Komatsu Pc300-7 Pc300lc-7 Pc350-7 Pc350lc-7 Shop Manual Sebm025810

SEBM025810
MACHINE MODEL SERIAL NUMBER

PC300-7 40001 and up
PC300LC-7 40001 and up
PC350-7 20001 and up
PC350LC-7 20001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• PC300, 300LC, PC350, 350LC-7 mount the SAA6D114E engine.

For details of the engine, see the 114 Series Engine Shop Manual.
© 2007
All Rights Reserved
Printed in Japan 06-07 (01) 00-1
(10)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ...................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 PC300/350(LC)-7
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.

Time of Time of Time of Time of Time of
Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (10) 01-1 10-16 (6) 10-46 (9) 10-78
00-2 (2) 01-2 10-17 (6) 10-47 10-79
q 00-2-1 (10) 01-3 10-18 10-48 (8) 10-80
q 00-2-2 (10) 01-4 10-19 (6) 10-50 (8) 10-81
q 00-2-3 (10) 01-5 10-20 (6) 10-51 (8) 10-82
q 00-2-4 (10) 01-6 10-21 (6) 10-52 10-83
q 00-2-5 (10) 01-7 10-22 10-53 10-84
00-3 01-8 10-23 10-54 10-85
00-4 01-9 10-24 10-55 10-86 (8)
00-5 01-10 10-26 10-56 10-87
00-6 01-11 10-27 10-57 10-88
00-7 q 01-12 (10) 10-28 10-58 10-89
00-8 10-29 10-59 10-90
00-9 10-30 10-60 10-91
00-10 10-1 (6) 10-31 10-62 10-92
00-11 10-2 10-32 10-63 10-94
00-12 10-3 10-33 (8) 10-64 10-95
00-13 10-4 10-34 10-65 10-96
00-14 10-6 10-35 10-66 10-97
00-15 10-7 10-36 10-67 10-98 (8)
00-16 10-7-1 (6) 10-37 (8) 10-68 10-99
00-17 10-7-2 (6) 10-38 (8) 10-69 10-100
00-18 10-8 10-39 10-70 10-101
00-19 10-9 10-40 (9) 10-71 10-102
00-20 10-10 10-41 (8) 10-72 10-103
00-21 10-12 10-42 (8) 10-74 10-104
00-22 10-13 10-43 10-75 10-105
10-14 (6) 10-44 10-76 10-106
10-15 (6) 10-45 (9) 10-77 10-107
PC300/350(LC)-7 00-2-1
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10-108 10-154 10-196 (4) 20-121 (8) 20-163 (7)
10-109 10-155 10-197 (4) 20-122 (8) 20-163-1 (7)
10-110 10-156 10-198 (4) 20-123 (8) 20-164 (1)
10-111 10-157 10-199 (4) 20-124 (8) 20-165 (5)
10-112 10-158 q 10-200 (10) 20-125 (9) 20-166 (5)
10-113 10-159 10-201 (4) 20-126 (8) 20-167 (5)
10-114 10-160 10-202 (4) 20-127 (8) 20-168 (5)
10-115 10-161 20-128 (9) 20-169 (5)
10-116 10-162 20-129 (9) 20-170 (5)
10-117 10-163 20-1 (1) 20-130 (8) 20-171 (5)
10-118 10-164 20-2 (9) 20-131 (8) 20-172 (5)
10-120 10-165 20-3 (1) 20-132 (9) 20-173 (5)
10-121 10-166 20-4 (1) 20-133 (8) 20-174 (5)
10-122 10-167 20-5 (1) 20-134 (1) 20-175 (5)
10-123 10-168 20-6 (1) 20-135 (9) 20-176 (5)
10-124 10-169 (8) 20-7 (1) 20-136 (9) 20-177 (5)
10-125 10-170 20-8 (1) 20-137 (8) 20-177-1 (5)
10-126 10-171 20-9 (1) 20-138 (8) 20-177-2 (5)
10-127 10-172 20-10 (1) 20-139 (8) 20-177-3 (5)
10-128 10-173 20-140 (8) 20-178 (7)
10-129 10-174 20-101 (8) 20-141 (1) 20-178-1 (7)
10-130 q 10-175 (10) 20-101-1 (8) 20-142 (1) 20-179 (1)
10-132 q 10-176 (10) 20-101-2 (8) 20-143 (1) 20-180 (1)
10-133 q 10-177 (10) 20-102 (9) 20-144 (1) 20-181 (1)
10-134 q 10-178 (10) 20-103 (8) 20-145 (1) 20-182 (1)
10-135 q 10-179 (10) 20-104 (8) 20-146 (1)
10-136 q 10-180 (10) 20-105 (9) 20-147 (7) 20-201 (1)
q 10-137 (10) 10-181 20-106 (9) 20-148 (1) 20-202 (1)
10-138 10-182 20-107 (7) 20-149 (1) 20-203 (1)
10-139 10-183 20-108 (8) 20-150 (1) 20-204 (1)
10-140 10-184 20-109 (8) 20-151 (1) 20-205 (1)
10-141 10-185 20-110 (8) 20-152 (1) 20-206 (1)
10-142 10-186 20-111 (1) 20-153 (1) 20-207 (3)
10-143 10-187 20-112 (8) 20-154 (1) 20-208 (1)
10-144 10-188 20-113 (9) 20-155 (1) 20-209 (1)
10-146 10-189 20-114 (8) 20-156 (1) 20-210 (1)
10-147 10-190 (4) 20-115 (8) 20-157 (1) 20-211 (1)
10-149 10-191 (4) 20-116 (8) 20-158 (1) 20-212 (1)
q 10-150 (10) 10-192 (6) 20-117 (8) 20-159 (1) 20-213 (7)
10-151 10-193 (4) 20-118 (8) 20-160 (1) 20-214 (7)
10-152 10-194 (4) 20-119 (7) 20-161 (1) 20-215 (7)
10-153 10-195 (4) 20-120 (7) 20-162 (1) 20-216 (7)
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20-218 (7) 20-246 (1) 20-319-1 (7) 20-342 (7) 20-383 (7)
20-219 (7) 20-247 (1) 20-319-2 (7) 20-343 (7) 20-384 (7)
20-220 (1) 20-248 (1) 20-320 (7) 20-344 (7) 20-385 (7)
20-221 (1) 20-249 (1) 20-321 (1) 20-345 (7) 20-386 (7)
20-222 (1) 20-250 (1) 20-321-1 (7) 20-346 (7)
20-222-1 (7) 20-251 (1) 20-321-2 (7) 20-347 (7) 20-501 (7)
20-222-2 (7) 20-252 (1) 20-322 (7) 20-348 (7) 20-502 (1)
20-222-3 (7) 20-253 (7) 20-323 (1) 20-349 (1) 20-503 (1)
20-222-4 (7) 20-254 (1) 20-323-1 (7) 20-350 (7) 20-504 (1)
20-223 (7) 20-255 (1) 20-323-2 (7) 20-351 (7) 20-505 (7)
20-224 (7) 20-256 (7) 20-324 (7) 20-352 (7) 20-505-1 (7)
20-225 (7) 20-257 (1) 20-325 (7) 20-353 (1) 20-506 (1)
20-226 (1) 20-258 (7) 20-325-1 (7) 20-354 (7) 20-507 (7)
20-227 (7) 20-260 (7) 20-325-2 (7) 20-355 (1) 20-507-1 (7)
20-228 (1) 20-261 (7) 20-326 (7) 20-356 (7) 20-508 (7)
20-229-1 (7) 20-327 (1) 20-357 (1) 20-510 (1)
20-229-2 (7) 20-301 (1) 20-327-1 (7) 20-358 (7) 20-511 (7)
20-229-3 (7) 20-302 (1) 20-327-2 (7) 20-359 (7) 20-511-1 (7)
20-229-4 (7) 20-303-1 (7) 20-328 (7) 20-360 (1) 20-512 (1)
20-229-5 (7) 20-303-2 (7) 20-329 (1) 20-362 (1) 20-513 (7)
20-230 (7) 20-303-3 (7) 20-329-1 (7) 20-363 (7) 20-513-1 (7)
20-231 (1) 20-303-4 (7) 20-329-2 (7) 20-363-1 (7) 20-514 (7)
20-231-1 (7) 20-303-5 (7) 20-330 (7) 20-364 (7) 20-515 (7)
20-231-2 (7) 20-303-6 (7) 20-331 (1) 20-365 (1) 20-516 (1)
20-232 (7) 20-304 (1) 20-331-1 (7) 20-366 (7) 20-517 (1)
20-233 (1) 20-305 (1) 20-331-2 (7) 20-367 (1) 20-518 (7)
20-233-1 (7) 20-306 (7) 20-332 (7) 20-368 (1) 20-519 (1)
20-233-2 (7) 20-307 (7) 20-333 (1) 20-369 (7) 20-520 (7)
20-234 (7) 20-307-1 (7) 20-333-1 (7) 20-369-1 (7) 20-521-1 (7)
20-235 (7) 20-307-2 (7) 20-333-2 (7) 20-370 (7) 20-521-2 (7)
20-235-1 (7) 20-308 (1) 20-334 (7) 20-371 (7) 20-522 (1)
20-235-2 (7) 20-309 (7) 20-335 (7) 20-372 (1) 20-523 (1)
20-236 (1) 20-310 (1) 20-335-1 (7) 20-374 (1) 20-524 (1)
20-237 (1) 20-311 (7) 20-335-2 (7) 20-375 (1) 20-525 (1)
20-238 (1) 20-312 (1) 20-336 (7) 20-376 (1) 20-526 (1)
20-239 (7) 20-313 (1) 20-337 (1) 20-377 (1) 20-527 (7)
20-240 (1) 20-314 (1) 20-337-1 (7) 20-378 (7) 20-528 (1)
20-241 (1) 20-315 (7) 20-337-2 (7) 20-379 (7) 20-530 (1)
20-242 (1) 20-316 (1) 20-338 (7) 20-380 (7) 20-531 (1)
20-243 (1) 20-317 (7) 20-339 (7) 20-381 (7) 20-532 (1)
20-244 (1) 20-318 (7) 20-340 (1) 20-381-1 (7) 20-533 (7)
20-245 (8) 20-319 (1) 20-341 (1) 20-382 (7) 20-534 (7)
PC300/350(LC)-7 00-2-3
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20-535 (7) 20-615 (1) 30-6-1 (8) 30-38 (8) 30-72-2 (8)
20-536 (7) 20-616 (1) 30-6-2 (8) 30-40 (8) 30-73 (9)
20-537 (7) 20-617 (1) 30-6-3 (8) 30-41 (9) 30-74 (2)
20-538 (7) 20-618 (1) 30-6-4 (8) 30-42 (9) 30-75 (9)
20-540 (7) 20-619 (1) 30-6-5 (8) 30-43 (8) 30-76 (9)
20-541 (1) 20-620 (1) 30-6-6 (8) 30-44 (9) 30-77 (8)
20-542 (7) 20-621 (7) 30-7 (8) 30-45 (8) 30-77-1 (8)
20-543 (7) 20-622 (7) 30-8 (8) 30-46 (9) 30-78 (8)
20-544 (7) 20-623 (1) 30-9 (8) 30-47 (9) 30-79 (8)
20-545 (1) 30-10 (8) 30-48 (9) 30-80 (9)
20-546 (7) 20-701 (7) 30-11 (8) 30-48-1 (9) 30-81 (8)
20-547 (1) 20-702 (9) 30-12 (8) 30-48-2 (8) 30-82 (9)
20-548 (7) 20-703 (7) 30-12-1 (8) 30-48-3 (9) 30-83 (9)
20-549 (7) 20-704 (7) 30-12-2 (8) 30-48-4 (9) 30-84 (9)
20-550 (7) 20-705 (7) 30-12-3 (8) 30-48-5 (9) 30-85 (2)
20-551 (7) 20-706 (7) 30-12-4 (8) 30-48-6 (9) 30-86 (2)
20-552 (7) 20-707 (7) 30-12-5 (8) 30-48-7 (8) 30-87 (8)
20-553 (7) 20-708 (7) 30-13 (2) 30-49 (8) 30-88 (8)
20-554 (7) 20-709 (7) 30-14 (2) 30-50 (8) 30-89 (8)
20-555 (7) 20-710 (7) 30-15 (2) 30-51 (2) 30-90 (8)
20-556 (7) 20-711 (7) 30-16 (2) 30-52 (2) 30-90-1 (8)
20-557 (7) 20-712 (7) 30-17 (2) 30-53 (2) 30-90-2 (9)
20-558 (7) 20-713 (7) 30-18 (2) 30-54 (2) 30-91 (8)
20-559 (7) 20-714 (7) 30-19 (2) 30-55 (2) 30-92 (8)
20-560 (7) 20-715 (7) 30-20 (2) 30-56 (2) 30-93 (8)
20-561 (7) 20-716 (7) 30-21 (2) 30-57 (8) 30-94 (8)
20-562 (7) 20-717 (7) 30-22 (2) 30-58 (8) 30-95 (8)
20-718 (7) 30-23 (2) 30-59 (2) 30-96 (8)
20-601 (1) 20-719 (7) 30-24 (2) 30-60 (2) 30-97 (8)
20-602 (1) 20-720 (7) 30-25 (2) 30-61 (2) 30-98 (8)
20-603 (1) 20-721 (7) 30-26 (2) 30-62 (2) 30-99 (8)
20-604 (1) 20-722 (7) 30-27 (2) 30-63 (9) 30-100 (8)
20-605 (1) 20-723 (7) 30-28 (2) 30-64 (9) 30-101 (8)
20-606 (1) 20-724 (7) 30-29 (8) 30-65 (2) 30-102 (8)
20-607 (1) 30-30 (8) 30-66 (2) 30-103 (8)
20-608 (1) 30-31 (2) 30-67 (9) 30-104 (8)
20-609 (1) 30-1 (8) 30-32 (2) 30-68 (2) 30-105 (8)
20-610 (1) 30-2 (8) 30-33 (2) 30-69 (2) 30-106 (9)
20-611 (1) 30-3 (2) 30-34 (2) 30-70 (2) 30-107 (8)
20-612 (1) 30-4 (2) 30-35 (2) 30-71 (8) 30-108 (8)
20-613 (1) 30-5 (3) 30-36 (2) 30-72 (8) 30-109 (8)
20-614 (1) 30-6 (2) 30-37 (2) 30-72-1 (8) 30-110 (8)
00-2-4 PC300/350(LC)-7
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30-111 (8)
30-112 (8)
30-113 (8)
30-114 (8)
90-1 (6)
90-3
90-5 (6)
90-7 (6)
90-9 (6)
90-11 (6)
90-13 (6)
90-15 (6)
90-17 (6)
90-19 (6)
PC300/350(LC)-7 00-2-5
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Safety Safety notice
Safety
Safety notice
Important safety notice

Proper service and repair is extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
Safety Safety notice
Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
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 onto 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 minimum of gas-
oline when washing electrical parts.
00-4
Foreword General
Foreword
General
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 judge-
ments. 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 the following chapters; these chapters are fur-
ther divided into the each main group of components.
Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
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” with “Causes” are also included in this section.
Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
How to read the shop manual Revised edition mark

W he n a m an ua l i s r ev i s e d, an e di t i on m a r k
Volumes ((1)(2)(3)....) is recorded on the bottom of the pages.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Revisions
Chassis volume: Issued for every machine model Revised pages are shown in the List of revised
Engine volume: Issued for each engine series pages next to the Contents page.
Each issued as one
Electrical volume:
volume to cover all
Attachments volume: Symbols
models
So that the shop manual can be of ample practical
use, important safety and quality portions are
These various volumes are designed to avoid dupli- marked with the following symbols.
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
Symbol Item Remarks
sis, engine, electrical and attachment volumes be
available. Special safety precautions
k Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
Places to be coated with
2
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
Places where oil, water or
5
each item.
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the
page number. File as in the example.
Example:
10-4 20-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the
part to the relative parts. 100% 88% 79% 71% 41%
2) Check for existence of another part causing SAD00479
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1
the residual pressure from the hydraulic tank.
For details, see “Tes ting and adjus ting”,
Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5 mm.
a Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
a When the hose is pulled back, the rubber cap
portion moves toward the hose about 3.5
mm. This does not indicate abnormality,
however.
00-8
Foreword Method of disassembling, connecting push-pull type coupler
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect it.
Connection
00-9
Foreword Coating materials
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
Foreword Standard tightening torque
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flats Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
Tightening torque for 102 and 114 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of
hose across flats Thread size Nominal thread size Root diameter
Range Target – Threads per inch, (mm)
(mm) (Reference)
Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} — – 18UN 14.3
16
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 — —
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —
00-14
Foreword 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
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 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 85 0.80 42.73 11.4 135 Starting
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

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
00-15
Foreword 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
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) 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 same 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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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
(C)
(A) 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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 = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 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
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 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 19.549 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

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 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
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 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
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
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
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 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 2845 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
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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 is desired 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–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 –6.7 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 0 140.0 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 79.4 175 347.0
00-21
Foreword Units
Units
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
Specification Dimension Drawings . . . 01-2

Specifications
PC300-7, PC300LC-7 . . . . . . . . . . . 01-4
PC350-7, PC350LC-7 . . . . . . . . . . . 01-6
Weight Table
PC300-7, PC300LC-7 . . . . . . . . . . . 01-8
PC350-7, PC350LC-7 . . . . . . . . . . 01-10
Fuel, Coolant, And Lubricants. . . . . . . 01-12
PC300-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
WORKING RANGES
01-2 PC300-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
DIMENSIONS
Item Unit PC300-7 PC300LC-7 PC350-7 PC350LC-7
A Overall length mm 11,140 11,140 11,140 11,140
B Overall height mm 3,280 3,280 3,280 3,280
C Overall width mm 3,190 3,290 3,190 3,290
D Track shoe width mm 600 700 600 700
E Height of cab mm 3,130 3,130 3,130 3,130

F Tail swing radius mm 3,450 3,450 3,450 3,450
G Track overall length mm 4,625 4,955 4,625 4,955
H Length of track on ground mm 3,700 4,030 3,700 4,030

Min. ground clearance mm 498 498 498 498
WORKING RANGES
Item Unit PC300-7 PC300LC-7 PC350-7 PC350LC-7
A Max. digging reach mm 11,100 11,100 11,100 11,100
B Max. digging depth mm 7,380 7,380 7,380 7,380
C Max. digging height mm 10,210 10,210 10,210 10,210
D Max. vertical wall depth mm 6,480 6,480 6,480 6,480

E Max. dumping height mm 7,110 7,110 7,110 7,110
F Min. dumping height mm 2,640 2,640 2,640 2,640
G Max. reach at ground level mm 10,920 10,920 10,920 10,920
PC300-7 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
PC300-7, PC300LC-7
Machine model PC300-7 PC300LC-7
Serial Number 40001 and up
Bucket capacity m³ 1.4 1.4
Operating weight kg 30,800 31,900
Max. digging depth mm 7,380 7,380

Working ranges
Max. vertical wall depth mm 6,480 6,480

Max. digging reach mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,210 10,210
Max. dumping height mm 7,110 7,110
Max. digging force kN {kg} 211.8 {21,600} 211.8 {21,600}

Performance
(using power max. function) kN {kg} (226.5 {23,100}) (226.5 {23,100})
Swing speed rpm 9.5 9.5

Swing max. slope angle deg. 21 21
Travel speed km/h Lo: 3.2 ( Mi: 4.5) Lo: 3.2 ( Mi: 4.5)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm²} 62.8 {0.64} 53.0 {0.54}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 11,140 11,140

Overall width mm 3,190 3,190
Overall width of track mm 3,190 3,290
Overall height (for transport) mm 3,280 3,280
Overall height to chassis mm 3,130 3,130
Dimensions
Ground clearance to bottom of upper structure mm 1,186 1,186

Min. ground clearance mm 498 498
Tail swing radius mm 3,450 3,450
Min. swing radius of work equipment mm 4,310 4,310
Height of work equipment at min. swing radius mm 8,520 8,520
Length of track on ground mm 3,700 4,030
Track gauge mm 2,590 2,590
Height of machine cab mm 3,130 3,130
: The "Mi" mode is on the multi-monitor specification machine only.
01-4 PC300-7
12
Model SAA6D114E
Type 4-cycle, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger and aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement l {cc} 8.27 {8,270}
Flywheel horsepower kW/rpm {HP/rpm} 180.3/1,900 {242/1,900}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 1,079/1,400 {110/1,400}

Max. speed at no load rpm 2,160
Min. speed at no load rpm 900
Min. fuel consumption g/kWh {g/HPh} 205 {153}
Starting motor 24V, 7.5 kW

Alternator 24V, 35 A
Battery 12V, 126 Ah x 2
Radiator core type CF19-4
Carrier roller 2 on each side
Track roller 7 on each side 8 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 45 on each grouser, 48 on each
side side
Hydraulic
Type x No. HPV125+125, variable displacement, Piston type x2

pump
Delivery l/min 267.5 x 2

Set pressure MPa (kg/cm²) 37.8 {380}
Control
Type x No. 6-spool type + 1-spool type x 1

valve
Control method Hydraulic
HMV160ADT-2, Piston type

Travel motor
Hydraulic
(with brake valve, parking brake): x 2

motor
KMF230ABE-5, Piston type

Hydraulic system
Swing motor
(with safety valve, holding brake): x 1
reverse rotation check valve
Type Boom Arm Bucket

Hydraulic cylinder
Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 140 160 140

Diameter of piston rod mm 100 110 100
Stroke mm 1,480 1,825 1,285
Max. distance between pins mm 3,525 4,255 3,155
Min. distance between pins mm 2,045 2,430 1,870
Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CFT-1 (Air cooled)
PC300-7 01-5
PC350-7, PC350LC-7
Bucket capacity m³ 1.4 1.4
Operating weight kg 32,300 33,400
Max. digging depth mm 7,380 7,380

Working ranges
Max. vertical wall depth mm 6,480 6,480

Max. digging reach mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,210 10,210
Max. dumping height mm 7,110 7,110
Max. digging force kN {kg} 212.8 {21,700} 212.8 {21,700}

Performance
(using power max. function) (227.5 {23,200}) (227.5 {23,200})

Swing speed rpm 9.5 9.5
Swing max. slope angle deg. 18 18

Travel speed km/h Lo: 3.2 ( Mi: 4.5) Lo: 3.2 ( Mi: 4.5)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm²} 65.7 {0.67} 62.8 {0.64}

[standard shoe width] [mm] [600] [700]
Overall length (for transport) mm 11,140 11,140

Overall width mm 3,190 3,190
Overall width of track mm 3,190 3,290
Overall height (for transport) mm 3,280 3,280
Overall height to chassis mm 3,130 3,130
Dimensions
Ground clearance to bottom of upper structure mm 1,186 1,186

Min. ground clearance mm 498 498
Tail swing radius mm 3,450 3,450
Min. swing radius of work equipment mm 4,310 4,310
Height of work equipment at min. swing radius mm 8,520 8,520
Length of track on ground mm 3,700 4,030
Track gauge mm 2,590 2,590
Height of machine cab mm 3,130 3,130
01-6 PC300-7
Model SAA6D114E
Type 4-cycle, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger and aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement l {cc} 8.27 {8,270}
Flywheel horsepower kW/rpm {HP/rpm} 180.3/1,900 {242/1,900}

Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 1,079/1,400 {110/1,400}

Max. speed at no load rpm 2,180
Min. speed at no load rpm 900
Min. fuel consumption g/kWh {g/HPh} 205 {153}
Starting motor 24V, 7.5 kW

Alternator 24V, 35 A
Battery 12V, 126 Ah x 2
Radiator core type CF19-4
Carrier roller 2 on each side
Track roller 7 on each side 8 on each side

carriage
Under-
Assembly-type triple Assembly-type triple

Track shoe grouser, 45 on each grouser, 48 on each
side side
Hydraulic
Type x No. HPV125+125, variable displacement, Piston type x2

pump
Delivery l/min 267.5 x 2

Set pressure MPa (kg/cm²) 37.8 {380}
Control
Type x No. 6-spool type + 1-spool type x 1

valve
Control method Hydraulic
HMV160ADT-2, Piston type

Travel motor
Hydraulic
(with brake valve, parking brake): x 2

motor
KMF230ABE-5, Piston type

Hydraulic system
Swing motor
(with safety valve, holding brake): x 1
reverse rotation check valve
Boom Arm Bucket

Type
Hydraulic cylinder
Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 140 160 140

Diameter of piston rod mm 100 110 100
Stroke mm 1,480 1,825 1,825
Max. distance between pins
mm 3,525 4,255 3,155
Min. distance between pins
mm 2,045 2,430 1,870
Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CFT-1 (Air cooled)
PC300-7 01-7
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is for use when handling components or when transporting the machine.
PC300-7, PC300LC-7
Unit: kg
Engine assembly 1,148 1,148
• Engine 860 860
• Damper 14.3 14.3
• Hydraulic pump 178 178

Radiator oil cooler assembly 153 153
Hydraulic tank, filter assembly (excluding hydraulic oil) 176 176
Fuel tank (excluding fuel) 238 238
Revolving frame 2,723 2,723
Operator’s cab 292 292
Operator’s seat 35 35
Counterweight 5,470 5,470
Swing machinery 442 442
Control valve 242 242
Swing motor 88 88
Travel motor 164 x 2 164 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,311 7,979
• Track frame 3,879 4,441
• Swing circle 487 487
• Idler 169 x 2 169 x 2
• Idler cushion 287.5 x 2 287.5 x 2
• Carrier roller 31.3 x 4 31.3 x 4
• Track roller 52.9 x 14 52.9 x 16
• Final drive (including travel motor) 583 x 2 583 x 2
01-8 PC300-7
12
Unit: kg
Track shoe assembly
• Standard triple grouser shoe (600 mm) 3,470 3,700
• Wide triple grouser shoe (800 mm) 4,380 4,680
• Road liner (rubber pad type) (600 mm) — —
Boom assembly 2,290 2,290
Arm assembly 1,105 1,105
Bucket assembly 1,015 1,015
Boom cylinder assembly 254 x 2 254 x 2
Arm cylinder assembly 382 382
Bucket cylinder assembly 228 228
Link assembly (large) 316 316
Link assembly (small) — —
Boom pin 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42
Arm pin 13 +17 13 +17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
PC300-7 01-9
PC350-7, PC350LC-7
Unit: kg
Engine assembly 1,148 1,148
• Engine 860 860
• Damper 14.3 14.3
• Hydraulic pump 178 178

Radiator oil cooler assembly 153 153
Hydraulic tank, filter assembly (excluding hydraulic oil) 176 176
Fuel tank (excluding fuel) 238 238
Revolving frame 2,828 2,828
Operator’s cab 287 287
Operator’s seat 35 35
Counterweight 6,370 6,370
Swing machinery 442 442
Control valve 242 242
Swing motor 88 88
Travel motor 164 x 2 164 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,538 8,183
• Track frame 4,074 4,602
• Swing circle 487 487
• Idler 169 x 2 169 x 2
• Idler cushion 287.5 x 2 287.5 x 2
• Carrier roller 31.3 x 4 31.3 x 4
• Track roller 52.9 x 8 52.9 x 8

58.3 x 6 58.3 x 8
• Final drive (including travel motor) 583 x 2 583 x 2
01-10 PC300-7
12
Unit: kg
Track shoe assembly
• Wide triple grouser shoe (800 mm) — —
• Road liner (rubber pad type) (600 mm) — —
Boom assembly 2,450 2,450
Arm assembly 1,211 1,211
Bucket assembly 1,508 1,508
Boom cylinder assembly 254 x 2 254 x 2
Arm cylinder assembly 382 382
Bucket cylinder assembly 228 228
Link assembly (large) 316 316
Link assembly (small) — —
Boom pin 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42
Arm pin 13 +17 13 +17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
PC300-7 01-11
GENERAL FUEL, COOLANT, AND LUBRICANTS
12
FUEL, COOLANT, AND LUBRICANTS
Unit: l
PC300/300LC-7, PC350/350LC-7
Reservoir
Specified (l) Refill (l)
Engine oil pan 38 35
Swing machinery case 16.5 16.5
Final drive case (each) 8.5 8.5
Damper case 1.3 1.3
Hydraulic system 365 188
Fuel tank 605 —
Cooling system 32 32
01-12 PC300-7
(10)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
1252
Engine Related Parts . . . . . . . . . . . . . .10-2 Multi Monitor System . . . . . . . . . . 10-173
Radiator • Oil Cooler • Aftercooler . . .10-3 7-Segment Monitor System . . . . . 10-193
Power Train . . . . . . . . . . . . . . . . . . . . .10-4 Sensor . . . . . . . . . . . . . . . . . . . . . . . 10-200
Final Drive . . . . . . . . . . . . . . . . . . . . . .10-6
Sprocket . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Swing Machinery. . . . . . . . . . . . . . . . .10-8
Swing Circle . . . . . . . . . . . . . . . . . . . .10-10
Track Frame • Recoil Spring . . . . . . .10-12
Idler. . . . . . . . . . . . . . . . . . . . . . . . . . .10-14
Carrier roller. . . . . . . . . . . . . . . . . . . .10-16
Track roller . . . . . . . . . . . . . . . . . . . . .10-17
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-18
Hydraulic Equipment Layout Drawing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22
Hydraulic Tank . . . . . . . . . . . . . . . . . .10-24
Hydraulic Pump . . . . . . . . . . . . . . . . .10-26
Variable Volume Valve . . . . . . . . . . .10-47
Control Valve . . . . . . . . . . . . . . . . . . .10-50
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-66
Self Pressure Reducing Valve. . . . . .10-69
Swing Motor . . . . . . . . . . . . . . . . . . .10-72
Reverse Prevention Valve . . . . . . . . .10-78
Center Swivel Joint . . . . . . . . . . . . . .10-80
Travel Motor . . . . . . . . . . . . . . . . . . .10-81
Travel Junction Valve . . . . . . . . . . . .10-91
Travel PPC Shuttle Valve . . . . . . . . .10-94
Valve Control . . . . . . . . . . . . . . . . . . .10-98
Work Equipment • Swing PPC Valve10-99
Travel PPC Valve . . . . . . . . . . . . . . .10-103
Service PPC Valve . . . . . . . . . . . . . .10-112
Solenoid Valve. . . . . . . . . . . . . . . . .10-115
PPC Accumulator. . . . . . . . . . . . . . .10-117
Return Oil Filter . . . . . . . . . . . . . . . .10-118
Boom Hydraulic Drift Prevention Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120
Quick Return Valve . . . . . . . . . . . . .10-126
Lift Check Valve . . . . . . . . . . . . . . . .10-128
Attachment Circuit Selector Valve .10-129
Hydraulic Cylinder . . . . . . . . . . . . . .10-132
Work Equipment . . . . . . . . . . . . . . .10-134
Air Conditioner . . . . . . . . . . . . . . . .10-140
Engine Control . . . . . . . . . . . . . . . . .10-141
Electronic Control System . . . . . . .10-149
PC300-7 10-1
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS
12
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount • The damper assembly is a wet type.
4. Friction plate 8. Front engine mount Oil capacity: 1.3
10-2 PC300-7
RADIATOR • OIL COOLER •
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AFTERCOOLER
12
RADIATOR • OIL COOLER • AFTERCOOLER
SWP08671
1. Reservoir tank SPECIFICATIONS

2. Oil cooler
3. Radiator Radiator : CF19-4
4. Radiator inlet hose Oil cooler : CF40-1
5. Radiator outlet hose
6. Net
7. Shroud
8. Radiator cap
9. Aftercooler
PC300-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
1. Idler 7. Hydraulic pump (HPV125+125)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor (HMV 160ADT-2) 11. Swing motor (KMF230ABE-5)
6. Engine (SAA6D114E) 12. Swing circle
10-4 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
10-6 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE
12
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 42)
4. No. 1 sun gear (No. of teeth: 11)
5. No. 2 sun gear (No. of teeth: 19)
6. No. 1 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 97)
10. Hub
11. Sprocket
12. Floating seal
13. Travel motor
14. No. 2 planetary gear (No. of teeth: 38)
SPECIFICATIONS
Reduction ratio:
 11+ 97   19 + 97 
− ×  = −58.943
 11   19 
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear and Standard clearance Clearance limit Replace
15
No. 1 planetary gear 0.12 ~ 0.44 0.90
Backlash between No. 1 planetary gear

16 0.18 ~ 0.62 1.20
and ring gear
Backlash between No. 2 planetary car-

17 0.06 ~ 0.25 —
rier and motor
Backlash between No. 2 sun gear and

18 0.15 ~ 0.51 1.00
No. 2 planetary gear
Backlash between No. 2 planetary gear
19 0.19 ~ 0.66 1.30
and ring gear
Backlash between No. 2 planetary car-

20 0.39 ~ 0.80 1.60
rier and No. 2 sun gear
21 Amount of wear on sprocket tooth Repair limit: 6

Rebuild or
Standard size Repair limit
22 Width of sprocket tooth replace
87 84
PC300-7 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SPROCKET
12
PC300-7
SPROCKET
Unit: mm
Standard clearance Clearance limit

1 Wear of tooth tip
336.5 324.5
Build-up
2 Thickness of tooth root 20 14
welding or
3 Width of tooth 87 84 replace
Repair limit: 6
4 Wear of tooth shape
(measure with sprocket tooth shape)
10-7-1 PC300-7
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
★ The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy
on an OHP sheet.
PC300-7 10-7-2
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
SWING MACHINERY
10-8 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY
12
1. Swing pinion (No. of teeth: 13)

2. Spacer
3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
13. Drain plug
SPECIFICATIONS
Reduction ratio:
 19 + 68   24 + 68 
 ×  = 17.553
 19   24 
Unit: mm
Backlash between swing motor shaft and Standard clearance Clearance limit
14
No. 1 sun gear 0.18 ~ 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.15 ~ 0.51 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.17 ~ 0.60 1.10
ring gear
Backlash between No. 1 planetary carrier
17 0.40 ~ 0.75 1.20
and No. 2 sun gear
Backlash between No. 2 sun gear and No. 2 Replace
18 0.16 ~ 0.55 1.00
planetary gear
Backlash between No. 2 planetary gear and
19 0.17 ~ 0.60 1.10
ring gear
Backlash between coupling and swing pin-
20 0.08 ~ 0.25 —
ion
Backlash between swing pinion and swing
21 0.00 ~ 1.21 2.00
circle
22 Clearance between plate and coupling 0.57 ~ 1.09 —
Apply hard chrome
Wear of swing pinion surface contacting
23 0 plating, recondi-
with oil seal 145 — tion, or replace
-0.100
PC300-7 10-9
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 90) SPECIFICATIONS

2. Ball
3. Swing circle outer race
90
a. Inner race soft zone S position Reduction ratio: − = −6.923
13
b. Outer race soft zone S position
Amount of grease: 33 l (G2-LI)
Unit: mm

Axial clearance of bearing
4 Replace
(when mounted on chassis) 0.5 ~ 1.6 3.2
10-10 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
TRACK FRAME • RECOIL SPRING
SWP08996
1 Idler • The dimensions and the number of track rollers depend

2 Track frame on the model, but the basic structure is not different.
3 Carrier roller • Number of track rollers
4 Final drive
5 Track roller Model Q’ty
6 Track shoe
7 Center guard PC300-7, PC350-7 7
8 Recoil spring
9 Front guard PC300LC-7, PC350LC-7 8
10-12 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING
12
Standard shoe
Model
PC300-7 PC300LC-7 PC350-7 PC350LC-7
Item
Shoe width 600 mm 700 mm 600 mm 600 mm
Link pitch 216 mm 216 mm 216 mm 216 mm
No. on track (one side) 45 (pieces) 49 (pieces) 45 (pieces) 48 (pieces)
Unit: mm
Standard
Tolerance Repair limit
size
10 Vertical width of idler guide +2
Track frame 123 127 Rebuild
-1
or
Idler support 120 ± 0.5 118
replace
Track frame 266 +3 271
Horizontal width of idler -1
11
guide Idler support 261 — 259
Free length Installation Installation Free Installation

12 Recoil spring x O.D. length load length load Replace
173.3 kN 138.56 kN
795 X 241 648 —
(17,680 kg) (14,140 kg)
PC300-7 10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD IDLER
12
IDLER
10-14 PC300-7
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD IDLER
12
Unit: mm

1 Outside diameter of protruding
635 —
2 Outside diameter of tread 590 578

Rebuild
3 Thickness of tread 32 26 or
replace
4 Width of protrusion 102 —
5 Total width 190 —
6 Width of tread 44 50
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
7
bushing
-0.225 +0.130
80 0.201 ~ 0.455 1.5
-0.325 -0.024 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler and size Shaft Hole interference limit
8
bushing
+0.087 -0.027
87.6 0.064 ~ 0.166 —
+0.037 -0.079
PC300-7 10-15
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CARRIER ROLLER
12
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
175 —
3 Width of tread 50.3 —
4 Thickness of tread 32 25
5 Width of flange 19 —

Interference between shaft size Shaft Hole interference limit
6 Replace
and bushing
-0.250 +0.099
50 0.218 - 0.369 —
-0.270 -0.032
Standard Tolerance Standard Interference

Interference between roller size Shaft Hole interference limit
7
and bushing
+0.117 +0.040
57 0.047 - 0.117 —
+0.087 0

8 Axial clearance of roller
0.5 - 0.7 —
10-16 PC300-7
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK ROLLER
12
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
216 —
3 Thickness of tread 54 48 Rebuild

or
4 Overall width 250 — replace
5 Inside width 98 —
6 Width of tread 49 —
7 Width of flange 27 —

Clearance between shaft and size Shaft Hole clearance limit
8
bushing
-0.250 +0.186
65 0.186 - 0.536 —
-0.350 -0.064 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
+0.108 -0.006
72 0.014 - 0.144 —
+0.008 -0.036
PC300-7 10-17
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE
12
TRACK SHOE
SWP09000
★ P portion shows the link of bushing press fitting end.
10-18 PC300-7
12
Unit: mm
No
Check item Criteria Remedy
.
1 Link pitch
216.3 219.3 Reverse
or
Standard size When turned replace
2 Bushing outside diameter
66.9 61.9

3 Link height
116 107 Repair or
replace
Thickness of link metal
4 30.7 21.7
(bushing press-fitting portion)
5 178.4
6 Shoe bolt pitch 140.4 Replace
7 76.2
8 Inside width 102

Repair or
9 Link Overall width 47.8
replace
10 Tread width 42.6
11 Protrusion of pin 4.2
12 Protrusion of regular bushing 5.25
13 Overall length of pin 242 Adjust or

14 Overall length of bushing 148.4 replace
Standard size When turned

15 Thickness of bushing metal
10.8 5.8
16 Thickness of spacer —
17 Bushing 98 - 264.6 kN {10 - 27 ton}
18 Press-fitting Regular pin 147 - 362.6 kN {15 - 37 ton} —

force
Master pin 98 - 215.6 kN {10 - 22 ton}
19
: Dry type track link
PC300-7 10-19
(6)
12
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
393 ± 39
Triple shoe 120 ± 10
{40 ± 4} Retighten
Shoe bolt
20 Tightening torque Additional tightening Lower limit torque
b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
— — —
PC300-7, PC350-7: 45
No. of shoes (each side) —
PC300LC-7, PC350LC-7: 48
Standard Tolerance Standard

Interference between size Shaft Hole interference
21
bushing and link
+0.464 +0.074
66.5 0.350 ~ 0.464
+0.424 0
Interference between +0.235 -0.188

22 44.6 0.273 ~ 0.485
regular pin and link +0.085 -0.250

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.235 +0.915 Adjust or
44.6 0.180 ~ 0.830
+0.085 +0.415 replace

Interference between master size Shaft Hole interference
24 pin and bushing
+0.03 -0.188
44.6 0.188 ~ 0.280
0 -0.250

Clearance between master pin size Shaft Hole clearance
25 and bushing
+0.050 +0.915
44.3 0.365 ~ 0.965
-0.050 +0.415
: Dry type track link
10-20 PC300-7
(6)
12
TRIPLE GROUSER SHOE
Unit: mm
1 Height 36 24
( ) 30 18
2 Thickness 11
32
3
( ) 29
Length of base
26
4 Rebuild or replace
( ) 24
24
5
( ) 22
18
6 Length at tip
( ) 16
18
7
( ) 22
: PC300-7, PC300LC-7 : 600 mm width shoe
PC300-7 10-21
(6)
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding valve
19. Accumulator
20. Solenoid valve assembly
20A PPC lock solenoid
20B Travel junction solenoid
20C Pump merge/divider solenoid
20D Travel speed solenoid
20E Swing brake solenoid
20F Machine push-up solenoid
20G 2-stage relief solenoid
10-22 PC300-7
HYDRAULIC EQUIPMENT LAYOUT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD DRAWING
12
PC300-7 10-23
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK
12
HYDRAULIC TANK
SPECIFICATIONS
1. Sight gauge Tank capacity: 275 l
2. Hydraulic tank Amount of oil inside tank: 188 l
3. Oil filler cap Pressure valve
4. Filter element Relief cracking pressure:
5. Strainer 16.7 ± 6.9 kPa
6. Bypass valve {0.17 ± 0.07 kg/cm²}
Suction cracking pressure:
0 - 0.49 kPa
{0 - 0.005 kg/cm²}
Bypass Valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm²}
10-24 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
HPV125 + 125
1. Front main pump IM : PC mode selector current PENR : Rear pump control pressure detec-
2. Rear main pump ISIG : LS set selector current tion port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pres- PLSFC: Front load pressure detection port
5. LS-EPC valve sure detection port PLSR : Rear load pressure input port
6. PC-EPC valve PAR : Rear pump delivery port PLSRC: Rear load pressure detection port
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PLSC : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash plate
piston pumps, PC valve, LS valve, and EPC valve.
10-26 PC300-7
12
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
PC300-7 10-27
12
SWP
Function
• The rotation and torque transmitted to the • Rocker cam (4) has flat surface A, and shoe
pump shaft are converted into hydraulic (5) is always pressed against this surface
energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4) brings high pressure oil at cyl-
• It is possible to change the discharge amount inder surface B with cradle (2), which is
by changing the swash plate angle. secured to the case, and forms a static pres-
Structure sure bearing when it slides.
• Cylinder block (7) is supported to shaft (1) by • Piston (6) carries out relative movement in
a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
• The tip of piston (6) is a concave ball, and • The cylinder block seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rota-
ton (6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
pressure balance is maintained at a suitable
level. The oil inside each cylinder chamber of
cylinder block (7) is sucked in and discharged
through valve plate (8).
10-28 PC300-7
12
Operation
1) Operation of pump
i Cylinder block (7) rotates together with
shaft (1), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
iii If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC300-7 10-29
12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal
pressure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving
the pressure is different on the left and
the right, so main pump discharge pres-
sure (self pressure) PP is always brought
to the chamber receiving the pressure at
the small diameter piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the
pressure at the large diameter end. The
relationship in the size of pressure PP at
the small diameter piston end and pres-
sure Pen at the large diameter end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (12).
10-30 PC300-7
12
LS VALVE
1. Plug PA : Pump port

2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port
6. Spool PPL : PC control pressure input port
7. Piston PSIG : LS mode selection pilot port
8. Sleeve
PC VALVE
PA : Pump port
1. Servo piston assembly
PA2 : Pump pressure pilot port
2. Plug
PDP : Drain port
3. Pin
PM : PC mode selector pressure pilot port
4. Spool
PPL : PC control pressure output port
5. Retainer
PPL2: LS control pressure output port
6. Seat
7. Cover
8. Wiring
PC300-7 10-31
12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
∆PLS (=PP - PLS) [called the LS differential
pressure] (the difference between main pump
09141
pressure PP and control valve outlet port
pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control
valve output, and pressure Psig {called the
LS selector pressure} from the proportional
solenoid valve enter this valve. The relation-
ship between discharge amount Q and differ-
ential pressure ∆PLS, (the difference between
main pump pressure PP and LS pressure
PLS) (= PP - PLS) changes as shown in the
diagram at the right according to LS pressure
selector current isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
valve between 0.98 ↔ 2.5 MPa {10 ↔ 25 kg/
cm²}.
(2) PC valve
When the pump discharge pressure PP1
(self-pressure) and PP2 (other pump pres-
sure) are high, the PC valve controls the
pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control
valve becomes larger. In this way, it carries
out equal horsepower control so that the 09142
horsepower absorbed by the pump does not
exceed the engine horsepower.
In other words, If the load during the opera-
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump. The
relationship between the average of the front
and rear pump discharge pressures (average
discharge amount of F, R pumps (PP1 +
PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to
the PC-EPC valve solenoid shown as a param-
eter. The controller senses the actual speed of
the engine, and if the speed drops because of the set value, the command current to the PC-
an increase in the load, it reduces the pump EPC valve solenoid from the controller
discharge amount to allow the speed to increases according to the drop in the engine
recover. In other words, when the load speed to reduce the pump swash plate angle.
increases and the engine speed drops below
10-32 PC300-7
12
OPERATION
SDP08884
(1) LS valve
1) When control valve is at neutral position At this point, spool (6) is pushed to the left,
• The LS valve is a three-way selector valve, and port C and port D are connected. Pump
with pressure PLS (LS pressure) from the pressure PP enters the large diameter end of
inlet port of the control valve brought to the piston from port K and the same pump
spring chamber B, and main pump discharge pressure PP also enters port J at the small
pressure PP brought to port H of sleeve (8). diameter end of the piston, so the swash plate
The size of this LS pressure PLS + force Z of is moved to the minimum angle by the differ-
spring (4) and the main pump pressure (self ence in the area of the piston (12).
pressure) PP determines the position of
spool (6). However, the size of the output
pressure PSIG (the LS selection pressure) of
the EPC valve for the LS valve entering port G
also changes the position of spool (6). (The
set pressure of the spring changes).
• Before the engine is started, servo piston (12)
is pushed to the right. (See the diagram on
the right)
• When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm²}. (It is interconnected
with the drain circuit through the control
valve spool.)
PC300-7 10-33
(8)
12
SDP08885
2) Operation in increase direction for pump • For this reason, the pressure at the large
discharge amount diameter end of servo piston (12) becomes
• When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure ∆PLS, servo piston (12) is pushed to the right. There-
becomes smaller (for example, when the area fore, the swash plate moves in the direction
of opening of the control valve becomes to make the discharge amount larger. If the
larger and pump PP drops), spool (6) is output pressure of the EPC valve for the LS
pushed to the right by the combined force of valve enters port G, this pressure creates a
LS pressure PLS and the force of spring (4). force to move piston (7) to the left. If piston
• When spool (6) moves, port D and port E are (7) is pushed to the left, it acts to make the set
joined and connected to the PC valve. When pressure of spring (4) weaker, and the differ-
this happens, the PC valve is connected to the ence between PLS and PP changes when
drain port, so circuit D - K becomes drain ports D and E of spool (6) are connected.
pressure PT. (The operation of the PC valve is
explained later).
10-34 PC300-7
12
SDP08886
3) Operation in decrease direction for

pump discharge amount
• The following explains the situation if the • Main pump pressure PP also enters port J at
servo piston (12) moves to the left (the dis- the small diameter end of the piston, but
charge amount becomes smaller). When LS because of the difference in area between the
differential pressure ∆PLS becomes larger large diameter end and the small diameter
(for example, when the area of opening of the end of servo piston (12), servo piston (12) is
control valve becomes smaller and pump pushed to the left.
pressure PP rises), pump pressure PP • As a result, the swash plate moves in the
pushes spool (6) to the left. direction to make angle smaller.
• When spool (6) moves, main port pressure • If LS selection pressure PSIG enters port G, it
PP flows from port C and port D and from acts to make the set pressure of spring (4)
port K, it enters the large diameter end of the weaker.
piston.
PC300-7 10-35
12
SDP08887
4) When servo piston is balanced

• Let us take the area receiving the pressure at • At this point, the relationship between the
the large diameter end of the piston as A1, area receiving the pressure at both ends of
the area receiving the pressure at the small piston (12) is A0 : A1 = 1:2, so the pressure
diameter end as A0, and the pressure flowing applied to both ends of the piston when it is
into the large diameter end of the piston as balanced becomes PP : Pen = 2:1.
Pen. If the main pump pressure PP of the LS • The position where spool (6) is balanced and
valve and the combined force of force Z of stopped is the standard center, and the force
spring (4) and LS pressure PLS are balanced, of spring (4) is adjusted so that it is deter-
and the relationship is A0 x PP = A1 x Pen, mined when PP - PLS = 2.5 MPa {25 kg/cm²}.
servo piston (11) will stop in that position, and However, if PSIG (the output pressure of 0 ↔
the swash plate will be kept at an intermedi- 2.9 MPa {0 ↔ 30 kg/cm²} of the EPC valve of
ate position. (It will stop at a position where the LS valve) is applied to port G, the balance
the opening of the throttle from port D to port stop position will change in proportion to
E and from port C to port D of spool (6) is pressure PSIG between PP - PLS = 2.5 ↔
approximately the same.) 0.98 MPa {25 ↔ 10 kg/cm²}.
10-36 PC300-7
12
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
i) Movement of PC-EPC solenoid (1)
• The command current from the pump • the pressure (pressure of port C) output
controller flows to PC-EPC solenoid from the PC valve changes according to
(1).This command current acts on the PC- this position.
EPC valve and outputs the signal pres- • The size of command current X is deter-
sure. When this signal pressure is mined by the nature of the operation
received, the force pushing piston (2) is (lever operation), the selection of the
changed. working mode, and the set value and
• On the opposite side to the force pushing actual value for the engine speed.
this piston (2) is the spring set pressure of ★ Other pump pressure
springs (4) and (6) and pump pressure This is the pressure of the pump at the
PP1 (self pressure) and PP2 (other pump opposite end.
pressure) pushing spool (3). Piston (2) For the F pump, it is the R pump pressure
stops at a position where the combined For the R pump, it is the F pump pressure
force pushing spool (3) is balanced, and
PC300-7 10-37
(8)
12
ii) Action of spring

• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC valve
PC valve is determined by the swash plate solenoid (1) changes further, the force push-
position. ing piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is springs (4) and (6) also changes according to
compressed, and if it moves further to the left, the valve of the PC-EPC valve solenoid com-
spring (6) contacts seat (5) and is fixed in mand current.
position. In other words, the spring load is
changed by piston (9) extending or compress-
ing springs (4) and (6).
10-38 PC300-7
(8)
12
• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pressure
entering the LS valve becomes drain pressure
PT. If port E and port G of the LS valve are
connected (see (1) LS valve), the pressure
entering the large diameter end of the piston
from port J becomes drain pressure PT, and
servo piston (9) moves to the right. In this
way, the pump discharge amount moves in
the direction of increase.
• As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes
weaker, spool (3) moves to the right, so the
connection between port C and port D is cut,
and the pump discharge pressure ports B and
C are connected. As a result, the pressure at
port C rises, and the pressure at the large
diameter end of the piston also rises, so the
movement of piston (9) to the right is
stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC valve
solenoid and the pushing force created by the
pressures PP1 and PP2 acting on the spool
(3) are in balance.
PC300-7 10-39
12
b. When load on actuator is large and

pump discharge pressure is high
• When the load is large and pump dis- • If main pump pressure PP increases fur-
charge pressures PP1 and PP2 are high, ther and spool (3) moves further to the
the force pushing spool (3) to the left left, main pump pressure PP1 flows to
becomes larger and spool (3) moves to port C and acts to make the discharge
the position in the diagram above. When amount the minimum. When piston (9)
this happens, as shown in the diagram moves to the left, springs (4) and (6) are
above, part of the pressurized oil from compressed and push back spool (3).
port B flows out through port C where the When spool (3) moves to the left, the
LS valve is actuated to port D, and the opening of port C and port D becomes
pressurized oil flowing from port C to the larger. As a result, the pressure at port C
LS valve becomes approximately half of (= J) drops, and piston (9) stops moving
main pump pressure PP. to the left.
• When port E and port G of the LS valve • The position in which piston (9) stops
are connected (see (1) LS valve), the pres- when this happens is further to the left
sure from port J enters the large diameter than the position when pump pressures
end of servo piston (9), and servo piston PP1 and PP2 are low.
(9) stops.
10-40 PC300-7
(9)
12
• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of
the double-spring effect of springs (4)
and (6). The relationship between aver-
age pump pressure (PP1 + PP2)/2 and
pump discharge amount Q is shown in
the figure at the right.
• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the
relationship between average pump
pressure (PP1 + PP2)/2, and pump dis-
charge amount Q is proportional to the
pushing force of the PC-EPC valve sole-
noid and moves in parallel. In other
words, the pushing force of PC-EPC
solenoid (1) is added to the force push-
ing to the left because of the pump pres-
sure applied to the spool (3), so the
relationship between the average pump
pressure (PP1 + PP2)/2 and Q moves
from [1] to [2] in accordance with the
increase in X.
PC300-7 10-41
(8)
12
2) When pump controller is abnormal and

emergency pump drive switch is ON
a. When load on main pump is light
• If there is a failure in the pump controller, • At this point, port C is connected to the
turn emergency pump drive switch ON to drain pressure of port D, and the large
switch to the resistor side. In this case, the diameter end of the piston of servo piston
power source is taken directly from the (9) also becomes the drain pressure PT
battery. But if the current is used as it is, it through the LS valve. When this happens,
is too large, so use the resistor to control the pressure at the small diameter end of
the current flowing to PC-EPC valve sole- the piston is large, so servo piston (9)
noid (1). moves in the direction to make the dis-
• When this is done, the current becomes charge amount larger.
constant, so the force pushing piston (2)
is also constant.
• If the main pump pressure PP1 and PP2
are low, the combined force of the pump
pressure and the force of PC-EPC valve
solenoid (1) are weaker than the spring
set force, so spool (3) is balanced at a
position to the right.
10-42 PC300-7
(8)
12
09147
b. When main pump load is heavy

• In the same way as in the previous item, and discharge amount Q is determined as
when the emergency pump drive switch shown in the diagram for the valve of the
is ON, the command current sent to PC- current sent to the PC-EPC valve solenoid
EPC valve solenoid (1) becomes constant. through the resistor.
For this reason, the force of piston (2) The curve when the PC prolix switch is
pushing spool (3) is constant. ON is curve ➁, which is to the left of curve
• If main pump pressures PP1 and PP2 ➀ for when the pump controller is normal.
increase, spool (3) moves further to the
left than when the main pump load is
light, and is balanced at the position in
the diagram above.
• In this case, the pressure from port A
flows to port C, so servo piston (9) moves
to the left (to make the discharge amount
smaller) by the same mechanism as
explained in item 2)-b, and stops at a
position to the left of the position when
the load on the pump is light. In other
words, even when the emergency pump
drive switch is ON, the curve for the
pump pressure PP
PC300-7 10-43
12
LS(PC)-EPC VALVE
1. Body 5. Coil PSIG(PM) : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self-reducing pressure valve
4. Rod
10-44 PC300-7
12O
FUNCTION
• The EPC valve consists of the proportional

solenoid portion and the hydraulic valve
portion.
• When it receives signal current i from the
pump controller, it generates the EPC out-
put pressure in proportion to the size of the
signal, and outputs it to the LS valve.
OPERATION
1. When signal current is 0 (coil de-ener-

gized)
• When there is no signal current flowing
from the controller to coil (5), coil (5) is de-
energized.
• For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
• As a result, port PEPC closes and the pres-
surized oil from the main pump does not
flow to the LS valve.
At the same time, the pressurized oil from 08890
the LS valve passes from port PSIG(PM)
through port PT and is drained to the tank.
PC300-7 10-45
(9)
2. When signal current is very small (coil

energized)
• When a very small signal current flows to
coil (5), coil (5) is energized, and a propul-
sion force is generated which pushes
plunger (6) to the left.
• Push pin (4) pushes spool (2) to the left,
and pressurized oil flows from port PEPC
to port PSIG(PM).
• When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface a of spool (2) becomes greater
than the propulsion force of plunger (6), 08891
spool (2) is pushed to the right. The circuit
between port PEPC and port PSIG(PM) is
shut off, and at the same time, port
PSIG(PM) and port PT are connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pres-
sure of port PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil

energized)
• When the signal current flows to coil (5),
coil (5) is energized.
• When this happens, the signal current is at
its maximum, so the propulsion force of 08892
plunger (6) is also at its maximum.
• For this reason, spool (2) is pushed fully to
the left by push pin (4).
• As a result, the maximum flow of pressur-
ized oil from port PEPC flows to port
PSIG(PM), and the circuit pressure
between the EPC valve and LS valve
becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.
10-46 PC300-7
(9)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VARIABLE VOLUME VALVE
12
VARIABLE VOLUME VALVE
1. Block PM: To PC valve

2. Plug PT: To tank
3. Spring PEPC: From self-reducing pressure valve
4. Piston
PC300-7 10-47
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VARIABLE VOLUME VALVE
FUNCTION
• This stabilizes the EPC output pressure.
OPERATION
• The output pressure from EPC flows to port

PM, and when the propulsion force of piston
(4) becomes larger than the load of spring (3),
piston (4) is pushed to the left and the volume
at port PM increases.
When the propulsion force of piston (4)
becomes less than the load on spring (3), pis-
ton (4) is pushed to the right and the volume
at port PM goes down.
09148
10-48 PC300-7
(8)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12
CONTROL VALVE
1. 6-spool valve OUTLINE

2. Cover 1
3. Cover 2 • This control valve consists of a 7-spool
4. Pump merge-divider valve valve (6 spool valve + boom, arm Hi valve)
5. Back pressure valve and a service valve. A merge-divider valve,
6. Boom lock valve back-pressure valve, boom hydraulic drift
7. Boom, arm Hi valve prevention valve, quick return valve, and Hi
8. Service valve valve check valve are installed to it.
9. Quick return valve • Since all the valves are assembled together
10. Boom Hi check valve with connecting bolts and their passes are
connected to each other inside the assem-
bly, the assembly is small in size and easy
to maintain.
• Since one spool of this control valve is
used for one work equipment unit, its struc-
ture is simple.
A1 : To bucket cylinder bottom

A2 : To left travel motor
A3 : To boom cylinder bottom
A4 : To swing motor
A5 : To right travel motor
A6 : To arm cylinder head P11 : From arm PPC valve
A-1 : To boom cylinder bottom P12 : From arm PPC valve
A-2 : To attachment P-3 : From service PPC valve
B1 : To bucket cylinder head P-4 : From service PPC valve
B2 : To left travel motor BP1 : Boom RAISE PPC output pressure
B3 : To bottom cylinder head PB5 : From 2-stage safety valve solenoid valve
B4 : To swing motor BP6 : From attachment circuit selector solenoid
B5 : To right travel motor valve
B6 : To arm cylinder bottom PLS1 : To rear pump control
B-1 : To arm cylinder bottom PLS2 : To front pump control
B-2 : To attachment PP1 : To rear pump control
P1 : From bucket PPC valve PP2 : To front pump control
P2 : From bucket PPC valve PPS1: From rear main pump
P3 : From left travel PPC valve PPS2: From front main pump
P4 : From left travel PPC valve PR : To solenoid valve, PPC valve, EPC valve
P5 : From boom PPC valve PS : From pump merge-divider solenoid valve
P6 : From boom PPC valve PST : From travel junction valve
P7 : From swing PPC valve PX1 : From 2-stage solenoid valve
P8 : From swing PPC valve PX2 : From 2-stage solenoid valve
P9 : From right travel PPC valve SA : Pressure sensor fitting port
P10 : From right travel PPC valve SB : Pressure sensor fitting port
T : To tank
T1 : To tank
TS : To tank
TSW : To swing motor
10-50 PC300-7
(8)
12
8-spool valve
(7-spool valve + 1 service valve)
(1/9)
PC300-7 10-51
(8)
12
(2/9)
S*P09099
10-52 PC300-7
12
(3/9)
1. Unload valve 10. Pressure compensation valve (Service)

2. Pressure compensation valve (Arm OUT) 11. Pressure compensation valve (Arm IN)
3. Pressure compensation valve (Right travel 12. Pressure compensation valve (Bucket DUMP)
reverse) 13. Pressure compensation valve (Left travel for-
4. Pressure compensation valve (Right swing) ward)
5. Pressure compensation valve (Boom RAISE) 14. Pressure compensation valve (Boom LOWER)
6. Pressure compensation valve (Left travel 15. Pressure compensation valve (Left swing)
reverse) 16. Pressure compensation valve (Right travel
7. Pressure compensation valve (Bucket CURL) forward)
8. Pressure compensation valve (Boom RAISE) 17. Pressure compensation valve (Arm IN)
9. Pressure compensation valve (Service) 18. Main relief valve
PC300-7 10-53
12
(4/9)
1. Spool (Arm) 7. Spool (Boom Hi)

2. Spool (Right travel) 8. Spool (Arm Hi)
3. Spool (Swing) 9. Spool (Service)
4. Spool (Boom) 10. Unload valve
5. Spool (Left travel) 11. Main relief valve
6. Spool (Bucket)
Unit: mm

Free length x Installed Installed Free Installed
12 Spool return spring Outside diameter length load length load
416.5 N 333.2 N
54.2 x 34.8 51.2 —
{42.5 kg} {34 kg} If damaged or
429.9 N 336.1 N deformed, replace
13 Spool return spring 54.6 x 34.8 51.2 — spring
{42.9 kg} {34.3 kg}
393 N 314.6 N
14 Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}
251 N 201.0 N
15 Spool return spring 54.9 x 24.2 51.2 —
{25.1 kg} {20.5 kg}
10-54 PC300-7
12
(5/9)
1. Safety-suction valve (Arm OUT) 10. Safety-suction valve (2-stage) (Boom LOWER)
2. Suction valve (Right travel reverse) 11. Suction valve (Right travel forward)
3. Suction valve (Boom RAISE) 12. Safety-suction valve (Arm IN)
4. Suction valve (Left travel reverse) 13. LS shuttle valve (Arm, right travel)
5. Safety-suction valve (Service) 14. LS select valve
6. Safety-suction valve (2-stage) (Service) 15. LS shuttle valve (Boom, left travel, bucket)
7. Safety-suction valve (Arm IN) 16. LS shuttle valve (Service)
8. Safety-suction valve (Bucket DUMP) 17. LS check valve
9. Suction valve (Left travel forward) 18. Pressure relief plug
Unit: mm

Free length x Installed Installed Free Installed If damaged or
19 Check valve spring Outside diameter length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
PC300-7 10-55
12
(6/9)
ARM CONTROL VALVE R. H. TRAVEL CONTROL

VALVE
1. Unload valve 5. Safety-suction valve
2. Main relief valve 6. Spool 12. Suction valve
3. Safety valve (Boom 7. Pressure compensation valve 13. Spool
RAISE) (OUT) 14. Pressure compensation valve
4. Lift check valve 8. LS shuttle valve (Reverse)
15. LS shuttle valve
9. Pressure compensation valve
16. Pressure compensation valve
(IN)
(Forward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration cir-
cuit
10-56 PC300-7
Unit: mm

Regeneration valve
18 Outside diameter length load length load
spring
6.2 N 4.9 N If damaged or
31.5 x 10.3 19.5 —
{0.6 kg} {0.5 kg} deformed, replace
spring
17.5 N 14.0 N
19 Piston return spring 48.1 x 10.8 28 —
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
PC300-7 10-57
(7/9)
SWING CONTROL VALVE BOOM CONTROL VALVE L. H. TRAVEL CONTROL

VALVE
1. Spool 5. Suction valve
2. Pressure compensation 6. Spool 13. Pump merge-divider valve
valve (Right) 7. Pressure compensation (Travel junction valve)
3. LS select valve valve (RAISE) 14. Return spring
4. Pressure compensation 8. Hydraulic drift prevention 15. Suction valve
valve (Left) valve 16. Spool
9. LS shuttle valve 17. Pressure compensation
10. Pressure compensation valve (Reverse)
valve (Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation
12. Check valve for regeneration valve (Forward)
circuit 20. Suction valve
10-58 PC300-7
Unit: mm

21 Regeneration valve spring Outside diameter length load length load
6.2 N 4.9 N
31.5 x 10.3 19.5 —
{0.6 kg} {0.5 kg} If damaged or
22 Piston return spring 48.1 x 10.8 28 — spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
50.0 N 40.0 N
24 Spool return spring 30.7 x 20.5 23 —
{5.1 kg} {4.1 kg}
PC300-7 10-59
12
(8/9)
BUCKET CONTROL VALVE BOOM, ARM HI VALVE SERVICE VALVE
1. Safety-suction valve 7. Boom Hi spool 14. Safety-suction valve

2. Spool 8. Pressure compensation valve 15. Spool
3. Pressure compensation (Boom RAISE) 16. Pressure compensation valve
valve (CURL) 9. Boom Hi check valve 17. LS shuttle valve
4. LS shuttle valve 10. Quick-return valve 18. Pressure compensation valve
5. Pressure compensation 11. Pressure compensation valve 19. Safety-suction valve
valve (DUMP) (Arm IN)
6. Safety-suction valve 12. Arm Hi spool
13. Safety-suction valve
Unit: mm

20 Piston return spring Outside diameter length load length load If damaged or
48.1 x 10.8 28 — spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
{3 kg} {2.4 kg}
10-60 PC300-7
12
(9/9)
1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball
10-62 PC300-7
Unit: mm

17 Check valve spring Outside diameter length load length load
1.5 N 1.2 N
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg} If damaged or
18 Spool return spring 46.6 x 21.8 3.3 — spring
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
19 Spool return spring 64.5 x 32.3 63 —
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
20 Sequence valve spring 70.9 x 18.0 59 —
{20.4 kg} {16.3 kg}
PC300-7 10-63
MAIN RELIEF VALVE
1. Spring
2. Poppet
FUNCTION
• The relief valve set pressure is set to 2 stages.

