Sm Pc300,350, Lc6

SEBM014302Pc300,300Lc-6 Pc350,350Lc-6 MACHINE PC300-6 PC3OOLC-6 PC350-6 PC35OLC-6 . MODEL SERIAL NUMBER 33001 and up 33001 and up 12001 and up 12001 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, 350-6 mount the SAAGD108-2 engine. For details of the engine, see the 108-2 Series Engine Shop Manual. . 0 1997 KOMAlbU All Rights Reserved 12-97(01)01301 00-l 0 CONTENTS No. of page 01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l IO STRUCTURE AND FUNCTION ... . ... . ... .. ... . ... .. .. .. . ... ... .. ... 10-I 20 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m....... 20-I 30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . ..a................. 30-I 40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . ..n........s....... 40-l SO OTHERS . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-I 00-2 0 PC300, 350-6 LIST OF REVISED PAGES The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below. Mark Indication Action required 0 0 Page to be newly added Add I Page to be replaced Replace I t 1 1 Page to be deleted Discard Pages h Gng no marks are those previously revised or made additions. LIST OF REVISED PAGE Mark Page Time of revision Vlark Page @ Ol- 3 Ol- 4 Ol- 5 Ol- 6 Ol- 7 Ol- 8 Ol- 9 01-10 01-11 01-12 01-13 Time oi Mark revision Page Time of Mark revision Page Time of vlark Page revision IO-78 IO-80 IO-81 IO-82 IO-84 IO-85 IO-86 IO-88 IO-89 IO-90 IO-92 IO-93 10-94 IO-96 IO-97 IO-98 10-100 10-101 IO-102 IO-104 IO-105 IO-106 lo-108 IO-109 10-110 IO-112 IO-113 IO-114 Time of revision 0 oo- 1 oo- 2 IO-18 IO-19 IO-20 IO-21 IO-22 IO-24 IO-25 IO-26 IO-27 IO-28 IO-29 IO-30 IO-31 IO-49 IO-50 IO-51 IO-52 IO-53 IO-55 IO-56 IO-57 IO-58 IO-59 lo-60 IO-61 IO-62 IO-63 IO-64 IO-65 IO-66 IO-67 IO-68 IO-69 IO-70 IO-71 IO-72 IO-73 IO-74 IO-75 IO-76 IO-77 0 @ @ @ @ @ @ 0 0 0 l 0 oo- 2-l oo- 2-2 00- 2-3 00- 2-4 oo- 2-5 oo- 3 oo- 4 oo- 5 00- 6 oo- 7 00- 8 oo- 9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 lo- 1 IO- 2 IO- 3 IO- 4 IO- 5 IO- 6 IO- 7 IO- 8 IO- 9 IO-IO IO-12 IO-13 IO-14 IO-32 IO-33 IO-34 IO-35 IO-36 IO-38 IO-39 IO-40 IO-41 IO-42 IO-43 IO-44 IO-45 IO-46 IO-48 Ol- 1 Ol- 2 IO-15 IO-17 PC300, 350-6 oo-2- 1 0 LIST OF REVISED PAGES Mark Page Time o Mark revisior Page Time o Mark revision Page Time o Mark revision Page Time o Mark revisior @ @ @ @ @ @ @ @ @ @ 0 @ @ @ @ 0 @ (iJ @ @ @ @ @ @ @ 0 @I @ 0 @ @ @) @ @ 0 0 @) Page Time of revision @ @ @ @ @ @ @ @ @ @ @ @ 0 @ @ 0 0 0 @ @ @ @ @ @ 0 @ @ @) @ @ @ @ 0 @ @ @ @ @ @ @ IO-116 IO-117 lo-118 IO-120 10-121 10-122 IO-123 lo-124 lo-125 lo-126 IO-128 IO-129 IO-130 IO-131 IO-132 IO-133 IO-134 10-135 IO-136 IO-137 IO-138 10-139 IO-140 10-141 IO-142 IO-143 10-144 IO-145 lo-146 10-147 lo-148 IO-149 IO-151 IO-152 IO-153 IO-154 IO-155 lo-156 10-157 IO-158 IO-159 IO-160 lo-162 lo-163 IO-164 lo-165 IO-166 IO-168 IO-169 IO-170 10-171 IO-172 IO-173 10-174 IO-175 IO-176 IO-178 IO-179 lo-180 lo-181 lo-182 lo-183 IO-185 IO-186 IO-187 IO-188 IO-189 IO-190 IO-191 IO-192 IO-193 IO-194 lo-196 10-197 IO-198 IO-199 IO-200 IO-201 IO-202 lo-203 IO-204 lo-205 IO-206 IO-207 lo-208 IO-209 IO-210 IO-212 IO-213 IO-214 IO-215 IO-216 IO-217 IO-218 IO-219 IO-220 10-221 IO-222 IO-223 20-102 20-103 20-104 20-105 20-106 20-107 20-108 20-109 20-110 20-111 20-112 20-113 20-114 20-115 20-116 20-117 20-118 20-119 20-120 20-121 20-122 20-203 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212 20-214 20-215 20-216 20-217 20-218 20-219 20-220 20-221 20-222 20-223 20-224 20-225 20-226 20-227 20-228 20-229 20-230 20-231 20-232 20-233 20-234 20-235 20-236 20-237 20-238 20-239 20-240 20-241 20- 1 20- 2 20- 4 20- 5 20- 6 20- 7 20- 8 20- 9 20-10 20-11 20-12 20-13 20-14 20-15 20-16 20-17 20-18 20-19 20-20 20-123 20-124 20-125 20-126 20-127 20-128 20-129 20-130 20-131 20-132 20-133 20-134 20-135 20-136 20-137 20-138 20-201 20-202 @ @ 20-242 20-243 00-2-2 0 PC300, 350-6 Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision @ @ @ @ Mark Page Time of revision @ @ @ @ @ @ @ @ @ @ @ @ @ 0 @ 0 @ 0 @ @ @ @ @ @ 0 0 @ @) @ @ 0 @ @ @ 0 @ 0 @ @ 0 . 20-244 20-245 20-246 20-247 20-248 @ @ @ @ @ 20-401 20-402 20-403 20-404 20-405 20-406 @ @ @ @ @ @ @ @ @ @ 0 @ @ @ @ @ @ @ @ @ @ @ @ 20-468 20-469 20-470 20-471 20-472 20-473 20-474 20-475 20-476 20-477 20-478 20-479 20-480 20-481 20-482 20-483 20-484 20-485 20-486 20-487 20-488 20-489 20-490 20-491 @ @ @ @ @ @ 0 0 @) @ 0 0 0 0 0 @ @ 0 @ @ @ @ @ @ @ @ @ @ @ 20-511 20-512 20-513 20-514 20-601 20-602 20-604 20-605 20-606 20-551 20-552 20-553 20-554 20-555 20-556 20-557 20-558 20-559 20-560 20-561 20-562 20-564 20-565 20-566 20-567 20-568 20-569 20-570 20-571 20-572 20-573 20-574 20-575 20-576 @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ 0 @ 20-607 20-608 20-609 20-610 20-611 20-612 20-613 20-614 20-615 20-616 20-617 20-618 20-619 20-620 20-621 20-622 20-623 20-624 20-625 20-626 20-627 20-628 20-629 20-630 20-631 20-632 20-633 20-634 20-635 20-636 20-638 20-639 20-640 20-641 20-642 20-301 20-302 20-303 0 @I 0 20-407 20-408 20-409 20-410 20-351 20-352 20-354 20-355 20-356 20-357 20-358 20-359 20-360 20-361 20-362 20-363 20-364 20-365 20-366 20-367 20-368 20-370 20-371 20-372 20-373 20-374 20-375 20-376 20-377 20-378 20-379 20-380 20-381 @ @ @ @ 0 @ @ @ 0 0 @ @ @ @ 0 @ @ @ @ 0 0 @ @ @) 0 @ 0 0 @ 20-411 20-412 20-413 20-414 20-415 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-423 20-451 20-452 20-454 20-455 20-456 20-457 20-458 20-459 20-460 20-461 20-462 20-463 20-464 20-465 20-466 20-467 @ 0 @ @ @ @ 0 @ @ @ 0 @ @ @ 0 @ 20-492 20-493 20-494 20-495 20-496 20-501 20-502 20-503 20-504 20-505 20-506 20-507 20-508 20-509 20-510 0 @ @ @ 0 0 @ @ @ @) 20-577 20-578 20-579 20-580 20-581 20-582 20-583 20-584 20-585 PC300, 350-6 00-2-3 0 LIST OF REVISED PAGES Mark Page Time oi Mark revisior Page Time of Wark revision 0 0 0 0 0 0 0 0 0 0 0 Page Time 01 Mark revisior Page Time of dark revision @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ Page Time of revision @ @ @ 20-643 20-644 20-645 0 0 0 0 0 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-46 30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97 30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152 30-153 30-154 30-155 0 0 0 30-156 30-157 30-158 0 0 30- 1 30- 2 30- 3 30- 4 30- 5 30- 6 30- 7 30- 8 30- 9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-29 30-30 30-31 30-32 30-33 30-34 30-35 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 40- 1 40- 2 40- 4 40- 5 40- 6 40- 8 40- 9 40-10 40-12 40-13 40-14 40-15 40-16 40-17 40-18 40-19 40-20 40-22 40-23 40-24 40-25 40-26 40-27 40-28 40-29 40-30 40-31 40-32 40-33 40-34 40-35 40-36 40-37 40-38 40-40 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00-2-4 0 PC300, 350-6 LIST OF REVISED PAGES Mark Page Time revisit t Mark Page Time o revision Mark Page Time c revisio Mark Page Time o revision Mark Page Time of revision 40-41 40-42 40-43 40-44 40-45 40-46 40-47 40-48 40-49 go- 1 gogogogo3 5 7 9 PC300, 350-6 00-Z-5 SAFETY SAFETY NOTICE r-~Proper service designed To prevent manual. Mistakes carefully in operation SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE and repair is extremely important for safe machine operation. The service and repair techniques are both effective by Komatsu recommended by Komatsu and described in this manual and safe. Some of these techniques for the specific purpose. require the use of tools specially injury to workers, the symbol A is used to mark safety precautions should always be followed arise, first consider in this care- The cautions accompanying situation these symbols fully. If any dangerous take the necessary arises or may possibly safety, and actions to deal with the situation. GENERAL PRECAUTIONS are extremely dangerous. Manual 6. Decide a place in the repair workshop to keep keep tools and removed the tools Always Smoke Read the Operation and Maintenance the machine. or repairs, parts. Always and parts in their correct places. keep the work area clean and make only in the areas provided for smok- BEFORE operating sure that there is no dirt or oil on the floor. ing. Never smoke while working. 1. Before carrying which 2. When out any greasing read all the precautions given on the decals are fixed to the machine. carrying out any operation, always PREPARATIONS FOR WORK Before adding oil or making or tracks any repairs, and the wear safety shoes and helmet. loose work clothes, missing. . Always . Always wear wear Do not wear park the machine on hard, level ground, to prevent or clothes with buttons hitting grind- safety glasses when safety glasses etc. when block the wheels machine Before ground. equipment parts with a hammer. ing parts with a grinder, 3. If welding trained, ways from moving. starting If this work, is not lower blade, ripper, to the the bucket or any other work equipment possible, out the work, alhand repairs are needed, experienced carrying welding welder gloves, always have a carry insert safety pin or use blocks to prevent the work from falling. In addition, be sure to lock all the control ing signs on them. 9. When disassembling or assembling, blocks, jacks support or stands levers and hang warn- work. When wear out welding apron, shield, cap and other clothes suited for welding work. When carrying out any operation before starting. with two Always in- the machine with or more workers, ating procedure always agree on the oper- before starting 10. Remove work. the steps or ladders or all mud and oil from use the handrails, form your fellow workers before starting any step of the operation. hang UNDER in the operator’s Keep all tools Before starting work, REPAIR signs on the controls compartment. in good condition and learn other places used to get on and off the machine. Always steps when Never jump impossible getting on or off the machine. If it is or ladders on or off the machine. to use the handrails, the correct way to use them. steps, use a stand to provide safe footing. 00-3 SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 11 When removing or hydraulic out. disconnecting of the oil, water the pressure or removing completely compofirst the from or air circuits, loosen them spurting Before nents remove circuit. 12. The when Wait water and oil in the circuits is stopped, are hot the oil filler cap, drain plug pressure measuring plugs, the oil from 19. Be sure to assemble original . When places. Replace any damaged installing all parts again in their parts with new parts. be sure is beby contact hoses and wires, slowly to prevent that they will not be damaged ing operated. 20. When sure installing that they high pressure with other parts when the machine hoses, make Damaged careparts are not twisted. tubes are dangerous, ful when circuits. installing Also, the engine so be careful to cool before so be extremely connecting tubes for high pressure check that installed. not to get burned. for the oil and water out any work carrying circuits. 13. Before starting work, remove the leads from the battery. the negative Always remove first. use a hoist the lead from (-) terminal on the oil or water are correctly 21 When assembling use the specified installing or parts which high speed, or installing tightening parts, always torques. When protective vibrate parts such as guards, violently correctly. or rotate at careful to check be particularly that they are installed 22. When fingers fingers 23. When which has aligning caught 14. When raising heavy components, or crane. two holes, never insert your Be careful not to get your in a hole. hydraulic pressure, check assem- or hand. Check that the wire rope, chains and hooks are free from damage. Always ample Install places. slowly use lifting equipment capacity. the lifting to prevent equipment or crane at the correct and operate from hitany Use a hoist measuring that the measuring tool is correctly bled before taking any measurements. 24. Take care when When removing removing the track, or installing the the component tracks of track-type rates suddenly, machines. the track sepa- ting any other part. Do not work with part still raised by the hoist or crane. 15. When ternal spring, removing pressure always covers which or under leave two are under infrom a so never let anyone stand at either end of the track. pressure bolts in position release the pres- on opposite sides. Slowly sure, then slowly loosen the bolts to remove. 16. When wiring 17. When removing components, be careful not Damaged fires. to break or damage the wiring. may cause electrical removing piping, stop the fuel or oil Fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor even start fires. 18. As a general mum parts. rule, do not use gasoline when washing to can cause you to slip, or can wash parts. In particular, of gasoline use only the minielectrical 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 the contents him the correct way to perform of this manual and use it to full repairs and make judgements. effect at every opportunity. Make sure you understand This shop manual service workshop. chapters are further mainly contains the necessary technical information is divided for operations performed in a For ease of understanding, divided the manual into the following chapters; these into the each main group of components. STRUCTURE AND FUNCTION This section explains an understanding the structure and function of each component. It serves not only to give for troubleshooting. of the structure, but also serves as reference material TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion charts correlating of the checks and repairs. to “Causes” are also included in this section. Troubleshooting “Problems” DISASSEMBLY AND ASSEMBLY This section assembling explains the order to be followed when removing, installing, disassembling or each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD standards when inspecting disassembled parts. This section gives the judgement NOTICE The time with specifications and the without latest date. contained any advance in this notice. shop manual are subject to change given in the at any book Use the specifications 00-5 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: REVISED EDITION MARK When pages. a manual is revised, an edition bottom mark of the ((iJ@@....) is recorded on the Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume: Each issued as one volume to cover all models REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page. I These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Symbol Item Safety Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening toraue during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water AL l-T Item number Y~~~~~~6,ge each item. Example 2 (Engine volume): (IO. Structure number for * Caution el kg Weight TT 12 - 5 lUnit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. Tightening torque & Coat Oil, water 3. Additional cated pages: Additional pages are indiafter the Q by a hyphen (-1 and number page number. Example: 1o-4 File as in the example. 12-203 IO-5 12-204 00-6 FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol & Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. . If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I) Check for removal of all bolts fastening parts. part causthe part to be reof another 100% 88% 79% 71% 41% SAM)0479 the part to the relative 2) Check for existence ing interference moved. with WIRE ROPES 1) Use adequate weight the table below: ropes depending on the to of parts to be hoisted, referring 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. A Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 * 4) l- Allowable kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 load tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0 Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN (1000 kg) vertically, at various hanging angles. When two ropes sling a load vertically, to 19.6 kN 12000 kg) of total weight suspended. (1000 hanging This weight two becomes make kg) when angle. ropes up can be 9.8 kN a 120” two force On the other hand, ropes are subjected to an excessive as large as 39.2 kN 14000 kg) if they sling a 19.6 kN (2000 kg) load at a lifting angle of 150”. The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. portion I I I I I I 2) Sling wire ropes from the middle of the hook. 30 Lifting 60 mole 90 (deoreel 17.0 150 SAD00480 00-7 FOREWORD COATING MATERIALS COATING MATERIALS used for Sr The recommended coating materials such as adhesives, gasket sealants and greases disassembly and assembly are listed below. Ir For coating materials not listed below, use the equivalent of products shown in this list. Category <omatsu code LT-IA Part No. 790-129-9030 Q’w 150 g I Container Tube l Main applications, features Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive or sealant for metal, glass and plastic. l LT-IB 790-I 29-9050 20 9 (2 pes.) I Polyethylene container l LT-2 0994040030 50 g Polyethylene container l 790-129-9060 Adhesive: l LT-3 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120 1 kg iardening agent: 500 g 250 g Can Adhesives LT-4 Holtz MH 705 Polyethylene container l Used as sealant for machined Used as heat-resisting ing engine. holes. l sealant for repair- l Three bond 1735 790-129-9140 50 g Polyethylene l l Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals. Features: Resistance to heat, chemicals Used at joint portions subject to high temperatures. Used as adhesive or sealant for gaskets and packing of power train case, etc. Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations, used to prevent seizure. Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc. l Aron-alpha 201 790-129-9130 29 Polyethylene container l l Loctite 649-50 l ‘9A-1299110 50 cc Polyethylene container l LG-1 790-129-9010 200 g Tube l l l Gasket sealant LG-3 790-129-9070 1 kg Can l 00-8 FOREWORD COATING MATERIALS ,,,.,,,,....,,.., o’w Container l Main applications, features Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc. Used as heat-resisting sealant for repairing engine. Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type l LG-4 790-129-9020 200 g Tube l l l LG-5 790-129-9080 1 kg Polyethyleni container l l Gasket sealant LG-6 09940-00011 250 g Tube l l l LG-7 09920-00150 150 g Tube l Three bond 1211 LM-G l 790-129-9090 l Molybdenum disulphide lubricant 09940-00051 l LM-P 09940-00040 Tube l G2-LI SYG2-4OOLI SYG2-35OLI SYG2-4OOLI-A SYG2-16OLI SYGA-16OCNLI l Various Various l Grease GS-CA SYG24OOCA SYG2-350CA SYGS-4OOCA-A Various SYG2-160CA SYGA-1 6OCNa 400 g (IO per case) Various Used for normal temperature, light load bearing at places in contact with water or steam. Molybdenum disulphide lubricant l Used for places with heavy load SYG2-400M Belows typ 00-9 35k7.7kO. (Always use torque wrench).4 196.1f0.5f 10.6 8.5f0.FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques Thread diameter of bolt mm 6 8 IO 12 14 16 18 20 22 24 27 3: 36 39 for metric bolts and nuts.2f 1. Tightening Nm 65.3 6.2+ 5.3+ 29.5f 4.2 1.7 11.6f 4.9 49f19.2f 49 torque km 2.6 137.8 TIGHTENING TORQUE OF HOSE NUTS Use these torques Nominal 02 03 04 05 06 10 12 14 for hose nuts. Width across flat mm 19 24 27 32 36 41 46 55 Nm Tightening 24.85 kgm 0.5fl 28.2kO.5+3 39f4 56+6 76f8.9 40.6 78.5 4.4 31f3 66f7 113flO 177+19 279f30 382539 549f59 745f83 927f103 1320f140 2210+240 1720+190 2750f290 3290f340 kgm 1.7 11. Width across flats mm IO 13 17 19 22 24 27 30 32 36 41 50 46 55 60 Nm 13.9kO.4 176.5 5+2 8f2 14f3 18f3 20+5 25f5 30+5 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques Thread diameter mm 10 12 16 for split flange Width across flat mm 14 17 22 bolts.1*49 245.8 112f9. Thread diameter mm 14 18 22 24 30 33 36 42 No.2f49 294.5 94.35kO.7f0.5f3 00-l0 .5fl 18f2 28.5k29.5+ 19.8 279f29 torque knm 6.7f6.4kO.8kO.85k 1.95 18.5 135+15 175+20 225f25 28Ok30 335f35 Thread diameter of bolt mm 6 8 10 12 Width across flats mm IO 13 14 27 Nm 7.9 82.15 3. 96 29.2 3f0.27f1.6 421.5 13f2 15. 12 14 for O-ring Thread boss connector diameter Width across flat mm Varies depending on type of connector.4 176.06 10.6 78.5 8 10 12 14 16 18 20 :: 33 36 42 52 - .4k 58.3 torque kgm 3.9 49f 19.8f0.lf 19.5f 13.4 196.6 137.5 210.6f9.5 7fl llf1.15 1.9 39.47 11.FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques Nominal 02 03.04 05. Tightening Nm 34.96 22.1&49 245.8f14.5+3 33f 4.5f2.8 107.9 93.47 17.Sealing surface TIGHTENING TORQUES OF FLARE NUT Use these torques Thread diameter mm 14 18 22 24 30 33 36 42 for O-ring Width boss connector Tightening torque across flat mm 19 24 27 32 36 41 46 55 I Nm 24.15f0.5f29. No.5 21.2+ 4.2+49 I km 2.35+ 1.2 2.3f 0.2+ 49 294.54k1.4+ 19.3+ 4.5+ 19.5 mm 14 20 24 33 42 TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques for O-ring Thread boss connector diameter mm 08 10 12 14 16 18 20 24 3: 36 42 52 Nominal No.64k1.9 49+ 4.75f0.7 127.5 5+2 8f2 14f3 18f3 20f5 25f5 30+5 00-l 1 .1 -r kw 0.4f44.5f0.6 151. Width across flat mm 14 17 19 22 24 27 30 32 32 36 - Tightenins I torque Nm 7.9 68.5 5kO.1f9.4 323.15 1.3f29.5fl 14.5 4co.1f 132.7f29.5+2 43f6 89.5 9.5k 4.4f 4.8 142.9524.5kO.8 877. 20 * 0.12 + 0. Tightening Nm 351 8f2 12+2 15+2 24 f 4 36 f 5 60 f 9 Use these torques Thread diameter torque kgm 0.20 0.22 TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS) Use these torques Thread for metric eye joints of 102 Series Engine.85 f 0.45 4.67 f * f f f 0.61 zk 1.02 2.10 f 0.20 0.45 3.67 6. Tightening Nm 10 24 43 77 + + + f 2 4 6 12 diameter mm 6 8 10 12 torque kgm 1.81 1.22 1.20 + 0.20 a 0.51 TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS) for inches tapered screws of 102 Series Engine.51 rk0.41 IL0.81 1.53 2.22 2.31 0.38 7.41 f 0.92 inches 1 I16 l/8 114 318 112 314 1 00-l 2 .45 3.FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS) Use these torques Thread for metric bolts and nuts of 102 Series Engine.20 0.41 f 0.02 1. Tightening Nm 8+2 IO rk2 12 *2 24 f 4 36 f 5 diameter mm 6 8 10 12 14 torque kgm 0.41 0. 36 42. wire NityaF.23 13. lighting.1 4.0 11.s$nds 0. Charging Starting Starting signal etc. Lighting.4 12 20 37 59 135 Applicable circuit Starting.sof 11 Dia. T.32 0.FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams.& IBlack & Yellow1 Red & Black Yellow & Black Green & Red BR RY Code WL YG GY 4 liary Color White & Blue Code WG Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow RG YL GB LB 5 Color White & Green Code 6 Color - Red & Green Yellow & Blue Green & Black Blue & Black RL Red & Blue YW GL - Yellow&White Green & Blue 00-l 3 .. This wire code table will help you understand WIRING DIAGRAMS.88 2.32 0.32 0. and signal (Glow plug) 2 5 15 40 60 100 26 65 84 85 127 217 I I 0.45 0. .6 7.1 I I 13.6 I I 178 230 I Starting I Starting CLASSIFICATION BY COLOR AND CODE ~x1 pfkr1 pri_ Charging / Ground B Black - 1 Starting B Black BW Black &White 1 Lighting R Red RW instrument Y Yellow YR I I Signal I I I Other L Blue LW Code W White WR White & Red WB G Green GW marY Color Code 2 Color ICode 3 Red & White Yellow & Red IGreen & White Blue & White 1 - 1 BY 1 RB YB GR LR Blue & Red LY 1 Color1 White & Black1 A.84 109..09 5. CLASSIFICATION BY THICKNESS Conner . various colors and symbols are employed to indicate the thickness of wires.4 3.80 I 63.80 0.73 2.80 Cross section (mm2) 0. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. signal etc.6 17. 307 3.992 3.874 3.FOREWORD CONVERSION TABLE CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion details Table in this section is provided to enable simple conversion of figures.638 3.787 1.701 3.03937 in 8 0.118 0. Convert 550 mm into inches. so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. then draw a horizontal line from @. . . 0.890 2.512 0. .394 0. .165 inches.157 0.362 2. 55 mm = 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value...953 3.228 3. 60 70 80 90 1.378: 1. . . . .283 2.780 7 0.244 2. Table to convert from millimeters to inches Locate the number 50 in the vertical column at the left side. ..457 1..819 1 mm = 0.433 0. .181 1. .315 0.929 2.354 0.913 2. .898 0 10 20 30 40 0 0.299 1.543 3. Convert (I) 55 mm into inches. Method of using the Conversion 1..008 . This gives 550 mm = 21.417 1. .. .260 1.906 1.520 2.811 2 205 2:598 2. see the example given below. .189 3.756 2.. Tvi 2.339 1.732 5.850 2.236 0. (I) The number 550 does not appear in the table. .110 3. .969 .2. EXAMPLE .165 inches.622 3.. take this as @I.661 ..835 2.858 9 0.268 3.079 0. .583 2.039 0. . ..709 1. ..402 2. . . 0. . (2) Carry out the same procedure as above to convert 55 mm to 2...2.. line (2) Locate the number down from @.795 3. . then draw a perpendicular the two lines cross as 0.551 0..063 1.654 3 0.. .150 3..504 3. take this as @.220 1.630 1.197: 0.866 1.677 3.472 0.669 1..425 3.496 1.142 1..102 1.126 .. (3) Take the point where from millimeters 2. .693 4 0. .717 3. 2.827 1. This point @ gives the value when converting to inches.071 3. .740 00-14 .465 3.276 0.614 2 0. Therefore.032 3.575 69 50 .772: 6 0.945 1.65 inches.559 2. .386 3. (3) The original value (550 mm) was divided by 10. so multiply 2.748 1.323 2. .. Millimeters to inches 0 1 0.591..536 1.024 1.984 i 1.346 3. . For of the method of using the Conversion Table... 5 in the row across the top. 2046 lb 0 0 10 20 30 40 11 2.087 2.677 3.07 55.39 209.780 2.30 165.299 1.03937 in 01---l / 2 / 3 ~1 4 1 5 1 6 1 7 1 8 1 9 0 IO 20 30 40 0 0.25 143.512 0.480 2.465 3.220 1.268 3.03 119.866 1.60 211.37 198.85 138.717 3.78 202.669 1.64 125.276 0.008 2.78 105.21 218.84 41.85 127.307 3.75 94.102 1.10 163.57 103.53 178.28 154.142 1.520 2.787 1.51 167.43 37.693 0.73 180.03 50 60 70 80 90 110.536 1.559 2.701 2.032 3.61 28.76 191.FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.82 9 0 22.21 6 13.12 174.614 0.748 1.394 0.42 112.638 3.929 50 60 70 80 90 1.71 72.984 1.244 2.598 2.91 74.66 147.378 1.071 3.53 81.551 0.94 182.26 00-15 .02 33.46 48.27 57.354 0.41 26.339 1.66 50.44 123.00 15.496 1.34 90.827 1.583 2.89 63.205 2.23 132.898 Kilogram to Pound 1 kq = 2.14 185.346 3.118 0.46 145.05 130.23 35.323 2.80 213.953 3.260 1.472 0.425 3.62 114.858 2.417 1.64 39.48 156.80 4 5 11.37 101.165 2.039 0.913 3.795 3.945 1.18 8.906 1.441 2.62 19.07 152.48 59.32 79.236 0.98 108.543 2.969 2.283 2.433 0.457 1.09 66.68 61.811 0.181 1.079 0.44 134.24 121.197 0.402 2.386 3.05 44.83 116.16 99.20 24.110 3.96 97.01 216.19 207.55 92.661 2.654 0.362 2.047 2.063 1.25 46.32 176.591 0.709 1.157 0.622 2.17 196.30 68.150 3.575 0.57 200.504 3.874 3.05 141.73 83.228 3.71 169.96 194.64 136.890 0.819 2.91 171.39 / 2 4.732 0.50 70.126 2.89 160.86 51.14 88.756 3.59 ~ 3 6.35 187.69 158.024 1.740 2.992 3.98 205.93 85.82 30.835 3.189 3.55 189.12 77.87 149.772 0.850 0.41 7 8 17.630 1.315 0. 511 26.680 2.076 8.113 4.799 0.158 19.518 16.397 0.719 7.586 18.119 1.418 15.661 10.529 17.457 11.473 16.897 12.700 20.917 21.839 7.906 5.378 5.078 16.019 0.279 7.559 1.775 13.283 7.870 23.579 10.838 18.756 21.285 21.679 1.019 7.982 11.737 16.198 15.760 3.755 7.322 17.228 20.640 4.159 8.039 9.818 20.K.339 1.379 19.357 21.040 13.568 14.398 17.944 50 60 70 80 90 13.189 10.618 17.340 8.831 0.624 1.813 22.793 3.278 18.398 24.420 4.117 12.880 3.774 12.662 24.171 19.459 0.738 16.888 1.379 8.153 Liter to U.919 10.209 15.264 2.619 6.983 25.179 6. Gal 1 2 3 4 5 6 7 8 9 0 0 10 20 30 40 0 2.246 11.359 1.642 5.FOREWORD CONVERSIONTABLE Liter to U.S.440 2.304 14.265 16. Gallon l! = 0.585 4.281 13.321 3.492 21.095 0.938 19. Gallon I! = 0.438 13.980 4.963 6.658 13.869 9.964 20.152 1.096 14.001 16.300 5.599 8.298 16.21997 U.540 3.303 12.170 5.577 21.548 8.643 19.454 11.K.499 7.858 16.625 5. Gal 1 2 3 4 5 6 7 0 8 / 9 0 10 20 30 40 0 2.907 19.318 14.958 17.416 2.259 9.058 18.510 12.100 3.227 6.479 9.080 5.059 7.320 3.797 11.S.247 25.337 12.115 18.098 14.134 23.718 11.077 22.257 20.899 1.926 24.491 7.190 24.605 23.795 17.341 22.697 20.237 11.058 17.200 4.832 14.020 21.850 18.528 3.638 15.2642 U.939 8.849 4.017 11.435 20.498 18.740 5.359 10.969 9.220 2.598 19.557 12.528 14.860 5.677 12.549 22.878 14.399 6.037 20.178 17.778 50 60 70 80 90 10.139 10.137 21.925 10.520 5.378 19.812 8.604 9.758 14.133 9.998 13.978 15.660 2.777 00-l6 .477 20.567 0.239 0.434 6.719 25.698 6.039 2.950 6.361 15.819 9.889 15.718 18.455 25.057 3. 9 224.9 441.9 397.3 795.7 188.1 976.0 817.6 1301.3 918.6 651.4 209.8 593.2 202.0 289.1 745.7 150 160 170 180 190 1084.8 1309.5 788.2 781.3 1200.2 1381.5 585.8 1027.7 1244.6 151.8 159.7 1106.4 1294.0 1345.7 1273.3 1092.6 1396.1 1193.8 998.2 376.8 282.0 368.4 549.3 701.0 1222.3 672.8 1432.1 571.4 1388.233 ft.7 434.1 137.8 687.7 1367.6 896.1 231.9 875.3 578.3 7.4 860.9 737.6 730.8 426.3 36.1 882.4 1265.5 614.9 130.6 1207.7 622.8 21.7 839.5 1359.3 484.9 535.9 1403.2 1121.0 166.9 658.3 1129.8 564.7 94.5 1048.3 267.0 1439.3 1323.5 1019.8 810.5 491.5 708.3 1012.2 65.8 904.6 556.9 318.FOREWORD CONVERSIONTABLE kgm to ft.4 238.7 1135.5 43.6 462.6 1179.6 245.2 824.3 173.8 470.3 144.1 100 110 120 130 140 723.1 448.3 752.7 311.2 1070.8 499.4 643.0 1251.5 1330.5 86.5 831.4 00-17 .4 954.3 1417.2 108.1 405.4 455.2 296.1 1005.1 1316.0 773.6 1424.7 933.2 947.0 195.4 983.9 1157.0 1034.9 1280.4 1128.2 325.9 629.6 868.4 332.9 1142.3 889.1 1410.1 1150. lb 1 knm = 7.2 1041.2 513.0 911.7 50.9 969.1 260.5 1236.7 528.2 853.6 14.7 716.5 180.5 520.9 846.1 354.2 636.5 759.0 694.4 115.0 600.8 1338.9 1186.7 962.9 101.4 1171.6 990.4 383.6 679.2 607.0 57.5 1099.4 50 60 70 80 90 361.5 303.6 419.1 477.2 1164.1 665.1 1352.5 802.4 412.5 274.2 1258.8 1215.0 1113.7 217.7 1056.0 506.9 1374.5 925. lb 0 1 2 3 4 5 6 7 8 9 \ 0 10 20 30 40 0 72.8 766.6 340.9 1063.0 28.7 390.1 1287.2 79.0 940.4 1077.6 123.2 542.8 253.9 347. 0 526.5 554.3 99.5 426.6 369.7 440.5 113.8 512.3 924.0 967.FOREWORD CONVERSIONTABLE kg/cm2 to lb/in2 1k&m* L = 14.4 995.7 184.2 853.9 14.7 953.6 241.4 483.2 284.6 1010 1152 1294 739.3 540.6 1138 1280 725.8 1024 1166 1309 753.5 298.0 1095 1237 1380 825.2 28.9 583.9 327.4 867.0 654.4 42.4 355.7 696.7 1081 1223 1365 810.1 910.7 568.9 50 60 70 80 90 711.6 497.3 227.4 611.5 1067 1209 1351 796.8 640.8 384.4 1124 1266 1408 100 110 120 130 140 1422 1565 1707 1849 1991 1437 1579 1721 1863 2005 1451 1593 1735 1877 2020 1465 1607 1749 1892 2034 1479 1621 1764 1906 2048 1493 1636 1778 1920 2062 1508 1650 1792 1934 2077 1522 1664 1806 1949 2091 1536 1678 1821 1963 2105 1550 1693 1835 1977 2119 150 160 170 180 190 2134 2276 2418 !560 2702 2148 2290 2432 2574 2717 2162 2304 2446 2589 2731 2176 2318 2460 !603 2745 2190 2333 2475 2617 2759 2205 2347 2489 2631 2773 2219 2361 2503 2646 2788 2233 2375 2518 2660 !802 !247 2389 2532 !674 !816 2262 2404 2546 2688 2830 200 210 220 230 240 2845 !987 3129 3271 3414 2859 3001 3143 3286 3428 2873 3015 3158 3300 3442 !887 $030 $172 3314 3456 2901 3044 3186 3328 3470 2916 3058 3200 3343 3485 2930 3072 3214 3357 3499 !944 3086 3229 3371 3513 !958 HOI i243 3385 3527 2973 3115 3257 3399 3542 00-18 .1 341.1 213.9 455.0 270.2 981.8 256.5 938.8 896.2233 lb/in* 8 9 0 1 2 3 4 5 6 7 0 10 20 30 40 0 142.4 170.3 1053 1195 1337 782.5 682.2 156.7 312.2 412.3 668.1 85.8 71.1 469.6 881.2 1109 1252 1394 839.6 56.7 128.0 398.1 1038 1181 1323 768.6 625.9 199.1 597. 0 -4.8 13.2 23.7 -11.9 14.7 37.6 10.3 -14 -13 -12 132.0 159.0 293.0 -22.4 -3.4 102.4 20. the center column as a table of Fahrenheit Fahrenheit to Centigrade Centigrade consider and read the corresponding temperature degrees.8 -7.9 24.7 -1.4 39.6 16.8 8.4 30.2 158.0 -28.3 -12.8 206.8 188.3 23.2 22.4 120.6 28.6 141.6 31.4 75.2 68.4 -23.8 107.2 131.1 16.0 15.0 320.0 186.1 73.9 19.4 25.4 -13.0 230.7 65.2 12.6 163.4 -18.4 210.7 2.0 96.9 9.8 53.9 76.6 181.0 -11 -10 -9 -8 -7 -6 5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 -22.2 168.4 57.8 161.2 122.2 27.6 43.8 89.2 -6.6 1.6 -25.4 -31.FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade ture reading These figures If it is desired temperatures Conversion .4 93.0 195.8 197.4 48.6 -15.8 179.4 15.1 31.2 176.7 54.0 30.7 -21.2 203.8 28.0 -14.6 -10.2 149.8 150.4 84.0 -4.6 73.3 13.8 44.2 185.8 3.2 212.4 -37.2 32.7 7.1 48.8 35.6 136.4 3.0 25.2 -1.1 11.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 “F 114.0 275.8 134.8 -12.0 221.0 62.8 62.6 0 0.0 10.2 60.6 109.1 -20.3 71.7 -6.8 143.8”F “C -40.0 78.8 80.2 37.9 34.4 201.8 18. 1°C = 33.9 29.2 5.0 347.8 17. If it is desired to convert from Centigrade and read the corresponding Fahrenheit to Fahrenheit temperature consider the center column on the right.4 192.2 41.8 26.7 12.2 194.6 199.6 118.6 21.8 23.3 -17.7 79.2 14.6 55.2 -26.6 172.1 -19 -18 -17 -16 -15 123.2 50.4 66. tempera- or vice versa is to enter the accompanying refer to the temperature to convert from in either table in the center or Centigrade degrees.6 37.3 -2.4 138.0 338.0 -19.7 -28.8 98.0 248.9 -3.4 147.4 165.4 57.1 -15.7 22.6 145.2 -34.8 -2.0 42.1 26.0 60.4 129.0 204.6 127.0 33.0 15.6 -5.8 125. a simple way to convert a Fahrenheit temperature or boldface reading column into a Centigrade of figures.6 64.2 32.2 167.9 4.2 86.2 -21.0 “C 27.9 -23.0 6.1 1.2 95.0 -31.0 266.2 113.1 6. as a table of Centigrade values.2 77.2 -16.7 -26.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 “F 117.2 2. in the column at the left.3 46.4 111.2 -0.1 36.0 -24.9 51.4 10.6 190.0 329.9 -8.6 82.0 -13.0 20.2 17.1 21.7 17.8 8.6 68.9 “F -40 -35 -30 -25 -20 “C -11.0 311.7 32.0 105.0 302.0 00-19 .6 19.6 26.0 257.6 208.0 -2.4 -8.4 156.0 69.3 33.8 -22.2 140.4 30. Fahrenheit degrees.0 5.0 24.6 91.4 174.6 154.7 -16.4 12.8 -27.6 100.4 21.4 5.8 40.9 -18.0 -17.8 116.8 170.0 87.0 -9.8 33.0 -40.3 18.6 46.6 6.3 8.0 239.0 -25.2 104.3 3.9 -13.2 59.1 -10.3 -27.4 1.0 -20.8 152.8 71.6 36.0 35.6 11.4 35.4 183.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 “F 51.0 “C 7.1 -0.0 284.3 -7.3 28.1 -5. . ... . 350-6 01-l ............. coolant and lubricants.. ..................01 GENERAL drawings ...........4 Ol........................................................ Fuel. Weight table ..................... Specification Specifications...........8 01-12 PC300...2 Ol............... Ol. The values marked ~4 are for shovel operations. 350-6 .3OOLC-6 Unit: mm 10935 7650 3285 ‘\ =- 5: II SAW0130 The figures in ( 1 indicate the PC3OOLC-6. 01-Z PC300.GENERAL SPECIFICATION DRAWINGS SPECIFICATION DRAWINGS PC300. GENERAL SPECIFICATION DRAWINGS PC350. SAP00131 * The figures in ( 1 indicate the PC35OLC-6. 350-6 01-3 .35OLC-6 Unit: mm 10920 11100 . PC300. Travel speed Gradeability Ground pressure [standard triple grouser shoe width1 Overall Overall Overall Overall Overall Ground length (for transport) width width height of track (for transport) mm mm mm mm mm mm mm mm mm mm mm mm height to top of cab clearance of counterweight Min.580 PC3OOLC-6 33001 and up 1.186 498 3. slope angle kN{kgl rpm deg.590 2. km/h deg.920 10.110 211.935 3.2 Mi: 4.935 3.300 4. ground Tail swing Min.9 {21.130 1.100 10.440 4. reach at ground Max.480 11.5 35 62. digging force (using power max.030 2.255 3.255 3.64} k:Pa{kg/cm21 1600 mm1 10.5 Hi: 5.9 {21.72 {0.190 3.0 21.310 8.440 3. digging Max.300 4.96 (0.290 3.700 2.580 Serial number Bucket capacity Operating Max.5 Hi: 5.0 21 . function) Swing Swing speed max.210 7.590 2.4 31. dumping height height Max.920 10. digging depth wall depth reach level weight I m3 kg mm mm mm mm mm mm Max.6001 10.380 6.2 Mi: 4.521 1700 mm1 10. 350-6 .110 211.0 Lo: 3.800 7.310 8.100 10.3OOLC-6 Machine model PC300-6 33001 and up 1. swing radius Length of track on ground Track gauge Height of machine cab mm 01-4 PC300.186 498 3. vertical Max.GENERAL SPECIFICATIONS SPECIFICATIONS PC300. swing clearance radius radius of work equipment Height of work equipment at min.4 30.o _o: 3.290 3. digging Max.190 3.380 6.480 11.210 7.900 7.130 1.5 35 50.600) 10. 050 897.2/1.bore model number PC300-6 33001 and up PC3OOLC-6 33001 and up SAAGDI 08-2 4-cycle.685 4. MPa{kg/cm*} 6-spool + l-spool 262 x 2 34.145) 172.5/1. 170 Ah x 2 Min. variable piston type JYmin. and aftercooler (air cooled) 6 . Hydraulic Hydraulic Hvdraulic PC300.500 {231.395 Box-shaped.7/2. Tank return sealed side Bucket Double acting piston 140 100 1. water-cooled. of cylinders Piston . Min. 7. 350-6 distance distance tank filter cooler between between pins pins diameter of cylinder rod mm mm mm mm mm Double-acting piston 140 100 1.300 900 205 {I511 24U.500} displacement horsepower Flywheel Max. 33A 12U. reverse preventi i valve): x 1 Boom Arm Double-acting.130 of piston Diameter Air cooled 01-5 .285 3. torque speed speed 2.5 kW 24U. vertical. direct injection. Piston type (with safety valve.990 Type Inside Stroke Max.h} in-line.275 1.080 2.145 {7. Max. shaft brake): x 2 KMFIGOABE-3. method motor motor + l-service valve x 1 Hydraulic HMUIGOADT-2.8 (355) type displacement x 2 Delivery Set pressure Type Control Travel Swing x No. Piston type (with brake valve. piston 160 110 1.610 2. with turbocharger x stroke mm e ICC1 kW/rpm{HP/rpm NmlrpmIkgmlrpm at no load at no load rpm rpm g/kW. fuel consumption Starting Alternator Battery Radiator Carrier Track Track core type roller roller shoe x No.480 3.h{g/HP.108 x 130 7. shaft brake.050} {91. Min.GENERAL SPECIFICATIONS Machine Serial Model Type No. motor cwx-4 2 on each side Type HPU160+160.8/2. digging Max.255 3.030 3.700) 10.080 10. ground Tail swing Min.080 10. digging reach level Max.130 1. swing clearance radius radius of work equipment Height of work equipment at min.130 1. digging force (using power max.5 35 62.0 21. 350-6 . km/h deg.4 32.030 212.580 length (for transport) width width height of track (for transport) mm mm mm mm mm mm mm mm mm mm height to top of cab clearance of counterweight Min.5 Hi: 5.9 (21.890 10.0 Lo: 3.580 Serial number Bucket capacity Operating Max.186 498 3.66 {0.64) 1600 mm] 11.400 11. reach at ground Max.350 8.190 3.2 Mi: 4.GENERAL SPECIFICATIONS PC350. vertical wall depth Max.190 3.700) 10. Max.255 3.030 212.380 6.4 33.070 7.5 Hi: 5. dumping height height mm mm mm Wkgl wm deg. digging depth weight m3 f 12001 and up 1.300 4.510 4.590 2.72 10.186 498 3.890 10.9 (21.350 8.380 6.300 7.190 3. swing radius Length of track on ground Track gauge Height of machine cab mm 01-6 PC300. function) Swing Swing Travel speed max.0 Lo: 3. slope angle speed Gradeability Ground [standard Overall Overall Overall Overall Overall Ground pressure triple grouser shoe width] :PaIkg/cm*} mm mm I600 mm] 11.67} f kg mm mm mm Max.070 7.2 Mi: 4.400 7.590 2.190 3.510 3.700 2.0 21.5 35 65.300 4.030 3.400 11.030 2. 35OLC-6 Machine model PC350-6 PC35OLC-6 12001 and up 1. 275 1. (with brake valve. vertical. reverse orevention valve): x 1 Boom Arm Double-acting. and aftercooler (air cooled) 6 .500} 2.145} 172.8 (355) type + l-service valve x 1 displacement x 2 Delivery Set pressure Type Control Travel Swing x No.7/2. Max. method motor motor Hydraulic HMVl60ADT-2. 7.300 900 205 {151} 24V.480 3.GENERAL SPECIFICATIONS Machine Serial Model Type No. Tank return sealed side Bucket Double acting piston 140 100 1.h{g/HP. piston 160 110 1. 350-6 distance distance tank filter cooler between between pins pins diameter of cylinder rod mm mm mm mm mm Double-acting piston 140 100 1. variable piston type 262 x 2 34.535 Box-shaped. 170 Ah x 2 core type roller roller cwx-4 2 on each side Track shoe Type x No. shaft brake.360 2.610 2. Piston type shaft brake): x 2 KMFIGOABE-3. Min.050) - Piston displacement horsepower Flywheel 8 E 8 t 5 Max. direct injection.h) in-line. with turbocharger x stroke mm Q {cc1 kW/rpm{HP/rprr NmlrpmIkgmlrprr at no load at no load rpm rpm g/kW.8/2. water-cooled.5 kW 24U. Piston type (with safety valve.108 x 130 7.bore model number PC350-6 12001 and up PC350LC-6 12001 and up SAAGDI 08-2 t-cycle.5/l . 33A L” - Min.990 Type Inside Stroke Max.145 {7.500 {91.825 4. MPa{kg/cm2} 6-spool + l-spool HPV160+160. of cylinders . Q/min. Min.285 3.050 897. Hydraulic Hydraulic Hydraulic PC300.130 of piston Diameter Air cooled 01-7 . torque speed speed . fuel consumption motor Starting Alternator Battery Radiator Carrier Track 12V.2/l {231. 7 200 165 226 218 2.695 487 166 257 x 2 31 x 4 52 x 14 629 x 2 Radiator. filter assembly Fuel tank (excl.420 380 236 82 173 x 2 37 8.420 380 236 82 173 x 2 37 7.970 4.560 5.182 487 166 257 x 2 31 x4 52 x 16 629 x 2 Engine Damper Hydraulic pump l l 200 165 (excl. fuel) Revolving Operator’s Operator’s frame cab seat Counterweight Swing machinery Control valve (standard) Swing Travel motor motor Center swivel joint Track frame l assembly Track frame Swing Idler Idler cushion Carrier roller Track roller Final drive (incl.100 785 14.621 287 29 5. travel motor) circle l l l l l l 01-8 PC300. 350-6 . Hydraulic oil cooler assembly tank. Unit: kg Machine model PC300-6 33001 and up PC3OOLC-6 33001 and up Serial number Engine assembly l 1.7 1.621 287 29 5. 3OOLC-6 guide for use when transporting or handling component.GENERAL WEIGHT TABLE WEIGHT TABLE g This weight table is a PC300. hydraulic oil) 226 218 2.100 785 14. 300 2.560 2.GENERAL WEIGHT TABLE Unit: kg Machine Serial Track shoe assembly Standard Standard triple grouser triple grouser shoe shoe (600 mm) (700 mm) (800 mm) 3.014 296 x 2 425 263 320 model number PC300-6 33001 and up PC3OOLC-6 33001 and up Wide triple grouser Wide triple grouser Swamp shoe shoe shoe ( ( ( mm) mm) mm) mm) Flat shoe Road liner (rubber Boom assembly Arm assembly Bucket assembly Boom cylinder Arm cylinder assembly assembly assembly (large) (small) pad type) ( Bucket cylinder Link assembly Link assembly Boom pin Arm pin Bucket pin Link pin ‘6 + 15 x 2 + 56 i 17 + 42 76 t 15 x 2 t 56 + 17 + 42 13 + 17 30 x 2 27 x 2 13 + 17 30 x 2 27 x 2 PC300.615 1.478 1.840 4.940 4.615 1.478 1.014 296 x 2 425 263 320 3.600 3.220 4. 350-6 01-9 . 320 380 236 82 173 x 2 37 8. fuel) Revolving Operator’s Operator’s frame cab seat Counterweight Swing machinery Control valve (standard) Swing Travel motor motor Center swivel joint Track frame assembly Track frame Swing circle Idler Idler cushion Carrier roller Track roller Final drive (incl. Hydraulic oil cooler assembly tank.7 200 165 226 218 2. travel motor) 01-10 PC300. hydraulic oil) Radiator.100 785 14.670 5. filter assembly 226 218 2.045 4. 350-6 .320 380 236 82 173 x 2 37 8.GENERAL WEIGHT TABLE PC350.741 287 29 6.295 487 166 257 x 2 31 x 4 52 x 16 629 x 2 Serial number Engine assembly l Engine Damper Hydraulic pump l l 200 165 (excl.35OLC-6 Machine model Unit: kg PC350-6 12001 and up 1.7 PC35OLC-6 12001 and up 1.100 785 14.741 287 29 6.770 487 166 257 x 2 31 x 4 52 x 14 629 x 2 Fuel tank (excl. 940 2.747 1.580 1.220 2.747 1.600 3.274 296 x 2 447 263 320 - 3.840 4. 350-6 01-11 .580 1.GENERAL WEIGHT TABLE Unit: kg Machine model PC350-6 12001 and up PC35OLC-6 12001 and up Serial number Track shoe assembly Standard Standard triple grouser triple grouser shoe (600 mm) shoe (700 mm) 3.274 296 x 2 447 263 320 - Wide triple grouser Wide triple grouser Swamp shoe shoe shoe ( ( ( ( mm) mm) mm) mm) mm) Flat shoe Road liner (rubber Boom assembly Arm assembly Bucket assembly Boom cylinder Arm cylinder assembly assembly assembly (large) (small) pad type) ( Bucket cylinder Link assembly Link assembly Boom pin Arm pin Bucket pin Link pin 76 t 15 x 2 t 56 + 17 t 42 76 + 15 x 2 t 56 t 17 t 42 13 + 17 30 x 2 27 x 2 13 + 17 30 x 2 27 x 2 PC300. 0. Add antifreeze Cooling system Coolant T-f-7 01-12 PC300. 350-6 .GENERAL FUEL. COOLANT AND LUBRICANTS FUEL.22 .22 .24 Carrier roller (1 each) Hydraulic system Hydraulic oil Diesel fuel 380 205 Fuel tank 540 7 I ma . COOLANT RESERVOIR AND LUBRICANTS KIND OF FLUID AMBIENT TEMPERATURE -22 -4 14 -10 32 0 50 10 68 20 86 30 104°F 40°C CAPACITY (t) Specified 31 1 Refill 28 I Engine oil pan 13 I 13 Damper case 1 Eni.24 0.0.re 0. 5%. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. Change interval of oil in engine oil pan l/2 of regular l/4 of regular interval interval Fuel sulphur content 0. change oil in the oil pan every periodic maintenance hours described in this manual.5 to 1. 350-6 01-13 . SAEIOW-30 and SAE15W-40. PC300. COOLANT AND LUBRICANTS NOTE: (I) When fuel sulphur content is less than 0. even though an atmospheric temperature goes up to 10°C more or less in the day time.0% Above 1. but be sure to add single grade oil that matches the temperature in the table on the left.GENERAL FUEL. Komatsu genuine oil which (5) We recommend has been specifically formulated and approved for use in engine and hydraulic work equipment applications. be sure to use engine oil of SAEIOW.0% (2) When starting the engine in an atmospheric temperature of lower than O”C. ASTM: SAE: API: American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute capacity: Specified Total amount of oil including oil for components and oil in piping. (4) There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30. (3) Use API classification CD as engine oil and if API classification CC. * For the H046-HM. use the oil recommended by Komatsu.5%. Change oil according to the following table if fuel sulphur content is above 0. reduce the engine oil change interval to half. 15W401. . 8 IO.. recoil spring ........................................................... ..................... CLSS ......... Track shoe............................................ Work equipment.. Air conditioner.......... Travel motor ......................................... . Hydraulic tank. oil cooler.......................10 STRUCTURE AND FUNCTION Parts related to engine ............................................2 IO... Center swivel joint .....................7 IO... Solenoid valve ................................................................................ PPC safety lock valve .........38 IO........... ......................... Engine control ........................... Travel PPC valve ................................................................... travel junction valve............ Suction safety valve.. ...........4 IO.......... .. Hydraulic pump ...... Swing machinery ........ hydraulic filter................................................... ....17 IO............................................................................................... Valve control ........ l IO...... Work equipment swing PPC valve ............. Electronic control system ........................6 IO.......... Boom holding valve............................................ PPC accumulator .... Power train ......... Front window auto pull-up system ....................................................... Hydraulic circuit diagram ......55 IO-120 IO-126 IO-128 IO-137 IO-138 IO-142 IO-146 IO-149 IO-149 IO-151 IO-158 IO-162 IO-164 IO-168 IO-169 IO-170 IO-174 IO-178 IO-185 IO-212 IO-222 PC300.. Service PPC valve ...........5 IO....15 IO............12 IO....... ............................. Hydraulic piping drawing ... Track frame..................................................... Radiator............... Swing motor ........................... .48 IO...... Control valve ....................................... Final drive .................................... Actual electric wiring diagram ......... PPC shuttle valve... ..... Self-reducing pressure valve ..........53 IO............................. .9 IO............ Swing circle ...............................................14 IO.. Electric circuit diagram .............. Machine monitor system.......................10 IO.......... 350-6 10-l ... LS-EPC valve................................... __. /__i+ ---./ ‘“=._ “\_ j 2::.‘%‘._. -- 7 1 / ___ -----------._J j ! I “\ ‘-_ “‘._-----__--_________---- _----_---- 11 ...===7\\/ ii N \ “1 ‘-.._-----___ ___________. j L__-_._----_ -.______---~-~- I ------_______ ___---. \:y-. -___ --===zz=:===_ SWPOOl34 1o-2 PC300.-----.._-_I /.STRUCTURE AND FUNCTION PARTS RELATED TO ENGINE PARTS RELATED TO ENGINE / -__--__--__-._. 350-6 . \:--w_ [::I_i:~-__-. 10. Air cleaner Intake connector Muffler Rear engine mount Front engine mount Outline l The damper type Oil capacity: assembly 0. 7.75 e is a wet PC300. 350-6 1o-3 . 5. 3. 2.STRUCTURE AND FUNCTION PARTS RELATED TO ENGINE A-A SWPOO135 1. 9. 8. Drive plate Torsion spring Stopper pin Friction plate Damper assembly 6. 4. 3. 350-6 .STRUCTURE AND FUNCTION RADIATOR. 11. 12. 5. Reservoir tank Oil cooler Radiator Fan Radiator inlet hose Radiator outlet hose 7. OIL COOLER A-A c-c SWPO4704 1. OIL COOLER RADIATOR. IO. Radiator Net Shroud Cushion O-ring Collar cap Specifications Radiator: CWX-4 Oil cooler: SF-4 1o-4 PC300. 2. 9. 8. 4. 6. Idler Center swivel joint Control valve Final drive Travel motor (HMV160ADT-2) Engine (SAAGD108-2) 7. 9. 2. 6. 8. 3. 350-6 1o-5 . 5. 10. Hydraulic pump (HPV160+160) Travel speed solenoid valve Swing brake solenoid valve Swing machinery Swing motor (KMFIGOABE-3) Swing circle PC300. 11.STRUCTURE AND FUNCTION POWER TRAIN POWER TRAIN SWPO4705 1. 12. 4. 4. 2 sun gear (No. 9. of teeth: 11) No. 1 planetary gear (No. 8. 14. of teeth: 19) No. of teeth: 42) No. 350-6 . 2. 3.STRUCTURE AND FUNCTION FINAL DRIVE FINAL DRIVE ’ 1. 11. 5. 12. 1 sun gear (No. of teeth: 97) Hub Sprocket Floating seal Travel motor No.943 A-A SWPO4706 1O-6 PC300. 7.58. 1 planetary carrier No. of teeth: 38) Specifications Reduction ratio: -(+)x(y)+1 = . 10. 2 planetary carrier Cover Ring gear (No. 6. 13. 2 planetary gear (No. Level plug Drain plug No. STRUCTURE AND FUNCTION SWING CIRCLE SWING CIRCLE SAW0143 A-A 1. Swing Ball Swing circle circle inner outer race (No.923 Inner race sof? zone S position Outer race soft zone S position Amount of grease: 33 e (G2-LI) PC300. 2. a.6. b. 350-6 1o-7 . 3. of teeth: race 90) Specifications Reduction ratio: z = . 2 sun gear (No. Coupling 5. of teeth: 21) 14. Drain plug Specifications Reduction ratio: 28+95 ___ 28 21+95 x 21 9 = 24. 350-6 . 1 sun gear (No. Cover 3. No. 2 planetary gear (No. No. No. Case 4.STRUCTURE AND FUNCTION SWING MACHINERY SWING MACHINERY 1. No. No. of teeth: 36) 6. Swing pinion (No. Ring gear (No. 1 planetary gear (No. No. 2 planetary carrier 15. Oil level gauge 11. Swing motor 10. Cover 9.265 0 IO 7 6 5 I3 4 I4 3 IS II 12 2 I A-A SWPO4707 1O-8 PC300. of teeth: 28) 12. of teeth: 13) 2. 1 planetary carrier 13. of teeth: 95) 7. of teeth: 33) 8. of track rollers. 350-6 PC3OOLC-6. . 2. Model PC300. 350-6 1o-9 . but the 1 No.STRUCTURE AND FUNCTION TRACK FRAME. 5. 4. 9. RECOIL SPRING TRACK FRAME. of rollers (each side) 7 8 PC300. The dimensions and number may differ according to the basic structure is the same. RECOIL SPRING * The diagram shows the PC3006 A-A 9 8 7 6 5 1. No. PC35OLC-6 of track rollers model. 8. 6. 3. 7. Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard . Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees Travel in Hi speed only on flat ground. when it is impossible to avoid traveling over obstacles. on rough ground Ir so be careful when traveling l C Extremely soft ground (swampy ground) l l D E Paved surface Paved surface l l Ir Categories “B” and “C” are wide shoes. Therefore. lower the travel speed to approx.STRUCTURE AND FUNCTION TRACK SHOE TRACK SHOE Standard shoe PC350-6 Shoe width (mm) (triple shoe) Link pitch (mm) No. l B Normal soil. give the customer guidance in their use. loosening of the shoe bolts. normal river soil l Precautions when using with Travel in Lo speed when traveling on rough ground obstacles such as large boulders and fallen trees.Specifications B A B 600 mm triple 700 mm triple ) 800 mm triple 1 B 1 1 1800 mm triple1 I I Category A Use Rocky ground. select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. When selecting the shoe width. The shoes are flat. If necessary. there will be a large load on the shoe. If a wider shoe than necessary is used. half of Lo speed. when it is impossible to avoid traveling over obstacles. cracking of the links. of shoes (each side) 600 216 45 600 216 45 PC3OOLC-6 700 216 48 PC35OLC-6 600 216 48 Selection of track shoe l Select the most suitable track shoe from the following table I I Standard Option Option PC300-6 C. breakage of the pins. lower the travel speed to approx. Use only for ground where “A” and “B” sink and are impossible to use. so they have low gradeability The shoes are made of rubber. so there are restrictions on their use. before using. and this may lead to bending of the shoe. check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width.teA B I I PC350-6 Specifications 600 mm triple 700 mm triple I PC3OOLC-6 I 1 PC35OLC-6 C$teA A Specifications 600 mm triple 700 mm triple cgte. half of Lo speed.Specifications A B 700 mm triple 600 mm triple czte. or other problems. soft land l Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. 