temperature is low, Repeat the above pattern 4 times,
increase the length of the and rotate the swing one turn.
operation in Steps i) and ii) to
* The purpose of swinging 90”
raise the temperature. The oil
each is to remove the dirt inside
temperature should be 50 - 80°C.
the center swivel from the oil
grooves on the rotor side and
shaft side around the whole
circumference.
30- 129
0
6) Restoring travel circuit 4. Flushing pattern LB1
i) Restore the travel circuit to the 1) Preparatory work for flushing
standard circuit. Install the flushing element, clean the
ii) Replace the flushing element with a small strainer and install it again.
new part. * For details, see “Installing filter
* For details, see “Installing filter element”.
element”. 2) Flushing PPC circuit
iii) Bleed the air from the travel motor. Flush the PPC circuit.
7) Flushing PPC circuit. * For details, see “Flushing PPC
i) Flush the PPC circuit circuit”.
* For details, see “Flushing PPC 3) Restoring PPC circuit
circuit”. Restore the PPC circuit to the standard
8) Restoring PPC circuit circuit.
i) Restore the PPC circuit to the 4) Flushing during actual operation
standard circuit. With the flushing element installed, carry
9) Flushing during actual operation out normal operations for IO - 20 hours.
i) With the flushing element installed, * If the oil temperature is low, carry
carry out normal operations for 10 - out the warming-up operation.
20 hours. 5) Replacing element
* If the oil temperature is low, carry Replace the return filter with a standard
out the warming-up operation. element, clean the small strainer and
IO) Replacing element install it again. Replace the pilot filter with
i) Replace the return filter with a a new part.
standard element, clean the small Ir For details, see “Installing filter
strainer and install it again. Replace element”.
the pilot filter with a new part.
* For details, see “Installing filter
element”.
ii) Add hydraulic oil to the specified
level.
iii) Bleed the air from the main pump.
5. Flushing pattern [Cl
* If the cylinder piping is connected and 4) Flushing during actual operation
the cylinder is operated before the i) With the flushing element installed,
system is flushed, there is danger that carry out normal operations for 10 -
the dirt that entered during assembly 20 hours.
operations will be circulated inside the + If the oil temperature is low, carry
cylinder. Therefore, do not wait until out the warming-up operation.
completion of assembly to flush the 5) Replacing element
system; carry out flushing before i) Replace the return filter with a
connecting the piping to the cylinder. standard element, clean the small
1) Preparatory work for flushing strainer and install it again. Replace
i) Short-circuit the cylinder circuit. the pilot filter with a new part.
* For details, see “Short-circuiting Ir For details, see “Installing filter
the piping”. element”.
ii) Install the flushing element, clean the ii) Add hydraulic oil to the specified
small strainer and install it again. level.
* For details, see “Installing filter iii) Bleed the air from the main pump.
element”.
2) Flushing
i) Run the engine at low idling for 30
minutes.
* The control levers must not be
moved during this time.
ii) Run the engine at midrange speed
for 30 minutes.
j, The control levers must not be
iii) Run the engine at high idling and
carry out the following operation.
. Operating pattern
Boom RAISE -+ Boom LOWER 4
Arm IN + Arm OUT + bucket
CURL -+ Bucket DUMP
. Operating time
Hold the lever in each position
for 2 minutes.
. Number of times of operation
Repeat the above pattern at least
5 times.
3) Restoring cylinder circuit
i) Restore the cylinder circuit to the
standard circuit.
level.
iii) Bleed the air from the main pump
and cylinders.
30-131
0
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
PC400, 4OOLC-5
Ir When carrying out flushing to remove the dirt in the hydraulic circuit, use the following procedure.
Select one of the patterns below to match the level of contamination in the hydraulic circuit.
Flushing
No. Contamination level
pattern
Hydraulic equipment is broken; there are
1 A
metal particles in the circuit
Parts in the circuit have been disassembled
2 and assembled
(there are no metal particles in the circuit) B
3 Periodic flushing
4 After assembly at jobsite following
C
disassemblv and transoortation
1. Parts to prepare
9~ The figures in the table below show the number of parts required.
In
x
%
Flange for short-circuiting
Main valve blind plug

and sleeve nut 07221-20210
6 Extension hose for 07102-20340 5 5 -

PPC circuit
7 Extension nipple for 21T-04-11580 5 5 -

PPC circuit
. In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
* For details, see “Installation of filter element”.
30-A32
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of the
filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
1) Short-circuiting the piping
Using the piping short-circuiting flange, short-circuit the following piping.
Method for short-circuiting piping

Position Attachment con~~~~ons Part No. O’ty The whole hydraulic circuit, including the
hoses and tubes, is flushed, so short-circuit
the supply and return pipes in the circuit.
1 1 Boom ~:Ei i:i IL\ ~ 07377-01018 ~ 2 / ,
7
, I 1
2 Arm (0 and (D) 07377-01018 1
3 Bucket ~(A) and (B) ~ 07377-01018 / 1 1
4 / Swing 1 (I) and (J) 1 07377-01018 / 1 1
5 1 Travel ~‘,“:~I~~~~ ~ 07377-01018 ~ 2 1
F&C!
F20505378
F20705341
30-A33
2) Installation of filter element
Plate-22
Spring -----A2
Relief valve--------
Small strainer-9
1
Flashing element
(Install)
Strainer (Clean)
o-ring -7 ‘,
8.
\
(Replace with new one)
F20705338
* When removing the element from the return

filter, use the stopper to prevent the dirt
inside the filter case from entering the tank.
. Inside diameter of hole: 53 mm
* When parts have been removed for short-
circuiting, clean the individual parts and blow
with air, then mask with tape to prevent dirt
from entering, and store in a safe place until
assembling again.
* When replacing the pilot filter, always use
the special tool. For details, see TESTING
AND ADJUSTING. F2070533! 3
30-A34
4) Flushing PPC circuit
Disconnecti PPC hose from