When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.
OPERATION
• The relief valve set pressure is determined by the installed load of spring (1). (First stage)
• It is unnecessary to set the first and second stage individually.
The second stage is set when the first stage is set.
1. When pilot pressure P is OFF: Low-pressure setting

The set pressure is determined by the installed load of spring (1).
2. When pilot pressure P is ON: High-pressure setting

In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter d1, so the
set pressure becomes higher.
10-64 PC300-7
12
VARIABLE PRESSURE COMPENSATION VALVE
PC300-7 10-65
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS
12
CLSS
OUTLINE OF CLSS
FEATURES STRUCTURE
• CLSS stands for Closed center Load Sensing • The CLSS consists of a main pump (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
1) Fine control not influenced by load • The main pump body consists of the pump
2) Control enabling digging even with fine con- itself, the PC valve and LS valve.
trol
3) Ease of compound operation ensured by flow
divider function using area of opening of
spool during compound operations
4) Energy saving using variable pump control
10-66 PC300-7
Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure ∆PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure ∆PLS = Pump discharge pres-
sure PP – LS pressure PLS)
• If LS differential pressure ∆PLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher
than the set pressure of the LS valve (when
the actuator load pressure is low), the
pump swash plate moves towards the min-
imum position.
PC300-7 10-67
2) Pressure compensation
• A pressure compensation valve is installed to In this way, the flow of oil from the pump is
the outlet port side of the control valve to bal- divided (compensated) in proportion to the
ance the load. area of opening S1 and S2 of each valve.
• When two actuators are operated together,
this valve acts to make pressure difference ∆P
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve
the same regardless of the size of the load
(pressure).
10-68 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
FUNCTION
• This value reduces the discharge pressure

of the main pump and supplies it as control
pressure for the solenoid valves, PPC
valves, etc.
OPERATION
1. When engine is stopped

• Poppet (11) is pressed by spring (12)
against the seat and port PR is not con-
nected to TS.
• Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
• Valve (7) is pressed by spring (8) against
the left side and port P2 is not connected to
A2.
PC300-7 10-69
2. When in neutral or load pressure P2 is

low (When boom is lowered and arm is in IN
position and they are moving down under
own weight)
Note: When load pressure A2 is lower than self-pres-
sure reducing valve output pressure PR.
• Valve (7) receives the force of spring (8) and
PR pressure (which is 0 MPa {0 kg/cm²} when
the engine is stopped) in the direction to close
the circuit between ports P2 and A2. If the
hydraulic oil flows in port P2, the φdx P2 pres-
sure becomes equal to the total of the force of
spring (8) and the value of area of ∅d x PR
pressure, then the area of the pass between
ports P2 and A2 is so adjusted that the P2
pressure will be kept constant above the PR
pressure.
• If the PR pressure rises above the set level,
puppet (11) opens and the hydraulic oil flows
from the PR port through orifice "a" in spool
(14) and open part of poppet (11) to seal drain
port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pressure
is controlled constant (at the set pressure) by
the area of the oil pass at this time and sup-
plied as the PR pressure.
3. When load pressure P2 is high
• If load pressure A2 rises and the pump dis-
charge increases because of operation of the
work equipment, the φdx P2 pressure rises
higher than the total of the force of spring (8)
and the value of ∅d x PR pressure, and then
valve (7) moves to the right stroke end.
• As a result, the area of the pass between ports
P2 and A2 increases and the pass resistance
lowers and the loss of the engine power is
reduced.
• If the PR pressure rises above the set pres-
sure, poppet (11) opens and the hydraulic oil
flows from the PR port through orifice "a" in
spool (14) and open part of poppet (11) to seal
drain port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool
(14) and then spool (14) moves to close the
pass between port P2 and PR. The P2 pressure
is controlled constant (at the set pressure) by
the area of the oil pass at this time and sup-
plied as the PR pressure.
10-70 PC300-7
12
4. When abnormally high pressure is

generated
• If the PR pressure on the self-pressure
reducing valve rises high abnormally, ball
(16) separates from the seat against the
force of spring (15) and the hydraulic oil
flows from output port PR to TS. Accord-
ingly, the PR pressure lowers. By this oper-
ation, the hydraulic devices (PPC valves,
solenoid valves, etc.) are protected from
abnormal pressure.
PC300-7 10-71
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR
12
SWING MOTOR
KMF230ABE-5
B : From swing lock solenoid valve SPECIFICATIONS

S : From control valve
T : To tank
MA : From control valve
MB : From control valve
Model KMF230ABE-5
Theoretical displacement 229.4 cm³/rev
+0.5
Safety valve set pressure 27.9 0 MPa {285 0+0.5 kg/cm2 }
Rated revolving speed 1,130 rpm
Brake release pressure 1.9 ± 0.4 MPa {19 ± 4 kg/cm²}
10-72 PC300-7
12
1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder block 17. Shuttle valve
4. Case 11. Valve plate
5. Disc 12. Reverse prevention valve
6. Plate 13. Center shaft
7. Brake piston 14. Center spring
10-74 PC300-7
12
Unit: mm

18 Check valve spring Outside diameter length load length load If damaged or
66.5 x 25.6 45 — spring
{0.71 kg} {0.57 kg}
7.7 N 6.18 N
19 Shuttle valve spring 24.5 x 11.6 14 —
{0.79 kg} {0.63 kg}
PC300-7 10-75
RELIEF VALVE PORTION
1) Outline
The relief portion consists of check valves
(2) and (3), shuttle valves (4) and (5), and
relief valve (1).
2. Function
When the swing is stopped, the outlet port
circuit of the motor from the control valve
is closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally
high, and this may damage the motor.
To prevent this, the abnormally high pres-
sure oil is relieved to port S from the outlet
port of the motor (high-pressure side) to
prevent any damage.
3. Operation
1) When starting swing
• When the swing control lever is operated
to swing right, the pressure oil from the
pump passes through the control valve and
is supplied to port MA. As a result, the
pressure at port MA rises, the starting
torque is generated in the motor, and the
motor starts to rotate. The oil from the out-
let port of the motor passes from port MA
through the control valve and returns to
the tank. (Fig. 1)
2) When stopping swing
• When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil
from the outlet port of the motor, the return
circuit to the tank is closed by the control
valve, so the pressure at port MB rises. As
a result, rotation resistance is generated in
the motor, so the braking effect starts.
• If the pressure at port MB becomes higher
than the pressure at port MA, it pushes
shuttle valve A (4) and chamber C
becomes the same pressure as port MB.
The oil pressure rises further until it
reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on
the motor and stops the motor. (Fig.2)
• When relief valve (1) is being actuated, the
relief oil and oil from port S passes
through check valve B (3) and is supplied to
port MA. This prevents cavitation at port
MA.
10-76 PC300-7
12
Operation of swing lock

1. When swing lock solenoid valve is deacti-
vated
When the swing lock solenoid valve is deacti-
vated, the pressurized oil from the main pump is
shut off and port B is connected to the tank cir-
cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied. 09149
2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited,
the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are separated
and the brake is released.
09150
PC300-7 10-77
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
REVERSE PREVENTION VALVE
Operation diagram
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
10-78 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE
12
Outline
This valve reduces the swing back genera-
tion in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machinery system, and the compression of
the hydraulic oil when the swing is
stopped. This is effective in preventing
spillage of the load and reducing the cycle
time when stopping the swing (the posi-
tioning ability is good and it is possible to
move swiftly to the next job.
Operation
1) When brake pressure is being gener-
ated at port MB
• Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected
to e.
When this happens, pressure MA is below
the set pressure of spring (3), so spool (2)
does not move. For this reason, the pres-
sure oil is closed by spool (2), and the brak-
ing force is ensured.
2) After motor stops

• The motor is reversed by the closing pres-
sure generated at port MB. (1st reversal)
When this happens, reversal pressure is
generated at port MA. Pressure MA goes
to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is con-
nected to B. At the same time, b is con-
nected to f through the drill hole in spool
(5), so the reversal pressure at port MA is
bypassed to port T to prevent the 2nd
reversal.
PC300-7 10-79
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT
1. Cover A1. To L.H. travel motor port PB T2. To tank

2. Body A2. From control valve port A2 T1. From L.H. and R.H. travel motors port T
3. Slipper seal C1. To R.H. travel motor port PA D2. From control valve port B5
4. O-ring B2. From control valve port B2 B1. To L.H. travel motor port PA
5. Shaft D1. To R.H. travel motor port PB C2. From control valve port A5
E. To L.H. and R.H. travel motors port P
Unit: mm
No. Check Item Criteria Remedy
Clearance between rotor Standard Size Standard clearance Repair limit

6 Replace
and shaft 80 — —
10-80 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV160ADT-2
P : From travel speed solenoid valve SPECIFICATIONS

T : To tank
PA : From control valve Type HMV160ADT-2
PB : From control valve Theoretical Min. 103.5 cm³/rev
Delivery Max. 160.8 cm³/rev
Brake releasing pressure 1.2 MPa {12 kg/cm²}
Travel speed
Differential
switching 0.8 MPa {8 kg/cm²}
pressure
pressure
PC300-7 10-81
12
1. Output shaft 11. Plate

2. Motor case 12. Disc
3. Rocker cam 13. Regulator piston
4. Piston 14. Check valve spring
5. Cylinder 15. Counterbalance valve
6. Valve plate 16. Safety valve
7. End cover 17. Ball
8. Slow return valve 18. Regulator valve
9. Brake spring 19. Spring
10. Brake piston
10-82 PC300-7
12
Unit: mm

20 Spool return spring Outside diameter length load length load
426.3 N 341 N If damaged or
58.43 x 30.0 42.0 —
{43.5 kg} {34.8 kg} deformed,
replace spring
1.27 N 1.0 N
21 Check valve spring 33.0 x 13.8 23.0 —
{0.13 kg} {0.10 kg}
398.9 N 319.5 N
22 Regulator piston spring 61.6 x 23.2 30.0 —
{40.7 kg} {32.6 kg}
PC300-7 10-83
OPERATION OF MOTOR
1) At low speed (motor swash plate angle
at maximum)
09151
• The solenoid valve is deactivated, so the pilot • At the same time, the pressurized oil at regu-
pressure oil from the main pump does not lator piston (13) passes through orifice c in
flow to port P. regulator valve (21) and is drained to the
For this reason, regulator valve (21) is pushed motor case.
to the right by spring (22). • As a result, rocker cam (3) moves in the maxi-
• Because of this, it pushes slow return valve mum swash plate angle direction, the motor
(8), and the main pressure oil from the control capacity becomes maximum, and the system
valve going to end cover (7) is shut off by regis set to low speed.
ulator valve (21).
• Fulcrum a of rocker cam (3) is eccentric to
point of force b of the combined force of the
propulsion force of cylinder (5), so the com-
bined force of the piston propulsion force acts
as a moment to angle rocker cam (3) in the
direction of the maximum swash plate angle.
10-84 PC300-7
12
2) At high speed (motor swash plate angle

at minimum)
09152
• When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to
port P, and pushes regulator valve (21) to the
left.
• Because of this, the main pressure oil from
the control valve passes through passage d in
regulator valve (21), enters regulator piston
(13) at the bottom, and pushes regulator pis-
ton (13) to the right.
• As a result, rocker cam (3) moves in the mini-
mum swash plate angle direction, the motor
capacity becomes minimum, and the system
is set to high travel speed.
PC300-7 10-85
OPERATION OF PARKING BRAKE

1) When starting to travel
When the travel lever is operated, the pres-
surized oil from the pump actuates coun-
terbalance valve spool (17), opens the
circuit to the parking brake, and flows into
chamber a of the brake piston (10).
It overcomes the force of spring (9), and
pushes piston (10) to the left.
When this happens, the force pushing plate
(11) and disc (12) together is lost, so plate
(11) and disc (12) separate and the brake is 09153
released.
2) When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (17) returns to
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber a of brake
piston (10) is drained to the case from the
orifice in the brake piston, and brake piston
(10) is pushed to the right in the direction
of the arrow by spring (9).
As a result, plate (11) and disc (12) are
pushed together, and the brake is applied. 09154
A time delay is provided by having the
pressurized oil pass through a throttle in
slow return valve (8) when the brake piston
returns, and this ensures that the brake is
still effective after the machine stops.
10-86 PC300-7
(8)
OPERATION OF BRAKE VALVE

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

Function
• When traveling downhill, the weight of the
machine makes it try to travel faster than
the speed of the motor. 09155
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run
away, which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).
Operation when pressure oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is sup-
plied to port PA. It pushes open suction
safety valve (18a) and flows from motor 09156
inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18b) and spool (19), so
the pressure at the supply side rises. (Fig.
2)
• The pressurized oil at the supply side flows

from orifice E1 and E2 in spool (19) to
chamber S1. When the pressure in cham-
ber S1 goes above the spool switching
pressure, spool (19) is pushed to the right
in the direction of the arrow.
As a result, port MB and port PB are con- 09157
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
PC300-7 10-87
Operation of brake when traveling downhill

• 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 S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops
below the spool switching pressure, spool
(19) is returned to the left, in the direction of
the arrow by spring (20), and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the rota-
tion of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a position
09158
where the pressure at the outlet port MB bal-
ances 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 travel speed according to
the amount of oil discharged from the pump.
(Fig. 4)
2) Safety valve (2-direction operation, 2-
stage set safety valve)
Function
• When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counter-
balance valve. However, the motor is rotated
by inertia, so the pressure at the outlet port
of the motor will become abnormally high
and damage the motor or piping. The safety
valve acts to release this abnormal pressure
and send it to the inlet port side of the motor
to prevent damage to the equipment.
09160
Operation in both directions
1) When pressure in chamber MB has
become high (when rotating clockwise)
• When the travel is stopped (or when travel-
ing downhill), chamber MB in the outlet port
circuit is closed by the check valve of the
counterbalance valve, but the pressure at the
outlet port rises because of the inertia. (Fig.
5)
• If the pressure goes above the set pressure,
the force produced by the difference in are
between D1 and D2 [π4(D12 - D22) x pres-
sure] overcomes the force of the spring and
moves the poppet to the left, so that the oil
flows to chamber MA in the circuit on the
opposite side. (Fig. 6)
10-88 PC300-7
2) When pressure in chamber MA has

become high (when rotating counter-
clockwise)
• When the travel is stopped (or when traveling
downhill), chamber MA in the outlet port cir-
cuit is closed by the check valve of the coun-
terbalance valve, but the pressure at the 09161
outlet port rises because of inertia. (Fig. 7)
• If the pressure goes above the set pressure,

the force produced by the difference in area
09162
between D1 and D3 [π4(D32 - D12) x pres-
sure] overcomes the force of the spring and
moves the poppet to the left, so the oil flows
to chamber MB in the circuit on the opposite
side. (Fig. 8)
Operation of mechanism for varying set

pressure
1) When starting travel (high-pressure set-
ting)
• When the travel lever is operated, the pres-
surized oil from the pump actuated counter-
balance valve spool (19), and opens the pilot
circuit to the safety valve. The oil passes from
chamber G to passage H and flows into
chamber J, pushes the piston to the right, and
compresses the spring to make the set load
larger. Because of this, the set pressure of the
safety valve is switched to the high pressure
setting, and a large drawbar pull is made
available.
09163
PC300-7 10-89
2) When stopping travel (low-pressure set-

ting)
• When the travel lever is placed in neutral, the
pressure in chamber PA drops and counter-
balance valve spool (19) returns to the neutral
position. While the counterbalance valve
spool is returning to the neutral position, the
pressurized oil in chamber J passes through
passage H, and escapes to chamber PA from
chamber G. The piston moves to the left, and
the set load becomes smaller. Because of this, 09164
the set pressure of the safety valve is
switched to the low-pressure setting and
relieves the shock when reducing speed.
[Set pressure of safety valve]
When starting, when

When stopping: Low-
traveling: High-pres-
pressure setting
sure setting
40.2 MPa {410 kg/cm2} 27.5 MPa {280 kg/cm2}
10-90 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE
Function Operation
• This valve connects both travel circuits to each When pilot pressure is turned ON
other so that the hydraulic oil will be supplied • If the pilot pressure from the travel junction sole-
evenly to both travel motors and the machine will noid valve becomes higher than the force of
travel straight. spring (14), travel junction spool (13) moves to the
• When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST closes the travel junction valve to secure port PTL (Left travel circuit) and PTR (Right travel
high steering performance. circuit) is closed.
09165
PC300-7 10-91
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
When pilot pressure is turned OFF

• If pilot pressure PST from the sole- • If the oil flow rates in both travel motors
noid valve is 0, travel junction spool become different from each other, the oil
(13) is pressed by the force of spring flows through the route between port PTL,
(14) against the right side and the travel junction spool (13), and port PTR so
pass between ports PTL and PTR is that the oil flow rates will be equalized again.
open.
09166
10-92 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE

Function
• If boom RAISE or arm IN are operated when
the machine is traveling, the stroke of the
spools for the boom and arm is controlled by
the travel PPC pressure and this limits the
flow of oil to the boom and arm cylinders.
• When the boom and arm stroke is controlled,
the travel PPC pressure passes through the
circuit inside the control valve to actuate the
system.
Operation
1 When travel is at neutral
• Stroke limit signal chambers a and b are con-
nected to the travel PPC valve through ori-
fices (5) and (6) in pistons (3) and (4) inside
the travel spring case, and the is drained.
• When arm IN is operated, spool (1) moves to the
right by stroke (st0) to a point where it contacts the
end face of spring case (2).
• When boom RAISE is operated, spool (9) moves to
the left by stroke (st3) to a point where it contacts
the end face of spring case (10).
10-94 PC300-7
09167
PC300-7 10-95
12
2. When travel is operated
• When the travel lever is operated to right
REVERSE (or FORWARD), the right (REVESE
(or FORWARD) PPC pressure pushes spool (7)
to the left (or right).
• Spool (7) pushes piston (3), orifice (5) closes,
and stroke limit signal chamber a is shut off
from the drain circuit of the travel PPC valve.
• At the same time, the right REVERSE (or FOR-
WARD) PPC pressure passes through orifice
(6) in piston (4), acts on the right end face of
piston (8), and pushes piston (8) to the left.
• If arm IN is operated, spool (1) moves to the
right, but the maximum stroke of the spool is
limited by the amount of movement st2 of
piston (8) and becomes st1.
• If boom RAISE is operated, spool (9) tries to
move to the left, but the travel PPC pressure
enters stroke control signal chamber b, so the
spool does not move.
10-96 PC300-7
09168
PC300-7 10-97
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Solenoid valve A. Hold J. Swing "RIGHT"
2. Service PPC valve 9. Accumulator B. Boom "RAISE" K. Swing "LEFT"
3. Service pedal 10. Control valve C. Boom "LOWER" L. Neutral
4. L.H. travel lever 11. Hydraulic pump D. Bucket "DUMP" M. Travel "REVERSE"
5. R.H. travel lever 12. Junction box E. Bucket "CURL" N. Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equipment F. Hold
7. R.H. work equipment control lever G. Arm "IN"
control lever 14. L.H. PPC valve H. Arm "OUT"
10-98 PC300-7
(8)
WORK EQUIPMENT • SWING PPC
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE
WORK EQUIPMENT • SWING PPC VALVE
P: From main pump P1: Left: Arm OUT / Right: Boom LOWER
T: To tank P2: Left: Arm IN / Right: Boom RAISE
P3: Left: Swing RIGHT / Right: Bucket CURL
P4: Left: Swing LEFT / Right: Bucket DUMP
PC300-7 10-99
12
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

Centering spring
12 Outside diameter length load length load
(For P3 and P4)
42.5 x 15.5 34 —
replace spring
Centering spring 29.4 N 23.5 N
13 44.5 x 15.5 34 —
(For P3 and P4) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.4 kg}
10-100 PC300-7
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) During fine control (neutral → fine

control)
When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is
shut off from drain chamber D, and at
almost the same time, it is connected to
pump pressure chamber PP, so pilot pres-
sure oil from the main pump passes
through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it is connected to drain chamber D to
release the pressure at port P1. When this
happens, spool (1) moves up or down so
that the force of metering spring (2) is bal-
anced with the pressure at port P1. The
relationship in the position of spool (1) and
body (10) (fine control hole f is at a point
midway between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control lever, so the pres-
sure at port P1 also rises in proportion to
the travel of the control lever. In this way,
the control valve spool moves to a position
where the pressure in chamber A (the
same as the pressure at port P1) and the
force of the control valve spool return
spring are balanced. (Fig. 2)
PC300-7 10-101
12
3) During fine control (when control

lever is returned)
• When disc (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
connected to drain chamber D and the
pressure oil at port P1 is released.
If the pressure at port P1 drops too far,
spool (1) is pushed down by metering
spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same
time, it is connected to pump pressure
chamber PP, and the pump pressure is sup-
plied until the pressure at port P1 recovers
to a pressure that corresponds to the lever
position.
When the spool of the control valve
returns, oil in drain chamber D flows in
from fine control hole f in the valve on the
side that is not working. The oil passes
through port P2 and enters chamber B to
fill the chamber with oil. (Fig. 3)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine
control hole f is shut off from drain cham-
ber D, and is connected with pump pres-
sure chamber PP. Therefore, the pilot
pressure oil from the main pump passes
through fine control hole f and flows to
chamber A from port P1, and pushes the
control valve spool.
The oil returning from chamber B passes
from port P2 through fine control hole f
and flows to drain chamber D. (Fig. 4)
10-102 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From main pump P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
PC300-7 10-103
12
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
10-104 PC300-7
12
Unit: mm

1 Metering spring Outside diameter length load length load
26.5 x 8.15 24.7 —
replace spring
108 N 86.3 N
2 Centering spring 48.1 x 15.5 32.5 —
{11 kg} {8.8 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}
PC300-7 10-105
12
OPERATION
1) At neutral
Ports A and B of the control valve and
ports P1 and P2 of the PPC valve are con-
nected to drain chamber D through fine
control hole f in spool (1). (Fig. 1)
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2), and moves
down.
shut off from drain chamber D. At almost
the same time, it is connected to pump
pressure chamber PP, and the pilot pres-
sure of the main pump is sent from port A
through fine control hole f to port P1.
When the pressure at port P1 rises, spool
(1) is pushed back. Fine control hole f is
shut off from pump pressure chamber PP.
At almost the same time, it is connected to
drain chamber D, so the pressure at port
P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure at port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump
pressure chamber PP) does not change
until retainer (9) contacts spool (1).
Therefore, metering spring (2) is com-
pressed in proportion to the travel of the
control lever, so the pressure at port P1
also rises in proportion to the travel of the
control lever. In this way, the spool of the
control valve spool moves to a position
where the pressure of chamber A (same as
pressure at port P1) and the force of the
return spring of the control valve spool are
balanced. (Fig. 2)
10-106 PC300-7
12
3) Fine control (control lever returned)

When lever (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port P1.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring
(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 P1 supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3)
4) At full stroke
Lever (5) pushes down piston (4), and
retainer (9) pushes down on spool (1). Fine
control hole f is shut off from drain chamber
D, and is connected to pump pressure
chamber PP. Therefore, the pilot pressure
oil from the main pump passes through fine
control hole f and flows to chamber A from
port P1 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. (Fig. 4)
PC300-7 10-107
2. Travel signal/Steering function

• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as
the travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the
higher one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in
neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1) While in NEUTRAL
The signals of the output ports (P1 - P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
10-108 PC300-7
2) While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor
is also operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber
(k) and right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal
valve is kept in neutral and the steering signal (Port P6) is not output.
PC300-7 10-109
12
3) When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the
difference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is
output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is
P2. The pressure in right spring chamber (l) is P4.
If (P4 - P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the
arrow and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is out-
put as the steering signal to port P6.
10-110 PC300-7
12
4) When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber
(l) of steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and out-
puts the steering signal (port P6).
PC300-7 10-111
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
Unit: mm

9 Centering spring Outside diameter length load length load If damaged or
124.5 N 100 N deformed,
33.9 x 15.3 28.4 — replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 x 8.1 22 —
{1.7 kg} {1.4 kg}
10-112 PC300-7
OPERATION
At neutral
• The pressurized oil from the main pump
enters from port P and is blocked by spool
(1).
• Ports A and B of the control valve and
ports a and b of the PPC valve are con-
nected to drain port T through fine control
hole X of spool (1).
WHEN OPERATED
• When lever (5) is moved, metering spring

(2) is pushed by piston (4) and retainer (7),
and spool (1) is pushed down by this.
• As a result, fine control portion Y is con-
nected with port a, and the pressurized oil
from port P flows from port a to port A of
the control valve.
PC300-7 10-113
• When the pressure at port a becomes

higher, spool (1) is pushed back by the
force acting on the end of the spool, and
fine control portion Y closes.
• As a result, spool (1) moves up and down
to balance the force at port a and the force
at metering spring (2).
• Therefore, metering spring (2) is com-
pressed in proportion to the amount the
control lever is moved. The spring force
becomes larger, so the pressure at port a
also increases in proportion to the amount
the control lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the control valve spool.
10-114 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction sole-
noid valves
1. PPC lock solenoid valve T : To tank A8 : To main valve (2-stage relief

2. Travel junction solenoid A1 : To PPC valve valve)
valve A2 : To main valve (Travel junc- P1 : From main pump
3. Merge-divider solenoid valve tion valve) ACC: To accumulator
4. Travel speed solenoid valve A3 . To main valve (Merge-
5. Swing brake solenoid valve divider valve)
6. Machine push-up solenoid A4 : To both travel motors
valve A5 : To swing motor
8. 2-stage relief solenoid valve A6 : To 2-stage safety valve at
boom cylinder head
PC300-7 10-115
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE
12
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
OPERATION
WHEN SOLENOID IS TURNED OFF
• Since the signal current does not flow from

the controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring
(6) against the left side.
By this operation, the pass from P to A is
closed and the hydraulic oil from the main
pump does not flow into the actuator.
At this time, the oil from the actuator is
drained through ports A and T into the
tank.
WHEN SOLENOID IS TURNED ON
The signal current flows from the controller

to solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to
the right side.
By this operation, the hydraulic oil from the
main pump flows through port P and spool
(4) to port A, then flows into the actuator.
At this time, port T is closed and the oil
does not flow into the tank.
10-116 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PPC ACCUMULATOR
PPC ACCUMULATOR
1 1. Gas plug
2. Shell
3. Poppet
4. Holder
2 5. Bladder
6. Oil port
3 SPECIFICATIONS
Gas capacity:300 cc (for PPC)
SBP00290
PC300-7 10-117
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER
FOR BREAKER
SPECIFICATIONS
1. Drain plug Rated pressure: 6.9 MPa {70 kg/cm2}

2. Element Flow : 200 l/min.
3. Case Relief valve cracking pressure:
4. Head cover 0.34 ± 0.05 MPa
5. Relief valve {3.5 ± 0.5 kg/cm2}
Filter mesh size: 6 µm
Filtering area : 4,570 cm2
10-118 PC300-7
BOOM HYDRAULIC DRIFT
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PREVENTION VALVE
BOOM HYDRAULIC DRIFT PREVENTION VALVE

Function
• When the boom lever is not being operated,

these valves act to prevent the oil at the boom
bottom from leaking from spool (1) and pre-
vent the boom from moving down.
Operation
1. Boom RAISE
When the boom RAISE is operated, the main
pressure oil acts in the left direction on ring-
shaped area A (= Area of ∅d1 - Area of ∅d2)
because of the difference in the outside diam-
eter d1 of poppet (5) and seat diameter d2.
When it overcomes the force of spring (4),
poppet (5) moves to the left.
In addition, the main pressure oil acts in the
right direction on seat diameter d3 of valve
(6). When it overcomes the force of spring (4),
valve (6) moves to the right.
As a result, the main pressure oil prom the
control valve passes through the opening of
poppet (5) and flows to the bottom end of the
boom cylinder.
10-120 PC300-7
09169
PC300-7 10-121
2. Boom at HOLD
• When the boom is raised and the control
lever is returned to the HOLD position, the oil
that has flowed into the inside of poppet (5)
through orifice a in poppet (5) is closed by
pilot piston (2).
The main pressure oil and hold pressure at
the bottom of the boom cylinder are shut off.
• At the same time, the hold pressure at the
bottom end of the boom cylinder acts in the
right direction on ring-shaped area A (= Area
of ∅d1 - Area of ∅d2) because of the differ-
ence in the outside diameter d1 of poppet (5)
and seat diameter d2. Poppet (5) is closed by
the total of this force and the force of spring
(4), so the main pressure oil and hold pres-
sure at the bottom of the boom cylinder are
shut off.
• In addition, the hold pressure at the bottom of
the boom cylinder acts in the left direction on
outside diameter d4 of valve (6).
• Valve (6) is closed by the total of this force
and the force of spring (4), so the main pres-
sure oil and hold pressure at the bottom of
the boom cylinder are shut off. As a result, the
boom is held in position.
10-122 PC300-7
09170
PC300-7 10-123
3. Boom LOWER
• When boom LOWER is operated, the pilot
pressure from the PPC valve pushes pilot
spool (2), and the pressure oil chamber b
inside the poppet is drained through ori-
fice c.
The oil at the bottom end of the boom
flows from orifice a to chamber b to ori-
fice c to drain, so the oil pressure in
chamber b drops.
When the pressure in chamber b drops
below the pressure at port b, poppet (4)
opens, and the pressure oil from port B
goes to port A and flows to the control
valve.
10-124 PC300-7
4. When abnormally high pressure is gener-

ated • If the hydraulic drift prevention valve for the
• If abnormally high pressure is generated in arm cylinder head circuit is installed
the boom cylinder bottom circuit, the hydrau- (optional), the hydraulic oil in the boom cylin-
lic oil in port B pushes check valve (6) open, der bottom circuit or that in the arm cylinder
then safety valve (3) operates. head circuit, having higher pressure, pushes
check valve (6) open, then safety valve (3)
operates.
09171
PC300-7 10-125
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD QUICK RETURN VALVE
QUICK RETURN VALVE

FUNCTION
When arm OUT is operated, this valve reduces

the pressure loss of the large amount of oil
returning from the cylinder bottom.
OPERATION
1. Arm at OUT
When arm OUT is operated, the pilot pressure
from the PPC valve pushes pilot spool (1), and
the pressure oil from chamber b inside the
poppet is drained through orifice c.
The oil at the bottom end of the arm flows
from orifice a to chamber b to orifice c to
drain, so the oil pressure in chamber b drops.
When the pressure in chamber b drops below
the pressure at port A, the pressure at port A
and acts on ring -shaped area C (= Area of
∅d1 - Area of ∅d2) because of the difference in
the outside diameter d1 of valve (2) and seat
diameter d2. Valve (2) moves to the left and
the pressure oil from port A goes to port B.
From port B, the oil is drained directly to the
tank.
10-126 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD QUICK RETURN VALVE
2. Arm at HOLD
The oil that has flowed through orifice a in
valve (2) is closed by pilot piston (1). At the
same time, the hold pressure at the bottom
end of the arm acts in the right direction on
ring-shaped area C (= Area of ∅d1 - Area of
∅d2) because of the difference in the outside
diameter d1 of valve (2) and seat diameter
d2. Valve (2) is closed by the total of this force
and the force of spring (3), so port A and port
B are shut off.
PC300-7 10-127
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD LIFT CHECK VALVE
LIFT CHECK VALVE
Function
This valve applies back pressure to the drain

circuit to prevent generation of negative pres-
sure on the hydraulic devices for the work
equipment (motors, cylinders, etc.)
Operation
1. While engine is stopped

Any oil is not supplied from the pump to
the self-pressure reducing valve and valve
(1) is pressed by only the force of spring (2)
toward the right and drain circuit "a" of the 09174
control valve is connected through orifice
"b" of valve (1) to port T.
2. While engine is running

• Output pressure PR of the self-pressure
reducing valve is applied through the con-
trol valve to spring chamber "c" of the back
pressure valve.
• Output pressure PR applied to spring
chamber "c" is applied to the left end of
valve (1) (area of ∅d) to push valve (1) to
the right. 09175
• At this time, pressure PA of drain circuit "a"
of the control valve is applied to the right
end of valve (1) (area of ∅d1) to push valve
(1) to the left.
• Valve (1) is balanced so that the back pres-
sure PA will be as follows.
PA = {(Area of ∅d) x PR + Force of spring
(2)} / (Area of ∅d1)
10-128 PC300-7
ATTACHMENT CIRCUIT SELECTOR
ATTACHMENT CIRCUIT SELECTOR VALVE
1. Spool V : To control valve

2. Spring T : To hydraulic tank
ATT: To attachment
ACC: To accumulator
P1 : From attachment circuit selector solenoid valve
TS : To hydraulic tank
Unit: mm

Replace spring if
Free length x Installed Installed Installed
Spool return Free length any damages or
3 Outside Dia. length load load
spring deformations are
833 N 666 N found
132.0 x 29 114.5 --
{85.0 Kg} {68.0 Kg}
PC300-7 10-129
ATTACHMENT CIRCUIT SELECTOR
Function
When a breaker is installed, the return oil from

the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
When other attachments (crusher, etc.) are
installed, the attachment and the main valve are
interconnected.
Operation
1. When attachment other than breaker is

installed
Spool (1) is pushed fully to the left by the 08901
force of spring (2), ATT port and port V are
interconnected, and ATT port and port T are
shut off, so the attachment and main valve are
interconnected.
2. When breaker is installed

When the pilot pressure from the attachment
circuit selector solenoid valve overcomes the
force of spring (2), the spool (1) moves fully to
the right. ATT port and port V are shut off and
ATT port and port T are interconnected, so the
oil returning from the breaker does not pass 08902
through the main valve, but passes through
port T and returns directly to the hydraulic
tank.
10-130 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-132 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER
12
Unit: mm
Standard Tolerance Standard clear- Clearance

Cylinder
size Shaft Hole ance limit
-0.036 +0.035
Clearance between Boom 100 0.041 ~ 0.125 0.412
-0.090 +0.005 Replace bush-
1 piston rod and bush-
ing
ing -0.036 +0.261
Arm 110 0.083 ~ 0.351 0.412
-0.090 +0.047
-0.030 +0.257
Bucket 100 0.083 ~ 0.347 0.447
-0.076 +0.047
-0.030 +0.190
Boom 100 0.100 ~ 0.250 —
-0.060 +0.070
Clearance between
-0.030 +0.190
2 piston rod support Arm 100 0.105 ~ 0.251 —
-0.076 +0.070
pin and bushing
-0.030 +0.190
Bucket 90 0.100 ~ 0.246 —
-0.076 +0.070 Replace pin or
-0.030 +0.190 bushing
Boom 90 0.075 ~ 0.225 —
-0.060 +0.070
Clearance between
cylinder bottom -0.030 +0.190
3 Arm 100 0.105 ~ 0.251 —
support pin and -0.076 +0.070
bushing
-0.030 +0.190
Bucket 90 0.100 ~ 0.230 —
-0.060 +0.070
PC300-7 10-133
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-134 PC300-7
Unit: mm
Tolerance
Standard Standard clear- Clearance
Clearance between connecting size ance limit
Shaft Hole
1 pin and bushing of revolving
frame and boom -0.036 +0.157
110 0.115 ~ 0.247 1.0
-0.090 +0.079
Clearance between connecting -0.036 +0.179

2 110 0.117 ~ 0.269 1.0
pin and bushing of boom and arm -0.090 +0.081

3 90 0.108 ~ 0.255 1.0
pin and bushing of arm and link -0.090 +0.072 Replace
Clearance between connecting

-0.036 +0.145
4 pin and bushing of arm and 90 0.119 ~ 0.235 1.0
-0.090 +0.083
bucket
Clearance between connecting

-0.036 +0.165
5 pin and bushing of link and 90 0.108 ~ 0.255 1.0
-0.090 +0.072
bucket

6 90 0.105 ~ 0.253 1.0
pin and bushing of link and link -0.090 +0.069
7 Bucket clearance (a) 0.5 ~ 1.0

Adjust shims
8 Bucket clearance (b) 2.0
PC300-7 10-135
1. DIMENSION OF ARM
10-136 PC300-7
Unit: mm
Model PC300-7, PC300LC-7 PC350-7, PC350LC-7

No.
1 φ 100 +0.1 –0.036

0 / –0.071 φ 100 +0.1 –0.036
0 / –0.071
+1.5 +1.5
2 119.3 0 / 116±1.2 119.3 0 / 116±1.2
+0.5 –0.3 +0.5 –0.3
3 320 0 / 316 –0.8 320 0 / 316 –0.8
4 φ 110 +0.1 –0.036

0 / –0.090 φ 110 +0.1 –0.036
0 / –0.090
5 470.6 ± 1 470.6 ± 1
6 236.5 ± 0.5 236.5 ± 0.5
7 1022.4 ±1 1022.4 ±1
8 3,178 ± 3 3,178 ± 3
9 2,975.6 ± 1 2,975.6 ± 1
10 472.5 472.5 ± 1.0
11 731.0 ± 0.2 731.0 ± 0.2
12 728.0 ± 0.5 728.0 ± 0.5
13 513.6 513.6
14 1,670 1,670
15 φ 90 +0.2 –0.036
0 / –0.090 φ 90 +0.2 –0.036
0 / –0.090
16 345.0 ± 0.5 345.0 ± 0.5
17 φ 90 +0.054
0 / –0.036
–0.090 φ 90 +0.054
0 / –0.036
–0.090
0 0
Arm as individual part 330 – 0.5 330 – 0.5
18
When pressfitting bushing 345 345
Min. 1,870 1,870

19
Max. 3,155 3,155
PC300-7 10-137
(10)
12
2.DIMENSION OF BUCKET
10-138 PC300-7
12
Unit: mm
Model
PC300-7, PC300LC-7 PC350-7, PC350LC-7
No.
1 512.2 ± 0.5 512.2 ± 0.5
2 37.9 ± 0.5 37.9 ± 0.5
3 94° 19’ 94° 19’
4 513.6 513.6
5 1,658 1,666
6 193 208
7 — —
8 50° 42°
+0.2
9 φ 90 0
+1
10 346 0
11 68 68
12 138 138
13 525.5 ± 0.5 525.5 ± 0.5
14 ∅ 26 ∅ 26
A ∅ 165 ∅ 165
15
B ∅ 150 ∅ 150
16 ∅ 200 ∅ 200
17 146.1 135.5
18 137.6 142.0
19 R115 R115
20 R100 R100
+2
21 370 0
22 60 60
PC300-7 10-139
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pickup piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Hot water return piping C. Hot air/cold air
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct
10-140 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery relay
OUTLINE
2. Battery
3. Starting switch • The engine can be started and stopped with
4. Fuel control dial only starting switch (3).
5. Linkage
• The engine throttle and pump controller(7)
6. Starting motor
receives the signal of fuel control dial (4) and
7. Engine throttle and pump controller
transmits the drive signal to governor motor
8. Fuel injection pump
(9) to control the governor lever angle of fuel
9. Governor motor
injection pump (8) and control the engine
speed.
PC300-7 10-141
12
1. OPERATION OF SYSTEM
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor
turns to start the engine.
When this happens, the engine throttle and
pump controller checks the signal from the
09176
fuel control dial and sets the engine speed
to the speed set by the fuel control dial.
• If the engine stop solenoid (shut-off valve)
is not driven before starting the engine, the
engine will not start.
(At the same time as the starting signal for
the starting motor is input from the control-
ler, the drive signal is output for 3 sec-
onds.)
Engine speed control
• The fuel control dial sends a signal to the
engine throttle and pump controller
according to the position of the dial. The
engine throttle and pump controller calcu-
lates the angle of the governor motor
according to this signal, and sends a signal 09177
to drive the governor motor so that it is at
that angle.
When this happens, the operating angle of
the governor motor is detected by the
potentiometer, and feedback is sent to the
engine throttle and pump controller, so
that it can observe the operation of the
governor motor.
Stopping engine
• When the engine throttle and pump con-
troller detects that the starting switch has
been turned to the STOP position, it drives
the governor motor so that it is set to the
low idling angle position. 09178
The engine stop solenoid signal (HOLD)
which drives directly from the ACC signal is
turned OFF and the engine stops.
• When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump
controller itself drives the battery relay.
10-142 PC300-7
12
1. COMPONENT
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed under the
monitor panel, and a potentiometer is
installed under the knob. The potentiome-
ter shaft is turned by turning the knob.
• As the potentiometer shaft is turned, the
resistance of the variable resistor in the
potentiometer changes and a throttle sig-
nal is sent to the engine throttle and pump
controller.
The hatched area in the graph shown at
right is the abnormality detection area.
PC300-7 10-143
Governor motor
1. Potentiometer • A potentiometer for feedback is installed to

2. Cover monitor the operation of the motor.
3. Shaft • Revolution of the motor is transmitted
4. Dust seal through the gear to the potentiometer.
5. Bearing
6. Motor Operation
7. Gear While motor is stopped
8. Connector
• Electric power is applied to both phases A
and B of the motor.
Function
• The motor is turned according to the drive
While motor is running
signal from the engine throttle and pump
controller to control the governor lever of the • The engine throttle and pump controller sup-
fuel injection pump. plies a pulse current to phases A and B, and
the motor revolves, synchronizing to the
This motor used as the motive power source
pulse.
is a stepping motor.
10-144 PC300-7
Engine throttle and pump controller
10-146 PC300-7
12
Input and output signals
CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 — 1 NC Output 1 VB (controller power) Input
2 R pump pressure sensor 2 Swing emergency switch Input 2 VIS (solenoid power) Input
3 — Input 3 NC Input 3 SOL_COM (solenoid common gnd)
4 Signal GND Input 4 232C_RxD Input 4 Battery relay drive Output
Abnormality in auto-greasing con- 5 Overload sensor (ON/OFF) Input 5 Governor motor A phase (+) Output
5 Input
troller 6 Overload alarm valid switch Input 6 LS-EPC Output
6 NC Input 7 Model selection 4 Input 7 Travel junction SOL Output
7 Overload sensor (analog) Input 8 Attachment circuit selector signal Output 8 Engine stop solenoid (Pull) Output
8 F boom pressure sensor Input 9 NC Output 9 Bucket CURL pressure SW Input
9 — 10 NC Input 10 Boom RAISE pressure SW Input
10 Signal GND Input 11 NC Output 11 VB (controller power) Input
11 Knob SW Input 12 CAN shield 12 VIS (solenoid power) Input
12 NC Input 13 Model selection 5 Input 13 SOL_COM (solenoid common gnd)
13 Governor motor FB potentiometer Input 14 232C_TxD Output 14 KEY_SIG Input
14 — 15 NC Input 15 Governor motor A phase (-) Output
15 NC Input 16 Travel steering signal pressure SW Input 16 PC-EPC Output
16 SENS_PWR Output 17 Model selection 3 Input 17 Pump merge/divider solenoid Output
17 Key Switch (Terminal C) Input 18 — 18 Heater relay drive Output
18 NC Input 19 NC Output 19 Bucket DUMP pressure switch Input
19 Throttle potentiometer Input 20 NC Input 20 Boom LOWER pressure switch Input
20 NC Input Input/ 21 GND (controller GND)
21 S_NET
21 GND (analog GND) output 22 VIS (solenoid PWR) Input
22 POT_PWR Output Input/ 23 SOL_COM (solenoid common gnd)
22 CAN0_L
23 Key switch (terminal ACC) Input output 24 KEY_SIG Input
Input/ 25 Governor motor B phase (+) Output
24 — 23 CAN1_L
output 26 Service flow adjustment EPC (1) Output
27 Travel Hi/Lo selector solenoid Output
24 —
28 2-stage relief solenoid Output
25 NC Input 29 Swing pressure switch Input
26 NC Input 30 Arm IN pressure switch Input
27 Model selection 2 Input 31 GND (controller GND)
28 NC Input 32 GND (controller GND)
29 GND (pulse GND) 33 GND (controller GND)
30 NC Input 34 NC
31 GND (S_NET GND) Input 35 Governor motor B phase (-) Output
Input/ 36 NC Output
32 CAN0_H
output 37 Swing parking brake solenoid Output
Input/ 38 NC Output
33 CAN1_H
output 39 Travel pressure switch Input
40 Arm OUT pressure switch Input
34 GND (232C GND)
35 Service valve pressure switch Input

36 NC Input
37 Model selection switch 1 Input
38 Swing lock switch Input
39 GND (pulse GND)
40 Engine speed sensor Input
PC300-7 10-147
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM
Control function 1
Engine/Pump composite control function
Pump/Valve control function
One-touch power maximizing function

Machine push-up function
Auto-deceleration function
Auto-warm-up/Overheat prevention function

Electronic control system
6
Swing control function
Travel control function
ATT flow control, circuit selector function (option)
Self-diagnosis function
★ For the self-diagnosis function, see "TROUBLE SHOOTING".
PC300-7 10-149
TOTAL SYSTEM DIAGRAM
10-150 PC300-7
(10)
09179
PC300-7 10-151
1. Engine and Pump control function
SJP09121
OR
08908
10-152 PC300-7
FUNCTION
• The operator can set the work mode switch

on the monitor panel to mode A, E, or B (or
L) and select proper engine torque and SJP08755
pump absorption torque according to the
type of work. OR
• The engine throttle and pump controller
detects the speed of the engine governor 08909
set with the fuel control dial and the actual
engine speed and controls them so that the
pump will absorb all the torque at each out-
put point of the engine, according to the
pump absorption torque set in each mode.
: The L mode is on the multi-monitor specifi-
cation machine only.
SJP09180
SJP08757
OR
08911
PC300-7 10-153
12
1) Control method in each mode

Mode A, Mode E
• Matching point in mode A: Rated speed
Mode A
180.2 kW/1,950 rpm {242 HP/1,950 rpm}
(Work)
Mode A 09181
180.2 kW/1,900 rpm {242 HP/1,900 rpm}
(Travel)
Mode E 154.4 kW/1,750 rpm {207 HP/1,750 rpm}
• If the pump load increases and the pressure

rises, the engine speed lowers.
At this time, the controller lowers the pump
discharge so that the engine speed will be
near the full output point. If the pressure low-
ers, the controller increases the pump dis-
charge so that the engine speed will be near 09182
the full output point.
By repeating these operations, the controller
constantly uses the engine near the full out-
put point.
SJP08760
OR
08914
10-154 PC300-7
12
Mode B / (Mode L)
Mode Mode B Mode L
Partial output point 82% 61%
09183
147.1 kW/1,800 rpm

Mode B
{197 HP / 1,800 rpm}
110.3 kW/1,550 rpm

(Mode ❈L)
{148 HP / 1,550 rpm}
• At this time, the controller keeps the pump

absorption torque along the constant horse-
power curve and lower the engine speed by
the composite control of the engine and
pump.
09184
By this method, the engine is used in the low
fuel consumption area.
: The L mode is on the multi-monitor specifica-
tion machine only.
09185
PC300-7 10-155
12
2) Function to control pump during

travel
• When the travel is operated in A operation,
or E or B working mode, the working mode
stays as it is, and the pump absorption
torque and engine speed rise to A travel
mode.
09186
• If the machine travels in mode L, the work-

ing mode and engine speed do not change,
but the pump absorption torque is
increased.
: The L mode is on the multi-monitor specifi-
3) Function to control when emergency

pump drive switch is turned ON
• Even if the controller or a sensor has a
trouble, the functions of the machine can
be secured with pump absorption torque
almost equivalent to mode E by turning on
emergency pump drive switch (10).
In this case, a constant current flows from
the battery to the EPC valve for PC and the
oil pressure is sensed by only the EPC
valve for PC.
4) Function of engine drive switch when

emergency occurs
• If there is a failure in the controller or any
problem in the chassis wiring or relays,
and the engine cannot be started because
the engine stop solenoid cannot drive, turn
the switch ON for approx. 5 seconds before
the starting signal comes ON. This makes it
possible to drive the solenoid forcibly.
(However, if current flows through this
solenoid continuously for more than 30
seconds, there is danger that it will burn
out, so correctly control the time that the
current flows.)
10-156 PC300-7
12
2. Pump/Valve control function
SJP08765
OR
08921
Function
• The machine is matched to various types of
work properly with the 2-stage relief function
to increase the digging force, etc.
PC300-7 10-157
12
1) LS control function
• The change point (LS set differential pressure)
of the pump discharge in the LS valve is
changed by changing the output pressure
from the LS-EPC valve to the LS valve accord-
ing to the operating condition of the actuator.
• By this operation, the start-up time of the
pump discharge is optimized and the com-
posite operation and fine control perfor-
mance is improved.
2) Cut-off function
09187
• When the cut-off function is turned on, the
PC-EPC current is increased to near the maxi-
mum value.
By this operation, the flow rate in the relief
state is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off
function
Condition
• The average value of the front and rear

pressure sensors is above 27.9 MPa {285
kg/cm²} and the one-touch power maximiz-
ing function is not turned on
The cut-off function does not work, however,

while the machine is travelling in mode A or the
arm crane operation width swing lock switch is
turned on.
1. 2-stage relief function
• The relief pressure in the normal work is 34.8
MPa {355 kg/cm²}. If the 2-stage relief function
is turned on, however, the relief pressure
rises to about 37.2 MPa {380 kg/cm²}.
By this operation, the hydraulic force is
increased further.
• Operating condition for turning on 2-stage
relief function
Condition Relief pressure
• During travel
• When swing lock switch is 34.8 MPa
turned on {355 kg/cm²}
• When boom is lowered ⇓
• When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm²}
• When L mode is operated
: The L mode is on the multi-monitor speci-

fication machine only.
10-158 PC300-7
12
3. One-touch power maximizing/machine

push-up function
09188
FUNCTION
• Power can be increased for a certain time by

operating the left knob switch.
• When the machine push-up switch is oper-
ated, the boom pushing force is increased.
PC300-7 10-159
12
1) One-touch power maximizing function

• When the operator needs more digging force
to dig up a large rock, etc., if the left knob
switch is pressed, the hydraulic force is
increased about 7% to increase the digging
force.
• If the left knob switch is turned on in working
mode "A" or "E", each function is set automat-
ically as shown below.
⇓
Software cut-off function
Software
Working Engine/Pump
2-stage relief function Operation time cut-off func-
mode control
tion
34.8 MPa {355 kg/cm²}
Matching at rated Automatically
A, E ⇓ Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm²}
2) Machine push-up function

• Operate switch (1) to increase the boom push-
ing force when digging ditches or holes on
hard ground.
2-stage safety valve

Switch
function
Setting of safety valve at

OFF boom cylinder
14.7 MPa {150 kg/cm²}
Setting of safety valve at

ON boom cylinder
28.4 MPa {290 kg/cm²}
10-160 PC300-7
12
4. Auto-deceleration function
SJP08767
OR
08924
FUNCTION
• If the all control levers are set in NEUTRAL

while waiting for a dump truck or work, the
engine speed is lowered to the medium level
automatically to reduce the fuel consumption
and noise.
• If any lever is operated, the engine speed
rises to the set level instantly.
PC300-7 10-161
12
OPERATION
WHEN CONTROL LEVERS ARE SET IN NEU-

TRAL
• If all the control levers are set in NEUTRAL

while the engine speed is above the decelera-
tor operation level (about 1,400 rpm), the
engine speed lowers instantly to the first
deceleration level about 100 rpm lower than
the set speed.
• If 4 more seconds pass, the engine speed
lowers to the second deceleration level
(about 1,400 rpm) and keeps at that level until
any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
• If any control lever is operated while the

engine speed is kept at the second decelera-
tion level, the engine speed rises instantly to
the level set with the fuel control dial.
10-162 PC300-7
12
5. Auto-warm-up/Overheat prevention
function
SJP08768
OR
08925
FUNCTION
• After the engine is started, if the engine cool-

ing water temperature is low, the engine
speed is raised automatically to warm up the
engine. If the engine cooling water tempera-
ture rises too high during work, the pump
load is reduced to prevent overheating.
PC300-7 10-163
12
1) Auto-warm-up function
• After the engine is started, if the engine cool-
ing water temperature is low, the engine
speed is raised automatically to warm up the
engine.
Operating condition (All) Operated
Water temperature: Below 30°C.

Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm
⇓
Resetting condition (Any one) Reset
⇒
Water temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.
Manual
or longer
2) Overheat prevention function • This function is turned on when the water

• If the engine cooling water temperature rises temperature rises above 95°C.
too high during work, the pump load and
engine speed are reduced to prevent over-
heating.
Operating condition Operation/Remedy Resetting condition

Water temperature: Below 105°C
Fuel control dial: Return to low idle
⇒ ⇒
Work mode: Any mode
Water temperature: Engine speed: Low idle position once.
Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller
Alarm buzzer: Sounds is set to condition before operation
of function. (Manual reset)

⇒ ⇒
Work mode: Mode A, E, OR B
Water temperature: Engine speed: Keep as is. • Under above condition, controller
Above 102°C Monitor alarm lamp: Lights up. is set to condition before operation
Lower pump discharge. of function. (Automatic reset)

⇒ ⇒
Work mode: Mode A
Water temperature: • Under above condition, controller
Engine speed: Keep as is.
Above 100°C is set to condition before operation
Lower pump discharge.
of function. (Automatic reset)

⇒ ⇒
Work mode: Travel
Water temperature: • Under above condition, controller
Engine speed: Keep as is.
Above 95°C is set to condition before operation
Lower travel speed.
of function. (Automatic reset)
10-164 PC300-7
12
6. Swing control function
SJP08769
OR
08926
FUNCTION
The swing lock and swing holding brake func-

tions are installed.
PC300-7 10-165
12
1) Swing lock and swing holding brake 2) Quick hydraulic oil warm-up function
functions when swing lock switch is turned on
• The swing lock function (manual) is used to • If swing lock switch (4) is turned on, the
lock machine from swinging at any position. pump-cut function is cancelled and the relief
The swing holding brake function (automatic) pressure rises from 34.8 MPa {355 kg/cm²} to
is used to prevent hydraulic drift after the 37.2 MPa {380 kg/cm²}. If the work equipment
machine stops swinging. is relieved under this condition, the hydraulic
• Swing lock switch and swing lock/holding oil temperature rises quickly and the warm-up
brake time can be shortened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in neutral,

Swing swing brake operates in
OFF OFF holding about 7 sec. If swing lever is
brake operated, brake is released
and machine can swing freely.
Swing lock operates and

machine is locked from
Swing swinging. Even if swing lever
ON ON
lock is operated, swing lock is not
reset and machine does not
swing.
Operation of swing holding brake release

switch
• If the controller, etc. has a problem, the swing
holding brake does not work normally, and
the machine cannot swing, the swing lock can
be reset with the swing holding brake release
switch.
Swing hold- ON OFF

ing brake (When control has (When controller is nor-
release switch trouble) mal)
Swing lock
ON OFF ON OFF
switch
Swing Swing Swing lock Swing hold-
Swing brake lock is lock is is turned ing brake is
turned on. canceled. on. turned on.
★ Even if the swing holding brake release

switch is turned on, if the swing lock switch is
turned on, the swing brake is not released.
★ If the swing lock is reset, swinging is stopped
by only the hydraulic brake of the safety
valve. Accordingly, if swinging is stopped on
a slope, the upper structure may drift hydrau-
lically.
10-166 PC300-7
12
7. Travel control function
SJP08770
OR
08927
FUNCTION
• The pumps are controlled and the travel

speed is changed manually or automatically,
to secure proper travel performance matched
to the type of work and jobsite during travel.
PC300-7 10-167
12
1) Pump control function during travel
• If the machine travels in a work mode other
than mode A, the work mode and the engine
speed are kept as they are and the pump
absorption torque is increased.
★ For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
1. Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the governor/
pump controller controls the pump capac-
ity and motor capacity at each gear speed
as shown at right to change the travel
speed.
Travel speed Lo (Low ( Mi) (Mid- Hi (High

switch speed) dle Speed) speed)
Pump capacity
90 82 100
(%)
Motor capacity Max. Max. Min.
Travel speed
3.2 4.5 5.5
(km/h)
ii) Automatic change according to engine

speed
If the fuel control dial is used to set the
engine speed to less than 1,200 rpm:
• When traveling in Lo, it will not switch
even when set to Hi or Mi.
• When traveling in Hi or Mi, it will switch
automatically to Lo.
iii) Automatic changes according to pump
discharge pressure
When traveling with the travel speed
switch set to Hi or Mi, it the load
increases, such as when traveling uphill,
and the travel pressure goes above 3.23
MPa {330 kg/cm²} for more than 0.5 sec,
the travel motor capacity will automati-
cally change to low speed (equivalent to
Lo). (The travel speed switch will stay at
Hi or Mi.)
After continuing to travel in Lo, if the load
increases, such as when traveling on level 09189
ground or traveling downhill, and the
travel pressure goes below 18.6 MPa {190
kg/cm²} for more than 0.5 sec, the travel
motor capacity will automatically change
and will return to Hi or Mi.
: The "Mi" mode is on the multi-monitor specifi-
10-168 PC300-7
8. ATT flow control, circuit selector function (if equipment)
FUNCTION
This function is available only with the ATT speci-

fication. The function acts as follows according to
the flow command and working mode from the
monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is
on the multi-monitor specification machine
only.
PC300-7 10-169
9. System component parts

1) Engine revolution sensor
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
• The engine revolution sensor is installed to

the ring gear of the engine flywheel. It electri-
cally calculates the number of the gear teeth
which pass in front of it and transmits the
result to the engine throttle and pump con-
troller.
• A magnet is used to sense the gear teeth.
Each time a gear tooth passes in front of the
magnet, a current is generated.
10-170 PC300-7
12
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
SPECIFICATIONS
Type of contacts: Normally open contacts

Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm²}
Resetting (OFF) Pressure: 0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm²}
FUNCTION
• The junction block has 9 pressure switches,

which check the operating condition of each
actuator by the PPC pressure and transmit it
to the engine throttle and pump controller.
PC300-7 10-171
12
3) Pump pressure sensor
1. Sensor
2. Connector
FUNCTION
• The pump pressure sensor is installed to the

inlet circuit of the control valve. It converts
the pump discharge pressure into a voltage
and transmits it to the engine throttle and
pump controller.
OPERATION
• The oil pressure applied from the pressure

intake part presses the diaphragm of the oil
pressure sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm mea-
sures the deformation of the diaphragm by
the change of its resistance, then converts the SJP08774
change of the resistance into a voltage and
transmits it to the amplifier (voltage ampli- OR
fier).
• The amplifier amplifies the received voltage 08930
and transmits it to the engine throttle and
pump controller.
• Relationship between pressure P (MPa {kg/
cm²}) and output voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5
10-172 PC300-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MULTI MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
PC300-7 10-173
12
1. Monitor panel
OUTLINE
• The monitor panel has the functions to dis-

play various items and the functions to
select modes and electric parts.
The monitor panel has a CPU (Central Pro-
cessing Unit) in it to process, display, and
output the information.
The monitor display unit consists of LCD
(Liquid Crystal Display). The switches are
flat sheet switches.
10-174 PC300-7
Input and output signals
CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 Key ON Input 1 Engine coolant temperature Input 1 NC Input
2 Key ON Input 2 Fuel level Input 2 NC Input
3 Washer motor output Output 3 Radiator coolant level Input 3 NC Input
4 Starting signal Input 4 (Hydraulic oil level) Input 4 NC Input
5 Limit switch (W) Input 5 Air cleaner clogging Input 5 NC Input
6 GND 6 NC Input 6 NC Input
7 GND 7 Engine oil pressure Input 7 RS230C CTS Input
8 VB + Input 8 Engine oil level Input 8 RS230C RXD Input
9 Wiper motor (+) Output Input/ Input/
9 N/W signal 9 RS230C RXD
10 Wiper motor (-) Output Output Output
11 Buzzer ON signal Input Input/ Input/
10 N/W signal 10 RS230C RXD
12 Limit switch (P) Input Output Output
11 Battery charge Input 11 BOOTSW Input
12 Hydraulic oil temperature (analog) Input 12 NC Input
13 GND (for analog signal) 13 GND
14 Personal code relay Output 14 CAN (SHIELD) Input
15 Limit SW (window) Input 15 CAN (+) Input
16 Buzzer cancel Input 16 CAN (-) Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND
PC300-7 10-175
(10)
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
08932
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Engine oil pressure caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Radiator coolant level caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
10-176 PC300-7
(10)
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF

Swing lock
ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status
Up to 30 sec. ON
Preheating
SAP00526
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power Max. switch status Power max. monitor status
Lights up but goes out after

Power Max. Being pressed
approx. 9 sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil See gauge display on the next page

temperature
Fuel level
PC300-7 10-177
(10)
Temperature, vol-
Gauge Range Indicator Buzzer sound
ume
A1 105 Red ❍
A2 102 Red
Engine coolant tem- A3 100 Green

perature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red ❍
B2 102 Red
Hydraulic oil tem- B3 100 Green

perature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 417 Green
C2 347.5 Green
C3 277.5 Green
Fuel level (L)
C4 139 Green
C5 100 Green
C6 62 Red
10-178 PC300-7
(10)
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions
are displayed.
Check before When engine is When engine is run-

Symbol Display item
starting item stopped ning
When abnormal,
Engine oil pressure ● -- lights up and buzzer
sounds
Lights up when abnor-

Battery charge ● --
mal
When abnormal,
Radiator coolant Lights up when abnor-
● lights up and buzzer
level mal
sounds

Engine oil level ● --
mal
SAP00523

Air cleaner clogging ● --
mal
SAP00521
Lights up when there is a warning. Lights up for

Maintenance only 30 sec. after key is turned ON, then goes
out.
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is
displayed.
Condition of hydraulic oil Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 - B2) No display
High temperature (above B2) White on red background
PC300-7 10-179
(10)
Display category Symbol Display item Display range Display method
INT ON OFF
Displays set con-
Wiper
dition
Working Displays set

mode mode
Monitor
Displays set
Travel speed
speed
Auto-deceler- Displays actua-

ON ⇔ OFF
ation tion status
Service Lights up when

Service meter meter indica- When service meter is working service meter is
tor working
10-180 PC300-7
(10)
SWITCHES
1. Working mode selector switch

2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
PC300-7 10-181
• Working mode selector switch

The condition of the machine changes accord- Switch that is Working mode sta-
ing to the switch that is pressed (A, E, L, B). It Display
pressed tus after setting
is possible to check the condition on the work-
ing mode monitor display. The relationship [A] A A mode (default)
between each working mode and the monitor [E] E E mode
display is shown in the table on the right.
[L] L L mode
• Selector switch [B] B B mode
This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)
• Maintenance switch
Check the condition of the maintenance
items. (For details, see MAINTENANCE FUNC-
TION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically
set to ON.
• Travel speed selector switch

Each time the travel speed selector switch is Display Setting
pressed, the travel speed changes.
Crawler symbol + Lo Low speed (default)
Lo → Mi → Hi → Lo. . . . . .
Use the travel speed monitor display to check Crawler symbol + Mi Medium speed
the present condition.
Crawler symbol + Hi High speed
The relationship between the set speed and
the monitor display in the table on the right.
• Wiper switch
Each time the wiper switch is pressed, the
wiper setting changes OFF → INT → ON → Wiper actuation
OFF → . . . . . . Display Setting
status
Use the wiper monitor display to check the
Stowing stopped
present condition. None OFF
or now stowing
The relationship between the wiper setting
and the monitor display is as shown in the Intermittent actu-
Wiper symbol + INT INT
table on the right. ation
Continuous actu-
Wiper symbol + ON ON
ation
10-182 PC300-7
• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the main-
tenance function or select function.
(For details, see each function.)
• Display brightness, contrast adjustment

switch
Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
PC300-7 10-183
SELECT MODE FUNCTION
• This is used when setting the flow in each

working mode. It is possible to make the set-
ting when genuine attachment piping is
installed and the initial value setting function
on the service menu has been used to set to
ATTACHMENT INSTALLED.
• It is possible to check on the working mode
monitor if this function can be set.
Working mode Monitor display
A mode [A] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
METHOD OF USE
★ Carry out the setting on the normal screen

1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
Control switch Actuation
Flow level bar graph

extends to the right

retracts to the left
3) After completing the level selection, press

input confirmation switch (3).
The selection flow level is confirmed and
Flow level Flow (L/min.) Remarks
the screen moves to the normal screen.
From the moment that the flow level is 8 530 ❈ Default
selected, the content of the selection is
7 430
reflected for the attachment flow.
★ Before the input confirmation switch 6 370
is pressed, the flow level is not con-
5 300
firmed, so press return switch (4) to
return to the normal screen. This func- 4 230
tion can be used to return to the previ-
ously set flow. 3 165
The relationship between the set flow 2 100
level and the flow value is as shown in
the table on the right. 1 30
10-184 PC300-7
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-
stage flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose
one on the three flow levels.
No. 10-key pad operation
01
02
03

The selected flow level is selected.
★ Before the input confirmation switch
firmed, so press return switch (4) to
return to the operator screen. This
No. Flow level (L/min.) Remarks
function can be used to return to the
previously set flow. 01 230 ❈ Default
4) After the flow level is confirmed, the 02 190
screen changes to the screen shown in
the diagram on the right. 03 150
With this screen, it is possible to make
fine adjustment to the flow.
5) Press control switch (2) and select the
flow level.


retracts to the left
PC300-7 10-185

The selected flow level is confirmed and When When When
Flow flow is flow is flow is
the screen moves to the operator screen. Remarks
level 100 l/ 140 l/ 180 l/
From the moment that the flow level is
min. min. min.
selected, the content of the selection is
reflected for the attachment flow. 7 180 220 250
★ Before the input confirmation switch
6 170 210 250
firmed, se press return switch (4) to 5 160 200 240
return to the normal screen. This func-
4 150 190 230 ❈ Default
tion can be used to return to the previ-
ously set flow. 3 140 180 220
The relationship between the set flow
2 130 170 210
level and the flow value is as shown in
the table on the right. 1 120 160 200
7) Check the set value with the working
mode monitor.
The relationship between the display
Display level Set value (ll/min.)
level and the set value is as shown in the
table on the right, and it is possible to 8 250 or 260
check the level of the flow that can be set.
7 230 or 240
6 210 or 220
5 190 or 200
4 170 or 180
3 150 or 160
2 130 or 140
1 120
10-186 PC300-7
MAINTENANCE FUNCTION
When the maintenance time for replacement,

inspection, or filling has approached for the 10
maintenance items, press maintenance switch (1)
and the caution display (yellow or red) appears
on the monitor display for 30 seconds after the
key is turned ON to remind the operator to carry
out lubrication maintenance.
★ Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor ❈ (1000)
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000

❈ Option, so not set
★ The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the remaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for

maintenance for all
None
items is more than 30
hours
There is one or more

Notice display (black
items with less than 30
symbol displayed on
hours remaining time
yellow background)
for maintenance
There is one or more

Warning display (wiper
items with less than 0
symbol displayed on red
hours remaining time
background)
for maintenance
PC300-7 10-187
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
★ Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
★ The maintenance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 - 10) of the mainte-
nance item to select the item.
★ The cursor moves and the item is high-
lighted.
★ The display method is the same as
described on the previous page (relation-
ship between remaining time and caution
display). If the remaining time is less than
30 hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed
in red.
MAINTENANCE OPERATION
1. After completing the selection, press input

confirmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check
the content, and if there is any problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen
returns to the maintenance list display
screen. To check the remaining time, or if the
wrong item is selected, press return switch (4)
to return to the maintenance list screen.
★ The check screen shows the symbol for
the maintenance item and the set time in
large letters.
★ The background color of the symbol for
the item where the maintenance item was
reset is the same as the background of the
screen, so it is possible to check that it has
been reset.
10-188 PC300-7
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
ADJUSTMENT METHOD
★ Operate as follows when on the operator

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
★ Relationship between menu symbol and con-
tent.
No. Symbol Content
01 Return mark Return
02 Contrast
03 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input
confirmation switch (3) and return to the
adjustment screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.


retracts to the left 08937
PC300-7 10-189
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF posi-

tion, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the dis-
play.
• This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 - 5 seconds after the
switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the nor-

mal screen, if monitor return switch (1) and
working mode (A) switch are kept pressed at
the same time, all the LCD display will light 08943
up and the whole screen will become white,
so the display can be checked.
• If any part of the display is black, the LCD is
broken.
10-190 PC300-7
4
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the

machine, the user code is displayed on the
monitor to advise the operator of the steps to
take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil
temperature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in
turn for 2 seconds each to display all the user
codes.
08945
PC300-7 10-191
4
• While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
• If there is more than one service code or fail-

ure code, the display switches every 2 sec-
onds and displays all the service codes/failure
codes that caused the user code to be dis-
played.
Even if service codes/failure codes have
occurred, if they did not cause the user code
to be displayed, this function does not display
them.
• If the telephone number has been set using

the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the tele-
phone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND
ADJUSTING section.
10-192 PC300-7
(6)
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition • The monitor panel also has various mode
of the machine with sensors installed on vari- selector switches and functions to operate the
ous parts of the machine. It processes and machine control system.
immediately displays the obtained informa-
tion on the panel notifying the operator of the
condition of the machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when
the machine has troubles
2. Gauge section to display the condition
constantly (Coolant temperature, hydrau-
lic oil temperature, fuel level, etc.)
PC300-7 10-193
4
12
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02
• The monitor panel has the functions to dis-
play various items and the functions to select Pin Pin
Signal name Signal Name
No. No.
modes and electric parts.
1 Key switch (Battery) 1 Engine water temperature
The monitor panel has a CPU (Central Pro- 2 Key switch (Battery) 2 Fuel
cessing Unit) in it to process, display, and out-
3 Washer motor output 3 Radiator water level
put the information.
4 Key switch (Terminal C) 4 NC
The monitor display unit consists of LCD (Liq-
5 Wiper contact W 5 Air cleaner clogging sensor
uid Crystal Display) and LED (Light Emitting
6 GND 6 NC
Diode). The switches are flat sheet switches.
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (-) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
10-194 PC300-7
4
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user
code are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
PC300-7 10-195
4
Monitored items and display

When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm Lights when normal.
Max. 0.05 MPa (Goes off when
{0.5 kg/cm²} engine is started.) Flashes and buzzer
Engine oil pressure
Min. 1,500 rpm sounds when abnormal.
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
SAP00521
Lights when normal.