10-10 PC300. Travel in Hi speed only on flat ground. 350-6 . . 17. 20. 19. Travel speed solenoid valve 20C.H. Bucket cylinder Arm cylinder Boom cylinder Center swivel joint Swing motor Oil cooler Control valve PPC shuttle valve Hydraulic filter Hydraulic pump L. Active mode solenoid valve (Boom) SWPO4708 + 10-12 PC300.H. 11. 18. 13. 7. 350-6 . 15. 12. 3.H. Boom Hi 2-stage safety solenoid valve 20E. PPC valve Travel PPC valve Boom holding valve Accumulator Active mode solenoid valve (Swing) Solenoid valve assembly 20A. 6. Swing brake solenoid valve 20B. Merge/flow divider solenoid valve 20D. 10. 4. travel motor Hydraulic tank PPC safety lock valve L. PPC valve R. 8. 5. 2. 14.STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING HYDRAULIC PIPING DRAWING 1. 16. 9. STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING + I 17 20 20E 20A + 2 SWPO4709 PC300. 350-6 10-13 . see Section 90. 350-6 .STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM HYDRAULIC CIRCUIT DIAGRAM Ir For details of this page. PC300. 6. . 5. Hydraulic filter IA.0. Strainer IC.9 + 19. 16.7 rf: 6. 350-6 10-15 .9 kPa (0.07 kg/cm*) Suction cracking pressure: 0 . Cooler check valve Hydraulic tank Suction strainer Hydraulic oil level sensor Sight gauge Oil filler cap Specifications Tank capacity: 315 e Amount of oil inside tank: 207 1 (at H level) Safety valve . HYDRAULIC FILTER HYDRAULIC TANK. Relief cracking . 4.STRUCTURE AND FUNCTION HYDRAULIC TANK.17 2 0.0.005 kg/cm*) Bypass valve set pressure: 102. HYDRAULIC FILTER IA 1B ii I! I A-A 5 -__-__ -----w __-_____ 4 SWPOOl53 1.6 kPa il.2 kg/cm*} pressure: PC300. Bypass valve 1 B.49 kPa 10 . Element 1 D. 2.05 f 0. 3. . 4. Front Rear Rear Front main main TVC. pump pump LS valve LS valve : : : : : : PLSl Fl : PdlF : Psig : PS PAF PAR PP2F PP2R PLSIR Pump suction Front delivery Rear delivery Front pump delivery pressure Rear pump delivery pressure Rear LS pressure Front LS pressure Pump drain LS control pressure EPC pressure Outline This pump consists of two variable ment swash plate type piston pumps LS valves. 3. PC300. 350-6 10-17 . displaceand TVC.STRUCTURE AND FUNCTION HYDRAULIC PUMP HYDRAULIC PUMP PdlF I PAF PAR 1 \ PLSl Fl PLSlR I PPLR Psia / i PPPF PS ‘3 SWPO4710 1. 2. TVC. STRUCTURE AND FUNCTION HYDRAULIC PUMP 1. MAIN PUMP HPV160 + 160 PdlF CI \ PAF I PenlF PARF PARR CZ P A-F F P‘S PenlR SWPO4711 : PS PAF : PAR : PAFF : PARF: Suction Front pump delivery Rear pump delivery Front delivery pressure Rear delivery pressure PARR : PdlF : Pen1 F : Pen1 R: Rear delivery pressure Pump drain Front control pressure Rear control pressure lo-18 PC300. 350-6 . 6. 10. 11. 3. 2. 5. 4. Cylinder block Valve plate End cap Shaft (rear) Case (rear) Servo piston PC300.STRUCTURE AND FUNCTION HYDRAULIC PUMP 2 4 5 6 7 6 9 10 B-B SAP00159 1. 9. 12. 8. Shaft (front) Cradle Case (front) Rocker cam Shoe Piston 7. 350-6 10-19 . The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. and shoe (5) is caulked to it to form one unit. and forms a static pressure bearing when it slides. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (21. which is secured to the case. This surface is designed so that the oil pressure balance is maintained at a suitable level. Structure Cylinder block (7) is supported to shaft (I) by spline S. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8). Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). . 350-6 . . and pressurized oil is discharged according to the load. . Piston (6) and shoe (5) form a spherical bearing. l Rocker cam (4) has flat surface A.STRUCTURE AND FUNCTION HYDRAULIC PUMP Function . 1O-20 PC300. and shaft (I) is supported by the front and rear bearings. and shoe (5) is always pressed against this surface while sliding in a circular movement. It is possible to change the delivery amount by changing the swash plate angle. The tip of piston (6) is a concave ball. The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy. (Angle a is called the swash plate angle. so a difference between volume E and F is created inside cylinder block (7). the oil is sucked in. The suction and discharge is equal to this difference F . the volume of chamber F becomes larger.) I 4 5 A ? 1) Center line X of rocker cam (4) maintains swash plate angle a in relation to the axial direction of cylinder block (7). so the pump does not carry out any suction or discharge of oil. In this way. Operation of pump . On the other hand. When this happens. 350-6 10-21 . when cylinder block (7) rotates and the volume of chamber E becomes smaller.E. Cylinder block (7) rotates together with shaft (I). the difference between volumes E’ and F’ inside cylinder block (7) becomes 0. so angle a between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 01.STRUCTURE AND FUNCTION HYDRAULIC PUMP Operation 1. and flat surface A moves as a cam in relation to shoe (5). the oil is discharged during that stroke. and shoe (5) slides on fiat surface A. rocker cam (4) moves along cylindrical surface B. In other words. piston (6) slides on the inside of cylinder block (71. and as the volume becomes bigger. ‘B SIP00163 2) 7 E SLPO0164 X 4 7 E’ SLPO0165 PC300. and the ratio between the area receiving the pressure at the small diameter piston end and the large diameter piston end controls the movement of servo piston (12). l . so main pump discharge pressure (self pressure) PP is always connected to the chamber receiving the pressure on the small diameter piston side (the self-pressure is brought in). Swash plate angle a is changed by servo piston (12). 1o-22 PC300. and rocker cam (4). The relationship in the size of self-pressure PP and the pressure at the small diameter piston end. Servo piston (12) moves in a reciprocal movement (++I according to the command from the control valve. Control of discharge amount SAP00166 . which is supported by the cylindrical surface to cradle (21. moves in a rocking movement on the cylindrical surface in ( $ direction). l If swash plate angle a becomes larger. the area receiving the pressure is different on the left and right. This straight line movement is transmitted through rod (13) to rocker cam (4).STRUCTURE AND FUNCTION HYDRAULIC PUMP 2. Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. 350-6 . the difference in volumes E and F becomes larger and discharge volume Q increases. l With servo piston (12). . STRUCTURE AND FUNCTION HYDRAULIC PUMP 2. TVC. LS VALVE Pa2 . 350-6 .2 port : Control valve LS pressure inlet port : Front pump delivery pressure inlet port Pa2 : Rear pump delivery pressure Pen1 : Signal pressure output Psigl : LS-EPC pressure inlet port inlet port 1 O-24 PC300.Pal Pen 1 PP2 SWPO4712 PP2 PLSI Pal : Pump pressure No. Piston 10. 350-6 1o-25 . 4. 2. Piston 7.STRUCTURE AND FUNCTION HYDRAULIC PUMP A-A ‘15 swP05001 LS 1. Spring Piston Lever Valve body PC300. Sleeve 11. 13. Plug TVC valve 8. Sleeve 6. Solenoid 9. 14. 3. 15. valve Locknut Plug Spring Spool 5. Spring 12. 1 O-26 PC300. with the current given to the TVC valve solenoid shown as a parameter. 2. MPa (10.2. and if the speed drops because of an increase in the load. the spring load changes according to this.9 MPa (0 . gine. 0 .98 . the TVC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In other words. In this way it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. it reduces the discharge amount from the pump. 01 pressure i kg/cm’] APLS SWPO5163 . in the heavy-duty operation mode. pressure PLS (called the LS pressure) coming from the control valve output. z 1.0 kg/cm*). when the load increases and the engine speed drops below the set value. TVC valve When pump discharge pressure Pal (selfpressure) and Pa2 (other pump pressure) are high.25.-: . 0 2. 5 Ps i 9=2. This valve controls main pump discharge amount 0 according to differential pressure APLS (=PPP-PLS) (the difference between main pump pressure PP2 and control valve outlet port pressure PLS) (called the LS differential pressure). z z 5 : _z . Main pump pressure PP2 coming from the control valve inlet port. The relationship between discharge amount 0 and differential pressure APLS. it reduces the pump discharge amount to allow the speed to recover. .30 kg/cm*).2. Function 1. When Psig changes between 0 . However. and pressure Psig (called the LS selector pressure) from the proportional solenoid valve enter this valve. In other words. and the point for switching the pump discharge amount changes at the rated central value between 0. and if the pump discharge pressure drops.0 . 350-6 . it increases the discharge amount from the pump.45 MPa (IO. if the load during the operation becomes larger and the pump discharge pressure rises. LS valve The LS valve detects the load and controls the discharge amount. 01 LS differential i25. there are cases where it is given the function of sensing the actual speed of the ena z z c? Pump discharge Pressure averaee(PF+PR)/2 SWPO5164 . (the difference between main pump pressure PP2 and LS pressure PLS) (=PP2-PLS) changes as shown in the diagram on the right according to LS selector pressure Psig. the command to the TVC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.STRUCTURE AND FUNCTION HYDRAULIC PUMP . The relationship between the average of the front and rear pump discharge pressures (PF + PRY2 and pump discharge amount 0 is shown on the right. 9MPa . ) At this point. and port d and port c are connected. (See the diagram on the right) When the engine is started and the control lever is at the NEUTRAL position. 1 O-27 PC300. and the same pump pressure PP also enters the small diameter end of the piston. so the swash plate is moved to the minimum angle by the difference in area of piston (1). with pressure PLS (LS pressure) from the outlet port of the control valve brought to spring chamber i. However. 350-6 .) Before the engine is started. spool (4) is pushed to the left. The size of the force of this LS pressure PLS + force F of spring (3) and the main pump pressure (self pressure) PP2 determines the position of spool (4). (It is intercon- SAW0173 netted with the drain circuit through the control valve spool. LS pressure PLS is 0 MPa (0 kg/cm*).STRUCTURE AND FUNCTION HYDRAULIC PUMP Operation 1. and main pump discharge pressure PP2 brought to chamber j of plug (6). the size of the output pressure Psig (the LS selection pressure) of the EPC valve for the LS valve entering port e also changes the position of spool (4). LS valve 1) When control valve is at NEUTRAL position (Direction of minimum discharge) SWPO5076 The LS valve is a three-way selector valve. Pump pressure PP enters the large diameter end of the piston from port h. (The set pressure of the spring changes. servo piston (1) is pushed to the right by spring (7) installed to rod (2). If piston (5) is pushed to the left. When this happens. the pressure at the large piston diameter end of servo piston (I) becomes drain pressure PT. 1 O-28 PC300. this pressure creates a force to move piston (5) to the left. rod (2) moves to the right and moves the swash plate in the direction to make the discharge amount larger. For this reason. so circuit c .h becomes drain pressure PT. and the difference between PLS and PP2 changes when ports b and c of spool (4) are connected. When spool (4) moves.STRUCTURE AND FUNCTIQN HYDRAULIC PUMP 2) Operation in maximum direction for pump discharge amount (Direction of maximum discharge) SWPO5077 l l When the difference between main pump pressure PP2 and LS pressure PLS.) l . (The operation of the TVC valve is explained later. 350-6 . spool (4) is pushed to the right by the combined force of LS pressure PLS and the force of spring (3). If the output pressure Psig of the LS-EPC valve enters port e. and pump pressure PP enters the small diameter end. LS differential pressure APLS. in other words. becomes smaller (for example. it acts to make the set pressure of spring (3) weaker. when the area of opening of the control valve becomes larger and pump pressure PP drops). the TVC valve is connected to the drain port. so servo piston (1) is pushed to the right. Therefore. port b and port c are joined and connected to the TVC valve. If LS selection pressure Psig enters port e. rod (2) moves in the direction to make the swash plate angle smaller. . main pump discharge pressure PP2 pushes spool (4) to the left. when the area of opening of the control valve becomes smaller and pump pressure PP rises). servo piston (I) is pushed to the left. it acts to make the set pressure of spring (3) weaker. end. . it enters the large piston diameter . The following explains the situation if servo piston (I) moves to the left (the discharge amount becomes smaller). Main pump pressure PP also enters the small piston diameter end. but because of the difference in area between the large piston diameter end and small piston diameter end of servo piston (I). As a result. When spool (4) moves.STRUCTURE AND FUNCTION HYDRAULIC PUMP 3) Operation in minimum direction for pump discharge amount (Direction of minimum discharge1 SWPO5078 . and from port h. main pump pressure PP flows from port d to port c. When LS differential pressure APLS becomes larger (for example. PC300. 350-6 1 O-29 . and the force of spring (3) is adjusted so that it is determined when PP2 . servo piston (I) will stop in that position.PLS = 2. and the swash plate will be kept at an intermediate position. Let us take the area receiving the pressure at the large piston diameter end as Al.98 MPa f25 . If main pump discharge pressure PP2 of the LS valve and the combined force of force F of spring (3) and LS pressure PLS are balanced. so the pressure applied to both ends of the piston when it is balanced becomes PP : Pen = 5 : 2. At this point. and the pressure flowing into the large piston diameter end as Pen. and the relationship is A0 x PP = Al x Pen.30 kg/cm*} of the EPC valve of the LS valve) is applied to port e. 350-6 . if Psig (the output pressure of 0 . However. 1O-30 PC300.2. (It will stop at a position where the opening of the throttle between port b and port c and between port d and port c of spool (4) is approximately the same.94 MPa IO . the relationship between the area receiving the pressure at both ends of piston (1) is A0 : Al = 2 : 5. the area receiving the pressure at the small diameter end as AO. l At this point.0.IO kg/cm*}. 2/5 pump pressure PP.STRUCTURE AND FUNCTION HYDRAULIC PUMP 4) When servo piston is balanced Area receiving Small d:ameter end h /8 Larbe dijmeter end SWPO5079 .45 . the pressure of port c is approx.45 MPa (25 kg/ cm*). the balance stop position will change in proportion to pressure Psig between PP2 . The position where spool (4) is balanced and stopped is the standard center.) .PLS = 2. and the set value and actual value for the engine speed. l When the load on the actuator is small and pump pressures Pal and Pa2 are low @ Action of solenoid (I) Command current x from the governor. This command current changes the internal force pushing solenoid push pin (11). the selection of the working mode.STRUCTURE AND FUNCTION HYDRAULIC PUMP 2. 350-6 10-31 . pump controller flows to solenoid (I). pump controller are normal 8 PT \ h 6 SBP00178 (Direct ion of maximum discharge) + Resistor SWPO5080 Other pump pressure This is the pressure of the pump at the opposite end. The size of command current x is determined by the nature of the operation (lever operation). For the front pump. PC300. Piston (2) stops at a position where the combined force pushing piston (2) is ball . 1) TVC valve When governor. On the opposite side to the force pushing this solenoid push pin (II) is the spring set pressure of springs (3) and (4) and pump pressure Pal and other pump pressure Pa2 (see *I. and the pressure (pressure of port c) output from the TVC valve changes according to this position. anced. it is the front pump pressure a. it is the rear pump pressure For the rear pump. spring (4) contacts seat (IO). Port c of the TVC valve is connected to port e of the LS valve (see 1. If piston (5) moves to the right. the spring load is changed by piston (5) extending or contracting springs (3) and (4). and if it moves further to the right. As servo piston (9) moves further. port c and port d are connected. When servo piston (9) moves. piston (5) is moved to the left by rod (81. so the movement of piston (9) to the right is stopped. piston (2) moves to the left. 350-6 . When pump pressures Pal and Pa2 are small. When this happens. and the spring load of springs (3) and (4) also changes according to the value of the solenoid command current. As a result. spring (3) is compressed. also moves. and the pump discharge pressure port b is connected to port c. the pushing force of solenoid push pin (11) changes. which is connected to rod (81. and piston (5) moves to the right or left. If command current x input to solenoid (I) changes further. If port h and port e of the LS valve are connected (see 1. In other words. the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (3) and (4) and the pushing force from the solenoid and the pushing force created by pressures Pal and Pa2 acting on piston (2) are in balance. so both spring (3) and spring (4) function. Self pressure Pal enters port b and the small piston diameter end of servo piston (9). the pump discharge amount moves in the direction of increase. LS valve).STRUCTURE AND FUNCTION HYDRAULIC PUMP Action of spring The spring load of springs (3) and (4) in the TVC valve is determined by the position of the swash plate. When the spring force becomes weaker. lever (6) is rotated by the angle of cam (71. At this point. and the pressure at the large piston diameter end also rises. and the pressure entering the LS valve becomes drain pressure PT. cam (71. In this way. and the other main pump pressure Pa2 enters port a. Springs (3) and (4) expand and the spring force becomes weaker. so the connection between port c and port d is cut. LS valve). piston (2) is on the right. cam (7). the pressure entering the large piston diameter end from port f becomes drain pressure PT. the pressure at port c rises. and servo piston (9) moves to the right. 1 O-32 PC300. In other words. and lever (6). PC300. When this happens. . LS valve). minimum. . . piston (2) cuts off the connection from port b to port c. main pump pressure Pal flows to port c and acts to make the discharge amount the . When load on actuator is small and pump discharge pressure is high When the load is large and pump discharge pressures Pal and Pa2 are high. When port h and port e of the LS valve are connected (see 1. The position in which piston (9) stops when this happens is further to the left than the position when main pump pressures Pal and Pa2 are low. the force pushing piston (2) to the left becomes larger and piston (2) moves to the position shown in the diagram above. the pressure at port c (= f) drops. Because of this force. with the pressurized oil flowing from port c to the LS valve.STRUCTURE AND FUNCTION HYDRAULIC PUMP Pal Pa2 ‘h 4 6 SBPO0178 (Direct ion of rn-inimum discharae) TVC prolix J Resistor xlP05081 b. If main pump pressures Pal and Pa2 increase further and piston (2) moves further to the left. 350-6 1 o-33 . part of the pressurized oil from port b flows out to port d and becomes approximately 2/5 main pump pressure Pal. springs (3) and (4) are compressed and push back piston (2). and servo piston (9) stops. and port c and port d are connected. the pressure from port f enters the large piston diameter end of servo piston (9). piston (5) is moved to the right by cam (7) and lever (6). As a result. When piston (9) moves to the left. For this reason. as shown in the diagram above. and piston (9) stops moving to the left. 0’ B(x:larae) A(x:small) Pump Pressure P SWPO5083 1o-34 PC300. the pushing force of solenoid (I) is added to the force pushing to the left because of the pump pressure applied to the piston (21. 0 Z : : : : : .. The relationship between average pump pressure Pal + Pa2 and pump discharge amount Q is shown in the figure on the right. the relationship between average pump pressure Pal + Pa2.STRUCTURE AND FUNCTION HYDRAULIC PUMP l The relation of average main pump pressure Pal + Pa2 and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (4) and (6). In other words. If command voltage X sent to solenoid (I) increases further. 350-6 . cl c Pump pressure PaltPaZ SWPO5082 . and discharge amount Q is proportional to the pushing force of the PC-EPC valve solenoid and moves in parallel. the relationship between the average pump purresure P and Q moves from A to 6 in accordance with the increase in X. port c is connected to the drain pressure of port d. so use the resistor to control the current flowing to solenoid (I). pump controller. PC300. When this is done. . 350-6 1o-35 . the current becomes constant. the pressure at the small piston diameter end is large. In this case. . so servo piston (9) moves in the direction to make the discharge amount larger. the combined force of the pump pressure and the force of solenoid (I) is weaker than the spring set force. turn TVC prolix switch ON to switch to the resistor side. it is too large. At this point. When load on main pump is light If there is a failure in the governor. When this happens. But if the current is used as it is. so the force pushing solenoid push pin (11) is also constant. the power source is taken directly from the battery. If main pump pressures Pal and Pa2 are low. and the large piston diameter end of servo piston (9) also becomes the drain pressure PT through the LS valve. pump controller is abnormal and TVC prolix switch is ON Pal Pa2 h 6 (Direction of maximum discharge) SBPOO178 Resistor SWPO5084 a. so piston (2) is balanced at a position to the right.STRUCTURE AND FUNCTION HYDRAULIC PUMP 2) When governor. In other words. If main pump pressures Pal and Pa2 increase. the curve for the pump pres- Pump discharge amount 0 SWPO5066 . piston (2) moves further to the left than when the main pump load is light. so servo piston (9) moves to the left (to make the discharge amount smaller) by the same mechanism as explained in Item 2. For this reason.1)-b. the command current x sent to solenoid (I 1 becomes constant. When load on main pump is heavy In the same way as in the previous item. 350-6 . pump controller is normal. sure P and discharge amount 0 is determined as shown in the diagram for the value of the current sent to the solenoid through the resistor. The curve when the TVC prolix switch is ON is curve B. the pressure from port b flows to port c. 1O-36 PC300. even when the TVC prolix switch is ON. . In this case. and is balanced at a position towards the left. Resistor SWPO5065 b. the force of solenoid push pin (11) pushing piston (2) is constant. and stops at a position further to the left than when the load on the pump is light. which is to the left of curve A for when the governor.STRUCTURE AND FUNCTION HYDRAULIC PUMP i I c ? PT h 6 1 (Direction of rn-inimum discharge) end TVC prolix SBPO0178 . when the TVC prolix switch is ON. . travel PPC valve P4 : From R.H. travel motor A3 : To boom cylinder bottom A4 : To swing motor A5 : To L. * This control valve is designed to assist only the boom and arm valves with their large flow using the Hi valve.H. 7. 2. Al : To bucket cylinder bottom A2 : To R. 8. travel motor 83 : To boom cylinder head 84 : To swing motor B5 : To L. The merge/flow divider valve is installed to this. 4.H. and the passages are internally connected.H.STRUCTURE AND FUNCTION CONTROL VALVE CONTROL VALVE Name.H. 5.H.H. so the structure is compact and is very easy to service. so it has a simple structure. travel PPC valve Pll: From arm PPC valve P12: From arm PPC valve Tl : To travel junction valve T2 : To travel junction valve T3 : To travel junction valve T4 : To travel junction valve A-l : To boom cylinder bottom A-2 : To attachment A-3 : To attachment A-4 : To attachment : To arm cylinder bottom : To attachment : To attachment : To attachment : From arm PPC valve : From arm PPC valve : From boom PPC valve : From service PPC valve : From service PPC valve : From service PPC valve : From service PPC valve : From service PPC valve : From service PPC valve : To tank : From LS divider solenoid valve : From 2-stage safety valve selector noid valve : From merge/flow divider solenoid : Pressure sensor mount port : Pressure sensor mount port : To tank : From active mode selector solenoid : From swing stroke control selector : From swing stroke control selector : From front main pump : From rear main pump : To front pump control : To rear pump control : To front pump control : To rear pump control : To travel junction valve : To travel junction valve solevalve valve valve valve 1 O-38 PC300. travel motor A6 : To arm cylinder head Bl : To bucket cylinder head 82 : To R. l All the valves are connected by a bolt to form one unit. travel PPC valve PlO: From L. B-l B-2 B-3 B-4 P-IA P-IB P-2 P-3 P-4 P-5 P-6 P-7 P-8 T BP CP PS SA SB TS BP4 BP5 BP6 PPI PP2 PLSI PLS2 PPSI PPS2 PTRI PTR2 Cover 1 Cover 2 Service valve Service valve Service valve Boom. 6. This control valve consists of a 7-spool valve (the 6-spool valve + Hi valve) and 3 sets of service valves. travel motor B6 : To arm cylinder bottom PI : From bucket PPC valve P2 : From bucket PPC valve P3 : From R. arm Hi valve Merge/flow divider valve 6-spool valve 3. 1.H. travel PPC valve P5 : From boom PPC valve P6 : From boom PPC valve P7 : From swing PPC valve P8 : From swing PPC valve P9 : From L. 350-6 . port name Outline . ps PTRP / p . 350-6 1o-39 .91 PT-R 1 I 8 T4 si \ 3 PP2 PPl T3 P-1A TS SWPO4713 PC300. P’6 p$ c P’2 p\ 2P-4 p\_.-8 PPSP Pll P7 P3 P-18 P-5 PP./2 P fop/.STRUCTURE AND FUNCTION CONTROL VALVE lo-spool valve (STD + service valve x 3) . Main relief valve (arm Lo) 16. Spool (swing) 4. 8. Unload valve (bucket) 17. Spool (service) 11. 9. Spool return spring 12. 7. 350-6 . Spool (arm Hi) 13.STRUCTURE AND FUNCTION CONTROL VALVE Main structure of IO-spool valve (l/3) K-K L-L SWPO4714 1. Unload valve (arm Lo) 15. Spool (arm Lo) 2. Piston (arm Lo stroke control) 14. Main relief valve (bucket) 1O-40 PC300.H. travel) 3. 6. travel) Spool (bucket) Spool (boom Hi) Spool (service) Spool (service) IO. Spool (L. Spool (R.H. Spool (boom Lo) 5. 3. 7.STRUCTURE AND FUNCTION CONTROL VALVE (2/3) 2 J-J 4. 6 EE-EE SWPO4715 1. 6. 350-6 10-41 . LS shuttle valve LS divider valve Merge/flow divider valve (main) Return spring Merge/flow divider valve (for LS) Return spring LS bypass valve PC300. 2. 5. 4. n m I I n m 0 I 0 . 3. Pressure compensation valve Variable type pressure compensation valve Safety-suction valve Safety-suction valve (for large flow) Safety-suction valve (2-stage) Check valve for regeneration circuit (arm) Check valve for regeneration circuit (boom) Suction valve PC300. IB.IA 2 IA 2 N-N NB-NB IA SWPO4717 IA. 6. 7. 4. 5. 2. 350-6 1o-43 .STRUCTURE AND FUNCTION CONTROL VALVE NA-NA . see IO-SPOOL VALVE G EiP6 TS \ P72 Ppl T3 P.lA T2 Tl SWPO4718 1o-44 PC300. 350-6 .STRUCTURE AND FUNCTION CONTROL VALVE 9-spool valve (STD + service valve x 2) * For details of the names of the ports and the main structure. 350-6 1 o-45 .PPF2 Al A2 A3 A4 A5 A6 BP B6 B5 84 B3 B2 Bl G BP6 PTR 1 0 TS T4 PP2 Ppl T3 P-IA T2 Tl SWPO4719 PC300.PS PTRP P12 P8 P4 P-2 BP5 .STRUCTURE AND FUNCTION CONTROL VALVE 8-spool valve (STD + service valve x 1) Ir For details of the names of the ports and the main structure. see IO-SPOOL VALVE . STRUCTURE AND FUNCTION CONTROL VALVE 7-spool valve (STD) + For details of the names of the ports and the main structure.Si -1 AAH t’d L PTR 1 sb\.s2 . 350-6 . ‘CP I 6 \ 5 1A SWPO4720 1 O-46 PC300.R2 P12 P1.0 P’6 G $4 P2 P’-2 PPSP A2 A3 A4 A6 A6 BP PP 06 B5 I34 . see IO-SPOOL VALVE .PS P7. . 1 O-48 PC300.STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE SELF-REDUCING PRESSURE VALVE Pl PC SWP04721 PI : T : PC: PR : From front pump To hydraulic tank To front pump LS valve Supply to electromagnetic PPC valve. 350-6 . solenoid valve valve. 11. 3. 350-6 1o-49 . 9.STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE / B-B \ 12 II SWP04722 1. 12. 6. Filter 8. 2. 10. Control valve block Valve (sequence valve) Spring Screw Poppet Spring (reducing valve pilot) 7. 5. Spring Spring Filter Spring Ball (reducing (reducing valve main) valve) (safety valve) PC300. 4. STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE Function l This valve reduces the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valve and PPC valve. I) :!. (See Fig. so the passage between port PI + P2 is closed. .:::: s SWPO5088 1O-50 PC300. PI? ---t-T HYDRAULIC CIRCUIT DIAGRAM l SWPO5087 Control valve t!r /I. and the passage from port PR + T is closed. When engine is stopped . Valve (9) is pushed to the left by spring (81. Valve (2) is pushed to the left by spring (31. Poppet (5) is pushed . Pl- t P2 PC Operation 1. 350-6 ./. against the seat by spring (61. and the passage from port PI + PR is open. : 5: : :: ::. 2) (F i 9. so spool (9) moves in the direction to close the opening from port PI + PR. (See Fig. As a result. poppet (5) opens and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (8) + opening of poppet (5) + tank port T. and the opening from port Pl + P2 is adjusted so that pressure PI is kept at a certain value above pressure PR. When pressure PR goes above the set pressure. the pressure is 0 MPa 10 kg/cm21).valve (2) moves to the right to the end of the stroke. . poppet (5) opens. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point. 3) (F i 9. 3) Control valve SWPO5090 PC300. so the loss of engine horsepower is reduced. As a result. and is supplied as pressure PR. and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (9) + opening of poppet (5) + tank port T. As a result. If pressure PR goes above the set pressure. so . At neutral and When load pressure P2 is low down under own weight (boom (when moving LOWER or arm IN)) Note: When load pressure P2 is lower than output pressure PR of the self-reducing pressure valve.STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE 2. and is supplied as pressure PR. a pressure difference is created on both sides of hole a inside spool (9). (See Fig. so spool (9) moves in the direction to close the opening from port PI + PR. pressure PI also increases (pressure Pl > force of spring (8) + (area 0d x pressure PR). the amount of opening from port PI + P2 increases and the resistance in the passage is reduced. 350-6 10-51 . 21 SWPO5089 3. . . Valve (2) receives force in the direction to close the passage from port PI + P2 from spring (3) and pressure PR (when the engine is stopped. the pressure is balanced so that pressure PI k force of spring (8) + (area Od x pressure PR). a pressure difference is created on both sides of hole a is inside spool (91. when hydraulic oil flows in from port PI. When load pressure P2 is high If load pressure P2 increases and the pump discharge amount also increases because of digging operations. However. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point. and allows hydraulic oil to flow from output port PR + T. When there is abnormal high pressure When pressure PR of the self-reducing pressure valve becomes abnormally high. This action protects the equipment at the destination for the hydraulic pressure supply (PPC valve. 350-6 . (See Fig.STRUCTURE AND FUNCTION SELF-REDUCING PRESSURE VALVE 4. etc. separates from the seat. so pressure PR goes down. electromagnetic valve.) from abnormally high pressure. 4) 12 (Fig. ball (12) pushes against the force of spring (II).41 II SWPO5091 1o-52 PC300. Poppet spring 7.7 MPa (170 kg/cm*) at 190rYmin 1 24. Suction valve spring 8. Sleeve 9. 709-70-74800 709-70-75100 709-70-75300 709-70-74600 Set pressure 20.STRUCTURE AND FUNCTION SUCTION SAFETY VALVE SUCTION SAFETY VALVE FOR SERVICE VALVE 1. Adjustment screw 10. Suction valve 2. Main valve 3.5 MPa 1250 kg/cm*) at 5e/min PC300. Poppet 6.1 MPa 1205 kg/cm*} at 5e/min 16. Piston 4.6 MPa (210 kg/cm? at 19Oelmin For breaker For breaker For breaker For crusher Use (Okada) (Mitsubishi (Matsuda) (Okada) Krupp) 20. Piston spring 5. Locknut SBPOO198 Part No. 350-6 1o-53 . . and has the following features. 350-6 1o-55 . Structure The CLSS consists of a main pump (2 pumps).-_ - :c LS valve I . the TVC valve and LS valve.- r_i l r-x--I I I I LSvalve I----- I I L___Jti_____ -- I J sBPoo199 Outline . . l PC300. CLSS stands for Closed center Load Sensing System. The main pump consists of the pump itself. . Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. and actuators for the work equipment... Energy saving using variable pump control .STRUCTURE AND FUNCTION CLSS CLSS Outline of CLSS To actuators -:_ I __---_--- I I -I Control valve ----__ 1 I I I I I I I I I I I I I I I I I I I I I I I I I TVC valve --L-J _ _ __ I I I I I I I I l. Features Fine control not influenced by load Control enabling digging even with fine control. . . control valve. the pump swash plate moves towards the minimum position. The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant.LS pressure PLS) Puma Passaoe Actuator @ Control valve _______~ _----_. LS differential pressure APLS SAP00384 1 O-56 PC300. t a 1 :: 0 Q Max.STRUCTURE AND FUNCTION CLSS Basic principle I) Control of pump swash plate angle . the pump swash plate moves towards the maximum position. If LS differential pressure APLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high). if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low). 350-6 . (LS pressure APLS = Pump discharge pressure PP . c E LS valve set Min. 0.I fferential Pressure SWPO5161 . the flow of oil from the pump is divided (compensated) in proportion to the area of openings Sl and S2 of each valve. this valve acts to make pressure difference AP between the upstream (inlet port) and downstream (outlet pot-t) of the spool of each valve the same regardless of the size of the load (pressure). In this way. 350-6 1o-57 . Pressure compensation A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.STRUCTURE AND FUNCTION CLSS 2) . Load Pump PC300. When two actuators are operated together. LL_. . 1 -7 I rrr. B_.-_------PTRI L.STRUCTURE AND FUNCTION CLSS Operation for each function of CLSS Hydraulic circuit diagram for system iPPS1 _____‘Ek-~:-fF. 350-6 .~~ ICC ------ A-. c:::: r< jA6 : B6 3 Arm cylinder I I I I ..__&__L_l I PPS2 SWPO5092 lo-58 PC300. FI ._ _ . 7 To travel junction val travel junction valve motor 3 9 Boom cylinder 12 To trave ‘1 junction A% 5% -IP”mP r solenoid valve Main Swins motor 13 valve Swing motor To wins stroke switch valve J9-t --__--L________ .____i_P_L1 . To travel junction va I ve I I I . . travel spool 15.5 MPa II50 f 5 kg/cm21 7.4 + 0. Safety-suction valve Set pressure: 17. LS shuttle valve 9. Bucket spool 8.8 2 0. Merge/flow divider valve PC300. Arm Lo spool 16. Check valve (for arm regeneration circuit) 17. Boom Hi spool 18. Main relief valve (arm group) Set pressure: 34. Pressure compensation valve 4A.H. Check valve (for boom regeneration circuit) 13. Safety-suction valve Set pressure: 35. Unload valve (arm group) Clutch pressure: 2.5 MPa (365 f 5 kg/cm21 6. travel spool IO.8 2 0. R.2 t 0.8 + 0. Swing spool 14. L.9 2 0. Safety-suction valve (for large flow) Set pressure: 35. Boom Lo spool 12.8 r 0. 350-6 1o-59 .STRUCTURE AND FUNCTION CLSS IA. Safety-suction valve (2-stage) Set pressure: l-stage: 28.5 MPa 1175 + 5 kg/cm*} 4B.9 + 0.H.5 MPa {355 2 5 kg/cm21 IB. Suction valve 11.2 MPa (30 + 2 kg/cm*1 3. Main relief valve (bucket group) Set pressure: 34.5 MPa (290 f 5 kg/cm21 2-stage: 14. 5 kg/cm’) 5.2 MPa (30 f 2 kg/cm21 2B. LS select valve 20.7 k 0.5 MPa (355 f 5 kg/cm*) 2A. Arm Hi spool 19. Unload valve (bucket group) Clutch pressure: 2.5 MPa {365 +. Valve 1 IA. 4. 38. Tank passage 9B. IB. 6B. (6A) at stroke end relief SWPO4730 IA. 2B. 7B. Control valve Control valve Actuator Actuator Pump passage Pump passage LS circuit LS circuit 9A. 350-6 . Valve 1OB. Spring 11 B. 8A. Spring 12. 8B.STRUCTURE AND FUNCTION CLSS SYSTEM DIAGRAM * This shows actuator in the merge mode. 5B. LS bypass valve 1 O-60 PC300. 2A. Main pump Main pump Main relief valve Main relief valve Unload valve Unload valve Merge/flow divider valve 5A. Tank passage 1OA. 6A. 3A. 7A. 9B SBPOO205 Function . IOB). When the unload operation is carried out. the LS control differential pressure (APLS) of the oil discharged at the minimum swash plate angle is the PI pressure. 8B) passes from orifice A through port C. so LS pressure g tank pressure $ 0 MPa (0 kg/cm?. ports B and C are connected and the pump pressure flows to tank passages (9A.8B lOA. 7B) is received by the end face of valves (IOA. 8B) is 0 MPa (0 kg/ cm?. The control valve is at neutral. There is no way for the pressurized oil discharged by the pump to escape. 1 IB). and is drained to tank passages (9A. so the pressure rises.LS circuit pressure) is greater than the pump LS control pressure. In other words. When all the control valves are at neutral. the pressurized oil in LS circuits (8A. 7B) is stopped by valves (IOA. IOB). IOB) move to the left. IIB) inside the valve (PI pressure). The pressure in pump passages (7A. When operated (for operations in the discharge range for the minimum swash plate angle).lOB llA.llB A C 9A. the oil discharged when the pump is at the minimum swash plate angle is drained. In addition. the differential pressure (pump discharge pressure . so the pressure in LS circuits (8A. Therefore. . the pump pressure becomes a pressure that matches the set load of springs (1 IA. valves (IOA. When this pressure becomes larger than the force of springs (1 IA. 9B). when the valve is actuated.lOB 757B llA. The pressurized oil in pump passages (7A. Operation .STRUCTURE AND FUNCTiON CLSS When unload valve is actuated 8A. 9B).ilB A- C 9A. the discharge pressure of the oil discharged with the pump at the minimum swash plate angle is LS pressure + PI pressure. . When this happens. 350-6 10-61 .9B SBPOO206 PC300. I 8A. The LS pressure is drained from LS bypass valve (121.8B / l?A. so a signal is sent to move the pump swash plate to the minimum angle. LS pressure 6 tank pressure. (2) Cut-off Qt Pump flow When cut-off is canceled Relief valve flow l 1 O-62 PC300. so there is no flow of oil upstream or downstream from the spool. because of the structure. main relief valves (2A. When this happens. The relief valve acts to relieve the oil flow when the pump is at the minimum swash plate angle in order to maintain the overall balance. In the power max. The spool is at the end of its stroke. so the overall balance is maintained. LS differential pressure APLS is lower than the LS set pressure of the LS valve. 350-6 . so the torque moves on the pump output curve. Operation of relief valve (1) Cut-off control actuated Function . However. travel) Function. mode. As a result. pump delivery pressure PP and LS pressure PLS are almost the same pressure. the action of the TVC valve is given priority over the action of the LS valve. so the pump is held at the minimum swash plate angle by the cut-off function of the TVC valve. so the LS valve acts to try to move the pump swash plate angle to the maximum. mode. operation . the pump discharge amount is relieved from the relief valve. or travel mode. the torque cut-off signal is not given. Balance point SAW0207 J canceled (power max. and LS differential pressure APLS becomes 0. Qt Pump flow l valve flow Operation When the cylinder reaches the end of its stroke. When cut-off control is being carried out on the pump by the NC valve.STRUCTURE AND FUNCTION CLSS 2. the governor. pump controller sends a signal to the solenoid of the TVC valve and carries out the cut-off function to make pump discharge amount Q the minimum. When pump delivery pressure PP comes close to the relief pressure. fine control mode. 9B). fine control mode. 2B) open and pump discharge amount Q is relieved to tank passages (9A. the pump swash plate angle is at the minimum. it is connected to port B of the actuator through valve (41. ball valve (5) opens. the pump pressure passes through introduction hole a. The upstream valve pressure I= spool meter-in downstream pressure) of pressure compensation valve (3) is introduced and goes to shuttle valve (7) as the LS pressure. When this happens. and is taken to the LS circuit. 3.STRUCTURE AND FUNCTION CLSS 3. and LS pressure % actuator load pressure. 6 7. * Introduction The IN. diagram of LS pressure shows the condition for arm Upstream pressure of pressure compensation valve (for spool meter-in downstream) 1. Operation . so it also acts as a throttle. 350-6 1O-63 . Introduction hole a inside the spool has a small diameter. PC300. When spool (2) is operated. enters port C. 4. 2. 5. When the pump pressure rises and reaches the load pressure of port B. Main pump Main spool Pressure compensation Valve Ball valve LS circuit LS shuttle valve Function . 4. the effective LS differential pressure drops. 5. Furthermore. The residual pressure in LS circuit (6) is released from orifices a and b. and prevents any sudden change in the oil pressure. 2. This reduces the speed of the rise in the LS pressure. a pressure loss is generated by the circuit resistance between throttle c of main spool (2) and LS shuttle valve (4) according to the bypass flow from LS bypass valve (5). 3. LS bypass valve SLFoo211 1. 350-6 . Main pump Main spool Pressure compensation LS shuttle valve LS bypass valve LS circuit Function l valve . and the dynamic stability of the actuator is increased. 6. As a result. 1O-64 PC300.STRUCTURE AND FUNCTION CLSS 4. this is employed for the bucket valve (at the cylinder bottom) and service va Ive. 6. the system is designed so that port C and spring chamber E are interconnected just before the bucket valve is seated. valve (2) may hit valve chamber seat s and generate a high stress. If the pump pressure (LS pressure) is lower than the load pressure at port C. valve (7) does not hit the valve chamber.) . so even if a high peak pressure is generated at port C. SAP00387 PC300. Piston Spring LS shuttle valve Function 1) During independent operation and at maximum load pressure (during compound operations. port C and spring chamber E are not interconnected. The pressure compensation valve acts as a load check valve. shuttle valve (3) inside pressure compensation valve piston (4) moves to interconnect spring chamber E and port C. 3. the force of spring (5) acts to move piston (4) and valve (2) in the direction of closing. Reference: Integrated pressure compensation va Ive When high peak pressure is generated in the actuator circuit or when peak pressure is generated repeatedly over a continuous period (such as when using a breaker). Main pump Valve Shuttle valve 4. 5. Pressure compensation valve . as a basic rule. To prevent this. when load pressure is higher than other work equipment) .STRUCTURE AND FUNCTION CLSS 5. (However. 2. On this machine. From this condition. an integrated pressure compensation valve combining valve (2) and piston (4) is used. Operation . 350-6 1 O-65 . With the integrated compensation valve.6 SLfoO212 1. the pump flow is divided in proportion to the area of the meter-in opening. Operation Spring chamber E is interconnected with port D. In other words.downstream pressure (pressure of port B)) becomes the same for all spools that are being operated. the valve upstream pressure of port B I= spool meterin downstream pressure) is controlled by the LS pressure.STRUCTURE AND FUNCTION CLSS From LS shuttle valve for other work equipment -t 3L Upstream pressure of pressure compensation (for spool meter-in downstream) valve Spool meter-in upstream pressurGe )c/ ’ SLWO213 2) l When receiving compensation (during compound operations. Piston (4) and valve (2) are actuated by the LS circuit pressure from the other work equipment at port F in the direction of closing (to the right). The spool meter-in upstream pressure of port A is the pump pressure. so spool meter-in differential pressure (upstream pressure (pressure of port A) . In this way. when load pressure is lower than other work equipment) The pressure compensation valve is closed by the LS pressure of port D. and the spool meter-in downstream pressure of port B becomes the same as the maximum pressure of the other work equipment. l 1O-66 PC300. 350-6 . c Pressure compensation valve for service valve > The service valve uses a variable type pressure compensation valve. When area ratio = 1: Spool meter-in downstream pressure = Max. so it can adjust the division of the oil flow suitably to match the attachment installed. When ratio is more than 1: Spool meter-in downstream pressure > Max. load pressure.STRUCTURE AND FUNCTION CLSS Shuttle valve From LS circuit Throttle. and a smaller oil flow is divided than the proportion between the areas of opening of the spool. Area ratio = A2/Al . load pressure. 350-6 1O-67 . 1 I I To actuator 1 Al t Spool meter-in downstream txessure SLPoo218 < Area ratio of pressure compensation valve > The condition of the flow division changes according to the ratio of the areas of portion Al and portion A2 of the pressure compensation valve. load pressure. When ratio is less than 1: Spool meter-in downstream pressure < Max. and oil flow is divided in proportion to area of opening of spool. l PC300. . and a larger oil flow is divided than the proportion between the areas of opening of the spool. . STRUCTURE AND FUNCTION CLSS 6. 350-6 . the holding pressure at port A is taken to spring chamber B. 3. In this condition. Main pump Valve Shuttle valve inside pressure va Ive Piston compensation Function When holding pressure at port A > LS pressure in spring chamber 6. and pushes piston (4) to the left to prevent piston (4) and valve (2) from separating. and the circuit between ports A and C is shut off. 2. 4. l Shuttle valve (3) is pushed to the right by the pressure of port A. 1O-68 PC300. Shuttle valve inside pressure compensation valve SLP00214 1. In this condition. piston (4) and valve (2) will separate. so a pressure compensation valve without a shuttle valve is used. Time lag / I- I-PL I Holding pressure w Time SAW0217 PC300. so there is a time lag. LS pressure . If there is no shuttle valve.STRUCTURE AND FUNCTION CLSS SLPuO215 < For travel> . the piston acts as an accumulator. if another actuator is operated. No holding pressure is generated at port A in the travel circuit. SBPOO216 Reference: When there is no shuttle valve . 350-6 lo-69 . . 350-6 . The pump pressure leaving the service valve spool acts on the left end of valve (I). 5. 8. 4. and at the same time passes through throttle a and enters chamber g. In addition. 2. and the force of spring (5) acts on poppet (4). At the same time.).STRUCTURE AND FUNCTION CLSS 7. The maximum LS pressure passes through throttle d and enters chamber e. (Variable in proportion to surface area) . It is possible to adjust the division of the oil flow to the service valve when the service valve (for attachment) is operated together with the main control valve (boom RAISE. Variable type pressure (for service valve) compensation valve From valve service ~~001 a binder port b Load other ~reeeure from work equipment SWPO5093 1. Valve Spring Sleeve Poppet Spring Screw Locknut Plastic cap Function . 7. The force of spring (5) can be adjusted with screw (6) 1O-70 PC300. 3. the force of spring (2) acts on valve (I). the cylinder port pressure passes through passage c and throttle f. etc. and goes to chamber h. 6. so the pump passage is connected to the cylinder port through throttle a. PxAl=PxA2+LS(A2-Al)+F Al: Cross-sectional area of diameter Dl A2: Cross-sectional area of diameter D2 ( F: Force of spring 2. When this happens. the area ratio becomes smaller. and the oil flows to the cylinder port. When the difference between the pump pressure and the cylinder pressure is less than the force of spring (51. 350-6 10-71 . In other words. The pump pressure and LS pressure are determined by the pressure of the other work equipment. Dl D2Dl I From valve service ~~001 port SWPO5094 @p From valve service spool CvI inder port SWPO5095 \ PC300. and the pressure in chamber g goes down. then balance of the force acting on valve (I) is as follows. a differential pressure is formed between the upstream and downstream sides of throttle a. If the difference between pump pressure P and the cylinder pressure becomes greater than the force of spring (51. so the force pushing valve (I) to the left is reduced. etc.) 1. chamber g.STRUCTURE AND FUNCTION CLSS Operation Simultaneous operation with work equipment under heavy load (boom RAISE. so valve (I) moves to the right and increases the flow from the pump to the cylinder. but the cylinder port pressure becomes the actuating pressure of the attachment. poppet (4) is pushed to the right and the passage opens. and passages b and c. goes through port B. etc. and passes through ports C and D to flow back to the cylinder head.) . 1 O-72 PC300. Main pump Main spool Pressure compensation valve Pressure compensation valve Suction valve (with safety) Suction valve Check valve LS shuttle valve Drain circuit circuit Regeneration Function I) Cylinder head pressure < cylinder bottom pressure (free fall. 350-6 . 2. enters regeneration circuit (81. part of the pressurized oil from the cylinder bottom passes through the notch in spool (21. 7. 3A. 5.STRUCTURE AND FUNCTION CLSS 8. When the cylinder head pressure < cylinder bottom pressure. 6. the return flow can be used to increase the flow of oil from the pump to the cylinder bottom. Boom regeneration circuit Raise Lower SWPO5096 1. 8. Operation . 4A. opens check valve (51. The rest of the oil goes from port C. 3B. 4B. and enters drain circuit (7). A return flow circuit is provided from the cylinder bottom to the cylinder head so that when the boom is lowered. PC300.STRUCTURE AND FUNCTION CLSS RAISE LOWE 2) . 350-6 1o-73 .) Check valve (5) in regeneration circuit (8) acts to shut off the flow from the cylinder head to the cylinder bottom. Cylinder head pressure > Cylinder bottom pressure (digging operations. etc. 350-6 . 4A. increases the cylinder speed. as a result. enters port C and opens check valve (8). and. 8. the pressurized oil from the cylinder head passes through the notch in spool (21. 4B. Arm regeneration circuit IN OUT 38 4A SWPO5097 1. 2. 6. A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved IN. Main pump Main spool Pressure compensation Pressure compensation Safety valve Safety valve Check valve LS shuttle valve Drain circuit circuit Regeneration valve valve Function Cylinder head pressure > cylinder bottom pressure .STRUCTURE AND FUNCTION CLSS 9. 5. 3B. the flow of oil to the cylinder becomes the pump discharge amount + the return flow. l 1o-74 PC300. 3A. Operation When the cylinder head pressure > cylinder bottom pressure. then passes through ports D and E to flow back to the cylinder bottom. This covers for any negative pressure at the cylinder bottom. 7. and are sent to the control valve that demands the oil. Pilot pressure PS is OFF. 6. 8. 3. pressurized oil flows PI and P2 discharged from the two pumps are merged at ports E and F. so the ports are connected as follows. At the same time. Connected ports: A ++ D. 7. 2. 4. PC300. . Therefore. so main spool (I) is pushed fully to the left by spring (21. Main spool Spring LS spool Spring LS circuit (bucket) LS circuit (arm) LS circuit (arm) LS circuit (bucket) Function This acts to merge or divide (send each to its own control valve group) oil flows PI and P2 of pressurized oil discharged from the two pumps. LS spool (3) is also pushed fully to the left by spring (41. (61. and ports E and F are interconnected. and (8) is all sent to the pressure compensation valve and other valves. 