It is not necessary to remove
main valve, then fit
oses for port P and Prt T.
ind plug in main valve
From charg
pump -
Use nipple to connect hose
Using extension hose, Replace element and clean

return PPC circuit hose Jlnn small strainer
directly to hydraulic filter case
NU I(LL
Hydraulic tank
I
F20505386
4) Flushing PPC circuit ii) Run the engine at high idling, operate
i) Disconnect PPC circuit hose from the control lever in each direction and
main valve, and return directly to hold it for 2 minutes in each position.
hydraulic tank filter case. iii) Repeat the procedure in Step ii) at
j, The ARM IN PPC circuit hoses are least 5 times.
connected to both the 4-spool iv) Carry out the procedure in Steps i),
and 5-spool main valves, so dis- ii), and iii) for each PPC circuit.
connect from both main valves,
and return to the hydraulic tank.
* Carry out the operation for one
PPC valve.
30-136
0
3. Flushing pattern [A]
I) Disassembly, cleaning, reassemble iii) Run the engine at high idling and
i) Failed parts carry out the following operation.
Sr If any part is badly damaged, . Operating pattern
replace it. Boom RAISE + Boom LOWER +
ii) Hydraulic tank Arm IN -+ Arm OUT -+ Bucket
iii) Suction strainer CURL + Bucket DUMP + Right
iv) Oil cooler swing + Left swing _j Left travel
* If excessive amounts of dirt and + Right travel
dust are stuck in the core, * For loader specification
replace. machines, continue the above
v) Cylinder operating pattern as follows:
* For details, see “Cleaning Bottom dump OPEN + Bottom
cylinder”. dump CLOSE.
vi) Other hydraulic equipment . Operating time
2) Preparatory work for flushing Hold the lever in each position
i) Install the flushing element, clean the for 2 minutes.
small strainer, then install it again. . Number of times of operation
Replace the pilot filter with a new Repeat the above pattern at least
part. 5 times.
* For details, see “Installing filter 4) Restoring cylinder circuit, swing motor
element”. circuit
ii) Short-circuit the cylinder circuit, swing i) Restore the cylinder circuit and swing
motor circuit, and travel motor circuit. motor circuit to the standard circuit.
+ For details, see “Short-circuiting * Keep the travel motor circuit
the piping”. short-circuited.
iii) Add hydraulic oil to the specified ii) Add hydraulic oil to the specified
level. level.
iv) Bleed the air from the main pump. iii) Bleed the air from the main pump,
3) Flushing cylinder circuit, swing motor cylinders, and swing motor.
circuit, travel motor circuit 5) Flushing center swivel joint
i) Run the engine at low idling for 30 i) Run the engine at high idling and
minutes. carry out the following operation.
+ The control levers must not be . Operating pattern
moved during this time. Left and right FORWARD + 90”
ii) Run the engine at midrange speed swing
for 30 minutes. Left and right REVERSE + 90”
Ir The control levers must not be swing
moved during this time. Ir Swing 90” to either the left or
Ir If the oil temperature is low, right, but swing in the same
increase the length of the direction each time.
operation in Steps i) and ii) to . Operating time
raise the temperature. The oil Hold the lever in each position
temperature should be 50 - 80°C. for 2 minutes.
Repeat the above pattern 4 times,
and rotate the swing one turn.
4. Flushing pattern [Bl
* The purpose of swinging 90” 1) Preparatory work for flushing
each is to remove the dirt inside Install the flushing element, clean the
the center swivel from the oil small strainer and install it again.
grooves on the rotor side and 1: For details, see “Installing filter
shaft side around the whole element”.
circumference. 2) Flushing PPC circuit
6) Restoring travel circuit Flush the PPC circuit.
i) Restore the travel circuit to the * For details, see “Flushing PPC
standard circuit. circuit”.
ii) Replace the flushing element with a 3) Restoring PPC circuit
new part. Restore the PPC circuit to the standard
j, For details, see “Installing filter circuit.
element”. 4) Flushing during actual operation
iii) Bleed the air from the travel motor. With the flushing element installed, carry
7) Flushing PPC circuit out normal operations for 10 - 20 hours.
i) Flush the PPC circuit. * If the oil temperature is low, carry
* For details, see “Flushing PPC out the warming-up operation.
circuit”. 5) Replacing element
8) Restoring PPC circuit Replace the return filter with a standard
i) Restore the PPC circuit to the element, clean the small strainer and
standard circuit. install it again. Replace the pilot filter with
9) Flushing during actual operation a new part.
i) With the flushing element installed, J, For details, see “Installing filter
carry out normal operations for 10 - element”.
20 hours.
Ir If the oil temperature is low, carry
out the warming-up operation.
IO) Replacing element
i) Replace the return filter with a
standard element, clean the small
strainer and install it again. Replace
the pilot filter with a new part.
Ir For details, see “Installing filter
element”.
level.
iii) Bleed the air from the main pump.
30-l 38
0
5. Flushing pattern [Cl
* If the cylinder piping is connected and 4) Flushing during actual operation
the cylinder is operated before the i) With the flushing element installed,
system is flushed, there is danger that carry out normal operations for 10 -
the dirt that entered during assembly 20 hours.
operations will be circulated inside the * If the oil temperature is low, carry
cylinder. Therefore, do not wait until out the warming-up operation.
completion of assembly to flush the 5) Replacing element
system; carry out flushing before i) Replace the return filter with a
connecting the piping to the cylinder. standard element, clean the small
1) Preparatory work for flushing strainer and install it again. Replace
i) Short-circuit the cylinder circuit. the pilot filter with a new part.
* For details, see “Short-circuiting * For details, see “Installing filter
the piping”. element”.
ii) Install the flushing element, clean the ii) Add hydraulic oil to the specified
small strainer and install it again. level.
* For details, see “Installing filter iii) Bleed the air from the main pump.
element”.
2) Flushing
i) Run the engine at low idling for 30
minutes.
Ir The control levers must not be
ii) Run the engine at midrange speed
for 30 minutes.
* The control levers must not be
iii) Run the engine at high idling and
carry out the following operation.
. Operating pattern
Boom RAISE + Boom LOWER +
Arm IN + Arm OUT + bucket
CURL + Bucket DUMP
. Operating time
Hold the lever in each position
for 2 minutes.
Repeat the above pattern at least
5 times.
3) Restoring cylinder circuit
i) Restore the cylinder circuit to the
standard circuit.
level.
iii) Bleed the air from the main pump
and cylinders.
30-139
a
40 MAINTENANCE STANDARD
Final drive .................... 40- 2

Swing machinery ............. 40- 6
Swing circle .................. 40-10
Track frame and recoil spring _ 40-I 2
Idler ......................... 40-14
Track roller ................... 40-18
Carrier roller .................. 40-20
Track shoe ................... 40-22
Charging pump and relief valve 40-26
Control valve ................. 40-27
Travel shuttle valve ........... 40-34
Swing motor ................. 40-35
Travelmotor ................. 40-36
PPC valve .................... 40-38
PPC shuttle valve ............. 40-40
Boom holding valve ........... 40-41
Hydraulic cylinder ............. 40-42
Work equipment .............. 40-44
40-l
Pc300,300Lc-5
m -6. 75+0.75kgm
Initial tightening torque:
Additional tightening angle: 120 “,”
&
--
m 6.75i-0.75kgm,
r- _-
1
f
m 73.5F4.5kgml
_--
-_
:
w 7+lkgmH
3QT
205FO5056- I
2
Unit: mm
5
0 -
No. Check item Criteria Remedy
Standard clearance Clearance limit