When charge is (Goes off when
Charge level engine is started.) Flashes when abnormal.
abnormal
Flashes when
Engine oil level Below low level Goes off.
SAP00523 abnormal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set

Preheating When preheated to HEAT. Then, flashes for 10 sec. to indicated
SAP00526 completion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
Fuel level Flashes when below low level.
10-196 PC300-7
4
12
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the
oil maintenance function is turned on to notify
the operator by the LED lamp on the monitor
panel that it is time to replace the oil. The func-
tion to indicate the phone number of the place to
make contact for service on the LCD unit is
installed, too.
1) Check of elapsed time

Nothing is displayed normally until point
B shown in the figure at right after this
function is reset. If the key is turned on
with the buzzer cancel switch processed
(for 2.5 seconds), however, the elapsed
time is displayed on the service meter
section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval set-
ting mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
the interval setting mode, the clock dis-
play section changes to "—" → "125" →
"250" → "500" → "d" in order. ("—" corre-
sponds to "Not set" and "d" corresponds
to "Demo-mode".)
4) To save the time interval, set a desired
time (mode) on the monitor panel and
press and hold the clock switch for 2.5
seconds.
PC300-7 10-197
4
12
3. Timing and contents of display

1) When replacement of oil is displayed
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
2) When elapsed time is checked
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer can-
cel switch 10 seconds after all segments
are turned on (while the elapsed time is
displayed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and
replacement of oil is displayed when the
key is turned on. The elapsed time does
not increase, however. The time can be
reset in this mode. Turn on the key 3
times in this mode, and the time interval
is automatically set to "Not set" at the 4th
time and after. The elapsed time is set to
"0h" and counting of elapsed time is
started.
10-198 PC300-7
4
12
Mode selector switches
1. Travel speed switch

2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
(Including setting switch)
• There are 4 sets of the mode selector Operations table of switch section
switches on the switch section. Each time one
switch is pressed, the machine condition ★ The bold letters are the positions of the
changes. The current condition is indicated by switches reset when the starting switch is
the lighting of the LED above the switch. turned on.
• The initial setting of only the work mode after Item Operation
the starting switch is turned on can be
changed. Work mode A↔E↔B
★ For how to change the setting, see "Work Auto-deceleration ON↔OFF
mode default setting mode" in TROUBLE-
SHOOTING-Display and special functions of Wiper OFF↔Intermittent↔ON
monitor panel.
Travel speed Hi↔Lo
PC300-7 10-199
4
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor When When

Type of sensor
name normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Engine oil OFF ON

Contact
pressure (Open) (Closed)
Hydraulic
oil tempera- Resistance — —
ture
Coolant
Resistance — —
temperature
Fuel level Resistance — —
Air cleaner ON OFF

Contact
clogging (Closed) (Open)
10-200 PC300-7
(10)
12
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC300-7 10-201
4
12
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
10-202 PC300-7
4
12
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC300-7 10-203
12
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
10-204 PC300-7
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
PC300/350(LC)-7 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicable model PC300, 300LC, 350, 350LC-7
Engine SAA6D114E-2
Standard value Service limit

Item Measurement condition Unit
for new machine value
High idle 2,160±70 2,160±70
Engine speed Low idle rpm 900 –+ 50

25
900 –+ 50
25
Rated speed 1,900 1,900
Intake air pressure kPa 133–160 Max. 120

At rated output
(boost pressure) {mmHg.} {1,000–1,200} {Max. 900}
At sudden acceleration Bosch Max. 4.5 Max. 6.5

Exhaust gas color
At high idle index Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.30 ± 0.05 —

mm
(Normal temperature) Exhaust valve 0.56 ± 0.05 —
Difference
between cyinders
Oil temperature: 40–60ºC MPa Min. 2.4 Min. 2.0
Compression pressure
Engine speed: 250–300rpm {kg/cm2} {Min. 24.6} {Min. 20.5}
Max. 0.7
{Max. 6.9}
(Coolant temperature: operating kPa Max. 1.0 2.0

Blow-by pressure
range) At rated output {mmH2O} {Max. 100} {200}
(Coolant temperature: operating

range) 0.36–0.61 0.18
Oil pressure MPa
At high idle {3.5–6.0} {1.8}
(SAE15W-40) {kg/cm2}
Min. 0.10 0.07
At low idle {Min. 1.0} {0.7}
Oil temperature Whole speed range (inside oil pan) °C 90–120 120
Fuel injection timing Before Top Dead Center °(degree) 9.5 9.5
Deflection when pressed with finger

Fan belt tension mm 8 Min. 6, Max. 10
force of approx. 58.8 N{6 kg}
Air conditioner Deflection when pressed with finger

mm 5–8 5–8
compressor belt tension force of approx. 63.7 N {6.5 kg}
20-2 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
• Engine water temperature:
Within operation range
• Hydraulic oil temperature: Within
2 pumps at relief 1,980±100 1,980±100
operation range
• Engine at high idling
• Arm in relief condition
• Engine water temperature:
Engine speed
Within operation range

At 2-pump relief + one rpm
operation range 1,870±100 1,870±100
touch power up
• Arm relief + One-touch power
max. switch in ON condition
• Auto-deceleration switch in ON
Speed when auto-
condition 1,400±100 1,400±100
deceleration is operated
• All control levers in NEUTRAL
condition
Boom control valve
Spool stroke
Arm control valve

Bucket control valve mm 9.5±0.5 9.5±0.5
Swing control valve
Travel control valve
Boom control lever 85±10 85±10
Travel of control
Arm control lever • Engine stopped 85±10 85±10

Bucket control lever • At center of control lever grip 85±10 85±10
levers
• Max. reading up to stroke end mm

Swing control lever (excepting lever play in NEU- 85±10 85±10
Travel control lever TRAL position) 115±12 115±12
Play of control lever Max. 10 Max. 15
15.7±3.9 Max. 24.5
Boom control lever
{1.6±0.4} {Max. 2.5}
15.7±3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within {1.6±0.4} {Max. 2.5}
of control levers
Operating force
operation range 12.7±2.9 Max. 21.6

Bucket control lever
• Engine at high idling {1.3±0.3} {Max. 2.2}
N{kg}
• At center of control lever grip 12.7±2.9 Max. 21.6
Swing control lever • At tip in case of pedal {1.3±0.3} {Max. 2.2}
• Max. reading up to stroke end 24.5±5.9 Max. 39.2
Lever
{2.5±0.6} {Max. 4.0}
Travel control lever
74.5±18.6 Max. 107.6
Papel
{7.6±1.9} {Max. 11}
PC300/350(LC)-7 20-3

Cate-
gory
• Hydraulic oil temperature: Within opera-
tion range
• Engine at high idling 3.9±1.0 3.9±1.0
Unload pressure
• Working mode: A mode {40±10} {40±10}
• Hydraulic pump output pressure with all
control levers in NEUTRAL position
34.81 +1.47
–0.98
33.34–37.23
RAISE (37.26 +1.47
–0.98 )
(35.80–39.23)
• Hydraulic oil tem- {355 +15 +15
–10 (380 –10 )}
{340–375(365–400)}
Boom perature: Within
At low-pres- 18.13±0.98 16.66–19.6
operation range
LOWER
sure setting {185±10} {170–200}
• Working mode: A At high-pres- 31.36±1.47 29.4–33.32
mode sure setting {320±15} {170–200}
• Hydraulic pump output pressure with all 34.81 +1.47 33.34–37.23
Arm –0.98
measurement circuits relieved
Hydraulic pressure
• Values inside parenthesis: Hydraulic oil (37.26 +1.47

–0.98 )
(35.80–39.23)
Bucket pressure with one-touch power max. {355 +15 +15
–10 (380 –10 )}
{340–375(365–400)}
switch in ON mode (reference only) MPa
{kg/cm2} 30.87 +1.47
–2.45 28.42–32.85
Swing
+15
{315 –25 } {285–335}
+2.94
37.27 –0.98 35.80–40.70
Travel
{380 +30 {365–415}
–10 }
tion range
Control circuit • Engine running at high idling 3.23±0.2 2.84–3.43
source pressure • Self-reducing pressure valve output pres- {33±2} {29–35}
sure with all control levers in NEUTRAL
position
• Hydraulic oil tempera- When all con-
ture: Within operation trol levers in 3.9±1.0 3.9±1.0
range NEUTRAL {40±10} {40±10}
Self-reducing pres- • Engine at high idling position
sure valve • Working mode: A mode
• Traveling speed: Hi When traveling
2.45±0.1 2.45±0.1
• Hydraulic oil pump pres- at half stroke
{25±1} {25±1}
sure - LS pressure (without load)
PC300, 300LC: PC300, 300LC:

Swing
deg. Max. 110 Max. 140

Swing brake angle • Hydraulic oil temperature: Within operation (mm) PC350, 350LC: PC350, 350LC:
range Max. 120 Max. 150
• Engine running at high idling
• Working mode: A mode
• Swing circle misalignment amount when
stopping after one turn
20-4 PC300/350(LC)-7

Cate-
gory
90° 3.3±0.4 Max. 4.2

• Hydraulic oil tempera-
ture: Within operation
Time taken to start range sec.
swing • Engine running at high
idling
• Time required for passing 180° 4.7±0.5 Max. 5.7
points 90 and 180
degrees from starting
point
Time taken to
• Hydraulic oil temperature: Within opera- sec. 31.6±2.9 Max. 38
swing
tion range
Swing
• Time required for 5 more turns after mak-

ing initial one turn
15
BKP00103
Hydraulic drift of • Hydraulic oil temperature: Within opera-

tion range mm 0 0
swing
• Engine stopped
• Keeping upper structure transverse on
slope of 15 degrees
• Notching a mating mark on inner and
outer races of swing circle
• Mating mark misalignment amount during
5 minutes
tion range
Leakage from • Engine running at high idling
¶/min Max. 5.5 Max. 11
swing motor • Swing lock switch: ON
• Leakage amount for one minute during
swing relief
PC300/350(LC)-7 20-5

Cate-
gory
PC300, 350: PC300, 350:
55.0±11.0 42.0–70.0
Lo
PC300LC, 350LC: PC300LC, 350LC:
58.0±11.5 45.0–74.5
PC300, 350: PC300, 350:
BKP00104
39.0±5.5 31.5–48.5
Travel speed (1) • Hydraulic oil temperature: Within ( Mi)
PC300LC, 350LC: PC300LC, 350LC:
operation range
41.5±6.0 34.0–51.5
• Working mode: A mode PC300, 350: PC300, 350:
• Time required for track shoes to 32.0±2.0 28.0–39.0
Hi
make 5 turns after making one ini- PC300LC, 350LC: PC300LC, 350LC:
tial idle turn 34.0±2.0 32.0–41.5
sec.
45˚
Lo 23.3±4.4 18.9–31.0
BKP00105
Travel speed (2) • Hydraulic oil temperature: Within ( Mi) 16.7±2.2 14.4–21.0
operation range
Travel

• Flat ground Hi 13.1±0.7 12.1–15.1
• Time required for traveling 20 m
after 10 m trial run
45˚
BKP00105
• Hydraulic oil temperature: Within operation
range
Travel deviation • Travel speed: Lo mm Max. 200 Max. 300
• Solid and flat ground
• Swerving amount while traveling 20 m (X)
after initial 10 m trial run
20m
10m BKP00107
: The “Mi” mode is on the multi-monitor specification machine only.
20-6 PC300/350(LC)-7

Cate-
gory
12˚
BKP00108
Hydraulic drift of travel • Hydraulic oil temperature: Within mm 0 0

operation range
• Engine stopped
Travel
• Parking machine on slope of 12

degrees with sprocket facing
upslope
• Sliding distance for 5 minutes
operation range
Leakage of travel motor • Traveling with sprocket locked ¶/min Max. 15 Max. 30
• Oil leakage amount for one
minute with traveling in relief con-
dition
PC300, 300LC: PC300, 300LC:
Whole work equip-
Max. 450 Max. 675
ment (tooth tip fall
PC350, 350LC: PC350, 350LC:
amount)
Hydraulic drift of work equipment
Max. 550 Max. 825

PC300, 300LC: PC300, 300LC:
BKP00110
Boom cylinder (cylin- Max. 25 Max. 38
Work equipment

der retraction amount) PC350, 350LC: PC350, 350LC:
operation range
Max. 30 Max. 45
• Flat and level ground mm
• Work equipment in measurement PC300, 300LC: PC300, 300LC:
Arm cylinder (cylinder posture as illustrated above Max. 135 Max. 203
extension amount) • Bucket load: 2,160 kg PC350, 350LC: PC350, 350LC:
• Engine stopped Max. 165 Max. 248
• Work equipment control lever in
NEUTRAL position PC300, 300LC: PC300, 300LC:
Bucket cylinder (cylin- • Fall amount for 15 minutes as Max. 20 Max. 30
der retraction amount) measured every 5 minutes start- PC350, 350LC: PC350, 350LC:
ing immediately after initial setting Max. 25 Max. 38
PC300/350(LC)-7 20-7

Cate-
gory
PC300, 300LC: PC300, 300LC:
RAISE
3.7±0.4 Max. 4.5
PC350, 350LC: PC350, 350LC:
3.8±0.4 Max. 4.6
Boom • Hydraulic oil temperature: Within
operation range
LOWER
2.5±0.3 Max. 3.0
• Time required from raise stroke
end till bucket touches ground
3.8±0.4 Max. 4.5
IN
Work equipment speed
Arm
sec.
operation range PC300, 300LC: PC300, 300LC:
2.9±0.3 Max. 3.5
OUT

• Working mode: A mode PC350, 350LC: PC350, 350LC:
3.1±0.4 Max. 3.7
Work equipment
• Time required from dumping stroke

end to digging stroke end
CURL
3.2±0.3 Max. 3.8
Bucket
operation range
DUMP
• Engine running at high idling 2.3±0.3 Max. 2.9

• Time required from dumping stroke
end to digging stroke end
Time lag
BKP00114
Boom sec. Max. 3.0 Max. 3.6
range
• Engine running at low idling
• Time required from raise stroke end till
bucket touches ground and pushes up
machine front
20-8 PC300/350(LC)-7

Cate-
gory
BKP00115
PC300, 300LC: PC300, 300LC:
Max. 3.0 Max. 3.6
Arm • Hydraulic oil temperature: Within operation
PC350, 350LC: PC350, 350LC:
range
Max. 4.0 Max. 4.6
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
Time lag
again sec.
Work equipment
BKP00116
Bucket • Hydraulic oil temperature: Within operation Max. 3.0 Max. 5.0
range
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
Cylinders range 4.5 20
leackage
Internal

cc/min
• Leakage amount for one minute with cylin-
Center
der or travel to be measured in relief condi- 10 50
swivel joint
tion
Performance in compound operation
range
• Traveling speed: Lo
Swerving amount • Flat and level ground
in simultaneous • Swerving amount (X) when traveling 20 m
operation of work after initial trial run of 10 m mm Max. 400 Max. 440
equipment and 20m
travel
10m BKP00107
Performance of
hydraulic pump
Hydraulic pump
See next page ¶/min See next page
delivery
PC300/350(LC)-7 20-9

Cate-
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump
• Pump speed: At 1,950 rpm, PC current 280 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (¶/min) (¶/min)
As desired P1 P2 P1+P2 See graph See graph

2
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-10 PC300/350(LC)-7
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ........................................................ 20-101-1

INSPECTION AND ADJUSTMENT OF ENGINE SPEED .......................................................................... 20-102
MEASUREMENT OF AIR BOOST PRESSURE......................................................................................... 20-104
MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-105
ADJUSTMENT OF VALVE CLEARANCE................................................................................................... 20-106
MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-108
MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-109
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20- 110
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 112
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 113
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20- 113
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 114
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20- 115
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20- 116
INSPECTION OF WEAR ON SPROCKET ................................................................................................. 20- 116
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE
IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20- 117
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-121
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-122
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-125
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE .............................................................. 20-129
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-132
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-133
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-134
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-135
MEASUREMENT OF OIL LEAKAGE AMOUNT ......................................................................................... 20-136
AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-138
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-140
SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-141
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL .................................................................. 20-165
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-178
PC300/350(LC)-7 20-101
(8)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part name Remarks
1 799-205-1100 Tachometer kit 1 Digital indication: 6 – 99,999.9 rpm

Engine speed A
2 795-790-2600 Take off drive 1
Intake pressure 1 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
B
(boost pressure) 2 799-101-5210 Nipple 1 R1/4
Handy smoke
1 799-201-9001 1
checker
Exhaust gas color C Bosch index: 0 – 9
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Commercially
Engine valve clearance D 2 Thickness gauge 1
available
3 795-799-1900 Pin assembly 1
1 795-790-3610 Compression gauge 1
Compression pressure E
2 795-790-3710 Tester 1
1 799-201-1504 Blow-by kit 1 0 – 4.9 kPa {0 – 500 mmH2O}
Blow-by pressure F
2 795-790-3300 Tool (Nozzle) 1
1 795-799-1131 Gear 1
Fuel injection timing G 2 795-799-1900 Pin assembly 1
3 795-799-1950 Lock pin 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Hydraulic tester
790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Engine oil pressure H (Digital type)
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
6732-81-3170 Joint 1
3
6215-81-9710 O-ring 1
Swing circle bearing Commercially
J Dial gauge 1
clearance available
Sprocket wear K 796-627-1130 Wear gauge 1
Work equipment, swing, Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
travel circuit hydraulic oil {25, 60, 400, 600 kg/cm2}
pressure 1
Hydraulic tester
Control circuit oil pres- L 790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(Digital type)
sure
799-101-5220 Nipple 1 10 x 1.25 mm
Pump PC control circuit 2
oil pressure 07002-11023 O-ring 1
{25, 60, 400, 600 kg/cm2}
1
Hydraulic tester
Pump LS control circuit (Digital type)
M
oil pressure 799-101-5220 Nipple 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Differential pressure
3 799-401-2701 1
gauge
20-101-1 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Q’ty
Test, measurement item Part No. Part name Remarks

{25, 60, 400, 600 kg/cm2}
1
Solenoid valve output Hydraulic tester
N 790-261-1204 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure (Digital type)
2 790-401-3100 Adapter 1 02 size
3 799-401-3200 Adapter 1 03 size
PPC valve output pres- {25, 60, 400, 600 kg/cm2}
P
sure Hydraulic tester
(Digital type)
Internal oil leakage inside Commercially
Q Cylinder 1
hydraulic cylinder available
Coolant temperature, oil
R 799-101-1502 Digital thermometer 1 –99.9 – 1,299 ºC
temperature
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating force S
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift T Scale 1
available
Commercially
Work equipment speed U Stopwatch 1
available
Commercially
Voltage, resistance V Tester 1
available
799-601-7400 T-adapter assembly 1
799-601-7310 Adapter 1 For SWP-12
799-601-7320 Adapter 1 For SWP-16
799-601-7330 Adapter 1 For S-16(white)
Troubleshooting of sen- 1
799-601-7340 Adapter For M-8
sors and wiring har- W
799-601-7350 Adapter 1 For S-12(white)
nesses
799-601-7360 Adapter 1 For relay (5-pin)
799-601-7520 Adapter 1 For AMP070-12
2 799-601-9000 T-adapter assembly 1 For DT connector
3 799-601-9300 T-adapter assembly 1 For DT connector (for 24, 40-pin)
PC300/350(LC)-7 20-101-2
(8)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE SPEED
INSPECTION AND ADJUSTMENT OF ENGINE SPEED

a Engine inspection and maintenance tools Inspection
1. Open up the engine hood and take off cover (1).
Mark Part No. Part name a Remove cover using filter wrench.
1 799-205-1100 Tachometer kit
A
2 795-790-2600 Take off drive
a Engine speed may be detected using a monitor-

ing function in the monitor panel (special function
furnished to the monitor panel).
• Multi monitor
2. Fit take off drive A2, and connect pickup set [1]
and tachometer [2] of tachometer kit A1.
• 7-Segment monitor
3. Measure the engine speed after setting each

measurement condition.
1) Engine speed at low idle:
i) Set the fuel dial at low idle (MIN).
ii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
k Be careful not to touch the strongly heated por- 2) Engine speed at high idle:
tion of the engine by accident while installing a i) Turn the auto-decelerator OFF.
measurement equipment. ii) Set the fuel dial at high idle (MAX).
iii) Operate any of the work equipment,
swing and travel control levers.
a Operate the lever lightly enough to turn
on the PPC hydraulic switch, but not to
start the work equipment, swing or travel.
3) Engine speed at 2 pump relief
i) Set the fuel dial at high idle (MAX)
ii) Put the arm in the digging relief position.
20-102 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE SPEED
4) Engine speed when 2 pump relief and one- Adjustment

touch power max. switch are set (near rated 1. Adjustment of engine speed at low idle
engine speed) a If the engine speed at low idle deviates from
i) Set the fuel dial at high idle (MAX). the standard value, make adjustment using
ii) Put the arm in digging relief position and the adjustment function provided in the mon-
keep the one-touch max. power switch itor panel.
depressed. a For the adjustment procedures, refer to the
a The one-touch power max. function is section, "Special Function of Monitor Panel"
automatically released in 8.5 seconds,
even if the knob switch is kept de- 2. Adjustment of Governor Spring
pressed. Take measurement during the a If the engine speed at high idle deviates from
period. the standard value, or it is unsteady (hunt-
5) Engine speed when auto-decelerator is set ing), adjust the governor spring securing di-
i) Turn the auto-decelerator ON. mensions, using the adjustment function in
ii) Set the fuel dial at high idle (MAX). the monitor panel.
iii) Move all the control levers of work a For the adjustment procedures, refer to the
equipment, swing and travel to the section, "Special Function of Monitor Panel"
NEUTRAL position.
a Approx. 5 seconds after all the control
levers are moved to the NEUTRAL po-
sition, the engine speed falls automati-
cally. That is when the engine speed
with the auto-decelerator in motion
should be measured.
4. Detach all the measurement tools after the

inspection, and make sure that the machine is
back to normal condition.
PC300/350(LC)-7 20-103
(8)
TESTING AND ADJUSTING MEASUREMENT OF AIR BOOST PRESSURE
MEASUREMENT OF AIR BOOST PRESSURE

a Air boost pressure measurement tool 6. Take measurement of air boost pressure at high
idle after setting the following measurement
Mark Part No. Part name conditions.
1 799-201-2202 Boost gauge kit • Working mode: A mode
B
2 799-101-5210 Fitting (R1/4) • Swing lock switch: ON (High pressure relief)
• Work equipment, swing and travel: Arm dig-
ging relief
1. Open up the engine hood.
2. Remove air boost pressure measurement plug

(1).
7. Detach the measurement tool after the mea-

surement, and return the machine to the normal
condition.
3. Install fitting B2 and connect it with gauge [1] of
air boost gauge kit B1.
4. Start the engine and wait for the engine coolant

temperature and hydraulic oil temperature to
rise to the operation range.
5. Run the engine at a medium speed and drain oil

in the hose.
a Oil can be drained by inserting the gauge
into the hose halfway and then repeating to
open and close the self- seal on the hose
side.
a If Pm Kit (A) is available, an air bleeding cou-
pling (790-261-1130) included in the kit may
well be used.
a Be sure to drain oil thoroughly. If there is oil
remaining in the hose, the gauge does not
function properly.
20-104 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR
MEASUREMENT OF EXHAUST GAS COLOR

a Exhaust gas color measurement tool
Mark Part No. Part name

1 799-201-9001 Handy smoke checker
C
2 Commercially available Smoke meter
k Be careful not to touch the highly heated parts,

while fitting and detaching a measurement tool.
a If no compressed air or power is not available in
the field, use Handy Smoke Checker C1. For re-
cording official data, use Smoke Meter C2.
1. Measurement with Handy Smoke Checker C1

1) Fit a filtering paper to Handy Smoke Checker 2) Connect the probe hose, accelerator switch
C1. outlet and air hose to the Smoke Meter C2.
2) Insert the exhaust gas intake pipe into the a Keep the pressure of the supplied com-
exhaust pipe. pressed air below 1.5 MPa {15 kg/cm2}.
3) Start the engine and keep it running until the 3) Connect the power cable to an outlet of AC
engine coolant temperature comes within socket.
the operating range. a Confirm that the Smoke Meter power
4) Let the exhaust gas stay on the filtering switch is in the OFF position, before con-
paper by operating a handle of Handy necting the power cable to an outlet.
Smoke Checker C1, when the engine speed 4) Fit a filtering paper by loosening the suction
is suddenly accelerated or kept at high idle. pump cap nut.
a Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter C2 power switch to
the ON position.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Detach the measurement tool after the
measurement, and make sure the machine
is back to normal condition. 6) Start the engine and keep it running until the
engine coolant temperature rises to the
2. Measurement with Smoke Meter C2 operating range.
1) Insert probe [1] of the Smoke Meter C2 into 7) Let the exhaust gas stay on the filtering
the exhaust gas pipe outlet, and fasten it to paper by depressing the accelerator pedal
the outlet with a clip. of Smoke Meter C2, when the engine speed
is suddenly accelerated or kept at high idle.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indi-
cated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
PC300/350(LC)-7 20-105
(9)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
ADJUSTMENT OF VALVE CLEARANCE

a Valve clearance adjustment tools a After setting the No. 1 cylinder to the top
dead center, stamp a counter mark on the
Mark Part No. Part name crank pulley and the front cover.
1 795-799-1131 Gear
D 2 Commercially available Thickness gauge
3 795-799-1900 Pin assembly
1. Open up the engine hood and remove air intake

connector (1).
2. Remove cylinder head covers (2).
5. When No. 1 cylinder is at the top dead center,

adjust valve clearances indicated with a black
bullet mark (z) in the valve layout chart in the
following manner.
• Valve layout chart
3. Take off cap (3) and fit gear D1.
1) Insert thickness gauge D2 in between

rocker arm (5) and valve stem (6), and
adjust the valve clearance "b" with adjusting
screw (7).
4. Turn the crankshaft clockwise (normal rotation) a For the adjustment, turn the adjusting
with gear D1 until yellow paint mark "a" on the screw with filler gauge D2 inserted to the
crank pulley comes up to the top. Then set the extent that filler gauge D2 can be lightly
No. 1 cylinder to the top dead center with timing moved.
pin (4). 2) Fix adjusting screw (7) and then tighten lock
a When No. 1 cylinder is at the top dead cent- nut (8).
er, its rocker arm can be manually moved as 3 Lock nut: 24±4 Nm{2.45±0.41kgm}
much as the valve clearance. If it cannot be a Check the valve clearance again after
moved, that means that No. 1 cylinder is not tightening lock nut (8).
yet at the top dead center. In that case, ro- a Return timing pin (4) to the original position
tate it by one more turn. and proceed to the next step, once all the
a Timing pin push-in depth: 8 mm measurements of valve clearance indicated
a If it proves difficult to make this check with with a black bullet mark (z) have been com-
the timing pin installed in the engine, metallic pleted.
pin assembly D3 may be used instead.
20-106 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE
6. Turn the crankshaft clockwise (normal rotation)

with gear D1 so as to match the counter marks
on the crank pulley and the front cover, and
bring up No. 6 cylinder to the top dead center.
7. When No. 6 cylinder is at the top dead center,

adjust valve clearances indicated with a white
bullet mark ({) in the valve layout chart.
a The adjustment procedures are the same as
introduced in Item 5 above.
8. After the adjustment, make sure that the

3 Cylinder head cover securing bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC300/350(LC)-7 20-107
(7)
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE
MEASUREMENT OF COMPRESSION PRESSURE

a Compression pressure measurement tools 7. Crank up the engine with the engine starting
motor, and measure the compression pressure.
Mark Part No. Part name a Read off the value, when the needle of the
1 795-790-3610 Compression gauge compression gauge steadies itself.
E
2 795-790-3710 Tester a When taking measurement of the compres-
sion pressure, be sure to measure the en-
k Be careful not to get burnt by touching the ex-
gine rpm, too, so that it stays within the range
of designated measurement conditions.
haust manifold or muffler, or get caught with a
rotating parts, while taking measurement of
8. Detach the measurement tools after the mea-
compression pressure.
surement, and make sure that the machine is
2 Nozzle holder rubber boot:
1. Adjust the valve clearances.
a For the adjustment, refer to the section, "Ad-
Engine oil (EO10-CD)
justment of Valve Clearance".
2. Make preparations for measuring the engine

rpm.
a For the preparations, refer to the section, "In-
spection and adjustment of engine speed".
3. Warm up the engine until the engine oil temper-

ature rises up to 40 – 60°C.
4. Detach nozzle holder (1) of a cylinder to be

measured.
5. Fit compression gauge E1 to the nozzle holder

mounting.
6. Disconnect E10 connector (2) of the engine stop

solenoid.
20-108 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE
MEASUREMENT OF BLOW-BY PRESSURE

a Blow-by pressure measurement tools

1 799-201-1504 Blow-by kit
F
2 795-790-3300 Tool (Nozzle)
1. Remove the engine under cover.
2. Fit tool F2 to blow-by hose (1) and connect it

with gauge [1] of blow-by kit F1.
3. Start the engine and keep it running until the

engine coolant temperature rises to the operat-
ing range.
4. Measure the blow-by pressure at high idle and

under the following conditions.
• Swing lock switch: ON (High pressure relief)
• Work equipment, swing and travel:
Arm IN relief
a Read off the blow-by pressure value, when
the needle of the gauge steadies itself.

PC300/350(LC)-7 20-109
(8)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

a Fuel injection timing inspection and adjustment 4. Disconnect plug (3) of the fuel injection pump.
tools
5. Reverse and push in timing pin (4) of the fuel
Mark Part No. Part name injection pump, and confirm its cut-out portion
1 795-799-1131 Gear matches with protruding portion "b" inside the
G 2 795-799-1900 Pin assembly pump.
3 795-799-1950 Lock pin a If timing pin (4) can be pushed in smoothly,
then injection timing is correct.
a If timing pin (4) cannot be pushed in smooth-
Inspection ly, injection timing is incorrect and requires
1. Open up the engine hood. adjustment.
a If it is found difficult to confirm the push-in
2. Take off cover (1) and fit gear G1. depth with timing pin (4) as installed in the
engine, metallic pin ass'y G3 may well be
used instead.
3. Turn the crankshaft clockwise (normal rotation)

with gear G1 until yellow paint mark "a" on the
crank pulley comes up to the top. Then set the 6. Detach the measurement tools after the mea-
No. 1 cylinder to the top dead center with timing surement, and make sure that the machine is
pin (2). back to normal condition.
a Remove the head cover and check that No. 3 Cylinder head cover securing bolt:
1 cylinder rocker arm moves as much as the 24 ± 4 Nm {2.45 ± 0.45 kgm}
valve clearance. If not, that means that the k Do not forget to bring driving gear timing pin
No. 1 cylinder is not yet at the top dead cent- (4) and injection pump timing pin (4) back to
er. In that case, turn the crankshaft by one the pre-inspection condition.
more turn. a In case the adjustment follows, leave gear
a Timing pin push-in depth: 8 mm G1 and timing pin (2) as they are.
a If the pin cannot be pushed in, turn the crank-
shaft slightly back and forth with gear G1.
a If it proves difficult to make this checking with
the pin installed in the engine, metallic pin
assembly G2 may be used instead.
20-110 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
Adjustment 4. Mount the fuel injection pump.

a If fuel injection timing is found incorrect, adjust it a For mounting the pump, refer to the same
in the following manner. section mentioned in Item 2 above.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (2). 5. Detach the measurement tools after the adjust-
a If timing pin was pulled back after the inspec- ment, and make sure that the machine is back
tion had been completed, push it in again fol- to normal condition.
lowing the foregoing inspection procedures. k Before starting the engine again, check that
driving gear timing pin (2) and fuel injection
pump timing pin (4) have been brought back
to the pre-adjustment condition.
2. Dismantle the fuel injection pump.

a For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".
3. Reverse and push in timing pin (4) of the fuel

injection pump, then match the pin cut-out por-
tion and protruding portion "b" inside the fuel
injection pump by turning the shaft.
a After fuel timing has been set, fix it by fitting
plug (3).
PC300/350(LC)-7 20-111
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE

a Engine oil pressure measurement tools 4. Measure engine oil pressure at low idle as well
as at high idle.
799-101-5002 Hydraulic tester
1 Digital type
790-261-1204
hydraulic tester
H Hydraulic tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
6732-81-3170 Joint
3
6215-81-9710 O-ring
1. Remove hydraulic measurement plug (1) on the

cylinder block.

2. Install joint H3, then fix nipple [1] and connect it

with hydraulic tester H2.
3. Start the engine and keep it running until the

engine coolant temperature rises to the operat-
ing range.
20-112 PC300/350(LC)-7
(8)
ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION
ADJUSTMENT OF ENGINE INSPECTION AND ADJUST-

SPEED SENSOR MENT OF AIR COMPRESSOR
BELT TENSION
a Detach engine speed sensor (1) before the ad- Inspection
justment, then check that there is no metal dust Check belt deflection amount "a" when depressing
stuck or damage at the tip and fit it again. the mid point between the fan pulley and the com-
pressor with a thumb.
• Belt depressing force:
Equivalent to 63.7 N {6.5 kg}
1. Screw in sensor (1) until its tip comes to contact

with the tip of flywheel ring gear teeth (2).
2 Threaded portion:
Gasket sealant (LG-6) Adjustment
a If the belt deflection amount is not proper, adjust
2. Screw back sensor (1) from that position by the it in the following manner.
prescribed angle. 1. Loosen two compressor bracket securing bolts
a Screw-back angle: 1±1/6 turn (1) (upper and lower).
a Adjust clearance "a" between the sensor tip
and gear tooth tip to be 1.25–1.75 mm. 2. Shift compressor mounting bracket (1) to adjust
the belt tension.
3. Fasten sensor (1) with nut (3).
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} 3. Tighten two compressor bracket (1) securing
bolts.
a Check the belt tension again after the adjust-
ment.
4. After the adjustment, confirm that correct engine

speed is displayed in the monitor panel, using
the special monitoring function.
a For monitoring engine speed, refer to the
section, "Special function of monitor panel".
PC300/350(LC)-7 20-113
(9)
TESTING AND ADJUSTING EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL

SYSTEM
a If a failure occurs on any of the engine control de- 3. Remove bolt (4), connect governor spring (3)
vices like fuel dial, governor pump controller or and fix it at the original position.
governor motor • potentiometer, and the engine a Tilt the governor motor lever to the fuel injec-
gets out of control, first fix the engine speed and tion pump side, but stop short of the gover-
take the following steps to avoid the immediate nor spring.
danger. a The governor lever of the fuel injection pump
a The suggested steps are provisional ones. Iden- is fixed at a near-idle position.
tify the cause for the failure and carry out repairs
promptly thereafter.
1. Disconnect E11 connector (1) of the governor

motor from E10 connector (2) of the governor
potentiometer.
k If the governor motor • potentiometer con-
nector is left connected, the governor motor
will be suddenly activated while the engine
is running, causing a mechanical damage.
Be sure to disconnect it.
4. Start the engine again and travel the machine to

a safe place.
5. Disconnect E10 connector (5) of the engine stop

solenoid.
k Operation of stopping the engine is to be
carried out while the engine is running at
high speed. Be careful not to touch the parts
of high temperature or get caught in rotating
parts.
2. Detach governor spring (3) on the governor

motor side.
20-114 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

a Swing circle bearing clearance measurement 4. Hold the arm nearly perpendicular to the
tools ground, and lower the boom until the track
shoes will be lifted at the machine front.
Mark Part No. Part name a The upper structure is raised at the front and
J Commercial product Dial gauge lowered at the rear at that time.
a Follow the steps explained below, when measur- 5. Read off the value in dial gauge J in this condi-
ing clearance in the swing circle bearing in the tion.
actual machine. a The value indicated in dial gauge J express-
k Be careful not to put a hand or foot under the un- es clearance in the bearings.
dercarriage, while taking measurement.
1. Fasten dial gauge J to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
a Set dial gauge J at the machine front or rear.
6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge J is
zero.
a If zero value is not indicated, repeat the
steps in Items 3 through 5.
2. Keep the work equipment in the max. reach pos-

ture and keep the height of the bucket teeth tip
level with the lower height of the revolving
frame.
a The upper structure is lowered at the front
and raised at the rear at that time.
3. Set dial gauge J at zero point.
PC300/350(LC)-7 20-115
(8)
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
TESTING AND ADJUSTING INSPECTION OF WEAR ON SPROCKET
INSPECTION AND ADJUST- INSPECTION OF WEAR ON

MENT OF TRACK SHOE SPROCKET
TENSION
Inspection a Inspection tool for sprocket wear
1. Travel the machine forward by the length of
track on ground, keeping the engine at low idle, Mark Part No. Part name
and stop the machine slowly. K 796-627-1130 Wear gauge
2. Place straight bar [1] on the track shoe between

the idler and the 1st carrier roller.
a L beam is recommended for bar [1], because
of its deflection-free nature.
3. Measure max. clearance "a" between bar [1]

and the track shoe.
• Max. standard clearance a: 10 – 30 mm
Adjustment
a If the track shoe tension is not proper, adjust it in
the following manner.
1. When the tension is too strong

Discharge grease by loosening valve (1).
k Do not loosen valve (1) by more than one
turn, because grease will spurt out due to its
internal high pressure.
2. When the tension is too weak

Add grease through grease fitting (2).
a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
20-116 PC300/350(LC)-7
(8)
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRES-

SURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING
AND TRAVEL
a Inspection and adjustment tools for hydraulic oil
pressure in hydraulic circuit for work equipment,
swing and travel

1 Digital type
790-261-1204
hydraulic tester
L
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
a Hydraulic oil pressure in the hydraulic circuit for

work equipment, swing and travel (hydraulic
pump output pressure) may be also confirmed 2) Fit nipple L2 and connect it to oil pressure
with a monitoring function in the monitor panel gauge [1] of hydraulic tester L1.
(special function of monitor panel). a Use an oil pressure gauge with the ca-
pacity of 58 MPa {600 kg/cm2}.
Measurement
1. Pre-measurement work
k Lower the work equipment to the ground,
then release the remaining pressure in the
piping by operating the control lever several
times after stopping the engine, and release
the pressure inside the hydraulic tank by
gradually loosening the oil filler cap.
1) Remove hydraulic oil pressure measuring
plugs (1) and (2).
• Plug (1): For the circuit of front hydraulic
pump (at the machine rear part)
• Plug (2): For the circuit of rear hydraulic
pump (at the machine front part)
3) Start the engine and keep it running until the
hydraulic oil temperature rises to the operat-
ing range.
PC300/350(LC)-7 20-117
(8)
2. Combination of pump, actuator and valve a Except in boom LOWER, the constant 2-
a You will know that when oil flow from the stage relief solenoid valve is turned ON and
pumps is divided, the front and rear pumps the relief pressure of high pressure is indicat-
work independently of each other for each ed, when the swing lock switch is turned ON.
actuator, as well as that different relief valves For this reason, keep the swing lock switch in
are activated then. the OFF position, while in the measurement.
a Oil flow from the pumps is merged in the sin- a In boom LOWER, pressure when the safety
gle pressure relief when the work equipment valve is relieved is indicated.
swings, while it is divided in the single pres- a The relief pressure in boom LOWER is lower
sure relief when the machine travels. than the main relief pressure.
a The actuators in the table below are ar- a In boom LOWER, the relief pressure of low
ranged in the order that the control valves pressure is indicated if the machine push-up
are viewed from the machine front. switch is turned OFF, and the relief pressure
of high pressure is indicated if it is turned ON.
Pump Actuator Relieved valve
(Front unload valve) (Front main relief valve) 5. Measurement of swing relief pressure
Service Service safety valve 1) Start the engine and move the swing lock
Boom Hi switch to the ON position.
Front main relief valve 2) Measure hydraulic oil pressure when the
Arm Hi
Front engine is running at high idle and the swing
Bucket Front main relief valve
circuit is relieved.
Left travel Front main relief valve a Hydraulic oil pressure when the swing motor
Raise: Front main relief valve safety valve is relieved is displayed.
Boom
Lower: Safety-suction valve a The swing motor relief pressure is lower than
(Merge-divider valve) (Travel junction valve) the main relief pressure.
(Self-reducing pressure valve)
Swing Swing motor safety valve 6. Measurement of travel circuit relief pressure
1) Start the engine and lock travel.
k Put pin [2] in between the sprocket and the
Rear Right travel Rear main relief valve
Arm Lo Rear main relief valve
track frame to make sure locking travel.
(Rear unload valve) (Rear main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Measurement of Unload Pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position.
a Hydraulic oil pressure when the unload valve
unloads is displayed.
4. Measurement of work equipment relief pres-

sure 2) Measure hydraulic oil pressure when the
1) Start the engine and move the cylinder to be engine is running at high idle and the travel
measured to its stroke end. circuit is relieved.
2) Measure hydraulic oil pressure, when the a Hydraulic oil pressure with the main relief
engine is running at high idle and the cylin- valve in relief condition is displayed. In the
der is in relief condition. travel circuit relief, the pressure is high pres-
a Except in boom LOWER, the relief pressure sure relief all the time.
of the main relief valve is indicated.
a Except in boom LOWER, the relief pressure
of low pressure is indicated when the one-
touch power max. switch is not depressed
and the relief pressure of high pressure is in-
dicated, when it is depressed.
20-118 PC300/350(LC)-7
(8)
Adjustment 5) Connect the pilot hose.

a The unload valve cannot be adjusted. 6) Check the pressure again after the adjust-
1. Adjustment of main relief pressure ment, following the aforementioned steps
a If relief pressure in the work equipment and for measurement.
travel circuits is not normal, adjust the high
pressure setting side of main relief valves (3) 2. Adjustment of relief pressure in boom
and (4) in the following manner. LOWER (High pressure setting side)
• (3): For the front main relief valve a If the relief pressure of high pressure in
• (4): For the rear main relief valve boom LOWER is not normal, adjust the high
a The main relief valve adjusts the relief pres- pressure setting side of safety and suction
sure of high pressure. (When the relief pres- valve (7) for boom LOWER in the following
sure of low pressure is adjusted, the relief manner.
pressure of high pressure is also adjusted a The relief pressure of high pressure is such
automatically) condition that the machine push-up switch is
a The relief pressure of low pressure is such in the ON position, and the switching port
condition that the 2-stage relief solenoid and the pilot pressure do not function.
valve is in the OFF position and no pilot pres-
sure is applied to the switching port.
1) Disconnect pilot hose.

2) Fix holder (9) and loosen lock nut (8).
1) Disconnect the pilot hose. 3) Adjust the pressure by turning holder (9).
2) Fix holder (6) and loosen lock nut (5). a If the holder is turned to the right, the
3) Adjust the pressure by turning holder (6). pressure rises.
a If the holder is turned to the right, the If the holder is turned to the left, the pres-
pressure rises. sure falls.
If the holder is turned to the left, the pres- a Adjustment amount per turn of holder:
sure falls. Approx. 21.8 MPa{approx. 222 kg/cm2}
a Adjustment amount per turn of holder: 4) Fix holder (9) and tighten lock nut (8).
Approx. 20.5 MPa{approx. 209 kg/cm2} 3 Lock nut:
4) Fix holder (6) and tighten lock nut (5). 93–123 Nm{9.5–12.5 kgm}
3 Lock nut:
49.0–58.8 Nm{5–6 kgm}
PC300/350(LC)-7 20-119
(7)
5) Connect the pilot hose. 4. Adjustment of swing relief pressure

6) Check the pressure again after the adjust- a If the swing relief pressure is not normal, ad-
ment, following the aforementioned steps just it with swing motor safety valve (12) in
for measurement. the following manner.
a If high pressure setting side is adjusted,
low pressure setting side is also affect-
ed, so adjust it, too.
3. Adjustment of relief pressure in boom

LOWER (Low pressure setting side)
a If the relief pressure of low pressure in boom
LOWER is not normal, or the high pressure
setting side has been adjusted, adjust the
low pressure setting side of safety and suc-
tion valve for boom LOWER in the following
manner.
a The relief pressure of low pressure is such
condition that the machine push-up switch is
in the OFF position, and the pilot pressure is 1) Fix adjusting screw (14) and loosen lock nut
applied to the switching port. (13).
1) Disconnect the pilot hose. 2) Adjust the pressure by turning adjusting
2) Fix holder (11) and loosen lock nut (10). screw (14).
3) Adjust the pressure by turning holder (11). a If the holder is turned to the right, the
a Turn the holder: pressure rises.
• To the right to increase the pressure If the holder is turned to the left, the pres-
• To the left to lower the pressure sure falls.
a Adjustment volume of holder per turn: a Adjustment amount per turn of adjusting
screw:
Approx. 21.8 MPa{Approx. 222 kg/cm2}
4) Fix holder (11) and tighten lock nut (10). Approx. 4.70 MPa{approx. 47.9 kg/cm2}
3 Lock nut: 78–93 Nm{8.0–9.5 kgm}
3) Fix adjusting screw (14) and tighten lock nut
(13).
3 Lock nut:
147–196 Nm{15–20 kgm}
5) Connect the pilot hose.

6) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement. 4) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement.
20-120 PC300/350(LC)-7
(7)
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL

PRESSURE
a Control circuit oil pressure inspection and adjust- 3. Start the engine and keep it running until the
ment tools hydraulic oil temperature rises to the operating
range.
799-101-5002 Hydraulic tester 4. Measure oil pressure with the engine running at
1 Digital type high idle and all the control levers in the NEU-
790-261-1204
hydraulic tester TRAL position.
L
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Measurement
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.
1. Remove oil pressure measurement plug (1).

5. Detach all the measurement tools after the mea-
a Do not attempt to adjust the control circuit oil
pressure relief valve.
2. Fit nipple L2 and connect it to oil pressure

gauge [1] of hydraulic tester L1.
a Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm2}.
PC300/350(LC)-7 20-121
(8)
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

CIRCUIT OIL PRESSURE
a Pump PC control circuit oil pressure inspection • Plug (3): For measuring the front pump
and adjustment tools PC valve delivery pressure
• Plug (4): For measuring the rear pump
Mark Part No. Part name PC valve delivery pressure
1 Digital type
790-261-1204
hydraulic tester
L
Nipple
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Measurement
a Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work
equipment, swing and travel circuit oil pressure
as well as the control circuit original oil pressure
are normal. 2) Fit nipple L2 and connect to oil pressure
k Lower the work equipment to the ground and gauge [1] of hydraulic tester L1.
stop the engine. After the engine stops, operate a Use an oil pressure gauge with the ca-
the control lever several times to release the re- pacity of 58.8 MPa {600 kg/cm2}.
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy- • Photo shows pump delivery pressure side.
draulic tank.
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
a Measure PC valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare the two
pressures.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
• Plug (1): For measuring the front pump
delivery pressure (at the machine rear
part)
delivery pressure (at the machine front • Photo shows PC valve output pressure side.
part)
20-122 PC300/350(LC)-7
(8)
3) Start the engine and keep it running until the 2. Measurement of PC-EPC output pressure
hydraulic oil temperature rises to the operat- 1) Remove oil pressure measurement plug (5).
ing range. a The plug is fitted at the machine front.
4) Measure the pump delivery pressure and 2) Fit nipple L2 and connect it to oil pressure
PC valve output pressure (servo piston inlet gauge [1] of hydraulic tester L1.
pressure) together with the engine running a Use an oil pressure gauge with the ca-
at high idle, after setting the machine at the pacity of 5.9 MPa {60 kg/cm2}.
following conditions.
• Swing lock switch: ON (switched to high
pressure relief with 2-stage relief turned
ON)
• Work equipment, swing and travel cir-
cuit: Arm digging relief
a Judgement method:
When the ratio between the pump deliv-
ery pressure and PC valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres-
sures are judged normal.
Pressure to be 3) Start the engine and keep it running until the

Pressure ratio hydraulic oil pressure rises to the operating
measured
Pump delivery range.
1
pressure
PC valve outlet
Approx. 0.6
pressure
a If there is any abnormality with PC valve

or servo piston, the PC valve output
pressure (servo piston output pressure)
equals to the pump delivery pressure, or
approximates to 0 pressure.
PC300/350(LC)-7 20-123
(8)
4) Measure the hydraulic oil pressure with all 2. Turn adjustment screw (9) to the right or left to
the control levers kept in the NEUTRAL adjust.
position and the engine running at high idle a Turn the adjustment screw in the following
and at low idle. directions.
a If PC-EPC valve output pressure chang- • In the work equipment speed is low, turn
es to the following values, it is judged the adjustment screw to the right (to in-
normal. crease the pump absorption torque).
• If the engine speed lowers, turn the ad-
Engine Control Hydraulic oil justment screw to the left (to decrease
speed lever pressure the pump absorption torque).
2.9 MPa 3. Tighten lock nut (8).
3 Lock nut:
Low idle
{30 kg/cm2}
Neutral 27.50 – 34.3 Nm {2.8–3.5 kgm}
0 MPa
High idle
{0 kg/cm2}
Adjustment
a If any of the phenomena mentioned below oc-
curs and PC valve malfunctioning is suspected,
adjust PC valves (6) and (7) in the following man-
ner.
• As workload increases, the engine speed
sharply drops.
• While the engine speed is normal, the work
equipment moves slowly.
• (6): Front pump PC valve
• (7): Rear pump PC valve
a The width across flats of the locknut for the PC 4. Confirm that the PC valve output pressure
valve is 13 mm and that of the adjustment screw (servo piston inlet pressure) is normal after the
(inside width) is 4 mm. Do not turn any other lock- adjustment, following the measurement steps
nut or adjustment screw since it has effects on explained earlier.
the performance of the hydraulic pumps.
1. Loosen lock nut (8).

a Before loosening the lock nut, make match
marks at the adjustment screw end so that
you can see the position of the lock nut be-
fore the adjustment (and you can return the
lock nut to its original position after turning it
in reverse).
20-124 PC300/350(LC)-7
(8)
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL

CIRCUIT OIL PRESSURE
a Pump LS control circuit oil pressure inspection • Plug (3): For measuring the front pump
and adjustment tools LS valve delivery pressure
Mark Part No. Part name LS valve delivery pressure
1 Digital type
790-261-1204
hydraulic tester
Nipple
M 799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Differential pressure
3 799-401-2701
gauge
Measurement
a Measure pump LS control circuit oil pressure af-
ter confirming that the work equipment, swing
and travel circuit oil pressure as well as control 2) Fit nipple M2 and connect it to oil pressure
circuit original pressure are normal.
k Lower the work equipment to the ground and
gauge [1] of hydraulic tester M1.
a Use an oil pressure gauge with the ca-
stop the engine. After the engine stops, operate pacity of 58.8 MPa {600 kg/cm2}.
maining pressure in the piping. Then loosen the • Photo shows pump delivery pressure side.
oil filler cap to release the pressure inside the hy-
draulic tank.
1. Measurement of LS valve output pressure

(servo piston inlet pressure)
a Measure LS valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare both pres-
sures thereafter.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
• Plug (1): For measuring the front pump de-
livery pressure (at the machine rear part)
• Plug (2): For measuring the rear pump de-
livery pressure (at the machine front part) • Photo shows LS valve output pressure side.
PC300/350(LC)-7 20-125
(9)
3) Run the engine and raise the hydraulic oil 2. Measurement of LS differential pressure
temperature to the operating range and a LS differential pressure can be obtained by
push up the track shoe on the side to be measuring pump delivery pressure and LS
measured with the work equipment. pressure (actuator loaded pressure) at the
• For measuring oil pressure in front cir- same time and computing the difference of
cuit: Right track shoe both pressures.
• For measuring oil pressure in rear cir- 1) Remove oil pressure measurement plugs
cuit: Left track shoe (1), (2), (5) and (6).
k Provide a working area of sufficient space, • Plug (1): For measuring the front pump
as the raised track shoe will be idly rotated. delivery pressure (at the machine rear
part)
delivery pressure (at the machine front
part)
4) Measure pump delivery pressure and PC

valve output pressure (servo piston inlet
pressure) together with the machine set at
the following conditions and the engine run-
ning at high idle. • Plug (5): For measuring the front pump
• Working mode: A mode LS pressure (at the machine rear part)
• All the control levers of the work equip- • Plug (6): For measuring the rear pump
ment, swing and travel are kept in the LS pressure (at the machine rear part)
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Judgement method:
When the ratio between the pump deliv-
ery pressure and LS valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres-
sures are judged normal.
Oil pressure ratio

Oil pressure to be 2) Fit nipple M2 and connect it to oil pressure
measured All control levers Travel at half
in NEUTRAL stroke gauge [1] of hydraulic tester M1 or differen-
tial pressure gauge M3.
Pump delivery
1 a When using a differential pressure gauge:
pressure Nearly equal
Connect pump delivery pressure to the
LS valve delivery pressure
Approx. 0.6 high pressure side and LS pressure to
pressure the low pressure side.
A differential pressure gauge requires DC
5) Detach all the measurement tools after the 12V power. Connect it with one battery.
measurement and make sure that the a When using an oil pressure gauge:
machine is back to normal condition. Use an oil pressure gauge with the ca-
pacity of 58.8 MPa{600 kg/cm2}.
20-126 PC300/350(LC)-7
(8)
The max. differential pressure is no 4) Measure pump delivery pressure and LS

more than approx. 3.9 MPa {40 kg/cm2}. p r e s s u r e ( a c t u a t o r l o a d e d p r e s s u r e)
The same gauge may be used through- together with the machine set at the follow-
out the measurement. ing conditions and the engine running at
high idle.
• Photo shows pump delivery pressure side. • Working mode: A mode
• Traveling speed: Hi
• All the control levers of the work equip-
ment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Calculation of LS differential pressure:
LS differential pressure = Pump delivery
pressure – LS pressure
a If LS differential pressure is in the follow-
ing conditions, it is judged normal.
• Photo shows LS pressure side.
Control lever position LS differential pressure
All levers in Unload pressure
NEUTRAL (see standard value table)
Travel lever at half Max. LS differential pressure
stroke (Run track idle) (see standard value table)
5) Detach all the measurement tools after the

3. Measurement of LS-EPC valve output pres-

sure
1) Remove oil pressure measurement plug (7).
3) Run the engine and raise the hydraulic oil a The plug is fitted on the rear pump.
temperature to the operating range and
push up the track shoe on the side to be
measured with the work equipment.
• For measuring oil pressure in front cir-
cuit: Left track shoe
• For measuring oil pressure in rear cir-
cuit: Right track shoe
k Provide a working area of sufficient
space, as the raised track shoe will be
idly rotated.
PC300/350(LC)-7 20-127
(8)
2) Fit nipple M2 and connect it with oil pressure Adjustment

gauge [1] of hydraulic tester M1. a When LS differential pressure is not normal, ad-
a Use an oil pressure gauge with the ca- just it with LS valves (8) and (9).
pacity of 5.9 MPa {60 kg/cm2}. • (8): Front pump LS valve
• (9): Rear pump LS valve

hydraulic oil temperature rises to the operat- 1. Fix adjusting screw (11) and loosen lock nut
ing range. (10).
2. Adjust the pressure by turning adjusting screw
(11).
a If the adjusting screw is turned to the right,
the differential pressure rises.
If the adjusting screw is turned to the left, the
differential pressure falls.
a Adjustment amount (LS differential pres-
sure) per turn of adjusting screw:
1.3 MPa {13.3 kg/cm2}
3. Fix adjusting screw (11) and tighten lock nut
(10).
3 Lock nut: 49 – 64 Nm {5–7 kgm}
4) Measure the oil pressure when the engine is

running at high idle and the travel speed
switch and travel lever are operated.
a If LS-EPC valve output pressure chang-
es to the following values, the pressure
is normal.
Travel Travel control Hydraulic

speed lever pressure
Approx. 1.4 MPa
Lo Neutral
{approx. 14 kg/cm2}
Hi Fine control (Note) 0 MPa {0 kg/cm2}
4. After the adjustment, confirm that LS differential
Note: Operate the travel control lever pressure is normal, following the steps for mea-
slightly to the extent that the PPC surement explained earlier.
hydraulic oil pressure is turned ON.
(Stop the operation short of starting
the machine)
5) Detach all the measurement tools after the
20-128 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

a Solenoid valve output pressure measurement
tools

1 Digital type
790-261-1204
N hydraulic tester
2 799-401-3100 Adapter (Size 02)
3 799-401-3200 Adapter (Size 03)
a Measure solenoid valve output pressure after

confirming that control circuit original pressure is
normal.
k Lower the work equipment to the ground and 2. Fix adapter N2 or N3 and connect the discon-
stop the engine. After the engine stops, operate nected hose again.
maining pressure in the piping. Then loosen the 3. Fit nipple [1] of hydraulic tester N1 and connect
oil filler cap to release the pressure inside the hy- it to oil pressure gauge [2].
draulic tank. a Use an oil pressure gauge with the capacity
of 5.9 MPa {60 kg/cm2}.
1. Disconnect the hoses of solenoid valve to be

measured at the outlet side.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 Travel interconnection solenoid valve
3 Merge/divide solenoid valve
4 Travel speed shifting solenoid valve
5 Swing and parking brake solenoid valve
6 Machine push-up solenoid valve
7 2-stage relief solenoid valve
a Hose (1) is installed at the rear of operator's 4. Start the engine and keep it running until the
cab, and hoses (2) through (7) are installed hydraulic oil temperature rises to the operating
at the center of revolving frame. range.
PC300/350(LC)-7 20-129
(9)
5. Run the engine at full throttle, then turn each

solenoid valve ON or OFF by operating the con-
trol lever switch, and measure the pressure.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing "Table
for Functioning Conditions" for each sole-
noid valve.
a How each solenoid valve functions can be
confirmed with monitoring function in the
monitor panel. (Special Function of Machine
Monitor)
a When each output pressure shows the fol-
lowing values, it is judged normal.
Solenoid valve Output pressure
OFF (Demagnetization) 0 MPa {0 kg/cm2}
ON (Excitation) 3 MPa {30 kg/cm2}
6. Detach all the measurement tools after the mea-