5. (71. In the same way. 350-6 1o-75 .STRUCTURE AND FUNCTION CLSS 10. Merge/flow 5 divider valve A 0 C D 7 8’ 'OFFJ PS To control valve To control valve P2 PI SWPO5098 1. the LS pressure supplied from the spools of each control valve to LS circuits (5). it also carries out merging and dividing of the LS circuit pressure. l l Operation I) When merging pump flow (when pilot pressure PS is OFF) . . B t) C Therefore. (7). main spool (I) is moved to the right by the PS pressure. . others are not connected. Connected ports: B t) D.STRUCTURE AND FUNCTION CLSS To bucket control To arm control P2 21 l When dividing pump flow (when pilot pressure PS is ON) When pilot pressure PS is ON. and (8) are all connected to their own control valve group. and the ports are connected as follows.H. L. travel.H. Pressure PI: To bucket. Therefore. (61. R. LS circuits (5). arm group In the same way. and ports E and F are disconnected. 1O-76 PC300. LS spool (3) is also moved to the right by the PS pressure. Therefore. travel. the pressurized oil discharged from each pump is sent to its own control valve group. boom group Pressure P2: To swing. 350-6 . 2) When pilot pressure BP is ON . 4 3 2 B 1 A Operation 1) When pilot pressure BP is OFF . (BP pressure ON) 1. it does not influence any other LS circuit. 9. Therefore. To LS shuttle valve SLFQO226 3 2 Bl p BY (ON) To LS shuttle valve SLPO0227 PC300. and even if swing LS pressure PI rises to a high pressure. Valve Spring Piston Piston Swing spool L. swing LS pressure PI flows to LS shuttle valve (8). It pushes valve (I) to the right and closes the circuit between ports A and B. As a result. 5. 7. 4. 350-6 1o-77 . swing LS pressure PI passes through swing spool (5) and enters port A. 2. so piston (3) is pushed to the left by spring (2). Pilot pressure BP is OFF.STRUCTURE AND FUNCTION CLSS 11. * LS select valve The diagram shows the situation when the swing and left travel are operated at the same time. 6. travel spool Arm spool LS shuttle valve LS circuit 9 SLPO0225 l Function This valve is used to increase the ease of operating the work equipmentlt prevents high pressure from being generated when the swing is operated. piston (3) is moved to the right against spring (2) by the BP pressure. If the swing is then operated. It also prevents the high LS pressure from the swing circuit from flowing into any other LS circuit when the swing is operated together with the work equipment.H. 3. 8. When pilot pressure BP is ON. It pushes valve (I) to the left and connects ports A and B. swing LS pressure PI stops flowing to LS shuttle valve (81. (Installed load of spring (1) c installed load of spring (3)).dl). passage B is connected to the drain circuit through passage C and chamber D. and is drained. the installed load becomes the minimum.STRUCTURE AND FUNCTION CLSS 12. In addition. 4. Spring Piston Spring Holder SAP00228 Function . Because of this. when digging with boom. so piston (2) is pushed to the left by spring (3). 21 When pilot pressure P is ON: low pressure setting . and the set pressure is set to low pressure. In addition. When this happens. 3.2~stage safety valve (installed to boom cylinder head) 1. Pilot pressure P is OFF. SAP00229 lA23B4 SAW0230 1 O-78 PC300. even if high pressure is brought to bear on the boom cylinder. and piston (2) acts on the diameter of portion A receiving the pressure (d2 . spring (I) extends. This makes it possible to carry out operations with high efficiency and with little vibration of the chassis. Operation . The set pressure of the safety valve is determined by the load pressure of spring (I). it is possible to let the boom escape without operating the control lever. the pilot pressure goes to portion A through passage B. Piston (2) is moved to the right against spring (3) by this pilot pressure. the installed load of spring (I) becomes the maximum. It moves the full stroke until it contacts holder (4). When pilot pressure P is ON. 2. an amount of oil equivalent to the piston stroke passes through passage C and chamber D. As a result. and the set pressure is set to high pressure. 1) When pilot pressure P is OFF: high pressure setting . The set pressure of the safety valve can be set to two stages and the low pressure setting can be made smaller. 350-6 . . 350-6 .STRUCTURE AND FUNCTION CLSS OPERATION When all work OF CLSS SYSTEM AS A WHOLE equipment is at neutral of the Sr The valves and circuits that are not connected with the explanation operation of the CLSS hydraulic system have been omitted. r SWPO4733 1 O-80 PC300. Mi'n I - SWPO4734 PC300. 350-6 lo-81 .STRUCTURE AND FUNCTION CLSS Max. 8. LS bypass valve 33. 29B). so the pump swash plate angle is the minimum. Suction valve 34. 13. LS select valve 31. 4B. 3B.H. boom Lo. LS shuttle valve (service) Note: Groups of control valves by main pump circuit Bucket group: Bucket. 6. 2B.STRUCTURE AND FUNCTION ass 1. LS shuttle valve (L. Plug 21. travel spool Boom Lo spool Swing spool L. Main relief valve (arm group) 29A. the pump is at the minimum swash plate angle. 5A. 350-6 . 17.H. 9. Service spool 35. 2A. 11.H. 3A. boom Hi. The LS pressure is connected to hydraulic tank (I) by LS bypass valve (32).H. l l 1 O-82 PC300. travel) 25. 18. 15. 4A.Main relief valve (bucket group) 28B. 19. Check valve (for arm regeneration circuit) 28A. 7. LS shuttle valve (boom) 24. 14. L.H. Arm Hi Arm group: Swing. LS shuttle valve (bucket) 22. IO. Variable type pressure compensation valve 36. travel. R. arm Lo Operation (When all work equipment is at neutral) When the levers are at neutral. 5B. LS shuttle valve (R.Unload valve (bucket group) 29B. The LS differential pressure APLS (unload pressure -tank pressure) at this point is APLS > pump LS control pressure. travel. Unload valve (arm group) 30. Check valve (for boom regeneration circuit) 27. travel) 23. integrated type) (bucket CURL) Pressure compensation valve (without shuttle valve) (travel) Safety-suction valve Safety-suction valve (bucket CURL) 2-stage safety-suction valve (boom LOWER) 20. travel spool Arm Lo spool Boom Hi spool Arm Hi spool Pressure compensation valve (with shuttle valve) Pressure compensation valve (with shuttle valve. Hydraulic tank Main pump (front) Main pump (rear) TVC valve (front) TVC valve (rear) LS valve (front) LS valve (rear) Merge/flow divider valve (main) Merge/flow divider valve (for LS) Bucket spool R. 16.H. LS check valve 32. 12. and the oil flow is drained from unload valves (29A. LS shuttle valve (arm) 26. . STRUCTURE AND FUNCTION CLSS When pump flow merged. B .D. bucket CURL operated independently I I i SWPO4735 Connection of ports when pump flow is merged Connected ports: A . 350-6 .C 1 O-84 PC300. STRUCTURE AND FUNCTION CLSS SWP04736 PC300. 350-6 1 O-85 . unload valves (29A. The swash plate of the main pump is controlled (LS control) to match the area of the meter-in opening of bucket spool (61. When the bucket CURL is operated. (APLS = pump LS control pressure) 1O-86 PC300. 29B) are closed. 350-6 .STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. so the pump swash plate is balanced at a position which matches the oil flow demanded by the spool meter-in. bucket CURL operated independently) . . . B .D.C 1O-88 PC300.STRUCTURE AND FUNCTION CLSS When pump flow merged. 350-6 . boom RAISE operated (Boom Lo valve + boom Hi valve) independently SWPO4737 Connection of ports when pump flow is merged Connected ports: A . 350-6 1O-89 .STRUCTURE AND FUNCTION CLSS Max Mi’n I I SWP04738 PC300. so the LS differential pressure is smaller than the LS control pressure and the swash plate angle is always at the maximum.STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. both pumps are at the maximum swash plate angle. unload valves (29A. 350-6 .) (APLS c pump LS control pressure) l 1O-90 PC300. (APLS = pump LS control pressure) . When the spool meter-in opening comes near the maximum. the maximum area of opening of the spool is also large. The swash plate of the main pump is controlled (LS control) to match the total area of the meter-in opening of boom Lo spool (8) and boom Hi spool (12). When the boom RAISE is operated. 29B) are closed. (When the pump discharge is the maximum. boom RAISE operated independently) . . 350-6 .D. B .STRUCTURE AND FUNCTION CLSS When pump flow merged.C 1 O-92 PC300. arm IN operated (Arm Lo valve + arm Hi valve) independently SWPO4739 Connection of ports when pump flow is merged Connected ports: A . 350-6 1o-93 .STRUCTURE AND FUNCTION CLSS SWPO4740 PC300. STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. 350-6 . the maximum area of opening of the spool is also large. 29B) are closed. . both pumps are at the maximum swash plate angle. When the arm IN is operated. (APE = pump LS control pressure) .) (APLS c pump LS control pressure) 1o-94 PC300. so the LS differential pressure is smaller than the LS control pressure and the swash plate angle is always at the maximum. arm IN operated independently) . The swash plate of the main pump is controlled (LS control) to match the total area of the meter-in opening of arm Lo spool (I I) and arm Hi spool (13). (When the pump discharge is the maximum. When the spool meter-in opening comes near the maximum. unload valves (29A. . arm OUT operated (Return circuit arm Lo + arm Hi) independently To Hi valve SWPO5133 Connection of ports when pump flow is merged Connected ports: A .D.C 1O-96 PC300. B . 350-6 .STRUCTURE AND FUNCTION CLSS When pump flow merged. 350-6 1o-97 .STRUCTURE AND FUNCTION CLSS SWP04742 PC300. The swash plate of the main pump is controlled (LS control) to match the area of the meter-in opening of arm Lo spool (II). When this happens. and then returned. the oil from the cylinder bottom is divided. arm OUT operated independently) When the arm OUT is operated. sent to the Lo and Hi spools. l 1O-98 PC300. unload valves (29A. so the pump swash plate is balanced at a position which matches the oil flow demanded by the spool meter-in. so it is possible to keep the pressure loss in the circuit small. . 350-6 . 29B) are closed.STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. (APLS = pump LS control pressure) . . travel operated independently SWPO4743 Connection of ports when Connected ports: B .D Disconnected ports: A.STRUCTURE AND FUNCTION CLSS When pump flow divided. 350-6 . C pump flow is divided 10-100 PC300. 350-6 10-101 .STRUCTURE AND FUNCTION CLSS SWPO4744 PC300. Flow of oil from main pump (2A): To L.STRUCTURE AND FUNCTION CLSS Operation (When pump divided.H. Pilot pressure PA of merge/flow divider valve (5A) ON I) . spool (7) (bucket group) .H. From the condition in I) above. 350-6 . 10-102 PC300. The straight travel is compensated by the travel junction valve. the oil flow from the pump is being divided. When the STRAIGHT TRAVEL is operated. if the lever on the side being steered is returned (the oil flow becomes small) or the lever on the other side is operated in the opposite direction (the direction of travel is reversed). spool (IO) (arm group) Flow of oil from main pump (28): To R. 2) . travel operated independently) . a flow of oil is supplied from the main pump to match the stroke of the left and right travel spools (IO) and (7). so the left and right travel circuits are controlled independently and the machine is steered. . 350-6 .C PC300. B .STRUCTURE AND FUNCTION CLSS When pump flow merged.D. arm IN + boom RAISE operated simultaneously c 10-104 SWPO4745 Connection of ports when pump flow is merged Connected ports: A . STRUCTURE AND FUNCTION CLSS SWP04746 PC300. 350-6 10-105 . Meter-in LS differential pressure APLS during boom RAISE + arm IN is APLS c pump LS control pressure. simultaneously. the oil flow is divided in proportion to the total area of opening of boom Lo spool (8) and boom Hi spool (121. When the arm and boom are operated . so the LS pressure passes through ports E and F of boom Lo spool (8). and acts to increase the set pressure of the pressure compensation valve. 350-6 .STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. and the spool meter-in LS differential pressure (pump pressure LS pressure = APL9 becomes the same as that at the boom end. Because of this. Because of the above operation. lo-106 PC300. the load pressure at the boom RAISE side is higher than at the arm side. . the pressure between port H of arm Lo spool (II) and port I of pressure compensation valve (14) rises. the swash plate angle for both pumps becomes the maximum. enters boom LS shuttle valve (23) and is sent to the LS circuit. When this happens. and the total area of opening of arm Lo spool (II) and arm Hi spool (13). 2) . so the main pump swash plate angle is set to maximum. boom RAISE operated simultaneously) arm IN + 1) . This LS pressure is transmitted to port G of pressure compensation valve (141. . D. 350-6 . B .C lo-108 PC300. swing + boom RAISE operated simultaneously SWPO4747 Connection of ports when pump flow is merged Connected ports: A .STRUCTURE AND FUNCTION CLSS When pump flow merged. 350-6 10-109 .STRUCTURE AND FUNCTION CLSS SWPO4748 PC300. the pump can deliver an ample flow of oil regardless of the pump output curve. The swash plate of the main pump is controlled (LS control) by the difference in pressure between the boom and LS pressure. 350-6 .STRUCTURE AND FUNCTION CLSS Operation (When pump flow merged. the LS divider valve is shut off. and the high pressure generated when the swing is operated does not flow to the LS circuit. so even if the swing drive pressure is high. swing + boom RAISE operated simultaneouslv) When the boom RAISE is being operated in the heavy-duty digging mode the swing is operated simultaneously. LS select valve ON LS select valve OFF P SWPO5099 10-l10 PC300. so the LS circuit pressure becomes the boom pressure. the pump pressure is determined by the boom pressure. the pilot pressure of LS divider valve (30) is turned ON. In addition. When this happens. . STRUCTURE AND FUNCTION CLSS When pump flow divided operated simultaneously (pump pressure: 19. C pump flow is divided 10-112 PC300.6 MPa (200 kg/cm21 or above). travel + boom RAISE SUP04149 Connection of ports when Connected ports: B . 350-6 .D Disconnected ports: A. 350-6 10-113 .STRUCTURE AND FUNCTION CLSS PLS2 @-I PLSl@---j’[ II- iTF--I w-l SWPO5134 PC300. so the travel pressure is maintained and it is possible to carry out compound operations easily. 10-114 PC300. the boom Hi spool does not move because of the travel PPC pressure.STRUCTURE AND FUNCTION CLSS Operation (When pump flow divided (pump pressure: 19. travel + boom RAISE operated simultaneously) l When the travel and boom RAISE are operated simultaneously (such as when raising the boom before traveling up a steep slope). The flow of oil to the boom at this point is restricted. .6 MPa I200 kg/cm*} or above). if the pump pressure rises to 19. 350-6 . In addition. the merge/flow divider valve pilot is turned ON and the pump flow is divided.6 MPa (200 kg/cm*). . 6 MPa (200 kg/cm*} or above).D Disconnected ports: A.STRUCTURE AND FUNCTION CLSS When pump flow divided simultaneously (pump pressure: 19. 350-6 . travel + arm IN operated Travel PPC Dressure SWPO5135 Connection of ports when Connected ports: B . C pump flow is divided 10-116 PC300. STRUCTURE AND FUNCTION CLSS SWPO4752 PC300. 350-6 10-117 . the stroke of the arm Lo spool is restricted by the travel PPC pressure. The flow of oil to the arm at this point is restricted. lo-118 PC300. In addition.STRUCTURE AND FUNCTION CLSS Operation (When pump flow divided (pump pressure: 19. .6 MPa I200 kg/cm21 or above).6 MPa (200 kg/cm*). so the travel pressure is maintained and it is possible to carry out compound operations easily. 350-6 . travel + arm IN operated simultaneously) When the travel and arm IN are operated l simultaneously (such as when using the digging action of the arm to help the machine travel up a steep slope). the merge/flow divider valve pilot is turned ON and the pump flow is divided. if the pump pressure rises to 19. . 4 MPa U8.7 cc/rev Safety valve set pressure: 28.8 + 0.4 f 4 kg/cm2} 10-120 PC300.STRUCTURE AND FUNCTION SWING MOTOR SWING KMFl60ABE-3 MOTOR T2 SWPO4753 B : From swing brake solenoid S : From lift check valve MA: From control valve MB: From control valve Tl :To tank T2 : To port S valve Specifications Model: Theoretical KMFlGOABE-3 160. kg/cm21 Rated speed: Brake releasing 1. 350-6 .680 rpm pressure: 1.7+Od5 MPa delivery: 1293’5. 4. 12. Piston assembly Cylinder block Spring Center shaft Valve plate Suction valve spring Suction-safety valve Reverse prevention valve PC300. 16. 15. 7.STRUCTURE AND FUNCTION SWING MOTOR A-A SWPO4754 1. 2. 11. 350-6 10-121 . 14. Spring Output shaft Oil seal Case Plate Disc Brake piston Housing 9. 5. 3. 10. 13. 8. 6. suction valve (2) opens and oil is supplied from port S to prevent cavitation. but the swing continues. . It acts to release the abnormally high pressure oil from the outlet port of the motor to port S. the pressure at port MA rises and the starting force is generated in the motor. the outlet port circuit of the motor is closed by the control valve. The suction valve supplies an amount of oil equivalent to the amount of oil released by the safety valve. so negative force is generated. No pressurized oil is supplied at port MA. and the circuit is closed. If the swing control lever is operated to swing to the right. the pressurized oil from the pump passes through the control valve and it supplied to port MA. The safety valve is installed to prevent this problem. When this happens. no more pressurized oil is supplied from the pump to port MA. At the same time. safety valve (I) opens and releases the pressurized oil at port MB to port S. As a result. It sends this oil from port S to the inlet port of the motor to prevent any cavitation. and also functions as a swing brake. . the oil from the outlet port of the motor returns from the control valve to the tank. When this negative pressure drops to the set pressure of suction valve (2). and rotating resistance to the motor is generated. 2. When starting swing . The oil from the outlet port of the motor flows from port MB through the control valve and returns to the tank. The pressure at port MB rises. SAP00246 10-122 PC300. so the brake starts to take effect. so the motor starts to turn. but the motor continues to be turned by the inertia of the swing. the pressure at the outlet port of the motor becomes abnormally high and there is danger that the motor will be damaged. When the swing control lever is returned to the neutral position. l Operation 1. When the swing is stopped. When stopping swing .STRUCTURE AND FUNCTION SWING MOTOR l SUCTION-SAFETY VALVE Function . . If the pressure at port MB rises to the set pressure of safety valve (I). 350-6 . Main PumP swP05100 2) Swing brake solenoid valve energized When the swing brake solenoid valve is energized. and pressurized oil from the main pump enters port B and flows to brake chamber a. the valve is switched. disc (6) and plate (5) are separated and the brake is released. The pressurized oil entering chamber a overcomes brake spring (1) and pushes brake piston (7) up. 350-6 lo-123 . the flow of pressurized oil from the main pump is shut off. brake piston (7) is pushed down by brake spring (I). and the brake is applied. pushes disc (6) and plate (5) together. SWPO5101 PC300. As a result.STRUCTURE AND FUNCTION SWING MOTOR Operation of swing brake 1) Swing brake solenoid valve de-energized If the swing brake solenoid valve is de-energized. As a result. and port B is connected to the tank circuit. 5.: 5: I. 5. . 350-6 . :. i // :: 1. I. 2. 5. I. . 6./ 8. 7. 3. :. .STRUCTURE AND FUNCTION SWING MOTOR REVERSE Operation PREVENTION VALVE . Valve body Spool (MA side) Spring (MA side) Plug Spool (MB side) Spring (MB side) Plug 5: 5. 4. WA Swind control valve NV SAP03475 Explanation of effect ---------Pressure MA Reversal Pressure :wlth :without reversal reverea pr ‘eventton Prevention valve valve Pressure MB Motor speed I L Start 1 Brake _I_ Reversa I Time - SAP03476 lo-124 PC300.. the pressure oil is closed by spool (21. reversal pressure is generated at port MA. For this reason. When this happens. / Notch SAP03477 Operation II When brake pressure is being generated at port MB . so spool (2) pushes spring (3) and moves to the right. Pressure MB passes through the notch and goes to chamber d. moves to the left. and the braking force is ensured. and the compression of the hydraulic oil when the swing is stopped. 2) After motor stops The motor is reversed by the closing pressure generated at port MB. the backlash and rigidity of the machinery system. b is connected to f through the drill hole in spool (5). Pressure MA goes to chamber a. (1st reversal) When this happens. and MB is connected to e. 350-6 lo-125 . so spool (2) does not move. and MA is connected to B. l SAP02642 PC300. At the same time. This is effective in preventing spillage of the load and reducing the cycle time when stopping the swing (the positioning ability is good and it is possible to move swiftly to the next job).STRUCTURE AND FUNCTION SWING MOTOR Outline This valve reduces the swing back generated in the swing body by the inertia of the swing body. spool (5) pushes spring (6) according to the difference in area Dl > D2. so the reversal pressure at port MA is bypassed to port T to prevent the 2nd reversal. pressure MA is below the set pressure of spring (3). travel motor port PB : From travel speed EPC valve : To L. and R.H. 350-6 .STRUCTURE AND FUNCTION CENTER SWIVEL JOINT CENTER SWIVEL JOINT El E2 A-A A-4 T2 D2 82 A2 c2 SBPOO249 1.H. 2. 3. travel motors port T Dl D2 El E2 lo-126 PC300.H. Cover Body Slipper O-ring Shaft seal Al A2 Bl B2 Cl C2 : From control : To R. 5.H. travel valve port 62 motor port PB valve port B5 motor port PA valve port A2 motor port PA : From control valve port A5 : To L.H. and R.H. travel : From control : To R.H. 4.H. travel motors port P Tl : To tank T2 : From L. travel : From control : To L. . 2 f 0.8 cc/rpm 1.1 cc/rpm Max 160.STRUCTURE AND FUNCTION TRAVEL MOTOR TRAVEL MOTOR HMVl60ADT-2 6 z SWPO4757 P : From travel speed solenoid T :To tank PA: From control valve PB : From control valve valve Specifications Model: Theoretical delivery: Brake releasing Travel speed pressure: pressure: switching HMVI 60ADT-2 Min 110. 350-6 .8 $1” MPa (8 :f kg/cm*) lo-128 PC300.4 MPa {I2 + 4 kg/cm21 0. valve Counterbalance Spool return spring Safety valve Ball Regulator valve Spring PC300. 5. Output shaft Motor case Rocker cam Piston Cylinder Valve plate End cover Slow return valve 9. 16. 10. Brake spring Brake piston Plate Disc Regulator piston Spring Check valve spring Check valve 17. 3. 4. 21. 6. 15. 22. 13. 12. 7. 11.STRUCTURE AND FUNCTION TRAVEL MOTOR ‘a 22 B-0 SWPO4758 21 1. 18. 20. 19. 350-6 lo-129 . 14. 8. 2. and the main pressure oil from the control valve going to end cover (7) is shut off by regulator valve (21). the motor capacity becomes maximum. regulator valve (21) is pushed fully to the right by spring (22). so the combined force of the piston propulsion force acts as a moment to angle rocker cam (3) in the direction of the maximum swash plate angle. 10-130 PC300. 350-6 . l At the same time. As a result. rocker cam (3) moves in the maximum swash plate angle direction. and the system is set to low speed. it pushes slow return valve (81. so the pilot pressure oil from the main pump does not flow to port P. Fulcrum a of rocker cam (3) is eccentric to point of application b of the combined force of the propulsion force of the piston of cylinder (51. For this reason. the pressurized oil at regulator piston (13) passes through orifice c in regulator valve (21) and is drained to the motor case. Because of this. .STRUCTURE AND FUNCTION TRAVEL MOTOR Operation of motor 1) At low speed (motor swash plate angle at maximum) I The solenoid valve is de-energized. rocker cam (3) moves in the minimum swash plate angle direction. and pushes regulator piston (13) to the right. enters regulator piston (131. When the solenoid valve is energized. . and the system is set to high travel speed. the motor capacity becomes minimum. As a result. PC300.STRUCTURE AND FUNCTION TRAVEL MOTOR 2) At high speed (motor swash plate angle at minimum) . 350-6 10-131 . the pilot pressure oil from the main pump flows to port P. Because of this. and pushes regulator valve (21) to the left. . the main pressure oil from the control valve passes through passage d in regulator valve (21). SWPO5104 21 When stopping travel . When the travel lever is placed in neutral. and flows into chamber a of brake piston (10). plate (11) and disc (12) are pushed together. counterbalance valve spool (17) returns to the neutral position and the circuit to the parking brake is closed. It overcomes the force of spring (91. 350-6 . SWPO5105 lo-132 PC300. When this happens. the pressurized oil from the pump actuates counterbalance valve spool (17). As a result. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (8) when the brake piston returns. so plate (11) and disc (12) separate and the brake is released. and pushes piston (IO) to the right.STRUCTURE AND FUNCTION TRAVEL MOTOR Operation of parking brake 1) When starting to travel l When the travel lever is operated. opens the circuit to the parking brake. The pressurized oil in chamber a of brake piston (10) is drained to the case from the orifice in the brake piston. and the brake is applied. and brake piston (IO) is pushed fully to the left by spring (9). the force pushing plate (II) and disc (12) together is lost. and this ensures that the brake is applied after the machine stops. The pressurized oil at the supply side flows from orifice El in spool (19) and orifice E2 in the piston to chamber Sl. the pressurized oil from the control valve is supplied to port PA. 350-6 . Operation when pressurized oil is supplied . As a result. 2). the motor will rotate without load and the machine will run away. (Fig. so the pressure at the supply side rises. When the pressure in chamber Sl goes above the spool switching pressure. 3) PC300. port MB and port PB are connected. When the travel lever is operated. The function and operation of each component is as given below. (Fig. the outlet port side of the motor is opened. . 3). and the motor starts to rotate. (Fig. check valve Function . the weight of the machine makes it try to travel faster than the speed of the motor. which is extremely dangerous. and safety valve in a circuit as shown in the diagram on the right. 1) Counterbalance valve.STRUCTURE AND FUNCTION TRAVEL MOTOR Operation of brake valve . if the machine travels with the engine at low speed. As a result. these valves act to make the machine travel according to the engine speed (pump discharge amount). I) SAW0262 Control valve -1 (Fig. To prevent this. counterbalance valve. 2) SAP00263 Control valve (Fig. It pushes open check valve (18a) and flows from motor inlet port MA to motor outlet port MB. However. the motor outlet port is closed by check valve (18b) and spool (191. 1) . spool (19) is pushed to the right. (Fig. The brake valve consists of a check valve. When traveling downhill. 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. resistance is generated to the rotation of the motor. and this prevents the machine from running away. As a result.D22) x pressure] overcomes the force of the spring and moves the poppet to the left. 6) P&et SBP00267 10-134 PC300. and the pressure in chamber Sl through orifices El and E2 will also drop. (Fig. 5) SBPO0266 Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) . (Fig. the pressure at the outlet port side rises. chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve. In other words. D2 Dl . the force produced by the difference in area between Dl and D2 [7c4(D12 . and outlet port MB is throttled. the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. 4) (Fig. (Fig. However. When the travel is stopped (or when traveling downhill). When the pressure in chamber Sl drops below the spool switching pressure. 2-stage set safety valve) Function When travel is stopped (or when traveling downhill). the motor is rotated by inertia. so the oil flows to chamber MA in the circuit on the opposite side. the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve. but the pressure at the outlet port rises because of inertia. 4) SBPO0265 2) l Safety valve (Pdirection operation.STRUCTURE AND FUNCTION TRAVEL MOTOR Operation of brake when traveling downhill . If the machine tries to run away when traveling downhill. so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping. 5) If the pressure goes above the set pressure. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. MB I (Fig. (Fig. spool (19) is returned to the left by spring (20). the motor will turn under no load. 350-6 . 6). so the pressure at the motor inlet port will drop. the pressurized oil from the pump actuates counterbalance valve spool (191. 350-6 10435 . 7) SBPC0268 . 8) Poppet (Fig. The oil passes from chamber G to passage H and flows into chamber J.STRUCTURE AND FUNCTION TRAVEL MOTOR 2) . so the oil flows to chamber MB in the circuit on the opposite side. Because of this. and compresses the spring to make the set load larger. (Fig. When the travel lever is operated. chamber MA in the outlet port circuit is closed by the check valve of the counterbalance valve. Piston \ Spr ino I MA Travel valve control IF i g. 9) SWPO5106 PC300. If the pressure goes above the set pressure. (Fig. the set pressure of the safety valve is switched to the high pressure setting. but the pressure at the outlet port rises because of inertia. 8) SBPOO269 Operation of mechanism for varying set pressure II When starting travel (high-pressure setting) . pushes the piston to the right.D12) x pressure] overcomes the force of the spring and moves the poppet to the left. 7) (Fig. and a large drawbar pull is made available. and opens the pilot circuit to the safety valve. the force produced by the difference in area between Dl and D3 [~/4(D3~ . When pressure in chamber MA has become high (when rotating counterclockwise) When the travel is stopped (or when traveling downhill). and escapes to chamber PA from chamber G. Because of this. When stopping travel (low-pressure setting) When the travel lever is placed at neutral. 101 SWPOSI07 10-136 PC300.8 MPa (385 kg/cm*) 1 27. the pressure in chamber PA drops and counterbalance valve spool (19) returns to the neutral position. when traveling > : High-pressure setting When stopping: Low-pressure setting 37. the set pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing speed. While the counterbalance valve spool is returning to the neutral position.5 MPa (280 kg/cm? (Fia. and the set load becomes smaller. The piston moves to the left. 350-6 . the pressurized oil in chamber J passes through passage H.STRUCTURE AND FUNCTION TRAVEL MOTOR 2) . of safety valve] Piston Sprina [Set pressure When starting. 350-6 10-137 .STRUCTURE AND FUNCTION VALVE CONTROL VALVE CONTROL SWPO4765 1. 12. 7. 3. 13. 6. travel lever Right PPC valve Right work equipment lever Active solenoid valve (Swing) Accumulator Solenoid block Control valve Hydraulic pump LS-EPC valve PPC shuttle valve Left work equipment lever 14. @ @ @ @I @ @ 0 @ @ Lever positions : NEUTRAL : Boom RAISE : Boom LOWER : Bucket DUMP : Bucket CURL : NEUTRAL : Arm IN : Arm OUT : Swing right @J : Swing left @ : NEUTRAL @I : Travel REVERSE @ : Travel FORWARD @ : LOCK @ : FREE PC300. 2. Left PPC valve 16. Travel PPC valve L. PPC safety lock valve 15. 10. travel lever R. 11.H. 4. 8. 5.H. Safety lock lever 9. * : L.H: Bucket CURL Left swing/R.H.H.H.H.* Bucket DUMP lo-138 PC300.* : L.* Boom RAISE Right swing/R.* : L.H.H.H.STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE WORK EQUIPMENT l SWING PPC VALVE SBP04416 P : From main T: To tank pump PI P2 P3 P4 : L.* Boom LOWER Arm IN/R. 350-6 .* Arm OUT/R. Disc 6. 9. 8. lever) Joint Plate Retainer Body Filter PC300. Piston 5. Nut (for connecting 7. Spool Metering spring 3. 1. 11.STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE uu 1' A-A c-c r----y 11 D-D B-B E-E SBpoO274 2. 10. Centering spring 4. 350-6 10-139 . I) 2) During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (51. Therefore.. In this way. . The relationship in the position of spool (I) and body (IO) (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 (I).21 I) Control valve iFia. When this happens. retainer (9) is pushed.. so pilot pressure oil from the main pump passes through fine control hole f and goes from port PI to port / : : (Fig. metering spring (2) is compressed proportionally to the amount of movement of the control lever. and moves down. and at almost the same time. 2) p@. spool (I) is pushed back and fine control hole f is shut off from pump pressure chamber PP.STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE OPERATION I) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). fine control hole f is shut off from drain chamber D. (Fig. spool (I) is also pushed by metering spring (21. I/ I/ SBPO3494 10-140 PC300. At almost the same time. When the pressure at port PI becomes higher. 1) SBPO3493 A. the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced. 3.. 350-6 . it is connected to drain chamber D to release the pressure at port PI. (Fig. spool (I) moves up or down so that the force of metering spring (2) is balanced with the pressure at port PI. so the pressure at port PI also rises in proportion to the travel of the control lever. When this happens. it is connected to pump pressure chamber PP. spool (I) is pushed down by metering spring (21. 4) (Fig. 4) SBPO3496 PC300. The oil passes through port P2 and enters chamber B to fill the chamber with oil. spool (1) is pushed up by the force of centering spring (3) and the pressure at port PI. and fine control hole f is shut off from drain chamber D. and is connected with pump pressure chamber PP. it is connected to pump pressure chamber PP. When this happens. The oil returning from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. and the pump pressure is supplied until the pressure at port Pl recovers to a pressure that corresponds to the lever position. oil in drain chamber D flows in from fine control hole f’ in the valve on the side that is not working. (fig. fine control hole f is connected to drain chamber D and the pressure oil at port PI is released. the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI. 350-6 10-141 . fine control hole f is shut off from drain chamber D. and pushes the control valve spool. (Fig. When the spool of the control valve returns.STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE During fine control (when control lever is returned) When disc (5) starts to be returned. and retainer (9) pushes down spool (I). Therefore. 3) SBPO3495 4) At full stroke When disc (5) pushes down piston (41. At almost the same time. If the pressure at port PI drops too far. travel pump REVERSE FORWARD REVERSE FORWARD lo-142 PC300. travel : R.H.STRUCTURE AND FUNCTION TRAVEL PPC VALVE TRAVEL PPC VALVE II nI nII 4 C-4 SWP04766 P T PI P2 P3 P4 : From main :To tank : L. travel : R.H. travel : L. 350-6 .H.H. STRUCTURE AND FUNCTION TRAVEL PPC VALUE A-A f 0 c-c D-D SAP01250 1. 2. Metering spring Centering spring Valve Bolt PC300. 7. 6. Plate Body Piston Collar 5. 3. 8. 4. 350-6 10-143 . spool (I) is pushed back. ‘2) SBPO3498 10-144 PC300. spool (I) moves up and down until the force of metering spool (2) is balanced with the pressure of port PI. and the pilot pressure of the main pump is sent from port A through fine control hole f to port PI. metering spring (2) is compressed in proportion to the travel of the control lever. the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port PI) and the force of the return spring of the control valve spool are balanced. so the pressure at port PI also rises in proportion to the travel of the control lever. it is connected to drain chamber D. (Fig. I) 2) Fine control (neutral -+ fine control) When piston (4) starts to be pushed by disc (51. fine control hole f is shut off from drain chamber D. it is connected to pump pressure chamber PP.2) (Fig. II SBPO3497 (Fig. When this happens. Therefore. so the pressure at port PI escapes. (Fig. At almost the same time. retainer (9) is pushed. At almost the same time. When the pressure at port PI rises. In this way. Spool (1) is also pushed by metering spring (2) and moves down.STRUCTURE AND FUNCTION TRAVEL PPC VALVE OPERATION 1) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). Fine control hole f is shut off from pump pressure chamber PP. 350-6 . As a result. The relationship of the position of spool (1) and body (IO) (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 (I). so the pressure at port PI supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. 4) f/1 Self-Reducing PP (Fig. the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI to push the control valve spool. fine control hole f is connected to drain chamber D. and the pressurized oil at port PI is released. Because of this. 3) (Fia 3) SBP03499 4) At full stroke Disc (5) pushes down piston (4). When the control valve returns. and is connected to pump pressure chamber PP. and retainer (9) pushes down spool (I). spool (I) is pushed up by the force of centering spring (3) and the pressure at port PI. Therefore. It passes through port P2 and goes to chamber B to charge the oil. it is connected to pump pressure chamber PP. (Fig. 350-6 10-145 . The return oil from chamber B passes from port P2 through fine control hole f’ and flows to drain chamber D. so fine control hole f is shut off from drain chamber D. If the pressure at port PI drops too much. Fine control hole f is shut off from drain chamber D. 4) PC300.STRUCTURE AND FUNCTION TRAVEL PPC VALVE 3) Fine control (control lever returned) When disc (5) starts to be returned. oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. (Fig. spool (1) is pushed up by metering spring (21. At almost the same time. 6. 350-6 .STRUCTURE AND FUNCTION SERVICE PPC VALVE SERVICE PPC VALVE 1. 10. 4. 2. 9. 3. 7. 5. 8. A: B: P: T : Pin Cam Ball Piston Cover Sleeve Centering spring Metering spring Spool Body To service valve P-l To service valve P-2 From main pump To tank q---f-rp -__----------------_ B SWP04767 10-146 PC300. As a result. ISelf-Reducing 1 SBPO3501 PC300. and sleeve (61. and the pressurized oil from port P flows from port a to port A of the control valve. At almost the same time. fine control hole X is shut off from the drain circuit. When cam (2) is moved. piston (41.STRUCTURE AND FUNCTION SERVICE PPC VALVE OPERATION At neutral . SBPO3500 When operated . The pressurized oil from the main pump enters from port P and is blocked by spool (9). 350-6 10-147 . and spool (9) is pushed down by this. . metering spring (8) is pushed by ball (3). . fine control portion Y is connected with port a. Ports A and B of the control valve and ports a and b of the PPC valve are connected to drain port T through fine control hole X of spool (9). the control valve spool moves to a position where the pressure of port A (the same as the pressure at port a) is balanced with the force of the return spring of the control valve spool. 350-6 . Therefore. metering spring (8) is compressed 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.STRUCTURE AND FUNCTION SERVICE PPC VALVE . spool (9) is pushed back by the force acting on the end of the spool. fine control hole X is connected to the drain circuit at almost the same time. l l When the pressure at port a becomes higher. SBPO3502 lo-148 PC300. spool (9) moves up and down to balance the force at port a and the force at metering spring (8). As a result. In this way. When fine control portion Y closes. 4. 4. Gas plug Shell Poppet Holder Bladder Oil port Specifications Gas volume: 500 cc SBPOO290 PC300. 5. Lever Body Seat Ball End cap PPC ACCUMULATOR 1. 3. 350-6 10-149 . 5. 2.STRUCTURE AND FUNCTION PPC SAFETY LOCK VALVE PPC ACCUMULATOR PPC SAFETY LOCK VALVE 1. 2. 6. 3. . The PPC shuttle valve valve form a combined and travel structure. 2. 350-6 10-151 . TRAVEL JUNCTION VALVE PPC SHUTTLE VALVE. PPC shuttle valve Travel junction valve Outline . TRAVEL JUNCTION VALVE SDP01315 1.STRUCTURE AND FUNCTION PPC SHUTTLE VALVE. junction PC300. It is provided with a mount port for the pressure switch for detecting the pilot pressure.STRUCTURE AND FUNCTION PPC SHUTTLE VALVE. TRAVEL JUNCTION VALVE PPC SHUTTLE VALVE P 6.1 P12 P22 Al P42 P32 P62 P52 P82 PB2 PC2 P72 A4 PA2 P92 A3 A7 A8 A2 P2 1 P71 / PA1 Pi1 PR \ PC1 \ PBl P‘81 V-AA AA PF SWPO476tl Function . 10-152 PC300. The PPC shuttle valve sends the PPC valve output pressure to the control valve and travel junction valve. 350-6 . travel PPC valve : To control valve (R. travel PPC valve : To control valve (L. TRAVEL JUNCTION VALVE Al A2 A3 A4 A5 A6 A7 A8 PI1 PI2 P21 P22 P31 P32 P41 P42 P51 P52 P61 P62 P71 P72 P81 P82 P91 P92 PA1 PA2 PBI PB2 PC1 PC2 PF PR PLS : Mount : Mount switch port for swing pressure switch port for bucket CURL pressure pot-t for arm IN pressure switch port for arm OUT pressure switch port for boom RAISE pressure port for travel pressure switch port for boom LOWER pressure pressure : Mount : Mount : Mount switch : Mount : Mount switch port for bucket DUMP switch : To control valve (swing) : From swing PPC valve : To control valve (swing) : From swing PPC valve : To control valve (bucket) : From bucket PPC valve : To control valve (bucket) : From bucket PPC valve : To control valve (boom) : From boom PPC valve : To control valve (arm) : From arm PPC valve : To control valve (arm) : From arm PPC valve : To control valve (boom) : From boom PPC valve : To control valve (R. 350-6 10-153 . travel) : From L.STRUCTURE AND FUNCTION PPC SHUTTLE VALVE.H.H.H. travel PPC valve : To travel junction valve : To travel junction valve : From LS select valve : Mount PC300.H.H.H. travel) : From R.H. travel) : From R. travel) : From L.H. travel PPC valve : To control valve (L. TRAVEL JUNCTION VALVE F-F A-A G-G B-0 N-N J-J (PPLACES) L -4 M-M K-K (2PLACES) D-D L-L E-E AA-AA SDP00293 1. 2.STRUCTURE AND FUNCTION PPC SHUlTLE VALVE. 3. 350-6 . Body Plug Ball 10-154 PC300. L. R. 350-6 10-155 . TRAVEL JUNCTION VALVE TRAVEL JUNCTION VALVE PF T2 T4 Tl T3 A-A SDP04412 1. Body Plug Spring Spool Spring Plug Tl T2 T3 T4 PF PR : From : From : From : From : From : From L. 5.H.H. R.H. 4. 6. 3. PPC PPC travel control travel control travel control travel control shuttle valve shuttle valve valve valve valve valve PC300.H. 2.STRUCTURE AND FUNCTION PPC SHUlTLE VALVE. ____________- swP05108 Function .. the travel junction valve is switched.travel motor R. travel REVERSE I I I R. The travel junction valve interconnects the travel circuits when the straight-travel is operated independently or when the straight travel + another actuator are operated simultaneously.travel FORWARD . travel L. the flow of oil to the left and right travel motors when traveling in a straight line is almost the same.H. Because of this.H. TRAVEL JUNCTION VALVE STRAIGHT-TRAVEL SYSTEM PPC shuttle valve assembly L.STRUCTURE AND FUNCTION PPC SHUTTLE VALVE. and the left and right travel circuits are shut Off. i-_-i travel :______. valve is installed between the travel valve and travel motor to compensate for any difference in the oil flow to the left and right travel circuits when traveling in a straight line. A travel junction .H.-_-‘-. if the difference in the movement of the travel levers is more than approx. ---A-r__+ (h-4 _.H.H. lo-156 PC300. r-----J j_____c_ I Travel i ! REVERSE L. When steering.travel motor Right PPC valve Bucket Boom Bucket CURL Bucket DUMP Boom Arm LOWER IN LS select Arm OUT RAISE aver ppc vaIveL---4-----i--)-t4-- Boom R. so there is no travel deviation..+____ .H. 10 mm. 350-6 .H.travel FORWARD L. 14 I-. and R. FORWARD) T----Y From control valve (R.H. REVERSE) From control valve (R.H. From control valve (L. travel FORWARD or L. Because of this. From control valve (L. there is no difference in the pilot pressure from the PPC shuttle valve (the output pressure of each PPC valve). FORWARD) From PPC shuttle . In this condition. REVERSE and L. so the spool is balanced in the middle.H.STRUCTURE AND FUNCTION PPC SHUTTLE VALVE.H. FORWARD. travel FORWARD) B: PPC output pressure (R. FORWARD and L. a difference in pressure is created in the left and right circuits. When steering in forward or reverse When the steering is operated in forward (or reverse). REVERSE) From control valve (L. REVERSE) From control valve (L.H. FORWARD) SBPOO296 . REVERSE) “f’ From control valve (R.H. and the steering can be operated. the spool moves to the right or left and the left and right forward and left and right reverse passages are separated.H.H. REVERSE are interconnected through the spool. travel REVERSE) When traveling in a straight line in forward or reverse . TRAVEL JUNCTION VALVE Operation A: PPC output pressure (R.H.H.H. travel REVERSE or L.H. When traveling forward (or in reverse). ^ t From control valve (R.H.H. the R.H. 350-6 10-157 .. FORWARD) SBPO0297 PC300.H. if the difference in the pilot pressure from the PPC shuttle valve becomes greater than the switching pressure (spring force). 7. Coil Pluger Connector C : To LS valve T : To tank P : From main pump lo-158 PC300. 3. 350-6 . 2. 6. 4. Body Plug Spring Push pin 5.STRUCTURE AND FUNCTION LS-EPC VALVE LS-EPC VALVE A-A SWPO4770 1. When it receives signal current i from the controller. For this reason.O_ (10) 0 200 400 600 800 1000 Current i WA) SAP00303 Operation 1.STRUCTURE AND FUNCTION LS-EPC VALVE l Function The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. coil (5) is de-energized. P h ej P 2 (20) 1.0 _ - l.5 (15) 2. ' SWPO5109 PC300. MPa kg/en+) 2. the pressurized oil from the LS valve passes from port C through port T and is drained to the tank. When signal current is 0 (coil de-energized) . spool (2) is pushed to the right by spring (3). . As a result. .9 (30) 2. 350-6 10-159 . There is no signal current flowing from the controller to coil (51. and outputs it to the LS valve. it generates the EPC output pressure in proportion to the size of the signal.5 (25) - - e . port P closes and the pressurized oil from the main pump does not flow to the LS valve. At the same time. so the propulsion force of plunger (6) is also at its maximum. operated fully) When the signal current flows to coil (51. the signal current is at its maximum. When the pressure at port C rises and the load of spring (3) + the force acting on surface a of spool (2) becomes greater than the propulsion force of plunger (61. port T closes and stops the oil from flowing to the tank. . the flow of pressurized oil from port P flows at its maximum to port C. a propulsion force is generated. and the circuit pressure between the EPC valve and LS valve becomes the maximum. When signal current is very small (coil energized. spool (2) is pushed to the right. 350-6 . . and this pushes plunger (6) to the left.STRUCTURE AND FUNCTION LS-EPC VALVE 2. . fine control) When a very small signal current flows to coil (51. Push pin (4) pushes spool (2) to the left. coil (5) is energized. . spool (2) moves up and down so that the propulsion force of plunger (6) is balanced with the load of spring (3) + pressure of port C. / LS valve +j+ SWPOSI 10 3. and at the same time. As a result. . port C and port T are connected. SWPO5111 lo-160 PC300. the circuit pressure between the EPC valve and the LS valve is controlled in proportion to the size of the signal current. When this happens. coil (5) is energized. The circuit between port P and port C is shut off. When signal current is maximum (coil energized. spool (I) is pushed fully to the left by push pin (4). . As a result. Therefore. . . and pressurized oil flows from port P to port C. At the same time. For this reason. . SWING BRAKE SOLENOID VALVE Pl n / ACC P6C SWPO4774 1. 3. 350-6 . travel motor To main valve (pump merge-divider To main valve (boom control valve) To swing motor From main pump To accumulator To PPC valve valve) 10-162 PC300. and R.H.STRUCTURE AND FUNCTION SOLENOID VALVE SOLENOID VALVE BOOM Hi 2-STAGE SAFETY VALVE.H. Active mode solenoid valve Boom Hi 2-stage safety valve solenoid Pump merge-divider solenoid valve Travel speed solenoid valve Swing brake solenoid valve valve : T Al : A2 : A3 : A4 : A5 : PI : ACC: PPC : To tank To main valve (active mode) To L. FOR ACTIVE MODE. PUMP MERGE-DIVIDER. TRAVEL SPEED. 2. 4. 5. the pressurized oil from the main pump flows from port P through the inside of spool (5) to port A. For this reason. 5. When the signal current does not flow from the PPC lock switch or swing lock switch. As a result. As a result. solenoid (3) is excited. and this stops the oil from flowing to the tank. 4. When the signal current flows from the PPC lock switch or swing lock switch to solenoid (3). 3. Connector Movable core Coil Cage Spool Block Spring 7 ‘6 SWPO4775 Deactiva Operation When solenoid is deactivated . the circuit between ports P and A closes and the pressurized oil from the main pump does not flow to the actuator. and then flows to the actuator.STRUCTURE AND FUNCTION SOLENOID VALVE 1. 350-6 lo-163 . When solenoid is excited . port T is closed. c SWPOSI 12 Exe i t SWPO5I13 PC300. At the same time. spool (5) is pushed fully to the right by spring (6). solenoid (3) is deactivated. the pressurized oil from the actuator flows from port A to port T. spool (5) is pushed to the left in the direction of the arrow. 7. and is then drained to the tank. 2. 6. For this reason. At the same time. 3.STRUCTURE AND FUNCTION BOOM HOLDING VALVE BOOM HOLDING VALVE A-A . 5. SWPO4778 1. Safety-suction Pilot spring Pilot spool Poppet spring Poppet valve T V Cy Pi : : : : To tank From control valve To boom cylinder bottom From PPC valve (pilot pressure) lo-164 PC300. 350-6 . 2. 4. Epobmjever a SWPOCl I5 PC300.STRUCTURE AND FUNCTION BOOM HOLDING VALVE Operation 1) At boom RAISE When the boom is raised. the main pressure from the control valve pushes poppet (5) up. As a result. the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spool (3). the main pressure from the control valve passes through the valve and flows to the bottom end of the boom cylinder. Because of this. the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5). ’ I Control lever (Boom) SWPOSI 14 2) Boom lever at HOLD When the boom is raised and the control lever is returned to HOLD. the boom is held in position. Cont. 350-6 lo-165 . At the same time. and then flows to the control valve.STRUCTURE AND FUNCTION BOOM HOLDING VALVE 3) At boom LOWER When the boom is lowered. poppet (5) opens. SWPO5Il6 10-166 PC300. 350-6 . the pressure of the pressurized oil in chamber b is lowered by orifice a. When the pressure at port Cy rises because of the pressurized oil from the bottom end of the boom cylinder. the pilot pressure flows to port Pi from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. safety valve (I) is actuated and drain oil from port Cy to port T. If the pressure in chamber b drops below the pressure at port V. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder. the pressurized oil flows from port Cy to port V. . 3. 5. Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket 10-168 PC300. 2. 6.STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT 6 SBP00311 1. 350-6 . 4. 8. 7. 4. 3.STRUCTURE AND FUNCTION AIR CONDITIONER AIR CONDITIONER AIR CONDITIONER PIPING SBP02755 1. 350-6 10-169 . Hot water pickup piping Air conditioner compressor Refrigerant piping Condenser Receiver tank Hot water return piping Air conditioner unit Duct A: Fresh air B: Recirculated C: Hot air/cold air air PC300. 2. 6. 5. 350-6 .STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM ACTUAL ELECTRIC WIRING (l/2) DIAGRAM 10-170 PC300. STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM PC300. 350-6 . 