Backlash between No. 1 sun
1
gear and No. 1 planet gear
0.19 - 0.54 1 .oo
-
Backlash between No. 1 planet
2 0.21 - 0.62 1.10
gear and No. 1 ring gear
-
Backlash between No. 1 planet -
3 carrier and idle 0.06 - 0.22
gear
Replace
Backlash between No. 2 sun 0.19 - 0.54 1 .oo
4

5 0.21 - 0.62 1.10
gear and ring gear I
6
carrier and No. 1 sun gear
0.39 - 0.67 1.20
I I I
7 End play of sprocket shaft 0.10 - 0.15 -

I I I
8 Amount of wear on sprocket tooth Repair limit: 6
Rebuild
Standard size Repair limit or
replace
9 Width of sprocket tooth
67 84
4%3
PC300HD-5
Pc400,400Lc-5
PC400HD-5
m 11.25i1.25kgm m 56_t6kgm
w Initial tightening torque: 11 kgm
Additional tiahtenina anole: 120 +?
L-- /
_.-r---
D 7ilkgm
205F05028- I
2 Unit: mm
2
0 -
No Check item Criteria Remedy
-

Backlash between No. 1 sun
1
0.20 - 0.57 1 .oo
Backlash between No. 1 planet 0.20 - 0.57 1.10

2
gear and No. 1 ring gear
Backlash
carrier andbetween
idle gearNo. 1 planet -
3 0.06 - 0.21
Replace
Backlash between No. 2 sun 0.19 - 0.53 1 .oo
4
Backlash between No. 2 planet 0.20 - 0.57 1.10

5
gear and ring gear
Backlashandbetween
carrier No. gear
No. 1 sun 2 planet 0.41 - 0.73 1.20
6
0.10 - 0.15 -
7 End play of sprocket shaft
-
8 Amount of wear on, sprocket tooth Repair limit: 6

-
Rebuild
Standard size Repair limit or
replace
9 Width of sprocket tooth
90 87
SWING MACHINERY
Pc300,300Lc-5
PC300HD-5
10
207FO5057
Unit: mm
Check item Criteria Remedy
, Backlash befween swing motor

I Standard clearance I Clearance limit I
z shaft and drove gear

0.07 - 0.18 -
G
2
2 Backlash between drive gear 1 .oo
0.18 - 0.49
and driven gear
3 Backlash between driven gear

0.07 - 0.18 -
and sun aear I I I
I I
1 Replace
4 Backlash between sun gear 1.10
0.21 - 0.59
and planet gear I I
6 Backlash between planet gear 0.22 - 0.63 1.10

and rtng gear
6 Backlash between planet carrier

0.07 - 0.22 -
I and swung prnron I I
7 Backlash bepeen swing pinion 0 - 1.21 1.90
and swing crrcle
8 End play of swing pinion 0.38 - 0.82

I -
Standard size Repair limit Apply hard-
chrome
g Wear of swing pinion surface plating,
contacting wrth 011 seal recondition
139.7 or replace
F40 -09100

10 Axial clearance of drive gear
0.08 - 0.32 - A$;st
11 Axial clearance of driven gear 0.08 - 0.32 -

I
I
I
I
1
I
I
40-7
Pc400,400Lc-5
PC400H D-5
I \
d 7
208FO5029
Unit: mm

, Backlash between swing motor
: shaft and dnve gear
0.07 - 0.18 -
5
0
2 Backlash between drive gear 0.18 - 0.50 1.oo
and drrven gear
3 Backlash between driven gear 0.09 - 0.21 -

and sun gear
- Replace
4 Backlash between sun gear 0.21 - 0.59 1.10

and planet gear
5 Backlash between planet gear 0.24 - 0.71 1.10

and ring gear I
8 Backlash between
and swung prnron
planet carrier
I 0.10 - 0.23
! -
7 Backlash between swing pinion 0 - 1.22 1.90
and swing circle I I
8 End play of swing pinion 0.39 - 0.87 - Adjust

I I I
Standard size Repair limit Apply hard-

chrome
g Wear of swing pinion surface - plating,
contactihg with oil seal recondition
149.7 or replace
@IS0 -04100
10 Axial clearance of drive gear

I Standard clearance
I
Clearance limit
I
0.08 - 0.32 - $;j;st
11 Axial clearance of driven gear 0.08 - 0.32 -

I I I
40-9
SWING CIRCLE
Pc300,300LC-5
PC300,3OOLC-5 MIGHT-Y
PC300HD-5
94.5 k 10.5 kgm
Section A - A
207FO5058
Unit: mm
No.
I Check item Criteria
I
Remedy
Standard size Clearance limit

1 Axial clearance of bearing Replace
0.5 - 1.6 3.2
Pc400,400Lc-5
PC400H D-5
Section B - B
f 10.5 kgm
m 94.5 k 10.5 kgm Section A - A 208FO5030
Unit: mm
Standard size Clearance limit

1 Axial clearance of bearing Replace
0.5 - 1.6 3.2
TRACK FRAME AND RECOIL SPRING
Pc300,300Lc-5
207FO5059
Unit: mm
Standard size Tolerance Repair limit
1 +2
Vertical width of idler guide Track frame 123 127
-1
I I
Idler support 120 Rebuild or

i-o.5 118
replace
+3
Track frame 266 271
I -1 I
2 Horizontal width of idler guide
Idler support 261 - 259
II /
- 1
Standard size Rapair limit

I
3 Free Installation Installation Free Installation

Recoil spring Replace
length length load length load
795 x 241 / 648 / 17,680 kg 1 - / ~m14;140i;

PC300HD-5
‘I
F207K5003
Unit: mm
Standard size Tolerance Repair limit
+2
1 Vertical width of idler guide Track frame 123 -1
127
Idler support 120 +0.5 118

I Rebuild or
-
replace
+3
Track frame 266 271
-1
I
Idler support 261 - 259
I
Standard size Repair limit

I
3 Recoil spring Replace

PC400HD-5
F207K5004
Unit: mm
-
1 Vertical width of idler guide
Idler support 145 +0.5 143

Rebuild or
replace
+3
Track frame 302 307
-1
! I
Idler support 297 295
-
3 Recoil sbring Replace
40-L3-2
IDLER
Pc300,300Lc-5
-7
r
_I-
i-
t-- ---1
L - - _-__I
207FO5060
40&l 4
Unit: mm
1 Outside diameter of protrusion