Table for Functioning conditions Table for Functioning conditions

- PPC lock solenoid valve - Swing and parking brake solenoid
Functioning condition Functioning Functioning condition Functioning

Locked OFF When all of them
OFF
Safety lock lever Work equipment, is OFF
Released ON
swing, travel, When any of
signaling them ON
Table for Functioning conditions is ON
- Machine push-up solenoid valve
Functioning condition Functioning
Machine push-up OFF ON
switch ON OFF
Table for Functioning conditions - Travel interconnection solenoid valve

When the travel steering signal is ON ON
If front or rear pump pressure
Traveling operation only ON
When the travel steering signal is OFF is over 24.5 MPa {250 kg/cm2}
In conditions other than above OFF
20-130 PC300/350(LC)-7
(8)
Table for Functioning conditions - Travel speed shifting solenoid valve

When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1,200 rpm
When the travel speed switch is at Lo (or Mi (*1))
OFF
The travel signal is OFF
If front or rear pump pressure is
When the travel speed switch is at Hi The travel 32.3 MPa {330 kg/cm2}
signal is ON If front or rear pump pressure is
18.6 MPa {190 kg/cm2} ON
In conditions other than above
*1: The "Mi" mode is on the multi-monitor specification machine only.
Table for Functioning conditions - 2-stage relief solenoid valve

When overheat setting of the 1st stage is ON
OFF
When all the signals for work equipment, swing and travel are OFF
When swing lock switch is ON
When travel signal is ON
When working mode is L mode (*2) ON
When boom LOWER signal is ON
When working mode is A or E When left knob If signals other than swing operation only is ON
mode switch is ON If swing operation only is ON
OFF
Table for Functioning conditions - Merge/divide solenoid valve

When working mode is B mode When service signal is ON
When travel signal only is ON
ON
When F or R pump pressure is higher than
2
Other than L 19.6 MPa {200 kg/cm }
When the work mode When F or R pump pressure is lower than
OFF
When the travel equipment and 14.7 MPa {150 kg/cm2}
signal is ON swing signals When F or R pump pressure is higher than
are ON ON
16.7 MPa {170 kg/cm2}
L mode (*2)
When F or R pump pressure is lower than
11.8 MPa {120 kg/cm2} OFF
*2: The "L" mode is on the multi-monitor specification machine only.
PC300/350(LC)-7 20-131
(8)
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

a PPC valve output pressure measurement tools 2. Fit nipple [1] of hydraulic tester P and connect
oil pressure gauge [2].
Mark Part No. Part name a Use an oil pressure gauge with the capacity
799-101-5002 Hydraulic tester of 5.9 MPa {60 kg/cm2}.
P Digital type
790-261-1204
hydraulic tester
a Measure PPC valve output pressure after con-

firming that control circuit original pressure is
normal.
1. Remove PPC oil pressure switches (1) through

(10) in the hydraulic circuits to be measured.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom, RAISE (S06) 7 Swing, left (S03)
2 Boom, LOWER (S02) 8 Swing, right (S07) 3. Start the engine and keep it running until the
3 Arm, DIGGING (S04) 9 Travel (black) (S30) hydraulic oil temperature rises to the operating
4 Arm, DUMPING (S08) 10 Steering (red) (S31) range.
5 Bucket, DIGGING (S01)
6 Bucket, DUMPING (S05)
a Oil pressure switches (1) through (8) are in-

stalled in the PPC relay block, and (9) and (10)
are installed at the rear of operator's cab.
4. Measure the pressure when the engine is run-

ning at high idle and the control lever of the cir-
cuit to be measured is kept in the NEUTRAL
position and at the full stroke.
a If PPC valve output pressure is at the level
shown below, it is judged normal.
Lever control Hydraulic pressure
In NEUTRAL 0 MPa {0 kg/cm2}
Nearly equal to control
At full stroke original pressure
(see standard value table)
5. Detach all the measurement tools, and make

sure that the machine is back to normal condi-
tion.
20-132 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

a If there is excessive play in the work equipment
or swing lever, adjust it in the following manner.
1. Remove work equipment and swing PPC valve

ass'y.
2. Take off boot (1).
3. Loosen lock nut (2) and screw in disc (3) until it

contacts the heads of four pistons (4).
a Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten lock nut (2) to

the specified tightening torque.
3 Lock nut: 98 – 127 Nm {10 – 13 kgm}
5. Install boot (1).
6. Install work equipment and swing PPC valve

assembly.
PC300/350(LC)-7 20-133
(8)
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK

EQUIPMENT
a If there is any hydraulic drift in the work equip- 2. Inspection of arm cylinder
ment (cylinders), check in the following manner 1) Operate the arm cylinder to move the arm to
to determine if the cause is in the cylinder pack- the position 100 mm before the digging
ing or in the control valve. stroke end, and stop the engine.
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Operate the arm control lever to move the

arm to the digging side.
• If the lowering speed increases, the cyl-
inder packing is defective.
• If there is no change, the control valve is
defective.
a Operate the control lever with the engine
2) Operate the control lever to the RAISE posi- starting switch in the ON position.
tion or the bucket control lever to the CURL a If pressure in the accumulator has
position. dropped, run the engine for approx. 10
• If the lowering speed increases, the cyl- seconds to charge the accumulator again.
inder packing is defective. [Reference]If the cause of the hydraulic drift is in the
• If there is no change, the control valve is defective packing, and the above opera-
defective. tion is carried out, downward movement
a Operate the control lever with the engine is accelerated for the following reasons.
starting switch in the ON position. 1) If the work equipment is set to the above pos-
a If pressure in the accumulator has ture (holding pressure applied to the bottom
dropped, run the engine for approx. 10 end), the oil at the bottom end leaks to the head
seconds to charge the accumulator end. However, the volume at the head end is
again. small than the volume at the bottom end by the
volume of the rod end, so the internal pressure
at the head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is main-
tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.
20-134 PC300/350(LC)-7
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
TESTING AND ADJUSTING RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASE OF REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
3. Inspection of boom lock valve k If the piping between the hydraulic cylinders or
1) Set the work equipment at the maximum the hydraulic motor and control valves is to be
reach and the boom top horizontal. Then disconnected, release the remaining pressure in
stop the engine. the following manner.
k Lock the work equipment control levers and a There is no pressure remaining in the swing mo-
release the pressure inside the hydraulic tor circuit and travel motor circuit, but the internal
tank. pressure in the hydraulic tank affects them. So
k Do not allow anyone to come under the open the oil filler cap of the hydraulic tank.
work equipment during the work.
2) Disconnect drain hose (1) of the control 1. Stop the engine, and loosen the oil filler cap
valve, and install a blind plug in the hose. gradually to release the pressure inside the
• Part No. for the blind hose: 07376-70210 tank.
a Leave the control valve end open.
a If any oil leaks out from the port that is 2. Turn the engine starting switch to the ON posi-
left open, following hydraulic drift of the tion and operate the control levers several
work equipment, the boom lock valve is times.
defective (loose contact). a There must be power supply to the PPC lock
valve. Be sure to operate the control levers
with the engine starting switch in the ON po-
sition.
a When the levers are operated 2-3 times, the
pressure stored in the accumulator is re-
moved.
3. Start the engine, run at low idle for approx. 10

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

times.
4. Inspection of PPC valve
Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the safety lock lever
is put to the LOCK and FREE positions.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has dropped,
run the engine for approx. 10 seconds to
charge the accumulator again.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal fail-
ure).
PC300/350(LC)-7 20-135
(9)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
MEASUREMENT OF OIL LEAKAGE AMOUNT

1. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
boom cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
ing range. Then extend the boom cylinder to
the stroke end.
k Release the pressure remaining in the pip-
ing, referring to the foregoing section of
"Release of remaining pressure in hydraulic
circuit".
2) Disconnect hose (1) at the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine running at high idle.
4) Continue this condition for 30 seconds, then 5) After the measurement, make sure that the
measure the oil leakage amount for one machine is back to normal condition.
minute.
3. Measurement of oil leakage amount from
bucket cylinder
ing range. Then extend the bucket cylinder
to the digging stroke end.
circuit".
2) Disconnect hose (3) at the cylinder head
end block the hose end with a plate.
5) After the measurement, make sure that the 3) Start the engine and apply the relief pres-
machine is back to normal condition. sure to the bottom end of the cylinder with
2. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
arm cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
ing range. Then extend the arm cylinder to
the digging stroke end.
circuit".
2) Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
5) After the measurement, make sure that the
20-136 PC300/350(LC)-7
(9)
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT
4. Measurement of oil leakage amount from 3) Disconnect drain hose (5) of the travel
swing motor motor and fit a blind plug in the hose end.
1) Disconnect drain hose (4) and fit a blind 4) Start the engine and apply the travel relief
plug in the hoses. pressure with the engine running at high
2) Turn the swing lock switch to the ON posi- idle, then measure an oil leakage amount
tion. under such conditions.
3) Start the engine. Apply the swing relief pres- kIn this measurement, an erroneous oper-
sure with the engine running at high idle and ation of the control lever will likely lead to
measure an oil leakage amount under such a serious accident. Make sure that all the
conditions. signals and confirmations are followed
a After keeping the conditions in 3) above without fail.
for 30 seconds, measure the oil leakage a After keeping the conditions in 4) above
amount for one minute. for 30 seconds, measure the oil leakage
a After the first measurement, turn the up- amount for one minute.
per structure by 180 degrees and take a Repeat the measurement several times,
measurement again in the same way. slightly rotating the motor, i.e. shifting
the position of valve plate and cylinder,
and the position of cylinder and piston,
and take measurement several times.
4) After the measurement, make sure that the

5. Measurement of oil leakage amount from 5) After the measurement, make sure that the
travel motor machine is back to normal condition.
1) Take off the travel motor cover.
2) Start the engine and lock the travel.
k Put pin [1] in between the sprocket and the
track frame to block the travel.
PC300/350(LC)-7 20-137
(8)
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
AIR BLEEDING OF VARIOUS PARTS

Steps for air bleeding
Air bleeding item
1 2 3 4 5 6
Hydraulic Cylinder Swing Travel
Engine Operation
pump air air motor air motor air
Contents of Work start start
bleeding bleeding bleeding bleeding
• Change of hydraulic oil
{ { { { { {
• Cleaning of strainer (Note) (Note)
• Replacement of return filter element { {
• Repair or replacement of
hydraulic pump { { { {
• Removing suction pipe
• Repair or replacement of control valve { { {
• Replacement of cylinder
{ { {
• Removing cylinder piping
• Replacement of swing motor
{ { {
• Removing swing motor piping
• Replacement of travel motor swivel
{ { {
• Removing travel motor swivel piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Air bleeding from hydraulic pump 2. Air bleeding from hydraulic cylinder
1) Loosen air bleeding plug (1) and confirm 1) Start the engine and kept it running at low
that oil seeps out from the plug. idle for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeding plug (1). the engine running at low idle.
3 Air bleeding plug: a Be careful not to apply the relief pres-
7.8 – 9.8 Nm {0.8 – 1.0 kgm} sure, stopping the piston rod approx.
a Precautions for starting engine 100 mm before its stroke end.
When starting the engine after the air bleed- 3) Repeat the steps in Item 2) above, but this
ing work explained above, run the engine at time with the engine running at high idle.
low idle for 10 minutes. 4) Apply the relief pressure by extending the
If the engine cooling water temperature is piston rod to its stroke end and with the
low and an automatic engine warming-up engine running at low idle.
function is relied on, use the fuel dial, when it 5) For bleeding air from the arm cylinder and
becomes necessary to cancel it. bucket cylinder, follow the same steps
explained in Item 2) through 4) above.
a In case a cylinder is replaced with new one,
it is advised to bleed air from the new one be-
fore mounting the work equipment. It is es-
pecially so with the boom cylinder, because
its rod does not extend to the stroke end of
LOWER side, after the work equipment is
mounted.
20-138 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS
3. Air bleeding from swing motor

1) Start the engine and run it at low idle.
2) Bleed air from the motor by swinging the
upper structure slowly.
4. Air bleeding from travel motor

1) Start the engine and run it at low idle.
2) Loosen air bleeding plug (2) and confirm
that oil seeps out from the plug.
3) If the oil seepage is confirmed, tighten air
bleeding plug (2).
3 Air bleeding plug:
27.5 – 35.3 Nm {2.8 – 3.6 kgm}
PC300/350(LC)-7 20-139
(8)
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE

a Check an assembled-type diode (8 pins) and sin- 3) Determine if a specific diode is good or no
gle diode (2 pins) in the following manner. good with the indicated value.
a The continuity direction of an assembled-type di- • No change in the indicated value: No
ode is as shown in the diagram below. continuity (defective).
a The continuity direction of a single diode is • Change in the indicated value: Continui-
shown on the diode surface. ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode (P) of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
1. When using digital type circuit tester • If the needle swings in Case i), but does
1) Switch the testing mode to diode range and not swing in Case ii): Normal (but the
confirm the indicated value. breadth of swing (i.e. resistance value)
a Voltage of the battery inside is displayed will differ depending on a circuit tester
with conventional circuit testers. type or a selected measurement range)
2) Put the red probe (+) of the test lead to the • If the needle swings in either case of i)
anode (P) and the black probe (–) to the and ii): Defective (short-circuited inter-
cathode (N) of diode, and confirm the dis- nally)
played value. • If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
20-140 PC300/350(LC)-7
(8)
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL
SPECIAL FUNCTION OF MULTI-MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
PC300/350(LC)-7 20-141
Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
ble-shooting or special setting of machines.
Operator's Menu Service Menu

1 Function for inputting and setting password 16 Function for monitoring [01]
2 Function for showing Komatsu's logo Function for fail- Electrical system
17
Function for machine inspection before start- ure history [02] Mechanical system
3
ing day's work
18 Function for maintenance history [03]
4 Function for showing machine maintenance
19 Function for maintenance mode change [04]
5 Function for showing precaution items
20 Function for recording phone No. [05]
Function for confirming working mode and
6 Mode with key ON
travel speed
Function for ini- Language
7 Function for display of ordinary items tial value set-
21 Unit
Function for adjusting display luminance and ting and default
8 [06] Attachment installed/No
contrast
attachment installed
Function for adjusting breaker and attach-
9 Adjustment of governor
ment flow rate
lever stroke
Function for confirming maintenance informa-
10 Fuel pump absorbin torque
tion Function for
22
11 Function for showing service meter reading adjustment [07] RPM at low idling
12 Function for checking display LCD Adjustment of oil flow to
attachment
Function for showing occurrence of caution
13
item
14 Function for showing users' code No.
Function for showing service code No. and
15
failure code No.
20-142 PC300/350(LC)-7
Operation of Operator's Menu and

Display (Outline)
This section introduces only the outline of the op-
erator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for inputting and setting password

When the engine starting switch is turned ON,
the password inputting display is shown.
This display is shown only when a password
is registered.
2. Function for showing KOMATSU logo

When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.
3. Function for machine inspection before

starting day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
4. Function for machine maintenance

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
This display appears only when the mainte-
nance function is set.
PC300/350(LC)-7 20-143
5. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
6. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two sec-
onds to urge an operator to confirm the setting.
7. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordi-
nary items.
If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for two seconds.
In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
8. Function for adjusting display luminance

and contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
20-144 PC300/350(LC)-7
9. Function for adjusting breaker and attach-

ment flow rate (For machines equipped with
breaker attachment)
When a breaker or other attachments are used,
hydraulic pump flow rate can be adjusted by
operating the select switch.
Note that the symbol mark and contents of
display partially differ between the breaker
and the other attachments.
10. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
Use service Menu for setting or releasing
maintenance items and setting maintenance
time.
11. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)
12. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of inputting and setting password as well as in
the display of ordinary items
• Switching operation: [ ] + [A] (synchro-
nized switching operation)
All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
This display returns to the immediately pre-
ceding one, if making any other switching
operation.
PC300/350(LC)-7 20-145
13. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
14. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 15)
Relation between User Code and Action Directed to Operator
User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive switch ON,
E02 PC-EPC Valve
but call for the inspection service immediately.
Release the brake after turning emergency swing and parking brake switch ON.
When applying the swing brake, operate the swing lock switch manually. The
E03 Swing Brake
swing brake may not be released depending on the nature of the trouble. In either
case, call for the inspection service immediately.
The governor control has become inoperable. Operate the governor control lever
E05 Governor manually. For fixing the lever at full throttle position, use a fixing bolt provided at
the bracket. In this case, call for the inspection service immediately.
20-146 PC300/350(LC)-7
15. Function for showing service code No. and

failure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if regis-
tered), service code No. and failure code No.
are shown in turn.
• Switching operation: [ ] (keep the switch
depressed)
a The following items are repeatedly displayed
in order according to the operation of the
switch.
Telephone symbol mark
Ø
Telephone No.
Ø
Service code No. and failure code No.
a The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
a For details on the displayed service code No.
and failure code No., refer to the Table for
Service and Failure Code Nos.
PC300/350(LC)-7 20-147
(7)
Table for Service and Failure Code Nos.
Classification
Service Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
Abnormality
– E101 Abnormal data in error history DAF0KT Failure history
in data
Short circuit in wiper motor drive, normal rota-
Windshield wiper motor (nor-
– E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-
Windshield wiper motor
– E113 DY2EKB Short circuit
tion system (reverse rotation)
– E114 Short circuit in windshield washer drive
DY2CKB Windshield washer motor Short circuit
– E115 Abnormality of windshield wiper in motion
DY20KA Windshield wiper motor Disconnection
– E116 Abnormality of windshield wiper in retraction
DY20MA Windshield wiper motor Malfunctioning
Travel interlocking solenoid
– E201 Short circuit in travel interconnection solenoid DW91KB Short circuit
valve
E03 E203 Short circuit in swing holding brake solenoid DW45KB Swing holding solenoid valve Short circuit
– E204 Short circuit in merge/divide solenoid DWJ0KB Merge solenoid valve Short circuit
– E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit
Travel Hi-Lo shifting solenoid
– E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit
valve
Travel interlocking solenoid
– E211 Disconnection in travel interlocking solenoid DW91KA Disconnection
valve
E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve Disconnection
– E214 Disconnection in merge/divide solenoid DWJ0KA Merge solenoid valve Disconnection
– E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
Electrical system
Travel Hi-Lo shifting solenoid
– E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
valve
Nonconfor-
– E217 Abnormality in model code input DA2SKQ S_NET mance in model
selecting signal
– E218 Disconnection in S_NET signal DA2SKA S_NET Disconnection
– E222 Short circuit in LS-EPC solenoid DXE0KB LS-EPC solenoid valve Short circuit
– E223 Disconnection in LS-EPC solenoid DXE0KA LS-EPC solenoid valve Disconnection
– E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning
– E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning
Lowering in out-
– E226 Abnormality in pressure sensor power source DA25KP Governor pump controller
put voltage
– E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning
– E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit
E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection
– E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection
ATT flow rate throttling EPC
– E245 Short circuit in ATT flow rate adjusting EPC DXE4KB Short circuit
valve
ATT flow rate throttling EPC
– E246 Disconnection in ATT flow rate adjusting EPC DXE4KA Disconnection
valve
Abnormality in
– E256 Incorrect nonvolatile memory data DA20KT Nonvolatile memory
data
– E304 Short circuit in engine stop solenoid relay DY45KB Engine stop solenoid relay Short circuit
Governor motor feedback
– E306 Abnormality in motor potentiometer DK54KZ Malfunctioning
potentiometer
20-148 PC300/350(LC)-7
Electrical system Classification

Service Code Failure Code
User Code
Failure
No.
Code
Content Code No. Location Phenomenon
No.
E05 E308 Abnormality in throttle potentiometer DK10KZ Throttle potentiometer Malfunctioning

– E314 Disconnection in engine stop solenoid relay DY45KA Engine stop solenoid relay Disconnection
– E315 Short circuit in battery relay output D110KB Battery relay Short circuit
– E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control
E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor Disconnection
E05 E318 Short circuit in both governor motors A and B DY10KB Governor motor Short circuit
– None Engine high idling out of rate A000N1 Engine Overrunning
Low idling out of
– None Engine low idling out of rate A000N2 Engine
rate
– None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient
Mechanical system
– None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
– None Engine oil pressure abnormally low B@BAZG Engine oil
ered
– None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
– None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
– None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
– None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
– None Auto-lubrication system abnormal DA80MA Malfunction
troller
This table is arranged in the sequence of Service Code No.

In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Service Code, the corresponding service code or failure code is not shown in the dis-
play of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in elec-
trical system or mechanical system) of Service Menu.
History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
"E" at the head of Code No. of Service Code means the following status of a specific failure.
• With "E": The failure is yet to be dissolved and continues.
• Without "E": The failure has already been dissolved.
PC300/350(LC)-7 20-149
Operation and Display of Service Menu
Way of switching to Service Menu

When using Service Menu, change the display to
Service Menu display through the following spe-
cial operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] [2] [3]
(Enter a figure, depressing [ ])
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 / Default
07 Adjustment
08 –
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.
20-150 PC300/350(LC)-7
16. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 999 and depress [ ]
switch.
The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
PC300/350(LC)-7 20-151
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, select mode, travel speed
and auto-decel while monitoring, depress
the corresponding switch, then the mode
confirmation display is shown.
An illustration at right shows the display in A
mode and E mode. Symbol marks are par-
tially different in B mode.
When a specific setting is confirmed, de-
press [ ] switch, then the display returns to
that of monitoring.
In case a specific setting has been changed
while monitoring, the new setting is still
maintained when returning from Service
Menu to Operator's Menu after the monitor-
ing is finished.
20-152 PC300/350(LC)-7
Table for Monitoring Items

Code Unit (Default: ISO)
Item to be monitored Remark
No. ISO Meter Inch
000 Return (Not displayed) Termination menu
Execute
999 To Display Screen (Not displayed)
Command menu
002 Controller Model Select Figure
003 Controller Model Select Figure
010 Engine Speed r/min rpm rpm
2
011 F Pump Pressure MPa kg/cm PSI
012 R Pump Pressure MPa kg/cm2 PSI
013 PC-EPC Sol. Curr. mA mA mA
015 LS-EPC Sol. Curr. mA mA mA
016 2nd Eng. Speed Command r/min rpm rpm
017 Service Sol. Curr. mA mA mA
Swing ON/OFF
Travel ON/OFF
Pressure Boom Lower ON/OFF
019
Switch 1 Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Pressure Bucket Dump ON/OFF
021
Switch 2 Service ON/OFF
Travel Steering ON/OFF
Lever Sw. ON/OFF
022 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
023 Solenoid valve 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
024 Solenoid valve 2 Service Return ON/OFF
Model Select 1 ON/OFF
027 Switch Input 2 Model Select 3 ON/OFF
030 Fuel Dial Vol. V V V
031 Gov. Motor Potentio Vol. V V V
032 Battery Voltage V V V
033 Gov. Motor Phase A Curr. mA mA mA
034 Gov. Motor Phase B Curr. mA mA mA
035 Battery Relay O/P Vol. V V V
036 Switch Input 3 Key Switch ON/OFF
Batt. Relay Dr. ON/OFF
037 Controller Output
Engine Stop SOL. ON/OFF
041 Engine Water Temperature ºC ºC ºF
042 Fuel Lever Sensor Vol. V V V
PC300/350(LC)-7 20-153
Code Unit (Default: ISO)

Item to be monitored Remark
No. ISO Meter Inch
043 Battery Charge Vol. V V V
044 Hydr. Oil Temperature ºC ºC ºF
Key Switch ON/OFF
Start ON/OFF
Preheat ON/OFF
045 Monitor Input 1
Light ON/OFF
Rad. level ON/OFF
Hydr. Oil Level ON/OFF
Aircleaner ON/OFF
Eng. Oil Press. ON/OFF
046 Monitor Input 2 Eng. Oil Level. ON/OFF
Spare ON/OFF
Battery Charge ABN•NOR
Swing Brake Sw. ON/OFF
Buzzer cancel Sw. ON/OFF
049 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
200 Monitor Prog. Version Figure
201 Controller Prog. Version Figure
Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
It cannot be monitored how the machine push-up solenoid valve works.
20-154 PC300/350(LC)-7
17. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Service Code
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
PC300/350(LC)-7 20-155
5) Resetting Electrical Systems

Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
• Switch operation: [ ] +[1] [2] [3]
This is the same switch operation in
changing the display to Service Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
When resetting all the information, a
display of any information will do.
20-156 PC300/350(LC)-7
18. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
PC300/350(LC)-7 20-157
19. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Use Default Values
01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
20-158 PC300/350(LC)-7
4) Set contents of individual items

: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
PC300/350(LC)-7 20-159
20. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone
Number Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
When entering a wrong number, de-
press [B] switch, then the cursor goes
back by one digit.
When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
20-160 PC300/350(LC)-7
21. Function for /Default

[06]
It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Working mode when the engine starting
switch is in the ON position.
• Display language in Service Menu
• Display unit in the monitoring function
• With/Without Service Cir.
Select 06 "/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
No. /Default submenu
00 Return (termination of /Default)
01 Key-on Mode
02 /Language
03 Unit
04 With/Without Service Cir.
3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
• A, E, L and B Modes: If any of them is
set, the machine always ramps up with
that working mode, when turning the en-
gine starting switch ON.
• Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
• Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
Irrespective of this setting mode, a ma-
chine "With attachment" always ramps
up with B mode, when the engine start-
ing switch is turned ON at the subse-
quent operation, if that was the working
mode used in the last machine work.
PC300/350(LC)-7 20-161
4) Function for /Language

In Service Menu, the language in use can
be changed between Japanese and Eng-
lish.
English is used as the language for de-
fault setting in the monitor panel.
If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
6) Function for selecting distinction of With/

Without Service Cir.
It is possible in this function to set a distinc-
tion between with or without attachment.
• With Service Circuit: When an attach-
ment is installed.
• Without Service Circuit: When no attach-
ment is installed.
If "With Service Circuit" setting is not
made in this display, while it is actually
installed on a specific machine, SELECT
function in Operator's Mode (attachment
oil flow rate adjustment) cannot be uti-
lized.
20-162 PC300/350(LC)-7
22. Function for Adjustment [07]

The monitor panel has a function of making vari-
ous adjustments of the machine.
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.
2) Selection of submenu
Select an item to change from the submenu
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjust.
3) Function for Governor Stroke Adjustment

a If the governor actuator, fuel injection
pump, or governor spring is removed
and installed or the high idling speed is
low or the engine speed is unstable, ad-
just the governor lever stroke according
to the following procedure.
i) Call the display of governor lever stroke
adjustment and set the fuel dial at MAX.
a Under this condition, the governor
actuator lever moves to the FULL
position. Keep this display until ad-
justment is finished.
a The engine speed is indicated in 10
rpm at the center of the display.
a The turning direction of the governor
spring when the fuel injection pump
is seen from the governor actuator is
indicated.
PC300/350(LC)-7 20-163
(7)
ii) Loosen locknuts (2) of rod (1).

a Locknut (2) has left-hand threads.
iii) Turn rod (1) counterclockwise to
increase installed length (a) of governor
spring (3) and return governor lever (4)
of the fuel injection pump to a position at
which it will not touch the full stop.
a Take care that the outer cylinder of
governor spring (3) will not be
dragged and the water drain hole will
not be moved from the bottom.
iv) Turn rod (1) clockwise to decrease
installed length (a) of governor spring
(3). If governor lever (4) touches the full
stop, stop turning the rod.
• Standard installed length (a): 261.75
mm (Reference)
v) Turn rod (1) 3 more turns to compress
the spring in governor spring (3).
a Since the internal spring is com-
pressed, only the outside cylinder of
governor spring (3) moves about
3.75 mm toward the governor actua-
tor (The installed length does not
change).
vi) Fixing rod (1), tighten locknuts (2).
a Before tightening the locknuts,
check that the water drain hole of the
3 Nut:
governor spring is directed down.
11.8 – 19.6 Nm {1.2 – 2.0 kgm}

vii) Return the fuel control dial to the MIN
position, and then turn it toward the
MAX side gradually. At this time, check
that governor spring (3) is lengthened
about 3.75 mm after governor lever (4)
touches the full stop.
20-163-1 PC300/350(LC)-7
(7)
4) Function for Pump Absorption Torque

adjustment
The pump absorption torque can be
adjusted within the range shown in the table
below.
Adjustment value Torque adjustment value
220 +4.0 kgm
221 +3.0 kgm
222 +2.0 kgm
223 +1.0 kgm
224 0.0 kgm
225 –1.0 kgm
226 –2.0 kgm
227 –3.0 kgm
228 –4.0 kgm
5) Function for Low Idle Speed adjustment

The engine rotation at low idling can be
adjusted within the range shown in the table
below.
Adjustment value Low idling rotation
320 900 rpm
321 1,000 rpm
322 1,100 rpm
323 1,200 rpm
6) Function for Service Current Adjust.

When a machine is used for a compound
operation, distribution of hydraulic pump oil
flow can be adjusted within the range shown
in the table below.
Distribution of oil flow
Adjustment value
to attachment
370 0.5 Time
371 0.7 Time
372 1.0 Time
373 0.4 Time
20-164 PC300/350(LC)-7
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display Section to operate special Section to operate special function 2

special functions function 1 (Basic operation) (Selecting operation and special operation)
1. Display section 3. Caution buzzer stop switch 7. Working mode selector (UP) switch
2. Service meter 4. Auto-decelerator switch 8. Working mode selector (DOWN) switch
section 5. Setting switch (Black switch)
6. Travel speed shifting switch
PC300/350(LC)-7 20-165
(5)
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function
Ordinary functions (Operator menu) Special functions (Service menu)
1 Function of displaying service meter <Operation of switch> O 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
2 Function of displaying user code 5 Function of adjusting governor [03]
6 Function of selecting maintenance period [04]
7 Function of selecting default working mode [05]
8 Function of setting installation of attachment [16]
Special function of monitoring replacement

9
of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
20-166 PC300/350(LC)-7
(5)
Display of operator menu
a Only outline of the operator menu is described in

this section. For details of each menu, see OP-
ERATION MANUAL or the volume of STRUC-
TURE AND FUNCTION.
1. Function of displaying service meter

While the machine is used normally, the monitor
panel displays the following information.
• Display section (1): Nothing is displayed
• Service meter section (2): Service meter
2. Function of displaying user code

If the machine has any trouble, the correspond-
ing user code is displayed automatically in dis-
play section (1) and the caution buzzer is turned
ON to urge the operator to take a proper rem-
edy, depending on the degree of the trouble.
a Service meter section (2) continues display-
ing the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the service code with the "Function of
displaying service code [01]" in the service
menu.
<Reference>
A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
a User codes and remedies shown to operator
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position, the
Error in pump
E02 machine can operate normally. Have the machine inspected immediately, q
control system
however.
Set the swing holding brake release switch in the upper position to release
Error in swing the brake. When applying the swing brake, operate the swing lock switch
E03 q
brake system manually. The brake may not be released, depending on the cause of the
failure. In this case, have the machine inspected immediately.
Error in governor
E05 Have the machine inspected immediately. q
system
PC300/350(LC)-7 20-167
(5)
Operation and display of service menu
How to select service menu

a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3. Function of displaying service code [01]
4. Monitoring function [02]
5. Function of adjusting governor [03]
6. Function of selecting maintenance period
[04]
7. Function of selecting default working
mode [05]
8. Function of setting installation of attach-
ment [16]
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
2) Displaying display section and service meter

section
If the switches are operated as shown above,
the first menu No. [01] (Monitoring function) is
displayed in service meter section (2).
a Nothing is displayed in display section (1).
3) Selecting menu
operate working mode selector switches (7) and
(8) to select a menu you will use.
• UP switch (7): Increase Menu No.
• DOWN switch (8): Decrease Menu No.
Menu Service menu

No. (Excluding special functions)
01 Function of displaying error code
02 Monitoring function
03 Function of adjusting governor
04 Function of selecting maintenance period
05 Function of selecting default working mode
16 Function of setting installation of attachment
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
5) Finishing service menu

hold auto decelerator switch (4) for 2.5 seconds
(similarly to the selecting operation).
a The service menu is finished and the ordi-
nary screen appears.
a The service menu can be also finished by
turning the starting switch OFF while the
service menu is selected. (In this case, the
ordinary screen appears when the starting
switch is turned ON again.)
20-168 PC300/350(LC)-7
(5)
a To use the following special function, you must

operate the switches differently from the above.
See details of this function "9. Special function
of monitoring replacement of engine oil".
3. Function of displaying service code [01]

With this function, you can check the service
code of a trouble which is occurring at present
or has occurred in the past.
1) Selecting and executing function

i) Select menu No. [01] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Information displayed in display section and

service meter section 1 (When service code
is recorded)
If a service code is recorded, the following
information is displayed in display section
(1) and service meter section (2).
(a): Service code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occur-
ring at present
a Mark [E] to indicate that a trouble is oc-
curring at present indicates that the serv-
ice code is being detected now. It is not
displayed if the trouble has been re-
paired or the service code is not detect-
ed.
a For the service codes which the monitor
panel and engine throttle and pump con-
troller can detect, see the "Service
codes table".

service meter section 2 (When service code
is not recorded)
If a service code is not recorded, display
section (1) and service meter section (2)
display as shown in the figure.
4) Number of recorded service codes and dis-

play order of them
This function can record up to 20 service
codes, which are displayed in order from the
latest one.
a If a new trouble occurs while 20 service
codes are recorded, the oldest service
code is deleted and the service code of
the new trouble is recorded.
PC300/350(LC)-7 20-169
(5)
5) Change of displayed service codes

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to change the displayed service
codes.
• UP switch (7):
Next service code appears.
• DOWN switch (8):
Previous service code appears.
6) How to delete service code

i) While holding caution buzzer stop
switch (3), turn the starting switch OFF
and keep holding caution buzzer stop
switch (3).
ii) Under the above condition, turn the
starting switch ON again and hold cau-
tion buzzer stop switch (3) for 5 sec-
onds.
a A service code having the mark [E] is not
deleted.
20-170 PC300/350(LC)-7
(5)
Service codes table

User code Service code Trouble
— E101 Abnormality in error history data
— E104 Clogging of air cleaner (Equivalent to error code [AA10NX])
— E108 Overheating of engine coolant (Equivalent to error code [B@BCNS])
— E112 Short circuit in wiper motor drive forward system
— E113 Short circuit in wiper motor drive reverse system
— E114 Short circuit in windshield washer drive system
— E115 Trouble in operation of windshield wiper
— E116 Trouble in storage of windshield wiper
— E201 Short circuit in travel junction solenoid
E03 E203 Short circuit in swing holding brake solenoid
— E204 Short circuit in merge-divider solenoid
— E205 Short circuit in 2-stage relief solenoid
— E206 Short circuit in travel speed shifting solenoid
— E211 Disconnection in travel junction solenoid
E03 E213 Disconnection in swing holding brake solenoid
— E214 Disconnection in merge-divider solenoid
— E215 Disconnection in 2-stage relief solenoid
— E216 Disconnection in travel speed shifting solenoid
— E217 Abnormality in input model code
— E218 Disconnection in S-NET signal line
— E222 Short circuit in LS-EPC solenoid
— E223 Disconnection in LS-EPC solenoid
— E224 Abnormality in F pump pressure sensor
— E225 Abnormality in R pump pressure sensor
— E226 Abnormality in pressure sensor power supply
— E227 Abnormality in engine speed sensor
— E228 Short circuit in ATT return selector relay
E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
— E238 Disconnection in ATT return selector relay
— E256 Illegal non-volatile memory data
— E304 Short circuit in engine stop solenoid relay
— E306 Abnormality in governor potentiometer
E05 E308 Abnormality in fuel control dials
— E313 Abnormality in auto grease system (Equivalent to error code [DA80MA])
— E314 Disconnection in engine stop solenoid relay
— E315 Short circuit in battery relay output line
— E316 Abnormality in step-out of governor motor
E05 E317 Disconnection in phases A and B of governor motor
E05 E318 Short circuit in phases A and B of governor motor
a For troubleshooting for a service code having the description of (Equivalent to error code [******]), see the
section of the corresponding "Error code of mechanical system".
a "E" at the head of each service code indicates the following condition.
• With E: The trouble has not been repaired.
• Without E: The trouble has been repaired.
PC300/350(LC)-7 20-171
(5)
4. Monitoring function [02]

With this function, you can monitor the revolu-
tion speed, oil pressure, current, voltage, input
condition, output condition, etc. in real time by
the signals from the sensors, switches, and
solenoids installed to various parts of the
machine.

tion mode.
function.
2) Selecting and executing monitoring code

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to select a monitoring code dis-
played in service meter section (1).
• UP switch (7): Increase code No.
• DOWN switch (8): Decrease code No.
a This function displays monitoring code
[001] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".

service meter section 1 (When numeral
code is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is dis-
played)

service meter section 2 (When 6-bit code is
displayed)
If a 6-bit monitoring code is selected, the fol-
lowing information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (6 pieces of
information are displayed in bits)
a In the 6-bit display mode, only the top
and bottom of the 7-segments mark are
used to display. "Solid black" indicates
the ON state, and "white on black back-
ground" indicates the OFF state.
a For the No. of each bit, see the "Monitor-
ing codes table" and the drawing at-
tached to it.
20-172 PC300/350(LC)-7
(5)
Monitoring codes table

Code Monitoring item Unit Remarks
002 Engine throttle and pump controller model code Numeral
003 Engine throttle and pump controller model code Numeral
010 Engine speed 10 rpm
011 F pump discharge pressure kg/cm2
012 R pump discharge pressure kg/cm2
013 PC-EPC solenoid output current 10 mA
015 LS-EPC solenoid output current 10 mA
016 2nd throttle speed 10 rpm
017 (Unused) —
a Swing oil pressure switch (ON) (6 bit)
b Travel oil pressure switch (ON) (6 bit)
c Boom LOWER oil pressure switch (ON) (6 bit)
019 Input condition 1 of switch
d Boom RAISE oil pressure switch (ON) (6 bit)
e Arm IN oil pressure switch (ON) (6 bit)
f Arm OUT oil pressure switch (ON) (6 bit)
a Bucket CURL oil pressure switch (ON) (6 bit)
b Bucket DUMP oil pressure switch (ON) (6 bit)
c (Unused) (6 bit)
d Service oil pressure switch (ON) (6 bit)
e Travel differential pressure switch (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
c One-touch power maximizing switch (ON) (6 bit)
d Swing holding brake release switch (RELEASE) (6 bit)
e Swing lock switch (LOCK) (6 bit)
f (Unused) (6 bit)
a (Unused) (6 bit)
b Travel junction solenoid (ON) (6 bit)
Drive condition of solenoid c Swing holding brake solenoid (ON) (6 bit)
023
valve 1 d Merge-divider solenoid (ON) (6 bit)
e 2-stage relief solenoid (ON) (6 bit)
f Travel speed shifting solenoid (ON) (6 bit)
a (Unused) (6 bit)
b (Unused) (6 bit)
Drive condition of solenoid c (Unused) (6 bit)
024
valve 2 d ATT return selector relay (ON) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
PC300/350(LC)-7 20-173
(5)

a Model selection 1 (Connected to ground) (6 bit)
b Model selection 2 (Connected to ground) (6 bit)
Input condition of model c Model selection 3 (Connected to ground) (6 bit)
027
selection signal d Model selection 4 (Connected to ground) (6 bit)
e Model selection 5 (Connected to ground) (6 bit)
f Kerosene mode (Connected to ground) (6 bit)
030 Fuel control dial input voltage 10 mV
031 Governor potentiometer input voltage 10 mV
032 Controller power source voltage 100 mV
033 Governor motor phase A output current 10 mA
034 Governor motor phase B output current 10 mA
035 Battery relay BR output voltage 100 mV
a (Unused) (6 bit)
b (Unused) (6 bit)
c (Unused) (6 bit)
036 Input condition of signal
d (Unused) (6 bit)
e Starting switch signal C (START) (6 bit)
f (Unused) (6 bit)
a Battery relay (DRIVEN) (6 bit)
b (Unused) (6 bit)
c Engine stop solenoid relay (DRIVEN) (6 bit)
037 Output condition of signal
d (Unused) (6 bit)
e (Unused) (6 bit)
f (Unused) (6 bit)
041 Engine coolant sensor input voltage 10 mV
042 Fuel level sensor input voltage 10 mV
043 Alternator input voltage 100 mV
044 Hydraulic oil temperature sensor input voltage 10 mV
a Starting switch signal ACC (ON) (6 bit)
b Starting switch signal C (START) (6 bit)
c Starting switch signal R1 (HEAT) (6 bit)
045 Input condition of switch 4
d Lamp switch (ON) (6 bit)
e Radiator coolant level switch (OPEN) (6 bit)
f (Unused) (6 bit)
a Air cleaner clogging switch (OPEN) (6 bit)
b (Unused) (6 bit)
c Engine oil pressure switch (OPEN) (6 bit)
046 Input condition of sensor
d Engine oil level switch (OPEN) (6 bit)
e (Unused) (6 bit)
f Alternator (Normal generation) (6 bit)
20-174 PC300/350(LC)-7
(5)

a Swing lock switch (LOCK) (6 bit)
b Caution buzzer stop switch (ON) (6 bit)
c Windows limit switch (ON) (6 bit)
049 Input condition of switch 5
d Wiper contact W (ON) (6 bit)
e Wiper contact P (ON) (6 bit)
f (Unused) (6 bit)
200 Monitor panel program version Numeral
201 Engine throttle and pump controller program version Numeral
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
Display of numeral code Display of 6-bit code
PC300/350(LC)-7 20-175
(5)
5. Function of adjusting governor [03]

This function is used to adjust the governor lever
stroke after the governor actuator, fuel injection
pump, or governor spring is removed and
installed or replaced, or when the high idling
speed is low or engine speed is not stabilized.

tion mode.
function.
2) Condition of governor motor

If this function is executed, all the governor
control functions are cancelled, and then the
operating angle of the governor actuator fol-
lows up only the operation signal of the fuel
control dial.
a While this function is executed, [GOV] is
displayed in display section (1) and
[gSET] is displayed in service meter sec-
tion (2).
3) Adjusting governor lever stroke

i) Keep the fuel control dial to the MAX
position.
ii) Loosen nuts (2) and (3) of governor
spring (1).
a Nut (2) is left-handed.
iii) Turn and adjust rod (5) so that governor
lever (4) of the fuel injection pump will
touch the full stopper.
iv) Tighten rod (5) a little less than 1 turn to
compress governor spring (1) by 2.0
mm.
a At this time, distance (a) between
the pins does not change but the
spring in the governor spring is com-
pressed.
3 Nut:
v) Tighten nuts (2) and (3).
11.8 – 19.6 Nm {1.2 – 2.0 kgm}

vi) Return the fuel control dial to the MIN
position, and then turn it again slowly
toward the MAX position. At this time,
check that governor spring (1) expands
by about 2.0 mm after it reaches the full
stopper.
20-176 PC300/350(LC)-7
(5)
6. Function of selecting maintenance period [04]

With this function, you can adjust the mainte-
nance period of the engine oil for the function of
the engine oil replacement monitor.

tion mode.
function.
2) Selecting maintenance period

The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a mainte-
nance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
Display mode/
Display
Maintenance period
0 Maintenance function is reset.
125 125-hour interval
d Demonstration mode
3) Settling maintenance period

The display or maintenance period
becomes effective when it is selected.
Accordingly, perform the ordinary finishing
operation.
<Special functions of engine oil replacement

monitor>
a For the method of displaying the engine oil
replacement monitor, method of checking
the elapsed time after replacement of engine
oil, method of clearing the elapsed time, and
method of displaying demonstration mode,
see "9. Special functions of engine oil re-
placement monitor".
PC300/350(LC)-7 20-177
(5)
7. Function of selecting default working mode [05]

With this function, you can freely select the
working mode which is set automatically when
the starting switch is turned ON (When the
machine is delivered, mode A is set).

tion mode.
function.
2) Selecting default working mode

The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
• UP switch (7): Next mode is displayed.
• DOWN switch (8): Previous mode is dis-
played.
a Nothing is displayed in display section
(1).
a The working mode changes in the fol-
lowing order: A o E o B
3) Settling default working mode

Press set switch (5) to settle the selected
working mode.
20-177-1 PC300/350(LC)-7
(5)
8. Function of setting installation of attachment [16]

With this function, you can set installation of
attachment.
a When an attachment is installed, if IN-
STALLED is not set with this function, the B-
mode function (automatic single/double op-
eration selecting function) cannot be used.

tion mode.
function.
a While this function is executed, [16SET]
is displayed in the service meter section
(2) and [0] or [1] is displayed in display
section (1).
2) Selecting installation of attachment

i) The current setting is displayed in serv-
ice meter section (1). Check the actual
installation of attachment and setting.
• [0]: Attachment is not installed.
• [1]: Attachment is installed.
ii) While holding caution buzzer stop
switch (3), operate working mode selec-
tor switches (7) and (8) to select [0] or
[1].
• UP switch (7): [1] is selected.
• DOWN switch (8): [0] is selected.
3) Settling installation of attachment

Press set switch (5) to settle the selected
setting of installation of attachment.
PC300/350(LC)-7 20-177-2
(5)
9. Special functions of engine oil replacement monitor

1) Ordinary display of engine oil replacement
monitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights
up and display the elapsed time in service
meter section (2) for 20 seconds each time
the starting switch is turned ON.
2) Checking elapsed time

To check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).
3) Clearing elapsed time

To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed in serv-
ice meter section (2).
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hours.
4) Function of demonstration mode

If the demonstration mode is selected, you
can perform demonstration of the oil mainte-
nance function when teaching the operation
to a customer.
The functions and display of the demonstra-
tion mode are as follows.
i) The internally set interval is recognized
as 250 hours and the elapsed time is
recognized as 240 hours.
ii) When the starting switch is turned ON
after the demonstration mode is set, the
ordinary display is repeated up to 3
times (number of the times of turning
the starting switch ON).
iii) After the demonstration is finished,
resetting of maintenance setting [0] is
recognized.
a When the demonstration is repeated 3
times, resetting of maintenance setting
is recognized. If setting is necessary at
this time, see "Function of selecting
maintenance period".
20-177-3 PC300/350(LC)-7
(5)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL

SYSTEM
PC300, 300LC-7 Serial No. 40001 – 45000 2. Governor pump controller
PC350, 350LC-7 Serial No. 20001 – 25000 a The governor pump controller is installed un-
der a cover behind the operator's seat.
a When diagnosing electric circuits related to the 1) Remove three caps (1) and then three
monitor panel and governor pump controller, first securing bolts.
open up the connector portions in the following a When removing the caps, use of a thin
manner. flat-head screw driver is recommended.
2) Take off cover (2).
1. Monitor panel
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
3) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gov-
ernor pump controller (3).
a The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
a When putting the connectors back into
2) Remove three securing screws and take position, tighten them to the specified
monitor panel (2) off the mount. torque.
a Be careful not to let fall the securing 3 Screw: 2.82 Nm{0.288 kgm}
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
20-178 PC300/350(LC)-7
(7)
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PC300, 300LC-7 Serial No. 45001 and up 2. Governor pump controller

PC350, 350LC-7 Serial No. 25001 and up a The governor pump controller is installed un-
der a cover behind the operator's seat.
a When diagnosing electric circuits related to the 1) Remove three bolts and then cover (5).
monitor panel and governor pump controller, first
open up the connector portions in the following
manner.
1. Monitor panel
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
a If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.
2) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gov-
ernor pump controller (6).
a The connectors are fixed with screws.
Loosen the screws and detach the con-
nectors.
a When putting the connectors back into
position, tighten them to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
2) Remove three securing screws and take

monitor panel (2) off the mount.
a Be careful not to let fall the securing
screws inside the console.
3) Insert or connect a T-adaptor for diagnosis
with P01, P02 and P70 (multi-monitor only)
connectors.
PC300/350(LC)-7 20-178-1
(7)
PC300/350(LC)-7 20-179
Engine Hydraulic system
20-180
PC300/350(LC)-7
Model Serial No. Service meter reading Client user's name Implemented on: Inspected by:
1. Engine
PC300/350(LC)-7
Condition setting Standard value
No. Working Auto One-touch po- Measurement item Unit Measured value Judgement
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure judgement
1 Operating travel control lever Engine rotation rpm 2,090 – 2,230 — Good / No good
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.36 – 0.61{3.5– 6.0} 0.18{1.8} Good / No good
OFF
3 Engine rotation rpm 850 – 925 — Good / No good
Low A OFF All control levers in NEUTRAL
4 Engine oil pressure MPa{kg/cm2} Min. 0.10{Min. 1.0} 0.07{0.7} Good / No good
5 Engine rotation rpm 1,770 – 1,970 — Good / No good
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.0{Max. 100} 2.0{200} Good / No good
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1,300 – 1,500 — Good / No good
2. Work equipment speed

Hydraulic oil temperature (45 – 55oC)
No. Unit PC300, 300LC-7 PC350, 350LC-7 Measured value Judgement
Fuel dial Working Work equipment posture Measurement item
mode New model Failure judgement New model Failure judgement
1 No load, fully extended Boom RAISE 3.3 – 4.1 Max. 4.5 3.4 – 4.2 Max. 4.6 Good / No good
2 A Arm DUMPING 2.6 – 3.2 Max. 3.5 2.7 – 3.5 Max. 3.7 Good / No good
3 3.4 – 4.2 Max. 4.5 3.4 – 4.2 Max. 4.5 Good / No good
Boom held level
4 E Arm DIGGING 3.6 – 4.6 Max. 4.9 3.5 – 4.5 Max. 4.8 Good / No good
5 ( L) 4.4 – 5.4 Max. 5.7 4.4 – 5.4 Max. 5.7 Good / No good
6 Boom and arm held level Bucket DIGGING 2.9 – 3.5 Max. 3.8 2.9 – 3.5 Max. 3.8 Good / No good
Right Good / No good
7 Full Fully extended Swing (5 turns) Sec. 28.7 – 34.5 Max. 30 28.7 – 34.5 Max. 30
Left Good / No good
Right PC300: 30.0 – 34.0 PC300: 28.0 – 39.0 PC350: 30.0 – 34.0 PC350: 28.0 – 39.0 Good / No good
Lo PC300LC: 32.0 – 36.0 PC300LC: 32.0 – 41.5 PC350LC: 32.0 – 36.0 PC350LC: 32.0 – 41.5
A Left Good / No good
Track shoe raised Travel Right PC300: 33.5 – 44.5 PC300: 31.5 – 48.5 PC350: 33.5 – 44.5 PC350: 31.5 – 48.5 Good / No good
8 at one side ( Mi) PC300LC: 35.5 – 47.5 PC300LC: 34.0 – 51.5 PC350LC: 35.5 – 47.5 PC350LC: 34.0 – 51.5
(5 turns) Left Good / No good
Right PC300: 44.0 – 66.0 PC300: 42.0 – 70.0 PC350: 44.0 – 66.0 PC350: 42.0 – 70.0 Good / No good
Hi PC300LC: 46.5 – 69.5 PC300LC: 45.0 – 74.5 PC350LC: 46.5 – 69.5 PC350LC: 45.0 – 74.5
Left Good / No good
: The "Mi" and "L" modes are on the multi-monitor specification machine only.
3. Work equipment hydraulic drift amount

Hydraulic oil temperature (45 – 55oC)
No. Working Measurement item Unit PC300, 300LC-7 PC350, 350LC-7 Measured value Judgement
Fuel dial mode Work equipment posture New model Failure judgement New model Failure judgement
Boom and arm held Hydraulic drift amount at 450 Max. 675 550 Max. 825 Good / No good
1 Engine stop level, Bucket loaded bucket tooth tip (15 min.) mm
20-181
4. Inspection of hydraulic circuit ➀ ➁ ➂ ➃ ➄
Condition setting 600 kg/cm2 600 kg/cm2 600 kg/cm2 600 kg/cm2 60 kg/cm2
No. Part to be checked Remarks
Working Auto-dece- One-touch po- F main pump R main pump F pump LS R pump LS Control circuit
Fuel dial Work equipment operation
20-182
mode lerator wer max. switch pressure
1 Self-decompression valve Circuit pressure 3.2 MPa {33 kg/cm2}
OFF Arm dumping relief
2 Main relief valve 34.8 → 37.3 MPa
3 (When power increased) ON {355 → 380 kg/cm2}
Neutral Main–LS=2.9 MPa{30 kg/cm2}
LS valve (LS differential pressure = Unload pressure)
4 (LS differential Travel without load, Right
pressure valve) Full A OFF engine at Hi idling and Main–LS=2.5 MPa{25.0 kg/cm2} (LS pressure)
control lever at half stroke Left
Swing lock Right relief

5 Swing safety valve OFF switch ON 30.9 MPa {315 kg/cm2}
Left relief
Right forward
Main relief valve, Right reverse
6 Travel safety valve, Track shoe 38.2 MPa {390 kg/cm2}
Travel interlocking valve locked Left forward
Left reverse
Connection to be changed to hoses ➂ and ➃
➀ ➁ ➂ ➃ ➄
No. Part to be checked Working Auto- One-touch po- circuit Remarks
Fuel dial mode decelerator wer max. switch Work equipment operation F main pump R main pump F pump servo R pump servo Control
pressure
Servo Full Arm dumping relief Main servo pressure balance

7 A OFF OFF ➂ / ➀ = ➃ / ➁ = 3/5
Connection to be changed to hoses ➂ and ➃, and gauge to be replaced
with one with 60 K capacity.
➀ ➁ ➂” ➃” ➄
No. Part to be checked Working Auto- One-touch po- Work equipment PC LS Control circuit Remarks <Reference value: kg/cm2>
Fuel dial mode decelerator wer max. switch operation Travel lever F main pump R main pump
EPC EPC pressure
Low <32>
A
< 0>
8 PC-EPC valve E OFF OFF Neutral Neutral <10>
Full
( L) <11>
B <10>
Neutral Neutral At neutral: 2.9 MPa {30 kg/cm2}
A
Neutral When 2 pumps relieved: 0 MPa {0 kg/cm2}
Arm dumping Right lever at
9 LS-EPC valve OFF OFF relief halfway position
Full Left lever at
halfway position
( L) Right lever at When one pump relieved: 1.5 MPa {15 kg/cm2}
halfway position
Arm IN relief Left lever at
halfway position
: The "L" mode is on the multi-monitor specification machine only Do not travel the machine.
PC300/350(LC)-7
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

"MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601
PC300/350(LC)-7 20-201
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
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 structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC300/350(LC)-7
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC300/350(LC)-7 20-203
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, 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 sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed 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.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector 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.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC300/350(LC)-7
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 crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
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 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 connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC300/350(LC)-7 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
If the connector is twisted up and down
or to the left or right, the housing may
break.
3) 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.
If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC300/350(LC)-7
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ 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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC300/350(LC)-7 20-207
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
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 fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before 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.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC300/350(LC)-7
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed 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 connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably
defective contact in that circuit.
PC300/350(LC)-7 20-209
3. 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 hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) 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.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
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 enter-
ing. 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, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing 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 containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 PC300/350(LC)-7
5) Change hydraulic oil when the temperature

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 together 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. (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 con-
taminants 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 equip-
ment, 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: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC300/350(LC)-7 20-211
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-212 PC300/350(LC)-7
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine assembly
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Ser-
vice Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code
is recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical sys-
tem Failure Code, using the failure history function of the monitor panel.
★ If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
★ Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC300/350(LC)-7 20-213
(7)
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2 (1)
6 Engine rotates, but there is no exhaust gas S-2 (2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 (3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power H-1 S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
Engine cooling water is mixed with engine oil, spurts out or
16 S-11
decreases
17 Engine oil amount increases. (Water or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop E-4
21 Auto-decelerator does not work E-5 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 H-3
27 There are abnormal noises from around hydraulic pump H-4
28 Fine control mode function works poorly, or shows slow response H-6
20-214 PC300/350(LC)-7
(7)
Troubleshooting
display
Work equipment-related failure
29 Boom moves slowly or lacks power E-21, 22 H-7
30 Arm moves slowly or lacks power E-23, 24 H-8
31 Bucket moves slowly or lacks power E-25, 26 H-9
32 Work equipment does not move singly H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 21–26 H-14
Compound operation-related failure
In compound operation, work equipment with larger load moves
37 H-15
slowly
38 In swing + boom RAISE operation, boom moves slowly H-16
39 In swing + travel operation, travel speed drops sharply H-17
Travel-related failure
40 Machine tends to swerve while in travel H-18
41 Travel speed is slow E-28 H-19
42 Machine is difficult to steer, or lacks power E-28, 29 H-20
43 Travel speed cannot be shifted or is slow or fast E-28 H-21
44 Track shoe does not move (only on one side) H-22
Swing-related failure
45 Machine does not swing E-27 H-23
46 Swing acceleration is poor, or swing speed is slow H-24
47 Upper structure overruns excessively, when stopping swing H-25
48 There is a big shock caused when stopping swing H-26
49 There is abnormal noise generated when stopping swing H-27
50 Hydraulic drift of swing is large H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all E-10
52 Part of display is missing in monitor panel E-11
53 Descriptions on monitor panel do not apply to the machine model E-12
In startup inspection, radiator water level monitor lamp lights up
54 B@BCZK
red ( )
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
: The multi-monitor specification machine only.
PC300/350(LC)-7 20-215
(7)
Troubleshooting
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine cooling water temperature monitor
60 B@BCNS
lamp lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red ( )
62 Engine cooling water temperature gauge does not display correctly E-14
63 Hydraulic oil temperature gauge does not display correctly ( ) E-15
64 Fuel gauge does not display correctly E-16
65 Swing lock monitor does not display correctly E-17
66 When operating monitor switch, no display appears E-18
67 Windshield wiper does not work E-19
68 Warning buzzer cannot be stopped E-20
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-26
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-27
76 In monitoring function, "Travel" cannot be displayed correctly E-28
In monitoring function, "Travel Differential Pressure" cannot be dis-
77 E-29
played correctly
78 In monitoring function, "Service" cannot be displayed correctly E-30
Other failure
79 Air conditioner does not work E-31
80 Travel alarm does not sound E-32
20-216 PC300/350(LC)-7
(7)
CONNECTOR LOCATION CHART AND ELECTRICAL
TROUBLESHOOTING CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-6 I-8
A02 X 4 Intermediate connector T-2 H-6 I-5
A03 D 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-7
A06 SWP 14 Intermediate connector N-1 H-5 I-5
A07 SWP 16 Intermediate connector S-1 H-4 I-4 I-4
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-3 J-4
A11 Terminal 1 Revolving frame grounding H-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-6 J-8
A14 Terminal 1 Revolving frame grounding C-2 I-1
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A20 Terminal 1 Battery relay (E terminal) C-1 J-5 J-5
A21 Terminal 1 Battery relay (BR terminal) C-2 J-6 J-5
A22 Terminal 1 Battery relay (M terminal) C-1 J-5 K-5
A23 Terminal 1 Battery relay (B terminal) C-2 J-6 K-5
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-4
A31 D 2 Air cleaner clogging sensor K-4 K-4
A33 X 2 Radiator water level sensor K-4 K-5
A34 L 2 Fusible link (65A) A-5 K-6 K-6
A35 M 2 Fusible link (30A) A-4 K-6 K-6
A36 M 2 Fusible link (30A) A-5 K-6
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector G-9 J-7
A43 X 2 Travel alarm J-2 K-4
A44 M 1 Front right lamp A-5 K-7
20-218 PC300/350(LC)-7
(7)
Address
Connector No. of
No. pin
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor J-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-3 K-4
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor L-5 K-5
A80 D 8 Intermediate connector S-1 I-3
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-3 A-4 A-4
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 I-1
E06 M 3 Fuel dial O-8 H-1
E07 D 2 Engine speed sensor L-8 L-8
E08 D 12 Intermediate connector K-9 J-3 J-3 K-8
E10 D 3 Fuel shut-off valve K-3
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor J-9 K-2
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 H-9 C-4 F-9
H08 M 8 Intermediate connector W-4 J-8
H09 S 8 Intermediate connector W-4 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 G-2 C-2
PC300/350(LC)-7 20-219
(7)
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM
Address
Connector No. of
No. pin
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 E-9 D-9
J04 J 20 Junction connector (green) W-7 D-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 F-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 G-9
J07 J 20 Junction connector (orange) U-9 F-9 G-9 H-9
J08 J 20 Junction connector (pink) U-9 H-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) U-2 E-3
K30 D 3 CAN terminating resistor S-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M02 D 2 Starting motor L-7 K-3
M07 M 3 Lamp switch O-8 C-1
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch T-1 B-9
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3) –
M34 X 2 Air compressor electromagnetic clutch W-8
M38 M 2 Machine push-up switch Q-9 D-2
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector J-3 J-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 C-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9
20-220 PC300/350(LC)-7
Address
Connector No. of
No. pin
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P05 D 2 Engine oil temperature switch K-9 K-2
P07 D 2 Engine cooling water switch L-8 K-1
P15 Y050 2 Air conditioner sun light sensor N-6
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 P-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R22 R 5 Engine stop solenoid relay L-8 D-1
S01 X 2 Bucket digging oil pressure switch L-7 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-6 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right K-3 K-2
S08 X 2 Arm dumping oil pressure switch J-3 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Safety lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 Q-9 F-2
switch
S23 Terminal 6 Emergency engine starting switch R-9 F-1
S25 S090 16 Intermediate connector R-9
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch O-1 A-1
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
PC300/350(LC)-7 20-221
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve L-3 K-6
V02 D 2 Travel interlocking solenoid valve L-3 K-6
V03 D 2 Merge/divide valve solenoid valve L-2 K-7
V04 D 2 Travel speed solenoid valve L-2 K-5
V05 D 2 Swing and parking brake solenoid valve L-2 K-6
V06 D 2 Machine push-up solenoid valve L-1 K-5
V08 D 2 2-stage relief solenoid valve L-1 K-6
V12 D 2 Attachment return switching solenoid valve G-9 K-4
V21 D 2 PC-EPC solenoid valve K-7
V22 D 2 LS-EPC solenoid valve L-6 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 K-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-1 C-2
Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
YAZAKI Yazaki-made connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.
20-222 PC300/350(LC)-7
PC300, 300LC-7 Serial No. 45001 and up