350-6 .STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM 38 43 44 48 45 47 62 63 49 64 72 71 i0 w '69 swPo4784 lo-172 PC300. Arm OUT pressure switch 29. Front pump pressure sensor 3. Horn (high tone) 12. Active (boom) solenoid valve 23. Window washer tank 9. Active (swing) solenoid valve 18. 66. 65. Engine speed sensor 6. 67. 72. 63. 42. 69. 62. Engine water temperature 32. 71. Horn (low tone) 13. Battery relay 14. 38. 49. Rear pump TVC solenoid 8. Travel speed solenoid valve solenoid valve 20. 46. 48. Hydraulic oil level sensor 10.STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM 1. 54. Pump merge/divider 21. Fuel level sensor 17. Battery 15. Alternator Additional right head lamp Right front lock Room lamp Auto pull-up motor Window limit switch (rear) Left front lock Window limit switch (front) Additional left head lamp Left knob switch Wiper motor Horn switch Fuse box Alarm buzzer Starting switch Fuel control dial Cigarette lighter Swing lock switch Wiper. Swing brake solenoid valve 19. Boom LOWER pressure switch 28. 41. 350-6 10-173 . Air conditioner compressor 36. 68. 56. 60. 47. Bucket CURL pressure switch 26. Rear pump pressure sensor 4. Working lamp 2. LS-EPC valve 11. Radiator water level sensor 5. 39. 43. Engine oil level sensor 37. 40. 50. Arm IN pressure switch 27. 64. 55. 58. 52. 45. Electrical intake air heater 33. Engine oil pressure sensor 34. 61. Boom Hi 2-stage safety solenoid valve 22. washer switch Lamp switch Buzzer cancel switch Car heater fan switch Machine push-up switch Front window auto pull-up switch Speaker Kerosene mode connector Air conditioner control panel Governor. 44. Swing pressure switch 24. pump controller Radio TVC prolix resistor Wiper motor controller Lamp relay Lamp relay Monitor panel Swing prolix switch Pump prolix switch PC300. Travel pressure switch 30. Bucket DUMP pressure switch 25. 51. 57. Right head lamp 16. Boom RAISE pressure switch sensor 31. 70. Starting motor 35. Front pump TVC solenoid 7. 59. 53. see Section 90.STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM ELECTRIC CIRCUIT DIAGRAM * For details of this page. 350-6 . (l/31 1 PC300. :” -a UY: “” ir [ ’I ~I (I i ! i i’ ! 350-6 10-175 . see Section 90.STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM * P/3) For details of this page. \uO LUBRICATION~OPTI (TO $1 CONTROLLER I I’ TO BATTERY’ RELAY ’ PANEL iR UNIT ‘cmi FOR A/C ~ ~~ -.~~ AIR CONDITIONI r . . 6. Battery relay Battery Starting switch Fuel control dial Governor motor Starting motor Governor. The engine can be started and stopped simply by using the starting switch (3). 8. The governor. 2. lo-178 PC300. 5. 3. 4. and controls the angle of the governor lever in the fuel injection pump. 7.STRUCTURE AND FUNCTION ENGINE CONTROL ENGINE CONTROL SWPO4786 1. pump controller Fuel injection pump Function . A dial-type engine control is used to control the engine speed. sends a drive signal to the governor motor (51. . pump controller (7) receives the control signal from the fuel control dial (4). 350-6 . so that it can observe the operation of the governor motor. Starting SBPOO322 Stopping engine . (Power source) SBPO0321 Engine speed control . the operating angle of the governor motor is detected by the potentiometer. 350-6 10-179 . the governor and pump controller itself drives the battery relay. and sends a signal to drive the governor motor so that it is at that angle. . When this happens. The governor and pump controller calculates the angle of the governor motor according to this signal. SEPOO323 PC300. When the starting switch is turned to the START position. Operation of system Starting engine . it drives the governor motor so that the governor lever is set to the NO INJECTION position. When governor and pump controller detects that the starting switch is turned to the STOP position. When this happens. The fuel control dial sends a signal to the governor and pump controller according to the position of the dial.STRUCTURE AND FUNCTION ENGINE CONTROL 1. and the starting motor turns to start the engine. to maintain the electric power in the system until the engine stops completely. and feedback is sent to the governor and pump controller. the starting signal flows to the starting motor. When this happens. the governor and pump controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial. Knob Dial Spring Ball Potentiometer Connector 31 U 2 3 l=D R w B Composition 1 2 3 of circuit 6 A-A SBPOO324 Function The fuel control dial is installed at the bottom of the monitor panel. A potentiometer is installed under the knob. The shaded area in the graph on the right is the abnormality detection area and the engine speed is set at low idling. Components of system Fuel control dial HIGH Front machi 1. l 10480 PC300. 5. 350-6 . the resistance of the variable resistor inside the potentiometer changes. 3. When the shaft rotates. it rotates the potentiometer shaft. and when the knob is turned. 2. 6. 4.STRUCTURE AND FUNCTION ENGINE CONTROL 2. and the desired throttle signal is sent to the governor and pump controller. A pulse current is applied to the A phase and B phase from the governor and pump controller to give synchronous rotation with the pulse. Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector Ar-a-l A-A @+--+ I L-l I L I T Composition \ of circuit 8 SBPOO326 Function The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the governor and pump controller. The rotation of the motor is transmitted to the potentiometer through a gear. and a holding torque is generated in the motor. 5. In addition.STRUCTURE AND FUNCTION ENGINE CONTROL Governor motor 1. 350-6 lo-181 . 2. 4. Both A phase and B phase of the motor are continuous. a potentiometer for giving feedback is installed to allow observation of the operation of the motor. 8. A stepping motor is used for the motor which provides the power. PC300. 3. 7. Operation Motor stationary . Motor rotating . 6. pump controller CN-Cl7 CN-co3 CN-Cl6 / x \ I \ II ++++++++ I I ~ 1 I x ++++++++++ ++++ +++++ ++++ ++++ x L I I SWPO4787 CN-co 1 CN-co2 lo-182 PC300.STRUCTURE AND FUNCTION ENGINE CONTROL Governor. 350-6 . 1 relay drive output Pump merge/divider solenoid/NC Swing holding brake solenoid I I 14 I I d. 1 2 3 input Name Engine Engine GND IGND pressure switch of signal GND Input/ output Input Input Input of signal Input/ output Output output output Pin uo.g 1 :. . 1 2 3 Name Battery signals CN-CO3 CN-16 Name of signal Input/ output Input Pin No.:: 4 Engine water temperature sensor speed sensor speed sensor 1 Throttle potentiometer 1 Input 1 I4 INC I I 5 /NC 6 . .STRUCTURE AND FUNCTION ENGINE CONTROL Input and output CN-CO1 Pin No.I:. (AC0 1 9 1Hydraulic I 10 I Engine oil level sensor GND 1 Input 1 I I 1Travel 1 Output Output Knob switch Hydraulic oil temperature sensor (monitor panel) Hydraulic sensor oil temperature type) (alternator input (thermistor speed sensor Active mode solenoid (swing) NC GND I 11 I Bucket CURL pressure switch 1 12 1 :. 350-6 lo-183 . Input Input I Bucket iTNrrl DUMP pressure switch pressure switch Input (+24V) Input 12 13 Name of signal source Input/ output Input Output 14 15 16 17 18 . Pressure source sensor (+24V) power power I output output Input Input input Input Input Input input Input Input sensor GND I I 5 I Swing Jl 8 9 IO 11 12 13 I 6 I Service I 8 I Radiator valve oressure switch I Input I I Input I I lnout I I Input ) 7 I Engine oil pressure sensor H water level sensor Potentiometer source (+5V) Starting switch I 1 I I I 1 I Input 1 Input Active mode solenoid (boom) selector solenoid Output 8 9 1. . 1 2 Name PPC pressure Boom RAISE pressure switch switch of signal 1TVC solenoid 1 (t) 2 (+) IOutDut I Outputl I 9 I TVC solenoid 11 12 13 14 Solenoid power source (t24V) NC NC Input I 3 I Arm IN pressure I Input I I I 4 5 6 S-NET(+) Model Model selection selection selection 1 3 5 I Input. Power source Battery charge terminal R) CN-CO2 Pin No. output I Input Input 7 I Model I Input I Input Input 8 18 19 20 121 Swing prolix switch sensor I TVC solenoid 1 (-) 2 (-) output output j 9 Overload I IO / Boom LOWER pressure switch1 Input TVC solenoid NC 11 Arm OUT pressure switch Input 1PGND I Input I / 15 I Kerosene 16 mode selection I Input Input I 1Swing lock switch PC300. (+24V) 2 3 4 5 6 7 8 Governor Governor Governor Governor NC LS-EPC solenoid I+) output motor phase A (+) Pump R pressure 15 I 16 17 Engine oil pressure sensor L Input Feedback potentiometer NC I Engine oil level sensor clogging sensor I but I Input Air cleaner Solenoid power I Pressure I lnwt I Input Input Potentiometer GND motor phase A 1-J Output motor phase B ItI motor phase B (-) Output Output Starting switch (terminal C) Automatic controller greasing abnormality filter sensor I Input I 20 I Hydraulic I Input I Input/ output Input Input CN-Cl7 Pin No. . prevention system overheat 6 ~ Swing control function 8 Active mode system l-1 Self-diagnostic function I * For details of the self-diagnostic function.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM ELECTRONIC CONTROL SYSTEM CONTROL FUNCTION 1 Pump & Engine Mutual control function 2 Pump and valve control function 3 Power maximizing function I 3 Electronic control system 5 Engine automatic warming-up. see TROUBLESHOOTING. 350-6 lo-185 . PC300. STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM TOTAL SYSTEM DIAGRAM ? r / Solenoid Active(Swina) valve r ___i i-~~____________________________________________----------____________________ 3- III !-)). Act i ve (Bppm).---c” ._/i\_____________________--------_ : Work levers eouiome Boom Hi 2-stat Swine brake i Travel lever 0 / If I’ II II /I II . 350-6 .~______________________------______________----_______----------------!---------____-----_________---------_________----------______----------J~ 6 1 R q ip 11 JS Starting switch box SWPO5120 lo-186 PC300. [--. _4________. 350-6 lo-187 . I I I / j : ?A ____________________----------------_-__________----------_________--________~ I ____________________----------------____________----------____________-________~ ii r rr Buzzer cancel switch knob switch Network Engine throttle controller 9 A-L 7 Lz______________ L4_____________ 1 Resistor I I I( 19 SWPO5121 PC300.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM -=I _L_________. : w Engine speed N SAP00330 Engine speed N SAP00331 Pump discharge amount Q SAP00332 10488 PC300. Function There are five modes available for selection with the working mode switch on the monitor panel. horsepower H/O. general operation mode (G/O). . It is possible to select the most suitable engine torque and pump absorption torque to match the nature of the work. These modes are the heavy-duty operation mode (H/O). & 3 x I b _c : . Engine torque curve . . lifting operation mode L/O). H i Engine throttle controller (Network signal) Monitor Panel SWP05122 . The governor and pump controller detects the actual engine speed and the speed set by the engine governor through the fuel control dial in accordance with the pump absorption torque set for each mode. 350-6 .STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM Pump & Engine Mutual control system w Work eauiDment levers knob switch Travel lever Shuttle Fuel control dial valve :. power curve max. and carries out control so that the pump absorbs all of the torque at each output point of the engine. finishing operation mode (F/O). power max. Pump output curve % H/O. and the breaker mode (B/O). Engine . 350-6 Heavy-duty 172. the engine is used in a range which provides good fuel efficiency F/O 136 kW (182 HP)/1. General. Matching point in heavy-duty mode: Rated output point operation l PC300. In this way. the engine speed goes down. and the engine speed is controlled so that it becomes near the rated output point. finishing operation mode .950 rpm When the load on the pump rises and the pressure rises. I- J B e F? Engine speed N F . -\ *._ --. -. and the engine speed is lowered while keeping the torque constant. the engine speed goes down.700 rpm PC300._ \. B/O 85% Mode Partial output F/O 80% When the load on the pump rises and the pressure rises. By repeating this control. ___. the engine can always be used at near the rated output point. breaker. -I Engine speed N SAP00337 Pump discharge amount Q SAP00338 . When this happens. mutual control of the engine and pump is used to control the system so that the pump absorption torque follows the equal horsepower curve of the engine. the pump discharge amount is reduced. the system is controlled so that the pump discharge amount is increased until the engine speed becomes near the rated output point. ‘\ ‘.--.8 kW (232 HP)/1. ‘-.ll ‘.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 1) Control Heavy-duty method in each mode operation mode Engine speed N SAP00333 Engine speed N SAP00334 Pump discharge amount %AP00335 .Lu SAP00336 LYm. When this happens. 350-6 lo-189 . Matching point G/O point 90% . If the reverse happens and the pressure goes down. point Power max. 1 Engine speed N SAP00339 Engine speed N SAP00340 Pump discharge amount Q SAP00341 . control is carried out in the same way as for the general operation. Power max. mode: Rated output PC300. 10-190 PC300. When this happens. 350-6 . travel Engine speed N SAP00342 Engine speed N SAP00343 Pump discharge amount Q SAP00344 . The cut-off at relief is canceled and the oil flow at relief is increased.9 kW (138 HP)/1. 350-6 l YO 102.? w :I --__ --.950 rpm When the pump load increases.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM Lifting operation mode + ? P s E . and breaker operation modes to match the load on the pump. the fuel consumption is reduced and the fine control ability is improved. the engine speed is automatically lowered to the partial position. 172. Matching point in lifting operation mode: 60% partial output point PC300. finishing. Matching point in power max.8 kW (232 HPV1. the engine speed drops. mode. 350-6 . In this way._ --__ -0 .500 rpm When the lifting operation mode is selected. In this condition. the pump discharge is reduced to prevent the engine speed from going down and to ensure that the engine is used at near the rated output point. the TVC prolix switch can be turned ON to provide an absorption torque more or less equivalent to the general operation mode. Even if any abnormality should occur in the controller or sensor. In this’ case.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2) Control ON function when TVC prolix switch is SBPO0348 Pump discharge amount 0 SAP00349 . PC300. thereby allowing the machine to maintain its functions. 350-6 10-191 . it is designed to allow a constant current to flow from the battery to the TVC valve. so oil pressure sensing is carried out only by the TVC valve. 350-6 . lo-192 PC300. Optimum matching under various working conditions with the fine control mode function which reduces the hydraulic loss and improves the ease of fine control. Electric BoVernor 1 \ Fuel control Hi dia G Servo valve LS-EPC valve t Monitor panel SWPO5123 Function .STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2. Pump and valve control function r--I LS select 1 ’ 1 m Merge/flow divider valve ‘-‘mi . MPa Pump discharge amount Q SAP00352 31 Cut-off cancel function . hydraulic oil temperature goes up more quickly.STRUCTURE AND FUNCTION ELECTRONiC CONTROL SYSTEM 1) * . the pump pressure sensor detects this. PC300. when work equipment is relieved. also when the swing lock switch is set to ON. and warming time is shortened. the timing for starting the discharge amount from the pump can be optimized. the relief pressure rises to approx.8 MPa {345 kg/cm*). but when the cut-off is canceled. to give excellent ease of compound operation and fine control. 34. . Because of this. . The cut-off cancel function stops the actuation of the cut-off function in order to ensure the flow of oil from the pump near the relief pressure. Because of this. Under these conditions. and the controller sends a signal to the TVC valve to reduce the discharge amount in order to reduce the relief loss. the hydraulic pressure is increased by one stage. the function is canceled. 350-6 10-193 . The relief pressure when the cut-off function is actuated is 33. hydraulic oil is quickly warmed. LS control function The switching point (LS set differential pressure) for the pump discharge amount inside the LS valve is changed by changing the output pressure from the LS-EPC valve to the LS valve according to the operating condition of the actuator. Cut-off function If the load becomes large during the operation and the pump discharge pressure rises to a point close to the relief pressure. Switches and cut-off functions Working mode switch Digging Actuated Swing ON Canceled MPa Cut-off canceled is is Cut-off Z Pump discharge amount 0 SWPO5124 lock switch OFF Actuated Knob switch ON Canceled OFF Actuated Heavy digging Cut-off function % Actuated When the swing lock switch is set to ON. thereby preventing any drop in speed. LS set differential pressure SAP00351 2) .8 MPa (355 kg/cm*). the pump LS valve is controlled. Fine control mode function When the finishing mode is selected as the working mode. 350-6 .STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 4) . 10-194 PC300. and the pump discharge amount is reduced to improve the ease of fine control and the precision when finishing. . the full flow of the pump at the set engine speed is taken as 100%. Relationship between working (for independent operation) mode and pump discharge amount * In each working mode. . l 10-196 PC300. they cannot both be operated together. swift slow-down function Engine Fuel Electric governor T 1 rzz R I Work equipment lever knob switch _ fuel control dial] I rl \ Monitor / Panel SWPO5125 Function This function provides an increase in the digging power for a certain time or switches the working mode to the fine operation to reduce the speed. function and swift slowdown function are operated with the same switch. 350-6 . knob switch to momentarily match the operating conditions. Power max.H.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3. Only one of these functions can be selected at any time. Ir The power max. It is operated using the L. function. when digging up boulders). Working mode Engine. . During digging operations. If the L. 10% and increase the digging force. if it is desired to carry out lifting operations or finishing operations for a moment. knob switch. Working mode Actuating time Lifting operation 1 While switch is kept pressed PC300. function . each function is automatically set as follows. During normal operations.H. the L. If the L.H. knob switch is pressed ON when the working mode is at H/O or G/O. . each function is automatically set as follows.H. knob switch can be pressed to raise the hydraulic pressure by approx.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 1) Power max. knob switch is pressed ON when the working mode is at H/O or G/O. when that extra bit of digging power is needed (for example.H. the working mode can be switched to L/O by operating the L. pump control Cut-off I function I Actuating time 2) Swift slow-down function . 350-6 10-197 . STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 4. the engine speed is automatically reduced to a midrange speed to reduce fuel consumption and noise. the engine speed returns immediately to the set speed. lo-198 PC300. If all the control levers are at neutral when waiting for work or waiting for a dump truck. . If any lever is operated. 350-6 . Auto deceleration system Right work equipment level Engine Fuel control dial 1 ~ Engine throttle controller Monitor Panel SWPO5126 Function . . If another 4 seconds passes. 1400 rpm).STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM Operation Control levers at neutral . 2 deceleration. the engine speed will immediately rise to the speed set by the fuel control dial. 2 deceleration position (approx. l Speed (rpm) 4 Less than 2 Less than 1 I ITime (set) Levers at neutral Lever operated SAP00356 PC300. and all the control levers are returned to neutral. When control lever is operated If any control lever is operated when the engine speed is at No. and is kept at that speed until a lever is operated. If the engine is running at above the deceleration actuation speed (approx. 1 deceleration position. the engine speed is reduced to the No. 1400 rpm). the engine speed drops immediately to approx. 350-6 10-199 . 100 rpm below the set speed to the No. STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 5. If the water temperature is low. (Engine overheat prevention function) 1O-200 PC300. 350-6 . Automatic warming-up and engine overheat prevention function (Water temDerature sisnall Monitor Panel SWPO5127 Function . this automatically raises the engine speed to warm up the engine after it is started. In addition. if the water temperature rises too high during operations. (Automatic warming-up function). it reduces the load of the pump to prevent overheating. the engine speed is automatically raised to warm up the engine.250 rpm or below Coolant temperature: Engine speed: Less than 30°C Less than 1. I Actuation Water temperature: Water temperature I Actuation. 350-6 10-201 . the system returns to the condition before the overheat prevention function was actuated (manual reset) PC300. Conditions for actuation (both are necessary) Actuation Engine speed: 1. After the engine is started. This system is actuated when the water temperature is 105°C and above. . remedy I 105°C and above gauge: Red range) d Working mode: In any mode Engine speed: Low idling Monitor warning lamp: Lights up Alarm buzzer: Sounds Cancel condition Water temperature: Fuel control dial: Below 105°C Return temporarily to low idling position l When the above conditions are met.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM function II Engine automatic warming-up .250 rpm Conditions I! I for cancellation temperature: condition (any one) 30°C or above Cancellation Engine speed: As desired Automatic Manual k Coolant Fuel control dial: Held at more than 70% of full throttle for more than 3 seconds 2) Engine overheat prevention function . if the engine coolant temperature is low. This function protects the engine by lowering the pump load and engine speed to prevent overheating when the engine coolant temperature has risen too far. STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 6. lock 1O-202 PC300. 350-6 . Swing control system Work equipment lever Swine motor HYdrauI switch ic Monitor Panel OFF I Main lock Pump switch ’ sional) prolix switch OFF (Drive sional) lever sional) (Swine Enoine throttle controller bins Battery relay Battery SWPO5128 Function l The system is provided with a swing and swing holding brake function. when swing lever is operated. there may be hydraulic drift. the hydraulic oil temperature will rise more quickly and the warming-up time can be reduced.z. L prolix Swing brake (when controller is abnormal) (when controller is normal) 1 Swing lock applied 1 Swing lock canceled 1 Swing lock applied / Swing holdi. 5 set. the swing has only a hydraulic brake operated by the safety valve. If the work equipment is relieved in this condition. so if the swing is stopped on a slope. swing holding brake function . Swing lock switch holding brake Lock switch Lock lamp Functior I and swing lock. * * Operation of swing lock prolix switch If any abnormality should occur in the controller. swing Operation When swing lever is placed at neutral. and the swing holding brake is not actuated normally and the swing cannot be operated. SBPOO362 PC300. . so it prevents any hydraulic drift after the swing is stopped. the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. 350-6 1 O-203 . swing lock is not canceled and swing does not move. When the swing brake is canceled.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 1) Swing lock.. and the swing holding brake (automatic) is interconnected with the swing. Even when the swing lock prolix switch is turned ON. the pump cut-off is canceled. oil quick warm-up function when swing lock switch is ON When the swing lock switch is turned ON. swing brake is applied after approx. the swing lock switch stays ON and the swing brake is not canceled.ie 2) Hydraulic . brake is canceled and swing can be operated freely Swing lock is actuated and swing is held in position.. Even when swing lever is operated. The swing lock (manual) can be locked at any desired position. OFF OFF Swing holding brake ON ON Swing lock + x . and the travel speed can be selected manually or automatically to give a travel performance that suits the nature of the work or the jobsite.. Function l When traveling.LS-EPC valve 1 < Fuel control Monitor Panel (Pressure seaser sianall Ie sianall I (Drive Engine throttle cant rol ler (Drive sianal) signal). Travel control system Travel Travel motor I 0 PPC % I---_-____A I L_ : Travel speed tioid valve .STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 7. 1 O-204 PC300. 350-6 . the pump control is carried out. (Thrott &ware sensor signal) (Switch signal) . If the machine is traveling in Mi.4 MPa (330 kg/cm? for more than 1. 4..2 ‘“.350 rpm by the fuel control dial: .9e 60 Min.6 MPa (220 kg/cm*) or less for more than 1. if the travel pressure continues at 32.. it will not shift even if Hi is selected. If the machine is traveling in Lo. If the machine is traveling in Hi.5 Hi (High speed) 100 Min. this increases the pump absorption torque while keeping the working mode and engine speed as they are.0 set. such as when traveling up a steep hill. (The travel speed switch stays at Hi. the pump volume is automatically switched and the travel speed returns to Hi.6 (220) 32. 5. it will automatically shift to Lo. . iii) Automatic selection according to pump discharge pressure If the machine is traveling with the travel speed switch at Hi. 350-6 1O-205 . For details. ii) Automatic selection according to engine speed If the engine speed is reduced to below 1. or Hi. see PUMP & ENGINE MUTUAL CONTROL.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 11 Pump control function when traveling .4 Travel (330) pressure (MPalkg/cmV SAP00364 PC300. the governor and pump controller controls the pump flow and motor volume at each speed range as shown on the right to switch the travel speed.0 set. Travel speed switch Pump flow (%) Motor volume CLow:peed) 80 Max. and when the load is reduced. it will not shift even if Mi or Hi are selected. Mi.) The machine continues to travel in Lo. * 2) Travel speed selection function i) Manual selection using travel speed switch If the travel speed switch is set to Lo. the pump volume is automatically switched and the travel speed changes to Lo.5 Travel speed (km/h) Travel speed Hi I Isec lsec Lo _---------__ I 21. 3. such as when the machine travels again on flat ground or goes downhill. If the travel is operated in any working mode other than the heavy-duty operation mode. and the travel pressure stays at 21. . and the load increases. so it is effective in loading dump trucks. position. the work equipment speed is increased. The bucket lift is also increased during swing + boom RAISE operations. ACTIVE MODE FUNCTION Work equipment IBoom) lever ~------------ ________---------___________. If the fuel control dial is not at the Max. position. When the active mode switch on the monitor panel is ON (lighted up). l 1O-206 PC300. The active mode is actuated only when the fuel control dial is at the Max. the load sensing function is actuated but the pump discharge increase function is not actuated.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 8. 350-6 . Active mode I I I I I I I I Active solenoid (Boom) mode valve /I / / Fuel Engine throttle controller SWPO5130 FUNCTION . 050rpm {231. so it is effective in loading dump trucks.5 mm (active mode OFF) D: 7. Change in spool stroke: A: 9.050rpm {231.050rom~ 172. 350-6 10207 .0 mm + 11.7HP/1.8kW/2.8kW/1. Change in spool stroke: C: 9.950rpm ~231.050rpml 172.5 mm (active mode ON) I -R SWPO47 ‘99 31 2-stage stroke for swing spool When the active mode switch is ON and the boom is operated to RAISE.7HP/2. This means that the cycle time can be reduced. This increases the bucket lift during swing + boom RAISE operations.950rpm {231.950rpmI 2) 2-stage boom lowering speed When the active mode switch is ON.7HP/2.5 mm) to increase the lowering speed. power UP) Engine speed (rpm) SWPO5131 I I PC300 I I Heavy-duty digging operations Active I 172.5 mm + 7. Heavy-duty operation Active (heavy-duty dissins.0 mm). the stroke of the boom LOWER spool is switched (9. the stroke of the swing spool is switched (9.0 mm (active mode OFF) B: 11.8kW/1.8kW/2.7HP/1.0 mm (active mode ON) SWPO4800 PC300. travel.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM II Increase in engine speed The pump discharge amount is increased by the increase in the engine speed.950rom~ pc35o 172. giving increased production. 1 MPa (5.05 MPa (3. Plug Switch Connector Specifications Composition of points: Normal open points Actuation (ON) pressure: 0. and an electric current is generated every time the gear tooth passes in front of the magnet. I) Components of system Engine speed sensor 1 2 3 4 -‘- &z-i I 1.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 9.5 + 0.0 & 1. Wire Magnet Terminal Housing Connector uComposition of circuit SBP00365 Function . 3.5 kg/cm*) Function Composition circuit of SBPOO366 dition of each actuator is detected from the PPC pressure. It counts electrically the number of gear teeth that pass in front of the sensor. 350-6 . 2. The engine speed sensor is installed to the ring gear portion of the engine flywheel.0 kg/cm*) Reset (OFF) pressure: 0. This detection is carried out by a magnet.3 + 0. 2. and this is sent to the governor and pump controller. 3. l 21 PPC hydraulic switch 1.0 f 0. and sends the results to the governor and pump controller. 5. 4. 1O-208 PC300. 0 (500) SAP00369 PC300.0 (strainless steel) 0 9. 1 Sensor Connector L~/____J Composition of circuit SBP00367 Insulation layer Function . V=O. 2.O08xP+ 1. The voltage is further amplified by the amplifier and is sent to the governor and pump controller.8 19. A gauge layer is installed to the face opposite the diaphragm. Relationship between P pressure (MPa (kg/ cm*)) and output voltage (VI.2 (100) (200) (300) (400) Pressure P (MPa (kg/cmz)) 49. Operation When the pressurized oil entering from the pressure introduction portion pressurizes the diaphragm of the pressure detection portion.4 39.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3) Pump pressure sensor 1 2 1. This sensor is installed to the inlet port circuit of the control valve. and the resistance of the gauge layer converts the deflection of the diaphragm into an output voltage and sends it to the amp (voltage amplifier). It converts the pump discharge pressure to a voltage and sends this to the governor and pump controller.6 29. 350-6 1 O-209 . the diaphragm deflects and changes shape. Resistor Connector Specification Resistance: 8. and pump controller * See ENGINE CONTROL Monitor panel Ir See MONITORING TVC valve + See HYDRAULIC governor 8) LS-EPC valve * See LS-EPC VALVE Solenoid valve . No current flows when the TVC prolix switch is OFF.5 51 l Function This resistor acts to allow a suitable current to flow to the TVC solenoid when the NC prolix switch is ON. 350-6 . Merge/flow divider valve solenoid valve Travel speed solenoid valve . Active solenoid valve (boom) . governor motor. Swing brake solenoid valve Ir See SOLENOID VALVE 91 6) SYSTEM 7) l PUMP 1o-21 0 PC300.STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 4) TVC prolix resistor swPo4aol 1. Boom Hi 2-stage safety valve solenoid valve . 2. l 5) Fuel control dial. . 350-6 .STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM MACHINE MONITOR SYSTEM Monitor panel G-? Network circuit 1110 H/O G.O F/O ooL/O 660 Caution. Engine throttle Pump controller I Sensor r \*8@> Sensor signal Power sour*e Buzzer signal f .-7zil . Coolant Fuel level signal temp..-I-I Q \ Buzzer Battery SAP03675 10-212 PC300. IMONITOR PANEL cN-P02_ CN-PO 1 SAP03677 OUTLINE . The monitor display and monitor display panels use a liquid crystal display (LCD) and LED lamp. . and mode selector switches. The monitor Input and output signals CN-PO1 CN-PO2 . panel consists of the time display. displays. PC300. It has a built-in CPU (Central Processing Unit). The mode switches are flat sheet switches. and processes.STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 1. monitor display. 350-6 10-213 . and outputs the data from the sensors and controllers. 14.STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM MONITOR DISPLAY SAP02731 1. Fuel level gauge 4. Clock 2. 15. 7. 13. 6. Fuel level caution lamp Engine oil level caution lamp Hydraulic oil level caution lamp Preheating pilot lamp Swing holding brake pilot lamp Oil maintenance pilot lamp Battery charge caution lamp Air cleaner clogging caution lamp Engine oil pressure caution lamp Coolant level caution lamp Coolant temperature caution lamp Coolant temperature gauge 10-214 PC300. 8. 9. 5. 10. Service meter 3. 11. 12. 350-6 . 05 MPa oil pressure {0.5 kg/cm*} Lights (goes up when out when starts) normal engine Flashes and buzzer abnormal sounds when SAP00521 Air cleaner clogging When clogged Flashes when abnormal normal engine OFF Charge SAP00522 level When charging defective is Lights up when (goes out when starts) Flashes when Flashes when abnormal Engine SAP00523 oil level Below low level abnormal OFF Hydraulic SAP00524 oil level Below low level Flashes when abnormal OFF SAT00098 Parking (Swing lock) When swing locked is Lights up when swing lock switch is ON. above flashes and Coolant SAP00527 Flashes buzzer when sounds temperature when 105°C B Fuel level Flashes when below low level SWPO4803 SAP00528 PC300.5 kg/cm*) Above 1500 rpm: above 0.“. flashes when swing lock prolix switch is ON Oil maintenance SAP02732 See next page “OIL MAINTENANCE FUNCTION.15 MPa {I .STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM Content of display Display item Symbol Display range When engine is stopped When engine is running 43 Coolant level Below low level Flashes when abnormal SAP00519 Flashes and buzzer sounds when abnormal Below below Engine SAP00520 1500 rpm: 0. then flashes for IO seconds to preheating is completed above 102”C. 350-6 10-215 . switch indicate is at that Preheating SAP00526 During preheating Lights up for 30 seconds when starting HEAT. [500 hl. 4) To save the change interval time. 350-6 . FUNCTION Function. Setting change interval 1) The change interval can be set by using the interval setting mode.. then keep the time switch and active mode switch (swing priority switch) pressed simultaneously for 2. keep the time switch and active mode switch (swing priority switch) pressed simultaneously for 2... A:Reset B:lOh before C:Set time set time swP04701 2. operation The oil maintenance function uses LED lamps on the monitor panel to inform the operator at a fixed interval after the engine oil is changed that the oil change interval has been reached. 2) To enter the change interval setting mode. the elapsed time is displayed on the service meter display. no display is given until the elapsed time reaches the point B on the right diagram after reset. the time display will change from [. I250 hl. 2) Oil change display When the elapsed time has reached or passed the point B on the right diagram. set the monitor panel display to the desired time (mode). it also functions to display the service contact telephone number on the liquid crystal display.5 seconds. the service meter display gives the elapsed time and the LED flashes when the key is turned ON. 1) Confirmation of elapsed time Normally. 3) If the buzzer cancel switch is pressed in the change interval setting mode.I -+ [I251 + 12501 -+ 15001 + [ dl ([. if the buzzer cancel switch is pressed and the key is turned to the ON position (with the buzzer cancel switch hold for 2. 10-216 PC300.5 seconds). The default setting is [no setting]. At the same time..STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM OIL MAINTENANCE 1.5 seconds. [no setting]. The time that can be set are [I25 hl. However.I indicates [no setting] and I dl indicates [demo model). and [demo model. . the telephone number is displayed. the elapsed time is reset. the elapsed time does not increase. In addition.STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 3. if no telephone number has been input. However. It is also possible to carry out the reset operation during this display. the elapsed time shows [Oh] for 1 second. I lioht UD IO set I I I I No Tel No. However. the elapsed time is displayed for 20 seconds after all the lamps light 2) up* Elapsed time confirmation After all the lamps light up. for 10 seconds after all lamps light up (during the elapsed time display). the elapsed time is reset to Oh. displayed 1I I I I / I I Time Elapsed timeldisplav J I I I I I I I Elapsed time confirmation’ k . For the next 10 seconds. When the key is turned ON. SWPO4702 4. Display timing. i input I I I . input . the interval setting is automatically set to [no setting] from the 4th time. content I) Oil change display After all the lamps light up. 5. Elapsed display time I I I . 2) When the set time is changed. Elapsed time reset I) During the oil change interval display and the elapsed time display. In the demo mode. I I L. after the key is turned ON three times. the elapsed time is displayed for IO seconds. When the elapsed time is reset. All IamPs Tel No. if the buzzer cancel switch is pressed and held for 3 seconds. Demo mode 1) The set time in the demo mode is 250h and the elapsed time is set to 240h. . the elapsed time is displayed for 10 seconds. 350-6 lo-217 . Elapsed display time Tel No. the elapsed time is reset to Oh and the elapsed time count starts. the oil change display is given. PC300. the auto-deceleration switch is automatically turned OFF if it is ON. 3. it stays ON. 4. Note 2: Even if it is ON. if it is operated G/O + F/O or B/O + L/O. Working mode switch Auto-deceleration switch Active mode switch Travel speed switch Knob button switch SWPO5132 Switch actuation table l The bold letters indicate Item WORKING AUTO MODE the default position of the switch when the starting Action switch is turned ON. the auto-deceleration switch is automatically turned ON if it is OFF. (If it is already ON. lo-218 PC300. 350-6 .STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM MODE SELECTION SWITCHES I 5 CZXZI A 1. 5. when the working mode switch is pressed. it is automatically turned OFF. r’ H/O * G/O tj ON tj F/O tj L/O H I) B/O ‘I DECEL OFF (Note KNOB BU-I-TON TRAVEL SPEED POWER UP tj SPEED DOWN Hi t) ON tj Mi t) Lo ACTIVE MODE OFF (Note 2) Note 1: If the working mode is operated F/O + G/O or L/O + B/O.) Conversely. 2. 3. Sensors The signals from the sensors are input directly to the monitor panel. Sub-tank Float Sensor Connector Composition of circuit SOP04068 PC300. OFF (open) OFF (open) OFF (open) (clzzded) ON (open) Contact Contact type tVpe Hydraulic level Engine oil pressure Coolant temperature Fuel level Air cleaner clogging Contact type Resistance Resistance type type Contact type Coolant level sensor 1.STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 2. 350-6 10-219 . The contact type sensors are always connected at one end to the chassis GND. Name Coolant Engine of sensor level oil level oil Type of sensor Contact type ntFi$ ON (closed) ON (closed) (clz!ed) OFF (open) OFF (closed) ab~~~~a. . 4. 2. 2. 3. 2. 4.BPoo376 Engine oil pressure sensor (both Lo and Hi) 1. 2. Plug Contact ring Contact Diaphragm Spring Terminal 1 2 3 4 5 6 Composition of circuit SBPOO378 Coolant temperature sensor 1. 350-6 .STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM Engine oil level sensor Hydraulic oil level sensor 1. 5. Connector Bracket Float Switch “00 0 0 Composition circuit of 4 . 6. 3. 4. Connector Plug Thermistor 1 Composition @=@a of circuit SBPOO379 1O-220 PC300. 3. : Q FULL 1. Float Connector Cover Variable resistor F Composition k E Y of circuit SBP00380 Air cleaner clogging sensor Composition of citcuit SBPO0381 PC300. 3. 4.STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM Fuel level sensor . 2. 350-6 10-221 . 22. 15. 19. 11. 24. 21. 9. 12. 18. 10. 7. 2. Rear cover Bracket (for motor mount) Cable assembly Motor assembly (for lifting) Motor output shaft Geared cable assembly Spoiler cover Limit switch (rear lock) Rear lock Left block (dovetail) Left block (return cable guide) Left block (return cable holder) Left cover (return cable holder) 1o-222 PC300. 17. 8. 26. 23. 5. 6.STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM FRONT WINDOW AUTO PULL-UP SYSTEM 4 SBPOO382 1. 20. 4. 13. 25. 350-6 . 3. 16. Front window assembly Bracket assembly (tension roller) Right block (roller support) Right geared cable Right return cable Controller Control switch Right lock assembly Right tightening motor Limit switch (front) Right bracket assembly (slide link) Harness Right rail 14. An electric motor is used for the front glass (top) of the operator’s cab. front window (I) is moved to the LOWER position by slide link (II). 3) When front window (I) has moved down fully. Operation 1. 2) Lift motor (17) moves in the CLOSE direction and moves front window (I) down. 2) When left and right front locks (8) are actuated in the OPEN direction. the motor stops.STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM Function . PC300. the movement of front lock (8) stops. of lift motor (17) 4) When the movement has been completed. will move and pull up front window 4) (I). operate lift motor (17) to the OPEN direction. When the release operation is completed. 2. 350-6 1 O-223 . front locks (8) are moved in the tightening direction by left and right tightening motors (9). Geared cable (191. lift motor (17) stops. close. Closing front window 1) Press the DOWN control switch. Opening front window 1) Press the UP control switch. and lift motor (17) stops operating at the point where rear lock (12) is engaged. which is meshed with motor output shaft (18). or tighten simply by operating the switch. This makes it possible to open. and push the release lever of rear lock (22) at the same time. When the tightening is completed. 3) After the movement of front lock (8) has been completed. Front window (I) is set at the OPEN position. . 20 STANDARD STANDARD STANDARD TESTING VALUE VALUE VALUE TESTING AND ADJUSTING TABLE FOR ENGINE TABLE FOR CHASSIS RELATED PARTS.. ............................................................ PARTS .......................................................... 2020204 5 13 RELATED TABLE FOR ELECTRICAL PARTS ....................................................................... AND ADJUSTING adjusting, and troubleshooting.. ..................................................................... 20-102 20-103 20-104 20-105 20-106 20-106 20-107 20-108 20-109 20-109 20-I 10 20-I 10 20-I 11 20-I 12 20-I 13 20-I 16 Tools for testing, Measuring Measuring Adjusting Measuring Measuring Testing engine speed ............................................................................................................... color ............................................................................................................... .............................................................................................................. pressure.. ............................................................................................... exhaust valve clearance compression blow-by pressure ......................................................................................................... fuel injection timing ................................................................................. and adjusting engine Measuring Testing Testing Testing Adjusting Measuring Testing Testing Testing Testing oil pressure alternator water ..................................................................................................... belt tension ............................................................................. ......................................................................... compressor.. ........................................ and adjusting and adjusting and adjusting engine pump belt tension belt tension for air conditioner speed ................................................................................................................. (boost pressure) governor hydraulic motor ......................................................................................... lever stroke ................................................................... in work equipment, pressure pressure pressure ................................................. swing, travel circuit ............. .................. air supply and adjusting and adjusting and adjusting and adjusting pressure TVC valve output LS valve output (servo piston input pressure) (servo piston input pressure) Testing control circuit oil pressure when and LS differential 20-I 18 (oil pressure Testing solenoid self-pressure is reduced) ........................................................................ 20-121 20-122 20-125 20-127 20-128 20-129 20-131 20-133 20-134 20-135 20-136 20-137 20-201 valve output pressure ....................................................................................... pressure and testing PPC shuttle valve.. .................................... Measuring Adjusting Testing Testing PPC valve output work equipment, swing PPC valve.. ............................................................................ travel deviation locations causing ................................................................................................................. hydraulic drift of work equipment ................................................... Measuring Releasing Testing Testing Testing Bleeding oil leakage .................................................................................................................... remaining pressure in hydraulic circuit.. .................................................................... ................................................................................... clearance of swing circle bearing wear of sprocket and adjusting ............................................................................................................... track shoe tension .................................................................................... air ..................................................................................................................................... .............................................................................................................................. TROUBLESHOOTING PC300, 350-6 20-l 0 Note the following troubleshooting. when making judgements using the standard value tables for testing, adjusting, or 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. 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. These standard values are not the standards used in dealing with claims. a a a a When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. 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. Be careful not to get caught in the fan, fan belt or other rotating parts. 20-2 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS STANDARD VALUE TABLE FOR ENGINE RELATED PARTS model PC300, 350-6 SAAGDI 08E-2 Standard value for new machine 2,050 f 70 rpm Service limit value Applicable Engine item f condition5 Unit Measurement High idling 2,050 + 50 900 Engine speed Low idling Rated speed 900 +‘O” l-8 - +‘0° 50 2,050 kPa mmH9 Bosch index 120 - 147 (900 - 1,100) Max. Max. 0.34 mm 0.66 5.5 1.5 120 - 147 1900 - l,lOO} 7.5 2.5 Rated speed Air supply pressure (boost pressure) At sudden acceleration Exhaust gas color At high idling Valve clearance (normal temperaure) Intake valve Exhaust valve - Compression (SAE oil) pressure Oil temperature: 40 - 60°C MPa kg/cm> (rpm) Min. 2.7 (28) (250 - 300) 2.3 (231 (250 - 300) (Engine (Water Blowby pressure (SAE oil) speed) temperature: Operating range) kPa nmHz0 Max. 1.47 I1501 2.94 (3001 At rated output (Water temperature: Operating range) At high idling (SAESO) Oil pressure At high idling (SAE 1 OW) At low idling (SAE30) At low idling (SAEIOW) Oil temperature Whole speed range (inside oil pan) timing Before top dead center Min. 78.4 (0.8} 49 IO.51 kPa (g/cm2 Min. 392 - 637 98 (1.0) 78.4 (4.0 - 6.5) 235.2 IO.81 (2.4) “C 0 80 - 110 120 Fuel injection degree: 17 f 0.75 17 f 0.75 Belt tension Deflection when pressed with finger force of approx. 58.8N (6 kg} Crankshaft pulleyalternator Fan pulley water pump Crankshaftpulley air conditioner compressor I mm 3 6- 10 3 6- 10 15- 18 15- 18 20-4 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS * The Standard value for new machine measured in the heavy-duty mode. Applicable model conditions Unit and Service limit value in the table below are all values when PC300, 350-6 Standard value For new machine When swing lock switch is OFF: 2,100 f 100 When swing lock switch is ON: 1,950 f 100 ;ervice limit value When swing lock switch is OFF: 2,100 I!I 100 When swing lock switch is ON: 1,950 f 100 1,950 f 100 Measurement At 2-pump relief . Engine water temperature: Within ooeratina ranae . Hydraulic oil tempergture: 45 - 55°C . Engine at full throttle . In H/O mode . Arm IN relief . Engine at full throttle . In H/O mode . Arm IN relief + power max. OF wm 1,950 f 100 Engine speed when auto-deceleration is actuated Boom Lo control valve Boom Hi control valve . Auto-deceleration switch ON 1,400 f 100 b l 1,400 f 100 a b . Fuel control dial at MAX. . Control levers at neutral. mm Bucket control valve P / BLPoolOl l---l 9.5 + 0.5 9.5 + 0.5 Max. 95 Min. 75 Max. 95 Min. 75 Max. 95 Min. 75 Max. 95 Min. 75 Max. 127 Min. 103 Max. 15 Max. 30 I Boom control lever . Center of lever knob . Read max. value to end of trave . Engine stopped . Exclude play at neutral. I 85+ 10 85 f 10 85+ 10 mm 85+ 10 T 1 Travel control lever Work equipment, swing Travel 115 + 12 Max. 10 Max. 20 PC300, 350-6 20-5 0 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable Cats gcr Item Boom control lever Arm control lever Bucket control lever Swing control lever model conditions Unit PC300, 350-6 f~~n~$ft!!!$$r~e 15.68 3.92 Il.6 f+_ 0.41 15.68 + 3.92 II.6 f 0.4) 12.74 f 0.3) 2.94 II.3 + 12.74 2.94 11.3 ff 0.3) Lever 24.5 +_5.88 I2.5 k 0.6) 74.48 18.62 (7.6 f +_1.9) Service limit value Measurement . Engine at full throttle . Oil temperature: 45 - 55°C . Fit push-pull scale to center of control lever knob or tip of pedal to measure . Measure max. value to end of travel Max. 24.5 12.5) Max. 24.5 f2.51 Max. 21.56 12.21 Max. 21.56 12.2) Max. 31.92 I4.0) Max. 107.8 1111 Travel control lever Pedal Unload pressure . Engine at full throttle . Oil temperature: 45 - 55°C . All levers at neutral . Pump outlet port pressure RAISE 33.81 3.92 f 0.98 140 +_101 f 0.98 (34.79 k 0.981 3.92 + 0.98 (40 +_IO) (345 * 10 (355 t 1011 ;;;; EYg){ ;“y; (;r,y;;)} Boom c 2 -1 At high-pressure setting At low-pressure setting 33.81 31.36 + 1.47 I320 f 15) 18.13 f 0.98 1185 f IO) i 0.98 (34.79 i 0.98) zz I345 * 10 (355 f 10)) Max. 33.32 I3401 Min. 29.4 {300) Max. 19.6 {200) Min. 16.66 (170) $Z){ rzfn (~Z)} Arm Bucket Swing Left travel Right travel Self-reducing valve . Oil temperature: 45 - 55’C All levers Engine at full at neutral throttle . In heavv-dutv mode ’ ’ b * LS-differential Travel Hi unde sssure= no load, travel :I’ mp outlet lever at halfport -I --assure prl nrClII_ l way position - LS pr,,,,,, . Oil temperature: 45 - 55°C . Engine at full throttle . In heavy-duty mode . Pump outlet port pressure . Relieve only circuit being measured j, The values in ( ) are the value: when using the power max. 33.81 t 0.98 (34.79 + 0.98) MtxJ5.77(MaxB){ Min.3234 Min.3332 Max265 (t&xX0)} Min. 330 Mm.340 1345 * 10 (355 * 1011 30.87+;;:; { 315;;; } MPa {kg/ cm*} 34.79;;;; 34.79;:;; { 355:;; } { 355:;; } Max. 32.34 I3301 Min. 28.42 1290) $;; ;;$! ;;$ ii;;; f$‘n”: ;.