630 -
-
z Rep3e;;,dor
s -
2 Outside diameter of tread 590 578
Z!
3 Width of protrusion 101 -
4 Total width 190 -
5 Width of tread 44.5 50.5
Clearance Replace
limit bushing
Clearance between shaft and
6
bushing
80 1;:;;; f0.130 0.215 -

1.5
-0.010 0.455
Clearance between shaft and 80 -0.225 -0.085 0.030 - -

7 Replace
support -0.290 -0.195 0.205
Tolerance
Standard Standard Inte$r;nce
size interference
Interference between idler and
8 Shaft Hole
bushing
- Replace
bushing

I
9 Side clearance of idler (each)
0.68 - 1.22 2
!
40-15
PC300HD-5
Pc400,400Lc-5
PC400HD-5
-
I I
------
-77---
2
208FO5032
Unit: mm

1 Outside diameter of protrusion
704 -
Z Rebuild or
replace
E
0
3 Width of protrusion 105 -
4 Total width 204

I
Tolerance
Standard Standard ClelT;,;ce Replace
size clearance bushing
6 Clearance between shaft and
Shaft Hole
bushing
-
95 -0.120 +0.360 0.340 1.5
-0.207 +0.220 0.567
7 Clearance between shaft and -

95 -0.120 +0.035 0.120 _ Replace
support -0.207 0 0.242
Tolerance
Standard Standard Interffyce
size interference
8 Interference between idler and
Shaft Hole
bushing
102.6 +0.087 x;:;;; 0.064 - - Replace

+0.037 0.149 bushing
I
9 Side clearance of idler (each)
0.46 - 0.86 1.5
40-17
TRACK ROLLER
Pc300,300Lc-5
PC300,3OOLC-5 MIGHTY - -67+7kgm
I ! /
‘i _ i
_I_
_ -7
/
I- _.----_J-_~__._.._
l---u3 4
207FO5061
Unit: mm

Outside diameter of flange
1
(outside)
216
-
2 Outside diameter of tread

-
3 Width of tread
4 Width of flange 27 -
I
Standard
size 1-1 ::aa”r:;;de C’e,Tz;ce
5
bushing
I I I I
0.151 -
65 I:.;; ; “;:;;: 1.5
0.501
- qeplace
oushing
Interference between roller and

6
bushing

I
7 Side clearance of roller
0.41 - 0.95 1.5
I
-
PC300HD-5
Pc400,400LC-5
PC400HD-5 BN76 f 8.5 kgm
c___-____________
207FO5601 A Unit: mm

-
0”
E I
z 1
Outside diameter
(outside)
of flange
240
Rebuild or
2 Outside diameter of tread
replace
-

I
-
4 Width of flange 34.4 -

/
Standard
size /qY&_./ $aa::;: C’e,??:ce
5
bushing
-
80 -0.250 f0.176 0.279 1.5
-0.350 f0.029 0.524
I I I I Replace
bushing
Standard
size &~i.:;ned$e inte;w$ce
Interference between roller and
6
bushing

I
7 Side clearance of roller Replace
0.41 - 0.95 I 1.5
CARRIER ROLLER
Unit: mm

I

Outside diameter of flange
1
(outside)
200 -
Rebuild or
replace
-
3 Width of tread
-
EIeaarr;ce between shaft and

4
55 +0.021 -EL01 0.002 - _

+0.002 5 0.036
Replace
interference between roller -0.021 0.009 - _
5 and bushing 80 -:.0,3 -0.051 0.059
6 Side clearance of roller

0.01 - 0.24 -
40-20
TRACK SHOE
Pc300,300Lc-5
A.-- /
/ II - 1
4
I
/
207FO5063
40622
Unit: mm
::
5
0
1 Link pitch
203.45 207.45 Turn or
replace
2 Outside diameter of bushing 66.9 61.9
3 Height of grouser 31 19 &$;;c&

replace
4 Height of link 116 107 Rebuild or

replace
Tolerance
Standard Standard Inte$r;nce
size interference
5 F;fdete,‘kence of bushing
Shaft Hole
Replace
-
66.5 +0.464 10.074 0.350 0.100
+0.424 0 0.464
f0.062 0.273 -
6 Interference of regular pin and link 4~‘!$(~ff$$ 0 0.485 0.140
%E
- Replace
7 ~;rtr~n~nce of master pin 44.4 (Shaft) 1-0.230 +0.062 0.188 0.080 with
44.35 (Hole) +0.200 0 0.280
larger one
8 Protrusion of bushing 5.25 & 0.3
Initial tightening torque: 40 + 5 kgm

9 Tightening torque of shoe bolt Additional tightening angle: 120 + 10 Replace
40-23
PC300HD-5
Pc400,400Lc-5
PC400HD-5
‘9 208FO5033
40624
Unit: mm
-
z No
s Check item Criteria Remedy
z -
1 Link pitch
Turn or
216.25 220.25
replace
2 Outside diameter of bushing 74.3 69.3
3 Height of grouser 36 21 $$$I&

replace
Rebuild or
4 Height of link 129 119
replace
Tolerance
Standard Standard Intetfi;nct
size interference
Interference of bushing
5 Shaft Hole
and link
Replace
71 E:E +0.074
0 0.380
0.494- 0.100
6 17.0 (Shaft) +0.235 10.062 0.303 -

Interference of regular pin and link f0.085 0 0.515 0.190
6.72 (Hole:
Interference of master pin .6.8 (Shaft) +0.230 +0.062 Re$ace

7 +0.200 0 “%%O 0.130
and link 6.72 (Hole;
larger one
8 Protrusion of bushing 5.25 + 0.3
9 Tightening torque of shoe bolt Initial tightening torque: 40 + 4 kgm

Replace
Additional tightening angle: 120 I 10
40-i4-’
HYDRAULIC PUMP
-7kO.lkgm m 3.15&0.35kgm -2.5F0.5kgm 14i-Zkgm -0.9+0. lkgm
n /
w
i \ \
w 7tO.lkgm w 7kO.lkgm m 2.2550.25kgm
2OSFO5774
CHARGING PUMP AND RELIEF VALVE
m 6.75 k 0.75 kgm
5.5 + 0.5 kgm

i I J
Section A - A
207FO5064
Unit: mm
-
I

1 Top clearance of gear
0.090 - 0.130 0.145
2 Side clearance of gear 0.055 - 0.075 0.105
Clearance between gear shaft 0.045 - 0.076 0.13 Replace