Address
Connector No. of
No. pin
A01 X 4 Intermediate connector T-1 H-6 I-6 I-8
A02 X 4 Intermediate connector T-1 H-6 I-5
A03 D 12 Intermediate connector N-2 H-6 I-2 I-8
A04 SWP 6 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-7
A06 SWP 14 Intermediate connector O-1 H-5 I-5
A07 SWP 16 Intermediate connector S-1 H-4 I-4 I-4
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-3 J-4
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-6 J-8
A14 Terminal 1 Revolving frame grounding C-2 I-1
A20 Terminal 1 Battery relay (E terminal) C-1 J-5 J-5
A21 Terminal 1 Battery relay (BR terminal) C-2 J-6 J-5
A22 Terminal 1 Battery relay (M terminal) C-1 J-5 K-5
A23 Terminal 1 Battery relay (B terminal) C-2 J-6 K-5
A31 D 2 Air cleaner clogging sensor K-4 K-4
A33 X 2 Radiator water level sensor K-4 K-5
A34 L 2 Fusible link (65A) A-5 K-6 K-6
A35 M 2 Fusible link (30A) A-4 K-6 K-6
A36 M 2 Fusible link (30A) A-5 K-6
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 D 1 Intermediate connector G-9 J-7
A43 X 2 Travel alarm J-2 K-4
A44 M 1 Front right lamp A-5 K-7
PC300/350(LC)-7 20-222-1
(7)
Address
Connector No. of
No. pin
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor J-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-3 K-4
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor L-5 K-5
Boom cylinder bottom pressure sensor (Over-
A70 D 3 G-1
load alarm)
A80 D 4 Intermediate connector S-1 I-3
C01 DRC 24 Governor pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller U-9 A-7 A-7
C03 DRC 40 Governor pump controller V-9 A-3 A-4 A-4
C09 S 8 Model selection connector W-9 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-5 A-8 D-1
D04 SWP 8 Assembled type diode W-5 A-8 I-1
E06 M 3 Fuel dial O-7 H-1
E07 D 2 Engine speed sensor L-8 L-8
E08 D 12 Intermediate connector K-9 J-3 J-3 K-8
E10 D 3 Fuel shut-off valve K-3
E10 D 3 Governor potentiometer J-9 K-2
E11 D 4 Governor motor J-9 K-2
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box V-2 H-9 C-4 F-9
H08 M 8 Intermediate connector W-6 J-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 G-2 C-2
20-222-2 PC300/350(LC)-7
(7)
Address
Connector No. of
No. pin
J01 J 20 Junction connector (black) T-9 C-9 D-9 C-9
J02 J 20 Junction connector (black) T-9 D-9 D-9 D-9
J03 J 20 Junction connector (green) U-9 D-9 E-9 D-9
J04 J 20 Junction connector (green) V-2 D-9 E-9 E-9
J05 J 20 Junction connector (pink) V-3 E-9 F-9 E-9
J06 J 20 Junction connector (orange) V-3 F-9 G-9
J07 J 20 Junction connector (orange) W-5 F-9 G-9 H-9
J08 J 20 Junction connector (pink) W-5 H-9 H-9
K19 M 2 Pump resistor (for driving emergency pump) W-5 E-3
K30 D 3 CAN terminating resistor A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M02 D 2 Starting motor L-7 K-3
M07 M 3 Lamp switch P-8 C-1
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch O-7
M23 Y090 2 One-touch power max. switch T-1 B-9
M26 S 12 Air conditioner unit W-4
M27 Y090 18 Air conditioner unit W-4
M29 040 20 Air control panel U-2
M30 040 16 Air control panel U-2
M31 M 2 Option power source (2) W-7
M32 M 2 Option power source (1) W-6
M33 M 2 Option power source (3) V-9
M33 SUMITOMO 4 Air conditioner unit W-4
M34 X 2 Air compressor electromagnetic clutch
M38 M 2 Machine push-up switch Q-8 D-2
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector J-3 J-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector W-7
M46 S090 4 RS232C relaying connector V-9 C-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9
PC300/350(LC)-7 20-222-3
(7)
Address
Connector No. of
No. pin
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-8 D-1
P05 M 2 Revolving warning lamp switch U-2
P05 D 2 Engine oil temperature switch K-9 K-2
P07 D 2 Engine cooling water switch L-8 K-1
P15 Y050 2 Air conditioner sun light sensor N-5
P17 090 2 Air conditioner high-low pressure switch
R10 R 5 Lamp relay P-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-8 F-1
code)
R20 R 5 Attachment circuit switching relay W-7 C-9
R22 R 5 Engine stop solenoid relay W-6 D-1
R30 SUMITOMO 5 Air conditioner blower relay W-4
R31 AMP 4 Air conditioner compressor relay W-3
S01 X 2 Bucket digging oil pressure switch L-7 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-6 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right K-3 K-2
S08 X 2 Arm dumping oil pressure switch J-3 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Safety lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 Q-8 F-2
switch
S23 Terminal 6 Emergency engine starting switch R-9 F-1
S25 S090 16 Intermediate connector R-9
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
T05 Terminal 1 Floor frame grounding V-3 J-8
T06 Terminal 1 Radio body grounding S-9
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding
20-222-4 PC300/350(LC)-7
(7)
Address
Connector No. of
No. pin
V01 D 2 PPC hydraulic lock solenoid valve L-3 K-6
V02 D 2 Travel interlocking solenoid valve L-3 K-6
V03 D 2 Merge/divide valve solenoid valve L-2 K-7
V04 D 2 Travel speed solenoid valve L-2 K-5
V05 D 2 Swing and parking brake solenoid valve L-2 K-6
V06 D 2 Machine push-up solenoid valve L-1 K-5
V08 D 2 2-stage relief solenoid valve L-1 K-6
V12 D 2 Attachment return switching solenoid valve G-9 K-4
V21 D 2 PC-EPC solenoid valve K-7
V22 D 2 LS-EPC solenoid valve L-6 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 K-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-1 C-2
Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
S090 Product of Sumitomo 090 type connector
YAZAKI Yazaki-made connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
Y090 Product of Yazaki Y090 type connector
AMP Japan AMP-made connector
PC300/350(LC)-7 20-223
(7)
CONNECTOR LOCATION STEREOGRAM
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
20-224 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-225
(7)
20-226 PC300/350(LC)-7
PC300/350(LC)-7 20-227
(7)
20-228 PC300/350(LC)-7
CONNECTOR LOCATION STEREOGRAM

20-229-1 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-229-2
(7)
20-229-3 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-229-4
(7)
20-229-5 PC300/350(LC)-7
(7)
Monitor Panel System Circuit Diagram (M Circuit)

PC300, 300LC-7 Serial No. 40001 – 45000
PC350, 350LC-7 Serial No. 20001 – 25000
20-230 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC300/350(LC)-7 20-231
Monitor Panel System Circuit Diagram (M Circuit)

20-231-1 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.
PC300/350(LC)-7 20-231-2
(7)
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller

PC300, 300LC-7 Serial No. 40001 – 45000
PC350, 350LC-7 Serial No. 20001 – 25000
20-232 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC300/350(LC)-7 20-233
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller

20-233-1 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.
PC300/350(LC)-7 20-233-2
(7)
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller

PC300, 300LC-7 Serial No. 40001 – 45000
PC350, 350LC-7 Serial No. 20001 – 25000
20-234 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC
lock system, machine push-up system and backup alarm system from the overall electrical circuit diagram.
PC300/350(LC)-7 20-235
(7)
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller

20-235-1 PC300/350(LC)-7
(7)
★ This circuit diagram has been compiled by extracting the governor•pump controller system (pump control), PPC
lock system, machine push-up system and backup alarm system from the overall electrical circuit diagram.
PC300/350(LC)-7 20-235-2
(7)
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-236 PC300/350(LC)-7
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC300/350(LC)-7 20-237
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-238 PC300/350(LC)-7
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC300/350(LC)-7 20-239
(7)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-240 PC300/350(LC)-7
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC300/350(LC)-7 20-241
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-242 PC300/350(LC)-7
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC300/350(LC)-7 20-243
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-244 PC300/350(LC)-7
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 7821-92-7330
12 799-601-7520
— Part No.: 7821-92-7340
14 799-601-7530
— Part No.: 7821-92-7350
18 799-601-7540
— Part No.: 7821-92-7360
20 799-601-7550
— Part No.: 7821-92-7370
PC300/350(LC)-7 20-245
(8)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-246 PC300/350(LC)-7
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC300/350(LC)-7 20-247
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-248 PC300/350(LC)-7
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC300/350(LC)-7 20-249
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-250 PC300/350(LC)-7

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC300/350(LC)-7 20-251

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-252 PC300/350(LC)-7

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC300/350(LC)-7 20-253
(7)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-254 PC300/350(LC)-7
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC300/350(LC)-7 20-255
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-256 PC300/350(LC)-7
(7)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC300/350(LC)-7 20-257
DRC26 Series connector

No.of
pins T-adapter Part
No.
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
20-258 PC300/350(LC)-7
(7)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

★ The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2600 Measurement box Econo-21P Q Q Q Q Q Q

799-601-3100 Measurement box MS-37P Q
799-601-3200 Measurement box MS-37P Q
799-601-3300 Measurement box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Additional cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
20-260 PC300/350(LC)-7
(7)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Measurement box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
press.
799-601-9430 PVC socket 2P Q
PC300/350(LC)-7 20-261
(7)
TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304

Service Code in Electrical System E101 (Abnormal data in Error History) ................................................ 20-306
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of
windshield wiper motor drive)............................................................................................................... 20-308
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of
windshield wiper motor drive)............................................................................................................... 20-310
Service Code in Electrical System E114 (Short-circuiting in window washer drive system) ...................... 20-312
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion) ........................................ 20-314
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) .............................. 20-316
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) ......................... 20-318
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid -
in governor • pump controller system).................................................................................................. 20-320
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)................................. 20-322
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)................................. 20-324
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ..................... 20-326
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)........................... 20-328
Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)..................... 20-330
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) .................................. 20-332
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) .................................. 20-334
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid)....................... 20-336
Service Code in Electrical System E217 (Abnormality in inputting model code)........................................ 20-338
Service Code in Electrical System E218 Disconnection of S-NET signal) ................................................. 20-340
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) ........................................ 20-342
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) ............................. 20-343
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor).................................. 20-344
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) ................................. 20-346
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source) ........................ 20-348
Service Code in Electrical System E227 (Abnormality in engine rotation sensor
in governor • pump controller system).................................................................................................. 20-350
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ............... 20-351
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid ........................................ 20-352
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)............................. 20-354
Service Code in Electrical System E238 (Disconnection in attachment return switching relay) ................ 20-356
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-358
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-359
Service Code in Electrical System E256 (Incorrect nonvolatile memory data) .......................................... 20-360
Service Code in Electrical System E304 (Short circuit of engine stop solenoid relay)............................... 20-362
Service Code in Electrical System E306 (Abnormality in governor potentiometer).................................... 20-364
PC300/350(LC)-7 20-301
Service Code in Electrical System E308 (Abnormality in fuel dial)............................................................. 20-366

Service Code in Electrical System E314 (Disconnection of engine stop solenoid relay) ........................... 20-368
Service Code in Electrical System E315 (Short-circuiting in battery relay) ................................................ 20-370
Service Code in Electrical System E316 (Step-out in governor motor) ...................................................... 20-372
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-374
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-376
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-378
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386
20-302 PC300/350(LC)-7
(7)
code
E116
E114
E113
E112
E211
E115
E246
E245
E233
E232
E225
E223
E222
E218
E217
E238
E228
E224
E215
E205
E101
E314
E308
E306
E304
E256
E227
E226
E216
E213
E206
E203
E201
E214
E204
Service
20-303-1
code
Failure
D196KA
D196KB
DK10KZ
DK54KZ
DA20KT
DAF0KT
DY45KA
DY45KB
DA25KP
DY20KA
DXE4KA
DXE4KB
DXA0KA
DXA0KB
DXE0KA
DXE0KB
DA2SKA
DY2EKB
DLE2MA
DY20MA
DY2CKB
DY2DKB
DWJ0KA
DWJ0KB
DA2SKQ
DW43KA
DW45KA
DW91KA
DW43KB
DW45KB
DW91KB
DHPAMA
DWK0KA
DWK0KB
DHPBMA
TROUBLESHOOTING
Defective battery relay
q
Defective fuse or fusible link
q
q
q
q
q
q q
Defective monitor panel
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q
q
q
q
q
q
q
q
q
q
q
Defective engine throttle and pump controller
q
q
q
q
Defective sensor power supply (5 V)
q
q
q
q
Defective wiper motor
q
Defective windshield washer motor
q
Defective swing lock switch
Error codes, failure codes, and possible causes
q
q
q
Defective emergency pump drive switch
q
q
Defective fuel control dial
Defective governor motor
q
q
Defective governor potentiometer
Defective engine stop solenoid relay
q
Defective engine speed sensor (including adjustment)
Possible causes
Defective engine oil pressure switch

Defective engine oil level switch
Defective engine coolant temperature sensor
Defective radiator coolant level switch
Defective air cleaner clogging switch
Defective alternator
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Defective mechanical system of engine

Defective adjustment of governor lever
Defective fuel control of engine
Lowering of engine oil pressure
Lowering of engine oil level
PC300/350(LC)-7
q
q
Overheating of engine
Lowering of water level in radiator sub tank
Clogging of air cleaner
q
q
Defective PC-EPC Solenoid
q
q
Defective LS-EPC Solenoid
PC300/350(LC)-7
q
q
Defective travel junction solenoid
TROUBLESHOOTING
q
q
Defective swing holding brake solenoid
q
q
Defective pump merge-divider solenoid
q
q
Defective 2-stage relief solenoid
q
q
Defective travel speed shifting solenoid
q
q
Defective attachment return selector relay
q
q
Defective attachment flow control EPC solenoid
Possible causes
q
F pump pressure sensor
q q
q
R pump pressure sensor
Defective hydraulic oil temperature sensor
Overheating of hydraulic oil
q
q
q
q
q
Defective concentrated diodes
q
q
q
q
q
q
q
q
q
q q
q
q
q
Disconnection in wiring harness
q
q
q q
q
q
q q
q q
q
q q
q
q
q
q
q
q
q
q q
Grounding fault in wiring harness
q
q q q
q q q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Short circuit with power source in wiring harness
(7)
20-303-2
(7)
—
—
—
—
—
—
—
—
code
E318
E317
E316
E315
Service
20-303-3
code
Failure
A000N2
A000N1
989EKX
DY10K4
AB00KE
— (E104) AA10NX
DY10KB
DY10KA
— (E313) DA80MA
B@BAZK
B@BCZK
B@BAZG
B@HANS
— (E108) B@BCNS
TROUBLESHOOTING
D110KB q
Defective battery relay
Defective fuse or fusible link
q
q
q
q
q
q
q
Defective monitor panel
q
q
q
q
q
q
q
Defective engine throttle and pump controller
Defective sensor power supply (5 V)
Defective wiper motor
Defective windshield washer motor
Defective swing lock switch
Defective emergency pump drive switch
They are not displayed in the multi-monitor panel.

Defective fuel control dial
q
q
Defective governor motor
q q q
Defective governor potentiometer
Defective engine stop solenoid relay
Defective engine speed sensor (including adjustment)
Possible causes
q
Defective engine oil pressure switch
q
Defective engine oil level switch
q
Defective engine coolant temperature sensor
q
Defective radiator coolant level switch
q
Defective air cleaner clogging switch
q
Defective alternator
q
q
Defective mechanical system of engine
★ Service codes (E104), (E108), and (E313) are displayed in only the 7-segment monitor panel.
Defective adjustment of governor lever
q q
Defective fuel control of engine

q
Lowering of engine oil pressure

q
Lowering of engine oil level
PC300/350(LC)-7
q
Overheating of engine
q
Lowering of water level in radiator sub tank
q
Clogging of air cleaner
Defective PC-EPC Solenoid
Defective LS-EPC Solenoid
PC300/350(LC)-7
Defective travel junction solenoid
TROUBLESHOOTING
Defective swing holding brake solenoid

Defective pump merge-divider solenoid
Defective 2-stage relief solenoid
Defective travel speed shifting solenoid
Defective attachment return selector relay
Defective attachment flow control EPC solenoid
Possible causes

R pump pressure sensor
Defective hydraulic oil temperature sensor
q q
Overheating of hydraulic oil
Defective concentrated diodes
q
q
q
q
Disconnection in wiring harness
q
q
q
q q
q
q
Grounding fault in wiring harness
Short circuit with power source in wiring harness
(7)
20-303-4
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Connection table of fuse box
★ This connection table shows the devices to which each power supply of the fuse box supplies power directly
(A switch power supply is a device which supplies power while the starting switch is at the ON position and
a constant power supply is a device which supplies power while the starting switch is at the OFF position).
★ When carrying out troubleshooting for an electric system, you should check its fuse box and fusible link to
see if the power is supplied normally.
Type of power
Fuse No. Fuse capacity Destination of power
supply
Engine throttle and pump controller (Controller power supply)
1 10A Emergency pump drive resistor
Swing holding brake release switch
Engine throttle and pump controller (Solenoid power supply)
Switch power
supply 2 20A Machine push up switch
(Fusible link: Attachment return switching relay (Coil side and contact side)
A34)
3 10A Work equipment lock switch
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn switch
6 10A (Spare)
7 10A Rotary lamp switch
Switch power
supply 8 10A Light relay (Contact side)
(Fusible link: One-touch power maximizing switch
A34) 9 10A
Radio
10 10A (Spare)
11 20A Air conditioner unit
Starting motor cut-out (Personal code) relay (Coil side)
12 20A
Switch power Monitor panel
supply
13 20A Light switch
(Fusible link:
A34) 14 10A Service power supply (M32 connector)
Travel alarm
15 10A
DC/DC converter
16 10A Radio
Constant power 17 10A Monitor panel
supply
18 10A Starting switch
(Fusible link:
A35) 19 10A Room lamp
20 10A (Spare)
20-303-5 PC300/350(LC)-7
(7)
TROUBLESHOOTING BEFORE TROUBLESHOOTING FOR DISPLAYED CODE
Problems which occur when solenoid power supply of engine throttle and pump controller is defective
★ The solenoid power supply (FB1-2) of the engine throttle and pump controller is used by the controller to drive
the solenoids and relays.
★ Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids
or relays, the power is not supplied to any of the solenoids and relays and all or some of the following error
codes are displayed simultaneously.
• [E211]: Disconnection in travel junction solenoid
• [E213]: Disconnection in swing holding brake solenoid
• [E214]: Disconnection in pump merge-divider solenoid
• [E215]: Disconnection in 2-stage relief solenoid
• [E216]: Disconnection in travel speed shifting solenoid
• [E223]: Disconnection in LS-EPC solenoid
• [E233]: Disconnection in PC-EPC solenoid
★ If the above problems occur, check the related fuse (FB1-2) and inlet voltage of the engine throttle and pump
controller.
1) Disconnect connector C03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2) and (12) and each of pins (31), (32), and (33).
Pins (2) and (3) are the power supply pins and pins (31), (32), and (33) are the ground pins.
If the voltage is 20 – 30 V, it is normal.
Power supply connector (C03) of engine throttle and pump controller
PC300/350(LC)-7 20-303-6
(7)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
User Code Service Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over the
presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

Presumed cause and standard value in normalcy
• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
• Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
• Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., disconnect
the connector and insert the T-adapter into both male and female sides.
4 • If there is an indication of "male" or "female" in a specific connector No., disconnect
the connector and connect the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the fol-
lowing manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring har-
ness.
20-304 PC300/350(LC)-7
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC300/350(LC)-7 20-305
TROUBLESHOOTING E101
Service Code in Electrical System E101 (Abnormal data in Error History)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine

If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
1 Fuse No. 17 defective
(See Cause 4)
Fusible link No. A35
2 If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
defective
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring Wiring harness from P01 (female) to J07 to FB1-17 out- Resistance
Above 1 Ω
harness let value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) Above 1 Ω
value
Wiring harness between A35 (male) and A23 (B termi- Resistance
Above 1 Ω
nal) value
Grounding fault of wiring Between wiring harness between P01 (female) to J07 Resistance Above
harness and FB1-17 outlet and grounding value 1 MΩ
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance Above
circuit) (male) and grounding value 1 MΩ
Between wiring harness between A35 (male) and A23 Resistance Above
(B terminal) and grounding value 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
5 Monitor Panel defective
C03 Voltage
Between and 20 – 30 V
20-306 PC300/350(LC)-7
(7)
Monitor Panel Power Source Electric Circuit Diagram
PC300/350(LC)-7 20-307
(7)

User Code Service Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine

If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
1 Fuse No. 18 defective
(See Cause 4)
Fusible link No. A35
2 If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
defective
Disconnection of wiring Wiring harness from P01 (female) to J07 to FB1-18 out- Resistance
Above 1 Ω
harness let value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-18 inlet and A35 (male) Above 1 Ω
value
Wiring harness between A35 (male) and A23 (B termi- Resistance
Above 1 Ω
nal) value
Grounding fault of wiring Between wiring harness between P01 (female) to J07 Resistance Above
harness and FB1-18 outlet and grounding value 1 MΩ
4
(Contact with grounding Between wiring harness between FB1-18 inlet and A35 Resistance Above
circuit) (male) and grounding value 1 MΩ
Between wiring harness between A35 (male) and A23 Resistance Above
(B terminal) and grounding value 1 MΩ
5 Monitor Panel defective
C03 Voltage
20-307-1 PC300/350(LC)-7
(7)
Monitor Panel Power Source Electric Circuit Diagram
PC300/350(LC)-7 20-307-2
(7)
Service Code in Electrical System E112

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Service Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 MΩ
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 MΩ
W04 (male) and grounding value
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-308 PC300/350(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-309
(7)

(Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code Service Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine

Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
or grounding fault) Between and Continued
harness for the troubleshooting.
2
W04 (male) and grounding value
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)
20-310 PC300/350(LC)-7
Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-311
(7)
TESTING AND ADJUSTING E114

(Short-circuiting in window washer drive system)
User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between and 5 – 20
Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) to J04 to
2
(Contact with 24 V A50 (female) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) and D04 (female) and
grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between and grounding
ON Below 1 V
20-312 PC300/350(LC)-7
Monitor Panel Window Washer Motor Electrical Circuit Diagram
PC300/350(LC)-7 20-313
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion)
User Code Service Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1
range
Between and
Outside upper end of
Above 1 M
operation range
Disconnection of wiring
harness Wiring harness between P01 (female) and W04 (male) Resistance
2 Below 1
(Disconnection or faulty value
contact with connector)
Resistance
Wiring harness between W04 (male) and grounding Below 1
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Outside upper end of
20 – 30 V
operation range
20-314 PC300/350(LC)-7
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-315
(7)
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper)
User Code Service Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)


Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Below 1 Ω
Between and
Operation range Above 1 MΩ
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P01 (female) and W04 (male) Resistance
2 (Disconnection or defec- Below 1 Ω
value
tive contact with connec-
tor) Resistance
Between wiring harness W04 (male) and grounding Below 1 Ω
value
during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Retraction range Below 1V
Operation range 20 – 30 V
20-316 PC300/350(LC)-7
Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-317
(7)

(Short-circuiting in travel interlocking solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits cannot be disconnected.)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)

Travel interlocking sole- during the troubleshooting.
noid defective V02 (male) Resistance value
1
or grounding fault) Between and 20 – 60 Ω
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
Between and Above 1 MΩ
Grounding fault of wiring during the troubleshooting.
harness Between wiring harness from C03 (female) to J06 to
3
(Contact with grounding V02 (female) and grounding, or between wiring har- Resistance
ness between C03 (female) and D03 (female) and value
grounding
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective
Straight forward Below 1 V
Steering 20 – 30 V
20-318 PC300/350(LC)-7
(7)
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-319

User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
Phenomenon
occurring on • It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits cannot be disconnected.)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)

Travel interlocking sole- during the troubleshooting.
noid defective V02 (male) Resistance value
1
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to V02 Resistance
(female) and grounding value
troubleshooting.
3
Straight forward Below 1 V
Steering 20 – 30 V
20-319-1 PC300/350(LC)-7
(7)
Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-319-2
(7)

(Short-circuiting in swing and parking brake solenoid - in governor • pump controller
system)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Short-circuiting in swing and parking brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing and parking brake solenoid circuit, when power was supplied to the
Failure content
circuit.
• Power supply to the swing and parking brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake cannot be released.)
machine
• Operation of the swing and parking brake solenoid (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the parking brake does not work, when stopping the machine)

Swing and parking brake during the troubleshooting.
solenoid defective V05 (male) Resistance value
1
2 D03 defective
Grounding fault of wiring
harness Wiring harness from C03 (female) to D01 to J02 to X05
3
(Contact with grounding to J06 to V05 (female) , or between wiring harness Resistance
between C03 (female) and D03 (female) and value
grounding
troubleshooting.
Governor • pump C03 Swing control lever Voltage
4
NEUTRAL Below 1 V
Swing 20 – 30 V
20-320 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Swing and Parking Brake of Governor • Pump Controller
PC300/350(LC)-7 20-321

User Code Service Code Failure Code Failure Short-circuiting in swing holding brake solenoid (in
E03 E203 DW45KB phenomenon governor • pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing holding brake does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the swing holding brake does not work, when stopping the machine)

Swing holding brake during the troubleshooting.
1
or grounding fault) Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
harness
2 Wiring harness from C03 (female) (37) to D01 to J02 to
(Contact with grounding Resistance
circuit) X05 to V05 (female) (2), or between wiring harness Above 1 Mz
value
between C03 (female) (37) and grounding
troubleshooting.
3
NEUTRAL Below 1 V
Between (37) and grounding
Swing 20 – 30 V
20-321-1 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake of Governor • Pump Controller
PC300/350(LC)-7 20-321-2
(7)
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps cannot be disconnected.)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Merge/divide solenoid during the troubleshooting.
defective V03 (male) Resistance value
1
2 D03 defective
harness
3 Wiring harness from C03 (female) to J06 to V03
circuit) (female) , or between wiring harness between C03 Above 1 MΩ
value
(female) and D03 (female) and grounding
troubleshooting.
4
controller defective NEUTRAL Below 1 V
Between and grounding When operating one side
20 – 30 V
only
20-322 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-323

User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(Front and rear pumps are not separated)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.


1
harness
2 Wiring harness from C03 (female) (17) to V03 (female)
circuit) (2), or between wiring harness between C03 (female) (17) Above 1 Mz
value
and grounding
troubleshooting.
3
controller defective NEUTRAL Below 1 V
Between (17) and grounding When operating one side
20 – 30 V
only
20-323-1 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-323-2
(7)
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set.)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid during the troubleshooting.
1
2 D03 defective
harness
value
Governor • pump C03 Working mode Voltage
4
Other than L mode Below 1 V
L mode 20 – 30 V
20-324 PC300/350(LC)-7
(7)
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-325
(7)

User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • The one-touch power max. switch does not work. (The main relief valve is not set to high pressure)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1
harness
value
and grounding
3
Other than L mode Below 1 V
L mode 20 – 30 V
20-325-1 PC300/350(LC)-7
(7)
Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-325-2
(7)

(Short-circuiting in travel speed shifting solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum.)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Travel speed shifting during the troubleshooting.
1
2 D04 defective
harness
value
troubleshooting.
Governor • pump C03 Travel speed Voltage
4
Lo Below 1 V
Hi + Travel operation 20 – 30 V
20-326 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-327

User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle is not set to the minimum)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.


1
harness
value
and grounding
troubleshooting.
Governor • pump Travel speed &
3 C03 Voltage
controller defective Travel lever
Lo + Neutral Below 1 V
Hi + Travel 20 – 30 V
20-327-1 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-327-2
(7)
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
(L.H. and R.H. travel circuits cannot be disconnected.)
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)

Travel interlocking during the troubleshooting.
1 solenoid defective
V02 (male) Resistance value

(Internal disconnection)
Between and 20 – 60 Ω
harness
Wiring harness from C03 (female) to J06 to V02 Resistance
(female) value
tor) Resistance
Wiring harness between V02 (female) and grounding Below 1 Ω
value
Short-circuiting of wiring during the troubleshooting.
harness
(Contact with 24 V cir-
cuit) (female) , or between wiring harness C03 (female) Voltage Below 1 V
and D03 (female) and grounding
Governor • pump
4
controller defective C03 (female) Resistance value
Between and grounding 20 – 60 Ω
20-328 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-329

User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
Phenomenon
• It is difficult to steer the machine while traveling.
occurring on
(The right and left travel circuits are not separated from each other)
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.

Travel interlocking during the troubleshooting.
Between (1) and (2) 20 – 60 z
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (7) to V02 (female) (2) Below 1 z
value
tor) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 z
V02 (female) (1) value
harness
3 Wiring harness from C03 (female) (7) to V02 (female) (2),
cuit) or between wiring harness C03 (female) (7) and ground- Voltage Below 1 V
ing
Governor • pump during the troubleshooting.
4
Between (7) and grounding 20 – 60 z
20-329-1 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-329-2
(7)

(Disconnection in Swing Parking Brake Solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Disconnection in swing and parking brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
• The machine's upper structure does not swing.
occurring on
(The swing holding brake cannot be released.)
machine
• Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the
OFF position.
★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing parking brake ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between and 20 – 60 Ω
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 Ω
Between and
LOCK Above 1 MΩ
Assembled-type ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between and Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) and D01 (female) Below 1 Ω
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) to J02 to X05 (male) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) to J06 to V05 (female) Below 1 Ω
value
Resistance
value
Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) and D01
(female) and grounding
Governor • pump
6 C03 (female) Disconnect D01 and con- Resistance value
nect pins and of the
Between and grounding male side. 20 – 60 Ω
20-330 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Swing and Parking Brake Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-331

User Code Service Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake is not released)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the
OFF position.
★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing holding brake ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V05 (male) Resistance value
tion) Between (1) and (2) 20 – 60 z
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
tion) OFF Below 1 z
Between (3) and (4)
LOCK Above 1 Mz
Assembled-type ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between (7) and (3) Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) (37) and D01 (female) (7) Below 1 z
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) (3) to J02 to X05 (male) (3) Below 1 z
value
defective contact
Wiring harness from X05 (male) (4) to V05 (female) (2) Below 1 z
value
Wiring harness between C03 (female) (3) (13) (23) and V05 Resistance
Below 1 z
(female) (1) value
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) (37) and D01
(female) (7) and grounding
Governor • pump
6 C03 (female) Resistance value
controller defective Disconnect D01 and connect pins
Between (37) and (3) (13) (3) and (7) of the female side. 20 – 60 z
(23)
20-331-1 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Swing Holding Brake Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-331-2
(7)
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(Front and rear pumps cannot be disconnected.)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

1 defective

harness
(female) value
tor) Resistance
value
harness
cuit) (female) , or between wiring harness between C03 Voltage Below 1 V
Governor • pump
4
20-332 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-333

User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast
occurring on
(Front and rear pumps are not separated)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

1 defective
Between (1) and (2) 20 – 60 z
harness
Resistance
2 (Disconnection or defec- Wiring harness from C03 (female) (17) to V03 (female) (2) Below 1 z
value
Below 1 z
Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Wiring harness from C03 (female) (17) to V03 (female) (2)
cuit) Voltage Below 1 V
and grounding
4
Between (17) and (3) (13) (23) 20 – 60 z
20-333-1 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-333-2
(7)
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on
(The main relief valve cannot be set to high-pressure set.)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1 defective V08 (male) Resistance value
harness
(female) value
tor) Resistance
value
harness
Governor • pump
20-334 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-335
(7)

User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on
(The main relief valve cannot be set to high-pressure set)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

1 defective
Between (1) and (2) 20 – 60 z
harness
Wiring harness between C03 (female) (28) and V08 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
Max. 1 z
3
cuit) Voltage Max. 1 V
and grounding
4
Between (28) and (3) (13) (23) 20 – 60 z
20-335-1 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-335-2
(7)

(Disconnection in travel speed shifting solenoid)
User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum.)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

1 solenoid defective V04 (male) Resistance value
harness
(female) value
tor) Resistance
value
harness
Governor • pump
20-336 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-337

User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Between (1) and (2) 20 – 60 z
harness
Wiring harness between C03 (female) (27) and V04 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
Max. 1 z
V04 (female) (1) and grounding value
3
cuit) Voltage Max. 1 V
and grounding
4
Between (27) and (3) (13) (23) 20 – 60 z
20-337-1 PC300/350(LC)-7
(7)
PC300/350(LC)-7 20-337-2
(7)
Service Code in Electrical System E217 (Abnormality in inputting model code)
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC300).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information ★Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Model selecting connec- during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between , and Below 1 Ω
Between , and Above 1 MΩ

Disconnection of wiring Wiring harness between C02 (female) and C09 Resistance
Below 1 Ω
harness (male) value
2 (Disconnection or defec-
tive contact with connec- Wiring harness between C02 (female) and C09 Resistance
Below 1 Ω
tor) (male) value
Between wiring harness between C09 (male) and J05 Resistance

Below 1 Ω
and grounding value
Between wiring harness between C02 (female) and Resistance
Grounding fault of wiring Above 1 MΩ
C09 (male) and grounding value
harness
3
(Contact with grounding Between wiring harness between C02 (female) and Resistance

Above 1 MΩ
Governor • pump C02 Voltage
4
Between , or and grounding 20 – 30 V
Between , and grounding Below 1 V
20-338 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC300/350(LC)-7 20-339
(7)
Service Code in Electrical System E218 Disconnection of S-NET signal)
User Code Service Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum ( )
• When the failure cause disappears of itself, the machine operation returns to normalcy.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
• This Service Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the governor • pump controller is returned to normalcy.
Relative
• The communication has already returned to normalcy by the time this Service Code No. is displayed.
information
But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a
failure in order to prevent recurrence of failures.

harness Wiring harness between P02 (female) and C02 Resistance
(female) value
tor) Wiring harness between P02 (female) and C02 Resistance

Below 1 Ω
(female) value
2
C02 (female) and grounding value
3
(Contact with 24 V cir- Between wiring harness between P02 (female) and
C02 (female) and grounding
4 Monitor panel defective P02 (male) Voltage
Between and 6–9V
Governor • pump
5 C02 (male) Voltage
Between and 6–9V
20-340 PC300/350(LC)-7
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor • Pump
Controller
PC300/350(LC)-7 20-341
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E222 DXE0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• The travel speed is slow at Mi and Lo, or in Lmode, speed of the work equipment and swing are too fast.
occurring on
(The LS valve set pressure cannot be controlled.)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

LS-EPC solenoid defec- during the troubleshooting.
tive V22 (male) Resistance value
1
or grounding fault)
2
V22 (female) and grounding value
Governor • pump C03 (female) Resistance value
3
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
20-342 PC300/350(LC)-7
(7)
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system)
User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the LS-EPC solenoid circuit.
Phenomenon
• The travel speed is slow at Mi and Lo, or in Lmode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled.)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

LS-EPC solenoid defec- during the troubleshooting.
1 tive

harness Between wiring harness between C03 (female) and Resistance
tor) Wiring harness between C03 (female) and V22 Resistance
Below 1 Ω
(female) value
3
(Contact with 24 V cir- Between wiring harness between C03 (female) and
V22 (female) and grounding
Governor • pump
Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-343
(7)
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: F pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
★Turn the engine starting switch OFF for the preparations, and keep the engine running
A51 Voltage
Between (B) and (A) Power supply 4.5 – 5.5 V
2 defective
(Internal failure) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for
another cause of the trouble, and then judge.

Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A51 Resistance
harness Max. 1 z
(female) (B) value
tive contact with connec- Wiring harness between C01 (female) (10) and A51 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (8) and A51 Resistance
Max. 1 z
(female) (C) value
4
(Contact with grounding Between wiring harness between C01 (female) (8) and Resistance
circuit) Min. 1 Mz
A51 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22), J07
5 Voltage Max. 1 V
(Contact with 24 V cir- and A51 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (8) and
Voltage Max. 1 V
A51 (female) (C) ang grounding
6
Between (22) and (10) Power supply 4.5 – 5.5 V
Between (8) and (10) Signal 0.5 – 4.5 V
20-344 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for F Pump Pressure Sensor in Governor • Pump Controller
PC300/350(LC)-7 20-345
(7)
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)
User Code Service Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 012: R pump pressure)

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
A52 Voltage
R pump pressure sen-
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sor defective
(Internal failure) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accrdinaly, if the voltage is abnormal, check the wiring harness and controller, too, for
another cause of the trouble, and then judge.

Disconnection of wiring Wiring harness from C01 (female) (22) to J07 to A52 Resistance
harness Max. 1 z
(female) (B) value
tive contact with connec- Wiring harness between C01 (female) (10) and A52 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (2) and A52 Resistance
Max. 1 z
(female) (C) value
4
(Contact with grounding Between wiring harness between C01 (female) (2) and Resistance
circuit) Min. 1 Mz
A52 (female) (C) and grounding value
harness Between wiring harness between C01 (female) (22), J07
5 Voltage Max. 1 V
(Contact with 24 V cir- and A52 (female) (B) and grounding
cuit) Between wiring harness between C01 (female) (2) and
Voltage Max. 1 V
A52 (female) (C) and grounding
6
Between (22) and (10) Power supply 4.5 – 5.5 V
Between (2) and (10) Signal 0.5 – 4.5 V
20-346 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for R Pump Pressure Sensor in Governor • Pump Controller
PC300/350(LC)-7 20-347
(7)
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source)
User Code Service Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.

★Turn the engine starting switch OFF for the preparations,
Disconnect the parts and hold it in the ON position during the troubleshooting.
shown at right in order.
Pressure sensor or Fuel dial E06 Connector
If the error code goes off

1 potentiometer defective
when one of those parts Governor motor potentiometer E10 Connector
(Internal short-circuit)
is disconnected, that part F pump pressure sensor A51 Connector
is defective.
R pump pressure sensor A52 Connector
Between wiring harness from C01 (female) (22) to J07 to Resistance
Min. 1 Mz
Grounding fault of wiring E06 (female) (1) and grounding [Fuel dial system] value
harness Between wiring harness from C01 (female) (22) to J07 to
2 Resistance
(Contact with grounding E10 (female) (A) and grounding Min. 1 Mz
circuit) value
[Governor potentiometer system]
Between wiring harness from C01 (female) (22) to J07 to
Resistance
A51 (female) (B) and grounding Min. 1 Mz
value
[F pump pressure sensor system]
3
controller defective C01 Voltage
Between (22) and (10) (21) 4.5 – 5.5 V
20-348 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Sensor Power Source in Governor • Pump Controller
PC300/350(LC)-7 20-349

(Abnormality in engine rotation sensor in governor • pump controller system)
User Code Service Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (in governor • pump controller system)
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)

Engine rotation sensor during the troubleshooting.
fault E07 (male) Resistance value
1
or disconnection) Between and 500 – 1,000 Ω

Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
2
adjustment improper Sensor" in this manual.
harness Wiring harness between C02 (female) and E07 Resistance
(female) value
tor) Wiring harness between C02 (female) and E07 Resistance
Below 1 Ω
(female) value
4
E07 (female) and grounding
5
Between and 500 – 1,000 Ω
Electrical Circuit Diagram for Engine Rotation Sensor in Governor • Pump Controller System
20-350 PC300/350(LC)-7
(7)

(Short-circuiting in attachment return switching relay)
User Code Service Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The switching valve is not switched to the tank circuit.)
machine
• In this code, a failure is diagnosed only when the setting mode is "with ATT". (Check the setting mode
shown in the monitor panel)
★This code detects only failures occurring on the primary ATT return switching relay (coil side). If the ATT
Relative
return switching solenoid is suspected of a defect, check the power source, wiring harness or solenoid
information
of the secondary relay (contact side).
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No. 024:Solenoid 2)

Attachment return during the troubleshooting.
1 switching relay defective
R20 (male) Resistance value
2
R20 (female) and grounding
3
Other than B mode 20 – 30 V
B mode Below 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC300/350(LC)-7 20-351
(7)
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information in a working mode equivalent to E mode by turning the emergency drive switch ON.
(At that time the monitor panel continues to display service code No. [E232], but this is not abnormal)
★Turn the emergency driving switch ON during the troubleshooting.

PC-EPC solenoid defec- during the troubleshooting.
tive V21 (male) Resistance value
1
Between (1) and (2) 7 – 14 z
or grounding fault)
Between (1) and grounding Min. 1 Mz
Emergency pump driving
switch defective Emergency pump
2 S25 (male) Resistance value
(Internal short-circuiting drive switch
or grounding fault) Between (3) and (4) Min. 1 Mz
Normal
harness Between wiring harness from C03 (female) (16) to S25 Resistance
3 Min. 1 Mz
(Contact with grounding (female) (3) and grounding value
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance
Min. 1 Mz
(female) (1) and grounding value
4
Between (16) and (3) (13) (23) 7 – 14 z
20-352 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-353
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)
User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information
in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the
monitor panel continues to display Service Code No. [E233], but this is not abnormal)

PC-EPC solenoid during the troubleshooting.
1 defective
Between (1) and (2) 7 – 14 z
Emergency pump
S25 Resistance value
Emergency pump driving driving switch
2 switch defective Normal Max. 1 z
(Internal disconnection) Between (2) and (5)

Emergency Min. 1 Mz
Normal Max. 1 z
Between (5) and (6)
Emergency Min. 1 Mz
Wiring harness between C03 (female) (16) and S25 Resistance
Disconnection of wiring Max. 1 z
(female) (3) value
harness
Wiring harness between S25 (female) (2) and V21 Resistance
3 (Disconnection or Max. 1 z
(female) (1) value
defective contact with
connector) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Max. 1 z
S25 (female) (6) value
Wiring harness between S25 (female) (5) and V21 Resistance
Max. 1 z
(female) (2) value
harness Between wiring harness between C03 (female) (16) and
4 Voltage Max. 1 V
(Contact with 24 V cir- S25 (female) (3) and grounding
cuit) Between wiring harness between S25 (female) (2) and
Voltage Max. 1 V
V21 (female) (1) and grounding
5
Between (16) and (3) (13) (23) 7 – 14 z
20-354 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller
PC300/350(LC)-7 20-355

(Disconnection in attachment return switching relay)
User Code Service Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage
Failure content
is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation
occurring on
(The switching valve is not switched to the tank circuit.)
machine
shown in the monitor panel)
★This code detects only failures occurring on the primary ATT return switching relay (coil side). If the ATT
Relative
return switching solenoid is suspected of a defect, check the power source, wiring harness or solenoid
information
of the secondary relay (contact side).
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No. 024:Solenoid 2)

If the fuse has been blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 2 fault
relay circuit. (See Cause 4)
Attachment return during the troubleshooting.
2 switching relay defective
Emergency pump driving
Wiring harness between C02 (female) and R20 Resistance
3 switch defective Below 1 Ω
(female) value
Wiring harness from R20 (female) to J03 to FB1-2 Resistance
Below 1 Ω
outlet value
Grounding fault of wiring
4 Above 1 MΩ
(Contact with grounding R20 (female) and grounding value
circuit)
Between wiring harness from R20 (female) to J03 to Resistance
Above 1 MΩ
FB1-2 outlet and grounding value
5
Other than B mode 20 – 30 V
B mode Below 1 V
20-356 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor • Pump
Controller
PC300/350(LC)-7 20-357
Service Code in Electrical Equipment E245

(Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only)
User Code Service Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
• The attachments do not move.
occurring on
(The PPC source pressure is not supplied to the service PPC valve.)
machine
Relative shown in the monitor panel)
information • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Attachment oil flow rate during the troubleshooting.
adjusting EPC defective V30 (male) Resistance value
1
2
3
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
20-358 PC300/350(LC)-7
(7)

(Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)
User Code Service Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
• The attachments do not move.
occurring on
(The PPC source pressure is not supplied to the service PPC valve.)
machine
Relative shown in the monitor panel)
information • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Attachment oil flow rate
adjusting EPC defective
1
(Internal short-circuiting V30 (male) Resistance value
or grounding fault) 7 – 14 Ω
Between and
V30 (male) and grounding value
tor) Between wiring harness between C03 (female) Resistance
Below 1 Ω
and V30 (male) and grounding value
3
V30 (female) and grounding
Governor • pump
4
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller
PC300/350(LC)-7 20-359
(7)
Service Code in Electrical System E256 (Incorrect nonvolatile memory data)
User Code Service Code Failure Code Failure Incorrect nonvolatile memory data
— E256 DA20KT phenomenon (in governor • pump controller)
Failure content • The data in the nonvolatile memory in the controller cannot be updated.
Response from
• Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
controller
Phenomenon
• In some cases control parameters of the machines change, resulting in increase or decrease of the ma-
occurring on
chine's power.
machine
Relative
• Recorded in the nonvolatile memory are part of the machine control parameters
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and As it is an internal failure, troubleshooting is impossible.
standard value Governor • pump
1 (There is no problem with continuing with use of the controller, so long as no
in normalcy controller defective
failure is visually evident)
20-360 PC300/350(LC)-7
Service Code in Electrical System E304 (Short circuit of engine stop solenoid relay)
User Code Service Code Failure Code Failure Short circuit of engine stop solenoid relay
— E304 DY45KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the engine stop solenoid relay circuit, when power is supplied to the circuit.
• Switch OFF power to the engine stop solenoid relay circuit.
Response from
• Even when the failure dissolves itself, the circuit does not return to normalcy, if the engine starting switch
controller
is not turned off once.
Phenomenon
occurring on • The engine cannot be started.
machine
• This code detects only failures occurring on the primary engine stop solenoid relay (coil side). If the en-
gine stop solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the
secondary relay (contact side).
Relative
• It can be checked in the monitoring function how the engine stop solenoid relay works (ON and OFF).
information
(Code 023: Controller output)
• If there is nothing abnormal with the relay or wiring harness, the engine can be started again by moving
the emergency fuel solenoid driving switch to the EMERGENCY side.

Fault of engine stop during the troubleshooting.
1 solenoid relay (Internal R22 (male) Resistance value

short circuiting)
Fault of emergency fuel during the troubleshooting.
2 solenoid driving switch S25 (male) Resistance value
(Internal short circuiting)
Between and grounding Above 1 M
harness
3 Wiring harness from C03 (female) to J01 to R22
circuit) (female) , or between wiring harness between C03 Above 1 M
value
(female) and S25 (female).
Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Engine starting switch Voltage
4
ON Below 1 V
Engine start-up 20 – 30 V
20-362 PC300/350(LC)-7
Electrical Circuit Diagram for Engine Stop Solenoid and Relay in Monitor Panel
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-363
(7)

20-363-1 PC300/350(LC)-7
(7)
Service Code in Electrical System E306 (Abnormality in governor potentiometer)
User Code Service Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
• The engine cannot attain the specified rotation at high idling. (A bit lower)
• The engine cannot attain the specified rotation at low idling (A bit higher)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
Governor potentiometer E10 (male) Resistance value
2 defective Between and 4.0 – 6.0 kΩ
(Internal failure)
Between and 0.25 – 5.0 kΩ


Disconnection of wiring Wiring harness from C01 (female) to J07 to E10 Resistance
Below 1 Ω
harness (female) value
tive contact with connec- Wiring harness between C01 (female) and E10 Resistance
Below 1 Ω
tor) (female) value
Wiring harness between C01 (female) and E10 Resistance
Below 1 Ω
(female) value
4
E10 (female) and grounding value
Short-circuiting of wiring
5 Voltage Below 1 V
(Contact with 24 V cir- E10 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
Governor • pump C01 Resistance value
6
controller defective Power
Between and 4.5 – 5.5 V
supply
Between and Signal 0.5 – 4.5 V
20-364 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller
PC300/350(LC)-7 20-365
Service Code in Electrical System E308 (Abnormality in fuel dial)
User Code Service Code Failure Code Failure Abnormality in governor fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idling and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
harness E06 (male) Resistance value
2 (Disconnection or defec- 4.0 – 6.0 kΩ
Between and
tor) Between and 0.25 – 5.0 kΩ

Disconnection of wiring Wiring harness from C01 (female) to J07 to E06 Resistance
harness Below 1 Ω
(female) value
tive contact with connec- Wiring harness between C01 (female) and E06 Resistance
Below 1 Ω
tor) (female) value
Below 1 Ω
(female) value
4
Short-circuiting of wiring
5 Voltage Below 1 V
(Contact with 24 V cir- E06 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
Governor • pump C01 Resistance value
6
controller defective Power
supply
Between and Signal 0.5 – 4.5 V
20-366 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Fuel Dial in Governor • Pump Controller
PC300/350(LC)-7 20-367
Service Code in Electrical System E314 (Disconnection of engine stop solenoid relay)
User Code Service Code Failure Code Failure Disconnection of engine stop
— E314 DY45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the engine stop solenoid relay, when power is supplied to it.
Response from • No response in particular (The solenoid does not function without current)
controller • When the failure dissolves itself, the relay returns to the normalcy.
Phenomenon
occurring on • The engine cannot be started.
machine
• This code detects only failures occurring on the primary engine stop solenoid relay (coil side). If the en-
gine stop solenoid is suspected of a defect, check the power source, wiring harness or solenoid of the
secondary relay (contact side).
• It can be checked in the monitoring function how the engine stop solenoid relay works (ON and OFF).
Relative
(Code 023: Controller output)
information
• If there is nothing abnormal with the relay or wiring harness, the engine can be started again by moving
the emergency fuel solenoid driving switch to the EMERGENCY side.
+The solenoid detects disconnection with power ON. Be sure to make a test for checking after the repair
with power ON. (For the operation with power ON and OFF, refer to Diagnosis of Service Code [E201].

+Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
1 solenoid relay

Between and 100 – 500 :
harness
Wiring harness from C03 (female) to J01 to R22 Resistance
2 (Disconnection or defec- Below 1 :
(female) value
tor) Wiring harness between R22 (female) to J08 to J04 and Resistance
Below 1 :
grounding value
+Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness
3 Wiring harness from C03 (female) to J01 to R22
cuit) (female) , or between wiring harness C03 (female) Voltage Below 1 V
and S25 (female) and grounding.
Governor • pump
6
controller defective C03 Resistance value
Between and grounding 100 – 500 :
20-368 PC300/350(LC)-7
Electrical Circuit Diagram for Engine Stop Solenoid and Relay in Monitor Panel
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-369
(7)

20-369-1 PC300/350(LC)-7
(7)
Service Code in Electrical System E315 (Short-circuiting in battery relay)
User Code Service Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop.
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)

Battery relay defective Battery relay Continuity & Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Continued
terminal)
Between A21 (BR terminal) and grounding Above 1 MΩ
2
(Contact with grounding Between wiring harness from C03 (female) to D01 to Resistance
J01 to A21 (BR terminal) and grounding value
Governor • pump
3 C03 Engine starting switch Voltage
20 – 30 V
Between and grounding ON → OFF
(for 4 to 7 seconds)
20-370 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Battery Relay in Governor • Pump Controller
PC300/350(LC)-7 20-371
(7)
Service Code in Electrical System E316 (Step-out in governor motor)
User Code Service Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.

Presumed cause and standard
1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective If Service Code [E306] is displayed, troubleshoot that failure first.
value in normalcy
3 Governor motor defective (disconnection) If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor • pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)
20-372 PC300/350(LC)-7
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idling.
Phenomenon
• There is hunting in the rotation
occurring on
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec-
1 tive E11 (male) Resistance value
(Internal disconnection) Between and 2.5 – 7.5

Between and 2.5 – 7.5
Below 1
Disconnection of wiring (female) value
harness Wiring harness between C03 (female) and E11 Resistance
2 (Disconnection or defec- Below 1
(female) value
tor) Wiring harness between C03 (female) and E11 Resistance
Below 1
(female) value
Below 1
(female) value
3
20-374 PC300/350(LC)-7
PC300/350(LC)-7 20-375

(Short-circuiting in governor motor Phase A and Phase B)
User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and
E05 E318 DY10KB phenomenon Phase B (in governor • pump controller system)
Failure content • Abnormal current flew to the governor motor, when power is supplied to the motor.
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idling.
occurring on
• There is hunting in the rotation.
machine
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Governor motor defec- E11 (male) Resistance value
1
tive Between and 2.5 – 7.5
or grounding fault) Between and 2.5 – 7.5

Above 1 M
Disconnection of wiring E11 (female) and grounding value
2 (Disconnection or defec- Above 1 M
tor) Between wiring harness between C03 (female) and Resistance
Above 1 M
Above 1 M
C03 (female) Resistance value
3
Governor • pump Between and 2.5 – 7.5
20-376 PC300/350(LC)-7
PC300/350(LC)-7 20-377
TROUBLESHOOTING A000N1 / A000N2
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)
User Code Service Code Failure Code Failure Out-of-rate engine rotation at high idling
— — A000N1 phenomenon (in mechanical system)
Failure content • Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
information (Code No. 010: Engine rotation)

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)
User Code Service Code Failure Code Failure Out-of-rate engine rotation at low idling
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
troller may be continued as it is)
20-378 PC300/350(LC)-7
(7)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code Service Code Failure Code Failure Air cleaner clogged
— — (E104) AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• Service code (E104) is displayed in the 7-segment monitor panel.
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative
panel while the engine is running.
information
• Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Air cleaner clogged
1 (when the system is in ★Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between and
When clogged Above 1 MΩ
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) and A31 Resistance
(female) value
tor) Resistance
Between wiring harness A31 (female) and grounding Below 1 Ω
value
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Below 1 V
When clogged 20 – 30 V
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC300/350(LC)-7 20-379
(7)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code Service Code Failure Code Failure Charging voltage abnormally lowered
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
monitor panel
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

troubleshooting.
Alternator defective
1 E12 (male) Engine rotation Voltage

(short generating output)
Between terminal R and
Above medium speed 27.5 – 29.5 V
grounding
Disconnection of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
tive contact with connec- Wiring harness from P02 (female) to J02 to alternator Resistance
Below 1 Ω
tor) terminal R. value
harness Wiring harness from P02 (female) to J02 to alternator
3
(Contact with grounding terminal R, or between P02 (female) and D01 (female) Resistance
, or between P02 (female) to M02 (female) and value
grounding
P02 Engine rotation Voltage
Between and grounding Above medium speed 27.5 – 29.5 V
20-380 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-381
(7)

20-381-1 PC300/350(LC)-7
(7)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)
User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
Relative while the engine is running.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.

Engine oil pressure low-
1 ered (the system in nor- ★Check the failure cause and damage to the engine, and then make repairs.
mal condition)
Engine oil pressure
2 switch defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Above 1 MΩ
grounding When lowered Below 1 Ω
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
(terminal) and grounding value
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 – 30 V
When lowered Below 1 V
Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel
20-382 PC300/350(LC)-7
(7)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Service Code Failure Code Failure Engine oil level abnormally lowered
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Engine oil level lowered
★Check the engine oil level, and refill oil.
1 (System in normal condi-
(If the phenomenon occurs frequently, check the cause)

tion)
Engine oil level switch
2 defective P05 (male) Engine oil level Resistance value
When lowered Above 1 MΩ
Disconnection of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
tive contact with connec- Wiring harness between P02 (female) and P05 (female) Resistance
Below 1 Ω
tor) value
4 Monitor panel defective P02 Engine oil pressure Voltage
When lowered 20 – 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC300/350(LC)-7 20-383
(7)
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating)
User Code Service Code Failure Code Failure Engine cooling water overheated
— — (E108) B@BCNS phenomenon (in mechanical system)
Failure content • The engine cooling water sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
monitor panel
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• Service code (E108) is displayed in the 7-segment monitor panel.
• This Failure Code is recorded, if the engine cooling water temperature gauge is displayed in the red
Relative
range, when the engine is running.
information
• Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)

Engine Overheating
1 (system in normal condi- ★Check the engine for the cause and damage, and repair it.
tion)
Engine cooling water
temperature sensor Engine cooling water tem-
2 P07 (male) Resistance value
defective perature
(Internal short-circuiting) Between and 90 – 3.5kΩ
10 – 100 °C
3
P07 (female) and grounding value
4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between and 90 – 3.5kΩ
10 – 100 °C
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor in Monitor Panel
20-384 PC300/350(LC)-7
(7)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
(Multi-monitor only)
User Code Service Code Failure Code Failure Radiator water level abnormally lowered
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
monitor panel
Phenomenon
machine
• This Failure Code is recorded, if the radiator water level caution symbol is displayed in the monitor panel,
Relative when the engine is running.
information • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.

Radiator water level low-
★Check the water level and refill cooling water.
1 ered (system in normal
(If this phenomenon occurs frequently, check the cause)
condition)
Radiator water level
2 switch defective A33 (male) Engine cooling water level Resistance value
Between and
When lowered Above 1 MΩ
harness
Wiring harness between P02 (female) and A33 (female) Resistance
value
tor) Resistance
Wiring harness between A33 (female) and grounding Below 1 Ω
value
4 Monitor panel defective P02 Engine water temperature Resistance value
When lowered 20 – 30 V
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC300/350(LC)-7 20-385
(7)
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)

User Code Service Code Failure Code Failure Hydraulic oil overheated
— — B@HANS phenomenon (in mechanical system)
Failure content • The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from
monitor panel
Phenomenon
machine
• This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
Relative the engine is running.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: hydraulic oil temperature)

Hydraulic oil overheat-
1 ing (system in normal ★Check the cause and damage to the hydraulic equipment, and repair it.
condition)
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between and 90 – 3.5kΩ
10 – 100 °C
3
A61 (female) and grounding value
4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between and 90 – 3.5kΩ
10 – 100 °C
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-386 PC300/350(LC)-7
(7)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

E-1 Engine does not start........................................................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-508
E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-510
E-4 Engine does not stop ........................................................................................................................ 20-512
E-5 Auto-decelerator does not work ........................................................................................................ 20-514
E-6 Auto engine warm-up device does not work ..................................................................................... 20-515
E-7 Preheater does not work................................................................................................................... 20-516
E-8 All work equipment, swing and travel do not move........................................................................... 20-518
E-9 One-touch Power Max. Switch does not work .................................................................................. 20-520
E-10 No display in monitor panel at all ................................................................................................... 20-521-1
E-11 Part of display on monitor panel is missing ...................................................................................... 20-522
E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-522
E-13 Fuel level monitor red lamp lights up while engine is running .......................................................... 20-523
E-14 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-524
E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-525
E-16 Fuel gauge does not display correctly .............................................................................................. 20-526
E-17 Swing lock monitor does not display correctly .................................................................................. 20-527
E-18 When the monitor switch is operated, no display appears ............................................................... 20-528
E-19 Windshield wiper does not work ....................................................................................................... 20-530
E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-532
E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-533
E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-534
E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-535
E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-536
E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-537
E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-538
E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-540
E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-542
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-544
E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-546
E-31 Air Conditioner does not work........................................................................................................... 20-548
E-32 Travel alarm does not sound ............................................................................................................ 20-561
PC300/350(LC)-7 20-501
(7)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a connec-
4
tor and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a con-
nector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the follow-
5 ing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
20-502 PC300/350(LC)-7
TESTING AND ADJUSTING E-1
E-1 Engine does not start
Failure
• The engine does not start (the engine does not rotate).
information (1)
• The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
1) Engine start locking by means of password in the monitor panel ( )
information
2) Engine start locking by means of safety lock lever
Shortage in battery Battery voltage Battery electrolyte specific gravity
1
capacity Above 24 V Above 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in
Fuse Nos. 3 and 18
the circuit.
2 and Fusible Link A35
If a monitor lamp does not light up in the monitor panel, check the power source circuit
fault
between the battery and the specific fuse.
Engine starting during the troubleshooting.
switch fault H15 (male) Position Resistance value
3
(Internal
disconnection) OFF Above 1 M
Between and
Start Below 1
Safety lock switch during the troubleshooting.
fault S14 (female) Lock lever Resistance value
4
(Internal
short-circuiting) Release Below 1
Between and
LOCK Above 1 M
Engine starting during the troubleshooting.
motor cut relay, R11
R11 (female) & R13 (male) Resistance value
and R13 defective
5 100 – 500
(Internal Between and
disconnection or Above 1 M
Between and
short-circuiting)
Between and Below 1
Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine start-
Engine starting
ing motor relay is defective)
motor fault
6 Engine start-
(Internal disconnec- Engine starting motor Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 – 30 V
Start
Engine start input: C terminal and grounding 20 – 30 V
Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
Alternator fault running during the troubleshooting.
7 (Internal
Alternator Voltage
short-circuit)
R terminal and grounding Below 1 V
PC300/350(LC)-7 20-503

Resistance
Wiring harness between FB1-18 outlet and H15 (female) Below 1 :
value
Resistance
Wiring harness from H15 (female) to J01 to R11 (female) Below 1 :
value
Disconnection of wir- Resistance
ing harness Wiring harness between R11 (female) and M02 (female) Below 1 :
value
8 (Disconnection or
Resistance
defective contact Wiring harness between FB1-3 and S14 (female) Below 1 :
with connector) value
Resistance
Wiring harness between S14 (female) and R11 (female) Below 1 :
value
Resistance
Wiring harness between R11 (female) and R13 (female) Below 1 :
value
Resistance
Wiring harness from R13 (female) to J04 to grounding Below 1 :
value
Between wiring harness from battery relay B terminal (A23) Resistance
Above 1 M:
to A35 to FB1-18 and grounding value
Between wiring harness between FB1-18 outlet and H15 Resistance
Above 1 M:
Between wiring harness from H15 (female) to J01 to R11 Resistance
Grounding fault of Above 1 M:
wiring harness
9
(Contact with Between wiring harness between R11 (female) and M02 Resistance
Above 1 M:
grounding circuit) (female) and grounding value
Between wiring harness between FB1-3 and S14 (female) Resistance
Above 1 M:
and grounding value
Between wiring harness between S14 (female) and R11 Resistance
Above 1 M:
Between wiring harness from R13 (female) to J05 to P02 Resistance
Above 1 M:
+Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness Wiring harness from P02 (female) to J02 to M02 (female)
10
(Contact with 24 V , or wiring harness between P02 (female) and D01
(female) , or between wiring harness between P02
(female) and alternator R terminal and grounding
20-504 PC300/350(LC)-7
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start and Battery Charging
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-505
(7)
TROUBLESHOOTING E-1

20-505-1 PC300/350(LC)-7
(7)
Failure
• The engine cannot be started. (The engine can be rotated)
information (2)
Relative
—
information

solenoid E10 (male) Resistance value
1
tion) Between and 0.6 – 1.0 :
Between and 37 – 46 :
Fault of engine stop
2 Check by replacing it with another relay
solenoid relay
Fault of fusible link When the fusible link is blown, there is a big possibility that grounding fault has occurred in
3
A36 the circuit.
Fault of assembled-
type diode
4
(Internal short-cir- D02 (male) Resistance value
cuiting) Above 1 M:
Between and
Wiring harness from battery relay M terminal (A22) to A36 to Resistance
Below 1 :
Wiring harness dis- R22 (female) value
connected
Wiring harness between R22 (female) and E10 (female) Resistance
5 (Disconnection or Below 1 :
value
defective contact of
connector) Wiring harness from the engine starting switch ACC terminal Resistance
Below 1 :
to J07 to J03 to E10 (female) value
Resistance
Wiring harness between E10 (female) and grounding Below 1 :
value
Wiring harness from battery relay M terminal (A22) to A36 to
Resistance
R22 (female) , or between wiring harness from battery Above 1 M:
value
relay M terminal (A22) to A34 to FB1 inlet and grounding
Grounding fault of
Between wiring harness between R22 (female) and E10 Resistance
wiring harness Above 1 M:
6 (female) and grounding value
(Contact with GND
circuit) Wiring harness from engine starting switch ACC terminal to
J07 to J03 to E10 (female) , or wiring harness between
engine starting switch ACC terminal and C01 (female) , or Resistance
Above 1 M:
wiring harness between the engine starting switch ACC ter- value
minal and D02 (female) , or wiring harness between S25
If the engine can be started with the engine starting switch ON, after the emergency fuel
Fault of governor •
7 solenoid driving switch is once moved to the EMERGENCY side, then the governor • pump
pump controller
controller is defective.
20-506 PC300/350(LC)-7
TROUBLESHOOTING E-1
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-507
(7)
TROUBLESHOOTING E-1

20-507-1 PC300/350(LC)-7
(7)
TROUBLESHOOTING E-2
E-2 Engine stops while in operation
Failure
• The engine suddenly stopped while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)

Governor potentiom- E06 (male) Resistance value
1 eter fault 4.0 – 6.0 kΩ

Between and
(Internal failure)
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Wiring harness between C01 (female) and E10 (female) Resistance
Below 1 Ω
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) and E10 Resistance
grounding circuit) Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
4
Electrical Circuit Diagram for Fuel Dial
20-508 PC300/350(LC)-7
(7)
E-3 Engine speed is irregular, or there is hunting
• Engine speed is irregular at low idling.

Failure
• There is hunting.
information
• Engine speed is lower than specified at high idling.
Relative • Engine rotation can be confirmed in the monitor function.

If the monitor display is not normal, proceed to Service Code [E217].
Model code signal
Monitoring Code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200

003
Governor lever
2 Refer to the section "Special Function of Monitor Panel" in this manual.
improperly adjusted
If the governor motor lever moves smoothly in the following operations, it is judged as normal.
Governor motor
3 • The fuel dial is operated between low idling and high idling.
improperly working
• The engine is stopped with the fuel dial.
Engine fuel control
4 Refer to the Engine Shop Manual.
system defective
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
5 (Disconnection or
Wiring harness from C01 (female) to J07 to H15 (female) Resistance
defective contact Below 1
Grounding fault of Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
6
(Contact with Between wiring harness between C01 (female) to J17 and Resistance
grounding circuit) Above 1 M
H15 (female) and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted.
7
controller defective (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)
20-510 PC300/350(LC)-7
TROUBLESHOOTING E-3
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-511
(7)
E-4 Engine does not stop
Failure
information
Relative
—
information

Fault of engine stop E10 (male) Resistance value
1 solenoid
(Internal fault)
If the plunger rod can be moved smoothly by hand, then the engine stop solenoid is normal.
Fault of engine stop
2 Check by replacing it with another relay.
solenoid relay
Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Fault of emergency
fuel solenoid driving
3 switch S25 (male) Switch Resistance value
(Internal short-cir- In normalcy Above 1 M
cuiting) Between and
In emergency Below 1
Between wiring harness between R22 (female) and E10
Voltage Below 1 V
Wiring harness
4 short-circuited (Con- Wiring harness from the engine starting switch ACC terminal
tact with 24 V circuit) to J07 to J03 to E10 (female) , or wiring harness between
the engine starting switch ACC terminal and C01 (female) ,
Voltage Below 1 V
or wiring harness between the engine starting switch ACC
terminal and D02 (female) , or wiring harness between S25
20-512 PC300/350(LC)-7
TROUBLESHOOTING E-4
Electrical Circuit Diagram for Engine Stop
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000
PC300/350(LC)-7 20-513
(7)
TROUBLESHOOTING E-4
Electrical Circuit Diagram for Engine Stop

20-513-1 PC300/350(LC)-7
(7)
TROUBLESHOOTING E-5
E-5 Auto-decelerator does not work
Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.