$;; 3.23 ? 0.2 I33 f 21 Max. 3.43 (351 Min. 2.84 129) 3.92 f 0.98 I40 f IO) 3.92 f 0.98 (40 + IO) LS differential pressure 2.45 f 0.1 I25 f 11 20-6 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model conditions Unit PC300, 350-6 Standard value for new machine PC300 iervice PC300 limit value PC350 ?Catr -qorY Item Measurement Work equipment posture Max. reach Overrun when stopping swing BKPOO102 Deg. . Engine at full throttle . Hydraulic oil temperature: 45 - 55-C . In H/O mode . Stop after swinging one turn and measure distance that swing circle moves Work equipment posture Max. reach 90’ Vlax. 110 Max. 120 Vlax. 140 Max. 150 3.6 f 0.4 Max. 4.5 Time taken to start swing . BKP00326 . Hydraulicoil temperature:45 - 55°C ,80Q . In H/O mode . Time taken to swing 90”and 180” from starting position Work equipment posture Max. reach Set Engine at full throttle 5.1 * 0.5 Max. 6.1 Time taken to swing Engine at full throttle BKpoo102 Hydraulic oil temperature: 45 - 55’C In H/O mode Swing one turn, then measure time taken to swing next 5 turns 30 * 1.5 Max. 35 Hydraulic drift of swing . Engine stopped . Hydraulic oil temperature: 45 - 55°C . Set machine on 15” slope, and set upper structure at 90’ to the side. - Make match marks on swing circle outer race and track frame. . Measure distance that match marks move apart after 5 minutes. mm 0 0 Leakage motor - from swing . Hydraulic oil temperature: 45 - 55’C ’ Swing lock switch ON . Relieve swing circuit. . Engine at full throttle Umin Max. 5.5 Max.11 PC300, 350-6 20-7 0 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model conditions T ravel apeed - PC300, 350-6 Jnit Standard value lr new machine xvice limit value -G -V’ Item Measurement Lo rravel speed (1) Engine at full throttle Hydraulic oil temperature: 45 - 55’C In H/O mode Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load. Mi 3.5 f 5.5 -t 43 f 6 Hi Set Lo 23.3 -+ 4.4 18.9 - 31.0 Travel speed (2) Engine at full throttle Hydraulic oil temperature: 45 - 55-c In H/O mode Run up for at least 10 m, and measuretime taken to travel next 20 m on flat ground. - Mi 16.7 4 2.2 14.4 - 21.0 Hi 13.1 I? 1.0 12.1 - 15.1 BKFW106 Travel deviation Engine at full throttle Hydraulic oil temperature: 45 - 55°C In H/O mode Travel speed : Hi Run up for at least 10 m, and measure deviation when travelins next 20 m on flat ground. * Use a hard horizontal surfact mm Max. 200 Max. 300 1 20m * - Measure dimension x. 20-8 a PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable te’W Item model conditions Unit T L PC300, 350-6 Standard value machine kervice limit value Measurement 1 For new Hydraulic drift of trave !I . Engine stopped mm 0 0 . Hydraulic oil temperature: 45 - 55’C i , . Stop machine on 12” slope with sprocket facing straight up the slope. . Measure the distance the machine moves in 5 minutes. Leakage of travel motor I Lock’pin BKP00109 !/mm Max. 15 Max. 30 . Engine at full throttle . Hydraulic oil temperature: 45 - 55’C . Lock shoes and relieve travel circuit. Posture for measurement Total work equipmen t (hydraulic drift at tip of bucket teeth) PC300 PC350 flax. 675 Max. 825 BKPOOllO Boom cylinder (amount of retraction of cylinder) Vlax. 25 Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Bucket: Rated load 21.2 kN (2160 kg) Horizontal, flat ground Levers at neutral Engine stopped Hydraulic oil temperature: 45 - 55-C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes. mm Max. 30 flax. 38 Max. 45 Arm cylinder (amount of extension of cylinder) lax. 135 Max. 165 lax. 203 Max. 248 Bucket cylinder (amount of retraction of cylinder) vlax. 20 Max. 25 Aax. 30 Max. 38 PC300, 350-6 20-9 0 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model conditions Unit PC300, 350-6 Standard value for new machine service limit value :e- ry Item T Measurement Boom 3.9 ?F0.4 Bucket teeth in contact with grounc 3 $rll$“e’dfU Ily BKWOlll Max. 4.7 . Enaine at full throttle . Hydraulic oil temperature: 45 - 55-c . In H/O mode 3.0 f 0.3 Max. 3.5 PC300 Arm Cylinder fully retracted 5: Fully extended . PC350 Max. 4.6 BKPOOllZ Max. 4.9 Engine at full throttle . Hydraulic oil temperature: 45 - 55°C . In H/O mode Vlax. 3.6 Max. 4.1 3ucket 3.2 + 0.3 Cylinder fully -etracted $ Fully extended BKP00113 Max. 3.8 Engine at full throttle Hydraulic oil temperature: 45 - 55°C In H/O mode Set 2.3 k 0.3 Max. 2.9 3oom BKP00114 Max. 3.0 Max. 3.6 . Lower boom and measure timl taken from point where bucket contacts ground to point wherl chassis rises from ground . Engine at low idling . Hydraulicoil temperature:45 - 55°C 9rm BKP00115 Max. 3.0 Max. 3.6 . Stop arm suddenly and measure time taken for arm to stop . Engine at low idling . Hydraulicoil temperature:45 - 55°C 20-10 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Applicable model Cat go’ Item T conditions Unil for new PC300, 350-6 machine service limit value Measurement Standard value (9. , Bucket //////////////////////, I_ BKP00116 Set Max. 3.0 Max. 5.0 . Stop bucket suddenly and measure time taken for bucket to stop at bottom and then start again . Engine at low idling . Hydraulic oil temperature: 45 - 55’C Cylinders . Hydraulic oil temperature: 45 - 55°C . Engine at full throttle . Relieve circuit to be measured Max. 4.5 Max. 20 ccl min Max. 10 Max. 50 Center swivel joint . Hydraulic oil temperature: 45 - 55’C * Use a hard horizontal surface. Ir Measure dimension x. 20m Travel deviation when work equipment + travel are operated mm Max. 400 Max. 440 BKP00107 . Oil temperature: 45 - 55°C Piston pump See next page /min e. See next page PC300, 350-6 20-l 1 0 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS Cat 901 PC300.350: Discharge amount of main piston pump (in H/O mode) (Urnin) 300 J i 1001 Pump discharge 9. 6 (2001 19. 6 29. 4 (3001 = 2 PltP2 34. 3 (3501 (MPa(ka/cm*l) pressure TWP01401 . Pump speed: At 2050 rpm, TVC current 180 mA Discharge pressure of other pump (MPa {kg/cm*}) Average pressure (MPa Ikg/cm21) Standard value for discharge Judgement standard lower limit Q (Urnin) Check point Test pump discharge pressure (MPa {kg/cm% amount Q U?/min) As desired PI P2 PI + P2 2 pressures PI and See graph See graph + As far as possible, bring pump pressure when measuring. The error is large near the point * When measuring with the pump the specified speed with the fuel the point of measurement, and specified speed. discharge P2 as close as possible to the average where the graph curves, so avoid measuring at this point. mounted on the machine, if it is impossible to set the engine speed to control dial, take the pump discharge amount and the engine speed at use them as a base for calculating the pump discharge amount at the 20-12 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS STANDARD Name of component VALUE TABLE FOR ELECTRICAL PARTS Zonnecto r In No. n Judgment table Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector. If the condition is within the range shown in the table below, it is normal Fuel control dial E06 (male) Between Between 1 Between (I) - (2) (2) - (3) (1) - (3) 0.25 - 7 kQ 0.25 - 7 kR 1 4-6kR I 1) Turn starting switch OFF. 2) Disconnect connector. If the condition is within the range shown in the table below, it is normal Potentiometer E04 [male) 1 Between I Between (I) - (2) (2) - (3) I I 0.25 - 7 kR 0.25 - 7 kR 4-6kR I I 1 Between (I) - (3) I 1) Turn starting switch OFF. 2) Disconnect connector. If the condition is as shown in the table below, it is normal Motor E05 [male) Between (I) - chassis Between (3) - chassis If the condition No continuity No continuitv I I I) Turn starting switch OFF. 2) Disconnect connector. in the table below, is within the range shown it is normal 500 - 1,000 a Min. 1 MQ BetweenLmale) (1) - (2) BetweenLmale) (2)- chassis Engine speed sensor E07 Measure with AC range Between (1) - (2) 0.5 - 3.0 V 1) Start engine. 2) Insert T - adapter. 1) Screw in rotation sensor until it contacts ring gear, then turn back 1 f l/6 turns. 2) &rnt;tvyrk normally when adjusted ravel SO1 DamRAISE SO2 rm OUTS03 3omLOWER SO 4 If the condition is as shown in the table below, it is normal When boom, arm, and bucket levers are operated Between (male) (1) - (2) - All levers at neutral Levers operated Min. 1 M&2 Max. 1 R PPC oil pressure switch 1) Start engine (or with engine stopped and accumulator charged) 2) Disconnect connectors SO1 - S08. rm IN SO5 ucket CURL SO 6 ’ Between (male) (l),(2) - chassis Min. 1 MR I Jcket DUMP SO; Ming SO8 PC300, 350-6 20-l 3 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS Name of component Zonnecto No. In d Judgment table in the table Measurement conditions 1) Start engine. 2) Turn fuel control dial to MAX position. 3) Insert T - adapter. If the condition is as shown below, it is normal CO7 (male (rear) CO8 (male (front; Between (2) - (1) All levers At arm 18-28V at neutral IN relief 0.5 - 1.5 V 3.1 - 4.5 v in the table Pump pressure sensor Between (3) - (1) If the condition is as shown below, it is normal Swing lock switch x05 (male) I I is OFF is ON When switch I Min. Max. I I 1 MR 1 R *etween (,1_,2I When switch Between 13) - (4) I I I) Turn starting switch OFF. 2) Disconnect connector X05. J 1) Turn TVC prolix switch OFF. 2) Turn starting switch OFF. 3) Disconnect connectors co4, c13. I) Turn starting switch OFF. 2) Disconnect connector V04. If the condition is within the range in the table below, it is normal TVC solenoid valve co4 (male) Cl3 (male) Between (1) - (2) Between(l), (2) -chassis IO-22R Min. shown 1 MR If the condition is within the range in the table below, it is normal Swing holding brake solenoid valve JO4 [male) Between (I) - (2) Between(l), (2) - chassis shown 20 - 60 Q Min. 1 MR shown If the condition is within the range in the table below, it is normal Travel speed solenoid valve JO6 :male) Between (1) - (2) Between(l), (2) - chassis 20 - 60 Q Min. 1 MR shown 1) Turn starting switch OFF. 2) Disconnect connector V06. _S select solenoid valve If the condition is within the range in the table below, it is normal JO2 male) Between (1) - (2) Between(l), (2) - chassis 20 - 60 S2 Min. 1 MR shown 1) Turn starting switch OFF. !I Disconnect connector V02. If the condition is within the range in the table below, it is normal ‘ump merge/divider solenoid valve IO3 male) Between (1) - (2) Between(l), (2) - chassis 20 - 60 L2 Min. 1 MR shown 1) Turn starting switch OFF. !I Disconnect connector V03. Machine push-up solenoid valve vo5 ~governor, pump controller (male) foes not carry out control) If the condition is within the range in the table below, it is normal Between (1) - (2) Between(l), (2) - chassis 20 - 60 R Min. 1 MR I) Turn starting switch OFF. 2) Disconnect connector V05. 20-14 0 PC300, 350-6 TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS sy! ter Name of component Connect0 r II r No. Judgment table Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector ClO. If the condition is within the range shown in the table below, it is normal LS-EPC solenoid Cl0 (male) Between (I) - (21 Between(l),(2) - chassis 7-14Q Min. 1 MQ If the condition is within the range shown in the table below, it is normal Power source voltage co1 co2 Between CO1 (71,113) - (61,112) Between CO2 (1 I),(211 - (6).(12) I 20 - 30 v 20 - 30 v I) Turn starting switch ON. 2) Insert T - adapter. If the condition is as shown in the table below, it is normal Between (7) - (17) (power source) Fuel control diaI co3 Between (4) - (17) (low idling) Between (4) - (17) (high idling) 4.0 - 4.75 v 0.25 - 1.0 V 4.75 - 5.25 V I) Turn starting switch ON. 2) Insert T - adapter. If the condition is as shown in the table below, it is normal Between (14) - (17) (low idling) Governor potentiometer co3 Between (14) - (17) (high idling) Between (7) - (17) (power source) 2.9 - 3.3 v 0.5 - 0.9 v I) Turn starting switch ON. 2) Insert T - adapter. i I 4.75 - 5.25 V I - L I I I) Turn starting switch OFF. 2) Disconnect connector P07. 3) Insert T - adapter. into connector at sensor end. II Turn starting switch ON. 2) Insert T - adapter. If the condition is as shown in the table below, it is normal Coolant temperature sensor PO7 (male) Normal temperature (25°C) Approx. 37 - 50 kf2 100X Approx. 3.5 - 4.0 kQ If the condition is within the range shown in the table below, it is normal Governor motel co2 Between (2) - (3) Between (4) - (5) 1.8 - 4.6 V 1.8 - 4.6 V I If the condition is within the range shown in the table below, it is normal Battery relay co1 Between (I) - (6) 20 - 30 v I 1) Turn starting switch ON. 2) Insert T - adapter. Ir This is only for 2.5 set after the starting switch is operated ON + OFF; at other times it must be 0 V. PC300, 350-6 20-15 0 adapter. 4) Operate the lever slightly not enough to move the machine.5 mm) 1) Turn starting switch ON. divided) When levers and pedals are at neutral (solenoid OFF. 2) Insert T . ’ the condition is as shown in the table elow. 3) Turn fuel control dial to MAX position. travel motor swash plate angle MIN) When travel speed switch is at Lo (solenoid OFF.adapter.30 V Between (9) (6). * The lever can be operated slightly (without moving the equipment). 2) Insert T . * The lever can be operated slightly (without moving the equipment).adapter. 20 . it is normal When either swing or work equipment control lever is operated (solenoid ON. boom lower spool stroke 9 mm) When active mode switch is ON (solenoid OFF. 5 set after swing lever and work equipment control levers are placed at neutral (solenoid OFF. merged) Pump merge/ divider valve solenoid co1 20-16 0 PC300.30 v Between (8) (6). measure with the fuel control dial at ~~lZI~1200 rpm or -r f the condition is as shown in the table below. it is normal When active mode switch is OFF (solenoid ON.(12) Swing holding brake solenoid co1 the condition is as shown in the table elow. When travel is operated independently (solenoid ON.(12) o-3v Travel speed solenoid co1 1) Start engine. Judgment table Measurement conditions 1) Start engine. swing holding brake applied) Between (3) (6). 2) Insert T . it is normal With travel speed switch at Hi or Mi (solenoid ON.(12) o-3v I) Turn starting switch ON. boom lower spool stroke 11. 350-6 .(12) o-3v Active (boom) solenoid co1 1 _ 20 . swing holding brake canceled) Approx.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS T Name of :omponent Zonnec No. 3) Turn swing lock prolix switch OFF.adapter. travel motor swash plate angle MAX) 20 . 4) Insert T .30 v Between (2) (6). To check that the solenoid is OFF. it is normal. 2) Turn swing lock switch OFF. ’ the condition is as shown in the table lelow. 2) Insert1 T .adapter.CO2lll) Cl7(14) .H. 2) Turn fuel control dial to MAX position 3) Turn prolix switch OFF.CO2(1I) C17(7) . it is normal . H/O mode Betweenfront (8) . knob switch. 3) Connect T .(19) switch ON.GND 4-8V 1) Turn starting switch ON. 1) Turn starting switch ON. 1700 1) Turn starting switch OFF.adapter.28 V o_2v If the condition is as shown in the table below.adapter. 1900 (idling) I) Start engine.adapter to wiring harness end.28 V O-IV When switch is OFF (‘I . it is normal Between selection 1 Model selectiol Cl7 . 4) All levers at neutral II Turn starting switch ON.H. it is normal I I I L. 2) Disconnect connector.(18) 360 + 100 mA Betweenrear (9) . 2200 (during opration) Approx. 1900 Approx. I) Turn starting switch ON. 2) Turn fuel control dial to MAX position 3) All levers at neutral.GND If the condition is as shown in the table below.CO2(11) Cl7(6) . Between (15)-GND 20 . it is normal Kerosene mod{ Cl7 Standard mode Kerosene mode . I Approx. 2) Insert1 T . LS-EPC solenoid valve (default value If the condition is as shown in the table below.CO2(11) Continuity PC300.co2 Between selection 2 Between selection 3 Between selection 4 Between selection 5 Cl7(5) . 2050 (idling) Approx. it is normal High idling (rpm) Active No. 2050 (during operation) Approx.n d Judgment table Measurement conditions 1) Turn starting TVC solenoid valvt (default value If the condition is as shown in the table below. knob switc co3 When switch is ON Between 20 . If the condition is as shown in the table below.(12) . 2303 (during operation) Approx. it is normal . 2) Set monitoring code to 10 or 16 (command value). H/O mode co2 Between (7) . 350-6 20-17 0 . 3) Operate working mode switch and L. (H/O) (G/O) Swiftslow-down (H/O)(G/O) Approx. 2) Insert1 T .CO2(11) No continuity Continuity No continuity No continuity Cl7(13) . code 16 H/O G/O F/O UO Power max. 2250 Approx. If the condition is as shown in the table below. 2050 (idling) Approx. 1700 Approx.TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS I sn Name of component Eonnecto r In No. n .(17) 900 f 80 mA If the condition is as shown in the table below. it is normal S-NET Cl7 Between (4). 2 throttle signal Monitorin! 3 . 3. it is normal Measurement conditions I) Start engine..4. 3. 3) Disconnect connector. it is normal Coolant temperature sensor PO7 (male) 1 Normal temperature (25’C) 1 Approx. then remove sensor. then turn back 1 ? l/6 turns 2) ltsm. Screw in rotation sensor until it contacts ring gear. Ke’ (female) I I I I If the condition is within the range shown in the table below. If the condition is as shown in the table below.(2) Between(l). 1OO’C 37 .chassis Engine speed sense E07 Measure with AC range Between (I) . Air cleaner clogging sensor 2) Disconnect Pll. 1 MQ I I Below LOW level in sub-tank connector P08. 1 R Min.0 V 500 . 3) Insert T-adapter into connector at sensor end.5 . 2) Disconnect Max.0 kR I) Turn starting switch OFF. 350-6 . 1 MQI If the condition is as shown in the table below. 3) Drain oil. I) Turn starting switch OFF. 1 Q Lowerfloat 1 Min. 1 MR 1) Turn starting switch OFF.5 . P12.tvyork normally when adjusted If the condition is as shown in the table below. PI1 Judgment table If the condition is as shown in the table below.50 kfi 1 Approx. 2) Disconnect connector P07. it is normal Coolant level sensor PO8 (male) Above LOW level in sub-tank I I 1) Turn starting switch OFF.(2) .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS G ten Name of component Ionnectol No. 3) Insert T .adapter. it is normal Between (I) . 20-18 0 PC300. I) Start engine. into connector at sensor end. 2) Insert T . it is normal v’ Engine oil level sensor PO5 (male) ly: BLPCOOOZ Raise float Max.adapter.1000 n Min. 2) Disconnect connector P05.(2) I) 0. adapter into sensor. I) Turn starting switch OFF. 3) Drain oil. 3) Put tester in contact with connector at sensor end to measure. I If the condition is as shown in the table below. it is normal . 1 RI (male) I IVY=’ BLW0003 Lowerfloat lfvlin.IIOR I) Turn starting switch OFF.. Fuel level sensor PO6 (male) ti BLmoo4 . 1 fvl*i I If the condition is as shown in the table below. 2) Disconnect Pll. BLFmo96 - PC300. Judgment table Measurement conditions I) Install oil pressure measurement gauge. it is normal Low pressure end Engine oil pressure sensor between sensor - If the condition is as shown in the table below. P12. it is normal 1-l Hydraulic oil level sensor PO9 BLRWOOZ Raise float / Max. * Connect the T . 3) Drain fuel. then remove sensor.adapter to the connector and sensor flange. 85. Raise float to stopper Approx. 2) Remove wirina ” harness terminal. 2) Disconnect connector PO9. 12 Q or below . 4) Inset-t T . 350-6 20-19 0 . it is normal Air cleaner normal Air cleaner clogged Air cleaner clogging sensor ‘I 1 ‘12 Continuity No continuity I) Start engine. 4) Insert T .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS telm - ‘SSY Name of component lonnecto #r Ir r No. If the condition is as shown in the table below. 3) Start engine. then remove sensor. 2) Disconnect connector P06.adapter into sensor. 4) Put tester in contact High pressure end terminal screw and chassis. k- Lower float * 1 to stopper ELF90005 Approx. 5 . 20-20 0 PC300.3.0.575 3.00 r 41.45 25.co3 (female) (’16) t 8 7 Display position 6 5 4 I .4.18 37.90 . or measure the resistance of the sensor. !igdh.60 .28.3.31.156 I) Insert a dummy resistance with the starting switch OFF.29.77 50.00 . or after starting in cold areas. 2) Check the display with the starting switch ON. the voltage may not rise for some time.0. Alternator When engine is running (l/2 throttle or above] below.E.55. .646 .TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS Name of component onnector No. Position of gauge display Starting switch Min. Displav level resistance (Monitor panel input resistance) Starting switch OFF kR Position of gauge display Starting switch ON Min.07 .85 .44.s(2) t 18.71 . Right side .13.708 . 2) Check the display with the starting switch ON.Max.82 Display position 5 4 3 2 29. 350-6 .5 V + If the battery is old.98 638.39.342 .77.21. between llternator erminal I and hassis Inspection method Judgment table Measurement conditions I) Start engine.900 .91 ..Max. the sensor is defective.600 L 3 2 -Gauges Left side 1 *_ Levels 8 and 9 flash. j27. or measure the resistance of the sensor.’ All OFF(10) 9 Measure resistance between coolant temperature gauge CO3 (female) (I 1 .14 .691.rn. Display level resistance [Monitor panel input resistance) ON Starting switch OFF kR I) Insert a dummy resistance with the starting switch OFF.25 Measure resistance between fuel level gauge CO3 (f.5 - I Left side * M 1 Level 1 flashes.422 3. .42 72.349 0. 3.82 11. . 490N {50 kg} Operating effort Stroke.5 (female PT l/8) Oil pressure C 3 l 790-261-1321 l 790-261-1331 Adapter 4 799-401-2701 790-261-1360 790-261-1370 Differential pressure gauge Adapter Nut Gasket 1 Plug 1 Hydraulic gauge gauge Both male and female 14 x 1.5 (female PT l/8) male and female 1.TESTING AND ADJUSTING TOOLS FOR TESTING.0 MPa {IO kg/cm21 0 .a~~bgcially Smoke meter 79A-264-0020 J drift speed and K L M ) 1 Push-pull scale 79A-264-0091 ~~~~~~cially $$$l!&$cial’y 79A-264-0211 799-601-7100 799-601-7070 Discoloration 0 .5 (female PT l/8) male and female 1.3 . AND TROUBLESHOOTING Engine speed Coolant and oil temperatures - 6 1799-101-1502 1 Digital temperature gauge ( -50 .200 kPa l-760 .1.1500 mmHn) H 2 $.25 Both 14 x Both 18 x Both 22 x male and female 1. hydraulic Work equipment Measuring voltage resistance values Scale Stop watch Tester T-adapter Adapter ) Wear gauge box For SWP14 For relay 5P Troubleshooting of wiring harnesses and sensors Measuring wear of sprockei v 2 P 799-601-7360 /796-627-1130 I 20-102 a PC300.4.: 795-502-1205 checker ) 0 .294N (30 kg} 0 .5 (female PT l/8) For 14 x 1. ADJUSTING.70% (with standard color) (Discoloration % x l/10 = Bosch index) 0 .500 mmHzO1 I 795-502-1590 795-472-l 370 I799-201-1504 799-201-2202 $$$)~~~cially 799-201-9000 I Compression Adapter I Blow-by Pressure gauge Feeler gauge Handy Smoke Checker -101.9 MPa IO -70 kg/cm? Kit Part No. 350-6 .5 blind For blind 5 07003-31419 (07040-11409 Compression Blowby pressure 3 pressure E F G 1 Exhaust color Air supply pressure (boost pressure) Valve clearance 6 ) 799-401-2320 1 2 I ( For 14 x 1. AND TROUBLESHOOTING TOOLS FOR TESTING. Check or measurement item ADJUSTING.9 kPa IO .5 blind 1 1.200”C 2 799-101-5220 07002-I 1023 l 790-261-1311 Nipple 0 ring 10 xl.6. be careful not to touch any high temperature parts./swift switch to the power max. Ir Measure in the heavy-duty mode with the auto-deceleration OFF. 4. i) Set the working mode the H/O mode. set the knob switch to the ON position. Remove Remove the fan guard. PC300. and measure the engine speed when it is set to the conditions for measuring.TESTING AND ADJUSTING MEASURING ENGINE SPEED MEASURING ENGINE SPEED AWhen removing or installing the measuring equipment. position. connect Al to the it to multi- 5. iii) Run the engine at full throttle. then tachometer Al. slow-down ii) Set the power max. Install the sensor of multi-tachometer speed pull out port. 1) Measuring low idling and high idling speeds Measure the engine speed with the fuel control dial set to low idling and high idling. knob switch is kept pressed. Measure the engine speed under the following * conditions. 3.55°C 1. and measure the speed when the arm IN circuit is relieved. and measure the engine speed when the arm IN circuit is relieved. operate the arm lever. function is automatically turned off after approx. i Install the gear box A2. ii) Run the engine at full throttle.H. 350-6 20. * Even if the L. . the power max. 2) Measure the speed at near the rated speed. 4 2. operate the arm lever. cover (1). Start the engine. 8 seconds. so measure during the first 8 seconds.103 0 . Hydraulic oil temperature : 45 . * Measuring speed when travel is operated: Knob switch ON 3) Measuring speed at 2-pump relief: i) Set the working mode the H/O mode. Coolant temperature: Within operating range . * When connecting the port. when recording official data. Remove the filter paper and compare it with the scale provided to judge the condition. Connect the power cord to the AC power source socket. then fit the filter paper. 1. Connect the probe hose.* t BKPOO215 7) 20-104 0 PC300. then tighten the clip to secure it to the exhaust pipe. 3) 2. use smoke meter H2. * The pressure of the air supply should be less than 1. Accelerate the engine suddenly. depress the accelerator pedal of tool H2 and catch the exhaust gas color on the filter paper. accelerate the engine suddenly. use handy smoker checker HI. accelerator switch plug. check first that the power switch of tool H2 is OFF. EXHAUST COLOR When measuring in the field when there is no air or power supply. Measuring with smoke meter H2 1) Insert the probe of tool H2 into the outlet port of exhaust pipe(l). Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (IO sheets or more) inside the filter paper holder.TESTING AND ADJUSTING MEASURING EXHAUST COLOR MEASURING . and at the same time operate the handle of tool HI to catch the exhaust gas on the filter paper. Measuring with handy smoke checker HI 1) Fit filter paper in tool Hl. and air hose to tool H2. and at the same time. 2) Insert the exhaust gas intake port into the exhaust pipe. Turn the power switch of tool H2 ON.47 MPa (15 kg/cm2). 2) 3) BLP00297 4) I 5) 6) f&Y. Loosen the cap nut of the suction pump. * Fit the filter paper securely so that the exhaust gas does not leak. and read the indicated value. be careful not to touch any high temperature part. AWhen removing or installing the measuring equipment. 350-6 . Raise the coolant temperature to the operating * range before measuring. 6 cylinder.5 kgm) The firing order is as follows: 1 . After adjusting No.6 line (1) on the crankshaft pulley with pointer (2). Remove 2. the cylinder head cover. To adjust the valve clearance.1 f 4. it is also possible to turn the crankshaft 120” each time and adjust the valve clearance of the intake and exhaust valves of each cylinder according to the firing order.9 Nm 14. Rotate the crankshaft in the normal direction to align TOP 1. When No.2 4.TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE 1. Next.6 . loosen locknut (61. check the movement of the intake valve of No. Then tighten locknut (6) to hold the adjustment screw in position. adjust the valves marked l in the valve arrangement chart.3 . * * I TYPO1432 * * BLPOO299 BLPOO300 PC300. After tightening the locknut.5 f 0. then insert feeler gauge G between rocker lever (3) and valve stem (41. and turn adjustment screw (5) until the clearance is a sliding fit. 1 cylinder at compression top dead center. check the valve clearance again. see the STANDARD VALUE TABLE for engine related parts. 350-6 . m Locknut : 44. For details of the valve clearance. VALVE ARRANGEMENT DIAGRAM 4. When rotating. 3.5 . rotate the crankshaft one turn (360”) in the normal direction and adjust the valve clearance of the remaining valves marked o. 1 cylinder is at compression top dead center. . see ADJUSTING VALVE CLEARANCE. Run the engine at near the rated output and read the gauge measurement. Coolant temperature: Within operating range . fan belt or other rotating parts. Remove nozzle holder assembly (I) from the cylinder to be measured. Ir Near rated output . After measuring the compression pressure. see MEASURING ENGINE SPEED. Connect the nozzle and gauge with the hose. MEASURING PRESSURE + BLOW-BY BLPOO303 1. then crank the engine with the starting motor and measure the compression pressure. 350-6 . install nozzle holder assembly (I). or to get your clothes caught in the fan. 3. 3. When measuring the compression pressure. 2.TESTING AND ADJUSTING MEASURING MEASURING COMPRESSION PRESSURE BLOW-BY PRESSURE MEASURING PRESSURE a COMPRESSION 1. Install adapter D2 in the mount of the nozzle holder. Disconnect the fuel control rod. 5. Warm up the engine to make the oil temperature 40 . measure the engine speed to confirm that it is within the specified range. Measure the compression pressure at the point where the pressure gauge indicator remains steady. place the governor lever of the injection pump in the NO INJECTION position. Connect tachometer Al and gear box A2. 2. BLP00304 zo106 0 PC300. Hydraulic oil temperature: 50 . For details. Relieve the arm IN circuit in the H/O mode and power max. 6. When measuring the compression pressure.80°C Install the nozzle of blow-by checker E to blowby hose (1). Measure the blow-by pressure under the following conditions. mode. Sr Measure the blow-by at the point where the gauge indicator remains steady. be careful not to touch the exhaust manifold or muffler. 4. then connect pressure gauge Dl.60°C. For details. Adjust the valve clearance. w Nut : 66. BLPOO305 Adjusting * If the lines are not aligned. check as follows. pump has been removed. For details. Loosen nut (1) at the oblong portion and pump mounting nut (21.107 0 .35 Nm (6. Check that line a on the injection pump is aligned with line b on the mounting case. Ir PC300.75 kgm} If the gear flange and gear train for the fuel injection pump drive has been disassembled. 1. see the 108-2 Series Shop Manual.TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING TESTING AND ADJUSTING FUEL INJECTION TIMING Testing Ir If the fuel injection 1. adjust as follows. adjust the fuel injection timing. pump Tighten nuts (I) and (2).75 + 0. 350-6 20.15 f 7. 2. then move fuel injection (3) to align the lines. 108 0 PC300. Remove engine oil low-pressure sensor (PTIB) (I) and high-pressure sensor (PTV8) (21. measure the engine oil pressure caution end and the controller trouble data display end with the engine at high idling. measure the engine oil pressure caution end with the engine at low idling. then install nipple C2 and oil pressure gauge C6 (1. and measure the oil pressure with the engine at low idling and at high idling.TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE MEASURING PRESSURE * ENGINE OIL l Measure the engine oil pressure under the following conditions. 350-6 . 2. Coolant temperature: Within operating range 1. * 20. For low-pressure sensor (I).0 MPa {IO kg/cm*)). Start the engine. and for high-pressure sensor (21. check again to confirm that the belt tension is within the standard value. QEI Locknut: 30. check again to confirm that the belt tension is within the standard value. Loosen locknut (41.43 Nm I3.25 f 12. . and move alternator (I) to adjust the tension of the belt. tighten locknut (4). tighten mounting bolts (2). PC300.15 f 7. 4. Turn belt tension adjustment bolt (4) and move tension pulley (I) to adjust the tension of the belt.25 _+1.87 f 3. adjust the belt tension as follows. m Mounting bolt : 66. Tighten mounting bolt (2) first. When the tension is adjusted. or after carrying out maintenance or replacing the belt.75 kgm} Loosen adjustment bolt (4) 112 turns. When the tension is adjusted. Remove the upper fan guard of the alternator. After adjusting the belt tension. 350-6 20. 4. Ir To prevent the adjustment bolt from falling out. turn belt tension adjustment bolt (51. adjust the belt tension as follows.15 + 0. 3. * pulley Crankshaft pulley BLPoo310 BLPOO311 TESTING AND ADJUSTING WATER PUMP BELT TENSION * If the deflection of the belt when it is pressed at a point a midway between the water pump pulley and the fan pulley is not within the standard value.25 Nm (11.75 f 0. Deflection of V-belt : 3 mm Loosen mounting bolts (2) and locknut (3) of tension pulley (1).35 kgm} After adjusting the belt tension. Deflection of V-belt : 3 mm 1. then tighten locknut (3).25 kgm1 5. . 2.35 Nm (6. a 1. u Crankshaft pulley BLPoO312 3. Loosen mounting bolts (2) and mount bolt (3) of alternator (I). loosen the tension applied to the bolt. then tighten mount bolt (3).TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION TESTING AND ADJUSTING WATER PUMP BELT TENSION TESTING AND ADJUSTING ALTERNATOR BELT TENSION If the deflection of the belt when it is pressed at a point a midway between the alternator pulley and the fan pulley is not within the standard value. 2. or after carrying out maintenance or replacing the belt.109 0 . w Mount bolt: 110. * Remove the upper fan guard of the air conditioner compressor. After adjusting the belt tension. Move the position of compressor (3) to adjust the tension of the belt. 5. turn back 1 f l/6 turns. m Locknut : 58. Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to the sensor tip. 4. tighten mount bolts (I) and (2) to secure in position. When gear (2) contacts sensor (I). a Crankshaft pulley Air conditioner compressor pulley BKP00314 2.18 mm Loosen mount bolt (I) and (2).TESTINGAND ADJUSTING TESTINGAND ADJUSTING BELTTENSION FORAIR CONDITIONER COMPRESSOR ADJUSTING ENGINE SPEED SENSOR TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 1. If the deflection of the belt when it is pressed at a point a midway between the drive pulley and the compressor pulley is not within the standard value. * ENGINE SPEED Screw in until the tip of sensor (I 1 contacts gear * (2). When the position of the compressor is fixed. 3. 350-6 . 3. adjust the belt tension as follows. . BWP03004 ADJUSTING SENSOR 1. Tighten locknut (3). BLPO0316 BLPO0317 20-110 a PC300. repeat the above procedure to check that the belt tension is within the standard value. or when carrying out maintenance after replacing the belt. Deflection of V-belt : 15 . 2.8 f 9.8 Nm {S f 1 kgm} Be particularly careful when handling the sensor wiring to ensure that no excessive force is brought to bear on the wiring. TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) A When removing or installing the measuring equipment or when carrying out the measurements. Insert the gauge about half way. plug 1. so always be sure to bleed all the oil. 350-6 20-l 11 0 . 2. * Near rated output . . Connect the oil pressure measurement hose to the coupler and pressure gauge F (-101.1. Run the engine at near the rated output. and use the self-seal portion of the gauge to bleed the oil from inside the hose. when measuring in the field. 3. mode.200 kPa I-760 .500 mmHg). a similar value can be obtained with the above conditions. Note: Run the engine at a mid-range speed or above. Run the engine at near the rated speed and measure the pressure indicated by the gauge. be careful not to touch any high temperature parts or rotating parts. The air supply pressure (boost pressure) should be measured with the engine running at rated output. However. * PC300.3 . then install the nipple C2. Ir The gauge does not work if there is any oil inside the hose. see the measurement of the engine speed when the arm IN circuit is relieved in the H/O mode and power max. Remove air supply pressure measurement (1) (PT1/8). and repeatedly open the self-seal portion to bleed the oil. For details. 5 seconds.TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE Testing * Use the governor motor adjustment mode. and the auto-deceleration switch to OFF. Caution When the spring assembly is removed and the starting switch is at the OFF position. 4.) switch + working mode (R. Adjusting 1. 2) Set the fuel control dial to MAX. From the above position. if the governor motor lever is moved suddenly. Turn the starting switch OFF. and secure in position with the locknut. 1. and this may cause a failure in the governor controller. then turn joints (I) and (4) to adjust the length of spring assembly (5) and adjust to the position of the hole of governor lever (2). 3. In this condition. then remove the nut and disconnect joint (I 1 from governor lever (2). 2. 2. Preparatory work 1) Keep the monitor panel time switch + travel speed (R.5 mm).) switch pressed for 2. 3.H. repeat the procedure in Step 1 to complete the governor motor adjustment mode. Repeat the procedure in Step 1 above to set to the governor motor adjustment mode. the governor motor will generate electricity. After checking. disconnect connector E05 first. When moving the governor motor lever. 2. check the governor lever and spring rod. Set governor lever (2) to a position where it contacts full speed stopper (3) of the fuel injection pump. shorten joints (I) and (4) a total of 2 turns (approx. * Any working mode can be used. 350-6 . II -- BLPW320 20-112 0 PC300.H. * To check the operation of the safety valve at the boom LOWER end. Pitch=1.TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC EQUIPMENT.8 MPa 1600 kg/cm*}). Measuring main relief pressure 1) Run the engine at full throttle and measure in the H/O mode. TRAVEL CIRCUIT Measuring Sr Oil temperature when measuring: 45 . * If the power max.=lOmm. Table 1 Combination of pumps and actuators controlled when flow from front and rear pumps is divided Pump Controlled actuator Boom cylinder (Lo.H. SWING. so the value measured will be the relief pressure of the safety valve. Then put the safety lock lever in the LOCK position. 3. measure the hydraulic pressure when the machine push-up switch is OFF (low pressure) and ON (high pressure). travel Service motor (Lo) Plug 1 Front pump 2 Rear pum Arm cylinder Swing motor L. then install the nipple C2 and oil pressure gauge Cl (58. 2) Measure the hydraulic pressure when each actuator is relieved. Ir When measuring the hydraulic pressure in the boom LOWER circuit. or put block between the sprocket and frame to lock the track.55’C &Lower the work equipment to the ground and stop the engine. switch is turned ON. 8 seconds. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. the pressure will rise. TRAVEL CIRCUIT PRESSURE IN WORK TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT. Remove pressure pick-up plug (I) or (2) (thread dia. SWING. travel motor PC300. Ir If the swing lock switch is turned ON. it is automatically turned OFF after approx.H. 2) Measure the hydraulic pressure when all levers are at neutral. Remove the upper cover of the main pump. (When the switch is turned ON. so measure during the first 8 seconds. so always keep the lock switch OFF when measuring.25mm) from the circuit to be measured. 1. * To relieve the travel circuit. 4. 2. 350-6 20-113 0 . Hi) Arm cylinder (Hi) Bucket cylinder R. put block under the track shoe grouser. block the hose (fit blind plug) at the boom cylinder head end.) * Note that the set pressure of the safety valve for the swing motor and head end of the boom is lower than the LS relief pressure. Measuring unload pressure I) Run the engine at full throttle and measure in the H/O mode. the pressure will rise. so measure with both the switch OFF and ON. 6 MPa (128 kg/cm*) m Locknut : 29. then turn holder (4) to adjust.123 Nm 19. 12. (I): Boom cylinder head (LOWER) end 1) Disconnect pilot hose (2). * Amount of adjustment for one turn of adjustment screw: Approx. 21.12. Machine push-up switch ON (high pressure): 0 MPa IO kg/cm*) Machine push-up switch OFF (low pressure): 2. then turn holder (6) to adjust. m Locknut : 93 . TRAVEL CIRCUIT PRESSURE IN WORK Adjusting * The unload valve cannot be adjusted.5 kgm} * Turn the holder to adjust as follows. then turn adjustment screw (4) to adjust.5 kgm} setting 3) Adjusting low-pressure Loosen locknut (51. 350-6 . . then adjust the low-pressure end. 2) Adjusting high-pressure setting Loosen locknut (31.74 MPa (28 kg/cm*} 3 456 CP 20-114 0 PC300. w Locknut : 78 . * Amount of adjustment for one turn of holder: Approx. * Turn the adjustment screw to adjust as follows. turn COUNTERCLOCKWISE. SWING.93 Nm IS . To DECREASE pressure.8 MPa (222 kg/cm*} l 8LFoO122 [Reference] The oil pressure acting on port Cp is as follows. turn CLOCKWISE. To INCREASE pressure.4 .4 kgm} l l l l 2.39. Boom cylinder head safety valve * Adjust the safety valve at the high-pressure end first.5 .2 Nm I3 . To INCREASE pressure. To DECREASE pressure. .9. Main relief valve (1): For front pump (2): For rear pump Loosen locknut (3). 1. turn COUNTERCLOCKWISE.TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC EQUIPMENT. turn CLOCKWISE. * Amount of adjustment for one turn of adjustment screw: Approx. SWING. then tighten the mounting bolts to the specified torque.15 kgm} After completing the adjustment.5 kgm} w kg/cm*) PC300. Carry out the adjustment with the valve * assembly installed to the motor. 3. install spring (4) and cover (31. To DECREASE pressure. TRAVEL CIRCUIT 3. turn CLOCKWISE. w Cover mounting bolt : 98 . . then remove cover (3) and spring (4).147 Nm I12 .TESTING AND ADJUSTING TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT. . then turn adjustment screw (6) to adjust.123 Nm {IO.5 3) Locknut : 118 .0 . 350-6 20-l 15 0 . Loosen locknut (51.12. (2): For starting right swing (stopping left swing) 1) Remove 2) the mounting bolts. To INCREASE pressure. turn COUNTERCLOCKWISE. (I): For starting left swing (stopping right swing) .9 MPa 139. * Turn the adjustment screw to adjust as follows. Swing motor safety valve . 4. Measuring * Oil temperature 1. then install nipple C2 and oil pressure gauge :. and measure the oil pressure when the arm IN circuit is relieved. so measure during the first 8 seconds.TESTING AND ADJUSTING TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) when measuring: 45 . Pitch=1. The power max.8 MPa 1600 kg/ cm21 gauge to the pump outlet port end. For the front pump. Check that the servo piston input pressure is 2/5 of the pump discharge pressure. Then put the safety lock lever in the LOCK position.~ * Install a 39.55°C ALower the work equipment to the ground and stop the engine. and a 58. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 350-6 . function is automatically turned OFF 8 seconds after it is switched ON. turn the L. measure the oil pressure at plugs (2) and (4) at the same time. 20-116 0 PC300. [Reference] If there is any abnormality in the LS valve or servo piston. lock switch ON. Remove pressure measurement plugs (I). (31.=10 mm.25 mm). knob switch ON. j Iltii BWP02976 2. the servo piston input pressure will be almost the same or 0 of the pump discharge pressure. Turn the swing Set the working mode to H/O mode and set the knob switch function to POWER MAX.2 MPa (400 kg/cm*Igauge to the servo valve end. for the rear pump. Run the engine at full throttle.H. (21. and (4) (Thread dia. measure the oil pressure at plugs (I) and (3) at the same time. 3. it will return to the original position. Loosen locknut (I). adjust the TVC valve as follows.5 kgm) Note: The screw is an eccentric cam. “!y$ flow (f!/min) so 180' 270' 360 BKPO0131 Angle of turning of eccentricpin PC300. and turn screw (2) to adjust. if the pump discharge pressure and LS differential pressure are normal. If engine speed drops. so check the mark before turning. the work equipment speed will drop. the stroke of the servo piston (change in oil flow) will move as shown in the graph. Punch mark Range @ Increase Decrease 1.5 . In such cases. 350-6 20-l 17 0 .5 . m the adjustment. * Turn the screw as follows. If work equipment is slow. .3. Af?ei completing (I). the engine speed will drop. Or if the engine speed remains normal. If it is turned one full turn. tighten locknut Locknut : 24. but the screw will become looser. so there will be play in the screw.34.3 Nm t2. Therefore. turn in DECREASE direction.TESTING AND ADJUSTING TESTING AND ADJUSTING NC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) Adjusting Ir If the load becomes larger. turn the screw a maximum of 90’ to the left or right from the position set when the machine was shipped. Ir The direction to turn differs according to the position of the eccentric position punch mark on the screw. turn in INCREASE direction . so if it is turned from the 0 position in the graph. Punch mark showing eccentric position Within 90’ in Within 90’ in counterclockwise clockwise direction direction Within 90” in Within 90” in counterclockwise direction BLPO0132 Range @ clockwise direction 2. = 10 mm.8 MPa 1600 kg/cm*} gauge to the pump outlet port end.92 + 1. Ir For the front pump. when measuring the rear pump.55°C Measuring LS valve output pressure (servo piston input pressure) 1) Rrimoie pressure measurement plugs (I 1. (21.(travel Approx. and measure the pump discharge pressure and servo inlet pressure. and a 58.0 {40 * IO) 3. measure the oil pressure at plugs (2) and (4) at the same time. Set the working mode to H/O mode. 350-6 .O~d~r 12. (31. and turn the travel speed switch to Hi. 4. and install nipple C2 and oil pressure gauge Cl. measure the oil pressure at plugs (I) and (3) at the same time. Run the engine at full throttle. push up the right track. 2) 3) IlV BWP02976 4) Table 1 Travel Servo inlet Pump pressure port pressure (MPa{kglcm2H (MPaIkg/cm*I) 3.%g H/O mode H/O mode lever Neutral valf.74 11301 20-118 0 PC300. Pitch=1.2 MPa (400 kg/cm21 gauge to the servo valve end.TESTING AND ADJUSTING TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE * 1.0 I40 + IO] Approx. Plugs and measured pressure ~ discharge pressure Install a 39. push up the left track.92 * 1. “r$‘.25 mm).9 {501 Remarks About same pressure About 2/5 of pressure wz. Use the work equipment to raise the track assembly on one side. for the rear pump. and (4) (Thread dia. set to the conditions shown in Table 1. Oil temperature when measuring: 45 . Ir When measuring the front pump. set to the conditions shown in Table 2 and measure the LS differential pressure. * Plugs and measured pressure Connect the pump discharge pressure to the high-pressure side of the differential gauge and the LS pressure to the low-pressure side. Pitch=l_25mm). 2) Measuring with oil pressure gauge differential pressure is * The maximum 2.TESTING AND ADJUSTING TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 2. and install the nipple C2. Table 2 Ir BWPO2977 H/O mode Neutral Half (travel circuit under no load) 3. ii) Set the working mode to H/O mode.94 f 1. when measuring the rear pump. push up the left track. iii) Use the work equipment to raise the track assembly on one side. PC300. plugs i) Remove pressure measurement (I). Ici BWPO2978 . Measuring LS differential pressure 1) Measuring with a differential pressure gauge i) Remove pressure measurement plugs (I).0 MPa (30 f 10 kg/cm*). (3).=lOmm. and install nipple C2 and differential pressure gauge C4. the LS differential pressure is the same as the unload pressure. iv) Run the engine at full throttle. iii) above. and (4) (thread dia. (2). 350-6 20-119 0 . (3).1 I25 + 1) (Note) H/O mode Note: When all control levers are at neutral.=lOmm.92 f 1. pitch=l. * When measuring the front pump. so measure with the same gauge. push up the right track. and (4) (Thread dia. (2). Carry out the same operation as in Step ii) I)-ii).45 f 0.0 I40 f IO} 2. and turn the travel speed switch to Hi.25mm). ) iv) Set to the conditions in Table 2 and measure the pump discharge pressure. adjust as follows. * Stand directly in front of the indicator and be sure to read it correctly. vi) Set to the conditions in Table 2 and measure the LS pressure. a 39. .8 MPa 1600 kg/cm*} pressure gauge is available. turn COUNTER-CLOCKWISE * Amount of adjustment for one turn of adjustment screw: Approx.(LS pressure) = LS Differential pressure iii) BWPO2978 Oil pressure gauge BLPOO138 3. Adjusting LS valve When the differential pressure is measured under the conditions above. * Turn the screw to adjust the differential pressure as follows. then install it to the LS pressure measurement plug. * Stand directly in front of the indicator and be sure to read it correctly. VI Remove oil pressure gauge Cl and nipple C2. 2) After adjusting. (If no 58.8 MPa (600 kg/cm*)) to the measurement plug for the pump discharge pressure.8 kgm) 20-120 0 PC300. Ir Use a gauge with a scale in units of 1.5 Nm (6 . 1. turn CLOCKWISE .8 .78. (Pump discharge pressure) .TESTING AND ADJUSTING TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE Install oil pressure gauge Cl (58. To INCREASE pressure. 350-6 . m Locknut: 58.2 MPa (400 kg/ cm*) pressure gauge can be used. tighten locknut.29 MPa (13. To DECREASE pressure. and the results show that the differential pressure is not within the standard value. 1) Loosen locknut (I) and turn screw (2) to adjust the differential pressure.2 kg/cm*) Note: Always measure the differential pressure while adjusting.0 MPa {IO kg/cm*). Remove oil pressure measurement plug (2) (PTl/ 8) from LS-EPC solenoid valve block (I). 350-6 20-l 21 0 . Start the engine and measure full throttle. Install nipple C2.8 MPa {60kg/cm21). Then put the safety lock lever in the LOCK position. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 3. Cl (5. with the engine at PC300.TESTING AND ADJUSTING TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED) TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED) when measuring: 45 . Measuring * Oil temperature 1.55°C ALower the work equipment to the ground and stop the engine. then connect oil pressure gauge 2. 55°C 1. 1500 output pressure MPaIkn/cm*I) 2.2 (30 + 21 Reference] Current (A) 900 + 30 l H/O mode or control lever with travel at Min. 350-6 .8 MPa 160 kg/cm*)) Measure the output pressure under the conditions in Table 1. Measuring valve output pressure of LS-EPC solenoid 1) Disconnect 2) 3) output hose (1) of the LS-EPC solenoid valve. Engine speed : 1101 or [401 . Install adapter C3 and nipple C2 in the oil pressure gauge kit. Table 1 ingine speed (rpm) Min. 1900 * The engine speed and LS-EPC current measured using the monitoring code monitor panel. and install oil pressure gauge Cl (5. LS-EPC current : 1151 can be on the 20-122 0 PC300.94 f 0. .TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE TESTING SOLENOID VALVE OUTPUT PRESSURE * Oil temperature when measuring: 45 . Measuring output pressure of ON/OFF solenoid valve I) Disconnect outlet hoses (I). (41. 1//f -’ -----A BWPO2987 PC300. and install oil pressure gauge Cl (5. 350-6 20-123 0 .8 MPa (60 kg/cm21). (2). 2) install adapter C3 and nipple C2.TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE 2. (31. 3) Measure the output pressure under the conditions in Table 2. (5) and (6) of the solenoid valve to be measured. 20.TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE Table 2 Hou 5 6 With monitoring code (231.124 0 PC300. check at the same time that the solenoid is switched ON/OFF electrically. The solenoid valve may be actuated (ON/OFF) under conditions other than the measurement conditions given above.) The measurement conditions in the table are typical conditions for measuring the output pressure. Operate the lever slightly not enough to move the machine. 350-6 . (The machine push-up solenoid is not displayed. 3) 4) Install oil pressure gauge Cl (5. 1) Disconnect hose (1) between the PPC valve and the shuttle valve of the circuit to be measured. Checking PPC shuttle valve It If the output pressure at the control PC300. * If the output pressure becomes normal. * Install a blind plug to the shuttle valve. if there is no change. 2. check for leakage of oil from the PPC shuttle valve as follows. operate the control lever.125 0 . the PPC valve is defective. PPC valve output pressure 1) Disconnect hose (I) of the circuit to be meas2) Install adapter C3 and nipple C2. Run the engine at full throttle.55°C Measuring ured. valve end is low. 2) Install adapter C5 and nipple C2 to the tip of the hose. then install oil pressure gauge Cl (5. there is leakage from the PPC shuttle valve.8 MPa I60 kg/cm*I). 