3
and bushing
-
Standard value Repair limit
En ine oil
&S&D SAEl OW
4 Delivery
F T
30 kg/cm*
L
Standard
I
size
I
I
I
Repair
I
limit Replace
spring if
any dama-
:ry$t;gth Installed Installed Free
5 Charging relief valve spring load length l%lr!ied
length
I / I 8Zo%a-
tions are
30.3 x 13.0 26.1 10.4 kg - 9.4 kg found
40-26
CONTROL VALVE
w 0.9 \: 0.1 kgm
207FO5065
40-27
?
-5
Section B - B
5.5 f 0.5 kgm 5.5 * 0.5 kgm 3.0 + 0.5 kgm
Unit: mm
-
1
Standard size I Repair limit I
Main relief valve FrT$rtgth Installed Installed Free

pilot poppet spring length load length lr%!ed
1 30.7 x 9.6 1 26.8 1 33.1 kg 1 - 1 26.5 kg 1

-
Replace
Main relief valve - spring if
2 30.4 x 11.3 25.0 4.6 kg 3.7 kg
main valve spring any dama-
-
Jet sensor relief valve %ZoZna-
3 26.3 x 8.0 26.1 0.39 kg - 0.31 kg tions are
pilot poppet spring
- ~ found
4
I Jet sensor relief valve
main valve spring I
23.8 x 7.8 18.1 2.41 kg - 1.93 kg
I
5 S
(.&aight-trave
001 return s Pvalve)
ring 78.3 x 22.1 54.5 14.3 kg - 11.4 kg
6 Spool
(Arm throttle
return spring
valve) 53.8 x 26.5 52.5 10.6 kg - 8.5 kg
40-28
w 1.9 + 1.0 kgm 1
\ I 3
m 5.5 + 0.5 kgm

14.5 k 2.0 kgm
Section C - C Section D - D
207FO5067
Unit: mm

I
Main relief valve

1
pilot poppet spring
-
Replace
Main relief valve 3.7 kg spring if
2 4.6 kg -
main valve spring anv dama-
- I
i aes or
Jet sensor relief valve deforma-
3 26.3 x 8.0 26.1 0.39 kg - tions are
pilot poppet spring
- found
Jet sensor relief valve 18.1 1.93 kg
4 23.8 x 7.8 2.41 kg -
main valve spring I I
-
Spool return PC300 53.8 x 27.5 52.5 12.2 kg - 9.8 kg
5
y!GZfg priority
valve) PC400 53.8 x 26.5 52.5 10.6 kg - 8.5 kg
40-29
Qa 9.0 i 0.5 kgm w 14.5 f 2.0 kgm
\
m 202 + 2.0 kgm
20.0 + 2.0 kgm
20.0 * 2.0 kgm
Section F - F
1 m.20.0 k 2.0 kgm
Section E - E
m 15.5 k 2.5 kgm -15.5*2.5kgm
.5 kgm
Section G - G Section H - H
207FO5068
40-30
Unit: mm
-
-
I

I
I
I
I I I I
Installed Installed Free
1 Check valve spring
I Frexedeigth
. . length load length ‘nEAed
I
I , I I I
31.1 x 12.2 19.5 1.33 kg - 1.06 kg
2 Check valve spring 31.8 x 7.6 26.5 0.1 kg - 0.08 kg Replace

- spring if
any dama-
3 Spool return spring 30.7 x 32.5 26.5 26 kg - 20.8 kg
%?oKna-
tions are
4 Spool return spring 54 x 34.2 52 26 kg - 20.8 kg found
5 Spool return spring 154.8~34 1 53.5 1 12.7kg 1 - 1 10.2kg (
6 Spool return spring 121x16.9 1 21 1 Okg 1 20 / - 1
7 Check valve spring 155.9x30.21 29 / 0.8kg 1 - 10.64kg 1
40-3 1
w 19.0 i 1 .O kgm
I /d c&a
i m \5.0 rt 0.5 kgm
19.0 & 1 .O kgm 1 1 5.0 + 0.5 kgm 19.0 * 1.0 kgm
Section J - J Section K - K
m 7.0 f 1 .O kgm 2 3 w 15.5 it 2.5 kgm
\ \ I /
Section L - L 2QlFQ5Q69
40-32
Unit: mm
NC Check item Criteria

T
L
Remedy
Fry$;gth Installed Installed Free Installed

1 Spool return spring
length load length load
Replace
54.8 x 34 53.5 12.7 kg - 10.2 kg spring if
any dama-
-
- %SoKna-
2 Spool return spring 30.7 x 32.5 26.5 26 kg 20.8 kg tions are
found
3 Spool return spring 54 x 34.2 52 26 kg - 20.8 kg
4 Check valve spring 55.9 x 30.2 29 0.8 kg - 0.64 kg
40-33
27.4 f 6.8
(2.8 I 0.7 Qa 8.8 * 1.0 Nm
(0.9 + 0.1 kgm)
Qa 98 i- 9.8 Nm
(10.0 +_ 1.0 kgm)
205FO5.359
, 186.3 + 9.8 Nm
, (19 $1.0 kgm)
142.2 + 19.
(14.5 i: 2.0
53.9 + 4.9 Nm 29.4 i 4.9 Nm Section B - B

53.9 + 4.9 Nm
(5.5 k 0.5 kgm) (5.5 + 0.5 kgm) (3.0 + 0.5 kgm)
Unit: mm

f
Main relief valve Free length Installed Installed Installed

1 Free length
pilot poppet spring x O.D. length load load
325 N 260 N
30.7 x 9.6 26.8
(33.1 kg) - (26.5 kg)
-
Replace
Main relief valve 45 N 36 N
2 30.4 x 11.3 25.0 spring if
main valve spring (4.6 kg) - (3.7 kg) any damages
or deforma-
Jet sensor relief valve 3.8 N 3.0 N
3 26.3 x 8.0 26.1 tions are
pilot poppet spring (0.39 kg) - (0.31 kg)
found
Jet sensor relief valve 23.6 N 18.9 N

4 23.8 x 7.8 18.1
main valve spring (2.41 kg) - (1.93 kg)
Spool return spring 140 N 112 N

5 78.3 x 22.1 54.5
(Straight-travel valve) (14.3 kg) - (11.4 kg)
Spool return spring 104 N 83 N

6 53.8 x 26.5 52.5
(Arm throttle valve) (10.6 kg) - (8.5 kg)
40-g3-2
w 186.3 + 9.8 Nm
(19 + 1.0 kgm)
\
m 142.2 f 19.
(14.5 + 2.0
w 142.2? 19.6 Nm
53.9 k 4.9 53.9 i 4.9 Nm (14.5 i 2.0 kgm)
(5.5 k 0.5 kgm)
Section D - D
Section C - C
6
205FO586 I
s:
Unit: mm
I I I
Standard size I Repair limit I
Main relief valve Free length Installed Installed Installed