Monitoring code Item Normal display
Boom RAISE signal Lever operation: ON
1 019 Boom RAISE
fault Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-21 Troubleshooting.
Boom LOWER sig- Lever operation: ON
2 019 Boom LOWER
nal fault Lever NEUTRAL: OFF
Arm DIGGING signal Lever operation: ON
3 019 Arm DIGGING

Arm DUMPING Lever operation: ON
4 019 Arm DUMPING
signal fault Lever NEUTRAL: OFF
Bucket DIGGING Lever operation: ON
5 021 Bucket DIGGING
Bucket DUMPING Lever operation: ON
6 021 Bucket DUMPING
Lever operation: ON
7 Swing signal fault 019 Swing
Lever NEUTRAL: OFF
Lever operation: ON
8 Travel signal fault 019 Travel
Lever NEUTRAL: OFF
Attachment signal Lever operation: ON
9 021 Service
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
controller defective causes listed in Item 1 through 9, the controller is judged as defective.
20-514 PC300/350(LC)-7
(7)
TROUBLESHOOTING E-6
E-6 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C,
Relative and raise the engine rotation up to 1,200 rpm.
information • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
value in normalcy
Engine cooling water

1 temperature signal
fault Compare with the actual
Engine cooling water tem-
041 engine cooling water tem-
perature
perature.
As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (If the fault mentioned in the above item is not found, the Governor • pump controller is
judged as defective)
PC300/350(LC)-7 20-515
(7)
E-7 Preheater does not work
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
information (1) light up.
Relative • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.

Engine starting If preheating does not occur (the heater is not warmed up), refer to Failure Phenome-
1
switch fault non (2) below.
Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
ing harness tion during the troubleshooting.

2 (Disconnection or
Resistance
defective contact Wiring harness between P02 (female) and J02 Below 1
Turn the engine starting switch OFF for the preparations.

P02 Engine starting switch Voltage
3 Monitor panel fault
OFF Below 1 V
HEAT 20 – 30 V
Failure
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
information (2)
Relative • In low cooling water temperature (lower than 30°C), the governor • pump controller drives the heater
information relay for 100 seconds after the engine is started and automatically warms up the engine.

Turn the engine starting switch OFF for the preparations.
Engine starting
switch fault H15 (male) Engine starting switch Resistance value
1
(Internal disconnec- OFF Above 1 M
tion) Between and
HEAT Below 1
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Heater relay fault
value in normalcy
2 (Internal disconnec- Heater relay Continuity and resistance value

tion) Between coil terminal and grounding Continued
Between contact terminals Above 1 M
Electrical intake air Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
heater tion during the troubleshooting.
3
tion) Between heater terminals Normal if continuity is established.
Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) to J02 to heater Resistance
4 (Disconnection or Below 1
relay terminal value
defective contact
with connector) Wiring harness between battery relay M terminal (A22) Resistance
Below 1
and heater relay terminal value
20-516 PC300/350(LC)-7
Electrical Circuit Diagram for Engine Preheater
PC300/350(LC)-7 20-517
TROUBLESHOOTING E-8
E-8 All work equipment, swing and travel do not move
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

1 Fuse No. 3 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Safety switch lock during the troubleshooting. (See Cause 6)
defective S14 (female) Safety control lever Resistance value
2
tion) Lock Above 1 MΩ
Between and
Release Below 1 Ω
PPC lock solenoid during the troubleshooting.
fault
3 (Internal disconnec- V01 (male) Resistance value
tion or short-circuit- Between and 20 – 60 Ω
ing)
Assembled-type
diode D01 fault
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Above 1 MΩ
Between and
Disconnection of wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) Below 1 Ω
value
5 (Disconnection or
defective contact Resistance
Wiring harness from S14 (male) to J02 to V01 (female) Below 1 Ω
Resistance
value
Grounding fault of
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Above 1 MΩ
6 (Contact with (male) and grounding value
grounding (GND) Wiring harness from S14 (male) to J02 to V01 (female) ,
circuit) Resistance
or between wiring harness between S14 (male) and D01 Above 1 MΩ
value
20-518 PC300/350(LC)-7
(7)
TROUBLESHOOTING E-8
Electrical Circuit Diagram for PPC Lock Solenoid
PC300/350(LC)-7 20-519
TROUBLESHOOTING E-9
E-9 One-touch Power Max. Switch does not work
Failure
information
• If the one-touch power max. switch is depressed, while the engine is running and the work equipment
Relative is operated in either A mode or E mode, the symbol mark is displayed in the monitor panel.
information • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function.
(Code No. 022: Switch input 1)

One-touch power during the troubleshooting. (See Cause 4)
max. switch fault M23 (male) One-touch power max. switch Resistance value
2
tion) Release Above 1 MΩ

Between and
Depress Below 1 Ω
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) Above 1 MΩ
value
defective contact
Wiring harness between M23 (female) and C01 (female) Above 1 MΩ
value
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Above 1 MΩ
(female) and grounding, or related circuits value
grounding (GND)
circuit) Between wiring harness between M23 (female) and C01 Resistance
Above 1 MΩ
Governor • pump C01 One-touch power max. switch Voltage
5
Release Below 1 V
Depress 20 – 30 V
Electric Circuit Diagram for One-Touch Power Max. Switch
20-520 PC300/350(LC)-7
(7)
TROUBLESHOOTING E-10
E-10 No display in monitor panel at all
Failure
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
—
information

Disconnection of wir- during the troubleshooting. (See Cause 3)
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) to J07 to FB1-12 Below 1 Ω
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) and grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) to J07 to Resistance
Above 1 MΩ
circuit) FB1-12 outlet and grounding value
Monitor panel P01 Voltage and resistance value
4
defective
Between and grounding Voltage: 20 – 30 V
Between and grounding Resistance value: Below 1 Ω
20-521-1 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Power Source in Monitor Panel
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-521-2
(7)
TESTING AND ADJUSTING E-11, E-12
E-11 Part of display on monitor panel is missing
Failure
• Part of the display in the monitor panel is missing.
information
Relative
—
information

standard value in normalcy
Presumed cause and
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
• Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the controller is judged as defective)
E-12 Monitor panel displays contents irrelevant to the model
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

standard value in normalcy
Presumed cause and
If the display on the monitor panel is normal, proceed to Service Code [E217].
Model code signal
1 fault
(Internal failure) 002
Controller model code 300
003
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
20-522 PC300/350(LC)-7
E-13 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)

Fuel level lowered
Refill fuel.
1 (system in normal
condition)
Fuel level sensor during the troubleshooting.
fault A60 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12
EMPTY (Lower limit) 85 – 110
3 (Contact with
Wiring harness between P02 (female) and A60 (female) Resistance
grounding (GND) Below 1
circuit) value
Monitor panel P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12
Electrical Circuit Diagram for Fuel Level Sensor
PC300/350(LC)-7 20-523
E-14 Engine cooling water temperature gauge does not indicate correctly
Failure • The engine cooling water rises normally, but the display does not exceed the white range (C).
information • The engine cooling water temperature remains stable, but the display rises to the red range (H).
Relative • Input from the engine cooling water temperature sensor can be confirmed in the monitor function.
information (Code No. 041: Engine cooling water temperature)

Engine cooling water during the troubleshooting.
temperature sensor
fault Engine cooling water
1 P07 Resistance value
(Internal disconnec- temperature
tion or short-circuit- Between and 90 – 3.5 k
ing) 10 – 100 °C
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and P07 (female) Below 1
value
defective contact
Wiring harness between P02 (female) and P07 (female) Below 1
value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and P07 Resistance
Above 1 M
circuit) (female) and grounding value
Short-circuiting of Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and P07
Monitor panel Engine cooling water

defective temperature
Between and 90 – 3.5 k
10 – 100 °C
Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor
20-524 PC300/350(LC)-7
E-15 Hydraulic oil temperature gauge does not display correctly

Failure • Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
information • Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 044: Hydraulic oil temperature)

Hydraulic oil temper- during the troubleshooting.
ature sensor fault Engine cooling water
1 (Internal disconnec- A61 Resistance value
temperature
tion or short-circuit-
ing) Between and 90 – 3.5 k
10 – 100 °C
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and A61 (female) Below 1
value
defective contact
Wiring harness between P02 (female) and A61 (female) Below 1
value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and A61 Resistance
Above 1 M
4
(Contact with 24 V Between wiring harness between P02 (female) and A61
Monitor panel Engine cooling water

defective temperature
Between and 90 – 3.5 k
10 – 100 °C
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC300/350(LC)-7 20-525
E-16 Fuel gauge does not display correctly
Failure • Though fuel was refilled, the display does not exceed the red range (E).
information • Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)

Fuel level sensor
fault
1 (Internal disconnec- A60 (male) Fuel level Resistance value
tion or short-circuit- FULL (Upper limit) Approx. 12
ing) Between and grounding

Disconnection of wir- Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
2 (Disconnection or
Resistance
defective contact Wiring harness between P02 (female) and A60 (female) Below 1
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and A60 Resistance
Above 1 M
4
(Contact with 24 V Between wiring harness between P02 (female) and A60
Monitor panel P02 Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12
Electrical Circuit Diagram for Fuel Level Sensor
20-526 PC300/350(LC)-7
E-17 Swing lock monitor does not display correctly
Failure • Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

Swing lock switch
fault
1 (Internal disconnec- X05 (female) Swing lock switch Resistance value
tion or short-circuit- OFF Above 1 MΩ
ing) Between and
ON Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness from P02 (female) to J02 to X05 (male) Below 1 Ω
value
defective contact
Wiring harness from X05 (male) to J05 to grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) to J02 to X05 Resistance
Above 1 MΩ
circuit) (male) , or C02 (female) and grounding value
4
(Contact with 24 V Between wiring harness from P02 (female) to J02 to X05
(male) , or C02 (female) and grounding
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
ON Below 1 V
Electrical Circuit Diagram for Swing Lock Switch
PC300/350(LC)-7 20-527
(7)
E-18 When the monitor switch is operated, no display appears
Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
—
information

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Relative
If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
information

cause and
Failure
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
information

cause and
Failure
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
information

cause and
• When operating the select switch, the adjustment display does not appear.
Failure
• When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
• When operating the maintenance switch, the item display does not appear.
Relative
—
information

cause and
20-528 PC300/350(LC)-7
E-19 Windshield wiper does not work
Failure
• The windshield wiper does not work.
information
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

Window rear limit
switch fault
1 (Internal disconnec- W03 (Switch side) Front window Resistance value
tion or short-circuit- When installed at front Above 1 M
ing) Between and
When retracted at rear Below 1
Windshield wiper during the troubleshooting.
motor fault
2 (Internal disconnec- W04 (male) Continuity and resistance value
tion or short-circuit- Between and Continued

ing)
ing harness
Resistance
3 (Disconnection or Wiring harness between P01 (female) and W04 (female) Below 1
value
defective contact
Wiring harness between P01 (female) and W04 (female) Below 1
value
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) Resistance
and W03 Above 1 M
cuit) value
Monitor panel fault
(Rear limit switch P02 Front window Voltage
system) When installed at front 20 – 30 V
When retracted at rear Below 1 V
5 Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Monitor panel fault P02 Windshield wiper switch Resistance value
(Windshield wiper
motor system) OFF Below 3 V
Below 3 V 20 – 30 V
Between and grounding ON
(Constant cycle)
20-530 PC300/350(LC)-7
Electrical Circuit Diagram for Windshield Wiper Motor
PC300/350(LC)-7 20-531
E-20 Alarming buzzer cannot be cancelled
Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.

Alarming buzzer
cancellation switch
fault Alarming buzzer
1 P03 (female) Resistance value
(Internal disconnec- cancellation switch
tion or short-circuit- Release Above 1 M

ing) Between and
Depress Below 1
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and P03 (male) Below 1
value
defective contact
Wiring harness from P03 (male) to J05 to grounding Below 1
value
3
(Contact with 24 V Between wiring harness between P02 (female) and P03
(male) and grounding
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Depress Below 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-532 PC300/350(LC)-7
E-21 "Boom RAISE" is not correctly displayed in monitor function
Failure
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Boom RAISE PPC
hydraulic switch fault
1 (Internal disconnec- S06 (male) Boom control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
RAISE Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S06 (female) Below 1 Ω
value
defective contact
Wiring harness between S06 (female) and grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S06 Resistance
Above 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) and S06
★Turn the engine starting switch OFF for the preparations, and start the engine during the
troubleshooting.
Governor • pump C03 Boom control lever Voltage
5
NEUTRAL 20 – 30 V
RAISE Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC300/350(LC)-7 20-533
(7)
E-22 "Boom LOWER" is not correctly displayed in monitor function
Failure
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Boom LOWER PPC
1 (Internal disconnec- S02 (male) Boom control lever Resistance value
ing) Between and
LOWER Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
Governor • pump C03 Boom control lever Voltage
5
NEUTRAL 20 – 30 V
LOWER Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-534 PC300/350(LC)-7
(7)
E-23 "Arm DIGGING" is not correctly displayed in monitor function
Failure
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DIGGING PPC
1 (Internal disconnec- S04 (male) Arm control lever Resistance value
ing) Between and
DIGGING Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
Governor • pump C03 Arm control lever Voltage
5
NEUTRAL 20 – 30 V
DIGGING Below 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC300/350(LC)-7 20-535
(7)
E-24 "Arm DUMPING" is not correctly displayed in monitor function
Failure
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DUMPING PPC ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
hydraulic switch ing the troubleshooting.
defect S08 (male) Arm control lever Resistance value
1
tion and short-circuit- NEUTRAL Above 1 MΩ
Between and
ing) DUMPING Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
Governor • pump C03 Arm control lever Voltage
5
NEUTRAL 20 – 30 V
DUMPING Below 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-536 PC300/350(LC)-7
(7)
E-25 "Bucket DIGGING" is not correctly displayed in monitor function
Failure
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DIGGING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S01 (male) Bucket control lever Resistance value
1
Between and
ing) DIGGING Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
Governor • pump C03 Bucket control lever Voltage
5
NEUTRAL 20 – 30 V
DIGGING Below 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC300/350(LC)-7 20-537
(7)
E-26 "Bucket DUMPING" is not correctly displayed in monitor function
Failure
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DUMPING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S05 (male) Bucket control lever Resistance value
1
Between and
ing) DUMPING Below 1 Ω
ing harness
Resistance
value
defective contact
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
Governor • pump C03 Bucket control lever Voltage
5
NEUTRAL 20 – 30 V
DUMPING Below 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-538 PC300/350(LC)-7
(7)
E-27 "SWING" is not correctly displayed in monitor function
Failure
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Swing PPC hydraulic
switch, left, fault
1 (Internal disconnec- S03 (male) Swing control lever Resistance value
ing) Between and
Left Below 1 Ω
Swing PPC hydraulic
switch, right, fault
2 (Internal disconnec- S07 (male) Swing control lever Resistance value
ing) Between and
Right Below 1 Ω
Disconnection of wir- Wiring harness between C03 (female) and S03 (female) , Resistance
ing harness or wiring harness between C03 (female) and S07 (female) Below 1 Ω
value
3 (Disconnection or
defective contact Resistance
with connector) Wiring harness between S03 (female) and grounding Below 1 Ω
value
Resistance
value
4 (Contact with Wiring harness between C03 (female) and S03 (female) ,
grounding (GND) Resistance
or wiring harness between C03 (female) and S07 (female) Above 1 MΩ
circuit) value
and grounding
wiring harness
5 Wiring harness between C03 (female) and S03 (female) ,
(Contact with 24 V
circuit) or wiring harness between C03 (female) and S07 (female) Voltage Below 1 V
and grounding
troubleshooting.
6
NEUTRAL 20 – 30 V
Right or left Below 1 V
20-540 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC300/350(LC)-7 20-541
E-28 "TRAVEL" is not correctly displayed in monitor function
Failure
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Travel PPC hydraulic
switch fault
1 (Internal disconnec- S30 (male) Travel control lever Resistance value
ing) Between and
Forward or reverse Below 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness from C03 (female) to J01 to S30 (female) Below 1 Ω
value
defective contact
Wiring harness from S30 (female) to J05 to grounding Below 1 Ω
value
3 (Contact with Wiring harness from C03 (female) to J01 to S30 (female)
, or between wiring harness between C03 (female) and Above 1 MΩ
circuit) value
A43 (female) and grounding
wiring harness
4 Wiring harness from C03 (female) to J01 to S30 (female)
(Contact with 24 V
circuit) , or between wiring harness between C03 (female) and Voltage Below 1 V
A43 (female) and grounding
troubleshooting.
5
NEUTRAL 20 – 30 V
Forward or backward Below 1 V
20-542 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

PC300/350(LC)-7 20-543
(7)
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function
Failure • "Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the mon-
information itor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
information differential mechanism is turned ON.

Travel steering PPC
1 (Internal disconnec- S31 (male) Travel control lever Resistance value
ing) Between and
One side of right or left only Below 1 Ω
ing harness
Resistance
value
defective contact
Wiring harness from S31 (female) to J05 to grounding Below 1 Ω
value
3 (Contact with
Above 1 MΩ
4
troubleshooting.
5
NEUTRAL 20 – 30 V
One side of right or left only Below 1 V
20-544 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC300/350(LC)-7 20-545
E-30 "Service" is not correctly displayed in monitor function
If attachment equipped
Failure
• "Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Service (front) PPC
1 (Internal disconnec- S10 (male) Service pedal Resistance value
ing) Between and
Front Below 1 Ω
Service (rear) PPC
2 (Internal disconnec- S11 (male) Service pedal Resistance value
ing) Between and

Rear Below 1 Ω
Disconnection of wir-
ing harness Wiring harness between C02 (female) and S10 (female)
Resistance
3 (Disconnection or , or wiring harness between C02 (female) and S11 Below 1 Ω
value
defective contact (female)
with connector)
Resistance
value
4 (Contact with Wiring harness between C02 (female) and S10 (female) ,
or between wiring harness between C02 (female) and S11 Above 1 MΩ
circuit) value
wiring harness
5 Wiring harness between C02 (female) and S10 (female) ,
(Contact with 24 V
circuit) or between wiring harness between C02 (female) and S11 Voltage Below 1 V
troubleshooting.
Governor • pump C02 Service pedal Voltage
6
NEUTRAL 20 – 30 V
Front or rear Below 1 V
20-546 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC300/350(LC)-7 20-547
E-31 Air Conditioner does not work

PC300, 300LC-7 Serial No. 40001 – 45000
PC350, 350LC-7 Serial No. 20001 – 25000
Failure
• The air conditioner does not work.
information
Relative • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.

1 Fuse No. 11 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Disconnection of wir- during the troubleshooting. (See Cause 3)
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) Below 1 Ω
value
defective contact
Wiring harness between M26 (male) and grounding Below 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Above 1 MΩ
circuit) (male) and grounding
Air conditioner unit
4
defective M26 Voltage
20-548 PC300/350(LC)-7
(7)
Electrical Circuit Diagram for Air Conditioner
PC300/350(LC)-7 20-549
(7)

Troubleshooting procedure for air conditioner system

★ The control panel of the air conditioner constantly monitors the sensors and other devices in the system .
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
★ If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to
the procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice

★ Check the “Self-diagnosis notice” on the control
panel according to the following procedure.
• How to display “Self-diagnosis notice”

1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the “Self-diagnosis notice” displayed
on display monitor (2).
• How to select “Self-diagnosis notice” Self-diagnosis

Failure mode
If multiple “Self-diagnosis notices” are recorded, notice
press the UP switch ( ) or DOWN switch ( ) E-- No failures
of temperature setting switch (3) to select Disconnection in recirculated air
E11
another notice. sensor
E12 Short-circuit in recirculated air sensor
• How to delete “Self-diagnosis notice” E15
Disconnection in water temperature
When reproducing the “Self-diagnosis notices” sensor
or after removing the cause of a failure, press E16
Short-circuit in water temperature
the switches on both sides of recirc/fresh air sensor
selector switch (4) simultaneously for 3 seconds E18 Short-circuit in daylight sensor
or more, and all the “Self-diagnosis notices” are E43 Abnormality in air outlet damper
deleted. E44 Abnormality in air mix damper
Abnormality in recirculated and fresh
• Finishing display of “Self-diagnosis notice” E45
air damper
To finish display of the “Self-diagnosis notice”,
press OFF switch (1) or turn the starting switch
OFF.
20-550 PC300/350(LC)-7
(7)
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without turning
Defective recirculated
standard value in normal state
starting switch ON.

1 air sensor
THI (male) Resistance
Possible causes and
Between (1) and (2) 300 z – 430 kz
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air
starting switch ON.

1 sensor (Internal short cir-
THI (male) Resistance
Possible causes and
cuit)
Between (1) and (2) 300 z – 430 kz
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
3
PC300/350(LC)-7 20-551
(7)
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
• Disconnection in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal dis-
THW (male) Resistance
Possible causes and
connection)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16
Contents of
• Short circuit in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal
THW (male) Resistance
Possible causes and
short circuit)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
20-552 PC300/350(LC)-7
(7)
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Related
information

Defective daylight sen-

1 The daylight sensor may be defective. Check it directly.
sor (Internal short circuit)
Possible causes and
harness (Disconnection Wiring harness between M30 (female) (16) and P15
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
Related ★ Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.

Defective air outlet servo-
1 The air outlet servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MV1 (female) (1) and M30
Possible causes and
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC300/350(LC)-7 20-553
(7)
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.

Defective air mix servo-
1 The air mix servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MAM (female) (1) and M29
Possible causes and
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
(female) (3)
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
Resistance Max. 1 z
(female) (4)
Resistance Max. 1 z
(female) (5)
3
20-554 PC300/350(LC)-7
(7)
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.

Defective recirculated
1 and fresh air servomotor The recirculated and fresh air servomotor may be defective. Check it directly.
(Internal defect)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
Check the related circuits.

starting switch ON.
Disconnection in wiring Wiring harness between MRF (female) (1) and M29
(female) (6)
defective contact in con- Wiring harness between MRF (female) (3) and M29
Resistance Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit,
Resistance Max. 1 z
and M33 (female) (3)
Defective air conditioner If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be
4
system defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC300/350(LC)-7 20-555
(7)
20-556 PC300/350(LC)-7
(7)
Troubleshooting by failure phenomenon
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information

1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.)
starting switch ON.
Wiring harness between fuse 11 outlet and M33 (male)
Disconnection in wiring Resistance Max. 1z
(3)
harness (Disconnection
Wiring harness between M27 (female) (14) and M30
2 in wiring harness or Resistance Max. 1z
(female) (6)
defective contact in con-
nector) Wiring harness between M33 (male) (3) and chassis
Resistance Max. 1z
ground
Wiring harness between M29 (female) (12) and chassis
Resistance Max. 1z
ground
Possible causes and
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
Resistance Min. 1 Mz
M30 (female) (6) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
troubleshooting.
M30, M29 Voltage
5 Defective control panel
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
PC300/350(LC)-7 20-557
(7)
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information

Defective blower relay starting switch ON.
2
(on coil side) R30 (male) Resistance
Between (1) and (3) 140 – 340 z
troubleshooting.
Defective blower relay
3 R30 Fan switch Voltage
(on contact side)
Between (4) and
ON (Operated) 20 – 30 V
chassis ground
Defective power transis- troubleshooting.
4
tor (Internal defect) Fan switch If air flow can be changed with fan switch,
Operate in range of Low, Medium, and High power transistor is normal.
troubleshooting.
Possible causes and
Defective blower motor MB (female) Fan switch Voltage

5
(Internal defect) Between (1) and (2) ON (Operated) 20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
starting switch ON.
Wiring harness between fuse 11 outlet, fuse in unit, R30
Resistance Max. 1 z
(3), R31 (female) (1), and M30 (female) (6)
Wiring harness between M29 (female) (3) and R30
Resistance Max. 1 z
(female) (1)
Disconnection in wiring Resistance Max. 1 z
ground
harness (Disconnection
Wiring harness between MB (female) (1) and R30
6 in wiring harness or Resistance Max. 1 z
(female) (4)
defective contact in con-
nector) Wiring harness between MB (female) (2) and PTR
Resistance Max. 1 z
(female) (3)
Wiring harness between PTR (female) (1) and chassis
Resistance Max. 1 z
ground
Wiring harness between PTR (female) (2) and M30
Resistance Max. 1 z
(female) (7)
Wiring harness between PTR (female) (4) and M30
Resistance Max. 1 z
(female) (8)
7
20-558 PC300/350(LC)-7
(7)
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information

Defective compressor starting switch ON.
2
relay (on coil side) R31 (male) Resistance
Between (1) and (2) 140 – 340 z
troubleshooting (Setting of temperature: Highest cooling position).
Defective compressor
3 R31 Fan switch Voltage
relay (on contact side)
Between (4) and chassis
ON (Operated) 20 – 30 V
ground
Defective thermostat
4 The thermostat may be defective. Check it directly.
(Internal defect)
Defective high/low pres- starting switch ON.
5 sure switch (Internal dis-

P17 (male) Resistance
connection)
Possible causes and
Between (1) and (2) Max. 1 z

6 The compressor clutch may be defective. Check it directly.
clutch (Internal defect)
7 The compressor may be defective. Check it directly.
(Internal defect)
starting switch ON.
Wiring harness between M30 (female) (4) and P17
Resistance Max. 1 z
(female) (1)
Wiring harness between P17 (female) (2) and chassis
Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between fuse 11 outlet, R31 (female)
(2), fuse in unit, R31 (female) (1), and M30 (female) (6)
defective contact in con- Wiring harness between ST1 (female) (1) and R31
Resistance Max. 1 z
Wiring harness between M29 (female) (2) and ST1
Resistance Max. 1 z
(female) (2)
Resistance Max. 1 z
ground
Wiring harness between R31 (female) (4) and M34
Resistance Max. 1 z
(female) (1)
9
PC300/350(LC)-7 20-559
(7)
20-560 PC300/350(LC)-7
(7)
E-32 Travel alarm does not sound
If travel alarm equipped
Failure • The travel alarm does not sound while the machine is traveling.
information • The alarm begins to sound when the machine is at a standstill.
Relative
—
information

When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
1 Fuse No. 15 fault
(See Cause 4)
If the monitor display is not correct, proceed to No. E-21 Troubleshooting.

2 Travel signal fault
Control lever operation: ON
019 Travel
Control lever NEUTRAL: OFF
ing harness
Wiring harness between FB1-15 outlet to J03 and A43 Resistance
3 (Disconnection or Below 1 Ω
(female) value
defective contact
Wiring harness between A43 (female) and J01 Below 1 Ω
value
4 (Contact with
grounding (GND) Between wiring harness between FB1-15 outlet to J03 and Resistance
Above 1 MΩ
circuit) A43 (female) and grounding value
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)
PC300/350(LC)-7 20-561
(7)
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC300, 300LC-7 Serial No. 40001 – 45000

PC350, 350LC-7 Serial No. 20001 – 25000

20-562 PC300/350(LC)-7
(7)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-602

H-1 All work equipment lack power, or travel and swing speeds are slow .............................................. 20-605
H-2 Engine speed sharply drops or engine stalls .................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................ 20-607
H-4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................ 20-608
H-6 Fine control mode does not function................................................................................................. 20-608
H-7 Boom moves slowly or lacks power .................................................................................................. 20-609
H-8 Arm moves slowly or lacks power..................................................................................................... 20-610
H-9 Bucket moves slowly or lacks power ................................................................................................ 20- 611
H-10 Work equipment does not move in its single operation .................................................................... 20-611
H-11 Work equipment has a bit too fast hydraulic drift .............................................................................. 20-612
H-12 Work equipment has big time lag...................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit .............................................................. 20-613
H-14 One-touch power max. switch does not operate .............................................................................. 20-613
H-15 In compound operation, work equipment with larger load moves slowly .......................................... 20-614
H-16 In swing + boom RAISE operation, boom moves slowly .................................................................. 20-614
H-17 In swing + travel, travel speed drops sharply.................................................................................... 20-614
H-18 Machine swerves in travel ................................................................................................................ 20-615
H-19 Machine travels slowly ...................................................................................................................... 20-616
H-20 Machine cannot be easily steered or lacks power ............................................................................ 20-617
H-21 Travel speed does not shift, or it is too slow or fast. ......................................................................... 20-618
H-22 Track shoe does not turn (on one side only)..................................................................................... 20-618
H-23 Machine does not swing ................................................................................................................... 20-619
H-24 Swing acceleration is poor, or swing speed is slow .......................................................................... 20-620
H-25 Excessive overrun when stopping swing .......................................................................................... 20-621
H-26 There is big shock when stopping swing .......................................................................................... 20-622
H-27 There is big abnormal noise caused when stopping swing .............................................................. 20-622
H-28 Swing natural drift is too big.............................................................................................................. 20-623
PC200/220(LC)-7 20-601
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-602 PC200/220(LC)-7
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
PC200/220(LC)-7 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting

2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand • References for making judgement of "good" or "no good"
for any priority)
4
20-604 PC200/220(LC)-7
TESTING AND ADJUSTING H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information • All the work equipment lack power, or their travel and swing speeds are slow.
Relative information • Set the working mode at A mode for troubleshooting.

Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Unload pressure
1 Malfunctioning of unload valve
3.9 ± 1.0 MPa
All control levers in NEUTRAL
{40 ± 10kg/cm2}
Control lever Main relief pressure
Improper adjustment or mal- 33.34 – 37.23 MPa

2 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunc-
tioning of main relief valve or its internal failure is suspected. In that case, check
the valve itself.
Malfunctioning of self pressure Control lever Control circuit source pressure
3
decompression valve 2.83 – 3.43 MPa

{29 – 35kg/cm2}
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
4
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of PC valve or its internal failure is suspected. In that case, check the valve
itself.
Travel speed Travel control lever LS-EPC output pressure
Malfunctioning of LS-EPC
5 Approx. 1.4 MPa
valve Lo NEUTRAL
{Approx. 14 kg/cm2}
Hi Travel control lever 0{0}
Oil pressure ratio
Oil pressure to be mea- Travel without load (con-
sured All control levers in
trol lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
6
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
tioning of LS valve or its internal failure is suspected. In that case, check the valve
itself.
7 Malfunctioning of servo piston Malfunctioning of servo piston is suspected. Check the piston itself.
If none of the above listed causes is detected, the piston pump is suspected of
8 Piston pump defective
deteriorated performance, malfunctioning or internal failure.
PC200/220(LC)-7 20-605
H-2 Engine speed sharply drops or engine stalls
Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Relative Information

Control lever Main relief pressure

1 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
tioning of the main relief valve or its internal failure is suspected. In that case,
check the valve itself.

Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
tioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
Oil pressure ratio
Oil pressure to be mea- Travel without load
sured All control levers in
(control lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
3
functioning of LS valve Pump delivery pressure 1
tioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check
4
ment clogged the equipment itself.
5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.
20-606 PC200/220(LC)-7
TESTING AND ADJUSTING H-3, H-4
H-3 No work equipment, travel or swing move
Failure information • No work equipment nor travel and swing functions can be set in motion.
Relative information • Set the working mode at A mode for the troubleshooting.


Safety lock lever Main relief pressure
Malfunctioning of PPC lock
1 Locked 0{0}
solenoid valve
2.84 – 3.43 MPa
Released
{29 – 35kg/cm2}
Malfunctioning of self pressure Control lever Control circuit source pressure
2
All control levers in NEUTRAL position
{29 – 35kg/cm2}
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it
in the following manner.
3 Piston pump defective
• Remove the oil pressure measurement plug and crank the engine. If oil flows out,
it is in normal condition.
It is presumed that the pump shaft does not rotate due to some internal failure of
4 Damper defective
the dumper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
PC200/220(LC)-7 20-607
H-5 Auto-decelerator does not work
Failure information • The auto-decelerator does not work.

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
Relative information
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

Presumed cause and stan-
dard value in normalcy

Travel control lever PPC valve output pressure
Malfunctioning of NEUTRAL 0{0}
1 travel PPC valve
(shuttle valve)
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
H-6 Fine control mode does not function
Failure information • The fine control mode poorly functions or its response is slow.

LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of pressure
1
LS-EPC valve Approx. 1.4 MPa
Lo NEUTRAL
{Approx. 14 kg/cm2}
Hi Travel control lever 0{0}
Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged
Oil pressure ratio
Oil pressure to be measured Travel without load

All control levers in
(control lever held at half
Improper adjust- NEUTRAL
stroke)
3 ment or malfunction-
ing of LS valve Pump delivery pressure 1
Nearly equal oil pressure
PC valve output pressure Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunction-
ing of the LS valve or its internal failure is suspected. In that case, check the valve
itself.
Malfunctioning of
4 Malfunctioning of the servo piston is suspected. Check the piston itself.
servo piston
20-608 PC200/220(LC)-7
H-7 Boom moves slowly or lacks power
Failure information • The boom moves slowly or lacks power


Boom lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (in boom circuit)
Above 2.7 MPa
RAISE or LOWER
{Above 28 kg/cm2}
Travel lever Solenoid output pressure
Malfunction of merge/divide
2 NEUTRAL 0{0}
solenoid valve
2.84 – 3.43 MPa
Operating one side only
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of boom control The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check
4
valve (spool) the valve itself.
Malfunctioning of boom control
The pressure compensation valve in the boom control valve (Lo • Hi) is presumed
5 valve (pressure compensation
to malfunction. Check the valve itself.
valve)
Malfunctioning of boom control The regeneration valve in the boom control valve (Lo) or the seal is presumed to
6
valve (regeneration valve) malfunction. Check the valve itself.
Malfunctioning of boom control The lock valve in the boom control valve (Lo) is presumed to malfunction. Check
7
valve (lock valve) the valve itself.
Malfunctioning of boom control The check valve in the boom control valve (Hi) is presumed to malfunction. Check
8
valve (check valve) the valve itself.
Malfunctioning of safety valve The safety valve for the lock valve is presumed to malfunction, or the seal is sus-
9
for lock valve or seal defective pected to be defective. Check the valve itself.
Malfunctioning of boom control
The suction valve in the boom control valve (Lo) is presumed to malfunction, or
10 valve (suction valve) or seal
the seal is suspected to be defective.
defective
Malfunctioning of boom control The safety and suction valves in the boom control valve (Lo) are presumed to
11 valve (safety and suction malfunction, or the seal is suspected to be defective. Check those valves them-
valves) or seal defective selves.
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service
12 valve (left travel, bucket and
control valve are presumed to malfunction. Check those valves themselves.
service valves)
13 Boom cylinder defective Boom lever Amount oil leakage from cylinder
Raise relief 20 cc/min
PC200/220(LC)-7 20-609
H-8 Arm moves slowly or lacks power
Failure information • The arm moves slowly, or lacks power.


+Stop engine for preparations. Start troubleshooting at engine high idling.
Arm lever PPC valve output pressure
Malfunctioning of left PPC
1 NEUTRAL 0{0}
valve (arm circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
Travel lever Solenoid output pressure
Malfunctioning of merge/divide
2 NEUTRAL 0{0}
solenoid valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of arm control The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the
4
valve (spool) valve itself.
Malfunctioning of arm control
The pressure compensation valve in the arm control valve (Lo • Hi) is presumed
to malfunction. Check the valve itself.
valve)
Malfunctioning of arm control The regeneration valve in the arm control valve (Lo) is presumed to malfunction,
6
valve (regeneration valve) or the seal is suspected to be defective. Check the valve itself.
Malfunctioning of arm control
The safety and suction valves in the arm control valve (Lo • Hi) are presumed to
7 valve (safety and suction
malfunction, or the seal is suspected of defect. Check those valves themselves.
valves) or seal defective
Malfunctioning of arm control The quick return valve in the arm control valve (Hi) is presumed to malfunction.
8
valve (quick return valve) Check the valve itself.
Malfunctioning of LS shuttle
LS shuttle valves in the right travel control valve, boom control valve, left travel
valve (right travel, boom, left
9 control valve, bucket control valve and service valve are presumed to malfunc-
travel, bucket and service
tion. Check those valves themselves.
valves)
10 Arm cylinder defective Arm lever Amount oil leakage from cylinder
Digging relief 20 cc/min
20-610 PC200/220(LC)-7
H-9 Bucket moves slowly or lacks power
Failure information • The bucket moves slowly, or lacks power.


Bucket lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (bucket circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
Malfunctioning of bucket con- The spool in the bucket control valve is presumed to malfunction. Check the
2
trol valve (spool) valve itself.
Malfunctioning of bucket con-
The pressure compensation valve in the bucket control valve is presumed to
3 trol valve (pressure compen-
malfunction. Check the valve itself.
sation valve)
Malfunctioning of bucket con- The safety and suction valves in the bucket control valve are presumed to
4 trol valve (safety and suction malfunction, or the seal is suspected to be defective. Check those valves
valves) or seal defective themselves.
Malfunction of LS shuttle valve The LS shuttle valve in the service control valve is presumed to malfunction.
5
(service valve) Check the valve itself.
6 Bucket cylinder defective Bucket lever Amount oil leakage from cylinder
H-10 Work equipment does not move in its single operation
• The boom does not move when operated independently.

Failure information • The arm does not move when operated independently.
• The bucket does not move when operated independently.


Work equipment control lever PPC valve output pressure
1 Malfunctioning of PPC valve NEUTRAL 0{0}
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
Malfunctioning of work equip- The spool in the work equipment control valve is presumed to malfunction.
2
ment control valve (spool) Check the valve itself.
PC200/220(LC)-7 20-611
H-11 Work equipment has a bit too fast hydraulic drift
Failure information (1) • Hydraulic drift of the boom is a bit too fast.


1 Boom cylinder defective Boom control lever Amount oil leakage from cylinder
Raise relief 20 cc/min
Boom control lever (lock valve) The seal at lock valve in the boom control valve (Lo) is suspected to be
2
seal defective defective. Check the valve itself.
Seal at safety valve for lock The seal at the safety valve in the lock valve is suspected to be defective.
3
valve defective Check the valve itself.
Failure information (2) • Hydraulic drift of the arm is a bit too fast.

1 Arm cylinder defective Arm control lever Amount oil leakage from cylinder

The seal for safety and suction valves in the arm control valve (Lo • Hi) is
suspected to be defective. Check the valve itself.
Arm control valve (safety and Whether the seal is defective or not may well be determined by changing
2
suction valves) seal defective for other safety and suction valves. (Do not attempt to change them for the
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Arm control valve (spool) seal The seal for spool in the arm control valve (Lo • Hi) is suspected to be defec-
3
defective tive. Check the seal itself.
Arm control valve (pressure
The seal for pressure compensation valve in the arm control valve (Lo • Hi)
4 compensation valve) seal
is suspected to be defective. Check the seal itself.
defective
Failure information (3) • Hydraulic drift of the bucket is a bit too fast.

1 Bucket cylinder defective Bucket control lever Amount oil leakage from cylinder

The seal for the safety and suction valves in the bucket control lever is sus-
pected to be defective. Check the seal itself.
Bucket control valve (safety
Whether the seal is defective or not may well be determined by changing
2 and suction valves) seal
for other safety and suction valves. (Do not attempt to change them for the
defective
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Bucket control valve (spool) The seal for spool in the bucket control valve is suspected to be defective.
3
seal defective Check the seal itself.
Bucket control valve (pres-
The seal for pressure compensation valve in the bucket control valve is sus-
4 sure compensation valve) seal
pected to be defective. Check the seal itself.
defective
20-612 PC200/220(LC)-7
TESTING AND ADJUSTING H-12, H-13, H-14
H-12 Work equipment has big time lag
Failure information • The work equipment has a big time lag.


LS-EPC valve output
Malfunctioning of LS-EPC pressure
1
valve Approx. 1.4 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Hi Operation 0{0}
Malfunctioning of control valve
The regeneration valve in the control valve is presumed to malfunction.
2 (regeneration valve) - with
Check the valve itself.
boom and arm only
The safety and suction valves of the control valve are presumed to malfunc-
tion. Check those valves themselves directly.
Malfunctioning of control For the arm and boom, whether they are defective or not may well be de-
3
valves (safety & suction valve) termined by changing them for other safety and suction valves. (Do not at-
tempt to change them for the safety and suction valves for the boom
LOWER and the lock valve, because each set pressure differs)
Malfunctioning of control valve
The pressure compensation valve of the control valve is presumed to mal-
4 (pressure compensation
function. Check the valve itself directly.
valve)
H-13 Other work equipment moves when relieving single circuit
Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.

Control valve (pressure com- The seal for pressure compression valve in the control valve is suspected to
1
pensation valve) seal defective be defective. Check the seal itself.
H-14 One-touch power max. switch does not operate
Failure information • The one-touch power max. switch does not operate.


Swing lock switch Solenoid valve output pressure
Malfunctioning of 2-stage sole-
1 OFF 0{0}
noid valve
2.84 – 3.43 MPa
ON
{29 – 35kg/cm2}
Malfunctioning of main relief
2 The main relief valve is presumed to malfunction. Check the valve itself.
valve
PC200/220(LC)-7 20-613
TESTING AND ADJUSTING H-15, H-16, H-17
H-15 In compound operation, work equipment with larger load moves slowly
Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —

The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.

Combination of compound operation Work equipment with larger load
Malfunctioning of pressure Boom RAISE + arm DIGGING Boom RAISE
1 compensation valve for work
Boom RAISE + arm DUMPING Arm DUMPING
equipment with larger load
Boom RAISE + bucket DIGGING Boom RAISE
Arm DUMPING + bucket DIGGING Arm DUMPING
Boom LOWER + arm DUMPING Arm DUMPING
H-16 In swing + boom RAISE operation, boom moves slowly
Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

Malfunctioning of LS select The LS select valve is presumed to malfunction, or the seal is suspected to
1
valve or seal defective be defective. Check the valve and seal themselves.
H-17 In swing + travel, travel speed drops sharply
Failure information • In a compound operation of swing + travel, the travel speed drops sharply.
Relative information • If the travel speed is slow in the single operation of travel, carry out the H-19 check first.

Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve
1
valve (left travel and swing) is presumed to malfunction. Check both of them directly.
20-614 PC200/220(LC)-7
H-18 Machine swerves in travel
Failure information • The machine tends to swerve while traveling.


Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Differential output between right
Below 0.4 MPa {Below 4 kg/cm2}
and left sides
Malfunctioning of self-pressure Control lever Control circuit source pressure
2

{29 – 35 kg/cm2}
Oil Pressure ratio
Oil pressure to be Travel without load
Improper adjustment or mal- measured All control levers in
3 (control lever held at half
functioning of LS valve NEUTRAL
stroke)
Pump delivery pressure 1
Travel control lever Solenoid valve output pressure
Malfunctioning of travel inter-
4 Operating one side only 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
Operating both sides
{29 – 35 kg/cm2}
5 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Malfunctioning of travel control The spool in the travel interlocking valve is presumed to malfunction. Check the
6
valve (spool) spool itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 30 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
8 Final drive defective
An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.
PC200/220(LC)-7 20-615
H-19 Machine travels slowly
Failure information • The machine's travel speed is slow.


Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Output differential between right and Below 0.4 MPa
left or front and rear {Below 4 kg/cm2}
Malfunctioning of self-pressure Control lever Control circuit source pressure
2

{29 – 35kg/cm2}
LS-EPC valve output
Malfunctioning of LS-EPC pressure
3
valve Approx. 1.4 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Hi Travel control lever 0 {0}
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
4
valve (spool) itself.
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
function. Check the valve itself.
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
6
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
7
valve (bucket) Check the valve itself.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
drive directly.
8 Final drive defective
An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.
20-616 PC200/220(LC)-7
H-20 Machine cannot be easily steered or lacks power
Failure information • The machine cannot be easily steered.


Travel control lever PPC valve output pressure (steering)
Malfunctioning of travel PPC
1 NEUTRAL on both sides 0 {0}
valve (steering spool)
Above 2.7 MPa
{Above 28 kg/cm2}
2 Operating both sides 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}

3 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
4 Operating both sides 0 {0}
solenoid valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
5 The merge/divide valve is presumed to malfunction. Check the valve itself.
valve
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
6
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
function. Check the valve itself.
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
8
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
9
valve (bucket) Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is suspected to be
10
LS oil pressure pickup port defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be defective.
Malfunctioning of travel motor Check the seal itself.
11
(safety valve) Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
The seal in the check valve of the travel motor is suspected of defect. Check the
Malfunctioning of travel motor seal itself.
12
(check valve) Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
PC200/220(LC)-7 20-617
H-21 Travel speed does not shift, or it is too slow or fast.
Failure information • Travel speed does not shift, or it is either too fast or slow.

Travel speed Travel control lever Monitoring [15]
Lo Fine control 690 mA

( Mi) (to the extent that the 740 mA
Hi decelerator is released) 0 mA
Malfunctioning of LS-EPC
1 Stop engine for preparations. Start troubleshooting at engine high idling.
valve
LS-EPC valve output
pressure
Approx. 1.4 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Hi Operation 0 {0}
Solenoid valve output
Malfunctioning of travel speed pressure
2
solenoid valve Lo NEUTRAL 0 {0}
2.84 – 3.43 MPa
Hi Operation
{29 – 35 kg/cm2}
Malfunctioning of travel motor The travel motor is presumed to malfunction when shifting speed. Check the
3
(speed shifting) speed shifting portion directly.
H-22 Track shoe does not turn (on one side only)
Failure information • A track shoe does not turn (only on one side).

Travel control valve (suction The suction valve seat in the travel control valve is suspected of defect. Check
1
valve) seat defective the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect. Check the seat
2
seat defective itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect. Check the seat
3
seat defective itself.
4 Travel Motor speed reduced Travel control lever Amount of oil leakage from travel motor
drive directly.
5 Final drive defective A failure inside the final drive may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained
oil.
20-618 PC200/220(LC)-7
H-23 Machine does not swing
Failure information (1) • The machine swings neither to the right nor to the left.

Malfunctioning of swing park- Swing Solenoid valve
1
ing brake solenoid valve NEUTRAL 0 {0}
Operation 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2
(parking brake) Check it directly.
Swing lock switch Swing control lever Swing relief pressure
3 functioning of swing motor ON Swing relief
{285 – 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 11 ¬/min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
5 Swing machinery defective A failure inside the swing machinery may well be determined by an abnormal
noise from within, abnormal heat generated or metal dust or chips contained in
the drained oil.
Failure information (2) • The machine does not swing in one direction.


Left control lever PPC valve output pressure
1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Swing operation Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the spool
2
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
3
seal defective Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching if there is any change.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
4
right and left check valves and watching the result.
PC200/220(LC)-7 20-619
H-24 Swing acceleration is poor, or swing speed is slow
Failure information (1) • Swing acceleration is poor, or swing speed is slow.


Malfunctioning of LS shuttle The LS shuttle valves for all the control valves are presumed to malfunction.
1
valve (all LS shuttles) Check them directly.
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. Check
2
(parking brake) it directly.
{285 – 335 kg/cm2}
(safety valve)
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 11 ¬/min
Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.

Swing control lever PPC valve output pressure

NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the valve
2
Malfunctioning of swing motor
The pressure compensation valve in the swing motor is presumed to malfunction.
3 (pressure compensation
valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
4
right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
5
right and left check valves and watching the result.
20-620 PC200/220(LC)-7
TROUBLESHOOTING H-25
H-25 Excessive overrun when stopping swing
Failure information (1) • The work equipment overruns excessively when stopping swing.

★Stop engine for preparations. Start troubleshooting at engine high idling.


{295 – 335 kg/cm2}
(safety valve)
Amount of oil leakage from swing
2 Swing motor defective Control lever
motor
Swing relief Below 10 l/min
Failure information (2) • The work equipment overruns excessivery only one side when stopping swing.

Swing control lever PPC valve output pressure
NEUTRAL 0 {0}
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 ★Whether the valve is clogged or not may well be determined by swapping
clogged
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Swing motor (suction valve) Check the seal itself.
4
seal defective ★Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Swing motor (check valve) Check the seal itself.
5
seal defective ★Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.
PC300/350(LC)-7 20-621
(7)
TROUBLESHOOTING H-26, H-27
H-26 There is big shock when stopping swing
Failure information • There is a big shock caused when stopping a swing motion.


Malfunctioning of swing PPC Swing control lever PPC valve output pressure
1
valve NEUTRAL 0 {0}
The swing PPC slow return valve is presumed to malfunction. Check the
Malfunctioning of swing PPC valve itself.
2
slow return valve ★Whether the valve malfunctions or not may well be determined by swap-
ping the right and left valves and watching the result.
H-27 There is big abnormal noise caused when stopping swing
Failure information • There is a big abnormal noise caused when stopping a swing motion.

Malfunctioning of backpres-
1 The backpressure valve is presumed to malfunction. Check the valve itself.
sure valve
Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
Malfunction of swing motor the seal itself.
3
(suction valve) ★Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective ★A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips contained
in the drained oil.
20-622 PC300/350(LC)-7
(7)
H-28 Swing natural drift is too big
Failure information (1) • Natural drift of the swing is too big (when the parking brake is activated).
• When the emergency swing release switch is in the OFF position (this is a normal condition), the
swing and parking brake is activated and the swing is fixed with a disc brake.


Swing and parking brake sole- Swing control lever Solenoid valve output pressure
1
noid valve malfunctioned NEUTRAL 0 {0}
Left or right 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.
Failure information (2) • Natural drift of the swing is too big (when the parking brake is released).
• When the emergency swing release switch is in the ON condition (this is an emergent condition),
the swing and parking brake is released and the swing is retained only hydraulically.

Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect.
1
malfunctioned Check the spool itself directly.

Swing control valve (pressure

The pressure compensation valve seal in the swing control valve is sus-
2 compensation valve) malfunc-
pected of defect. Check the valve itself directly.
tioned
Swing motor (safety valve) The safety valve seal in the swing motor is suspected of defect. Check the
3
defective valve itself directly.
Swing motor (suction valve) The suction valve seal in the swing motor is suspected of defect. Check the
4
Swing motor (check valve) The check valve seal in the swing motor is suspected of defect. Check the
5
PC200/220(LC)-7 20-623
TROUBLESHOOTING OF ENGINE
(S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-702

S-1 Starting performance is poor (Starting always takes time)................................................................ 20-706
S-2 Engine does not start ........................................................................................................................ 20-708
(1) Engine does not turn ................................................................................................................... 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............................... 20-709
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................. 20-710
S-3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 711
S-4 Engine stops during operations ........................................................................................................ 20-712
S-5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-713
S-6 Engine lacks output (or lacks power) ................................................................................................ 20-714
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-715
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-716
S-9 Oil becomes contaminated quickly ................................................................................................... 20-717
S-10 Fuel consumption is excessive ......................................................................................................... 20-718
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-719
S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-720
S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-721
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-722
S-15 Abnormal noise is made ................................................................................................................... 20-723
S-16 Vibration is excessive ....................................................................................................................... 20-724
PC300/350(LC)-7 20-701
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(1) (2) (3)
(a)
Questions
[A] (b)
(c)
(d)
[B]
(e)
Check items
[C]
i
shooting
Trouble-
ii
iii
20-702 PC300/350(LC)-7
(9)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use Causes
as reference for locating the cause of
tion)
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
erence for [Degree of use (Operated for
zzle
xces
nce
long period)] in the [Questions] section
n no
p (e
fere
g
as reference. As a rule, do not use it
jectio
men
timin
pum
inter
r
nde
when calculating the points for locating
le
uel in
tion
ction
er e
ger,
, cyli
the cause, but it can be included if nec-
injec
lean
ed f
l inje
char
ring
essary to determine the order for trou-
, seiz
fuel
air c
r fue
bleshooting. urbo
ton
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
Degree of use Operatred for long period
PC300/350(LC)-7 20-703
(7)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
d
hea
tion)
)
ized
der
injec
r se
cylin
fuel
n ge
e, va rger and
sive
k, plu
eat
zle
xces
lve s
(rac
ction tion noz
leme nce
a
boch
p (e
re
ump
g
nt
terfe
timin
pum
r
n tu
jec
der
ance
on p
uffle
valv
er, in
el in
tion
e
cylin
er e
etwe
jecti
lear
dm
ct of
injec
d fu
harg
lean
l inje
,
lve c
el in
ring
gge
b
conta
eize
Legend
ir
rboc
fuel
air c
of a
r fue
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items)
to
s
ed tu
ctive
ctive
,
n pis
ectiv
kage
hed
ged
ged
rope
rope
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period) Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting
Check items
engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on fuel injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating on
Troubleshooting
reduced cylinders
When check is made using delivery method, fuel injection timing

is found to be incorrect
Fuel injection pump test shows that fuel injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not
return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-704 PC300/350(LC)-7
(7)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
PC300/350(LC)-7 20-705
(7)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel Causes
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
eat
ater
temperature
lve s
ir he
filter
20°C 1.28 1.26 1.24 1.23 1.22
ner
e, va
t
ke a
men
der li
0°C 1.29 1.27 1.25 1.24 1.23
uze
iner
f valv
l inta
r ele
–10°C 1.30 1.28 1.26 1.25 1.24
p ga
, stra
cylin
act o
trica
pum
• The specific gravity should exceed the value for the
filter
lean
ing,
cont
elec
charging rate of 70% in the above table.
ton r
feed
air c
fuel
• In cold areas the specific gravity must exceed the value
ctive
ctive
n pis
ged
ged
ged
for the charging rate of 75% in the above table.
Defe
Defe
Clog
Clog
Clog
Wor
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Preheating monitor does not light up

Replacement of filters has not been carried out according to Operation Manual
Non-specified fuel has being used
Air cleaner clogging monitor lights up
Battery charging monitor lights up
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
Heater mount does not become warm

Is voltage 26 30V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Use a test stand when adjusting.
20-706 PC300/350(LC)-7
(7)
Replace Defe
ctive
Replace Defe regu
lator
ctive
Replace Defe alter
nato
ctive r
Replace Defe or de
terio
ctive rated
Adjust Defe injec
tion batte
tive nozz ry
Replace injec
tion le
PC300/350(LC)-7
Defe
tive timin
Correct injec g
Leak tion
age, pum
Clean c lo p
TROUBLESHOOTING
Clog ggin (rack

ged g, air , plu
nger
Replace Defe
air b
reath
in fu
el pip stuc
ctive er ho ing k)
Replace Defe feed
p
le in
f
Causes
ctive ump uel t

boos ank
t com
pens
ator
canc
el
(7)
20-707
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn Causes
• Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for S-4 "Engine stops
during operations".
n
ectio
it
• Failure in hydraulic pump system
ttery
circu
conn
noid
• Defective electrical system
d ba
sole
ting
inal
ch
otor
e
star
lay
t
term
swit
top
iora
lay
ng m
ry re
ty re
ine s
g of
eter
ting
ery
ear
e
tarti
wirin
safe
or d
star
batt
eng
batt
ing g
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions

Condition of horn when Horn sounds
starting switch is turned ON
Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
Check items
move out
When starting switch is turned to ON, there is no clicking

sound
Troubleshooting of defective wiring in starting circuit
Battery terminal is loose

When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
Troubleshooting
connected, engine starts

2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) There is no 24V between battery relay terminal b and terminal
E
When ring gear is inspected directly, tooth surface is found to be
chipped
When linkage of engine stop solenoid is disconnected, engine does
not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-708 PC300/350(LC)-7
(7)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
General causes why engine turns but no exhaust

smoke comes out
• Supply of fuel impossible

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter) Causes
a Standards for use of fuel
)
ized
r se
nge
y
nk
t, ke
el ta
k, plu
n
shaf
pisto
d
n fu
i
c
leno
p (ra
er
g
drive
ole i
pipin
r
mp
rain
e
p so
n
pum
u
i
h
stra
tank
ump
t
p
fuel
her
e sto
eed
d
pum
tion
ilter,
on p
l use
reat
el in
king
en f
ngin
injec
uel f
air b
jecti
feed
nt fu
r fue
, lea
brok
e
f
ctive
ctive
en in
fficie
ged
ged
ged
rope
ged
ed,
Defe
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
Check items

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
When starting switch is turned to ON, linkage does not move
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
When linkage of engine stop solenoid is disconnected, engine does
not start
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
PC300/350(LC)-7 20-709
(7)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes

engine does not start
.)
r, etc
• Lack of rotating force due to defective electrical
k)
stuc
r leve
system
cap
y
spra
r
rocke
nge
tank
em
tive
lu
syst
alve,
ck, p
ery
fuel
• Improper selection of fuel
efec
liner
m (v
batt
fuel
t
p (ra
le in
n
aine
le, d
ter
leme
e r
syste
der
ted
r in
rain
r ho
hea
pum
p str
nozz
n
iora
i
er e
g, a
i
t
, cyl
alve
e
e air
d
h
pum
tion
eter
l use
lean
filter
tion
reat
ggin
ken v
ring
intak
injec
or d
injec
feed
air b
air c
, clo
r fue
fuel
, bro
ton
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
ctive
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Preheating monitor does not light up
Starting motor cranks engine slowly
When fuel dial is placed at FULL position, it does not contact stopper
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
Troubleshooting
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-710 PC300/350(LC)-7
(7)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up Causes

smoothly

ap
y
seat
spra
• Improper condition of fuel injction
nk c
alve
• Improper fuel used
tive
el ta
nce
nd v
efec
ger
in fu
r
fere
r line
nt
g
iner
ve a
plun
le, d
pipin
leme
inter
aine
ance
hole
inde
stra
f val
nozz
mp
er e
, str
fuel
ger,
lear
her
, cyl
mp
act o
n pu
lean
filter
tion
char
reat
king
lve c
u
ring
p
jectio
cont
injec
feed
air c
air b
, lea
urbo
l
r va
e
ton
fu
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
PC300/350(LC)-7 20-711
(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations
• Seized parts inside engine

• Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
• Failure in hydraulic pump

a If the engine stops because of a failure in the
hydraulic pump, carry out troubleshooting for
H mode.
20-712 PC300/350(LC)-7
(7)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)
Gener al caus es why engine does not r otate Causes

smoothly
p
zzle
pum
• Air in fuel system
d no
feed
• Defective governor mechanism
p an
and
• Defective governor motor mechanism
pum
nk
a If hunting stops when governor spring is dis-
tank
el ta
ck
r
feed
erno
ol ra
connected, carry out troubleshooting for E
rnor
fuel
in fu
r
n
v
mode.
r
gove
een
aine
f go
twee
low
t
ner
n
hole
of co
betw
i
p str
nt o
too
stra
it be
tank
n of
her
tion
stme
cuit
ed is
pum
circu
lter,
ratio
el in
reat
ir
pera
c
i
adju
uel f
ope
feed
air b
air in
nt fu
air in
g sp
o
f
ctive
ctive
ctive
fficie
idlin
ged
ged
ged
ged,
ged,
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according
to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
PC300/350(LC)-7 20-713
(7)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes

t
men
y
eat
ragm
spra
• Improper fuel used
t
lve s
djus
nk
iaph
(if non-specified fuel is used, output drops)
tive
el ta
nce
ve a
d va
• Lack of output due to overtaking
efec
or d
in fu
er
fere
i
e an
t
g
nt
a If there is overheating and lack of output,
efec
iping
r
nsat
e, d
aine
plun
er
leme
inter
hole
e
der
valv
train
c
carry out troubleshooting for overheating.
g, d
ozzl
uel p
mpe
n
p str
mp
cylin
a
er e
ger,
her
lear
prin
t of
s
on n
n pu
st co
pum
f
,
filter
reat
lean
char
king
,
ntac
lve c
ring
or s
jecti
boo
air b
feed
jecti
air c
, lea
urbo
fuel
o
vern
r va
ton
c
i n
ctive
ctive
ed in
n pis
ged
ged
ged
ged
rope
ged
ged
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When fuel dial is placed at FULL position, lever does not contact stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-714 PC300/350(LC)-7
(7)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes
ifold
man
d)
on)
eize
take
jecti
seat
er s
y
nd in
spra
ve in
lung
alve
ger a
timin efective
essi
nce
ck, p
nd v
char
fere
(exc
nt
p (ra
ve a
turbo
le, d
leme
inter
ance
r
r
p
inde
uffle
f val
pum
pum
nozz
een
er e
ger,
lear
, cyl
dm
act o
tion
tion
betw
ction
lean
tion
char
ve c
gge
ring
injec
injec
cont
injec
of air
air c
r inje
, clo
l
urbo
r va
ton
ctive
ctive
ctive
n pis
hed
ged
rope
ged
rope
age
ed t
Defe
Defe
Defe
Crus
Clog
Leak
Clog
Seiz
Wor
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting
is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
PC300/350(LC)-7 20-715
(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 Causes

minutes continuously. (Both low and high idling)
rger
ocha
General causes why oil consumption is excessive
Turb
• Abnormal combustion of oil
seal
ad
e
• External leakage of oil
r he
c
stem
hose
a
oler
ken
r f
• Wear of lubrication system
al su
inde
il co
, bro
e sy
her
plug
r cyl
l, se
or o
reat
r
intak
ide)
nde
d
nd
n
ing
an o
a
rain
ine e
er e
or b
lter
, gu
e
, cyli
l pip
ar s
om
oil d
oil p
oil fi
blow
ring
stem
ther
turb
in fr
oler
ring
n re
o i
from
from
from
from
iston
brea
il co
al at
lve (
al at
ked
roke
ton
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-716 PC300/350(LC)-7
(7)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated

quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
PC300/350(LC)-7 20-717
(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
• Leakage of fuel
n)
jectio
n)
er
pisto
el filt
g
sprin
ive in
mp (
g, fu
r
rnor
cess
cove
er
d pu
pipin
lung
ay
gove
p (ex
timin
head
e fee
r spr
fuel
p
nt of
pum
pum
olde
ction
id
side
from
s
al in
stme
h
tion
el in
l inje
io
age
le
t
oil se
nozz
injec
injec
adju
of fu
e
leak
fu
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

Timing lock on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
When check is made using delivery method, injection timing is

found to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 PC300/350(LC)-7
(7)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
t
aske
k
bloc
ring
ad g
r
oole
, O-
der
, he
ting
cylin
core
oil c
ead
y pit
er h
ks in
oler
aulic
b
used
ylind
il co
crac
y d r
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil is cloudy white
When hydraulic oil is drained, water is found

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Remove oil pan and inspect directly
Replace
Replace
Replace
Replace
Replace
Remedy
PC300/350(LC)-7 20-719
(7)
S-12 Oil pressure monitor lights up (Drop in oil pressure)
General causes why oil pressure monitor lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
20-720 PC300/350(LC)-7
(7)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trou- Causes

bleshooting for "Oil is in cooling water".
General causes why oil level rises
r
cove
al
ead
• Water in oil (milky white)
nt se
ide h
mp
• Fuel in oil (diluted, and smells of diesel fuel)
et
ipme
ace
gask
n pu
• Entry of oil from other component
g ins
eve
surf
ring
equ
ectio
k
d
le
bloc
hea
pipin
, O-
seal
s
iary
lder
n j
ad,
der
core
ting
i
l
om
rear
t
side
i
osta
x
le ho
p au
r he
cylin
y pit
el fr
oler
rt in
ged
erm
nozz
nde
pum
de b
of fu
side
il co
a
ama
h
p
l i
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
Check items
an abnormal number of bubbles appear, or water spurts back