350-6 20. Disconnect the hose from the shuttle valve together with the nipple. operate the control lever of the circuit to be measured.TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUlTLE VALVE MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHlJlTLE VALVE Sr Oil 1. and measure the output pressure. and measure the oil pressure. 3) Run the engine at full throttle.8 MPa (60 kg/cm*)). temperature when measuring: 45 . H. travel REVERSE shuttle valve All travel shuttle valves (L. H. R.TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE Checking defective operation of PPC shuttle valve I) Remove the applicable oil pressure switch. the shuttle valve is defective. * Disconnect the outlet hose of the LS select shuttle valve before installing the oil pressure gauge. work PPC “a Ive eauioment (Bucket DUMP) PPC travel iunctron “*lye shuttle. * If no output pressure is generated all the applicable operations. 2) Run the engine at full throttle. * If output pressure is generated for all the applicable operations. travel FORWARD shuttle valve Pressure arrangement switch diagram Bucket 606) CURL \ Arm IN (SO5) / @ QPL -. FORWARD. R. arm OUT shuttle valve L. the shuttle valve is normal. then install nipple C2 and oil pressure gauge Cl (5.‘Boom 602) I ’ Boom LOWER (SO4) ‘Arm OUT (SO3) Trave / I (SOI) RA ISE TWP01402 R.8 MPa (60 kg/cm2)). all travel) Boom RAISE. TWP01403 ZO-126 0 PC300.H.H. right shuttle valve LS select shuttle valve (boom RAISE.H. R. arm OUT.H.H. operate the applicable lever. travel FORWARD. and measure the output pressure. 350-6 . travel REVERSE. REVERSE) L.. Swing left. see DISASSEMBLY AND ASSEMBLY. 2. Remove the PPC valve assembly. then tighten locknut (2) to the specified torque. Removal of work equipment PPC valve assembly. SWING PPC VALVE ADJUSTING WORK EQUIPMENT.127 0 . be- PC300. 350-6 20. the clearance tween disc (3) and piston (4) becomes 0. Secure disc (3) in position. Then set the safety lock lever to the LOCK position. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. For details.13 kgml 4. 3. m Locknut : 98 . do not move the piston. l-.TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT. adjust as follows. Remove boot (I).--III BLPOO154 5. Ir With the above adjustment. SWING PPC VALVE Ir If there is excessive play in the work equipment or swing lever. Install boot (I).127 Nm {IO . Loosen locknut (21. A 1. -)r When doing this. Lower the work equipment to the ground and stop the engine. then screw in disc (3) until it contacts the 4 heads of piston (4). then measure the deviation when traveling for the next 20 m. * For the travel posture. Travel posture ?I 2. BKW0156 20m p I- Run up for IOm Make a mark Make a mark at the 10m midway point Make a mark 10m midway 20m point Lay out a string \ point 0 /\ Measure distance the amount of a at this point hark Mark BLW0157 20-128 0 PC300. + Set to H/O mode and measure with the engine at full throttle. * Install the hydraulic pressure gauge and measure the pump discharge pressure at the same time. Travel for 10 m. Set the machine in the travel posture. and hold the boom angle at 45”. When traveling on level ground. 350-6 .TESTING AND ADJUSTING TESTING TRAVEL DEVIATION TESTING TRAVEL DEVIATION Sr 1. extend the bucket and arm cylinder rods fully. the control valve is defective. the downward movement becomes slower. If there is no change. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end). and stop the engine. and the above operation is carried out. then stop the engine. . the packing is defective. the pressure at the bottom end also rises in proportion to this. [Reference] If the cause of the hvdraulic drift is in the packing. ii) Operate the boom control lever to RAISE or the bucket control lever to CURL. If the lowering speed increases. the packing is defective. . the downward movement becomes faster for the following reasons. Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift. the oil at the bottom end leaks to the head end. 3) When the pressure is balanced. . ii) Operate the control lever to arm IN. the volume at the head end is smaller than the volume at the bottom end by the volume of the rod. 10 seconds to charge the accumulator again before operating. check as follows to determine if the cause is in the cylinder packing or in the control valve. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. If the lever is then operated according to the procedure given above. . so the oil at the head end flows to the drain circuit and the downward movement becomes faster.TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT Ir If there is any hydraulic drift in the work equipment (cylinders). so the internal pressure at the head end increases because of the oil flowing in from the bottom end. SKW015S I BKFO0159 PC300. 2) Checking arm cylinder i) Operate the arm cylinder to move the arm in fully. the boom lock valve (boom) or the control valve (bucket) is defective. 2) When the internal pressure at the head end increases. If there is no change. the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve). If the lowering speed increases. However. + If the pressure in the accumulator has dropped. 350-6 20-129 0 . 1. run the engine for approx. then stop the engine. Lock the work equipment control levers and release the pressure inside the hydraulic tank. 1) Disconnect pilot hose (I) of the boom lock valve and drain hose (21. EKP00572 3. Checking PPC valve If the hydraulic drift differs when the safety lock lever is in the LOCK or FREE position. and the top of the boom horizontal. then stop the engine. * When disconnect hoses. the boom lock valve is defective. (engine running). * Pilot hose side blind plug: 07376-50315 * Blind plug for drain hose: 07376-50522 * Leave the boom lock valve end open. 20-130 0. and loosen them gradually. Checking boom lock valve ASet the work equipment at the maximum reach. the PPC valve is defective. and install a blind plug in the hose. 350-6 . take care to spout of oil and movement of work equipment.TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT 2. 2) Start the engine. charge the accumulator. the boom control lever to the 3) Operate LOWER position. * If any oil leaks from the port that is left open. PC300. then measure the oil leakage for the next one minute. If the leakage is within the standard value. 350-6 20431 0 . ABe careful not to disconnect the piping at the bottom end. the problem is in the control valve. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at full throttle. the problem is in the cylinder. BLWO161 Posture for measuring arm. bucket cylinder BLPOO162 Arm cylinder BLPO0164 PC300. measure the leakage inside the cylinder as follows. If the leakage is greater than the standard value. . . then block the piping at the chassis end with a blind plug.55°C Work equipment cylinder If the hydraulic drift of the work equipment is outside the standard value. then stop the engine.TESTING AND ADJUSTING MEASURING OIL LEAKAGE MEASURING + 1. and judge if the cause of the hydraulic drift is in the cylinder or in the control valve. OIL LEAKAGE Posture for measuring boom cylinder Oil temperature when measuring: 45 . 1) Fully extend the rod of the cylinder to be measured. + Boom cylinder : RAISE Arm cylinder : IN Bucket cylinder : CURL 4) Continue this condition for 30 seconds. 2) Disconnect piping (I) at the head end. Swing motor 1) Disconnect drain hose (I) from the swing motor. then install a blind plug at the tank end. 350-6 . 4) Continue this condition for 30 seconds.TESTING AND ADJUSTING MEASURING OIL LEAKAGE Bucket cylinder BLPOO165 BLPOO166 2. 20-132 0 PC300. swing 180’ and measure again. 3) Start the engine and operate the swing relief with the engine at full throttle. then measure the oil leakage for the next one minute. Jr After measuring. 2) Turn the swing lock switch ON. then measure the oil leakage for the next one minute. then stop the engine and operate the control levers. the pressure stored in the accumulator is removed. Travel motor 1) 2) Disconnect drain hose (I) from the travel motor. 3. Start the engine and operate the travel relief with the engine at full throttle. Continue this condition for 30 seconds. mistaken operation of the control lever may lead to a serious accident. 3) 4) BLWO170 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT * If the piping between the hydraulic cylinder and the control valve is to be disconnected. Ir When measuring.3 times. 1. A When measuring the oil leakage from the travel motor. * When the levers are operated 2 . Fit block @ under the track shoe grouser. Ir Repeat the above operation 2 . Loosen the oil filler cap slowly to release the pressure inside the tank. then fit a blind plug at the hose end. move the motor slightly (to change the position between the valve plate and cylinder. The travel circuit is an open circuit. PC300. It is enough to remove the oil filler cap.133 0 .3 times to release all the remaining pressure. and measure several times. release the remaining pressure from the circuit as follows. Start the engine. 350-6 20. and piston and cylinder).TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 3. so there is no remaining pressure. or fit block @ between the sprocket and frame to lock the track. so always use signals and check when carrying out this operation. Operate the control levers. 5 minutes. run at low idling for approx. 2. 134 a PC300. When this is done. If it has not returned to the zero point. Read the value on the dial gauge at this point. Set the dial gauge at the front or rear. zo. and set the tip of the bucket to the same height as the bottom of the revolving frame. the upper structure will back. and put the tip of the probe in contact with the inner circle (or outer circle). When carrying out the measurement. the the tilt go 5. so the front will rise and the rear will down. BLP00172 2. then lower the boom until front of the machine comes off the ground. When this is done. Set the dial gauge to the zero point. Extend the work equipment to the maximum reach. and check that the dial gauge has returned to the zero point. 3. Return to the condition in Step 2. BKPOO173 4. BKP00174 6. Fix a magnet-type dial gauge to the outer circle (or inner circle) of the swing circle. so the front will go down and the rear will rise. the upper structure will tilt forward. Set the arm more or less at right angles to ground surface. repeat Steps 3 to 5. The value on the dial gauge is the clearance of the swing circle bearing. 350-6 . do not a put your hand or feet under the undercarriage.TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING TESTING CLEARANCE OF SWING CIRCLE BEARING Method of testing clearance of swing circle bearing when mounted on machine 1. REMOVAL OF TRACK SHOE ASSEMBLY. 350-6 zo. + If the sprocket wave pattern is above the wear limit line. see TESTING AND ADJUSTING. * Align the benchmark line. then align the sprocket wave pattern and wear gauge wave pattern.135 0 . 2.TESTING AND ADJUSTING TESTING WEAR OF SPROCKET TESTING WEAR OF SPROCKET Wear limit line TWP01404 1. Judge the wear of the sprocket. Align wear gauge P with the sprocket. * If the sprocket wave pattern has reached the wear limit line. 3. replace the sprocket with a new part. PC300. * For details. it is possible to use the sprocket as it is. Remove the track shoe assembly. 1. and release the grease. * If the grease cannot be pumped in easily. . BWPO3019 zo. move the machine backwards and forwards slowly. so never loosen plug (I) more than 1 turn. AThere is danger that the plug may fly out under the high internal pressure of the grease.136 0 PC300. 2. * If the grease does not come out easily.TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION TESTING AND ADJUSTING TRACK SHOE TENSION Testing 1. move the machine backwards or forwards slowly. Measurement position STD : 4th track roller from the sprocket. 350-6 . 2. If the track tension is too high: Loosen plug (1) gradually. Raise the track frame and boom. . Midway between the 4th and 5th LC : track roller from the sprocket. adjust as follows. on one side using the arm Measure the clearance a (tension) between the bottom of the track frame and the top of the track shoe. If the track tension is too low: Pump in grease through grease fitting. Standard clearance a (tension) : 331 + 20 mm Adjusting * If the track shoe tension is not within the standard value. 8 . Pour in oil through the elbow mount hole until oil oozes out from plug (1).0 kgm} Precautions when starting the engine After completing the above procedure and starting the engine.8 Nm IO. if the coolant temperature is low and automatic warming-up is carried out.8.L 0 Note: Bleed the air from the swing and travel motors only when the oil inside the has been drained. * 3) 4) 5) 6) Air bleed plug: 7.0 kgm} If no oil oozes out from the air bleed plug: Leave plug (I) loosened and remove drain hose (2) and elbow (3).8 .Clean strainer O + O j+ O -j+ Ofnote. tighten plug(l).1.Replace l Remove travel motor. m * * PC300.Remove cylinder l piping 0 -L 0 > Reoplace swing motor * Remove swing motor piping 0 0 -0 I -0 I motor . w Air bleed plug: 7.8 .8 Nm IO. Fit elbow (3) and install drain hose (2). 2) When oil oozes out. repair control valve 0 -! 0 I I > l Replace cylinder . run the engine at low idling for 10 minutes.) O * Replace return filter element 0 0 + 0 * Replace.1.TESTING AND ADJUSTING BLEEDING AIR BLEEDING AIR Order for operations and procedure for bleeding air Air bleeding procedure 1 Bleedingair Nature l Air bleeding item 2 Start engine 3 Bleedingair from cylinder 4 5 6 Start operations of work oil from pump Bleeding air from Bleeding air from travel motor swing motor Change hydraulic .8 . Tighten air bleed plug (I). 350-6 . and check that oil oozes out from the plug. swivel travel motor.9. Bleeding air from pump 1) Loosen air bleed plug (11. 1. repair pump * Remove suction piping l I -! 0 I I I I I I > I I I I > 0 0 0 0 Replace.T’ I ‘(noter. swivel piping I ) case 0. cancel it by using the fuel control dial after starting the engine. 1 Boom cylinder BLPO0179 3. 2) Inside brake case + Normally. 100 mm before the end of its stroke. and check that oil oozes out from the plug. 4) Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. then raise and lower the boom 4 . * When the cylinder has been replaced.5 times in succession. but if it feels that the brake is dragging when operating the swing. Bleeding air from hydraulic cylinders 1) Start the engine-and run ai idling for approx. w Air bleed plug: 7.8 . 350-6 . When oil oozes out. 5 minutes. run the engine at low idling. Loosen the sleeve nut of brake hose (I). and operate the piston rod to the end of its stroke to relieve the circuit. bleed the air as follows. 3) Run the engine at full throttle and repeat Step 21.TESTING AND ADJUSTING BLEEDING AIR 2. start the engine. Bleeding air from swing motor I) Inside motor case Run the engine at low idling for 5 minutes. * This operation will bleed the air inside the motor case automatically. tighten air bleed plug (II again.8 Nm IO. the air inside the brake case is bled automatically. Ir Operate the piston rod to approx. tighten the sleeve nut. bleed the air before connecting the piston rod.84 . Bleeding air from travel motor 1) Run-the engine at low idling.1. Do not relieve the circuit under any circumstances. After that. 2) When oil oozes out.0 kgm1 4. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder.9. BLPOOl81 20-138 0 PC300. loosen air bleed plug (I). and operate the swing prolix switch ON-OFF repeatedly. 2) Run the engine at low idling. . or air.TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING POINTS TO REMEMBER g WHEN TROUBLESHOOTING Stop the machine in a level place. do not carry out any investigation or measurement that may make the problem worse. carrying out the operation with two or more workers. always release A When the internal pressure first. water.4 to narrow down the causes of failure. 4. When carrying out troubleshooting. When disconnecting wiring. and at the same time. When carrying out troubleshooting. removing the plug or cap from a location which is under pressure from oil. remove the root cause. 1. or oil or grease. 350-6 . Measures to remove root cause of failure . always disconnect the negative (-) terminal of the battery first. blocks. be sure to connect it properly. 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. Parts that have no connection with the failure or other unnecessary parts will be disassembled. 5. 3. Troubleshooting . and judge whether to handle it as a real failure or as a problem with the method of operation. and check that the safety pin. For this reason. To prevent this. so wait for the engine to cool down before starting troubleshooting. . If components are disassembled immediately any failure occurs: . Use the results of the investigation and inspection in Items 2 . Even if the failure is repaired. hot water may spurt out and cause burns. when carrying out troubleshooting. 2. Then. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. to carry out repairs swiftly. so check any item that is considered to be necessary. A When A A A If the radiator cap is removed when the engine is hot. etc. 1) Start from the simple points. do not hurry to disassemble the components. 3) Investigate other related parts or information. and to prevent reoccurrence of the failure. Confirming failure . However. It will become impossible to find the cause of the failure. 4) 5) 20-202 0 PC300. 6. Confirm the extent of the failure yourself. and do not allow any unauthorized person to come near. then use the troubleshooting flowchart to locate the position of the failure exactly. The aim of troubleshooting is to pinpoint the basic cause of the failure. and parking brake are securely fitted. * When operating the machine to reenact the troubleshooting symptoms. and important point is of course to understand the structure and function. It will also cause a waste of manhours. always investigate why the problem occurred. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly. if the root cause of the failure is not repaired. parts. Check the stroke of the control valve spool. keep strictly to the agreed signals. 3) Check the travel of the control levers. will also lose the confidence of the user or operator. Other maintenance items can be checked externally. the same failure will occur again. 2) Start from the most likely points. or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. * The basic procedure for troubleshooting is as follows. it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. When installing measuring equipment. Past history. etc. Condition failure * .TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING ----. . T-adapter Hydraulic pressure gauge and prepare the necessary kit. Ask questions lem. . Check before Other check items select a troubleshooting the symptoms. . Details serial number of jobsite. 2) Look in the parts book and prepare essary replacement parts. / step 2 lDetermining probable location of cause TEP01348 . Operating to gain an outline of failure Work being carried out at the time of the environment details of maintenance. the nec11 Before * 2) starting troubleshooting. etc. of machine of the probetc. 350-6 20-203 0 . 21 Type. See the Troubleshooting manual. . / >tep 3 Preparation 11 of troubleshooting tools tools in Look at the table of troubleshooting the shop manual tools. starting items Section of the shop flowchart out locate and repair simple failures. that matches and carry Drive Shoe manual and operate the machine if there to confirm is really a the condition and judge r L Was there - anything strange about the ma- chine before the failure Did the failure occurred? occur suddenly? Had any repairs been carried out before the TEWOOl9 PC300. For this purpose. so they are likely to suffer deformation or damage. and to prevent failures or other troubles before they occur. connectors used for connecting and disconnecting one wire from another wire. they are frequently removed and installed again. POINTS TO REMEMBER ELECTRIC EQUIPMENT WHEN HANDLING 1) Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component. and protectors or tubes used for protecting the wiring. the plating at the joint will peel and cause improper connection or breakage. it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). but if there is excessive force brought to bear on the wiring. TEW00191 Main failures occurring in wiring harness 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. maintenance and inspection. 350-6 . heat. water.TROUBLESHOOTING 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 repairs must be carried out. For this reason. correct operation. or because one or both of the connectors is deformed or the position is not correctly aligned. ImProPer insertion TEP01352 Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. Furthermore. or because there is corrosion or oxidization of the contact surfaces. it is necessary to be extremely careful when handling wiring harnesses. troubleshooting. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. or vibration. wiring harnesses are more likely to be affected by the direct effects of rain. 1. Improper comDression TEP01353 20-204 0 PC300. Compared with other electrical components fitted in boxes or cases. during inspection and repair operations. TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE @ Disconnections in wiring If the wiring is held and the connectors are pulled apart. but at the same time. As already said. water may enter the connector. so remove the oil and water from the .compressed air completely before cleaning with compressed air. If there is oil or grease stuck to the connector. wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. or the soldering may be damaged. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins. or components are lifted with a crane with the wiring still connected. but if high-pressure water is sprayed directly on the connector. \’ @ High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure). the contacts will become even dirtier. the pins will be shortcircuited by the water. if water should get into the connector. the oil will not let the electricity pass. immediately dry the connector or take other appropriate action before passing electricity through it. if water does enter. so if any water gets in. so there will be defective contact. * If there is oil or water in the compressed air. depending on the direction of the water jet. TEW00194 TEW00195 @ TEW00196 PC300. * When wiping the mating portion of the connector. be careful not to use excessive force or deform the pins. or a heavy object hits the wiring. the crimping of the connector may separate. it is difficult for it to be drained. Therefore. the connector is designed to prevent water from entering. 350-6 20-205 0 . or the wiring may be broken. For connectors which have a lock stopper. so always cover the connector. oil. 0 Press when Iiohtlv removing TEPOl35 TBW00484 I 0 Action to take after removing connectors After removing any connector. hold the connectors and not the wires.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 2) Removing. * If the connector is twisted up and down or to the left or right. cover it with a vinyl bag to prevent any dust. it is particularly easy for improper contact to occur. the housing may break. * Never pull with one hand. For connectors held by a screw. and drying connectors and wiring harnesses Disconnecting connectors Hold the Connectors when disconnecting. press down the stopper with your thumb and pull the connectors apart. loosen the screw fully. 350-6 . then hold the male and female connectors in each hand and pull apart. When disconnecting the connectors. TEP01355 TEW00198 20-206 0 PC300. or water from getting in the connector portion. When removing from clips When removing a connector from a clip. Ir If the machine is left disassembled for a long time. dirt. pull the connector in a parallel direction to the clip. installing. fective contact. If the connector cannot be corrected eas* ily. dirt. then insert it securely. corrosion. 3) Check that there is no damage or breakage to the outside of the connector. de2) Check that there is no deformation. Cliks into position II TEP01356 TEWOOZOO TBW00487 PC300. Align the position of the connector correctly. Fix the connector securely. 350-6 20-207 0 . If the connector clamp has been removed. warm the inside of the wiring with a dryer. * If there is any oil. adjust it to its correct position. but be careful not to make it too hot as this will cause short circuits.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 0 Connecting connectors 0 Check the connector visuallv. water. replace the connector. or the clamp is out of position. In addition. 1) Check that there is no oil. be sure to return it to its original position. * If there is any damage or breakage. If any water has got inside the connector. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots. push in the connector until the stopper clicks into position. wipe it off with a dry cloth. or dirt stuck to the connector. Check also that there are no loose clamps. correct any protrusion of the boot. remove the clamp and adjust the position. or water stuck to the connector pins (mating portion). if the wiring harness is misaligned. For connectors with lock stopper. or damage to the connector pins. do as follows. * After completely drying the connector. TEW00202 Carry out a continuity test on the connector.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE l Drying wiring harness If there is any oil or dirt on the wiring harness. * If the connector is blown dry with compressed air. wipe it off with a dry cloth. 350-6 . If water gets inside the connector. If the connector must be washed in water. T-adapter TEP01357 20-208 0 PC300. @ Disconnect the connector and wipe off the water with a dry cloth. After drying. use a dryer to dry the connector. as this will cause deformation or damage to the connector. Ir 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 related parts too hot. there is the risk that oil in the air may cause defective contact. TEW00196 Dry the inside of the connector with a dryer. If water gets directly on the connector. so remove all oil and water from the compressed air before blowing with air. blow it with contact restorer and reassem ble. leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. do not use high-pressure water or steam directly on the wiring harness. Avoid washing it in water or using steam. or current). Fit an arc welding ground close to the welding point. unnecessary abnormality displays will be generated. water.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3) Handling control box The control box contains a microcomputer and electronic control circuits. Never touch the connector contacts with your hand. 3) Always connect any disconnected connectors before going on to the next step. TEW00205 Do not place the control box on oil. there is probably defective contact in that circuit. continuity. Before carrying out troubleshooting. Cover the control connectors with tape or a vinyl bag. PC300. Ir If the power is turned ON with the connectors still disconnected. 2. (Place it on a suitable dry stand). 350-6 20-209 0 . Points to remember 1) 2) when troubleshooting electric circuits Always turn the power OFF before disconnecting or connect connectors. * Disconnect and connect the related connectors several times to check. check that all the related connectors are properly inserted. Precautions when carrying out arc welding When carrying out arc welding on the body. or soil. even for a short time. so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary. or in any hot place. 4) When carrying out troubleshooting of circuits (measuring the voltage. move the related wiring and connectors several times and check that there is no change in the reading of the tester. TEW00204 Do not place objects on top of the control box. These control all of the electronic circuits on the machine. disconnect all wiring harness connectors connected to the control box. resistance. * If there is any change. During rainy weather. do not leave the control box in a place where it is exposed to rain. so this is an even more effective method. it is necessary to be particularly careful. If an oil cleaning device is used. or or 21 Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field. 350-6 . replacing filters. places where there is a lot of dust. 3) Sealing openings After any piping or equipment is removed. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop. there is danger of dust entering the equipment. 11 Be careful of the operating environment. If the opening is left open or is blocked with a rag. repairing the machine in rain or high winds. the most common cause of failure is dirt (foreign material) in the hydraulic circuit. so it is desirable to use unit exchange. Avoid adding hydraulic oil. or vinyl bags to prevent any dirt or dust from entering. or take it back with you for disposal. or when disassembling or assembling hydraulic equipment. and also use clean pumps and oil containers. tapes. TEW00208 41 Do not let any dirt or dust get in during refilling operations.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3. Do not simply drain oil out on to the ground. and the performance should be confirmed with special test equipment. Always keep the oil filler and the area around it clean. it is possible to filter out the dirt that has collected during storage. When adding hydraulic oil. It is also difficult to confirm the performance after repairs. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. the openings should be sealed with caps. POINTS TO REMEMBER HYDRAULIC EQUIPMENT WHEN HANDLING With the increase in pressure and precision of hydraulic equipment. there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. TEW00209 20-210 0 PC300. collect it and ask the customer to dispose of it. control valve. and old oil from the hydraulic circuit. sludge.) or when running the machine. also drain the oil from the filter and from the drain plug in the circuit. use flushing oil to remove the contaminants. flushing is carried out twice: primary flushing is carried out with flushing oil. Normally. so it is best to change the oil when it is still warm.TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 5) Change hydraulic oil when the temperature is high. Flushing operations After disassembling and assembling the equipment.) If any old oil is left. and secondary flushing is carried out with the specified hydraulic oil. In addition. When changing the oil. etc. (Do not drain the oil from the hydraulic tank. carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. When hydraulic oil or other oil is warm. 350-6 20-211 0 . or changing the oil. The oil cleaning equipment is used to remove the ultrafine (about 3~) particles that the filter built into the hydraulic equipment cannot remove. the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. it flows easily. 61 Flushino oil TEP01358 7) Cleaning operations After repairing the hydraulic equipment (pump. I TEW00211 PC300. as much as possible of the old hydraulic oil must be drained out. so it is an extremely effective device. the sludge can also be drained out easily from the circuit together with the oil. 9. Check for looseness. Add oil Clean. Add oil Add oil Add water Clean or replace Replace Tighten Tighten Tighten Repair Repair Bleed air Replace Add or replace Replace Repair Disconnect connector running at l/2 throttle or above) 4fter running for several minutes: 27. 2. 2. 5. type of oil level Check dust indicator Check hydraulic filter Check for looseness.5 . Check for missing Check for water to water leaking burnt. Check for abnormal Check for oil leakage Carry out air bleeding Check battery Check battery voltage - of alternator of starting terminal. Check alternator fuses (engine 8. 3. on wiring wiring wiring careful attention - wiring hanging leaking (be particularly on connectors corroded voltage or terminals) 6. 2. Check operating sound of battery (when switch is turned ON/OFF) Replace 20-212 a PC300. 1. 8.3ov - electrolyte Check for discolored. Check for looseness. motor terminal. 2. 3.5V Replace Replace and dry or replace or replace or replace drain drain oil level strainer machinery oil level (oil pan oil level). type of fuel Check for impurities Check hydraulic Check hydraulic Check swing Check engine Check coolant in fuel $Jtyment oil level for clogging corrosion corrosion corrosion of battery terminal.TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING Item 1. 5. wiring wiring wiring Action Add fuel Clean. 7. 4. exposed clamps. 350-6 . 7. smell (engine level stopped) 20 . 6. 1. Check fuel level. noise. 1. Check for blown. 4. 3.29. 3. . 350-6 . 20-214 0 PC300.TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS CONNECTOR Ir TYPES AND MOUNTING LOCATIONS in the connector arrangement drawing The Address column in the table above shows the address (2-dimensional drawing). TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS Add. 7:: z:i B-8 l-8 J-6 L-9 P-8 N-9 . with power window) Intermediate Wiper motor connector 1 wo3 )2Lorl W04 W05 W06 W07 W08 wo9 WI0 WI2 X01 X05 X07 M KESI 070 KESI 070 070 M MIC M MIC 6 2 14 2 18 14 4 3 21 4 17 K-6 h:i N-l O-l N-l - Power window motor (with power windowi Intermediate connector (with power window) Front limit switch (with power window) Wiper motor controller Wiper motor controller (with power window) Intermediate connector (with power window) Power window switch connector Intermediate Swing c-2 o-5 M-4 P-3 lock switch connector Intermediate I I I I I I I I PC300. Mounting SW1 vo2 vo3 vo4 vo5 V06 vo7 WOI W02 x x x x X x KESl KESI 20 2 2 2 2 2 2 4 4 Air conditioner LS select location control panel ress P-2 A-5 U-R solenoid valve Pump merge/divider solenoid valve Swing holding brake solenoid valve Machine push-up solenoid valve Travel speed selector solenoid Active (swing) solenoid valve 7:. with power window) Left front lock (option. K-2 Right front lock (option. 350-6 20-215 0 . 350-6 .TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM CONNECTOR ARRANGEMENT * For details of this page. see Section 90. DIAGRAM PO8 SO4 SO7 SO8 ' Ml2 \ M28 Cb3 BWPO3002 t 20-216 0 PC300. TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM + . 350-6 .” so4 SO6 so3 ___ Fl 1 _. \ PC300. . 350-6 .TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM M22 X iO6 M38 PO3 / x0 I M20 x05 \ PO4 PO2 \ w M46 \ \ \ co5 -w10 ROS -- R04 BWPO3030 20-218 0 PC300. 350-6 20-2 19 0 . while refer to the mating portion of the housing. No. of pins T Male (female housing) X type connector Female (male housing) 2 I ‘2 1 3 3 1 2 TEW00223 2 TEW00224 1 3 TEW00225 TEWOO226 PC300.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION * TABLE FOR CONNECTOR the terms PIN NUMBERS male housing and female housing The terms male and female refer to the pins. z= 14 -I 3 7 8 11 11 8 4 1 10 i4 TEW00239 14’16 TEW00240 1 5 4 5 9 8 2 16 9 20-220 0 PC300. of pins T Male (female housing) SWP type connector Female (male housing) 6 TEWOO235 BLmOO33 8 4 8 TEW00237 Ei b TEW00238 1 5 9 4 8 12 BLF0JO35 12 1 4 . 350-6 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. 350-6 20-221 0 . 2 3 1 TEW00243 x TEW00244 ‘1 3 1 4 DS 2’ ‘4 TEW00245 4 4 2 TEW00246 1 6 \ 3’ ‘6 TEW00247 6’ 3 TEWO0248 8 -5 Bl_P00040 PC300.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins T Male (female housing) M type connector Female (male housing) 2 1 BLPOoO38 i 3 I. TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins r Male (female housing) S type connector Female (male housing) 8 / 4 \ 8 TEW00249 1 6 10 6 io 1 TEW00251 Id 5 BLPOOO42 6 6 1 12 5 12 BLPooO43 TEW00254 8 8 I 16 4=E0 7 16 ELF00044 16 7 TEW00256 20-222 0 PC300. 350-6 . _/ BLPOOO51 BLPOO052 1 11 12 21 21 I J TEW00259 TEW00260 PC300. 350-6 20-223 0 . of pins -lMale (female housing) MIC connector Female (male housing) 5 BLPQOO45 BLPOoO46 9 BLPOCQ47 BLPOOO46 8 13 13 t BLPOOO49 BLPoOO50 9 17 17 L-___.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. BLPOCk355 7 i BLFOOO56 8 16 16 8 16 1 10 9 BLPoOO57 20 20 BLWOO5B 1 ii i TEW00234 20-224 0 PC300. 350-6 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins T Male (female housing) AMP040 type connector l- Female (male housing) n 8 8 4 I I I BLPOO053 BLW0054 12 6 12 I I . TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. 350-6 20-225 0 . of pins Male (female housing) 1 AMP070 type connector Female (male housing) 7 8 6 BLP03059 4 14 9 1 '6 BK=UCGC 12 BLW0062 PC300. of pins T Male (female housing) L type type connector Female (male housing) 2 El q q TEW00257 1 2 EliI 20-226 0 PC300. 350-6 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. 350-6 20-227 0 . of pins Automobile Male (female housing) connector Female (male housing) 2 B BLPmO63 BLPOfmi4 3 3 2 BVLO1140 BVL01141 BVLOl142 BVLO1143 4 8 BLPiXO72 PC300.TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. 350-6 .TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS No. of pins T Male (female housing) Relay connector Female (male housing) 5 1 3 6 5 6 3 BLFWO73 BLPC0074 6 5 6 I M I J BLFQOO75 BLFO0076 20-228 0 PC300. Fuel dial signal m TWPOl405 PC300. r--1 /3' -___i ra Fuel level sensor level sisnal Governor motor Power source drive Hydraulic oil sensor signal . The monitor panel and the governor and pump controller input the signals that are necessary.1 L___ra -___i Air cleaner clogging sensor signal Coolant signal Coolant sensor level sensor Battery c relay drive 0 temperature signal Governor signal potention.TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM EXPLANATION SYSTEM OF CONTROL MECHANISM FOR ELECTRICAL 1. R control IIMN oil Each solenoid Work equipment Pressure switch Boom Ra i se/Lower Arm Bucket In/Out CurI/DumP Travel oil Pressure F DUMP Pressure sensor irt. and together with the signals selected by the monitor panel. Explanation of machine control functions The control mechanism for the electrical system consists of the monitor panel and governor and pump controller.y I Engine sensor Ensine sensor oil level sensor Engine throttle controller R Pump Pressure sensor oil pressure signal oil PressureIHii sIanal (Lo) c Air cleaner closaina sensor r-X. the governor and pump controller outputs or inputs the necessary signals and control the pump absorption torque and engine output.t. 350-6 20-229 0 . TVC output source power F. Actual display (Example: Disconnection in the cancel solenoid system for the swing holding brake) l OFF OFF 5-----+~~~V OFF OFF User code OFF OFF OFF BKF90077 20-230 0 PC300. 3 seconds. it displays the user code on the time display panel to advise the operator of the action to take. 2) Types of user code and system E02 E03 E05 * (TVC system) (Swing holding brake system) (Governor motor system) For details of the service codes included in the user code. depending on the nature of the abnormality. 2. AND SPECIAL FUNCTIONS OF MONITOR Display on machine monitor When the starting switch is turned on. all the monitor and gauge lamps light up for approx. However. When the monitor panel receives this data. the time displayed panel is automatically switched to advise the operator to take the necessary action. During this time. 350-6 . it returns to the normal display. the monitor itself carries out self diagnosis. see the action taken by the controller when an abnormality occurs. and after it has finished. and no display is given. 3) Displaying user code If it becomes necessary to display the user code. in cases of abnormalities which are not urgent and do not require the user code to be displayed. it records the abnormality data. only the content of the abnormality is recorded. 1 second. and the buzzer sounds for approx.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL DISPLAY METHOD PANEL 1. Recording of service codes and user code display function 1) All the abnormality data for the governor and pump controller is sent to the monitor panel. and at the same time. the symptoms on the machine or the judgement table. and service codes which are not included. Example of display : When E212 has occurred 12 hours before (service meter) 2) Display of elapsed time 1) Display of service code OFF OFF Operation 1. This data can be displayed on the time display as follows. see ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGEMENT TABLE Time di splay . Keep the TIME switch + L. Note: It is possible to call it up at the following times.H. 1) In the normal mode 2) In the user code display mode 3) In the machine data monitoring mode 4) In the time adjustment mode WW-VV-V OFF OFF Service code OFF OFF 2. travel speed switch pressed for 2. BKPOOOEO PC300. press the time switch + L. press the time switch + R. 3. Elapsed ON time data BKP00079 3) If any abnormality displayed. On the time display and service meter display. For details of the service codes that are not included in the user code. . To go to the next service code display. the service code and number of hours (service meter hours) that have elapsed since the occurrence of the abnormality are displayed.H. woking mode switch. To go back to the previous service code display.5 seconds. exists at this time. To set to the trouble data display mode. and E is displayed. self diagnosis.H. the E mark is If there is an abnormality. woking mode switch. 350-6 20-231 0 .Servi ce meter Time SW Workinc I mode switch Travel switch speed Monitor Panel front Monitor Panel rear TWP01406 i) Method of displaying trouble data Display 1.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 4) * Display of trouble data The monitor panel records both service codes which are included in the user code. the output or the controller is carrying out is shut off. To finish with the trouble data display mode. . and keep the time switch pressed for 5 seconds. toring mode. Example of display 1) When engine speed is monitored (monitoring code IO) OFF 0.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Operation 4. 350-6 .H.FF 1. keep the TIME switch + L. 1) During the normal mode 2) During the user code display mode 3) During the time adjustment mode 4) During the trouble data display mode v-w OFF OFF Monitoring code vv-wv OFF OFF (example Monitoring code data OFF OFF of 1950 rpm) BKP00083 20-232 0 PC300. To erase the memory. Machine data monitoring function The input signals from the sensors and the output the time display and service meter display. keep the time switch pressed. travel speed switch pressed for 2. Note: This is possible at the following times.vice meter Time swi Working switch mode Knob b utton funct i on switch .5 seconds.5 seconds. Display 4) If there is no abnormality OFF code in memory OFF 5. Monitor Panel front Monitor Panel rear TWP01407 1) Method of displaying Operation monitoring code Display On the time display and service meter display. do as follows. Keep the time switch + knob button function switch pressed for 2. To set to the machine data moni. turn the starting switch from OFF to ON. the monitoring code and data are displayed. signals to drive the solenoid are displayed on Time di SPlaY .1 1. W-V-V OFF is displayed OFF is displayed OFF BKP00081 3. Table of machine data monitoring codes Ir For details of the B in the Unit column. Governor. pump pump pump pump pump pump controller controller controller controller controller controller actuation Input condition 1 of sensor for governor. pump controller Governor. pump controller Governor. Fuel control Potentiometer dial input voltage value PC300.H. 36. OFF OFF Displays monitoring code OFF Displays bit pattern OFF OFF BKW0084 . To go back to the previous monitoring code display. pump controller IOmA IOmA 10mA 10mA switch input signal (I) Governor.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Operation 2. 47 49. Governor. press the time switch + L. Item see the bit pattern chart in the next section. pump controller MPa{kg/cm2} Governor. 2) Display When displaying bit pattern . 4A. pump controller Governor.H. and the display lights up to display bit patterns (I) .(6). press the time switch + R. Dump controller Governor. pump controller model code S-NET component condition display Engine speed Pump discharge pressure (F) input Pump discharge pressure (R) input TVC current (F) output TVC current (R) output LS-EPC current output 10 11 12 13 14 15 MPa{kg/cm2} Governor. pump controller PPC oil pressure Governor. pump controller Governor. For monitoring codes 08. 2) No. keep the time switch + knob button function switch pressed for 2.24. is displayed in the monitoring code portion. Example of monitoring code 20 OFF -Displays OFF 3. 350-6 20-233 0 . working mode switch. pump controller model code Governor. 37. The code No. . pump controller Governor. To go to the next monitoring code display. Governor. Governor. pump controller 16 20 21 22 23 24 25 30 31 No. Name of component Monitor panel Governor. Governor. 4. pump controller monitor warning pump controller monitor warning Input condition 2 of sensor for governor. 2 throttle command Governor. To finish with the machine data monitoring code mode. pump controller Governor. Governor. working mode switch. 20 . oump controller Governor.5 seconds. pump pump pump controller controller controller B B B B B B IOmV IOmV PPC oil pressure switch input signal (2) PPC oil pressure solenoid switch input signal (3) Governor. pump controller Unit B IOrpm 01 02 03 08 Monitor model code Governor. display the bit pattern. Governor. Governor. Monitor Monitor Monitor Monitor Monitor Engine speed Coolant temperature sensor voltage IOmV IOmV IOOmV Fuel sensor input voltage Battery charge input voltage Monitor Monitor Monitor Monitor Monitor panel output condition panel input condition panel input condition panel input condition panel input condition 1 2 3 4 I 1 B B B B B 20-234 0 PC300. Governor. Governor. Governor. pump controller pump controller pump controller pump controller pump controller pump controller pump controller pump controller pump controller pump controller panel panel panel panel panel VBB voltage Governor Governor (batten/ voltage) motor A phase current motor B phase current IOmV IOmV 100mV B B IOrpm Battery relay output voltage governor governor input condition output condition 36 1Governor 37 40 41 42 43 47 48 49 4A 4C Governor 1Governor. Governor. Unit 1OOmV Name of component Governor. Governor. Item see the bit pattern chart in the next section. Governor. 350-6 . Governor.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Ir No. 32 33 34 35 For details of the B in the Unit column. pump controller 08 Connection of S-NET components !Swing switch ON fravel switch ON 20 Input condition pump controller of governor. CODE. model selection (2) (3) (4) (5) (6) (1) (2) and other switches !Solenoid ON: Active mode (boom).TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL 3) Bit pattern chart As shown in the diagram below.) OFF the time display has bit numbers which light up to show that (For details. OFF: Standard mode !Swing holding brake ON f‘ump merge/divider solenoid I4ctve mode (swing) rravel speed selector solenoid solenoid ON ON ON 23 Drive condition controller of governor. solenoid pump valves (3) (4) (5) (6) ON/OFF PC300. PPC switches and (2) (3) (4) (5) (6) (I) Service switch ON I Model selection 5 . PPC switches (3) (4) (5) (6) (1) E 3oom LOWER switch ON E 3oom RAISE switch ON I Qrn IN switch I Irm ON ON OUT switch E 3ucket CURL switch ON E 3ucket DUMP Swing switch ON lock switch ON input condition 21 pump controller other switches of governor. the signal is being transmitted.Swing prolix switch ON IModel selection IModel selection IModel selection IModel selection I<erosene mode I<nob switch ON 1 GND connected 2 GND connected 3 GND connected 4 GND connected input GND connected Input condition 22 pump controller of governor. see METHOD OF DISPLAYING MONITORING OFF OFF OFF Code portion OFF OFF OFF BKP00085 Code Content Bit (1) (2) (3) (4) (5) (6) (1) (2) Details ISovernor. 350-6 20-235 0 .pump (condition controller when lighted up) connected connected (ID=2) (ID=31 ISovernor. TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Code Content Bit (1) Above Above Details engine engine water (condition when sensor lighted up) oil pressure oil pressure Lo set pressure Input condition 1 of sensor for monitor (2) (3) (4) (5) (6) (1) sensor Hi set pressure 24 Radiator Hydraulic level sensor abnormal governor. pump (3) (4) (5) (6) (1) (2) Battery relay: Actuated Starting switch ON 37 Output condition of governor. 350-6 . warning pump controller 36 Input condition controller of governor. warning pump controller Engine oil level sensor abnormal oil level sensor abnormal clogging sensor abnormal Air cleaner Input condition 2 of sensor for monitor (2) (3) (4) (5) (6) (1) (2) Auto greasing control abnormal 25 governor. (3) (4) (5) (6) (1) (2) Alarm Wiper Wiper Window buzzer: when motor motor operated machine operated operated operated machine machine machine (3) (4) (5) (6) (I) (2) (3) (4) (5) (6) (1) (2) (3) Wiper Wiper Wiper (ON) (INT) (washer) limit switch (P) OFF OFF OFF OPEN OPEN OPEN OFF Voltage OFF switch OFF Sometimes output turns ON OFF Hi drive (RI: when drive IL): when drive: when pump controller 47 Monitor panel output condition 1 washer 48 Monitor panel input condition 1 Window Limit switch Limit switch (W) KEY ON SW Terminal Preheating START C Monitor BR LIGHT SW 49 Monitor panel input condition 2 (4) (5) (6) panel LED lighting 20-236 a PC300. OFF W-W-V OFF Displays “g-SET’ OFF OFF OFF BKP00086 2. working mode to advance the hour. To set to the time adjustment mode. switch flashes 0. Governor motor adjustment mode This is used when adjusting the linkage between the governor details of the procedure. The time mark portion OFF I 1. To set to the governor motor adjustment mode.H. keep the time switch depressed for 2. OFF 1 1. travel speed switch + R. Use the R. To return to the time display mode use the same procedure as in Step 1.FF 2. Use the L. (For Display 1. Operation Display 1.H. working mode switch. Flashes 3. Buzzer sounds once a second 5. --KG+ (24-hour clock) -i&shows w-v ON Normal display ON BKP00087 4. Time adjustment mode To adjust the time. working mode switch to advance the minute. press the time switch + R.H.TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL Code Content Bit (I) (2) (3) (4) (5) (6) (1) (2) Time Details switch (condition when lighted OFF up) PPC oil pressure Overload STD/DLX Swing Buzzer selector selection lock switch cancel selector switch switch OFF OFF STD OFF OFF 4A Monitor panel input condition 3 switch Wiper motor normalrotationrelay output:when specified voltage is abnormal Wiper motor reverse rotation relay output: when specified voltage is abnormal Window washer motor drive output 4c Monitor panel input condition 4 (3) (4) (5) (6) 4. 350-6 20-237 a . To return to the time display mode use the same procedure as in Step 1. The example 12:34. do as follows. 2.) Operation motor and the injection pump.5 seconds. see TESTING AND ADJUSTING.H. the situation when setting to PC300. . .... go to the point where the failure mode matches the troubleshooting code on the right of the judgement table (E-90 or %X0.. S40. Go to troubleshooting mechanical system Starting motor does not rotate. ... 