1 Free length
pilot poppet spring x O.D. length load load
I / I I I
I I
30.7 x 9.6 26.8 325 N 260 N
(33.1 kg) - (26.5 kg) Replace
spring if
2 Main relief valve 30.4 x 11.3 25.0 45 N 36 N any damages
main valve spring (4.6 kg) - (3.7 kg) or deforma-
tions are
3 Jet sensor relief valve 26.3 x 8.0 3.8 N 3.0 N found
pilot poppet spring 26.1
(0.39 kg) - (0.31 kg)
i
4 Jet sensor relief valve 23.6 N 18.9 N
main valve spring 23.8 x 7.8 18.1
(2.41 kg) I - (1.93 ka)
6 Spool return spring 104N 8.3 N
53.8 x 26.5 52.5
(Swing priority valve) (10.6 kg) - (8.5 kg)
40-23-3
m 88.2 + 4.9 Nm w 142.2 i 19.6 Nm
(9.0 k 0.5 kgm)
m 196.1 + 19.6 Nm
(2O;O + 2.0 kgm)
,2
m
.34.3 + 4.9 Nm
(3.5 + 0.5 kgm)
sa
‘196.1 + 19.6 Nm
(20.0 & 2.0 kgm)
m
\
‘196.1 I 19.6 Nm
(20.0 22.0 kgm)
1 w 196.1 & 19.6 Nm Section F- F

(20.0 I 2.0 kgm)
Section E- E
m w w
152.0 + 24.5 Nm 152.0 + 24.5 Nm 186.3 k 9.8 Nm 3
(15.5 + 2.5 kgm) (15.5 + 2.5 kgm) (19.0 k~1.0 kgm) \
: 24.5 Nm
2.5 kgm)
3’ -5
‘6 m 186/.3 i 9.8 Nm
Section G - G (19.0 i 1.0 kgm)
Section H - H
207FO5068
40-$3-5
Unit: mm
-
NC). Check item Criteria
1 Remedy
T
-
Free length Installed Installed Installed

1 Check valve spring Free length
x O.D. length load load
19.5 13.0 N - 10.4 N

31.1 x 12.2
(1.33 kg) (1.06 kg)
26.5 0.98 N - 0.78 N

2 Check valve spring 31.8 x 7.6
3 Spool return spring 30.7 x 32.5

4 26.5
(0.1 kg)
265 N -
(0.08 kg)
204 N
Replace
spring if
any damages
(26 kg) (20.8 kg) or deforma-
tions are
52 255 N - 204 N found
4 Spool return spring 54 x 34.2
(26 kg) (20.8 kg)
-
53.5 125 N - 100 N
5 Spool return spring 54.8 x 34
(12.7 kg) (10.2 kg)
-
6 Spool return spring 21 x 16.9 20 -

21 (&
29 7.8 N - 6.3 N
7 Check valve spring 55.9 x 30.2
(0.8 kg) (0.64 kg)
w 186.3 rt 9.8 Nm
4 (19.0 + 1 .O kgm)
w’ I w /
1 m
\
49.0 + 4.9 Nm
\
1
186.3 + 9.8 Nm 1 186.3 + 9.8 Nm
(19.0 + 1.0 kgm) (5.0 + 0.5 kgm)
(19.0 + 1 .O kgm)
Section J - J Section K - K
m 68.6+9.8Nm 2 3 w 152.0 + 24.5 Nm

(7.0 t 1.0 \kgm) \ , (15.5 t 2.5 kgm)
Section L - L
205FO5662
Unit: mm
Free length Installed Installed Installed

1 Spool return spring Free length
x O.D. length load load
Replace
125 N 100 N
54.8 x 34 53.5 spring if
(12.7 kg) - (10.2 kg)
any damages
or deforma-
255 N 204 N
2 Spool return spring 30.7 x 32.5 26.5 tions are
(26 kg) - (20.8 kg)
found
255 N 204 N
3 Spool return spring 54 x 34.2 52
(26 kg) - (20.8 kg)
7.8 N 6.3 N
4 Check valve spring 55.9 x 30.2 29
(0.8 kg) - (0.64 kg)
40-83-8
TRAVEL SHUTTLE VALVE
m 2.25 F 0.25 kgm

/
m 2.;5 + 0.25 kgm m 2.25 + 0.25 kgm
207FO5070
Unit: mm
Replace
spring if
any dama-
8ZoKa-
;t;ida re
34.0 4.6 kg - 3.7 kg
40-34
SWING MOTOR
m 56.; f 6.0 kgm

1
Section I3 - B
207FO5071
Section A - A
Unit: mm
Standard size Repair limit Replace

spring if
any dama-
Fryz;eth Installed Free
1 Check valve spring length ‘“ZZed
length ‘“EZed
%%%a-
tions are
66.5 x 25.6 45 0.71 kg - 0.57 kg found
40-35
TRAVEL MOTOR
Pc300,300Lc-5
.5 km
A
---I
2.4 i: 0.4 kgm
w 37.0 L! 4.0 kgm \
-
4 m b.9 k 0.1 kgm
Section B - B
Unit: mm

IFrexec%gth
. .
Installed
length
Installed
load
Free
length
Installed
load I
42.5 x 40 41 37.8 kg 26.5 kg Replace

spring if
Check valve spring 52.7 x 22.4 37 any dama-
2 0.5 kg 0.4 kg
%ZoEna-
Regulator piston spriring 55 x 9 50 10 8.0 $O;ida re
3 kg kg
-
4 Pilot piston spring 82.7 x 19.4 60.5 63.7 kg - 51 .O kg

I I
5 Check valve spring 9.4 x 4.6 7.75 0.05 kg - 0.04 kg

PCBOOHD-5
Pc400,400Lc-5
PC400HD-5
76 i 8.5 kgm
2.4 i 0.4 kgm

A
1 2 m 42.8 k 4.7 kgm
5.4 * 0.6 kgm
Qz??E 26.0 i 3.0 kgm m 66.5 * 7.5 kgm

.O kgm
Section A - A 0.9 + 0.1 kgm Section B - B

208FO5034
Unit: mm
-
No Check item Criteria
-
Standard size
2 Check valve spring
3 Regulator piston spriring
4 Pilot piston spring
40-37
8
PPC VALVE
FOR WORK EQUIPMENT AND SWING
m 11.5 + 1.5 kgm
m 11.5 f- 1.0 kgm
w 3.5 k 0.5 kgm
205FO5 198
Unit: mm
-
Pilot spring
Replace
12.6 x 3.85 11.9 0.018 kg - 0.16 kg spring if
any dama-
ges or
31.4 x 7.4 29.4 1.7 kg 1.4 kg deforma-
2 Metering spring tions are
- found
3 Centering spring (For P,, P,) 47.4 x 16.8 36.5 2.3 kg - 1.8 kg
4 Centering spring (For P,, P2) 45.2 x 16.8 36.5 3.8 kg - 3.0 kg
I
-
FOR TRAVEL
-1.5-3.5 kgm
m 3.5 i 0.5 kgm
Unit: mm
-
Nc Check item Criteria Remedy
-
Replace
Fry$;gth Installed Free spring if
1 Metering spring length ‘“EZzled length ‘nE%ed any dama-
ges or
deforma-
31.4 x 7.4 29.4 1.7 kg - 1.4 kg tions are
found
Centering spring 47.4 x 16.8 36.5 2.3 kg - 1.8 kg