Oil level goes down in damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC300/350(LC)-7 20-721
(7)
S-14 Water temperature becomes too high (Overheating)
General causes why water temperature becomes Causes

too high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
re
)
ratu
pen
• Rise in oil temperature in hydraulic pump system
t
aske
aug
mpe
ot o
a Carry out troubleshooting for H mode.
pulle
g
ins
ad g
es n
oil te
ure
tor f
fan
ler
, he
erat
e
t (do
o
valv
radia
ump
worn
o
core
ting
ead
ater
oil c
p
osta
tem
p
ure
lic p
pum
y pit
shed
er h
w
ing,
ator
ken
herm
ress
r
oling
wate
drau
b
ylind
ater
slipp
, bro
radi
, cru
e
p
d
t
of co
in hy
en w
s ma
ctive
ctive
ctive
en c
ged
ged
ged
belt
Lack
Defe
Brok
Brok
Defe
Clog
Hole
Defe
Clog
Rise
Clog
Fan
Suddenly overheated
Questions
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level monitor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Hydraulic oil temperature enters red range faster than
engine water temperature
Temperature difference between top and bottom radiator tanks

is excessive
Carry out troubleshooting for H mode.
Temperature difference between top and bottom radiator tanks

is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
20-722 PC300/350(LC)-7
(7)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter- Causes

nal noise.
ifold
.)
man
, etc
General causes why abnormal noise is made
d)
n)
n )
eize
ositio
lever
ta ke
t i o
injec
er s
nd in
ance
t of p
cker
• Abnormality due to defective parts
ner
lung
e, ro
• Abnormal combustion
d ou
ger a
lear
der li
ce
v
essi
nce
ck, p
eren
e
(valv
• Air sucked in from intake system
boar
ve c
ozzl
ch a r
cylin
fere
(exc
ash
f
p (ra
r
f val
ystem
on n
iding
turbo
e
ing,
inter
ackl
n
mp
g
i
pum
nt o
ton r
r (div
jecti
l t
n pu
lve s
een
ushi
ain b
n be
ger,
tme
of pis
ed in
tion
b e tw
uffle
ic va
o
ed b
char
n, fa
ar tr
i
djus
t
injec
injec
ide m
wear
seiz
ynam
of air
seiz
urbo
d fa
r ge
a
ctive
ctive
ctive
ct ins
,
ssive
rme
rope
ged
en d
ed t
ing,
age
Defe
Defe
Defo
Defe
Leak
Clog
Miss
Defe
Seiz
Exce
Brok
Imp
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
PC300/350(LC)-7 20-723
(7)
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra- Causes

tion, carry out troubleshooting also for "Abnormal
k)
. stuc
noise is made".
tion)
d
gne
r, etc
ion
injec
isali
General causes why vibration is excessive
cush
r leve
fuel
pm
ocke
ken
sive
pum
• Defective parts (abnormal wear, breakage)
ring
lve, r
, bro
xces
• Improper alignment
bea
ulic
m (va
bolts
ash
• Abnormal combustion
ydra
p (e
main
r
mpe
ackl
syste
ting
pum
h
rod,
e da
ain b
and
alve
oun
g
tion
shin
cting
nsid
mic v
gine
ar tr
em
injec
u
art i
dyna
f en
ngin
nne
r ge
mb
ctive
en p
ter o
n co
n ca
rope
se e
ctive
Defe
Brok
Wor
Wor
Cen
Defe
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Troubleshooting
Inspect inside damper directly

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 PC300/350(LC)-7
(7)
30 DISASSEMBLY AND ASSEMBLY
12
HOW TO READ THIS MANUAL . . . . . . . . . . 30-3 Disassembly . . . . . . . . . . . . . . . . . . . . . 30-41
Removal and Installation of Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-43
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 30-3 SWING MOTOR, SWING MACHINERY
Disassembly and Assembly of ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-48
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 30-4 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-48
PRECAUTIONS WHEN PERFORMING Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-48
OPERATION . . . . . . . . . . . . . . . . . . . . 30-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-48-2
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . 30-6-1 CARRIER ROLLER ASSEMBLY . . . . . . . . . . 30-49
SKETCHES OF SPECIAL TOOLS . . . . . . . . 30-6-5 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-49
STARTING MOTOR ASSEMBLY . . . . . . . . . 30-7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 TRACK ROLLER ASSEMBLY . . . . . . . . . . . . 30-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-50
FUEL INJECTION PUMP ASSEMBLY . . . . . . 30-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 30-8 IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-51
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . 30-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 RECOIL SPRING ASSEMBLY . . . . . . . . . . . . 30-54
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-12-1 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-54
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . 30-12-2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-54
Special Tools . . . . . . . . . . . . . . . . . . . . . 30-12-2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-12-2 SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-12-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
CYLINDER HEAD ASSEMBLY . . . . . . . . . . 30-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-15 TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . 30-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Expansion . . . . . . . . . . . . . . . . . . . . . . . . 30-57
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . 30-21 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . 30-59
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
HYDRAULIC OIL COOLER ASSEMBLY . . . 30-23 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 REVOLVING FRAME ASSEMBLY . . . . . . . . 30-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
ENGINE AND HYDRAULIC PUMP Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-62
ASSEMBLIES . . . . . . . . . . . . . . . . . . 30-25 CENTER SWIVEL JOINT ASSEMBLY . . . . . 30-63
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-64
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-28 DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . 30-29 Special Tools . . . . . . . . . . . . . . . . . . . . 30-65
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 Disassembly . . . . . . . . . . . . . . . . . . . . 30-65
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-29 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-65
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY . . . . . . . . . 30-66
Special Tools . . . . . . . . . . . . . . . . . . . . 30-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
Disassembly . . . . . . . . . . . . . . . . . . . . 30-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-67
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-33 CONTROL VALVE ASSEMBLY . . . . . . . . . . 30-68
SWING MOTOR, SWING Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68
MACHINERY ASSEMBLY . . . . . . . . 30-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 DISASSEMBLY AND ASSEMBLY
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-40 Special Tools . . . . . . . . . . . . . . . . . . . . 30-71
DISASSEMBLY AND ASSEMBLY Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-72
Special Tools . . . . . . . . . . . . . . . . . . . . 30-41
PC300/350(LC)-7 30-1
(8)
DISASSEMBLY AND ASSEMBLY
12
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . 30-73
Special Tools. . . . . . . . . . . . . . . . . . . . . . 30-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Installation. . . . . . . . . . . . . . . . . . . . . . . . 30-75
OIL SEAL IN HYDRAULIC PUMP
INPUT SHAFT . . . . . . . . . . . . . . . . . . 30-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-76
WORK EQUIPMENT PPC VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-77
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
TRAVEL PPC VALVE ASSEMBLY . . . . . . . . 30-78
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
HYDRAULIC CYLINDER ASSEMBLY . . . . . 30-79
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-79
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
WORK EQUIPMENT ASSEMBLY . . . . . . . . 30-85
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-85
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-86
AIR CONDITIONER UNIT ASSEMBLY. . . . . 30-88
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-88
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-90
COUNTERWEIGHT ASSEMBLY . . . . . . . . . 30-91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-91
OPERATOR’S CAB ASSEMBLY . . . . . . . . . 30-92
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-93
OPERATOR’S CAB GLASS
(STUCK GLASS) . . . . . . . . . . . . . . . . 30-97
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-99
FRONT WINDOW ASSEMBLY. . . . . . . . . . 30-107
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-109
MONITOR ASSEMBLY . . . . . . . . . . . . . . . 30-113
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-113
GOVERNOR PUMP CONTROLLER
ASSEMBLY . . . . . . . . . . . . . . . . . . . 30-114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-114
30-2 PC300/350(LC)-7
(8)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES

SPECIAL TOOLS INSTALLATION OF PARTS
• Special tools that are deemed necessary for • Except where otherwise instructed, install
removal or installation of parts are listed. parts is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing
kind of information. parts are shown with mark in the
1) Necessity INSTALLATION Section, identifying which
■: Special tools which cannot be substi- step the instructions are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
●: Special tools which are very useful if stand for the following.
available, can be substituted with
commercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special doing the work.
tools ★ This mark gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
developed for this model.
R: Tools with upgraded part numbers, This mark stands for a specific coating
remodeled from already available agent to be used.
tools for other models. This mark indicates the specified
Blank: Tools already available for other mod- torque.
els, used without any modification.
This mark indicates an amount of oil or
3) Circle mark ({) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
★ Part No. of special tools starting with 79*T
• Various special tools are illustrated for the
means that they are locally made parts and as
convenience of local manufacture.
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,

precautions and the amount of oil or water to
be drained.
• Various symbols used in the REMOVAL Sec-
tion are explained and listed below.
This mark indicates safety-related pre-

cautions which must be followed
when doing the work.
★ This mark gives guidance or precau-
tions when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing
parts.
This mark shows oil or water to be

drained.
PC300/350(LC)-7 30-3
c
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS ASSEMBLY
• Special tools which are deemed necessary for • Section titled ASSEMBLY contain proce-
disassembly and assembly are listed in this dures, precautions and the know-how for the
section. work, as well as the amount of oil or water to
• List of the special tools contains the following be added.
kind of information. • Various symbols used in the ASSEMBLY Sec-
1) Necessity tion are explained and listed below.
■: Special tools which cannot be substi-
tuted, should always be used.
●: Special tools which are very useful if doing the work.
available, can be substituted with ★ This mark gives guidance or precautions
commercially available tools. when doing the procedure.
2) Distinction of new and existing special
tools This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
developed for this model. This mark indicates the specified torque.
R: Tools with upgraded part numbers,
remodeled from already available This mark indicates an amount of oil or
tools for other models. water to be added.
Blank: Tools already available for other mod-
els, used without any modification. SKETCHES OF SPECIAL TOOLS
3) Circle mark ({) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts
and as such not interchangeable with
those made by Komatsu in Japan e.g.
79*T--- xxx --- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-

dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.

doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing parts.
This mark shows oil or water to be

drained.
30-4 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
PRECAUTIONS WHEN PERFORMING OPERATION
Be sure to follow the general precautions given below when performing removal or installation (disassem-
bly or assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it properly.
• After disconnecting hoses or tubes, cover them or install 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 necessary
places before removal to prevent any mistake during assembly.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force
to the wiring, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify them and show their installation position. This helps pre-
vent any mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and
safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt
from entering after removal.
★ Precautions when handling piping during disassembly
Install the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes

Nominal number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used:
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC300/350(LC)-7 30-5
3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
2. Precautions when carrying out installation work
• 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 two or three 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 anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect it securely.
• When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and
align the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1. Start the engine and run it at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping
the cylinders 100 mm from the end of their stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the
specified level. Run the engine to circulate the coolant water through the system. Then check the
coolant water level again.
• 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.
• If the piping or hydraulic equipment have been removed for repair, bleed the air from the system
after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
30-6 PC300/350(LC)-7
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-
tured).
★ Necessity: ■ ............ Cannot be substituted, must always be installed (used)

●............. Extremely useful if available or can be substituted with commercially available
part
★ New/Remodel :N............ Tools with new part numbers, newly developed for this model
:R ............ Tools with upgraded part numbers, remodeled from items already available
for other models
:Blank: ... Tools already available for other models, can be used without any modifica-
tion
★ Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part name Nature of work, remarks
1 795-799-1131 Gear ■ 1 Removal of fuel injection

A 2 795-799-1390 Remover ■ 1 pump
3 795-931-1100 Seal puller ■ 1 Removal of engine seal

Engine assembly Removal and installation
1 795-799-1170 Puller ■ 1 of nozzle holder assem-
B bly
Retightening of cylinder
2 790-331-1110 Wrench ■ 1 head bolt
Engine, hydraulic pump assem- 796-460-1210 Oil stopper ● 1

C Oil stopper
bly 796-770-1320 Adapter ● 1
796-627-1610 Wrench assembly ■ 1 N
• 796-627-1620 • Wrench 1 N Removal and installation
1 of nut
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
796T-627-1630 Push tool ■ 1 N
790-101-2510 Block ■ 1
791-830-1320 Rod ■ 2
Final drive assembly D 01580-11613 Nut ■ 2
2 Installation of bearing
790-101-2570 Washer ■ 2
01643-31645 Washer ■ 2
790-105-2100 Jack assembly ■ 1
790-101-1102 Pump ■ 1
Installation of floating
3 791-580-1510 Installer ■ 1 seal
4 790-331-1110 Wrench ■ 1 Tightening of cover bolt
PC300/350(LC)-7 30-6-1
(8)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
1 796T-626-1110 Push tool ● 1 Press-fitting of bearing

2 796T-626-1140 Push tool ■ 1 Press-fitting of oil seal
3 790-201-2480 Push tool ■ 1 Press-fitting of bearing
Swing motor, swing 790-101-5401 Push tool kit ■ 1

machinery assembly E
• 790-101-5521 • Plate 1
4 Press-fitting of oil seal
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
5 793T-815-1110 Push tool ■ 1 Press-fitting of bearing
791-601-1000 Installer ■ 1
Carrier roller assembly F Refilling oil
791-430-3230 Oil pump ■ 1
796-670-1010 Installer ■ 1
Track roller assembly G
791-601-1000 Oil pump ■ 1
Refilling oil
796-570-1020 Installer ■ 1
Idler assembly H
791-601-1000 Oil pump ■ 1
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
Disassembly and assem-
1 Cylinder bly of recoil spring
790-101-1600
(686 kN {70 t} ) ■ 1
Recoil spring assembly J 790-101-1102 Pump ■ 1

790-201-1500 Push tool kit ■ 1
• 790-201-1620 • Plate 1
2 Installation of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
791-630-3000 Remover & installer ■ 1
Cylinder
1 790-101-1300
(980 kN {100 t} ) ■ 1 Extraction of master pin
Track shoe assembly K
790-101-1102 Pump ■ 1
2 790-331-1110 Wrench ■ 1 Tightening of shoe bolt
790-101-2501 Push-puller ■ 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint assembly L • 790-101-2540 • Washer 1 bly of center swivel joint
assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
30-6-2 PC300/350(LC)-7
(8)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
796-946-1310 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
■ 1
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
■ 1
(For 723-46-44100)
796-946-2210 Guide
■ 1
(For 723-46-45100)
796-946-1320 Guide Replacement of pres-
■ 1 sure compensation valve
(For 723-46-40100, 723-46-40601) seal
796-946-1820 Guide
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2 ■ 1
(For 723-46-44100)
Control valve assembly M
796-946-2220 Guide
■ 1
(For 723-46-45100)
796-946-1420 Guide
■ 1
(For 723-46-42800)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
1
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve Replacement of pres-
3 1 sure compensation valve
(For 723-46-44100) seal
796-946-2230 Sleeve
1
(For 723-46-45100)
796-946-1430 Sleeve
■ 1
(For 723-46-42800)
PC300/350(LC)-7 30-6-3
(8)
New/Remodel
Necessity
Symbol
Sketch
Q'ty

1 790-502-1003 Cylinder repair stand ■ 1 bly of hydraulic cylinder
assembly
790-102-4300 Wrench assembly ■ 1 Removal and installation
2 of piston assembly
790-102-4310 Pin ■ 2
3 790-720-1000 Expander ● 1
796-720-1680 Ring ● 1 Installation of piston ring
4
07281-01589 Clamp ● 1
790-201-1702 Push tool kit ■ 1
Hydraulic cylinder assembly N • 790-201-1851 • Push tool kit 1

(for bucket, boom)
5 Press-fitting of bushing
• 790-201-1861 • Push tool (for arm) 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-1500 Push tool kit ■ 1
• 790-101-5021 • Grip 1
6 • 01010-50816 • Bolt 1 Press-fitting of dust seal

• Plate
• 790-201-1660 (for bucket, boom) 1
• 790-201-1670 • Plate (for arm) 1

796-670-1100 Remover ■ 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
• 796-670-1130 • Screw 1
Work equipment assembly P • 791-775-1150 • Adapter 1 Removal of foot pin

• 01643-33080 • Washer 1
• 01803-13034 • Nut 1
Puller
790-101-4000
(490 kN {50 t} long) ■ 1
790-101-1102 Pump (294 kN {30 t} ) ■ 1

799-703-1200 Service tool kit ■ 1
799-703-1100 Vacuum pump (100V) ■ 1
Charging of air condi-
Air conditioner assembly Q 799-703-1111 Vacuum pump (220V) ■ 1 tioner gas
799-703-1121 Vacuum pump (240V) ■ 1
799-703-1401 Gas leak detector ■ 1
1 793-498-1210 Lifter (Suction cup) ■ 2 Removal and installation
Operator’s cab glass Y of operator’s cab glass
2 20Y-54-13180 Adapter ■ 2
30-6-4 PC300/350(LC)-7
(8)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
D2 Push tool
E1 Push tool
PC300/350(LC)-7 30-6-5
(8)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
E2 Push tool
E5 Push tool
30-6-6 PC300/350(LC)-7
(8)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF STARTING MOTOR
ASSEMBLY
REMOVAL INSTALLATION
k Disconnect the cable from the negative (–) ter- • Install in reverse order of removal.
minal of the battery.
1. Open up the engine hood. 3 Engine starting motor terminal B

Securing nut:
2. Disconnect the two wires from the engine 19.6 – 25.5 Nm {2.0 – 2.6 kgm}
2 Both faces of engine starting motor

starting motor at:
• Wire (1) and (2) from terminal B.
gasket: Gasket sealant (LG-1)
3. Remove 3 mounting bolts (3) to detach engine
starting motor assembly (4).
30-7
(8)
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
ASSEMBLY
SPECIAL TOOLS 8. Disconnect engine stop motor rod (7).
Distinction
9. Disconnect governor rod (8).
Necessity
Sketch
Qty
1 795-799-1131 Gear ■ 1
A
2 795-799-1390 Remover ■ 1
REMOVAL
k Disconnect the negative (–) terminal of the

battery.
2. Remove radiator fan guard (1).

10. Disconnect exhaust brake hose (9) and lubri-
3. Disconnect air compressor hose clamp (2). cation tube (10).
4. Remove bracket (3). 11. Disconnect tube (11) between the fuel filter
and the fuel injection pump.
5. Remove two hose clamps (4).
12. Disconnect fuel return hoses (12) and (13).
6. Disconnect tube (5).
★ When disconnecting hoses, fuel flows
out. Put a wooden plug in them to stop
the spillage.
7. Disconnect engine stop motor connector (6).
30-8
(8)
12
13. Disconnect M34 air compressor connector
(14).
14. Loosen adjusting bolts (15), (16) and (17) to

remove fan belt (18).
15. Remove bracket (19).
18. Turn cap (22) to remove it.

★ When removing the cap, use a filter
wrench.
16. Disconnect 6 delivery tubes (20).
19. Remove nut (23) and washer (24) from the

fuel injection pump.
★ Be careful, do not let the nut and washer
fall inside the case.
17. Set the fuel injection timing to the top of the

No. 1 cylinder according to the following pro-
cedure.
1) Using tool A1 (gear), rotate the engine.
★ Refer to the "Testing and adjusting
fuel injection timing" section in this
manual.
★ Set yellow mark "a" of the crank pul-
ley to the top.
2) Push in timing pin (21) of the fuel injec-
tion pump drive gear.
★ If timing pin (21) cannot be pushed in,
the piston of the No. 6 cylinder is at
the top. In this case, rotate the engine
further to set yellow mark "a" of the
crank pulley to the top again.
30-9
(8)
12
20. Using tool A2, separate shaft and drive gear INSTALLATION
from the fuel injection pump.
• Install in reverse order of removal.
3 Joint bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
★ Refer to the "Inspection and adjustment of

air compressor belt tension" section of
the TESTING AND ADJUSTING chapter in
this manual.
3 Sleeve nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
21. Remove 2 mounting brackets (25) at the lower
3 Nut: 178 ± 13 Nm {18.2 ± 1.3 kgm}

part of the fuel injection pump.
• Mount the fuel injection pump assembly

in the following manner.
1) Check that the timing pin is properly
adjusted to the fuel injection timing.
★ Refer to Item 10 in the preceding
REMOVAL procedure.
2) Remove plug (28). Reverse fuel injec-
tion pump timing pin (29) and reinstall
the plug.
★ Check that the cutout on the timing
pin is engaged with protrusion "a"
22. Remove 4 nuts (26) and remove fuel injection inside the pump.
pump assembly (27). ★ Refer to the "Inspection and adjust-
ment of fuel injection timing" section
in the TESTING AND ADJUSTING
chapter, in this manual.
30-10
(8)
12
3) Install the fuel injection pump assem-
bly (27) and secure it with 4 nuts (26).
3 Securing nut:
44 ± 6 Nm {4.49 ± 0.61 kgm}
4) Install washer (24) and temporarily

secure it with nut (23).
★ When installing the nut and washer,
be careful not to let them fall into the
case.
k Tighten the nut temporarily to the fol-
lowing torque. Take care not to dam-
age the timing pin.
3 Nut:
178 ± 13 Nm {18.2 ± 1.3 kgm}
5) Disengage the fuel injector pump tim-

ing pin (on the timing gear side) from
protrusion "a", and return the pin to
its original position.
• Air bleeding
Bleed air from the fuel injection system.
30-11
(8)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
REMOVAL 7. Remove 5 mounting nuts to take off seal (8)
from seal carrier (9).
1. Remove the radiator and hydraulic oil cooler
assembly, refer to the "Removal of radiator
and hydraulic oil cooler assembly" in this
manual.
2. Remove radiator fan (1).
3. Loosen tension pulley (2) to remove fan belt

(3).
4. Loosen tension pulley (4) to remove alterna-

tor belt (5).
5. Remove the 4 mounting bolts to detach

damper (6).
6. Remove the 4 mounting bolts to detach front

pulley (7).
★ Make counter marks on front pulley (7)
and front cover (since the stamping mark
of 1-6 TOP is on front pulley (7)).
30-12
(8)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
12
INSTALLATION
★ The plastic part P in the engine front seal is

provided as a pilot (guide) that is used in
installing the crankshaft. So, do not remove it.
1. Apply some amount of neutral detergent to

the outer periphery of engine front seal.
5. Push pilot P against the crankshaft and push

it together with seal carrier (9) into the crank-
shaft.
6. Remove pilot P.
7. Tighten 5 seal carrier (9) mounting bolts

using the sequence shown in the figure
below.
2. Using a clean cloth, remove adherents from 3 Seal carrier mounting bolt:
the crankshaft flange. 9.8 ± 2 Nm {1 ± 0.2 kgm}
★ Check that the engine front seal has been
mounted to the seal carrier to 0.5 – 1 mm.
3. Apply the following to the mounting hole for

the seal carrier.
2 Inside of seal carrier mounting hole: • Carry out installation in the reverse order to
Apply a 1 – 2 mm diameter Three- removal.
Bond 1207D or its equivalent.
[*1]
3 Fan mounting bolt:
4. Install engine front seal (8) to seal carrier (9).
★ Mounting dimension: 0.5 – 1 mm
59 – 74 Nm {6 – 7.5 kgm}
[*2]
★ Temporarily install the front pulley and
apply the fan belt and then tighten them
to the specified torque.
3 Front pulley mounting bolt:
200 ± 10 Nm {20.4 ± 1 kgm}
30-12-1
(8)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
12
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOLS 4. Remove the mounting bolt, set the guide bolt,
and then lift off flywheel (4) to remove it. [*2]
4
Distinction
Necessity
Flywheel assembly: 45 kg
Sketch
Qty
5. Temporarily lift off flywheel housing (5),
remove the mounting bolts, set the guide
A3 795-931-1100 Seal puller ■ 1 bolt, and then lift off the flywheel housing to
remove it. [*3]
REMOVAL 4 Flywheel housing (5): 70 kg
k Disconnect the cable from the negative (–) ter- 6. Remove rear cover (6).
7. Remove rear seal (7) from rear cover (6).
1. Remove the hydraulic pump assembly, refer ★ Take care not to damage the seal attached
to the "Hydraulic pump assembly removal" to the flywheel housing and the surface of
section in this manual. the seal in contact with the crankshaft.
2. Remove damper assembly (10).
★ If you cannot easily remove engine rear

seal (7) from the crankshaft, drill a hole in
3. Disconnect engine speed sensor connector
the right and left sides of engine rear seal,
(1) and loosen locknut (2) to disconnect
approximately 3 mm in diameter. Using
engine speed sensor (3) from flywheel hous-
seal puller A3, remove the seal through
ing (5). [*1]
the pulling impact created by slide ham-
mer (SH).
30-12-2
(8)
12
INSTALLATION
5. Using alignment tool A provided with the
1. Clean and degrease the surface of gasket
engine rear seal, push rear seal (7) into rear
between the rear cover and the cylinder block
cover (6) until the desired depth is reached.
and let dry.
6. Remove alignment tool A.
2. Clean and degrease the surface of seal lip (on
the crankshaft periphery) and let dry.
7. Push pilot P against the crankshaft and push

it together with rear cover (6) into the crank-
3. Apply some amount of neutral detergent to
shaft.
the outer periphery of engine rear seal.
★ Remember to put gasket G between the
★ The plastic part P in the engine rear seal
cylinder block and the rear cover.
is provided as a pilot (guide) that is used
in installing the crankshaft. So, do not ★ Use guide pin [2].
remove it.
8. Remove pilot P.
4. Install engine rear seal (7) to rear cover (6).
30-12-3
(8)
12
9. Reinstall alignment tool A to check that rear [*1]
seal (7) is fitted up to the desired depth. 2 Thread of engine speed sensor: LG-6
★ The difference between the cylinder block ★ Installing the engine speed sensor:
bottom and rear cover (6) bottom must be
within 0.00 ± 0.10 mm. 1) Screw the sensor until it comes into con-
tact with the gear.
2) Back off it 1 ± 1/6 turns and tighten the
locknut.
★ Clearance between engine speed sensor and
flywheel: 0.75 – 1 mm
3 Engine speed sensor locknut:
69 – 74 Nm {7 – 7.5 kgm}
[*2]
★ Tighten the mounting bolts using the
sequence shown in the figure.
3 Flywheel mounting bolt:
137 ± 7 Nm {13.97 ± 0.71 kgm}
★ Do the above procedure without remov-

ing alignment tool A.
10. Remove guide pin [2] and tighten 8 rear cover

mounting bolts using the sequence shown in
the figure below.
3 Rear cover mounting bolt:
10 ± 2 Nm {1.02 ± 0.2 kgm}
★ The projection of rear cover gasket G
above the cylinder block bottom must be
within 0.25 mm. (See mark a portion.)
★ There should not be more than 0.2 mm varia-

tion of flywheel to flywheel housing.
11. Remove alignment tool A.
• Carry out installation in the reverse order to

removal.
30-12-4
(8)
12
[*3]
2 Apply a 1 – 3 mm diameter gasket
sealant to the periphery of mounting
bolt hole at the cylinder block:
Gasket sealant (LG-6)
★ Tighten the mounting bolts using the
sequence shown in the figure.
3 Flywheel housing mounting bolt:
77 ± 12 Nm {7.85 ± 1.22 kgm}
30-12-5
(8)
12
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
1. Remove the Hydraulic Pump Assembly, refer • Install in reverse order of removal.
to the Hydraulic Pump Assembly Removal
section in this manual.
Flywheel mounting bolt:
2. Remove damper assembly (1). 137 ± 7 Nm (13.97 ± 0.71 kgm)
★ Tighten the mounting bolts in the
sequence illustrated below.
3. Remove flywheel assembly (2).
★ Install the oil seal in the following man-

ner.
1) Fit pilot b to new oil seal (3).
★ Before installing the oil seal, clean the
crankshaft sealing face and the seal
lip face. Remove all oil and dry thor-
oughly to prevent oil leakage.
4. Remove seal (3).

★ Remove the seal, inflicting no damage to
the crankshaft.
PC300/350(LC)-7 30-13
c
2) Push the oil seal into the flywheel by

inserting pilot b with oil seal (3) into the
crankshaft.
3) Pull out pilot b. Push the oil seal into the
front cover from the inside to the outside.
4) Install the oil seal on the flywheel housing
to the proper depth. Use an alignment
tool.
★ Tap the head, bottom, right and left
sides of the alignment tool to make
sure that the seal carrier is not
twisted, when it is being pushed in.
30-14 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
12
REMOVAL AND INSTALLATION OF CYLINDER HEAD
ASSEMBLY
SPECIAL TOOLS 8. Remove bracket (9) and remove air compres-
sor assembly (10).
Part
Mark Part No. Necessity Qty Distinction* Sketch ★ Remove the air compressor assembly in
Name
one piece with the bracket and put them
1 795-799-1170 Puller ■ 1
B aside near the control valve upper cover.
2 790-331-1110 Wrench ■ 1
*Distinction between new and existing part.
REMOVAL
Disconnect the cable from the negative (-)

terminal of the battery.
1. Drain engine coolant.
Engine coolant: Approx. 32 l

9. Disconnect exhaust brake hose (11) and lubri-
3. Remove bracket (1), and then detach clamp cation tube (12).
(2) and hose clamp (3). ★ When disconnecting the exhaust brake
hose, also separate the clamp mounting
4. Disconnect tube (4). plate from the head cover.
★ Remove the tube in one piece with the
bracket. 10. Disconnect after-cooler hose (13).
11. Remove protective cover (14).
5. Disconnect air compressor wiring connector

(5).
6. Remove radiator fan guard (6).
7. Loosen adjusting bolt (7) to remove belt (8).
PC300/350(LC)-7 30-15
c
12
12. Disconnect lubrication inlet hose (15) and 16. Disconnect air feeding hose (21).
lubrication outlet hose (16).
17. Separate gauge (22) from mounting plate.
18. Disconnect fuel filter tubes (23) and (24).
19. Disconnect electrical intake air heater wiring

harness (25).
21. Remove blow-by hose mounting clamp to

detach bracket (27).
★ Detach the bracket in one piece with the
fuel filter.
13. Remove protective covers (17) and (18).
14. Remove muffler connector V clamp (19).
22. Remove head cover (28).
15. Lift off turbocharger and exhaust manifold

assembly (20).
★ Note that two different length mounting

bolts are used for the exhaust manifold.
Be careful when installing them.
23. Disconnect fuel return tube (29).
24. Disconnect six delivery tubes (30).
30-16 PC300/350(LC)-7
c
27. Remove rocker arm assembly (33) to remove

oil tube (34).
25. Remove cover (31).
★ Know that the delivery tubes, fuel tube

fixing plate and the mounting bolts have
different lengths. Be careful when install- 28. Remove push rod (35).
ing them.
29. Lift off cylinder head assembly (36) after

26. Remove six nozzle holder assemblies (32). removing the 26 mounting bolts.
★ Use tool B1, when it is difficult to remove Cylinder head assembly: 65 kg

the nozzle holder assembly.
★ Take care so that no dust or foreign object
enters through the base of the nozzle
holder assembly.
PC300/350(LC)-7 30-17
c
12
30. Remove cylinder head gasket (37).
INSTALLATION Fuel tube joint bolt:

36 ± 5 Nm {3.67 ± 0.51 kgm}
Joint bolt :
24 ± 4 Nm {2.45 ± 0.41 kgm}
★ Refer to the Inspection and Adjustment of
Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter in
this manual. Head cover mounting bolt:
23.5 ± 3.9 Nm {2.4 ± 0.4 kgm}
V clamp:
6.9 - 8.8 Nm {0.7- 0.9 kgm}
Sleeve nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
★ Tighten the bolts in the sequence indi-
cated in the figure at right.
Mounting bolt:
Exhaust manifold mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
1st step: Tighten to 23.5 ± 4 Nm {2.4 ± 0.41 kgm}
in the sequence of b through 1@.
2nd step: Tighten to 23.5 ± 4 Nm {2.4 ± 0.41 kgm} ★ Coat the surface of the oil boot with oil
in the sequence of b through e. when installing the nozzle holder assem-
3rd step: Tighten to 43.1 ± 6 Nm {4.4 ± 0.61 kgm} blies.
in the sequence of b through 1@ ★ Coat a shim at the tip of the nozzle holder
4th step: Tighten to 43.1 ± 6 Nm {4.4 ± 0.61 kgm} assembly with a small amount of grease
in the sequence of b through e. so that it will firmly stay on the tip.
, ,
• Mount the rocker arm assembly and the
cylinder head assembly in the following
manner.
30-18 PC300/350(LC)-7
c
12
★ Check that there is no dust or foreign matter 4) Install oil tube (34) and rocker arm assembly
sticking to the cylinder head mounting face or (33). Tighten their mounting bolts by hand.
inside the cylinders. ★ Make sure that the ball portion of the
1) Set cylinder head gasket (37) on the cylinder adjusting screw is properly seated in the
block. push rod socket.
★ Check that the gasket is correctly aligned
with the corresponding cylinder holes.
5) Tighten cylinder head mounting bolts in the

sequence shown in the figure below.
★ Coat the threads and seat surface of the
2) Lift the cylinder head assembly (36) and place mounting bolts with engine oil (15W-40).
it on the cylinder block.
Cylinder head mounting bolts:
1st step: Tighten to 70 ± 5 Nm {7.1 ± 0.51 kgm}

in the sequence of b through 2^.
★ Check that each bolt is tightened to
the torque specified above, following
the same sequence.
2nd step: Tighten to 145 ± 10 Nm {14.8 ± 1.0 kgm}
in the sequence of b, c, h, i, j,
1), 1%, 1^, 1&, 1*, 2#, 2$, 2%, and 2^.
★ Check that each bolt is tightened to
the torque specified above, following
3) Install push rods (35).
the same sequence.
PC300/350(LC)-7 30-19
c
12
3rd step:
i) When using tool B2.
For tightening, turn the bolts with an
angle tightening wrench by 90 ± 5° in
the sequence of b to 2^.
6) Tighten the rocker arm mounting bolts.

Rocker arm assembly mounting bolt:
65 ± 5 Nm {6.6 ± 0.5 kgm}
ii) When not using tool B2.

Tighten the bolts by turning them to
90 ± 5°. Put a punch mark on the bolt
head after tightening the bolt to show
the frequency of tightening.
• Do not use a bolt with 5 punch marks.
Replace it with a new one.
7) Adjust the valve clearance.

★ Refer to the Adjustment of Valve Clear-
ance section in the TESTING AND
ADJUSTING chapter in this manual.
• Refilling engine coolant

Fill engine coolant through the water filler
port up to the specified level. Start the engine
★ Install the rocker arm assembly and to allow the coolant to circulate and release
tighten the bolts by hand. any air pockets. Check the water level again.
• Check that the adjusting screw ball is
well seated in the push rod socket.
30-20 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL 8. Remove fan cover (7).
★ First remove the clamp for mounting the
1. Drain the engine coolant. after-cooler hose which is tightened
together and then remove the fan cover.
2. Lift off engine hood (1) temporarily.

★ Be careful not to damage the rubber seal
when lifting the engine hood.
★ Support the engine hood with an appro-
priate sling and lifting device.
9. Disconnect radiator hose (8).
3. Remove engine hood mounting bolt to

remove pin (2).
4. Lift off engine hood (1).
10. Lift off radiator assembly, using two slings b.
5. Disconnect reservoir tank hose (3).

★ Disconnect the hose on the radiator side.
6. Disconnect radiator hose (4).
7. Remove fan guards (5) and (6).
PC300/350(LC)-7 30-21
c
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
12
11. Lift off radiator assembly (9) after removing

mounting bolts.
Radiator assembly: 45 kg
INSTALLATION

• Refilling engine coolant
Refill engine coolant through the water filler
port up to the specified level. Start the engine
to allow the coolant to circulate and release
any air pockets. Check the water level again.
30-22 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC OIL
COOLER ASSEMBLY
REMOVAL
4. Remove engine hood mounting bolt and

remove pin (4).
2. Remove plug (2) from the hydraulic oil drain 5. Lift off engine hood (3).
hose to drain the hydraulic oil.
★ Unscrew the cap on the hydraulic tank
before draining oil to release the remain-
ing pressure inside the tank. Then drain
oil through the cooler hose.
3. Lift off engine hood (3) temporarily.

when lifting off the engine hood.
★ Support the engine hood with an appro-
PC300/350(LC)-7 30-23
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY
12
7. Remove hydraulic oil cooler drain hose (6).

INSTALLATION

• Refilling hydraulic oil (hydraulic tank)
Refill hydraulic oil through oil filler port up to
the specified level and circulate oil in the
hydraulic system by starting the engine. Then
check the oil level again.
8. Remove hydraulic oil cooler mounting bolts

(7) and (8).
9. Lift off hydraulic oil cooler assembly (9),

using two slings b.
30-24 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES
12
REMOVAL AND INSTALLATION OF ENGINE AND
HYDRAULIC PUMP ASSEMBLIES
SPECIAL TOOLS ★ Support the engine hood with an appro-
Part
Mark Part No. Necessity Qty Distinction* Sketch
Name
Oil
796-460-1210
Stopper
● 1
C
796-770-1320 Adapter ● 1
REMOVAL
Lower the work equipment to the ground
for safety and stop the engine. Disconnect
the cable from the negative (-) terminal of
the battery.
To release the internal pressure, gradually
loosen the oil filler cap on the hydraulic 4. Remove engine hood mounting bolts and
tank. then remove pin (2).
★ Attach an identification tag to each pipe. This 5. Lift off engine hood (1).
will avoid a possible mistake when reinstall-
ing.
1. Remove the hydraulic tank strainer and stop

the flow of oil, using Tool C.
★ When not using tool C, remove the drain
plug to drain oil from the hydraulic tank
and piping.
Hydraulic tank: Approx. 365 l
6. Disconnect air feeding hose (3).
7. Remove bracket (4) and disconnect clamp (5)

and hose clamp (6).

★ Remove the tube in one piece with the
bracket.
2. Drain engine coolant.
3. Lift up engine hood (1).

when lifting off the engine hood.
PC300/350(LC)-7 30-25
c
12
9. Disconnect air compressor wiring connector 14. Remove cover (17).

(8).
10. Remove fan guard (9).
11. Loosen adjusting bolt (10) to remove fan belt

(11).
12. Remove bracket (12) with compressor assem-

bly (13).
★ Remove the compressor assembly in one
piece with the bracket and put them aside
near the control valve upper cover.
15. Remove covers (18), (19) and (20).
16. Disconnect hydraulic pump wiring connectors

at two places.
• (21): V22 (PC-EPC solenoid valve)
Color band: Red
• (22): V21 (LS-EPC solenoid valve)
Color band: White
30-26 PC300/350(LC)-7
c
12
17. Disconnect eight hoses (23) through (30) and 19. Disconnect compressor hose clamp (35).
tube (31).
• (23): Drain port hose 20. Disconnect fuel inlet hose (36), Fuel return
• (24): Front load pressure input port hose hoses (37) and (38).
• (25): Rear load pressure input port hose
(Color band: Red)
• (26): EPC source pressure port hose
(Color band: Yellow)
• (27): Rear pressure input port hose
(Color band: Yellow)
• (28): Front pressure input port hose
• (29): Rear pump discharging port hose
• (30): Front pump discharging port hose
• (31): Pump suction port tube
21. Disconnect radiator hose (39) and remove fan

guard (40).
18. Disconnect wiring connectors (32), (33) and

(34).
• (32): E08 (Intermediate connector)
• (33): E11 (Governor motor)
• (34): E10 (Potentiometer) 22. Disconnect after-cooler hose (41) and radiator
hose (42).
PC300/350(LC)-7 30-27
c
12
23. Disconnect engine starting motor wiring (43)

and heater hose (44). Engine and Hydraulic Pump Assembly:
1,200 kg
24. Disconnect two engine filter hoses (45).
INSTALLATION
★ Refer to the Inspection and Adjustment of

Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter of
this manual.
Engine mounting bolt:

(Front) 384.9 ± 41.7 Nm {39.25 ± 4.25 kgm)
25. Disconnect engine grounding wiring (46). (Rear) 926.7 ± 103.0 Nm {94.5 ± 10.5 kgm}
26. Remove four front and rear engine mounting • Refilling engine coolant
bolts (47). Refilling engine coolant
Refill engine coolant through the water filler
port up to the specified level.

Refill hydraulic oil through oil filler port up to
the specified level.
★ Let the water circulate to release any air pock-

ets by starting the engine. Check the water
27. Lift off engine and hydraulic pump assembly level again.
(48). ★ Circulate oil in the hydraulic system by start-
★ Lift off the assembly only after making ing the engine. Then check the oil level again.
sure that there is no wiring or piping • Air bleeding
which is left still connected. Refer to the Air Bleeding of Various Part sec-
tion in the INSPECTION AND MAINTENANCE
chapter of this manual.
30-28 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
REMOVAL 4. Remove the 21 mounting bolts from final
drive assembly (6) and lift it off to remove.
1. Remove the sprocket, refer to the "Removal of
sprocket" section in this manual.
k Lower the work equipment to the ground for
★ Be careful. Do not damage the face of the
fitting seal at the base of the hose.
safety. Stop the engine and loosen the oil
★ When lifting off the final drive assembly,
filler cap on the hydraulic tank to release pres-
do not use a tapped hole for lifting the
sure inside.
cover.
2. Remove cover (1). 4 Final drive assembly: 500 kg
3. Disconnect drain hose (2), travel speed shift- INSTALLATION

ing hose (3) and travel motor hoses (4) and
(5). • Install in reverse order of removal.
3 Final drive assembly mounting bolt:

490 – 608 Nm {50 – 62 kgm}
• Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to
the specified level, and let the oil circulate in
the hydraulic system by starting the engine.
Then check the oil level again.
• Air bleeding
Refer to the "Air bleeding of various part" sec-
tion in the TESTING AND ADJUSTING chapter
of this manual.
30-29
(8)
12
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE
ASSEMBLY
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
Wrench
796-627-1610 assembly ■ 1 N
1 796-627-1620 • Wrench 1 N
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-627-1630 Push tool ■ 1 N Q
790-101-2510 Block ■ 1
D 791-830-1320 Rod ■ 2 3. Spacer
01580-11613 Nut ■ 2 Remove spacer (2).
2
790-101-2570 Washer ■ 2
01643-31645 Washer ■ 2
790-105-2100 Jack ass’y ■ 1
790-101-1102 Pump ■ 1
3 791-580-1510 Installer ■ 1
4 790-331-1110 Wrench ■ 1
DISASSEMBLY
1. Draining Oil
Remove drain plug and drain oil from final
drive case.
6 Final drive case: Approx. 8.5 l 4. No. 1 carrier assembly
2. Cover 1) Remove No. 1 carrier assembly (3).
1) Remove mounting bolts, then use forcing

screws [1] to disconnect cover (1).
2) Disassemble No. 1 carrier assembly as

follows.
i) Push in pin (4) and pull out shaft (5)
2) Use eyebolts [2] to remove cover (1). from carrier (6).
★ After removing the shaft (5),
remove pin (4).
30-30
(8)
ii) Remove thrust washer (7), gear (8), 8. Ring gear

bearing (9), and thrust washer (10). Using eyebolts d, remove ring gear (14).
5. No. 1 sun gear shaft 9. No. 2 carrier assembly

Remove No. 1 sun gear shaft (11).
1) Remove No. 2 carrier assembly (15)
6. No. 2 sun gear
Remove No. 2 sun gear (12).
2) Disassemble No. 2 carrier assembly as

follows.
i) Push in pin (16) and pull out shaft (17)
7. Thrust washer from carrier (18).
Remove thrust washer (13). ★ After removing the shaft, remove
pin (16).
ii) Remove thrust washer (19), gear (20),
bearing (21), and thrust washer (22).
PC300/350(LC)-7 30-31
c
10. Nut 2) Disassemble hub assembly as follows.

1) Remove lock plate (23). i) Remove floating seal (26).
2) Use tool D1 and remove nut (24). ii) Remove bearings (27) and (28) from
hub (29).
3) Remove floating seal (30) from travel

11. Hub assembly motor (31).
1) Using eyebolts e, remove hub assembly
(25) from travel motor.
30-32 PC300/350(LC)-7
c
12
ASSEMBLY 3) Using tool D3, install floating seal (30)

onto travel motor (31).
★ Clean all parts and check for dirt or damage.
★ The procedure for installation is the
Coat the sliding surfaces of all parts with
same as in the previous Step 2).
engine oil before installing.
1. Hub assembly
1) Assemble hub assembly as follows.
Using push tool, press fit bearings (27)
and (28) to hub (29).
4) Using eyebolts e, set hub assembly (25)

onto the travel motor. Use the push tool
and tap to press fit the bearing.
2) Using tool D3, install floating seal (26).

★ Remove all oil and grease from the O-
ring and O-ring contact surface. Dry
the parts before installing the floating
seal.
★ After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
★ After installing the floating seal, coat
the sliding surface thinly with engine 2. Nut
oil.
1) Install nut as follows.
i) Using tool D2, push bearing inner
race (27).
★ Pushing force:
12.7 - 16.7 kN {1.3 - 1.7 tons}
★ Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race.
PC300/350(LC)-7 30-33
c
ii) Measure dimension a in the condition vii) Install lock plate (23).
in Step 1) above.
★ Install the lock plate as shown in the dia-

iii) Measure thickness b of the nut (24) as gram below.
an individual part. Thread of mounting bolt:
iv) Calculate a - b = c. Thread tightener (LT-2)
v) Tighten nut (24) with tool D1 until
dimension c is obtained. ★ Do no coat the threaded portion of the
nut with thread tightener (LT-2).
Mounting bolt: 49 - 74 Nm
{6 - 7.5 kgm}
vi) Using push-pull scale f, measure tan-

gential force in the direction of rota-
tion of the hub in relation to the motor
case.
★ Tangential force: Max. 490 N
{50 kg}
★ The tangential force is the maxi-
mum force when starting rotation.
30-34 PC300/350(LC)-7
c
12
3. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as fol-
lows.
★ Replace thrust washers (19), (22) and
pin (16) with new ones.
★ There are remains of caulking when
the pin is inserted at the end face of
hole e at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
i) Assemble bearing (21) to gear (20), fit
top and bottom thrust washers (19)
and (22), and set gear assembly in
carrier (18). ★ After inserting the pin, caulk the pin
portion of the carrier.
★ After assembling the carrier assembly,
check that gear (20) rotates smoothly.
ii) Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (17). 2) Install No. 2 carrier assembly (15).
★ When installing the shaft, rotate ★ Align the three tips of the gear shafts
the planetary gear. Be careful not of the carrier assembly (15) to enter
to damage the thrust washer. the three hollows in the end face of
iii) Insert pin (16). the motor case, then install.
★ Insert the pin in such a way that any
of the three claws (f portions) on the
periphery will not fall on the slender
(g) portion of the carrier. Take note,
however, that depending on the
actual carriers, this slender portion is
on the opposite side. Hence when
inserting the pin, check them carefully
to see on which side of the carrier a
thin portion is, and insert the pin the
way its claw does not come to the thin
portion. If there is a groove, mean-
while, avoid it.
PC300/350(LC)-7 30-35
c
12
4. Ring gear 7. No. 1 carrier assembly

Install O-ring on hub end. Use eyebolts d to 1) Assemble No. 1 carrier assembly as fol-
install ring gear (14). lows.
★ Remove all grease and oil from the mat- ★ Replace thrust washers (7) and (10),
ing surface of the ring gear and hub. and pin (4) with new ones.
★ Do not put any gasket sealant on the mat- ★ There are remains of caulking when
ing surface of the ring gear and hub under the pin is inserted at the end face of
any circumstances. hole h at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
i) Assemble bearing (9) to gear (8), fit
top and bottom thrust washers (7) and
(10), and set gear assembly in carrier
(6).
5. Thrust washer
Install thrust washer (13).
6. No. 2 sun gear

Install No. 2 sun gear (12).
ii) Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (5).
★ When installing the shaft, rotate
the planetary gear. Be careful not
to damage the thrust washer.
30-36 PC300/350(LC)-7
c
12
iii) Insert pin (4). 2) Install No. 1 carrier assembly (3).

★ Insert the pin in such a way that any
of the three claws (f portions) on the
periphery will not fall on the slender
(g) portion of the carrier. Take note,
however, that depending on the
actual carriers, this slender portion is
on the opposite side. Hence when
inserting the pin, check them carefully
to see on which side of the carrier a
thin portion is, and insert the pin the
way its claw does not come to the thin
portion. If there is a groove, mean-
while, avoid it.
8. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).
★ After inserting the pin, caulk the pin

portion of the carrier.
★ After assembling the carrier assembly,
check that gear (8) rotates smoothly.
9. Spacer
Install spacer (2).
★ Take measurement of dimension "i" after
installing the spacer. If "i" dimension
exceeds 15 mm, the spacer is not installed
correctly. In that case, check it again and if
necessary, try to install it correctly once
more.
PC300/350(LC)-7 30-37
c
11. Refilling with oil

★ Tighten drain plug and add engine oil
through oil filler.
5 Final drive case: Approx. 8.5 l
★ Do a final check of the oil level at the
determined position after installing the
final drive assembly to the chassis.
10. Cover
Using eyebolts [2], lift and install cover (1),
then tighten mounting bolts with angle tight-
ening wrench D4.
2 Mounting surface of cover:
3 Mounting bolt:
Initial torque: 98.1 Nm {10 kgm}
Additional tightening angle:
Turn 100 – 110°
30-38
(8)
DISASSEMBLY AND ASSEMBLY SWING MOTOR, SWING MACHINERY ASSEMBLY
12
REMOVAL AND INSTALLATION OF SWING MOTOR, SWING
MACHINERY ASSEMBLY
REMOVAL 4. Lift and remove swing motor and swing
k Release the residual pressure in the hydraulic
machinery assembly (7).
★ When lifting the swing motor and swing
circuit. Refer to the "Releasing of residual
machinery assembly for removal, do
pressure in hydraulic circuit" section in the
slowly so that the hoses and other parts
TESTING AND ADJUSTING chapter of this
will not be damaged.
manual.
k Lower the work equipment to the ground for
★ Take good care, when lifting the
assembly, until the spigot joint por-
safety. After stopping the engine, loosen the tion is pulled out.
4
oil filler cap on the fuel tank to release the
residual pressure inside the tank and move Swing motor and swing machin-
the safety lock lever to the LOCK position. ery assembly: 450 kg
1. Disconnect 5 swing motor hoses (1) through
(5).
• (1): Between swing motor and control
valve (MA port)
• (2): Between swing motor and control
valve (MB port)
• (3): Suction hose (S port)
• (4): Drain hose (T port)
• (5): Swing brake releasing pilot hose (B
port)
2. Disconnect arm cylinder hose (6).
INSTALLATION
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

the specified level. Let the oil circulate in the
3. Detach the swing motor and swing machin- hydraulic system by starting the engine. Then
ery assembly, using forcing screw [1] after check the oil level again.
removing the mounting bolts.
• Air bleeding
Refer to the "Air bleeding of various parts"
section in the TESTING AND ADJUSTING
chapter of this manual.
30-40
(8)
12
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING
MACHINERY ASSEMBLY
PC300, 300LC-7 Serial No. 40001 – 40573
PC350, 350LC-7 Serial No. 20001 – 20337
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
1 796T-626-1110 Push tool ● 1 Q

E
2 796T-626-1140 Push tool ■ 1 Q
DISASSEMBLY
1. Draining oil
Loosen the drain plug and drain oil from the 1) Disassemble No. 1 carrier assembly (3).
swing machinery case.
6 Swing machinery case:
Approx. 13.4 l
2. Swing motor assembly

1) Place swing motor and swing machinery
assembly on block [1].
2) Remove the 6 mounting bolts to discon-
nect swing motor assembly (1).
4 Swing motor assembly: 70 kg
2) Disassemble the No. 1 carrier assembly in

i) Remove snap ring (4) first and then
remove thrust washer (8), planetary
gear (6), bearing (7), thrust washer (8)
and plate (9).
ii) Using the press, remove shaft (5).
★ Press fitting force for assembly
(Reference value)
29.2 – 54 kN {2,980 – 5,510 kg}
3. No. 1 Sun gear

1) Remove No. 1 sun gear (2).
30-41
(9)
5. Ring gear 7. Bolt

Remove the mounting bolts and remove ring Remove the holder mounting bolt (12).
gear (10).
1) Remove No. 2 carrier assembly (13).
6. No. 2 sun gear

2) Disassemble the No. 2 carrier assembly
by hand in the following manner.
i) Push in pin (14) and knock out shaft
(15) from carrier (16).
★ After removing the shaft, remove pin
(14) .
ii) Remove thrust washer (17), planetary
gear (18), bearing (19) and thrust
washer (20).
iii) Remove plate (21).
30-42
(9)
12
9. Shaft assembly ASSEMBLY

1) Place the shaft case assembly on a press, ★ Clean all related parts and check that there is
and push shaft assembly (22) out of shaft no dirt or damage on the surface. Coat sliding
case assembly (23), using push tool [2]. surfaces with engine oil and then assemble
the parts.
★ Do not reuse the removed bearing and oil
seal (since their durability cannot be assured).
1. Shaft and case assembly

1) Set plate (25) to shaft (26).
2) Set bearing (24) to shaft (26). Using push
tool [5], press fit the inner race of the
bearing.
★ Use a new bearing.
★ Install the bearing with the sealed side
down (on the gear side).
2) Disassemble the shaft assembly in the fol- ★ Press fitting force (Reference value):
lowing manner. 35.3 – 102 kN {3,600 – 10,400 kg}
Remove bearing (24) and plate (25) from
shaft (26), using push tool [3].
3) Fill the hatched area (Part "a") with grease

(G2-LI).
2 Injected grease amount:
10. Bearing
Remove bearing (27) and oil seal (28) from
case (29), using a push tool. Approx. 200 – 340 g
30-43
(8)
4) Set shaft assembly (22) on case assembly 3. Bearing

(23) and press fit it with push tools [6] and 1) Using tool E1, press fit bearing (27).
[7].
★ Press the bearing inner race and outer
★ Press fitting force: race simultaneously. Do not press
0 – 28.4 kN {0 – 2,900 kg} only the inner race.
★ After press fitting the bearing, check
that the case rotates smoothly.
★ Press fitting force (Reference value):
Inner race side:
16.7 – 47.1 kN {1,700 – 4,800 kg}
Outer race side:
0 – 16.7 kN {0 – 1,700 kg}
5) Reverse the shaft and case assembly.
2. Oil seal
1) Set case assembly (23) on block [8] hori-
zontally.
2) Set block [9] under the shaft so that the
shaft will not lean.
3) Using tool E2 and push tool [10], press fit
oil seal (28). 1) Assemble the No. 2 carrier assembly
according to the following procedure.
★ Use new oil seal (28).
2 Outside of oil seal:
★ There is caulking mark h made when
the pin was inserted around the side
Gasket sealant (LG-6) hole of carrier (16) (See v)) and the
★ When press fitting the oil seal, take inside wall of the hole is swelled at
care that gasket sealant (LG-6) will not that mark. Flatten the swelled part in
stick to the oil seal lip.
2 Oil seal lip: Grease (G2-LI)
advance.
i) Install plate (21) to carrier (16).
★ Check the press fitting finish point in
ii) Install bearing (19) to planetary gear
advance and make a mark on it (since
(18) and fit top and bottom thrust
you cannot see if the oil seal has been
washers (17) and (20), and then set
inserted to the end).
the gear assembly to carrier (16).
★ Outside diameter of push tool E2:
174 – 174.5 mm
30-44
(9)
iii) Aligning the pin holes of shaft (15) 5. Bolt

and carrier (16), lightly hit the shaft
1) Tighten bolt (12).
2 Threads of mounting bolt:
with a plastic hammer to install.
★ When installing the shaft, revolve the
Adhesive (LT-2)
3 Mounting bolt:
planetary gear and take care not to
damage the thrust washers.
iv) Insert pin (14). 343 – 427 Nm {34 – 43.5 kgm}
★ When inserting the pin, do not set the 2) Install the O-ring to the case.
3 claws (parts "a") on the periphery to
the thin part of the carrier (part "b").
The thin part may be on the opposite
side, however. Check the thin part
and avoid setting the claws to it.
v) After inserting the pin, caulk 2 parts
"h" around the pin hole of the carrier.
★ Check that all the gears turn smoothly.
6. No. 2 sun gear

2) Install No. 2 carrier assembly (13).
30-45
(8)
7. Ring gear 8. No. 1 carrier assembly

Using eyebolts (M10 x 1.5), install ring gear 1) Assemble the No. 1 carrier assembly
(10). according to the following procedure.
★ Degrease the mating surfaces of ring gear
i) Press fit shaft (5) to the carrier in the
(10) and case (29).
direction of the arrow until the snap
★ Do not stick gasket sealant to the mating
ring groove is seen.
surfaces of ring gear (10) and case (29).
★ Press fitting force (Reference
★ When installing the ring gear, match
value):
counter mark (part "d") to the projection
29.2 – 54 kN {2,980 – 5,510 kg}
(part "c") of the case flange.
★ Install the washer. ii) Install snap ring (4), and then push it
3 Mounting bolt:
back until it is fitted to face "P" of the
carrier. Take care not to push it back
245 – 309 Nm {25 – 31.5 kgm}
too much.
iii) Install plate (9).

iv) Install thrust washer (8), bearing (7),
planetary gear (6), and thrust washer
(8).
v) Install snap ring (4) to shaft (5).
30-46
(9)
2) Install No. 1 carrier assembly (3). 10. Swing motor assembly

Fit the O-ring to ring gear (10) and install
swing motor assembly (1).
★ Degrease the mating surfaces of swing
motor assembly (1) and ring gear (10).
surfaces of swing motor assembly (1) and
ring gear (10).
★ Set motor port (part "f") and projection
(part "c") of the case as shown in the fig-
ure.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
9. No. 1 sun gear
★ Take care not to install the No. 1 sun gear
upside down.
★ Install the No. 1 sun gear with the tooth
side (part "e") down.
★ "P": Press fitting plate
• Refilling with oil

Tighten the drain plug and add engine oil
through the oil filler to the specified level.
Approx. 13.4 l
30-47
(9)
12
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING
MACHINERY ASSEMBLY
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
1 796T-626-1110 Push tool ● 1 Q

E
2 796T-626-1140 Push tool ■ 1 Q
DISASSEMBLY
1. Draining oil
Loosen the drain plug and drain oil from the 1) Disassemble No. 1 carrier assembly (3).
swing machinery case.
Approx. 13.4 l

1) Place swing motor and swing machinery
assembly on block [1].
2) Remove the 6 mounting bolts to discon-
nect swing motor assembly (1).
2) Disassemble the No. 1 carrier assembly in

i) Remove snap rings (4) first and then
remove thrust washer (8), planetary
gear (6), bearing (7), thrust washer (8)
and plate (9).
ii) Using the press, remove shaft (5).
★ Press fitting force for assembly
(Reference value)
29.2 – 54 kN {2,980 – 5,510 kg}
3. No. 1 Sun gear

1) Remove No. 1 sun gear (2).
30-48
(9)
5. Ring gear 2) Disassemble the No. 2 carrier assembly

Remove the mounting bolts and remove ring by hand in the following manner.
gear (10). i) Push in pin (14) and knock out shaft
(15) from carrier (16).
★ After removing the shaft, remove pin
(14) .
ii) Remove thrust washer (17), planetary
gear (18), bearing (19) and thrust
washer (20).
iii) Remove plate (21).
6. No. 2 sun gear

9. Shaft assembly
1) Remove mounting bolts (23).
2) Set shaft and case assembly to press,
then using push tool [2], remove shaft
assembly (24) from case assembly (25).
7. Bolt
Remove the holder mounting bolt (12).

1) Remove No. 2 carrier assembly (13).
30-48-1
(9)
3) Disassemble shaft assembly as follows. ASSEMBLY

i) Using push tool [3], remove cover a Clean all parts and check for dirt or damage.
assembly (26) and bearing (27) from Coat the sliding surfaces of all parts with
shaft (28). engine oil before installing.
ii) Remove oil seal (29) from cover (30). a Do not reuse the removed bearing and oil
seal since their durability cannot be assured.
Prepare new ones.
1. Bearing
Using push tool E3, [4], press fit bearing (27)
to case (32).
a Use new bearing (27).
a Press fitting force (Reference value):
0 – 26.4 kN {0 – 2,690 kg}
10. Bearing
Using push tool, remove bearing (31) from
case (32).
2. Cover assembly
1) Using push tool E4, press fit oil seal (29)
to cover (30).
a Use new oil seal (29).
a When not using push tool E4, use another
push tool to push the outside frame of the
oil seal evenly.
a Take care that oil seal (29) will not lean.
2 Outside circumference of oil seal:
a Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press
fitting.
30-48-2
(8)
12
2) Fit cover assembly (26) to case (32), and
tighten mounting bolts (23).
a Match the oil passage of cover assem-
bly (26) to drilled hole A of case (32).
2 Cover mounting surface :
a Take care that LG-6 will not stick to
drilled hole A.
3 Mounting bolt :
98 – 123 Nm {10 – 12.5 kgm}
2 Lip of oil seal : Grease (G2-LI)
3) Using push tool E1, [6], press fit bearing

(31).
★ Use a new bearing.
★ Press the bearing inner race and outer
race simultaneously. Do not press
only the inner race.
★ After press fitting the bearing, check
that the case rotates smoothly.
★ Press fitting force (Reference value):
Inner race side:
15.3 – 43.2 kN {1,560 – 4,410 kg}
Outer race side:
3. Case assembly 0 – 16.2 kN {0 – 1,650 kg}
1) Reverse case assembly (25) and set it to
shaft (28).
a Take extreme care not to damage the
oil seal.
2) Using push tool E5, [5], [7], press fit the
bearing inner race.
a Using push tool E5, [5], hit shaft
lightly with a plastic hammer so that it
will not come off, and then press fit it
with the press.
a Press fitting force (Reference value):
39 – 110 kN {3,980 – 11,260 kg}
a Set push tool [7] so that case assem-
bly (25) will not slant largely.
★ Hit the flange of case assembly (25)
frequently and lightly to correct the
lean of case assembly (25). In particu-
lar, adjust the flange so that oil seal
mating face B of the shaft will be at
the center of oil seal (29).
30-48-3
(9)
4. No. 2 carrier assembly v) After inserting the pin, caulk 2 parts

1) Assemble the No. 2 carrier assembly "h" around the pin hole of the carrier.
according to the following procedure. ★ Check that all the gears turn smoothly.
★ There is caulking mark "h" made
when the pin was inserted around the
side hole of carrier (16) (See v)) and
the inside wall of the hole is swelled
at that mark. Flatten the swelled part
in advance.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to planetary gear
(18) and fit top and bottom thrust
washers (17) and (20), and then set
the gear assembly to carrier (16).
iii) Aligning the pin holes of shaft (15)

and carrier (16), lightly hit the shaft 2) Install No. 2 carrier assembly (13).
with a plastic hammer to install.
★ When installing the shaft, revolve the 5. Bolt
planetary gear and take care not to 1) Tighten bolt (12).
2 Threads of mounting bolt:
damage the thrust washers.
iv) Insert pin (14). Adhesive (LT-2)
3 Mounting bolt :
★ When inserting the pin, do not set the
3 claws (parts "a") on the periphery to
343 – 427 Nm {34 – 43.5 kgm}
the thin part of the carrier (part "b").
★ The thin part may be on the opposite 2) Install the O-ring to the case assembly.
side, however. Check the thin part
and avoid setting the claws to it.
30-48-4
(9)
6. No. 2 sun gear


1) Assemble the No. 1 carrier assembly
7. Ring gear according to the following procedure.
Using eyebolts (M10 x 1.5), install ring gear
(10). i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap
★ Degrease the mating surfaces of ring gear
ring groove is seen.
(10) and case (32).
★ Press fitting force (Reference
value):
surfaces of ring gear (10) and case (32).
29.2 – 54 kN {2,980 – 5,510 kg}
★ When installing the ring gear, match
counter mark (part "d") to the projection ii) Install snap ring (4), and then push it
(part "c") of the case flange. back until it is fitted to face "P" of the
★ Install the washer. carrier. Take care not to push it back
3 Mounting bolt : too much.
245 – 309 Nm {25 – 31.5 kgm}
30-48-5
(9)
iii) Install plate (9). ★ "P": Press fitting plate

iv) Install thrust washer (8), bearing (7),
planetary gear (6), and thrust washer
(8).
v) Install snap ring (4) to shaft (5).