1) 2) If a service code is being displayed on the monitor panel .. If a problem has appeared but no service code is displayed on the monitor panel..) . (A 0 mark is put at the places where the failure mode and service code match. When using judgemen? table for governor. Procedure: Check if the service code is being displayed on the monitor panel... The symptoms are then used to decide which troubleshooting table (E40. . Go to troubleshooting electrical system S-2 of l Check that starting motor rotates E-8 of PC300.). go to the troubleshooting code at the bottom of the judgement table (E-00).... (See troubleshooting of the machine monitor system) 1. F40.. If a service code is displayed on the monitor panel.go to troubleshooting [E3:001 for the governor. The judgement table is designed so that it is easy to determine from the user code and service code which troubleshooting table to go to. <Example> Failure mode “Engine does not start” . N-OO. If no service code is displayed on the monitor panel. 350-6 20-239 0 ... C40.... MOO) matches the symptoms. * The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the machine monitor (M4C..TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE METHOD OF USING JUDGEMENT TABLE This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system.. H40. pump controller (governor control system).. and the engine does not start: Starting motor rotates . pump controller (governor control system) and engine related parts . If the input signal is not displayed on the monitor panel.TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE 2.. If it is displayed normally. Go to troubleshooting F-00 of governor. and check the display for the input signal (the display at the place with a 0 mark). When using judgement table for governor.. If a service code is displayed on the monitor panel. There is no signal . pump controller (pump control system). Check governor. go to troubleshooting [E2:001 for the governor. (A 0 mark is put at the places where the failure mode and service code match. pump controller input signal (Check in monitoring mode) i There is a signal. . go to the point where the failure mode matches the input signal. pump controller input signal system (F mode for applicable system) 20-240 0 PC300.. If no service code is displayed on the monitor panel.) . Procedure: Check if the service code is being displayed on the monitor panel. <Example> Failure mode “Upper structure does not swing”. go to the troubleshooting code at the bottom of the judgement table (F-00). [JIJdgementl 1) 2) If a service code is being displayed on the monitor panel... go to the troubleshooting code at the bottom of the judgement table (&IO). If a problem has appeared but no service code is displayed on the monitor panel. Go to troubleshooting mechanical system H-25 of . pump controller (governor control system) and hydraulic related parts . ... and the upper structure does not swing: . 350-6 .. go to the troubleshooting code on the right of the judgement table (H-OO). component. if the judgement value is not correct. prepare the necessary troubleshooting tools. If this preparatory work is neglected. Check or measure the item inside v. tools 5) Troubleshooting When carrying out the troubleshooting. Category OF USING TROUBLESHOOTING of troubleshooting code number Component Troubleshooting of communication abnormality system CHARTS Troubleshooting Code No. The precautions marked * are not given in the I. and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES. (Note: The number written at the top right corner of the I is an index number. Below the I is given the preparatory work needed for inspection and measurement. Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. and start the work in order from Item I). 4) General precautions When carrying out troubleshooting for the failure mode (problem). of hydraulic. Below the / there are the methods for inspection or measurement. PC300. N-00 E-00 s-00 c-00 F-00 H-00 M-00 Service code E218 group E3-00 group group Troubleshooting of electrical system for governor. Check the cause and take the action given in the Remedy column on the right. 350-6 20-241 0 . and failure mode (problem with the machine). the method of troubleshooting may differ according to the model. before starting inspection or measurement. pump controller (pump control system) I_ ~~~ 1Troubleshooting Troubleshooting Troubleshooting of governor. (See Example (I)) 2) Distinguishing conditions Even with the same failure mode (problem). (See Example (2)) If the troubleshooting table is not divided into sections. Method of using troubleshooting table for each troubleshooting mode code number and problem 1) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code. it does not indicate the order to follow. see TOOLS FOR TESTING. chart 3) Method of following troubleshooting YES . there is danger that it may cause mistaken judgement. of machine pump controller mechanical monitor (input signal system) I El-00 group system 2. . For details. and the judgement values. (See Example (3)) . service code. In such cases. or the method of operation or handling is mistaken.) . follow the NO line.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS METHOD 1. and according to the answer follow either the YES line or the NO line to go to the next I. precautions that apply to all items are given at the top of the page and marked with * (See Example (4)) . always read the instructions carefully. follow the YES line. Therefore. a). the failure mode (problem) is further divided into sections marked with small letters (for example. ADJUSTING. pump controller (governor control system) Troubleshooting of engine related parts E2-00 1Troubleshooting of electrical system for governor. so go to the appropriate section to carry out troubleshooting. AND TROUBLESHOOTING. or the answer to the question is NO. but must always be followed when carrying out the check inside the I. start troubleshooting from the first check item in the failure mode. or the equipment may be damaged. or problem. Turn starting switch ON. check that all the related connectors are properly inserted.\ ___I l-l I NO .PO8 (female) (1) Defective contact. check item for previous troubleshooting flashes (4) * * * Before carrying out troubleshooting. <Example> (I) M-9 When starting switch is turned ON (engine stopped). Check that the coolant is at the specified level before carrying out troubleshooting (coolant (engine SAP00523 (2) a) 0 SAP00519 level) flashes Divided oil level) flashes into sections a) and b) (3) Cause Remedy Defective coolant level sensor system (see M-26: - out when short connected to PO8 * Disconnect P08. _ . NO * Disconnect C16. * Turn starting switch OFF. or disconnection in wiring harness between Cl6 (female) (8) . p$zKz-[ 24 lighted up? (female ) (8) and chassis as shown 4 YES Defective governor.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS 6) Installation position. pin number A diagram or chart is given for the connector type. or disconnection in wiring harness between PO8 (female) (2) -chassis ground Replace Repair or replace Repair or replace Table 1 20-242 0 PC300.. Defective monitor panel Defective contact. When carrying out troubleshooting. .. pump controller Replace IL 1 PO8 I. installation position.Set to monitoring :ode 24. * Connect H disconnect short connector to PO8 (female). . Always connect any disconnected connectors before going on the next step. P08. see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem). 350-6 . 9 Disconnect P08. and connector pin number connection. Turn starting NO switch ON. Turn starting switch OFF. it is necessary to go to the correct troubleshooting chart in accordance with the judgement table for that type of failure (governor. When carrying out troubleshooting. and check the following items before starting. 30. ask the operator as much as possible about the condition of the machine. JUDGEMENT TABLE.31.03. .Pump lo-24 .08. 3 and 4 in the flow chart below is given on the YI E E0. * Governor controller: 33.) Carry out troubleshooting for engine (S mode) Carrywt troubleshooting for engine electrical system (E mode). controller: * Check connection condition of S-NET in monitoring codes O&03.03) (2) Blown fuses (3) Battery voltage (monitoring mode 32) (4) Electricity generation (charge input) voltage (monitoring code 43) The procedure for carrying following pages. pump controller (governor control system ) (E mode) Carry out troubleshooting in applicable mode (Note: For E218. IO * For details. * Is all work equipment slow and does engine speed drop under heavy load? IO Carry out troubleshooting for hydraulic (mechanical) system (H mode) NC I Are monitor codes 02. pump controller (pump control system). 08 normal? Carry out troubleshooting for input signal system (F mode). refer to this flow chart. Are governor. out check items No. pump controller (governor control system) (pump control system) in the PC300. judge from system engine weed. For details of the troubleshooting and troubleshooting procedure. YI 3 * Check using monitoring code. carry out troubleshooting of the communication abnormality system (N mode). pump controller (governor control system) and governor. (Use flow chart for items where there is no display)lEll . 350-6 20243 0 .TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE DETAILS OF TROUBLESHOOTING PROCEDURE AND TROUBLESHOOTING If any abnormality should occur. Valve controller: 50-69 Carry out troubleshooting for communication abnormality system (N comde). see governor. (I) Condition of controller connection (check with monitoring codes 02 .E15) Is service code I YE 4 * Operate and check service code. pump controller (pump control system ) (C mode) E3a group: Troubleshooting for governor.34 * After adjusting 1Hydraulic (mechanical) oil pressure.2 (TVC system) Go to Item 2 E03 (Swing holding brake system) E05 (Governor motor system) 1 Yf r E200 group: Troubleshooting for governor. Approx. even if there is no abnormality display. possible) Lo - Governor H/O mode FULL ON (deceleration - control Working mode Throttle signal Auto-deceleration Coolant temperature Active mode Power max. Connection condition of components 1) Set to the monitoring mode and display monitoring code 08. For details of operating the monitoring mode. so be careful when carrying out troubleshooting. However. 2 throttle signal (monitoring code 16) at the same time) 1) Set to the monitoring mode and display monitoring code 10. Working H/O 2220cduring operation> 2050 <idling> 2050 <during 1900 <idling> operation> (1950) (1850) I I G/O I I F/O L/O Active Approx. 2) Switch the working mode as shown in Table 1 and check that the engine speed changes. pump controller (governor control system) (2) will light up. Approx. Checking working mode signal {check No. Table 1 mode High idling speed (rpm) [The figures in ( ) are the rated speed1 Approx. I 2. 1. 350-6 . mode Travel speed Automatic warming mode) signal up ON (automatic warming-up mode) l. Approx. if the operation is defective. 2) The time display (bits) will light up to display the components that are connected. Default Mode when pump controller Set mode 1 2 3 4 5 6 7 8 I- communications cannot be carried out for the monitor and governor. Pump control G/O mode FULL ON (deceleration mode OFF OFF ON (power max. * Governor. Approx. Approx. 1900 (1700) 1700 (1500) operation> (2050) 2300 <during 2050 <idling> 20-244 a PC300.TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE If there is no abnormality display in the communications system transmitted in S-NET. Procedure for checking monitor panel output signal j. use the following procedure when checking directly. the system is automatically switched to the following default mode. see MONITOR PANEL DISPLAY AND SPECIAL FUNCTIONS. If any abnormality occurs in the S-NET system. it can be taken that the output signal from the monitor panel has been transmitted. pump controller (pump control system) (I) and governor. Approx. the flow from the front * and rear pumps will remain divided. and display monitoring * Code 11 is for the front pump and code 12 is for ii) Refer to Table 2 and measure the hydraulic pressure Table 2 Pump merge/flow logic and pumps actuated codes 20 and 21.6 MPa (200 kg/cm2}.34 MPa I220 . operate the travel lever slightly or connect a short connector (X-2P) to the travel oil pressure switch connector (CN-SOI). (I) When measuring the oil pressure for any circuit other than travel. Checking travel speed selection signal mode and display monitoring code 23. mode and display monitoring code 23. the bit pattern lights up.TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 3. see MONITOR FUNCTIONS.330 kg/cm*} Checking swing priority mode signal If the travel oil pressure switch signal is not input to the controller. pump controller Ir Check the input signals for each controller as follows. measure the speed when this is codes 11 and 12. 3) Check pump discharge pressure sensor i) Set to the monitoring mode. Checking input signal 1) Check hydraulic switch i) Set to the monitoring mode.32. the rear pump. and display monitoring ii) Use the fuel control dial to change the speed. by control levers % Conditions for compound operation with travel. and display monitoring ii) Operate each work equipment lever. Ir Check the operating condition of the pump merge/divider solenoid valve 2. 350-6 20-245 0 . PANEL DISPLAY AND SPECIAL code 10. 4. and done. . Checking input signal of governor. (2) The circuits merge when the pressure of the front pump or rear pump is more than 19. Pump control system 1. 2) Check speed sensor (check engine speed) i) Set to the monitoring mode.56 . and check how * For details of the bit pattern chart. PC300. I) Set to the monitoring 2) Change the speed selector switch to Hi or Mi and run the engine at 1500 rpm or above. at the front or rear pump. Check that bit (6) lights up when traveling at Hi or Mi (front or rear pump oil pressure: 21. 1) Set to the monitoring 2) Check that bit (4) lights up when the travel is operated (even when operated slightly). and display monitoring code 22. ii) Refer to Table 3 and check that the applicable bit lights up. any lever operated (other than travel): 0 A 2) No. i) Set to the monitoring mode. and display monitoring code 15. Check knob switch input signal . Code 13 is for the front pump and code 14 is for the rear pump. 2 throttle signal i) Set to the monitoring mode. l Check TVC solenoid output current i) Set to the monitoring mode. . and display monitoring codes 13 and 14. 3) Checking ON ++ OFF solenoid condition i) Set to the monitoring mode. and display monitoring code 16. and measure the current. measure the current when the fuel control dial is turned to the MAX position. Table 3 Types of solenoid Name of solenoid (boom) brake Swing and conditions Actuation Active for actuation Bit that lights up (2) (3) (4) (6) (5) condition Active Swing Pump Travel mode switch OFF lever operated holding or work equipment Travel operated merge/divider speed selector (swing) independently switch Hi or Mi Travel speed selector Active * 4) Operate Active mode switch raise lever operated not enough ON + swing + boom simultaneously the lever slightly to move the machine. 350-6 .TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE 4) 5) Check kerosene mode input signal i) Set to the monitoring mode. Current with starting switch ON (G/O mode) and fuel control dial at MAX : 520 f 80 (mA) l Governor control system 20-246 0 PC300. ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode. 2. ii) With the starting switch kept at the ON position (G/O mode). ii) Connect the CN-M36 connector and check that bit (5) lights up. Check output signals 1) Check LS-EPC solenoid output current i) Set to the monitoring mode. and display monitoring code 22. ii) Turn the knob switch ON and check that bit (6) lights up. and display monitoring code 23. and measure the engine speed. * All levers at neutral: 900 + 80 mA Engine at high idling. ii) Use the procedure in Item 2 for checking the monitor panel output signal. or iii) Set to the monitoring mode. and display monitoring code 37.25 . and display monitoring codes 33 and 34. and display monitoring code 35. * Voltage: 0. iv) Check that bit (I) lights up when the starting switch is turned from ON to OFF. and display monitoring code 30. ii) Measure the battery relay drive output voltage when the starting switch is turned from ON to OFF. * Code 33 is the A phase (engine speed acceleration direction) and code 34 is the B phase (engine speed deceleration direction) ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration direction and deceleration direction. 350-6 20-247 0 . Check output signal 1) Check governor motor drive current i) Set to the monitoring mode. * Voltage: 0. Check input signal 1) Check fuel control dial input voltage i) Set to the monitoring mode.3.4. ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to high idling.3 V 2.l Governor control system 1. PC300. ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.5 . and display monitoring code 31.75 V 2) Check governor potentiometer voltage i) Set to the monitoring mode. + Current: 700 + 70 (mA) 2) Measure battery relay drive output voltage i) Set to the monitoring mode. with 24V wiring harness E316 E317 E318 Step-out in governor for buzzer Disconnection Short circuit in governor El04 El06 El08 E 112 E 113 El14 Air cleaner clogging detected in governor motor system Abnormality in engine oil pressure sensor (Hi) detected Water temperature over 105°C 1Short circuit in wiper motor drive normal rotation system I I I ( I I 1Short circuit in wiper motor drive reverserotation system I 1Short circuit in window washer drive system 1 ( E207 E208 Short circuit in active mode (boom) solenoid Disconnection system in active mode (boom) solenoid system E217 E218 E222 E223 E224 E225 E226 E227 E231 E232 E233 E235 E236 E237 E306 E308 Error in model Network selection input error system system response overtime 1Short circuit Disconnection Abnormality in LS-EPC solenoid in LS-EPC solenoid I I in F pump pressure sensor system in R pump pressure sensor system 1Abnormality I 1Ab normality in pressure sensor system power source Abnormality I E02 E02 I I in engine speed sensor system system system Short circuit in active mode (swing) solenoid Short circuit in F pump in F pump TVC solenoid TVC solenoid Disconnection I I Disconnection in active mode (swing) solenoid system Short circuit in R pump TVC solenoid Disconnection Abnormality Abnormality in R pump TVC solenoid in feedback potentiometer dial input system system system value E05 E02 E02 in fuel control 20-248 0 PC300.TROUBLESHOOTING SERVICE CODE TABLE SERVICE CODE TABLE Service code Abnormal in error system history data Service code Abnormal Error Short in auto-greasing circuit in battery system controller relay output motor motor system E05 E05 (option) system I I User code El01 1Abnormality El02 Abnormality I I E313 E315 in time data contact drive El03 Short circuit in buzzer output. 350-6 . .TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE) N-l [E2181 Communication abnormality . . . . . . . . . . .. .. . . . . .. . . ... ..... . ... . . . .. . 20-302 PC300.. . .. . . .. . . . . . . . 350-6 20-301 a . . . . .. . . . . . . . ... .. . .. .. . . .. .. . . . . 7.) Before carrying out troubleshooting. punp controller (2) Governor. c17. the problem has been removed.. (If it is not displayed. if the service code E is not displayed. punp controller . so when disconnecting the connector and inserting the T-adapter. Defective governor. or when removing the T-adapter and returning the connector to its original position. *Turn starting switch ON. (12) normal? * Disconnect POI. and install monitoringcode OS? T-adapter to POI. code 0 panel model code model code model code pump controller pump controller When each controller is connected to the network. Table 2 08 Network connection condition . Therefore. NO (11) and Cl7 (4).TROUBLESHOOTING N-l N-l [E218] Communication abnormality This troubleshooting is carried out when there is still an abnormality. * Min. Max. Defective monitor panel Replace * Disconnect C17. If the starting switch was turned off after the abnormality occurred. the problem has been removed. (11) and Cl7 (4). 350-6 . Light up when connected (I) Governor. 1 MR * Disconnect connector ~17. (1) and (2) light up in POl. NO * Turn starting switch ON. . Note: Checks can be carried out with code 08 only when there is a disconnection. Disconnection is betweer POl(4) (11) and PO1 (12) or chassis Defective governor. IQ N( I Defective monitor panel Replace Disconnection in wiring harness between POl(4). 1Uisplay I 300 300 300 Monitoring Monitor Governor. Has been reset 4 YE: Is resistance YES between PO1 (4) . YES 5 Is voltage bwtween Cl7 (4) h t (12) and chassis normal? * Turn starting switch ON. pump controller Repair Replace * See Table 2. The display does not change when there is a short circuit. 20-302 0 PC300. (12) l Table 01 I 02 03 1 I -. * Min.5 V * Disconnect Cl7 and measure voltage at harness end. * Turn starting switch ON. __ . each controller shows model selection abnormal. Always connect any disconnected connectors before going on the next step. turn the starting switch on and check that the service code displays E. U-fl is displayed. * See Table 1. pump controller Replace 6 YE! Is resistance between POl(4).(I 1) and chassis or 3 ~ PO1 (4) (11) and PO1 (12) normal? When Cl7 is . disconnected.do bits * Disconnect Nr connector C17. check that all the reCause Remedy lated connectors are properly inserted. checks when there is a short circuit should be carried out basically using Table 1. Governor. If the correct alphanumerics are not displayed (another model is displayed). pump controller C16(MIC17) Monitor panel PO1 (04020) @ AT C17(04016) HI4 (M6) BKFQ0092 PC300. 350-6 20-303 0 .TROUBLESHOOTING N-l N-l Related electric circuit diagram Governor. . ... .. . .... . . ......... ...... ..... . ......... . ....7 E...... E-10 E-l 1 E-12 Lack of output (engine Engine does not stop ... .... ...... . . ..... .. . ... ..... ... ..1 E..6 E..... .. .. .... .. . ............. ....... .. . ... .... related pump controller and engine Electrical E.... .... .... ...... .. .. .. .. ...20-368 20-370 20-372 20-372 20-374 .. . . ....... .. .... . .. ...... ..... . .. ....... ............ . ..... . ... 20-367 ............. . ... ..... pump controller power source (controller LED is OFF) ..... .. .. .. . . .. ... .... ..... . 20-352 when abnormality occurs and problems (governor control on machine . ....9 parts ....... .... ...... .. ...... . . ... _ .. ... ..... ........ . ...... .. ...... .... ....... . .2 E..... ... ........ ..... .... . ..... . Engine does not start ....... . .. . . PC300. .. ...... ..... .. .. . ... . ... ... . Defective operation of battery relay system (engine does not stop)........... .. ....... .. . PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE) Points to remember pump controller when carrying out troubleshooting of governor.... ... ... . . .. .TROUBLESHOOTING OF GOVERNOR. ... . . . ........ ............. .. ...... system . . ......... ... ..... .... ......4 E..... high idling speed is too low).............. .............. ..... ..... .............. .. . . ..... (short circuit) (step-out) relay output is displayed .. .. ....... . ... . .. .... ....... ........... .. .. ... . .. .... .. ....... ................. ... ... ... ... ...... . ..... ........ .. ........ 20-358 for E mode system .. ... ..... .8 E... ...... .20-363 20-364 20-365 20-366 circuit diagram Abnormality IE3081 Abnormality [E3171 Abnormality [E3181 Abnormality IE3061 Abnormality [E3151 Abnormality [E3161 Abnormality in fuel control (disconnection) dial input value is displayed in motor drive system . . ... . ... . .. . ... ..... ........ .. ....... . . .... ............. . ... ...... .. ... ... . ...... ...... There is hunting .... . ... . . ... . ....... . ..... . .... 20-354 system) Action taken by controller Judgement table for governor..... ........ .. .. ...... . . ..... .. is displayed (short circuit) in motor drive system in feedback potentiometer in battery system is displayed is displayed system . .... ... .. .20-376 20-378 20-380 in motor is displayed......... .. .......... ......... .. ............. ....... Idling speed is irregular ... ...3 E. .... 350-6 20-35 1 0 ..... .. 20-362 ... . .............5 E.... ..... .. . ...... .... .. . . .. ... 20-360 in governor....... ... .. .... .. .... ... . ..... ..... ......... . ..... .... ..... ... Engine speed a) b) is irregular ......... .. .. .. ... ..... The problems that may occur with this system include the following. If linkage between governor motor and does operation of injection pump is governor motor disconnected and _ become normal? NO pump lever is *With starting switch at ON. User code memory retention function When displaying the abnormality code in memory and carrying out troubleshooting. push governor lever to STOP position and check if engine stops. but one of problems 1 to 6 above has occurred. so it is desirable to follow up this problem carefully. Engine speed for automatic warming-up operation is too high (too low) 5. note down the content of the display. then erase the display. carry out troubleshooting as follows. and the service code is no longer displayed. Engine does not stop If any abnormality occurs. there is a high probability that the same problem will occur again. Therefore. I) If any abnormality returns to normal by itself. (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function.TROUBLESHOOTlNG TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT OF GOVERNOR. carry out troubleshooting according to the failure code that is displayed. it is necessary to determine whether the problem is in the mechanical system or in the electrical system. 350-6 . or check the adjustment flow chart for the mechanical system or electrical system. Go to troubleshooting electrical system E-9-E-12 of Go to troubleshooting engine system S-l -S-l6 of * If engine does not stop.is disconnected. Erasing the data in this way saves any wasted work. Idling speed is too high (too low) 2. and the abnormality is displayed on the time display portion of the monitor panel. use the troubleshooting table to determine the appropriate troubleshooting flow chart from E-l to E-12.However. 3) After completing troubleshooting. control dial and working mode switch. High idling speed is too low 3. Auto-deceleration speed is too high (too low) 4. 1. or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure.) 3. always erase the service code from memory. PUMP CONTROLLER SYSTEM 1. PUMP CONTROLLER SYSTEM POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR. and go to the troubleshooting AND ADJUSTING. 20-352 a PC300. There is hunting 6. problems 1 to 6 listed above may occur. Points to remember if abnormality returns to normal by itself In the following two cases. After trying to re-enact the problem. For details of the procedure for adjusting the linkage. see TESTING 2. if there is no abnormality display. Disconnect the linkage as explained above. or if the monitor display returns to normal. Points to remember when there is abnormality which is not displayed by user code The engine is controlled by the governor and pump controller. operate fuel operated by hand or is fixed with wire. if there is any abnormality in the machine and no abnormality display is given. If the linkage between the governor motor and the injection pump is not properly adjusted. YES 2 ~ YES h If linkage between governor motor 1 and injection pump . or 2) If the connector is disconnected and the T-adapter is inserted. does condition NO retUren t0 nOrrd? Defective adjustment of governor motor likage See TESTING AND ADJUSTING. . E06 (1) 6. Short circuit in wiring harness between CO3 (7) . Disconnection in wiring harness between CO3 (17) . 3. Disconnection in wiring harness between CO3 (4) . Wiring harness between CO2 (4) . 6. Short circuit inside governor motor 2.E05 (2) 3. Disconnection in wiring harness between CO3 (7) . (2) . 4.(2). (7) .X07 (6) .E05 (4) 4. E06 connectors E05 E317 Abnormality (disconnection) drive system in motor 1. 5.E05 (3) and between CO2 (2) . 2.E05 (1) short circuiting with wiring harness between CO2 (5) . Wiring harness between CO2 (2) .E06 (3) 8. Defective fuel control dial 9. (2) .X07 (4) .(14).(3) 4. X07. Short circuit in wiring harness between CO3 (7) .(4).TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code Service code Abnormal system Nature of abnormality E308 Abnormality in fuel control dial input value 1.E05 (3) short circuiting with wiring harness between CO2 (3) . (I) (3). (1) (3). Short circuit in wiring harness between E04 (1) . Short circuit in wiring harness between E06 (I) . Wiring harness in Items 2 and 3 short circuiting with ground 20-354 0 PC300.(171. Defective contact of C03. Disconnection inside governor motor Disconnection in wiring harness between Disconnection in wiring harness between Disconnection in wiring harness between Disconnection in wiring harness between Defective contact of E05 connector CO2 CO2 CO2 CO2 (2) (4) (3) (5) - E05 E05 E05 E05 (I) (3) (2) (4) E318 Abnormality (short circuit) drive system in motor 1.(17) 2. (14) .(21.X07 (5) . 350-6 .E06 (2) 7.E05 (I) and between CO2 (4) . (4) (17) 5.(3) 3. 25 .(4) (4) . (31.7kQ 0.(3) (4) . (2).7kQ Min. When there is a disconnection in both the A phase and B phase at the same time.(5) (2) .25 .(5) (2) .84 A 1. 1 MD Min. When there is a disconnection in only one of A phase or B phase I) Engine does not stop 2) Stops moving at position immediately before failure. the problem is the same as for a short circuit in the governor motor system 2.25 . 1 MI Min. but stays at low idling 2) Engine does not stop after starting 3) There are cases of hunting PC300.(17) Between each pin and chassis E06 (male) (1) . so engine speed cannot be controlled 3) There are cases of hunting E05 (male) (1) . 1 MR and chassis chassis Motor drive current: Hold: 0. 1 MR and chassis chassis Motor drive current: Hold: 0.(4) (1) . 350-6 20-355 0 . (4) and (4). (31.7kQ 2 .7kR 0. current.(2) (3) .(3) Resistance value 0.(4) (2) .(4) (2) . and (5) Min.(5) Between Resistance value 0.25 .(17) (7) . 1 MR Sets motor drive current to 0 pins (I). (31. (2).(3) (1) .(2) (2) . 1 MD Takes no particular action pins (11. (4) and (41.7 A Start: 0.6kR _ Min. and (5) Min. resistance) co3 (female) (7) .25 . 1 MD Action by controller when abnormality is detected Problem that appears on machine when there is abnormality Maintains engine speed at position of fuel control dial immediately before abnormality occurred 1.(3) (1) . If during operation 1) Set to low idling 2) Engine does not stop 3) There are cases of hunting 2.(4) (I) .(3) (4) .84 A 1.(4) Between co2 (female) (2) .7k. pins (21.ACTION TROUBLESHOOTING TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal (voltage. Does not reach high idling when set at partial speed 3.Q Min.(2) (3) .3kR 4 .(3) (1) . (3). pins (21.(5) Between Resistance value 0. speed of engine is too low) E05 (male) (1) .7kR 0. When stopped I) Engine starts. Lacks output (max.25 . Does not become partial speed when set at MAX position 2. There are cases of hunting 4.(4) Between co2 (female) (2) .7 A Start: 0. Defective contact of C03. (4) (17) 5.(2). (2) .(17) 2.(3) 4. Disconnection in wiring harness between CO3 (7) . Short circuit in wiring harness between E04 (1) . pump controller 20-356 0 PC300. (1) (3).E04 (3) 8. Short circuit in wiring harness between CO3 (7) . (7) .E04 (2) 7. 350-6 .(2). Defective adjustment of rod or scuffing of loose spring Abnormality (step-out) in motor E316 2.(3) 3. (1) (3). Defective governor motor potentiometer 9.(4). Disconnection in wiring harness between CO3 (17) . (14) . Short circuit in wiring harness between CO3 (7) . E04 connectors Abnormality (short cir- - E315 cuit) in battery relay output system If excess current flows between CO3 (1) and battery relay -k This occurs only when turning starting switch to OFF and stopping engine 1. Abnormality in governor motor 3. (2) .(14).E04 (I) 6. Disconnection in wiring harness between CO3 (14) . Short circuit in wiring harness between E06 (I) .(17).TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code Service code Abnormal system Nature of abnormality - E306 Abnormality in feedback potentiometer system 1. Abnormality in governor. 2. In some cases it may not display when returning from partial speed to low idling Engine speed cannot be controlled (particularly at high idling). 350-6 20-357 0 . 1 MR Calculates position of motor and carries out control from value of voltage immediately before abnormality occurred Between CO3 (1) and chassis: 20 .30 V *_ Holds with the motor in the stop position for 2 . Must move lightly when connector is removed 3.(3) - Resistance value 0.3kR 4 .25 .(14) (7) .6kR Min. Precision of engine speed control may be reduced.(2) (2) . returns to the low idling position. Displays when returning from high idling to low idling * $t&rt$4gain trepeats 2. current.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal (voltage. then turns the battery relay OFF.7kQ 0.25 . For example: 1) Engine does not rise to high idling speed (a little too low) 2) Engine does not go down to low idling speed (a little too high) 3) Defective engine speed for autodeceleration or automatic warming-up 4) Engine may not stop * The governor motor moves in the direction to stop the engine.7kQ 2 .5 set. 5) There are cases of hunting co3 (female) (7) . Normal 1. but the motor may not move completely to the position to stop the engine. so there is hunting PC300.(3) (1) .(17) (14) .(17) Between each pin and chassis E04 (male) (I) . Linkage adjustment correct 2. ~~~~t~~ry relay drive cur_ Engine does not stop 1. resistance) Action by controller when abnormality is detected Problem that appears on machine when there is abnormality 1. o E s x % m g .r > C z E : $ Governor. 350-6 . PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS JUDGEMENT TABLE FOR GOVERNOR. - - 73 ii 2 z & E . - Engine does not stop Warming-up operation is defective 5 rises too high (overheating) - . pump controller. PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS EI f!ngine related parts (E3: system m f Self-diagnostic display 2i 8 5 s t 3 x : = e E 8 . and does not follow accelerator. E-5 - Exhaust gas is black is excessive.TROUBLESHOOTING JUDGEMENT TABLE FOR GOVERNOR. or engine pickup is poor Engine stops during operation When idling speed is irregular Engine rotation is irregular When there is hunting Lack of output (engine high idling speed is too low) Auto-deceleration does not work i - G - .? . 2 z E $ 8 . or exhaust gas is blue Fuel consumption Oil is mixed in coolant Engine oil pressure caution lamp lights up Oil level rises Coolant temperature Abnormal noise is generated There is excessive vibration Engine speed does not change even when working mode is switched Troubleshooting Troubleshooting code when service code is displayed code when there is abnormality in monitoring or machine monitor check I-1 - 0 : This shows applicable item for service code % : This shows item that needs only checking with monitoring 20-358 0 PC300.S > C -5 E i 9 E05 306 - Failure mode 1 2 3 4 5 6 7 8 9 10 Engine does not start easily Engine does not start User code Service code _ Engine speed stays at low idling. or exhaust gas is blue 1 11 1 Oil consumption 1 12 13 14 15 16 17 18 19 20 1 Oil becomes dirty prematurely is excessive. . Is red range displayed? F : ‘_ Does starting motor turn? - . ?) _. 350-6 . lsATTERY m JQy.Y I I I p -62 I IJ’. I . L . Y. I 5 6 _I -II’ a 9 10 MACHINE SELECT CONNECTOR Cl6 (MIC17) TWP01409 20-360 0 PC300.__ CO3 (04020) / "V I I-. I I GND POWER SUPPLYh24Vl 7* . 3 n" .. 1 12*2w .R SUPPLY (+24V) LI..TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM FUEi-!!L STARTING SWITCt E06 (M3) FNCINE THROTTLE CONT ROLLER CO1 (MICl.J” A A .-. 2 r-----’ 1 I a 9 lo__-----. 350-6 20-36 1 0 . ------- J H15(L2) Fuse box 2w Battery ’ 858 IIII II.’ l II 85B II l I I=$ BKP00095 PC300.--1 Potentiometer 1 otor. DlB(KES1) 1 2 085~’ Oi5BRI I :.TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM Electric governor actuator .. Before carrying out troubleshooting. so when disconnecting the connector and inserting the T-adapter. or disconnection in wiring harness between fuse 1 and CO1 (female) (7) (13) Defective contact. go to E-8. (If the starting motor also does not rotate. Always connect any disconnected connectors before going on the next step. the problem has been removed. if the service code E is not displayed. Check that fuse 1 is not blown. *20-30V NO Repair or replace Repair or replace E-l Related electric circuit diagram Governor. or disconnection in wiring harness between fuse l-HI5 (2kM14 (2) Ilkbattery relay M Replace Is voltage between CO1 (7) (13) and CO2 (11) (21) normal? _ * Turn starting switch ON. pump controller Defective contact.TROUBLESHOOTING E-l E-l Abnormality LED is OFF) in governor. pump controller I COl(MIC13) H14fM6) 1 Fuse H15(L2) 4 0 2 O- C02(MIC21) Battery /l-II BKl-20096 20-362 0 PC300. When the starting motor rotates correctly. check that all the related connectors are properly inserted. or when removing the T-adapter and returning the connector to its original position. 350-6 .) YES 1 1 - Defective governor. ~20-30V 2 YES Is voltage between fuse 1 NO and chassis normal? * Turn starting switch ON. pump controller power source (controller * * * * * This troubleshooting is carried out when there is still an abnormality. so when disconnecting the connector and inserting the T-adapter.E04 (female) (I) short circuiting contact with other wiring harness with ground.(2) (2) .25 .7kQ 2-3k!S 4-6kL2 Min. Wiring harness between CO3 (female) (7) . check the wiring harness below. pump controller CO3104020) Throttle command Throttle power source (+I Feedback Throttle power source (-1 BKW0097 PC300. Is Defective governor. or when removing the T-adapter and returning the connector to its original position.TROUBLESHOOTING E-2 E-2 [E308] Abnormality in fuel control dial input value is displayed * * * This troubleshooting is carried out when there is still an abnormality.(7) (17). W (3) as show in Tablel? * Turn starting switch OFF. the problem has been removed. . Cause Remedy 1 2 rescstance between each pin YES of CO3 (female) (4) . . * Disconnect E06. Defective wiring harness in system with defective resistance Replace I Defective fuel control dial Replace NO Jr If E306 also occurs at the same time.(17) Between each pin and chassis E-2 Related electric circuit diagram Governor. 1 MQ co3 (female) (7) .7kQ 0. pump controller Replace Is resistance between E06 (male) W(2). if the service code E is not displayed. Always connect any disconnected connectors before going on the next step. check that all the related connectors are properly inserted.25 .(4) (4) . 350-6 20-363 0 . or between each pin and chassis as shown in Table l? *Turn starting switch OFF. * Disconnect C03.(3) Resistance value 0.(17) (7) . Before carrying out troubleshooting. or Table 1 E04 (male) (1) .(3) (I) . 7. 350-6 . Cause Remedy 2 YES Defective governor. check that all the related connectors are properly inserted. if there is 1) a simultaneous disconnection in A phase and B phase: 1) the engine will run at low idling 2) the engine will not stop 2) a disconnection in either A phase or B phase. .(2) (3) . * A Ir * This troubleshooting is carried out when there is still an abnormality. if the service code E is not displayed. During operation.5 .(4) I Resistance value 2. or 2) it will not stop after it is started. C02(MIC21) . Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step.(3) (4) .Disconnect E05. the engine speed will remain the same as before the abnormality occurred If the problem occurs when the engine is stopped. pump controller Replace Defective wiring harness in system with defective resistance Replace . Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position).7.5 . E05(X4) I I Governor motor BKW0098 20-364 0 PC300.5kQ 2. so when disconnecting the connector and inserting the T-adapter. pump controller . 1) the engine can be started.Turn starting switch OFF.TROUBLESHOOTING E-3 E-3 [E317] Abnormality displayed * (disconnection) in motor drive system is *. the problem has been removed. or when removing the T-adapter and returning the connector to its original position.5kR I E-3 Related electric circuit diagram Governor. I NO Defective governor motor Replace Table 1 co2 (female) (2) .(5) I E05 (male) (1) . but it stays in low idling. the problem has been removed.(4) (l)-(3) (2) . . or between each pin and chassis as shown in Table 17 * Turn starting switch OFF. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position).5k!L! 2.5 . 1) the engine will run at low idling 2) the engine will not stop If the problem occurs when the engine is stopped. so when disconnecting the connector and inserting the T-adapter.7. * Disconnect E05. 1 MQ 1 (2) .(5) . pump controller Replace between each pin of J ~ and chassis as shwon in Table l? E05 (male). I) the engine can be started. If the abnormality occurs during operation. but it stays in low idling.7. check that all the related connectors are properly inserted. (l)-(4) Between chassis Between chassis and pins and pins (l)(2)(3)(4) G!)(3)(4)(5) E-4 Related electric circuit diagram Governor. 350-6 20-365 0 .TROUBLESHOOTING E-4 E-4 [E3181 Abnormality displayed (short circuit) in motor drive system is a * + This troubleshooting is carried out when there is still an abnormality.or 1 . 1 MR Min. or 2) it will not stop after it is started. Always connect any disconnected connectors before going on the next step.(2) (3) . NO NO Defective wiring harness in system with defective resistance Replace Defective governor motor Replace Table 1 co2 (female) E05 (male) 1 Resistance value 2. Cause Remedy 2 YES -IS resistance YES coz wemaw. pump controller C02(MIC21) Governor motor A(+) N-1 @ @ B(+) @ &-I I $0 BKP00098 PC300. 1 MQ Min. _ * Turn starting switch OFF. * Disconnect C02.5kQ Min. or when removing the T-adapter and returning the connector to its original position.(3) (1) .between each pin Is resitiance between each pin of ~ Defective governor. because of the force of the spring.(4) (4) . if the service code E is not displayed.(5) (2) . Before carrying out troubleshooting.5 . TROUBLESHOOTING E-5 E-5 [E306] Abnormality in feedback potentiometer system is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are oroperly inserted. Always connect any disconnected connectors before going on the next step. ’ Defective governor, pump controller Replace Defective wiring harness in system with defective resistance 1Table l? * Turn starting switch OFF. - Disconnect E04. Replace I ?risconnect C03. 1 Defective governor motor Replace + If E308 also occurs at the same time, check the wiring harness below. . Wiring harness between CO3 (female) (7) - X07 (6) - E06 (female) ground, or contact with other wiring harness 1 E04 (male) (1) - (2) (2) - (3) (1) - (3) - (1) short circuiting with Table co3 (female) (7) - (4) (14) - (17) (7) - (17) Between each pin and chassis I Resistance value 0.25 - 7kQ 0.25 - 7kQ 2-3kQ 4-6kQ Min. 1 MQ I E-5 Related electric circuit diagram X07(MIC17) $) 3 -3 7 . @ E06(M3) 3 -3 $J E04(X3) Fuel control dial Governor, pump controller CO3(04020) Throttle command @ Throttle power source (+I Feedback Throttle power source (-) c 3 3 3 I Governor potentiometer BKFO0097 20-366 0 PC300, 350-6 TROUBLESHOOTING E-6 E-6 [E315] Abnormality displayed (short circuit) in battery relay output system is a * * Ir This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or.when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed, the problem has been removed. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. This only occurs when the engine is stopped and the starting switch is turned OFF. Cause Remedy YES I Defective governor, pump controller Replace Defective battery relay I) Contact between other wiring harness and wiring harness between CO1 (female) (II-HO2 KU-battery relay BR. 2) When light is connected Replace * Turn starting switch OFF. - Disconnect COl. - Between CO1 NO (female) (1) and battery relay BR: Max 1 R - Beetween wiring harness and chassis: Min. 1 MR. - Turn starting switch OFF. - Disconnect CO1 and battery relay BR. E-6 Related electric circuit diagram Fuse Hi4 (MI 8 Start switch ins a Ml 1 IL21 Engine throttle controller CO1 (MIC13) relay drive 1 B D13 (KEsi 2) m CO3 (04020) TWP01410 PC300, 350-6 20-367 0 TROUBLESHOOTING E-7 E-7 [E316] Abnormality (step-out) in motor is displayed This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the service code E is not displayed. the problem has been removed. If any other service code [E3061- [E318] has occurred at the same time, start troubleshooting from the code except codeIE3161. Check that the fuse is normal. “Adjusting travel of governor motor Read the precautions given in TESTING AND ADJUSTING, lever” before carrying out the troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause Remedy YES Go to applicable failure mode - 1 J ., I YES Defective governor, pump controller Replace YI3 *Turn starting switch ON. ,,Ll;:,“$;:%t;; / -Turn starting switch ON. *Turn autodeceleration OFF. * Set to governor motor adjustment mode. . See TESTING AND ADJUSTING. Id I N0 operate fuel control dial 0 ++ MAX and turn starting switch OFF. Is operation normal? P *Turn starting switch ON. ND *Turn auto deceleration OFF. 4YE! Is there any scuffing when spring rod is moved to injection pump end? * Disconnect E05 * Disconnect linkage at governor motor end. NC 1) Defective linkage 2) Defective injection pump Adjust or replace Defective governor motor Replace Defective governor linkage Adjust (For details, see TESTING AND ADJUSTING) 20-368 0 PC300, 350-6 TROUBLESHOOTING E-8 E-8 Engine does not start When starting motor does not rotate. Check that fuse No. 14 is not blown before starting troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 4 YES Is voltage between YES starting motor terminal B and chassis normal? 3 * Turn starting Is there sound of switch ON. starting motor - . Approx.24” pinion engaging? 5 Is voltage between _ starting switch NO terminal C and chassis normal? . Turn starting switch to START. * Approx. 24V NO inserted. NO Yl YES 2 When starting switch is turned OFF, is sound heard from batten/ relay? . Turn starting switch ON-OFF SYES Is there continuity YES between chassis ground and battery 8 relay terminal E? NO Is there continuity YE? between starting switch terminal B 6 andBR? _ * Turn starting switch ON. * Remove terminal B. Is resistance ofwiring harness YES between starting switch BR and battery relay BR 7 normal? _ - Betweenstarting switchBRand banery NO relayBR:Max. 1 R * Betweenwiringharnessand chassis: Min. 1 MR *Disconnect bothstartingswitchand batteryrelayends. NO specific gravity of ~ * Min. 24V * Specific gravity: Min. 1.26 Is voltage of starting switch b , terminal B normal? + Connect f-J end of tester to battery terminal H. *20-29v NO E-8 Related electric circuit diagram Fusible link a Start motor ins R B TWP0141 I 20-370 0 PC300, 350-6 TROUBLESHOOTING E-8 Cause Remedy f Defective starting motor Defective contact of wiring harness between battery (+)-battery relay B-batten/ relay M-starting motor terminal B (including battery relay) Defective contact, or disconnection in wiring harness between starting switch terminal C-X07 (lONO (1) -M2 (I)-starting motor terminal S Defective starting switch (between terminals B and C) Replace Replace Defective battery relay Defective contact of wiring harness between battery relay terminal E and revolving frame grond connection terminal Defective contact, or disconnection in wiring harness between starting switch terminal BR-DlSbattery relay terminal BR Defective starting switch (between B and BR) Defective contact, or disconnection in wiring harness between battery terminal (+)-Mll-HO5 (6)-X07 (l&starting switch terminal B (including fusible link) Lack of battery capacity Replace Replace Replace Charge or replace PC300, 350-6 20-371 0 TROUBLESHOOTING E-9 E-9 Engine speed is irregular j, * Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. inserted. a) Idling speed is irreaular YES 4 YES 2 Is E218 displayed? .---I l ‘When hnkage between governor 33 motor and pump is Yf adjusted, does condition become normal? * See TESTING AND ADJUSTING. NO Turn starting switch ON. Starting motor signal 7 YES 1 1 Is controller *Turn starting switch ON. Fuel control dial * Turn starting switch ON. Set to monitoring code 03 or 02. l YEiS 5 1 . At MIN: 2.9 - 3.3V I_ 7 Is voltage 1 between CO3 (41 NO * At MIN : 4.0 - 4.75v : NO NO Table 1 Controller model code I Ir The diagram code 03. shows BKFO0210 I monitoring 20-372 0 PC300, 350-6 TROUBLESHOOTING E-9 I Cause Remedy Defective linkage adjustment of Adjust Defective injection pump See S mode Replace starting switch ACC-X07 (17)-CO3 (fernal) (8), or defective starting switch See E-5 Repair or replace - See E-2 - See C-14 - E-9 Related electric circuit diagram Starting switch X0 Engine throttle controller co3 (0 I Sta ON Fue S tins ianal dial switch B 1 2 3 17) E06 Fuel dial Power SUDDIY for fuel dial (+I Feedback signal Power SUPPIY for fuel dial (-1 Governor Potent iometer TWP01412 PC300, 350-6 20-373 0 TROUBLESHOOTING E-9 b) There is hunting 2 co&i,yn . Turn starting switch ON. disconnectedand become 11 NO Potentiometer * model code as shown in Table * Turn starting switch ON. * Set to monitoring code 03 or 02. l Turn starting switch ON. Turn fuel control dial from MIN to MAX and stop also at midway L, YES Fuel control dial 5 ~ Is voltage between CO3 (4) _ , and (17) normal and stable? . At MIN : 4.0 - 4.75V *At MAX : 0.25 - 1 .OV Is voltage between CO3 (14) _ and (17) normal and stable? . At MIN : 2.9 - 3.3v *At MAX : 0.5 - 0.9v motor signal 7 YES IF Is voltage between YES ~03 (8) and 6 chassis normal and stable? Starting * During operation :20-30V L NO NO Table 1 Controller model code BKP00210 I * The diagram code 03. shows monitoring 20-374 0 PC300, 350-6 TROUBLESHOOTING E-S F Defective linkage =I Defective Cause See N mode - adjustment of Adjust injection pump See S mode Replace Defective contact of wiring harness between starting switch ACC X07 (17) - CO3 (female) (81, or defective starting switch See E-5 Repair or replace - See E-2 - . SeeC-14 - E-S Related electric circuit diagram Start insxch X07(MI~I{) 714 (F6,l Fuse I Engine throttle controller CO3 (040201 ON signal Fuel dial Fuel dial supply for fuel dial !+) Feedback signal Power supply for fuel dial (-) Power Governor Potent iometer TWPOl412 PC300, 350-6 20-375 0 TROUBLESHOOTING E-10 E-10 Lack of output * Jr (engine high idling speed is too low) inserted. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. YES ‘ES Is E218 displayed? H 2 Y I * Turn starting switch ON. 9 Potentiometer Is voltage and (17) normal Fuel control dial ! 6 dYES * Start engine. * Set fuel control dial to MAX. * H/O mode. 1Is voltage YES between CO3 (4) 4 r(:,:z;LG’““’ *At MAX : 0.5 - 0.9v * At MIN : 4.0 - 4.75v * At MAX : 0.25 - l.OV NO * Turn starting switch ON. Set to monitoring code 03 or 02. l * See TESTING AND ADJUSTING. No Table 1 Controller model code I Ir The diagram code 03. shows BKP00210 I monitoring 20-376 0 PC300, 350-6 TROUBLESHOOTING E-10 Cause Remedy See N mode - Defective injection pump See S mode Starting motor signal Is voltage between CO3 (8) and chassis normal and stable? * During operation: 20 3ov 7 YES Defective governor motor Defective contact of wiring harness between starting switch ACC X07 (17) - CO3 (female) [8), or defective starting switch See E-5 NO Repair or replace - - See E-2 - defective adjustment of Jovernor motor linkage 1 Adjust see S mode - See C-l 4 - E-10 Related electric circuit diagram Start ina switch X07(MIC17) H14 (M6) Fuse Engine throttle controller CO3 (04020) Start ina switch ON signal Fuel dial x07 (MI Cl_71 Q.a 3 3 -3 E06 (hi31 Fuel dial a 3 I I I I I tu4 l-n. IV.31 \AJl fuel dial Feedback fuel dial I+) signal (-1 K7-l (IJ 3 Governor potent iometer TWP01412 PC300, 350-6 20-377 0 TROUBLESHOOTING E-II E-II a * * * Engine does not stop Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor lever” before carrying out the troubleshooting. YES YES YI r Trun starting switch ON+ OFF. Potentiometer GYES model code as shown in Table *Turn starting switch ON. . Set to monitoring code 03 or 02. * See TESTING AND ADJUSTING. fi Starting motor chassis normal? . Max. 1V n NO re’ay fBR) Relav drive sional ~_~ IES FH ! _ i When starting YES switch is OFF, does * When engine is voltage bwtween stopped _ CO1 (1) and (6) (12) 4 change as shown in * 2.9-3.3v Table2 ? 