PPC SHUTTLE VALVE
FOR BOOM - BUCKET AND TRAVEL
m 3.5 k 0.5 kgm

\
w 3; + 0.5 kgm
207FO5073
FOR ARM AND SWING
m 7.0 * 1 :O kgm
I
m 3.5 + 0.5 kgm

207FO5074
40-40
BOOM HOLDING VALVE
m 4.0 + 0.5 kgm /
m 11.25 k 1.25 kgm
/ Section A - A
m 19.0 f 1.0 kgm
207FO5075
Unit: mm
Replace
Fryt;gth Installed Installed Free Installed spring if
1 Pilot valve spring length load length load any dama-
%SoFLa-
26.0 x 11.5 24.5 0.64 kg - 0.51 kg tions are
- found
40-41
HYDRAULIC CYLINDER
Pc300,300Lc-5
PC300HD-5
* The drawing shows boom cylinder
w Boom: 38.0 f 5.5 kgm m Boom: 11.5 i 1.0 kgm

Arm: 54.0 f 8.0 kgm Arm: 18.0 it 2.0 kgm
Bucket: 38.0 i. 5.5 kgm Bucket: 11.5 f 1 .O kgm
207FO5076
0”
Unit: mm
NC). Check item Criteria Remedy

l-- E
I
Tolerance
Cylinder ~ Standard Standard Cle,yrms;ce
name size clearance
Shaft Hole
/Clearance between
1 Boom 100 -0.036 f0.257 0.083 - Replace
-0.090 +0.047 0.347 0.447
Ipiston rod and bushing bushing
Arm
Bucket
110
100
I -0.036
-0.090
-0.036
-0.090
+0.261
f0.047
+0.257
+0.047
0.083 -
0.351
0.083 -
0.347
0.451
0.447
Boom 100 -0.036 +0.457 0.406 -

-0.071 +0.370 0.528 1.0
IClearance between
2 100 -0.036 +0.457 0.406 -
Ioiston rod support and Arm -0.090 +0.370 0.547 1.0
wshing
Bucket 90 I;+$; +0.370

+0.457 0.406
0.547- 1.0
- knPp$
bushing
Boom 90 z;.o”;; +0.370
+0.457 0.406
0.547- 1.0
IClearance between
3 I:ylinder bottom support Arm 100 z;:;$j +0.370
+0.457 0.406
0.547- 1.0
,snd bushing
Bucket -0.036 f0.457 0.406 -

90 1.0
-0.090 +0.370 0.547
-L
Pc400,400Lc-5
PC400HD-5
-k The drawing shows boom cylinder
m Boom: 54.0 + 8.0 kgm

Arm: 91 .O + 14.0 kgm
Bucket: 54.0 & 8.0 kgm w Boom, Arm, Bucket: 18.0 f 2.0 kgm
\ I
208FO5035
::
2s Unit: mm
z -
-
No. Check item T Criteria
T Remedy
Tolerance
Cylinder Standard _ Standard
name size clearance
Shaft Hole
Clearance between 110 -0.036 +0.257 0.083 - Replace

1 Boom 0.451
piston rod and bushing -0.090 f0.047 0.351 bushing
120 -0.036 f0.263 0.083 -

Arm 0.453
-0.090 f0.048 0.353
-0.036 f0.261 0.083 -

Bucket 110 0.451
-0.090 f0.047 0.351
c
110 -0.036 f0.457 0.406 -
Boom 1.0
-0.071 f0.370 0.528
Clearance between
110 -0.036 to.457 0.406 -
2 piston rod support and Arm 1.0
-0.090 Jro.370 0.547
bushing
100 -0.036 1-0.457 0.406 -

Bucket 1.0
-0.090 f0.370 0.547 Replace
pin and
bushing
Boom 1.0
L
Clearance between
3 cylinder bottom support Arm 1.0
and bushing
-0.036 0.406 -
Bucket 100 1.0
-0.090 :%I: 0.547
m Boom : 529 + 78 Nm (54.0 + 8.0 kgm)

Arm : 892 & 137 Nm (91.0 k 14.0 kgm)
Bucket : 372 I 54 Nm (38.0 i 5.5 kgm) m 176120 Nm
Bottom dump : 372 + 54 Nm (38.0 + 5.5 kgm) (18.0 rt 2.0 kgm)
205FO5664
Unit: mm
-
NC).
- -II
T Check item Criteria Remedy
Tolerance
Cylinder Standard Standard
name size clearance
Shaft Hole
-
Boom 110 -0.036 $0.261 0.083 0.451
-0.090 +0.047 0.351
Clearance
1 between piston Replace
-
Arm 120 -0.036 +0.263 0.084 0.453 bushing
rod and bushing -0.090 f0.048 0.353
I I I I !
-
Bucket 95 -0.036 +0.222 0.083 0.412
-0.090 +0.047 0.312
Bottom -0.036 f0.257 0.084 -

dump 90 -0.090 f0.048 0.347 0.447
-
-
Boom 100 -0.036 f0.457 0.406 1.0
-0.090 f0.370 0.547
-
Clearance -0.090 f0.370 0.547 1.0
between piston Arm 110 -0.036 f0.457 0.406 I
I / I I
2 1
rod support
-
snd bushing
Bucket 100 -0.090
-0.036 +0.370
+0.457 0.547
0.406 1.0 I
Bottom -0.030 +0.457 0.400 -
dump 80 -0.076 +0.370 0.533 1.0
Replace
-
oin and
Boom 100 -0.036 f0.457 0.406 - 1.0 bushing
-0.090 f0.370 0.547
I I I I I
I
-
Zlearance
Ietween cylinder Arm 110 -0.090
-0.036 +0.370
+0.457 0.547
0.406 1.0 I
3
)ottom support
and bushing -
Bucket 80 -0.030 +0.457 0.400 1.0
-0.076 +0.370 0.533
Bottom -0.030 +0.457 0.400 -

dump 80 -0.076 +0.370 0.533 1.0
-
40-$3-l
Pc300,300Lc-5
PC300HD-5
207FO5077
Section D - D
Section H - H
I I/I/ I
Section A - A
Section E - E
Section 6 - B
Section F - F
Section C - C Section K - K
Section G - G
207F05078A
4oi144
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between bushing and size clearance limit
1 connecting pin of revolving Shaft Hole
frame and boom
-0.036 f0.351 0.306 -