Fit the O-ring to ring gear (10) and install
swing motor assembly (1).
★ Degrease the mating surfaces of swing
motor assembly (1) and ring gear (10).
2) Install No. 1 carrier assembly (3). ★ Do not stick gasket sealant to the mating
surfaces of swing motor assembly (1) and
ring gear (10).
★ Set motor port (part "f") and projection
(part "c") of the case as shown in the fig-
ure.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
9. No. 1 sun gear

★ Take care not to install the No. 1 sun gear
upside down.
★ Install the No. 1 sun gear with the tooth
side (part "e") down.
30-48-6
(9)
• Refilling with oil

Tighten the drain plug and add engine oil
through the oil filler to the specified level.
Approx. 13.4 l
30-48-7
(8)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER
ASSEMBLY
★ This section deals only with precautions to be • Carrier roller
followed when reassembling the carrier roller ★ Check the amount of air leakage from the
assembly. seal with tool F by applying the standard
SPECIAL TOOLS pressure to the oil filler port.
★ Check that the gauge needle does not go
down, when the below standard pressure
Distinction
Necessity
Sketch
is applied for 10 seconds.
Qty
Standard pressure: 0.1 MPa {1 kg/cm²}
791-601-1000 Installer ■ 1
F
791-430-3230 Oil pump ■ 1
ASSEMBLY
• Floating seal
★ Before installing a floating seal, com-
pletely degrease both contact surfaces of
the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take
care so that no dust or dirt sticks to the
contact surface of the floating seal.
★ Be sure to use the installer to insert the
floating seal. ★ Fill the carrier roller assembly with oil,
using tool F, and screw in the plug.
5
★ After inserting the floating seal, check that
the inclination of the seal is less than 1 Carrier roller:
mm and that protrusion "a" of the seal 145 – 155 cc (EO30-CD)
remains within the range of 5 – 7 mm.
30-49
(8)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER
ASSEMBLY
★ This chapter deals only with precautions to be • Track roller cover mounting bolt.
followed when reassembling the Track Roller 3 Track roller cover mounting bolt:
Assembly. 44.12 – 53.93 Nm {4.5 – 5.5 kgm}
SPECIAL TOOLS • Track roller
★ Using tool G, apply the specified air pres-
Distinction*
sure to the oil filler port to check air leak-
Necessity
Sketch
age from the seal.
Qty
★ Keep applying the following specified air
pressure for 10 seconds to check that the
796-670-1010 Installer ■ 1 gauge needle does not go down.
G Specified air pressure:
791-601-1000 Oil Pump ■ 1
0.1 MPa {1 kg/cm²}
ASSEMBLY
• Floating seal
★ Before installing a floating seal, com-
pletely degrease both contact surfaces of
area in the illustration). Furthermore, take
care so that no dust or dirt sticks to the
inclination of the seal is less than 1 mm
and that protrusion "a" of the seal
remains within the range of 7 – 11 mm.
★ Fill the track roller assembly with hydrau-
lic oil. Use tool G and screw in the plug.
5 Track roller:
250 – 280 cc (EO30-CD)
3 Plug: 10 – 20 Nm {1 – 2 kgm}
30-50
(8)
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
SPECIAL TOOLS 3. Detach idler (4) from shaft (5) and support
assembly (7).
Mark Part No.
Part
Necessity Qty Distinction* Sketch ★ The idler contains 230 ± 10 cc of oil. Drain
Name
the oil at this stage of disassembly. Take
796-570-1020 Installer ■ 1 care and spread a cloth on the floor to
H
791-601-1000 Oil pump ■ 1 prevent smearing the floor with flushing
*Distinction between new and existing part. oil.
DISASSEMBLY 4. Remove floating seal (6) on the opposite side

of idler (4), shaft (5) and support assembly (7).
5. Remove dowel pin (8) to detach support (7)

from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
1. Remove dowel pin (1) and then support (2).
2. Remove floating seal (3) from support (2) and

idler (4).
PC300/350(LC)-7 30-51
c
12
ASSEMBLY
★ Before installing the floating seal, com-
1. Press fit bushing (9) and (10) to idler (4). pletely degrease both contact surfaces of
2. Fit O-ring and install support (7) to shaft (5) area in the illustration). Furthermore, take
with dowel pin (8). care so that no dust or dirt sticks to the
inclination of the seal is less than 1 mm
and that protrusion a of the seal remains
within the range of 5 - 7 mm.
★ Install the shaft with UP mark facing

upward.
3. Using tool H, install floating seal (6) to idler

(4), shaft (5) and support (7) assembly.
4. Assemble shaft (5) and support (7) assembly

to idler (4).
30-52 PC300/350(LC)-7
c
12
5. Using tool H, install floating seal (3) to idler 6. Install O-ring, then install support (2) with
(4) and support (2). dowel pin (1).
★ After inserting the pin, caulk the support
pin.
7. Add oil and tighten plug.
Oil: Approx. 230 ± 10 cc (EO 30-CD)
Plug: 130 - 180 Nm {13 - 18 kgm}
★ Coat the sliding surface of the floating seal

with oil, and be careful not to let any dirt or
dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
PC300/350(LC)-7 30-53
c
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
ASSEMBLY
SPECIAL TOOLS 1. Remove piston assembly (2) from recoil
spring assembly (1).
Mark Part No. Part Name Necessity Qty Distinction* Sketch
791-685-8006 Compressor ■ 1 2. Disassembly of recoil spring assembly
791-635-3160 Extension ■ 1
1
1) Set tool J1 to recoil spring assembly (1).
Cylinder
790-101-1600 ■ 1
686 kN {70 T} The recoil spring is under large
J 790-101-1102 Pump ■ 1 installed load, so be very sure to set
790-201-1500 Push tool kit ■ 1 the tool properly.
• 790-201-1620 • Plate 1 Failure to do this is dangerous.
2
• 790-101-5021 • Grip 1
★ Installed load of spring: 208.6 kN
• 01010-50816 • Bolt 1
{21,280 kg}
DISASSEMBLY
2) Apply hydraulic pressure slowly to com-

press the spring. Remove lock plate (3).
Then remove nut (4).
★ Compress the spring to a point where
the nut becomes loose.
★ Release the hydraulic pressure slowly
to decompress the spring.
★ Free length of spring: 814 mm
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
3. Dissassembly of piston assembly

1) Remove lock plate (11) from piston (10),
then remove valve (12).
2) Remove snap ring (13), then remove U-
packing (14) and ring (15).
30-54 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY
12
ASSEMBLY 2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylin-
der (7).
2) Assemble cylinder (7) collar (8), and yoke

(6) to spring (5), and place in tool J1.
Sliding portion of cylinder:
Grease (G2-L1)
1. Assembly of piston assembly

1) Assemble ring (15) and U-packing (14) to
piston (10) and secure with snap ring (13).
2) Tighten valve (12) temporarily, and secure
with lock plate (11).
PC300/350(LC)-7 30-55
c
DISASSEMBLY AND ASSEMBLY SPROCKET
12
REMOVAL AND
INSTALLATION OF
SPROCKET
3) Apply hydraulic pressure slowly to com- REMOVAL
press the spring and tighten nut (4) so
that the installed length of the spring is 1. Remove track shoe assembly. For details, see
dimension a, then secure it with lock plate TRACK SHOE ASSEMBLY, REMOVAL.
(3).
★ Installed length a of spring: 2. Swing work equipment 90°, push up chassis
655 mm with work equipment and place block b
between track frame and track shoe.
4) Remove recoil spring assembly (1) from

tool J1.
3. Remove mounting bolts and lift off sprocket
(1).
3. Assemble piston assembly (2) to recoil spring
assembly (1).
Sliding portion of wear ring: Sprocket: 65 kg
Grease (G2-L1)
★ Install the piston assembly so the valve
installing position is on the outside.
★ Fill the inside of the cylinder with 180 cc
of grease (G2-L1), then bleed the air and
check that grease comes out of the grease
hole.
INSTALLATION
Thread of sprocket mounting bolt:

Sprocket mounting bolt:

640 - 785 Nm {65 - 80 kgm}
30-56 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
12
REMOVAL AND INSTALLATION OF TRACK SHOE
ASSEMBLY
SPECIAL TOOLS 3. Disassemble track shoe (3) above master pin
(2).
Distinction
Necessity
Sketch
Qty
791-630-3000 Remover & ■ 1

installer
1 790-101-1300 Cylinder ■ 1
K (980 kN {100 t} )
790-101-1102 Pump ■ 1
2 790-331-1110 Wrench ■ 1
EXPANSION
1. Set master pin at the position for expanding.

★ Start the engine and bring the master pin 4. Using tool K1, pull out master pin (2).
in front of the idler.
★ Put block [1] under the track shoe in front
of the idler.
2. Lower the work equipment, then loosen lubri-

cator (1), and relieve track tension.
k The adjustment cylinder is under extremely

high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
5. Travel machine backward to expand track

shoe.
30-57
(8)
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY
12
ASSEMBLY
• Assemble in reverse order of expansion.
★ Refer to the "Inspection and adjustment of

track shoe tension" section in the TEST-
ING AND ADJUSTING chapter of this
manual.
★ Using tool K2, tighten the bolt by angle

tightening method.
2 Mounting bolt:
Anti-seizure compound
(equivalent to "Maruzen molymax
No. 2")
3 Mounting bolt:
1st time:
393 ± 39 Nm {40 ± 4 kgm}
2nd time:
120 ± 10° (Angle tightening)
★ Press-fit the master pin with a proper tool

until dimension "a", master pin protrusion
amount, is obtained.
Master pin protrusion amount "a":
4.2 ± 2 mm
30-58
(8)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE ASSEMBLY
12
REMOVAL AND INSTALLATION OF SWING CIRCLE
ASSEMBLY
1. Remove revolving frame assembly. Refer to • Install in reverse order of removal.

the Removal and Installation of Revolving
Frame Assembly section in this manual.
Thread of swing circle mounting bolt:
2. Sling swing circle assembly (1) at three Thread tightener (LT-2)
points. Remove the mounting bolts and lift off
the swing circle assembly. Swing circle mounting bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
★ Install the inner race to the track frame
with the S mark of its inner soft zone spot
Swing circle assembly: 500 kg
facing the right side of machine as shown
in the figure below.
Grease bath fill:
Grease (G2-L1) 33 l
PC300/350(LC)-7 30-59
c
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
12
REMOVAL AND INSTALLATION OF REVOLVING FRAME
ASSEMBLY
REMOVAL
Extend the arm and bucket fully, then lower

the work equipment to the ground and move
the safety lock lever to the LOCK position.
1. Remove the work equipment assembly, refer

to the Removal of Work Equipment Assembly
section in this manual.
2. Remove the counter weight assembly, refer to

the Removal of Counterweight Assembly sec-
tion in this manual.
6. Support the engine hood (5) with an appropri-
3. Disconnect four boom cylinder hoses (1). ate sling and lifting device.
★ Plug the hose to stop oil flow-out. ★ Remove any parts which may interfere
with a sling, when removing the revolving
frame.
4. Sling boom cylinder assembly (2).
7. Remove engine hood mounting bolts to pull

out pin (6).
8. Lift and remove engine hood (5).
5. Remove plate (3) and pin (4). Lift and remove

the boom cylinder assembly (2).
★ Remove the boom cylinder assembly on
the opposite side in the same manner.
Boom cylinder assembly: 280 kg
30-60 PC300/350(LC)-7
c
12
9. Remove plates (7) and (8).
10. Remove U bolt (9) and plate (10) to discon-

nect after-cooler tube (11).
★ If any other parts may interfere with the
slings, remove them before lifting the
assembly.
13. Sling revolving frame assembly (20) then

remove 40 mounting bolts and lift off revolv-
ing frame assembly.
★ Use two lever blocks.

★ Leave the two mounting bolts at the front
and rear and adjust the center of gravity
with the lever blocks while lifting off.
Remove the mounting bolts afterwards..
11. Disconnect seven hoses (12) through (18). When removing the revolving frame
• (12): Center swivel joint (D port) - assembly, take care so that it will not
Swing motor (T port) bump the center swivel joint assembly
• (13): Center swivel joint (D port) -
Hydraulic tank
• (14): Center swivel joint (E port) - Revolving frame assembly: 7,800 kg
Solenoid valve
• (15): Center swivel joint (B port) -
Left travel control lever (B2 port)
Right travel control lever (B5 port)
• (17): Center swivel joint (A port) -
Left travel control lever (A2 port)
• (18): Center swivel joint (C port) -
Right travel control lever (A5 port)
12. Pull out pin (19) on the side of center swivel

joint and detach turning stopper plate from
center swivel joint.
PC300/350(LC)-7 30-61
c
12
INSTALLATION
Swivel circle mating surface:

Threads of revolving frame mounting
bolt: Adhesive compound (LT-2)
Revolving frame mounting bolt:

926.7 ± 103 Nm (94.5 ± 10.5 kgm)

Then check the level again.
• Air bleeding
Bleed air from the travel motor, refer to the
Air Bleeding of Various Parts section in the
manual.
30-62 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY
12
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT
ASSEMBLY
REMOVAL 2. Disconnect seven hoses (9) through (15).
Release the remaining pressure in the Swing motor (T port)
hydraulic circuit. For details, see TESTING • (10): Center swivel joint (D port) -
AND ADJUSTING, release of remaining Hydraulic tank
pressure in hydraulic circuit.
• (11): Center swivel joint (E port) -
Solenoid valve
★ Mark all the piping with tags to prevent mis-
takes in the mounting position when install- • (12): Center swivel joint (B port) -
ing. Left travel control valve (B2 port)
1. Disconnect eight hoses (1) through (8) Right travel control valve (B5 port)
between travel motor and center swivel joint. • (14): Center swivel joint (A port) -
• (1): Center swivel joint (T port) - Left travel control valve (A2 port)
Left travel motor (T port) • (15): Center swivel joint (C port) -
• (2): Center swivel joint (T port) - Right travel control valve (A5 port)
Right travel motor (T port)
• (3): Center swivel joint (B port) - 3. Pull out pin (16) on the side of center swivel
Left travel motor (PA port) joint and remove the jam plate from the cen-
ter swivel joint.
Right travel motor (PB port)
• (5): Center swivel joint (A port) -
Left travel motor (PB port)
• (6): Center swivel joint (C port) -
Right travel motor (PA port)
Left travel motor (P port)
Right travel motor (P port)
30-63
(9)
12
4. Remove four mounting bolts (17). INSTALLATION
Install the center swivel joint facing in the

direction shown in the diagram.
(The diagram shows the machine as seen
from above)
5. Remove center swivel joint assembly (18).
4 Center swivel joint assembly: 40 kg
• Refilling with oil (hydraulic tank)

★ Add oil through the oil filler to the speci-
fied level. Run the engine to circulate the
oil through the system. Then check the oil
level again.
• Bleeding air
★ Bleed the air from the travel motor. For
details see TESTING AND ADJUSTING,
Air Bleeding of Various Parts.
30-64
(9)
12
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT
ASSEMBLY
SPECIAL TOOLS 3. Using tool L. pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
790-101-2501 Push puller ● 1 4. Remove seal (6) from swivel shaft (5).
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
• 791-112-1180 • Nut 1
L • 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
DISASSEMBLY
ASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to

swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic ham-
mer to install.
Contact surface of rotor, shaft:
Grease (G2-L1)
★ When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.
4. Install ring (3) and secure with snap ring (2).
5. Install O-ring and cover (1).
Mounting bolt: 31.4 ± 2.9 Nm

{3.2 ± 0.3 kgm)
2. Remove snap ring (2).
PC300/350(LC)-7 30-65
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC TANK
ASSEMBLY
REMOVAL
1. Remove covers (1) and (2).
7. Disconnect drain hoses (9), (10) and (11).
8. Detach clamps (12) at four points.

2. Drain oil from hydraulic tank.
3. Open up engine hood.
4. Remove upper cover (3).
9. Disconnect suction tube (13) after removing

four mounting bolts.
5. Disconnect drain hoses (4) and (5).
6. Detach clamp (6) and then disconnect control

valve return hose (7) and oil cooler return
hose (8).
30-66 PC300/350(LC)-7
c
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
12
10. Lift hydraulic tank assembly temporarily to

remove six mounting bolts (14).
11. Lift off and remove hydraulic tank assembly

(15).
4 Hydraulic tank assembly: 200 kg
INSTALLATION

fied level.
Start and run the engine to circulate the
level again.
5 Hydraulic tank: Approx. 365 l
• Air Bleeding
★ Bleed the air.
For details. see TESTING AND ADJUST-
ING. Air Bleeding of Various Parts.
30-67
(9)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY
12
REMOVAL AND INSTALLATION OF CONTROL VALVE
ASSEMBLY
REMOVAL 4. Disconnect four boom hoses (5).
Lower the work equipment to the ground 5. Remove boom tube mounting clamps (6) and
completely and stop the engine. Then (7).
loosen the cap on the hydraulic tank slowly
to release the remaining pressure inside the
tank, and put the safety lock lever to the
LOCK position.
★ Attach a tag to each pipe to avoid making an

error when installing them again later.
1. Open up engine hood (1).
2. Remove control valve upper cover (2).
6. Remove plate (8).
3. Remove partition covers (3) and (4) between

engine and control valves.
7. Disconnect eight control valve hoses and

eight tubes.
• (9): TSW port hose (Swing motor S port)
• (10): T1 port hose (to hydraulic tank)
• (11): In the sequence of top to bottom
A-1 port tube (Boom Hi bottom side)
A1 port tube (Bucket bottom side)
A2 port hose (Swivel joint A port)
A3 port tube (Boom bottom side)
A4 port hose (Swing motor MB port)
A5 port hose (Swivel joint C port)
A6 port tube (Arm head side)
30-68
2
12
• (12): In the sequence of top to bottom 9. Disconnect two hoses between control valves
B-1 port hose (Arm Hi bottom side) and solenoid.
B1 port hose (Bucket head side) • (19): PS port hose (Hose band:
Yellow - blue)
B2 port hose (Swivel joint B port)
• (20): PST port hose (Hose band: Brown)
B3 port tube (Boom head side)
B4 port hose (Swing motor MA port) 10. Disconnect drain hose (21).
B5 port hose (Swivel joint D port)
B6 port tube (Arm bottom side)
11. Disconnect seven PPC hoses and five control

valve hoses on the left side.
8. Disconnect six PPC hoses on the right side. • (22): PLS2 port hose (Hose band: Red)
• (13): Bucket DUMP (Hose band: Black) • (23): PLS1 port hose
• (14): Left FORWARD (Hose band: Red) • (24): PX1 port hose (Hose band: Green)
• (15): Boom LOWER (Hose band: Brown) • (25): In the sequence of top to bottom,
• (16): Right SWING Bucket DIGGING (Hose band: White)
• (17): Right FORWARD (Hose band: Green) Left REVERSE
Boom RAISE (Hose band: Green)
• (18): Arm DIGGING (Hose band: Green)
SWING LS divider valve
BP5 port hose (to solenoid)
Left SWING (Hose band: Red)
Right REVERSE (Hose band: Blue)
Arm DUMP (Hose band: Yellow)
• (26): PX2 port hose
PC300/350(LC)-7 30-69
c
12
12. Disconnect 7 hoses and wiring connectors at

two points.
• (27): PPS1 port hose (Front pump)
• (28): PPS2 port hose (Rear pump)
• (29): PR port hose (Solenoid)
• (30): PR port hose (Pump)
• (31): PP1 port hose (Front pump)
• (32): PP2 port hose (Rear pump)
• (33): T port hose (Oil cooler)
• (34): A51 (Front pump pressure sensor)
INSTALLATION

fied level.
Run the engine to circulate the oil through
• (35): A52 (Rear pump pressure sensor) the system. Then check the oil level again.
• Bleeding air
★ Bleed the air from the circuit between the
valve and the hydraulic cylinder.
For details, see TESTING AND ADJUST-
ING, Air Bleeding of Various Parts.
13. Lift and remove control valve assembly (36)

after removing three mounting bolts.
Control valve assembly: 250 kg
30-70 PC300/350(LC)-7
c
12
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE
ASSEMBLY
★ This chapter deals only with precautions to be Procedures for replacing pressure compen-
followed when disassembling and reassem- sation valve seal
bling the control valve assembly. ★ Since there are many types of the pressure
compensation valves, make a mark on each
SPECIAL TOOLS valve to indicate from where it was removed.
Distinction
Necessity
1. Remove piston (2), plug (3), and string (4)
Sketch
Qty
Mark Part No. Part name from pressure compensation valve (1).
2. Remove seal (5) and O-ring (6) from piston

796-946-1310 Guide (2).
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
■ 1
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
■ 1
(For 723-46-44100)
796-946-2210 Guide
■ 1
(For 723-46-45100)
796-946-1320 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1820 Guide
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2 ■ 1 ★ There are many types of the pistons.
(For 723-46-44100)
M ★ Clean the pressure compensation valve
796-946-2220 Guide thoroughly. Install the seal using a tool, as
■ 1
(For 723-46-45100) indicated in the diagram.
796-946-1420 Guide
■ 1 3. Install O-ring (6) onto piston (2).
(For 723-46-42800)
796-946-1330 Sleeve 4. Place tool M1 onto piston (2) and push it in
1
(For 723-46-40100, 723-46-40601) slowly by hand so that seal (5) spreads out
796-946-1830 Sleeve evenly.
1
(For 723-46-43100, 723-46-43400) ★ The seal may be also installed by pushing
it down to the flat surface of the tool and
796-946-2130 Sleeve
3 1 then pushing it in with the tool fitted to
(For 723-46-44100) the piston.
796-946-2230 Sleeve
1
(For 723-46-45100)
796-946-1430 Sleeve
■ 1
(For 723-46-42800)
30-71
(8)
12
5. Likewise, set tool M2 to piston (2) in the same ASSEMBLY
direction and push it slowly by hand so that • Coat the sliding surface with engine oil and
the other seal (6) may be spread out evenly. then reassemble the control valve assembly.
★ The seal may be also fitted by pushing it • When installing spools (7) and (10) in the
down to the flat surface of the tool and valve chamber, direct drilled holes (8) and (11)
then pushing it in with the tool fitted to toward cylinder ports (9) and (12).
the piston. ★ Install the other spools shown in sections H –
H, K – K, L – L and M – M similarly.
6. Keep compensation tool M3 fitted to piston

(2) for about one minute so that seals (5) and
(6) will become well adapted.
★ Check that there is no protrusion or cut on
the seal.
7. Assemble the piston in the sleeve.

★ If it is difficult to install the sleeve, do not
attempt to push it in forcibly, but try it
again after repeating the same process in
Step 6. above and confirming the seals
are well adapted.
8. Fit plug (3) and spring (4) to piston (2) and

assemble pressure compensation valve (1).
★ After the installation, push the piston by
hand and check that the piston reacts only
with spring force.
30-72
(8)
• Control valve top and bottom covers

2 Mating faces of control valve top and
bottom covers:
SEALEND 242 or equivalent
★ Use 2 washers (W2) each for only 2 places
of the control valve top cover.
• Tighten the mounting bolts of the control
valve top and bottom covers in the following
order: (A o D o C o B)
3 Mounting bolt of control valve top
and bottom covers:
156.9 – 176.5 Nm {16 – 18 kgm}
• Install filters (13) to the bottom of PLS1 port

and PLS2 port as shown (Take care of the
caulked parts (*).)
30-72-1
(8)
• Merge-divider valve
2 Mating face of merge-divider valve:
SEALEND 242 or equivalent
• Tighten the mounting bolts of the merge-
divider valve similarly to those of the control
valve covers.
3 Mounting bolt of merge-divider valve:
156.9 – 176.5 Nm {16 – 18 kgm}
• Tighten the mounting bolts of the boom Hi
check valve, quick return valve, lock valve,
and arm plate similarly to those of the control
valve covers.
3 Mounting bolt of boom Hi check
valve, quick return valve, lock valve,
and arm plate:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• After assembling, fit the cap so that oil and
cleaning liquid will not enter the engine
through the ø12 hole.
• Pressure compensation valve
★ Install each pressure compensation valve,
paying attention to the counter mark that
was put when removing it.
• Main relief valve assembly
After building the main relief valve assembly
in the control valves, refer to the Inspection
And Adjustment of Hydraulic Oil Pressure In
Hydraulic Circuit For "Work equipment, swing
and travel" section in the TESTING AND
ADJUSTING chapter, in this manual.
30-72-2
(8)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP
ASSEMBLY
SPECIAL TOOLS 3. Remove covers (1), (2) and (3).

796-460-1210 Oil stopper ■ 1
C
796-770-1320 Adapter ■ 1
REMOVAL
Disconnect the negative (-) terminal of the

battery before starting with the work.
Lower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap on the hydraulic tank slowly to
release pressure inside the tank.
★ Attach identification tags to all piping to avoid
mistakes when installing.
1. Remove hydraulic tank strainer and stop oil

flow-out using tool C.
★ If tool C is not used, remove the drain
plug and drain oil from the hydraulic tank
and piping.
5 Hydraulic tank: Approx. 365 l
2. Drain oil from the damper case.
6 Damper case: Approx. 13.5 l
30-73
(9)
12
6. Disconnect pump wiring connectors at two 8. Disconnect muffler drain tube (21).
points.
• (8): V22 (PC-EPC solenoid valve)
Color band: Red
• (9): V21 (LS-EPC solenoid valve)
Color band: White
9. Disconnect clamps (22) at two points.
10. Remove muffler clamp (23) and two U bolts

(24) to detach muffler (25).
11. Remove muffler bracket (26).

7. Disconnect ten hoses and one tube.
• (11): Front pump discharging port hose
• (12): Drain port hose
• (13): Front load pressure input port hose
• (14): Rear load pressure input port hose
Color band: Red
• (15): EPC source pressure port hose
Color band: Yellow
• (16): Rear pressure port hose
Color band: Yellow
• (17): Front pressure input port hose
• (19): Front pump discharging port hose 12. Lift and remove hydraulic pump assembly
• (20): Pump suction port tube (27).
4 Hydraulic pump assembly: 220 kg
30-74
2
12
INSTALLATION
2 Hydraulic pump involute spline:

Anti-friction compound (LM-G)
2 Hydraulic pump case mating surface:
• Refilling hydraulic oil (Damper case)

the specified level.
5 Damper hydraulic oil : Approx. 13.5 l

Then check the oil level again.
5 Hydraulic tank : Approx. 365 l
• Bleeding air
★ Bleed the air.
For details. see TESTING AND ADJUST-
ING. Air Bleeding of Various Parts.
30-75
(9)
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
12
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC
PUMP INPUT SHAFT
1. Remove the hydraulic pump assembly. Refer • Install in reverse order of removal.
to the Removing Hydraulic Pump Assembly
section.
2. Remove snap ring (1) and then remove spacer 2 Oil seal lip portion: Grease (G2-LI)
2 Oil seal outer circumference:

(2).
Grease (G2-LI)
3. Pry off oil seal (3) with a screwdriver.
★ When attempting to pry off the seal, do ★ Coat the oil seal outer circumference
not damage the shaft. thinly with grease.
★ Press-fit oil seal (3), using tool [1].
30-76
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC
VALVE ASSEMBLY
PC300, 300LC-7 Serial No. 40001 – 40314 ★ When assembling piston (8), coat the piston
PC350, 350LC-7 Serial No. 20001 – 20221 outer periphery and body hole inner periph-
ery with grease.
3 Plate (5) mounting bolt:
★ This section deals only with precautions to be
followed when reassembling the PPC valve
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Joint (4) sliding surface:
assembly for work equipment.
Grease 2 – 4 cc (G2-LI)
2 Body female screw portion:
Adhesive compound (LT-2)
★ Coat the female screw portion A of body with
Loctite at 2 spots as shown in the diagram
below. Each spot is to be coated with a drop
(approx. 0.02 g).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
★ Strictly follow the specified torque for the
joint.
2 Contact surfaces of piston (8) and

disc (2): Grease 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 98 – 127 Nm {10 – 13 kgm}
ASSEMBLY
★ Install spring (11 ) so that the end surface of ★ After assembling the disc, refer to the
smaller end coil diameter (inner diameter) "Adjustment of work equipment and swing
will face the shim (12) side. PPC valve" section of the TESTING AND
★ Springs (10 ) in use differ in the number of ADJUSTING chapter of this manual.
turns according to hydraulic ports as classi-
fied in the table below. Hence, take care when
installing one.
Port location Spring free length
P1, P2 44.4 mm
P3, P4 42.4 mm
★ The location of each port is stamped in the

lower part of the valve body.
2 Piston (8): Grease (G2-LI)
30-77
(8)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC
VALVE ASSEMBLY
PC300, 300LC-7 Serial No. 40315 and up ★ When assembling piston (8), coat the piston
PC350, 350LC-7 Serial No. 20222 and up outer periphery and body hole inner periph-
ery with grease.
3 Plate (5) mounting bolt:
★ This section deals only with precautions to be
followed when reassembling the PPC valve
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Joint (4) sliding surface:
assembly for work equipment.
Grease 2 – 4 cc (G2-LI)
2 Body female screw portion:
Adhesive compound (LT-2)
★ Coat the female screw body with Loctite at 2
spots as shown in the diagram below. Each
spot is to be coated with a drop (approx. 0.02
g).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
★ Strictly follow the specified torque for the
joint.
2 Contact surfaces of piston (8) and

disc (2): Grease 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 69 – 88 Nm {7 – 9 kgm}
ASSEMBLY
★ Install spring (11) so that the end surface of ★ After assembling the disc, refer to the
smaller end coil diameter (inner diameter) "Adjustment of work equipment and swing
will face the shim (12) side. PPC valve" section of the TESTING AND
★ Springs (10) in use differ in the number of ADJUSTING chapter of this manual.
turns according to hydraulic ports as classi-
fied in the table below. Hence, take care when
installing one.
Port location Spring free length
P1, P2 44.4 mm
P3, P4 42.4 mm
★ The location of each port is stamped in the

lower part of the valve body.
2 Piston (8): Grease (G2-LI)
30-77-1
(8)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE
ASSEMBLY
★ This chapter deals only with precautions to be 7. Tighten each part to the following torque.
followed when reassembling. • Plug (11): 6 – 11 Nm {0.6 – 1.1 kgm}
ASSEMBLY • Bolt (12): 3.9 – 4.9 Nm {0.4 – 0.5 kgm}
(Apply LOCTITE #262.)
★ When assembling, clean and inspect the
• Screw (13): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
paets closely and take care fully so that dirt,
• Plug (14): 4 – 9 Nm {0.4 – 0.9 kgm}
rush, flaw, etc. will not cause a trouble.
• Bolt (15): 25 – 31 Nm {2.5 – 3.2 kgm}
1. When installing piston (1), apply grease (G2- • Bolt (16): 27 – 34 Nm {2.8 – 3.5 kgm}
LI) to its outside and the inside of the body
hole.
2. Install spring (2) with its small diameter side

on the shim (3) side.
• Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
3. Do not drive in bushing (4) by hitting it

directly with a hammer.
4. Do not drive in pin (5) by hitting it directly

with a hammer.
5. Apply grease (G2-LI) to the rocking part of

shaft (6) and the contact surfaces of lever (7)
and piston (1) and the contrast surfaces of
plate (8) and pin of lever (9).
2 Quantity of grease (G2-LI)
Rocking part of shaft (6):
4 – 8 cc/periphery
Connecting part of lever (7) and pis-
ton (1): 0.3 – 0.8 cc/part
Connecting part of plate (8) and lever
(9): 0.3 – 0.8 cc/part
6. Install washer (10) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end
of the lever exceeds 0.7°, change the washer
thickness to reduce the difference to below
0.7°. (If the washer thickness is reduced by 0.3
mm, the stroke end angle is increased by
0.39°.)
• Thickness of washer: 1.0, 1.3, 1.6 mm
30-78
(8)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY
12
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
ASSEMBLY
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
Cylinder
1 790-502-1003 repair stand ■ 1
Wrench
790-102-4300 Assembly ■ 1
2
790-102-4310 Pin ■ 2
3 790-720-1000 Expander ● 1
796-720-1680 Link ● 1
4
07281-01589 Clamp ● 1
4) Disassemble piston rod assembly as fol-
790-201-1702 Push tool kit ■ 1
lows.
• Push tool i) Set piston rod assembly (2) in tool N1.
• 790-201-1851 (for bucket 1
and boom)
N 5
• Push tool
• 790-201-1861 (for arm) 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-1500 Push tool kit ■ 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
6 • Plate
790-201-1660 (for boom 1
and bucket)
• Plate
790-201-1670 (for arm) 1
ii) Remove stopper screw (3) of piston

assembly.
DISASSEMBLY
★ Common screw size for boom,
1. Piston rod assembly arm, and bucket cylinder:
M12 x Pitch 1.75.
1) Remove piping from cylinder assembly.
2) Remove mounting bolts and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
★ Place a container under the cylinder to
catch the oil.
30-79
(8)
12
★ If the caulking of screw (3) is too

strong and it cannot be removed,
tighten the screw fully, then fit a tap to
the thread and remove the screw.
vii) Remove cap (8), and pull 12 balls (9),

then remove plunger (10).
• Arm cylinder only
★ Since cap (8) is made of nylon,
iii) Using tool N2, remove piston assem- tighten a screw into it and pull it
bly (4). out with pliers.
• When not using tool N2, use the
drill holes (DH) (∅ 10, 4 places)
and loosen the piston assembly.
2. Disassembly of piston assembly

1) Remove rings (11).
2) Remove wear rings (12).
iv) Remove plunger (5).
3) Remove piston ring (13).
• Boom and arm cylinder only
4) Remove O-ring and backup ring (14).
v) Remove collar (6).
• Boom and arm cylinder only
vi) Remove head assembly (7).
30-80
(9)
12
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
2. Assembly of piston assembly

1) Using tool N3, expand piston ring (13).
★ Set the piston ring on tool N3, and
turn the handle 8 – 10 times to expand
the ring.
2) Set tool N4 in position, and compress pis-
ton ring (13).
ASSEMBLY
★ Be careful not to damage the packing, dust

seals, and O-rings.
★ Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
★ Do not try to force the backup ring into posi-
tion.
Warm it in warm water (50 – 60°C) before
installing it.
1. Assembly of head assembly

1) Using tool N5, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool N6, install dust seal (17), and
secure with snap ring (16).
5) Install backup ring and O-ring (15).
30-81
(8)
12
3) Install backup ring and O-ring (14). 2) Assemble head assembly (7).
4) Assemble wear rings (12). 3) Fit O-ring and backup ring to collar (6),
5) Assemble rings (11). then assemble.
★ Be careful not to open the end gap of • Boom and arm cylinder only
the ring too wide. 4) Assemble plunger (5).
2 Ring grove: Grease (G2-LI) • Boom and arm cylinder only
3. Piston rod assembly 5) Set cushion plunger (10) to piston rod,

1) Set piston rod assembly (2) to tool N1. then assemble 12 balls (9) and secure
with cap (8).
★ Check that there is a small amount of
play at the tip of the plunger.
• Arm cylinder only
30-82
(9)
12
6) Assemble piston assembly (4) as follows. • When using a new part for either or both of
• When using piston rod assembly (2) piston rod assembly (2) and piston assembly
and piston assembly (4) again: (4).
★ Wash thoroughly and remove all ★ For the rod with bottom cushion, mark the
metal particles and dirt. cap (8) position on the end of the rod.
i) Screw in piston assembly (4), then (See step 5))
use tool N2 to tighten piston • Arm cylinder only
assembly (4) so the position of the i) Screw in until piston assembly (4) con-
screw thread H hole matches. tacts end face of rod, then use tool to
★ Remove all burrs and flashes with tighten.
a file. 3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
★ After tightening the piston, check that
there is play in plunger (5).
• Boom, arm cylinder only
ii) Tighten screw (3).

2 Screw thread:
Loctite No. 262
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm} ii) Machine one of the holes used to install
iii) Punch threads [1] at 4 points for screw (3).
caulking. ★ Align a drill horizontal with the V-
groove of the thread of piston rod
assembly (2) and piston assembly (4),
then carry out machining.
★ For the cylinder with bottom cushion
(arm cylinder), avoid cap (8) machin-
ing holes position when machining.
(See step 5))
• Screw machining dimension (mm)
Drill Bottom
Tap used Tap depth
diameter hole depth
10.3 27 12 x 1.75 20
30-83
(9)
12
iii) After machining, wash thoroughly to 7) Assemble piston rod assembly (2).
remove all metal particles and dust. ★ Set the end gap of the ring horizontally (at
the side position), align axial center of cyl-
inder tube, then insert.
★ After inserting, check that the ring is not
broken and has not come out, then push
in fully.
iv) Tighten screw (3).

3 Screw:
58.9 – 68.6 Nm {6 – 7 kgm}
v) Caulk thread at 4 places with punch.
8) Tighten head assembly (1) with mounting

bolts.
3 Mounting bolt:
Cylinder Tightening torque

Bucket 373 ± 54 Nm {38.0 ± 5.5 kgm}
Arm 490 ± 49 Nm {50.0 ± 5.0 kgm}
Boom 373 ± 54 Nm {38.0 ± 5.5 kgm}
9) Install piping.
30-84
(9)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
12
REMOVAL AND INSTALLATION OF WORK EQUIPMENT
ASSEMBLY
SPECIAL TOOLS 4. Start the engine and retract the piston rod.
★ Fasten the piston rod with wire so that it
Distinc- will not slip out. Lower the cylinder onto a
Mark Part No. Part Name Necessity Qty Sketch
tion*
stand or place a support under the bottom
796-670-1100 Remover ■ 1 of the cylinder to support it. In the latter
• 796-670-1110 • Sleeve 1 case, remove the grease fitting on the bot-
• 796-670-1120 • Plate 1
tom side first.
• 796-670-1130 • Screw 1
★ Remove the boom cylinder on the other
• 791-775-1150 • Adapter 1
side in the same manner.
P
• 01643-33080 • Washer 1
★ Remove the working lamp on the work
• 01803-13034 • Nut 1
equipment if slings will hit the lamp when
Puller
lifting the work equipment off.
790-101-4000
(490 kN {50T}long)
■ 1
Pump 5. Disconnect A42 intermediate connector (6)

790-101-1102
(294 kN {30T})
■ 1
from working lamp.
6. Disconnect three arm cylinder hoses (7) and
REMOVAL two bucket cylinder hoses (8).
Extend the arm and bucket fully. Lower the ★ Plug them to stop oil spillage and fasten
work equipment to the ground and set the the hoses with a rope on the valve side.
safety lock lever to the lock position.
Release the residual pressure in the hydrau-
lic circuit. Refer to the Release of Remaining
Pressure in Hydraulic Circuit section in the
manual.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and

remove lock bolt (3).
3. Remove plate (4), then remove head pin (5).

7. Lift off work equipment assembly, remove
★ There are shims installed, so check the plate (9) and then pin (10) at the foot.
number and thickness, and keep them in a
safe place.
PC300/350(LC)-7 30-85
c
12
INSTALLATION

• When removing them, first remove plate
(9) and then remove pin (10) at the foot,
using Tool P. ★ When tightening the locknut, tighten so
★ Shims are installed, so do not forget to that clearance a between the plate and
check their number and each location of nut is 0.5 - 1.5 mm.
installation.
Inside surface of bushing when

8. Lift off work equipment assembly (11) and dis-
assembling pin:
assemble it.
Anti-friction compound (LM-P)
Work equipment assembly: Grease after assembling pin:
5,800 kg Grease (LM-G)
When aligning the position of the pin

hole, never insert your fingers into the
pin hole.
★ Adjust the shim thickness so that clear-

ance b between cylinder rod (12) and
plate (4) is below 1.5 mm.
★ Standard shim thickness: 1.0 mm and
2.0 mm.
30-86 PC300/350(LC)-7
c
12
2 Inside surface of bushing when

assembling pin:
Anti-friction compound (LM-P)
2 Grease after assembling pin:
Grease (LM-G)
k When aligning the position of the pin
hole, never insert your fingers into the pin
hole.
★ Adjust clearance "c" between the foot end
surface of boom (13) and bracket (14) with
shims so that it will be less than 1 mm.
Thickness of standard shims: 2.0, 2.5 and 3.5
mm
• Bleeding air
★ Bleed the air from the cylinder. For
details, see TESTING AND ADJUSTING,
Air Bleeding of Various Parts.
fied level. Run the engine to circulate the
level again.
30-87
(8)
12
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
ASSEMBLY
PC300, 300LC-7 Serial No. 40001 – 45000 3. Pull down outside air filter cover opening-
PC350, 350LC-7 Serial No. 20001 – 25000 closing lever (2).
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
Service tool
799-703-1200 kit ■ 1
Vacuum
799-703-1100 Pump (100 V) ■ 1
Vacuum
Q 799-703-1111 Pump (220 V) ■ 1
Vacuum
799-703-1121 ■ 1
Pump (240 V) 4. Remove outside air filter (3).
Gas leak
799-703-1401 detector ■ 1
REMOVAL
k First, disconnect the cable from the negative

(–) terminal of the battery.
k Collect the air conditioner refrigerant.
1. Drain coolant.
6 Coolant: Approx. 22.8 l
2. Remove floor mat (1). 5. Remove monitor panel lower covers (4) and
(5).
★ When removing cover (4), first remove
the M19 wiring for cigarette lighter.
30-88
(8)
12
6. Remove duct (6) on the right side. 11. Remove cover (15).
7. Remove rear covers (7), (8) and (9). 12. Disconnect cab intermediate connectors (18)
at the following 2 points.
• H09: Upper side
• H08: Lower side
13. Disconnect radio antenna (19).
14. Remove plate (20) and then remove cover

(21).
8. Remove rear duct (10).
9. Remove plate (11) and then remove duct (12).
10. Remove plate (13) and right duct (14).
15. Remove duct (22).
16. Disconnect connectors at the following 7

points.
• (23): D01
(Assembled-type diode connector)
• (24): D02
(Assembled-type diode connector)
• (25): C09 (Model selection switch connec-
tor)
• (26): Air conditioner unit connector
From top to bottom, M26, M27, M28
and M33 option power source con-
nector
30-89
(8)
12
17. Remove the mounting clamp and disconnect INSTALLATION
air conditioner wiring connector (27).
18. Remove the 4 mounting bolts and remove ★ Install hoses in the air conditioner circuit with
governor pump control assembly (28). care so that dirt, dust, water, etc. may not
★ Put the governor pump control assembly enter them.
aside. ★ Install air conditioner hoses only after check-
ing that an O-ring is in place at the connecting
19. Remove cover (29). part.
★ Check that there is no damage on O-rings, or
that they have not deteriorated.
★ When connecting the refrigerant piping,

coat the O-ring with compressor oil for
R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100
PG (PAG 46 or equivalent)) and tighten
the nuts with 2 spanners.
3 Hose clamp screw:
8.83 – 14.7 Nm {0.9 – 1.5 kgm}
3 Hose screw M16 x 1.5:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
20. Disconnect air conditioner hoses (30) and (31) 3 Hose screw M24 x 1.5:
as well as air conditioner tubes (32) and (33). 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
• Filling air conditioner gas

21. Remove the 8 mounting bolts and remove air Fill the air conditioner circuit with air condi-
conditioner unit assembly (34). tioner gas (R134a), using tool Q.
★ When removing the air conditioner unit
assembly, do not forget to disconnect the
2 air conditioner hoses connected to the
bottom.
30-90
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
12
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
ASSEMBLY
PC300, 300LC-7 Serial No. 45001 and up 6. Remove ducts (10) and (11).
SPECIAL TOOLS
Distinction
Necessity
Sketch
Qty
Service tool
799-703-1200 kit ■ 1
Vacuum
799-703-1100 pump (100V) ■ 1
Vacuum
Q 799-703-1111 pump (220V) ■ 1
799-703-1121
Vacuum
■ 1 7. Disconnect connectors D01 (12), D02 (13), C09
pump (240V) (14), R22 (15), R20 (16), and K19 (17).
Gas leak
799-703-1401 detector ■ 1
8. Remove and sling controller (18).
REMOVAL 9. Remove plate (19).
k Disconnect the cable from the negative (–) ter- 10. Disconnect air conditioner unit connectors
minal of the battery. M27 (20) and M33 (21).
k Collect the air conditioner refrigerant.
1. Swing the upper structure by 90°.
2. Open the engine hood.
3. Remove rear covers (1), (2), (3), and (4).
11. Remove the air conditioner unit undercover.

★ Part A
4. Remove duct (5), cover (6), and plate (7).
5. Remove plate (8) and duct (9).

★ Remove the duct lock clip.
30-90-1
(8)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY
12
12. Remove mounting bolt (24) and connector INSTALLATION
(25). • Carry out installation in the reverse order to
removal.
13. Disconnect heater hoses (22) and (23) and air ★ When installing the air conditioner circuit
conditioner tubes (26). hoses, take care that dirt, water, etc. will
★ Put tags to the disconnected hoses and not enter them.
tubes to prevent a mistake in re-connect- ★ When connecting each air conditioner
ing them. hose, check that the O-ring is fitted to the
joint.
★ Check that each O-ring is free from flaw
and deterioration.
★ When connecting the refrigerant piping,

coat the O-ring with compressor oil for
R134a (DENSO: ND-OIL 8, ZEXEL: ZXL 100
PG (PAG 46 or equivalent)) and tighten
the nuts with 2 spanners.
3 Hose clamp (M6 bolt):
7.84 – 11.8 Nm {0.8 – 1.2 kgm}
3 Hose screw of M16 x 1.5:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
14. Remove the 7 mounting bolts and air condi-
tioner unit assembly (27).
19.6 – 24.5 Nm {2.0 – 2.5 kgm}
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
• Charging air conditioner with refriger-

ant gas
Using tool Q, charge the air conditioner cir-
cuit with refrigerant (R134a) from the com-
pressor.
★ Quantity of refrigerant: 950 ± 50 g
30-90-2
(9)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT ASSEMBLY
12
REMOVAL AND INSTALLATION OF COUNTERWEIGHT
ASSEMBLY
1. Attach eyebolts [1] to counterweight assem- • Install in reverse order of removal.

bly (1), and sling.
2. Remove 4 mounting bolts (2) 2 Thread of counterweight mounting

bolt: Thread tightener (LT-2)
3 Counterweight mounting bolt:
★ Take note of where shims were inserted.
3. Lift off counterweight (1) horizontally with 1,814.1 ± 98.1 Nm {185 ± 10 kgm}
wire or chain block.
★ Be careful not to hit the engine, radiator ★ Installing and adjusting counterweight
or cooler.
4
1) Adjust clearance on the upper and
Counterweight assembly: 5,500 kg lower sides with shims.
2) Install counterweight in such a way
that clearance between the door and
counterweight as well as clearance
between the revolving frame and
counterweight become 10 ± 5 mm.
30-91
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
REMOVAL AND INSTALLATION OF OPERATOR’S CAB
ASSEMBLY
PC300, 300LC-7 Serial No. 40001 – 45000 3. Remove rear covers (4), (5) and (6).
PC350, 350LC-7 Serial No. 20001 – 25000
REMOVAL

1. Remove floor mat (1).
4. Disconnect cab wiring intermediate connec-

tors H10 (7), H11 (8) and H12 (9).
5. Remove duct (10) on the right side and rear

duct (11).
6. Remove left plates (12) and (13).

2. Remove covers (2) and (3) under the monitor
panel.
★ When removing cover (2), first disconnect
the CN-M19 wiring for cigarette lighter.
7. Pull down outside air filter cover opening-

closing lever (14).
30-92
(8)
12
8. Remove outside air filter (15).
9. Remove duct (16). 15. Remove step plate (24).
10. Remove cover (17). 16. Remove 5 mounting bolts (25) and 4 mount-
ing nuts (26).
★ Check the bolt length beforehand.
11. Disconnect cab wiring intermediate connec-

tors (20) at the following 2 points.
• H09: Upper side 17. Lift and remove operator's cab assembly (27).
• H08: Lower side 4 Operator's cab assembly: 290 kg
13. Remove duct (22) on the right side. INSTALLATION
14. Remove window washer hose (23). • Install in reverse order of removal.
30-93
(8)
12
PC300, 300LC-7 Serial No. 45001 and up 4. Remove clip (10) and disconnect cab wiring
PC350, 350LC-7 Serial No. 25001 and up connectors M45 (11), H08 (12), and H09 (13).
REMOVAL
k Disconnect the cable from the negative (–) ter-

5. Remove air conditioner connector plate (14).
1. Remove rear covers (1), (2), (3), and (4).
6. Disconnect connectors M71 (15), H10 (16), H11

(17), and H12 (18).
7. Disconnect upper and lower duct joints (19)

2. Remove duct (5), cover (6), and plate (7). and (20).
3. Remove plate (8), duct (9) and the element. 8. Remove controller sub-plate (21) and incline it
against the air conditioner.
★ Remove the duct lock clip.
9. Remove cover (22) and floor mat (23).
30-94
(8)
12
10. Move right console (24) into the cab. 17. Take grommet (35) out of the right front of the
cab.
11. Remove monitor panel undercover (25).
18. Disconnect the windshield washer hose from
(36).
19. Remove 4 mounting bolts (37) and 5 mount-

ing bolts (38).
★ Check the types of the bolts.
★ In the initial period, 7 mounting bolts (38)
are used.
12. Disconnect cab wiring connector W04 (26)

(Wiper motor).
13. Remove ducts (27) and (28).

★ Both (27) and (28) are 2 in number.
★ Cut the tie-wrap on the monitor wiring
harness.
14. Remove cover (29) and monitor assembly 20. Using lever block [1], lift off operator's cab
(30). assembly (39).
4 Operator's cab assembly: 300 kg
16. Remove clip (32) and take wiring harness (33)

out of grommet (34).
30-95
(8)
12
REFERENCE INSTALLATION
When starting the engine while the operator's • Carry out installation in the reverse order to
cab is removed (for transportation, etc.), use the removal.
following brackets.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
2) Bracket (42) for monitor panel assembly (30)

Part No.: 208-53-13910
30-96
(8)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
12
GLASS (STUCK GLASS)
★ Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 4 panes (1) – (4) (2) : Left side rear window glass
are stuck. (3) : Door lower window glass
In this section, the procedure for replacing the (4) : Front window glass
stuck glass is explained. (5) : Front window assembly
When replacing front window glass (4), (Front window glass + Front frame)
remove front window assembly (5). (It is (6) : Both-sided adhesive tape
impossible to replace only the front window (16): Center trim seal
glass while the front window assembly is
installed to the operator's cab.)
For the procedure for replacing the front win-
dow assembly, see REMOVAL AND INSTAL-
LATION OF FRONT WINDOW ASSEMBLY.
30-97
(8)
12
SPECIAL TOOLS (The figure shows the operator's cab of a
wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
1 793-498-1210 ■ 2
Y (Suction cup)
2 20Y-54-13180 Adapter ■ 2
REMOVAL
★ Remove the window glass to be replaced

according to the following procedure.
1. Using seal cutter [1], cut the adhesive ★ If the window glass is broken finely, it
between broken window glass (7) and opera- may be removed with knife [4] and a
tor's cab (metal sheet) (8). screwdriver.
★ Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].
(The figure shows the operator's cab of a

wheel loader.)
★ If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire
(piano wire, etc.) [2] through the holes.
Grip the both ends of the wire with priors
[3], etc. (or hold them by winding them
onto something) and move the wire to the 2. Remove the window glass.
right and left to cut the adhesive and
both-sided adhesive tape. Since the wire
may be broken by the frictional heat,
apply lubricant to it.
30-98
(8)
12
INSTALLATION 3. Apply primer (10).
★ The using limit of primer (10) is 4 months
1. Using a knife and scraper [5], remove the after the date of manufacture. Do not use
remaining adhesive and both-sided adhesive primer (10) after this limit.
tape from the metal sheets (glass sticking sur- ★ Use the primer within 2 hours after
faces) of the operator's cab. unpacking it.
★ Remove the adhesive and both-sided ★ Even if the primer is packed again just
adhesive tape to a degree that they will after it is unpacked, use it within 24 hours
not affect adhesion of the new adhesive. after it is unpacked for the first time. (Dis-
Take care not to scratch the painted sur- card the primer 24 hours after it is
faces. (If the painted surfaces are packed.)
scratched, adhesion will be lowered.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
wheel loader.) ★ If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accord-
ingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it
in white gasoline.
★ After washing the brush, check it
again for dirt and foreign matter.
★ Prepare respective brushes for the
paint primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
★ If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
★ Clean the all black part on the back side of
the window glass.
★ After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.

wheel loader.)
30-99
(8)
12
3) Evenly apply paint primer to the surfaces
to stick both-sided adhesive tapes and the
surfaces out of those surfaces on opera-
tor's cab (8) which will be coated with the
adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalent
★ Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
★ Parts to be coated with primer: Apply ★ Never apply wrong primer. If the glass
the primer all over dimension "a". primer is applied by mistake, wipe it
off with white gasoline.
• Dimension "a" to apply primer: 25
mm
4) Evenly apply glass primer to the sticking
surfaces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalent
★ Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
★ In addition to the above parts, apply

the primer to right side window glass
(1) and door lower window glass (3).
• Range to apply primer additionally for
right side window glass (1): "b"
• Range to apply primer additionally for
door lower window glass (3): "c"
★ After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
30-100
(8)
12
★ Parts to be coated with primer: Apply ★ When sticking both-sided adhesive tape
the primer to the sticking surfaces of (6) around a frame, do not lap its finishing
window glass (9) and all over dimen- end over the starting end but make clear-
sion "d" which will be on both-sided ance "e" of about 5 mm between them.
adhesive tape (6) and operator's cab 1) Stick both-sided adhesive tape (6) for
(8). right side window glass (1) as shown in
★ Do not apply the primer to the the figure.
boarder about 5 mm wide between
the black part and transparent part of
the glass.
★ After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
★ Never apply wrong primer. If the
glass primer is applied by mistake,
wipe it off with white gasoline.
★ Stick both-sided adhesive tape (6a) addi-

tionally for right side window glass (1).
• Positions to stick additional both-sided
adhesive tape for right side window glass:
f : 50 mm
g : 90 mm
h : 250 mm
4. Stick both-sided adhesive tape (6) along the

inside edge of the glass sticking section.
★ Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
★ When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
★ Take that the both-sided adhesive tape
will not float at each corner of the window
frame.
30-101
(8)
12
2) Stick both-sided adhesive tape (6) for left 4) Stick both-sided adhesive tape (6) for
side rear window glass (2) as shown in front window glass (4) as shown in the
the figure. figure.
3) Stick both-sided adhesive tape (6) for ★ Stick both-sided adhesive tape (6c) of
door lower window glass (3) as shown in the lower side of the front window
the figure. glass along the outside edge of the
lower line, differently from other both-
sided adhesive tapes (6). (If it is stuck
along the inside, it will be seen
through the transparent part of the
glass.)
★ Stick both-sided adhesive tape (6b)

additionally for door lower window
glass (3).
★ Positions to stick additional both-
sided adhesive tape for door lower
window glass: 5. Position the new window glass.
j : 110 mm 1) Check the clearance between the window
k : 90 mm glass and the operator's cab on the right,
m : 200 mm left, upper, and lower sides, and then
adjust it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line "n".
★ Stick tapes [6] to the right, left, and
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass for accurate
positioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
30-102
(8)
12
★ Do not remove the tapes left on the 6. Apply adhesive.
window glass and operator's cab ★ Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
before installing the window glass.
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
★ The using limit of the adhesive is 4
months after the date of manufacture. Do
not use the adhesive after this limit.
★ Keep the adhesive in a dark place where
the temperature is below 25°C.
★ Never heat the adhesive higher than 30°C.
★ When reusing the adhesive, remove the
all hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
★ When positioning front window glass

(4), set its horizontal position to the
frame width and set its vertical posi-
tion so that height difference "p"
between it and the frame top will be 3
mm. 2) Cut the tip of the adhesive nozzle (14) so
that dimensions "q" and "r" will be as fol-
lows.
• Dimension "q": 10 mm
• Dimension "r": 15 mm
30-103
(8)
12
3) Set adhesive cartridge (12) to caulking
gun [7].
★ An electric caulking gun is more effi-
cient.
★ Apply adhesive (15) additionally for

additional both-sided adhesive tape
(6a) of the right side window glass
and additional both-sided adhesive
tape (6b) of door lower window glass.
4) Remove the release tape of the both-sided
adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of
both-sided adhesive tape (6) of the opera-
tor's cab.
★ Apply adhesive (15) to dimensions "s"

and "t" of both-sided adhesive tape
(6) of operator's cab (8).
• Dimension "s": 10 mm
• Dimension "t": 15 mm
★ Apply adhesive (15) higher than both-
sided adhesive tape (6).
★ Apply the adhesive evenly.
30-104
(8)
12
7. Install the window glass. ★ After installing front window glass (4),
1) Install window glass (9), matching it to the fill the clearances between it and cen-
lines of the positioning tapes drawn in ter trim seal (16) with caulking mate-
step 5. rial in range "s" to dimensions "t" and
"u".
★ Since the window glass cannot be
removed and stuck again, stick it very After applying the primer to glass (4)
carefully. of section A – A, apply adhesive as
caulking material.
★ Stick the glass within 5 minutes after
applying the adhesive. • Caulking dimension "t": 2 mm
• Caulking dimension "u": 5 mm
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided ★ When caulking, mask the glass side
adhesive tape. and form the adhesive with a rubber
spatula as shown in the figure.
★ Press the corners of the window glass
★ Wipe off projected adhesive.
2 Glass primer:
firmly.
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
★ You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup Y1.
30-105
(8)
12
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right side window glass (1) primer and adhesive from the operator's cab
to the operator's cab, insert stopper rub- and window glass.
bers Y2 to 2 places "v" at the bottom of ★ Using white gasoline, wipe off the adhe-
the glass to fix the glass. sive before it is dried up.
★ When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them com-
pletely.
30-106
(9)
12
REMOVAL AND INSTALLATION OF FRONT WINDOW
ASSEMBLY
k Lower the work equipment to the ground and 5. Release the rear locks.
stop the engine.
★ To replace the front window glass, the front 6. Lower the front window assembly carefully a
window assembly must be removed from the little. Put out rollers (8) and (9) under the both
operator's cab. The procedure for removing sides of the front window through the portion
and installing the front window assembly from which the corner blocks were removed
(front frame and front window glass) is in step 3 (the portion where the rail is open)
explained below. and hold them.
7. Remove rollers (8) and (9) under the both

REMOVAL sides of the front window.
1. Raise the front window assembly to the ceil-

ing and fix it with the rear locks (on both
sides).
2. Remove left corner blocks (1) and (2) and right

corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt

(5), left corner block bracket (6), and right cor-
ner block bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
★ This bolt will be used to hang the pull-up
assist cable in step 8.
8. Remove left lower pin (10). [*3]

★ If left lower pin (10) is removed, plate (12)
at the end of pull-up assist cable (11)
comes off.
★ Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied
to the rear of the operator's cab. Accord-
ingly, take care when removing left lower
pin (10) to disconnect pull-up assist cable
(11).
30-107
(8)
12
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front
window assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and
lower it gradually.
10. Lower front window assembly (13) com-

pletely.
★ Do not let the front window assembly
touch the monitor.
30-108
(8)
12
INSTALLATION 4. Install right corner block (3) and fix right cor-
ner block bracket (7) with right striker bolt (5).
• Carry out installation in the reverse order to ★ Tighten the striker bolt securely after
removal. adjusting it in step 6.
★ Install the right corner block so that there
[*1] [*2] will be no level difference at part "a".
• Adjust opening and closing of the front win- ★ Install the right corner block so that level
dow assembly according to the following pro- difference "b" between the rail and right
cedure. corner block (3) will be 0 – 1.0 mm. Check
that the right corner block is not projected
1. Open and close the front window to check from the rail at the rolling surface of the
that it does not interfere with the rails and the roller.
rollers are not hitch.
★ Secure roller clearance "c" at part P.
2. If there is any problem in opening or closing
of the front window, loosen the mounting
bolts of roller adjustment brackets (16) and
(17) and adjust the condition of the front win-
dow, and then tighten the mounting bolts
again.
3 Mounting bolt: 9.8 Nm {1.0 kgm}
3. Raise the front window assembly and fix it

with the rear locks (on both sides).
★ Check that the locks in the rear of the
operator's cab are applied securely.
30-109
(8)
12
5. Install left corner blocks (1) and (2) and secure 6. Adjust the striker bolts according to the fol-
left corner bracket (6) with left striker bolt (4). lowing procedure (Adjust the "CLOSE" posi-
★ Tighten the striker bolt securely after tions of the front window assembly locks).
adjusting it in step 6. 1) Tighten left striker bolt (4) and right
★ Install the left corner blocks so that there striker bolt (5) at roughly right positions
will be no level difference at 2 part "d". so that front window glass (18) will be fit-
★ Secure roller clearance "e". ted to cab-side trim seal (19).
30-110
(8)
12
2) Open and close the front window assem- 3) After checking the above items, if neces-
bly and check the working condition of sary, adjust them by moving right and left
both locks (20) and (21). striker plates (22) at the rear of the opera-
tor's cab.
i) If both locks do not work normally,
move the striker bolts toward the rear
of the cab and tighten them again.
ii) After moving the striker bolts, check
the fitness of the front window glass
and cab-side trim seal which was
checked in step 1).
iii) Repeat the work in i) and ii) until the
fitness of the front window and the
working condition of both locks (20)
and (21) are acceptable, and then
tighten the striker bolts.
7. After adjusting the striker bolts, splash water

heavily over the front window glass and check 9. Adjust the front window stoppers.
that the water does not leak into the cab. 1) After adjusting "opening" lock of the front
window assembly in step 8, check the
8. Adjust the "opening" lock of the front window contact of both front window stoppers
assembly. (23).
1) After adjusting the "closing" lock of the 2) If both stoppers (23) do not contact nor-
front window in steps 6 and 7, raise the mally, adjust and fix them at places where
front window assembly to the ceiling. they contact normally.
2) Set the right and left front window assem-
bly locks at the rear of the operator's cab
to the "OPEN" positions, and then check
the following items.
• heck that right and left locks (20) and
(21) are closed normally.
• Check that right and left locks (20) and
(21) are inserted in parallel in right
and left striker plates (22).
• Check that right and left rubber stop-
pers (24) are in contact with the front
window assembly and their deflection
allowance is 1.5 – 3.0 mm.
30-111
(8)
12
10. Check the latching effort of the front window

assembly.
1) After finishing steps 6 – 9, check that latch-
ing efforts of both locks (20) and (21) are
even.
★ Check the latching efforts on both
"closing" side (in the front of the oper-
ator's cab) and "opening" side (in the
rear of the operator's cab).
[*3]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
30-112
(8)
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY
12
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
REMOVAL

1. Remove cover (1) and then disconnect the

wiring connector P15 for air conditioner sun-
light sensor (2).
★ Lift the cover up to remove it.
2. Remove the three mounting screws and

remove monitor assembly (3).
★ Disconnect monitor panel wiring connec-
tors P01, P02 and P03 at the three points,
and then remove the monitor assembly.
INSTALLATION
30-113
(8)
DISASSEMBLY AND ASSEMBLY GOVERNOR, PUMP CONTROLLER ASSEMBLY
12
REMOVAL AND INSTALLATION OF GOVERNOR,
PUMP CONTROLLER ASSEMBLY
PC300, 300LC-7 Serial No. 40001 – 45000 PC300, 300LC-7 Serial No. 45001 and up
PC350, 350LC-7 Serial No. 20001 – 25000 PC350, 350LC-7 Serial No. 25001 and up
REMOVAL REMOVAL
k First, disconnect the cable from the negative k First, disconnect the cable from the negative
(–) terminal of the battery. (–) terminal of the battery.
1. Remove cover (1). 1. Remove covers (1), (2) and (3).
2. Disconnect governor, pump controller wiring 2. Disconnect governor, pump controller wiring
connectors C01 (2), C02 (3) and C03 (4). connectors C01 (4), C02 (5) and C03 (6).
3. Remove the four mounting bolts and remove 3. Remove the four mounting bolts and remove
governor, pump controller assembly (5). governor, pump controller assembly (7).
INSTALLATION INSTALLATION
• Install in reverse order of removal. • Install in reverse order of removal.
30-114
(8)
90 OTHERS
Hydraulic Circuit Diagram . . . . . . . . . . 90-3
PC300-7,PC300LC-7: Serial No. 40001–45000

PC350-7,PC350LC-7: Serial No. 20001–25000
Electrical Circuit Diagram (1/4) . . . . . 90-5
Electrical Circuit Diagram (4/4) . . . . 90-11
PC300-7,PC300LC-7: Serial No. 45001 and up

PC350-7,PC350LC-7: Serial No. 25001 and up
PC300-7 90-1
(6)
OTHERS HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
PC300-7 90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4)
PC300-7, PC300LC-7: Serial No. 40001 – 45000
PC350-7, PC350LC-7: Serial No. 20001 – 25000
FOR MULTI MONITOR
PC300-7 90-5
(6)
PC300-7, PC300LC-7: Serial No. 40001 – 45000
PC350-7, PC350LC-7: Serial No. 20001 – 25000
FOR MULTI MONITOR
PC300-7 90-7
(6)
PC300-7, PC300LC-7: Serial No. 40001 – 45000
PC350-7, PC350LC-7: Serial No. 20001 – 25000
FOR MULTI MONITOR
PC300-7 90-9
(6)
PC300-7, PC300LC-7: Serial No. 40001 – 45000
PC350-7, PC350LC-7: Serial No. 20001 – 25000
FOR MULTI MONITOR
PC300-7 90-11
(6)
PC300-7, PC300LC-7: Serial No. 45001 and up
PC300-7 90-13
(6)
PC300-7 90-15
(6)
PC300-7 90-17
(6)
PC300-7 90-19
(6)

Komatsu Pc300-7 Pc300lc-7 Pc350-7 Pc350lc-7 Shop Manual Sebm025810

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Komatsu Pc300-7 Pc300lc-7 Pc350-7 Pc350lc-7 Shop Manual Sebm025810

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SEBM025810

MACHINE MODEL SERIAL NUMBER

• PC300, 300LC, PC350, 350LC-7 mount the SAA6D114E engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ...................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Important safety notice

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual Revised edition mark

3. Additional pages: Additional pages are indi-

• If a part cannot be smoothly removed from the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

Standard tightening torque

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque (Nm {kgm})

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque (Nm {kgm})

Tightening torque for 102 and 114 engine series

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —

(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —

Electric wire code

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 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 85 0.80 42.73 11.4 135 Starting

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

Millimeters to inches (B)

Liter to U.S. Gallon

Liter to U.K. Gallon

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0