110 1.0
-0.090 to.270 0.441
2
Clearance
connecting
between bushing and
pin of boom and arm
110
-8fD 0.311 -
0.444
1.0
Replace
Clearance between bushing and -0.036 f0.338 0.308 -
3 90 1.0
connecting pin of arm and link -0.090 1-0.272 0.428
Clearance between bushing and -0.036 1-0.337

4 90 1.0
connecting pin of arm and bucket -0.090 +0.271
Clearance between bushing and -0.036 1-0.346 0.311 -

5 90 1.0
connecting pin of link and bucket -0.090 +0.275 0.436
-0.036 +0.346 0.311 -

6 90 1.0
-0.090 +0.275 0.436
- - - -
E
7 Bucket clearance (a) 0.5 - 1.0
- Shim
adjust
8 Bucket clearance (b) 2.0
40-45
0
Pc400,400Lc-5
Pc400,400Lc-5 MIGHTY
PC400HD-5
207FO5077
Section D - D
Section A - A
Section E - E
Section B - B
Section F - F
Section C - C Section K - K
Section G - G
207F05078A
40646
Unit: mm
-
NC Check item Criteria Remedy
Standard Standard
Clearance between bushing and size h clearance
1 connecting pin of revolving
frame and boom
120 -0.036 +0.351 0.306 -

1.0
-0.090 +0.270 0.441
-
Clearance between bushing and 120 -0.036 +0.316 0.255 -
2
connecting pin of boom and arm 1.0
-0.090 +0.219 0.406
Replace
100 -0.036 -to.379
3 1.0
-0.090 10.259 “2E6~
-
Clearance between bushing and 100 -0.036 $0.340 0.303 -
4
connecting pin of arm and bucket 1.0
-0.090 10.267 0.430

5 1.0
connecting pin of link and bucket -0.090 +0.259 0.419

6 1.0
connecting pin of link and link -0.090 +0.259 0.419
7 Bucket clearance (a) 0.5 - 1.0

Shim
Adjust
8 Bucket clearance (b) 2.0
205FO5865
Section A - A Section B - B Section C - C
Section E- E Section F- F
Section D - D
Section I- I
Section G - G Section H - H
Section J - J Section K - K Section L - L Section M - M

205FO5866
40-48
0
Unit: mm
Tolerance
Standard _ Standard Clearance
Clearance between
size clearance limit
bushing and connecting
1 Shaft Hole
pin of revolving frame
and boom
-0.036 f0.348 0.303 -
120 1.0
-0.090 f0.267 0.438
I
Clearance between
-0.036 f0.356
2 bushing and connecting 120 1.0
-0.090 f0.278
oin of boom and arm
/ I I 1 I I I
Clearance between
-
3 bushing and connecting 100 -0.036 f0.352 0.319 1.0
pin of arm and link -0.090 f0.283 0.442
Replace
Clearance between
4 bushing and connecting
pin of arm and bucket
Clearance between
-
5 bushing and connecting 100 -0.036 +0.346 0.314 1.0
pin of link and bucket -0.090 1-0.278 0.436
4
Clearance between
6 bushing and connecting
pin of link and link
Clearance between
-
7 bushing and connecting 95 -0.036 +0.344 0.308 1.0
-0.090 f0.272 0.434
Din of bucket hinae
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

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Time 01 Time of Time of Time of Time of

30-70 30-87 0 30-113-2 40- 5 40-36

30-71 30-88 0 30-114 40- 6 40-37

30-72 30-89 0 30-115 40- 7 40-38

30-73 30-90 0 30-115-I 40- 8 40-39

30-74 30-91 0 30-115-2 40- 9 40-40

30-75 30-92 0 30-115-3 40-10 40-41

30-76 30-93 0 30-115-4 40-11 40-42

30-77 30-94 0 30-115-5 40-12 40-43

30-78 30-95 0 30-115-6 40-13 0 40-43-I

30-79 30-96 0 30-116 40-13-I . 40-44

30-80 30-97 30-117 40-13-2 40-45

30-81 30-98 30-118 40-14 40-46

30-82 30-99 30-119 40-15 40-47

30-83 30-100 0 30-119-I 40-16 0 40-48

30-84 30-101 0 30-119-2 40-17 0 40-49

30-85 30-102 30-120 40-18

30-85-I 30-103 30-121 40-19

30-85-2 30-104 30-122 40-20

30-85-3 30-105 30-123 40-22

30-85-4 30-105-I 30-124 40-23

30-85-5 30-105-2 30-125 40-24

30-85-6 0 30-105-3 30-126 40-24-I

30-85-7 0 30-105-4 30-127 40-25

30-85-8 . 30-106 30-128 40-26

30-85-g 30-107 30-129 40-27

30-85-10 . 30-107-I 30-130 40-28

30-85-11 . 30-107-2 30-131 40-29

30-85-12 0 30-107-3 30-132 40-30

30-85-13 0 30-107-4 30-133 40-31

30-85-14 0 30-107-5 30-134 40-32

30-85-15 0 30-107-6 30-135 40-33

30-85-16 0 30-107-7 30-136 0 40-33-I

30-85-17 0 30-107-8 30-137 0 40-33-2

30-85-18 30-108 30-138 0 40-33-3

30-85-19 30-109 30-139 0 40-33-5

30-85-20 30-110 0 40-33-6

30-85-21 30-111 40- 1 0 40-33-7

30-85-22 30-112 40- 2 0 30-33-8

30-85-23 30-113 40- 3 40-34

30-86 0 30-113-I 40. 4 40-35

2.When carrying out any operation, always PREPARATIONS FOR WORK

work. 9 When disassembling or assembling, sup-

16. When removing components, be careful not

17. When removing piping, stop the fuel or oil

18.As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

So that the shop manual can be of ample

2. Following examples shows how to read the A Safety necessary

12-410 Places that require special

Slinging near the edge of the hook may

1. If a part cannot be smoothly removed from

4) Do not sling a heavy load with ropes

The allowable load value is estimated to

2) Sling wire ropes from the middle portion

The following charts give the standard tightening

of bolts and nuts. Exceptions are given in

Thread diameter Width

6 10 1.35rto.15 13.22 1.4

27 41 135+15 1320? 140