1 . 20-30V hIO NO Table 1 Controller model code BKP00210 * The diagram code 03. shows monitoring Table 2 When ON (Approx. 24V) Voltage from starting switch (CO3 (8)) iL OFF See Note ______ __ Condition of actuation of controller circuit co1 (1) 1 H Voltage output from controller when starting switch is OFF When ON (Approx. 24V) OFF[ Drive time 1 _ Min. 4,0;anen/ To baaenl relay (8R) Max. 7sec. (when it is impossible to set to NO IINJECTION because of failure in motor) BKP00206 Note 1:When the starting switch is ON, the controller end is OFF, but a voltage always flowing from starting switch BR, so if the voltage is measured voltage of 20 - 3ov. of approx. 20 - 30V is at CO1 (I), there is a 20-378 0 PC300, 350-6 TROUBLESHOOTING E-11 F Defective motor See E-5 Cause Remedy governor I Replace - Defective governor, pump controller Contact with 24V harness of wiring harness between switch ACC -X07 CO3 (female) (8). defective starting wiring starting (17) or switch Replace - Replace . See C-14 - E-II Related electric circuit diagram Engine throttle controller CO3 (04020) Starting switch ON signal Power SUPPIY for x07 (MIC17) mm_ Start switch ine I Battery drive relay Battery relay co1 (MIC13) D13 (KESl 2) 7iT TWP01413 PC300, 350-6 20-379 0 TROUBLESHOOTING E-12 E-12 Defective operation stop) Ir A * j, of battery relay system (engine does not This only occurs when the engine is stopped and the starting switch is turned OFF. Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION position). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause Remedy YES See E-6 - II Is E315 displayed? l Turn starting switch ON. H. YES Relay drive signal 2 I monitoring code u * Between Defective governor, pump controller Replace 3 YES Defective battery relay Replace * Turn starting switch OFF. *20-30V NO harnessand chassis normal? I I)Disconnection in wiring harness between CO1 (female) (1) -battery relay BR !)When light is connected Replace CO1 (female) (1) and battery relay RR: Max. 1 0 * Between wiring harness and chassis: Max. 7 MD *Turn starting switch OFF. * Disconnect CO1 and battery relay RR. Table 1 Voltage from starting switch (CO3 (81) ~~prox~ OFF See Note 1 .___----. 1 When Condition of actuation of controller circuit co1 (1) OFF i Drive time ON (Approx. 24V) ) 24v) To banery relay (gR) Voltage output from controller when starting switch is OFF I _ Min, 4.0Eanery re’av ‘BR) Max. 7sec. (when it is impossible to set to NO IINJECTION because of failure in motor) BKP00206 J Note l:When the starting switch is ON, the controller end is OFF, but a voltage always flowing from starting switch BR, so if the voltage is measured voltage of 20 - 30V. of approx. 20 - 30V is at CO1 (I), there is a 20-380 0 PC300, 350-6 TROUBLESHOOTING E-12 E-12 Related electric circuit diagram x07 (MIC17) H 14 (M6) Fuse M_l 1 (L2) I IEngine throttle controller Fusible link Battery relay CO3 (04020) TWP01414 PC300. 350-6 20-38 1 0 . . .................................. PC300.....................................................2 of using troubleshooting Starting Engine (I) performance charts ................................................................................. is excessive (or exhaust gas is blue)......................................................................................................................... Oil consumption Oil becomes contaminated quickly ......... 20-409 20-410 20-41 1 ........TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) Method s......................................... ......................... Engine does not turn .................. 350-6 20-401 0 ..... becomes noise is made ....................................................................................................8 S..4 S..................... Water temperature Abnormal Vibration fuel in oil) ..............................................................6 S........................................ ....................................... or water caution lamp lights up (drop in oil pressure) Oil level rises (water........................ 20-402 ..........................................20-415 20-416 20-417 20-418 20-419 20-420 ........................ . spurts back........................ does not rotate smoothly lacks output (no power) ....................................................................1 S........................................................................ Fuel consumption Oil is in cooling Oil pressure is excessive water... (hunting) ..................3 S.................... ................................... too high (overheating) .........7 S................................................................................................... but engine does not start (fuel is being injected) ..................... 20-408 is poor (starting does not start .................... ...........................20-421 20-422 20-423 Engine does not pick up smoothly Engine Engine Engine Exhaust stops during operations ........................................... or water level goes down.............................. smoke comes out (fuel is not being injected) (2) Engine turns but no exhaust (3) Exhaust S........................................................................20-412 20-413 20-414 .............. gas is black ...20-406 20-407 20-407 ................................................................. always takes time) .............5 S............9 S-IO S-l 1 S-12 S-13 S-14 S-15 S-16 smoke comes out..................................... is excessive ................................................................................................... 350-6 . starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. depending on the user’s level. check items. and troubleshooting. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. The items in @ are items that can be obtained from the user. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. The items under @ in the chart on the right correspond to this. [Check items] The serviceman carries out simple inspection to narrow down the causes. [Troubleshooting] Troubleshooting is carried out in the order of probability. [Questions] Sections @ + @I in the chart on the right corresponds to the items where answers can be obtained from the user. 20-402 a PC300.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions. Next. As a rule. and mark the Cause column with A to use as reference for locating the cause of the failure. items listed for [Questions] and [Check items1 that have a relationship with the Cause items are marked with 0. causes that have a high probability are marked with Q. and of these. and marked the 0 or Q in the chart for items where the problem appeared. ask the user. Check each of the [Questions] and [Check items1 in turn. For [Confirm recent repair history] in the [Questions] Section. . PC300. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. so start troubleshooting for that item to make final confirmation of the cause. but it can be included if necessary to determine the order for troubleshooting. The vertical column (Causes) that has the highest number of points is the most probable cause. do not use it when calculating the points for locating the cause. How+ ever.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS The basic method of using the troubleshooting chart is as follows. do not use this when making calculations to narrow down the causes. ’ %I.%2. 350-6 20-403 0 . [Power slowly became weaker]. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. 350-6 . If we look from these three symptoms to find the causes. and [Dust indicator is red]. Insufficient intake of air . Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black]. Improper condition of fuel injection . Excessive injection of fuel 20-404 a PC300. 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. we find that there is a relationship with five causes.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS . combustion) s-7 Exhaust gas is black (incomplete General causes why exhaust gas is black . cylinder: 0 Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. J Three symptoms t 4 ’ Step 2 Add up the total of Oand Omarks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. so carry out cleaning. valve seat: 0 (5) Worn piston ring.TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column. PC300. and the exhaust gas color should return to normal. The Remedy is given as [Clean]. (I 1 Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 0 (3) Clogged. 350-6 20-405 0 . Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. seized injection nozzle: (4) Defective contact of valve. The specific gravity should exceed the value for the charging rate of 70% in the above table. Improper selection of fuel (At ambient temperature of 10°C or below. IRemedylilg1i1i1g1 20-406 0 PC300..24 l . Insufficient supply of fuel .25 1.24 1.* 1.--.30 1 1.26 1.22 20°C 1.--+ I I I I I I I I I 17 I I I I ion pump sleeve ed I I I I I I I I I I I I I I. . . temperature of some cylinders is low ~~~ ’ . Insufficient intake of air . In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.27 1.29 -10°C 1 1.23 0°C 1.TROUBLESHOOTING S-l S-l * Starting performance is poor (starting always takes time) Check that the monitor panel does not display any abnormality in the governor control system.26 1 1. L Replacement of filters hasnotbeencarried outaccording to Operation Manual I I engine.-----._ .. 1) * Battery c harging rate Am&mrnny lob% 90% 80% 75% 70% XaWW. use ASTM D975 No..28 1. General causes why exhaust smoke comes out but engine takes time to start Defective electrical system .28 1 1. Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use (used for a long period) 0 : Items to confirm the cause Confirm recent repair history Degree of use of machine 1Operated f8 1Gradually became \ Ease of starting c-__.23 1.1 sx It is not permitted to replace only the regulator. 350-6 .L__ .24 1.25 1 1. 5).TROUBLESHOOTING s-2 S-2 Engine does not start (I) Engine does not turn General . seized Ir If internal parts of the engine are seized.o ‘u 0) I) When terminal B and terminal C of starting switch are connected. engine starts 4) When terminal of safety switch and terminal B of starting motor are connected. but k C Makes rattlingnoiseand does notturn 0 When starting switch isturned to START. engine starts 5) There is no 24V between battery relay terminal M and terminal E When ring gear is inspected directly. I does not turn Causes I causes why engine parts of engine . there is no clicking sound Battery terminal is loose When battery is checked. engine starts 2) When terminal B and terminal C of starting motor are connected. voltage of battery is low For the following conditions 1) . pinion does not move out When starting switch is turned to ON. turn the starting switch OFF. 350-6 20-407 0 . connect the cord. battery electrolyte is found to be low Specific gravity of electrolyte. engine starts 3) When terminal B and terminal C of safety relay are connected. Defective electrical system Internal e causes (judging from Questions and check items) e to length of use (used for a long period) turned to START. carry out troubleshooting for “Engine stops during operations”. and carry out troubleshooting at ON 1 1 1 1 1 1 1 1 0 0 0 al 6 % E 4 2 z . pinion moves out. tooth surface is found to be chipped % zz !G ‘: e + I I 1 0 6 PC300. General causes why engine turns but no exhaust smoke comes out l Supply of fuel impossible l Supply of fuel is extremely small . it is found to be clogged 1 When fuel cap is inspected directly. +I ?? ‘: e I- When control rack is pushed. 350-6 . Improper selection of fuel (particularly in winter) * Standards for use of fuel Ambient temprature Type of fluid -22 -30 -4 -20 14 -10 32 0 50 10 66 20 86 30 104°F 40°C * / Causes I Diesel fuel Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. they are found to be clogged When feed pump strainer is inspected directly. When engine C % al i: 1) Injection fuel does not come out motor. Mud is stuck to fuel tank cap When fuel filter is drained.TROUBLESHOOTING s-2 (2) Engine turns but no exhaust smoke comes out (fuel is not being injected) Check that the monitor panel does not display any abnormality in the governor control system. it is found to be clogged # 20-408 0 PC300. 0 0 0 0 00 0 0 0 0 a 0 00 0 is cranked with starting pump coupling does not turn 2) No fuel comes out even when fuel filter air bleed plug is loosened 3) No fuel spurts out even when injection pipe sleeve nut is loosened 0 Rust and water are found when fuel tank is drained Inspect injection pump directly P ‘+= . or does not return Inspect feed pump directly When fuel filter. it is found to be heavy. strainer are inspected directly. 350-6 20-409 0 . .TROUBLESHOOTING s-2 (3) Exhaust smoke comes not start (Fuel is being injected) * . out but engine does General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) A : Possible causes due to length of use fused for a long period) 0: 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately starting engine. . . temperature after of some cylinders is low I lb I I I I I I I I I I PC300. it is found to be heavy after :. it is found to be low When turbocharger is rotated by hand. operation is too light or too heavy Remedy 20-410 0 PC300. 350-6 . General causes why engine does not pick up smoothly .TROUBLESHOOTING s-3 S-3 Engine does not pick up smoothly Check that the monitor panel does not display any abnormality in the governor control system.it is foundto be clogged ? ‘E z 5 2 .a 2 .strainerare inspected directly. temperature Blow-by gas is excessive 1 When air cleanerelementis inspected directly. or does not return When compression pressure is measured. it is found to be outside standard value 1 When fuel cap is inspected directly. it is foundto be clogged 1 When fuel filter. Insufficient supply of fuel . Confirm recent repair history z . Improper condition of fuel injection . but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately starting engine.. Insufficient intake of air . 000 0 00 0 of some cylinders is low Whenvalveclearance is checked directly.B I 2 CY Degree of use of machine Replacement to Operation Operated for long period of filters has not been carried out according Manual Non-specified fuel is being used Engine oil must be added more frequently Rust and water are found when fuel tank is drained Air cleaner clogging caution lamp flashes Noise of interference is heard from around turbocharger Engine pick-up suddenly became poor Blue under light load Color of exhaust gas Black Clanging sound is heard from around cylinder head 1 1 Mudisstucktofueltankcap There is leakage from fuel piping High idling speed under no load is normal. they are found to be clogged Whenfeed pumpstraineris inspected directly. Speed does not change when operation of certain cylinders is stopped When control rack is pushed. it is found to be heavy. it is found to be clogged 1 When feed pump is operated. Improper fuel used (follow-up is poor) * Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n : Possible causes due to length of use fused for a long period) l : Items to confirm the cause. Sr Causes Legend 0: Possible causes (judging from Questions and check items) 0 n : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. Seized parts inside engie . 350-6 20-411 0 . Failure in main piston pump * If the engine stops because of a failure in the main piston pump. . Abnormal Condition when noise was heard engine stopped Engine overheated and stopped hey are found to be clogged PC300. General causes why engine stops during operations . Insufficient supply of fuel . carry out troubleshooting for overheating. overheating Ir If there is overheating and the engine stops. carry out troubleshooting for the hydraulic system (H MODE).TROUBLESHOOTING s-4 S-4 Engine stops during operations Check that the monitor panel fuel level display shows that there is still fuel remaining. General causes why engine does not rotate smoothly Air in fuel system .TROUBLESHOOTING s-5 S-5 Engine does not rotate smoothly Check that the monitor panel does not display any abnormality in the governor control system. Defective governor mechanism . strainer are inspected directly. or does not return When fuel cap is inspected directly. l (hunting) * Legend 0 : Possible causes 0 n (judging from Questions and check items) : Most probablecauses (judgingfrom Questionsand Check items) : Possible causes due to length of use fused for a long period) : Items to confirm the cause. 350-6 . it is found to be clogged When feed pump strainer is inspected directly. it is found to be heavy. Defective electric governor mechanism * If hunting does not occur when the rod between the governor motor and the injection by uspump is disconnected. they are l l 0 .c 5 e 1 o : . improperly adjusted When control rack is pushed. governor is found to be _ _. troubleshoot ing the electrical system troubleshooting mode). 0 0 a 4 I I I I I found to be clogged 20-412 0 PC300. it is found to be clogged When fuel filter. Condition of hunting When governor lever is moved it is found to be stiff When injection pump is tested. output drops) . Improper fuel used (if non-specified fuel is used. carry out troubleshooting for overheating. Measure the engine speed and judge if the cause is in the engine or in the chassis. Improper condition of fuel injection . but speed There is huntino from enaine (rotation is irreaular) Clanging sound is heard from around cylinder head High idling speed of engine is low Leakage from fuel piping Water temoerature oauoe is in red ranoe PC300. General causes why engine lacks output . Lack of output due to overheating * If there is overheating and insufficient output. Insufficient supply of fuel . 350-6 20-413 0 . Questions and check items) om Questionsand Check items) of use (used for a long period) Replacement of filters has not been carried out according Air cleaner clogging caution lamp flashes Black Color of exhaust gas Blue un Blow-by gas is excessive Engine pickup is poor and combustion suddenly drops when load is applied starting engine.TROUBLESHOOTING S-6 S-6 Engine lacks output * (no power) Check that the monitor panel does not display any abnormality in the governor control system. Insufficient intake of air . temperature of some cylinders is low is irregular High idling speed under no load is normal. Excessive injection of fuel Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) l : Items A: Possible causes due to length of use fused for a long period) to confirm the cause 1 Confirm recent repair history 1 Dearee of use of machine 1 Ooerated for Ion Color of exhaust gas Power was lost 1 When turbocharger is rotated by hand._ B 2 4 _o 2 E When compression pressure is measured. it is found to be heav\ / When air cleaner is inspected directly. 350-6 . or does not return Remedy 20-414 0 PC300. it is found to be clogged r” . insufficient intake of air . improper condition of fuel injection . it is found to be heavy. it is found to be low Speed does not change when operation of certain cylinders is stopped Whencheck is madeusingdelivery method.TROUBLESHOOTING s-7 S-7 Exhaust smoke is black (incomplete combustion) llllJllll/ Causes General causes why exhaust smoke is black . exhaust color returns to normal When control rack is pushed. injection riming is found to be incorrect Injection pump test shows that injection amount is incorrect Whenvalve clearanceis checkeddirectly it is found to be outside standardvalue When muffler is removed. External leakage of oil Wear of lubrication system l Causes Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n l : Items to confirm - : Possible causes due to length of use (used for a long period) the cause. (Both low and high idling) General causes why oil consumption is excessive . inside is found to be dirty with oil PC300.= :: m 6 When exhaust oioe is removed. Confirm recent repair history Degree of use of machine E . 350-6 20-4 15 a . inside is found to be dirty with oil Oil level in PTO chamber rises - Clamps for intake system are loose I When compression pressure is measured. it is found to be low When breatherelementis inspected.P $ S c1 Oil consumption 1 Operated for long period suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load 1 yk? Amount of blow-by gas I Area around engine is dirty with oil There is oil in engine cooling water E . inside is found to be dirty with oil When turbocharger air supply pipe is removed. it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage shaft r Excessive play of turbocharger 1 When intake manifold is removed.TROUBLESHOOTING S-8 S-8 Oil consumption + is excessive (or exhaust smoke is blue) Do not run the engine at idling for more than 20 minutes continuously. Abnormal combustion of oil . dust is found inside 1 When intake manifold is removed. Operation under excessive load Legend 0 : Possible causes (judging from Questions and check items) 0 : Mo9 probable causes (judgingfrom Questionsand Check items) A: l : Items to confirm 1 Possible causes due to length of use (used for a long period) the cause.TROUBLESHOOTING s-9 S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly . Intake of exhaust gas due to internal wear . 1 Confirm recent repair history Amount of blow-by gas 20-416 0 PC300. 350-6 . Clogging of lubrication passage . Improper fuel . Improper oil used . Condition of fuel PC300. Leakage of fuel . 350-6 . Excessive injection of fuel Legend 0: Possible causes (judging from Questions and check items) 0 A: : Most probable causes (judgingfrom Questionsand Check items) Possible causes due to length of use (used for a long period) l : Items to confirm the cause. Improper condition of fuel injection .TROUBLESHOOTING s-10 S-IO Fuel consumption is excessive General causes why fuel consumption is excessive . TROUBLESHOOTING S-l 1 S-II Oil is in cooling water. or water level goes down General causes why oil is in cooling water . : Possible causes due to length of use (used for a long period) Confirm recent repair history ‘G 8 ga p Pressure-tightness test of oil cooler shows there is leakage I0 Pressure-tightness test of cylinder head shows there is leakage Remove cylinder head and inspect directly Remove oil pan and inspect directly + w a I0 1 14 20-418 0 PC300. 350-6 . or water spurts back. Internal leakage in lubrication system . Internal leakage in cooling system Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) n l : Items to confirm the cause. General causes why oil pressure lamp lights up . Leakage. Confirm I recent repair history Operated for long period nn 0 00 Lights up at low idling @ fin_ g . Defective oil pressure control . Metal particles Metal particles Oil is cloudy are found when oil is drained are stuck to oil filter element or smells of diesel oil 0 G ti white m When oil filter is inspec j ve or regulator valve. spring or standard value PC300. clogging. Ir When the oil pressure sensor is normal (see M mode). Improper oil used (improper viscosity) . high idling lamp lights up Sometimes lights up piping (external) leakage from hydraulic / 1 E P) C pressure 1 / V~V~V60~0~ 0 Q 0 1 1 Y 6 There is clogging. Deterioration of oil due to overheating Sr Standards for engine oil selection * Ambient temperature Type of fulid -4 -20 32 0 50 10 68 20 86 30 104°F 40°C 1 -?I I Engine oil Legend @: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) 0: Items to confirm the cause.o 5 2 Degree of use of machine Replacement to Operation Non-specified Condition of filters Manual oil is being used a 1 has not been carried out according when oil Lrghts up at low. wear of lubricating system . 350-6 20-419 0 .TROUBLESHOOTING s-12 S-12 Oil pressure caution lamp lights up (drop in oil pressure) Check that the monitor panel engine oil level lamp is not lighted up. There is oil in radiator cooling water Leave radiator cap open. General causes why oil level rises . fuel in oil) If there is oil in the cooling water.5 2 4 ‘: e IRemove water pump and inspect directly Remove rear seal and inspect directly When main pump is removed. 350-6 . Water in oil . and smells of diesel fuel) l Entry of oil from other component * Causes Legend 0 0 n : Possible causes (judging from Questions and check items) : Most probable causes (judgingfrom Questionsand Check items) : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. an abnormal number of bubbles appear. or water spurts back Water pump breather hole is clogged with mud When water pump breather hole is cleaned. seal is found to be damaged Remove head cover and inspect directly Remove injection pump and inspect directly 1 Defective contact of thermostat seal valve Remove oil pan and check directly / 20-420 0 PC300. carry out troubleshooting for “Oil is in cooling water”. When engine is run at idling. Fuel in oil (diluted. it is found to be low P . water comes out Oil level goes down in damper chamber Oil level goes down in hydraulic tank Engine oil smells of diesel fuel Fuel must be added more frequently 1 Pressure-tightness test of oil cooler shows there is leakaae 1 Pressure-tiahtness test of cvlinder head shows there is leakaae When compression pressure is measured.TROUBLESHOOTING s-13 S-13 Oil level rises (water. General causes why water temperature becomes too high . damage of fan) . Defective cooling circulation system * Carry out troubleshooting for chassis. Ir When the monitor panel water temperature gauge is normal. Lack of cooling air (deformation. go to troubleshooting of machine monitor system (M mode). Drop in heat dissipation efficiency . Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questionsand Check items) a: Possible causes due to length of use (used for a long period) Condition of overheating PC300.TROUBLESHOOTING s-14 S-14 Water temperature Ir becomes too high (overheating) Check that the monitor panel coolant level caution lamp is not lighted up. 350-6 20-42 0 1 . 350-6 . temperature of some cylinders is low Leakage of air between turbocharger and head.TROUBLESHOOTING s-15 S-15 Abnormal * noise is made l l Judge if the noise is an internal noise or an external noise. loose clamp Vibrating noise is heard from around muffler 20-422 0 PC300. General causes why abnormal noise is made Abnormality due to defective parts Abnormal combustion Air sucked in from intake system l starting engine. 1 0 I 0 I I I I I 0 0 0 a Y e I- PC300. 350-6 20-423 0 . Improper alignment . Abnormal combustion Legend 0: Possible causes (judging from Questions and check items) 0 A: : Most probable causes (judgingfrom Questionsand Check items) Possible causes due to length of use (used for a long period) .5 2 I :: Remove side cover and inspect directly Inspect directly for loose engine mounting bolts. General causes why vibration is excessive l Defective parts (abnormal wear.TROUBLESHOOTING S-16 S-16 Vibration + is excessive If there is abnormal noise together with the vibration.I5 I 2 Degree of use of machine erated for ion Condition of vibration Kr eased Exhaust smoke is black Remove oil pan and inspect directly p . carry out troubleshooting for “Abnormal noise is made”. broken cushion Inspect inside of output shaft (damper) directly Remove front cover and inspect directly Remove head cover and inspect directly Injection pump test shows that injection amount is incorrect I. breakage) . . ..... ............................................ [E2031 Short circuit in swing IE2131 Disconnection in swing is displayed is displayed system system ........................ speed sensor system solenoid system is displayed ......7 C..... for C mode ...... .............................. ............................. [E2221 Short circuit in LS-EPC solenoid [E2231 Disconnection [E2241 Abnormality IE2251 Abnormality IE2261 Abnormality [E2271 Abnormality Abnormality in LS-EPC solenoid in front pump in rear pump in pressure in engine system pressure pressure sensor system sensor system is displayed. is displayed..........20-494 [E2171 Model input error is displayed system ....20-487 ....5 C............20-484 20-485 c......... Short circuit in active mode (swing) Disconnection selection circuit in active mode solenoid (swing) is displayed system is displayed .... brake solenoid [E2041 Short circuit in pump IE2141 Disconnection merge/divider merge/divider solenoid solenoid system system is displayed......... ....9 C-IO C-l 1 c-12 c-13 C-l 4 c-15 C-16 c-17 C-18 c-19 c-20 c-21 c-22 C-23 iE2321 Short circuit in front pump TVC solenoid in front pump TVC solenoid is displayed is displayed IE2331 Disconnection IE2361 Short circuit in rear pump TVC solenoid IE2371 Disconnection in rear pump TVC solenoid system system is displayed.4 c................................. is displayed sensor power source system is displayed..................... ............. ... in pump IE2061 Short circuit in travel speed solenoid [E2161 Disconnection IE2311 [E2351 in travel speed solenoid is displayed is displayed system solenoid ...........................8 c..2 c...................... PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE) Points to remember when troubleshooting when abnormality pump controller system . ............................... ...... related pump controller system) parts ........ .. is displayed........................ [E2071 Short circuit in action mode (boom) (E2081 Disconnection in action mode (boom) brake solenoid solenoid solenoid system system system system is displayed is displayed............................20-477 ....................... on machine................................... in machine push-up (no service code displayed) .........................................................20-483 .............. ........6 c................................... 20-495 PC300...........20-452 20-454 Action taken by controller Judgement hydraulic Electrical occurs and problems (pump control table for governor........20-489 .........3 c.. ................................ power source system (controller system system LED is OFF) ................ .......................................... 350-6 20-451 0 ..........TROUBLESHOOTING OF GOVERNOR......20-479 20-481 20-482 .. .................................... ... 20-486 ....... ................................ and ......... ..................... 20-462 20-464 circuit diagram Abnormality c- 1 in controller 20-466 20-467 20-469 20-471 20-473 20-475 20-476 ................................................ is displayed...............................20-490 20-491 20-492 20-493 .............. is displayed .... note down the content of the display. 1) If any abnormality returns to normal by itself. Erasing the data in this way saves any wasted work. 3) After completing troubleshooting. then erase the display. 2. WHEN TROUBLESHOOTING PUMP Points to remember if abnormality returns to normal by itself In the following two cases. always erase the user code from memory. 350-6 .POINTS TROUBLESHOOTING TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM POINTS TO REMEMBER CONTROLLER SYSTEM 1. there is a high probability that the same problem will occur again. or if the monitor display returns to normal. or 2) If the connector is disconnected and the T-adapter is inserted. and the service code is no longer displayed. carry out troubleshooting according to the failure code that is displayed. or if the T-adapter is removed and the connector is returned to its original position when carrying out troubleshooting of the failure. User code memory retention function When displaying the abnormality code in memory and carrying out troubleshooting. (There are cases where mistaken operation or abnormalities that occur when the connector is disconnected are recorded by the memory retention function. After trying to re-enact the problem.) 20-452 0 PC300. so it is desirable to follow up this problem carefully. . defective contact. defective contact. defective contact in wiring harness between solenoid V04 (I) and chassis ground ((-1 side) 4. Short circuit with ground in wiring harness between controller CO1 (3) and solenoid V04 (2) ((+) side) 3.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code Service code Abnormal system Nature of abnormality ~232 Short circuit in front &HT~~~TVC solenoid 1. defective contact in wiring harness between controller CO2 (8) and TVC solenoid Cl3 (1) ((+) side) 3. short circuit inside rear pump TVC solenoid 2. short circuit inside front pump TVC solenoid 2. Short circuit with ground. Short circuit with ground. defective contact inside rear pump TVC solenoid 2. pump controller 1. Defective governor. Short circuit with power source in wiring harness between controller CO2 (19) and TVC solenoid CO4 (2) ((-1 side) 4. Disconnection. Defective governor. Disconnection. pump controller E03 in Disconnection swing holding brake solenoid system E213 1. pump controller 1. defective contact inside front pump TVC solenoid 2. Disconnection. short circuit with ground in wiring harness between controller CO2 (18) and TVC solenoid Cl3 (2) (1-I side) 4. pump controller 20-454 0 PC300. 350-6 . defective contactin wiring harness between controller CO2 (9) and TVC solenoid CO4 (1) ((+I side) 3. Disconnection. short circuit with ground in wiring harness between controller CO2 (8) and TVC solenoid Cl3 (I) ((+I side) 3. Defective governor. defective contact inside swing holding brake solenoid 2. Defective governor. Disconnection. pump controller E237 Disconnection in rear pump TVC solenoid system E203 Short circuit in swing holding brake solenoid system 1. short circuit inside swing holding brake solenoid 2. Short circuit with power source. short circuit with power source in wiring harness between controller CO1 (3) and solenoid V04 (2) ((+) side) 3. short circuit with ground in wiring harness between controller CO2 (19) and TVC solenoid CO4 (2) ((-1 side) 4. Short circuit with power source. Disconnection. Short circuit with ground. Disconnection. Short circuit with power source in wiring harness between controller CO2 (18) and TVC solenoid Cl3 (2) ((-1 side) 4. Defective governor. short circuit with ground in wiring harness between controller CO2 (9) and TVC solenoid CO4 (1) ((+) side) 3. pump controller E233 Disconnection in front pump TVC solenoid system E02 E236 Short circuit in rear pump TVC solenoid system 1. Defective governor. Disconnection. Disconnection. defective contact. the motor brake is not released. fuel control dial at MAX. the current (min. (However. 3. The current stops flowing to the solenoid.ys user code E02 on monitor 2. Ir If the abnormality is restored by the vibration of the machine.) 1. it resets the power source to restore to the proper condition. current. 2. (However. the current (min.60 Q of solenoid: Same as display for ~203 PC300. the current (min. In the case of 2. Ir If the abnormality is restored by the vibration of the machine. It displays user code E02 on the monitor panel. The swing acceleration is poor . there is a big drop in the engine speed which may result in the engine stalling. The current stops flowing to the TVC solenoid. the service code display does not go out. the service code display does not go out. it resets the power source to restore to the proper condition. 1A) continues to flow to the front pump TVC solenoid. 2. Makes output to TVC solenoid 0. auto-deceleration ON. 2. so no particular action is taken. Resistance 20 . Displays user code E03 on monitor panel. * If the abnormality is restored by the vibration of the machine. fuel control dial at MAX. levers at neutral.) 1. when the load is large. Makes output to TVC solenoid 0. the service code display does not go out. (However.) pump) Same as E233 (but for the rear Resistance 20 . Resistance IO-22R of solenoid: 1. resistance) Action by controller when mality is detected abnor- Problem that appears on machine when 1. 2. so the output of the front pump TVC valve increases and the overall speed becomes slower. 2. Displays user code E03 on monitor panel.) 1.60 R of solenoid: When the swing is operated. it resets the power source to restore to the proper condition. so no particular action is taken. it resets the power source to restore to the proper condition. It displays user code E02 on the monitor panel. Displays user code E02 on monitor panel. 1. If there is a short circuit with the ground at the (-1 end. so the upper structure does not swing. Ir If the abnormality is restored by the vibration of the machine.) 1. so no particular action is taken. there is abnormality No current flows to the front pump TVC solenoid. Makes output to TVC solenoid 0. (However. the service code display does not go out. it is the same as E232. levers at neutral. Resistance of solenoid: IO-22R Current: 1000 mA (H/O mode. the service code display does not go out. 2. * If the abnormality is restored by the vibration of the machine. 3. lI~n~. IA) continues to flow to the TVC solenoid. The current stops flowing to the TVC solenoid.) In the case of 1.) Same as E232 pump) (but for the rear Resistance of solenoid: 10-22 R Current: 1000 mA (H/O mode.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal voltage.) 1. IA) continues to flow to the TVC solenoid. it resets the power source to restore to the proper condition. Resistance IO-22a of solenoid: * If the’abnormality is restored by the vibration of the machine. it resets the power source to restore to the proper condition. (However. (However. the service code display does not go out. If there is a short circuit with the ground at the (-1 end. 2. Therefore. 350-6 20-455 0 . auto-deceleration ON. defective contact in wiring harness between solenoid V02 (1) and chassis ground ((-) side) 4. Short circuit with ground in wiring harness between controller CO1 (8) and solenoid V02 (2) ((+I side) 3. Short circuit with ground. Short circuit with ground. Disconnection. pump controller 1. Disconnection. pump controller 1. Disconnection. Disconnection.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code Service code Abnormal system Nature of abnormality - E204 Short circuit in pump merge/divider solenoid system 1. Disconnection. defective contact in wiring harness between solenoid V03 (2) and chassis ground ((-) side) 4. Disconnection. Defective governor. Disconnection. short circuit inside travel speed solenoid 2. Defective governor. pump controller 1. 350-6 . Defective governor. Defective governor. pump controller - E208 Disconnection in active mode (boom) solenoid system - E214 Disconnection in pump merge/divider solenoid system - E216 Disconnection in travel speed solenoid system - E217 Model selection input error 20-456 0 PC300. defective contact inside active mode (boom) solenoid 2. Disconnection. short circuit with power source in wiring harness between controller CO1 (2) and solenoid V03 (2) ((+I side) 3. Defective governor. defective contact. short circuit with power source in wiring harness between controller CO1 (9) and solenoid V02 (2) ((+I side) 3. defective contact. short circuit inside active mode (boom) solenoid 2. Defective governor. Disconnection. defective contact. pump controller 1. defective contact. short circuit inside pump merge/divider solenoid 2. short circuit with ground in model selection wiring harness C17(5) (6) (7) (13) (14) 2. defective contact inside pump merge/divider solenoid 2. short circuit with power source in wiring harness between controller CO1 (9) and solenoid V06 (2) ((+I side) 3. defective contact in wiring harness between solenoid V06 (1) and chassis ground ((-) side) 4. Short circuit with ground. Disconnection. pump controller - E206 Short circuit in travel speed solenoid systern - E207 Short circuit in active mode (boom) solenoid system 1. Short circuit with ground in wiring harness between controller CO1 (9) and solenoid V06 (2) ((+I side) 3. Short circuit with ground in wiring harness between controller CO1 (2) and solenoid V03 (2) ((+I side) 3. Defective governor. defective contact inside travel speed solenoid 2. pump controller 1. (7). it resets the power source to restore to the proper condition. 2. swing. Makes output to solenoid 0. it resets the power source to restore to the proper condition. it resets the power source to restore to the proper condition.) 1. (13) and chassis: Max. Even if the travel speed is switched. (However.) Detects abnormality in input 1) Retains data when starting switch is ON 2) Functions as PC100 when non-set conditions are input Same content as display for E204 . so no particular action is taken. travel speeds are all slow.60 R 1. resistance) Action by controller when mality is detected abnor- Problem that appears on machine when there is abnormality The pump merge/divider valve continues to merge the oil flow.60 R Same content as display for E206 . (However. (However. Resistance of solenoid: 20 .60 Sz . the service code display does not go out.) 1. . 1. Resistance of solenoid: 20 . or 2. * If the abnormality is restored by the vibration of the machine. it resets the power source to restore to the proper condition. (However.60 R Same content as display for E207 . the work equipment and swing speeds become faster. Ir If the abnormality is restored by the vibration of the machine. The steering is difficult to turn. it resets the power source to restore to the proper condition. the service code display does not go out. In the L/O and F/O modes.ACTION TROUBLESHOOTING TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal (voltage. The current stops flowing to the solenoid. the service code display does not go out. 350-6 20-457 0 . The current stops flowing to the solenoid.(14) and chassis: Min. Makes output to solenoid 0. Makes output to solenoid 0. Resistance of solenoid: 20 . Work equipment. 1 Q Between Cl7 (5). * If the abnormality is restored by the vibration of the machine. the service code display does not go out.60 R When mode is STD (active mode OFF). current. Resistance of solenoid: 20 . Resistance of solenoid: 20 .60 Q 1. the travel speed does not change (remains at Lo) . it resets the power source to restore to the proper condition. so no particular action is taken. so no particular action is taken. Engine stalls. 1 MR 1. the service code display does not go out. * If the abnormality is restored by the vibration of the machine. The current stops flowing to the solenoid. * If the abnormality is restored by the vibration of the machine. Ir If the abnormality is restored by the vibration of the machine.) 1. (However.) . the service code display does not go out. and there is no power PC300. the boom lower speeds become faster. Resistance of solenoid: 20 . (However.) 1. Between Cl7 (61. short circuit in wiring harness between controller CO3 (6) and pressure sensor CO8 (2) ((+I side) and between CO3 (16) and CO8 (1) ((-1 side) 3. pump controller 3. short circuit in wiring harness between controller CO3 (6) and pressure sensor CO7 (2) ((+I side) and between CO3 (16) and CO7 (1) ((-1 side) 3. short circuit with ground in wiring harness between controller CO2 (7) and solenoid Cl0 (1) ((+I side) 3.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User Service code code Abnormal system Nature of abnormality 1. defective contact. Disconnection. Defective governor. Abnormality in monitor in network - E218 Network overtime response error - E222 Short circuit in LSEPC solenoid system 1. short circuit with power source. short circuit with ground in wiring harness between controller CO2 (17) and solenoid Cl0 (2) ((-1 side) 4. defective contact inside LS-EPC solenoid 2. short circuit with ground inside front pump pressure sensor or rear pump pressure sensor 2. Disconnection. short circuit with ground in wiring harness between controller CO3 (6) and front pressure sensor CO8 (2) or rear pressure sensor CO7 (2) ((+) side) 3. Short circuit with power source. Disconnection. Defective governor. Disconnection. defective contact. defective contact. Disconnection. short circuit inside engine speed sensor 2. Short circuit with ground. pump controller 1. Short circuit. short circuit with ground in wiring harness between controller Cl6 (1) and speed sensor E07 (2) ((-1 side) and between Cl6 (2) and E07 (I) (SIG side) 3. Disconnection. pump controller 20-458 0 PC300. Disconnection. defective contact. Defective governor. Abnormality in governor. short circuit. Disconnection. defective contact. short circuit. Disconnection. defective contact in wiring harness between controller CO2 (7) and solenoid Cl0 (1) ((+) side) 3. short circuit inside LS-EPC solenoid 2. Short circuit with power source in wiring harness between controller CO2 (17) and solenoid Cl0 (2) ((-) side) 4. Defective governor. short circuit with ground in wiring harness between controller CO3 (13) and pressure sensor CO7 (3) (SIG side) 4. defective contact. short circuit with ground inside front pump pressure sensor 2. short circuit with power source. short circuit. Disconnection. Disconnection. pump controller 1. defective contact. defective contact. pump controller - E225 Abnormality in rear pump pressure sensor system - E226 Abnormality in pressure sensor power source system - E227 Abnormality in speed sensor system 1. pump controller 1. Disconnection. 350-6 . defective contact. Defective governor. short circuit with ground inside rear pump pressure sensor 2. pump controller - E223 Disconnection in LSEPC solenoid system - E224 Abnormality in front pump pressure sensor system 1. short circuit with ground in wiring harness between controller CO3 (3) and pressure sensor CO8 (3) (SIG side) 4. Defective governor. Short circuit. short circuit with ground wiring harness 2. 1. travel. (3) and chassis Resistance: Min. the panel display is switched.) 1.) 1.0 V (engine started) It operates about the same as G/O mode (prolix) (the power is slightly lower) PC300. (However. * If the abnormality is restored by the vibration of the machine. * If the abnormality is restored by the vibration of the machine. it switches the output OFF. @ Even when travel is operated. When communications are impossible with the monitor. and when all levers are returned to neutral.3. the service code display does not go out. Takes rear pump pressure as 0 MPa IO kg/cm*) when actuating. Takes front pump pressure as 0 MPa IO kg/cm21 when actuating.1000 R Voltage (AC range) : 0. it is the same as E222 2.4. (However. it resets the power source to restore to the proper condition.5 . Sr If the button is operated manually. 1 MR (Disconnect connectors CO3 and CO8.) 1. 1 MR (Disconnect connectors CO3 and CO7. electric current (min. The Lo travel speed is too fast. t If the button is operated manually. Makes output to LS-EPC solenoid 0.ACTION TROUBLESHOOTING TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal voltage. : ON (others are as usual) Resistance 7-14R of solenoid: 1.) Between CO3 (13) and (16): 0. Takes front pump and rear pump pressure as 0 MPa 10 kg/cm*} when actuating. the service code display does not go out. * If the abnormality is restored by the vibration of the machine. 1.5 v Between CO3 (6) and (16): 18-28V Between CO3 (female) (3) and (161. it resets the power source to restore to the proper condition.5 . * If the button is operated manually. 350-6 20-45 . In L/O and F/O modes. 3. When abnormality is detected. current.) Current: Approx. (13) and chassis Resistance: Min. Resistance: 500 . function does not work @ The swift speed-down function does not wor @II The auto-deceleration cannot be canceled @I The travel speed does not increase 5 The priority mode has no effect 6 The automatic mode has no 8 effect 1. When the engine is running at low idling. 2. the swing speed is too fast. The travel speed does not automatically shift (it does not change from Hi to Lo). If there is a short circuit with the ground at the (-1 end. the power max. Ir This automatic resetting is repeated up to 3 times. 1A) continues to flow to the LS-EPC solenoid. * If the abnormality is restored by the vibration of the machine. the service code display does not go out. In the case of 2. so the work equipment. the work equipment speed is too fast. Voltage between CO3 (6) and (16): 18 . 705 mA (Levers at neutral. 1 Working mode: G/O 2 Priority mode: OFF 3 Travel speed: Lo 4 Auto-deceleration: ON 15 Power max.5 .4. (However. the panel display is switched. and swing speeds are slow 1. 2. The travel speed does not automatically shift (it does not change from Hi to Lo). resistance) Action by controller when mality is detected abnor- Problem that appears on machine when there is abnormality 1. 2.28 V 1. it outputs again. the panel display is switched. control is carried out with the following settings. it resets the power source to restore to the proper condition. It functions in the equivalent 0 mode (the speed rises) of the G/ 1. low idling) Between CO3 (3) and (16): 0. (However.5 V Between CO3 (6) and (16): 18-28V Between CO3 (female) (13) and (16). The travel speed does not automatically shift (it does not change from Hi to Lo).) 1. IA) continues to flow to the LS-EPC solenoid. so no particular action is taken. the current (min. In the case of 1. The current stops flowing to the LSEPC solenoid. the service code display does not go out. it resets the power source to restore to the proper condition. 1. pump controller - E235 Disconnection in active mode (swing) solenoid system 20-460 0 PC300. Short circuit with ground in wiring harness between controller CO1 (10) and solenoid V07 (2) ((+I side) 3. defective contact inside active mode (swing) solenoid 2. short circuit inside active mode (swing) solenoid 2. short circuit with power source in wiring harness between controller CO1 (IO) and solenoid V07 (2) ((+I side) 3. Short circuit with ground. Defective governor. Defective governor. pump controller 1. Disconnection. defective contact in wiring harness between solenoid V07 (1) and chassis ground ((-1 side) 4. 350-6 . Disconnection. defective contact. Disconnection.TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User code Service code Abnormal system Nature of abnormality - E231 Short circuit in active mode (swing) solenoid system 1. current. ip?. the service code display does not go out. so no particular action is taken. .60 R Same as E231 PC300. (However. resistance) Action by controller when mality is detected abnor- Problem that appears on machine when there is abnormality In active mode and heavy-duty mode. Makes output to solenoid 0. Ir If the abnormality is restored by the vibration of the machine. it resets the power source to restore to the proper condition.gn. The current stops flowing to the solenoid. (However.) . 350-6 20-461 0 . the rise in the bucket edge is the same in swing + boom RAISE. * If the abnormality is restored by the vibration of the machine. Resistance of solenoid: 20 .ACTION TROUBLESHOOTING TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal (voltage.) 1. of solenoid: 1. the service code display does not go out. There is no priority. it resets the power source to restore to the proper condition. work equipment speed is faster than specified speed Machine push-up function does not work -c 5 : E 6 E 0 z 2 B 5 Travel deviation Deviation is excessive during normal travel Deviation is excessive when starting Travel speed is slow Steering does not turn or lacks power Travel speed does not switch or is faster than specified speed Does not move (one side only) Does not swing Swing acceleration is poor Both left and right One direction onlv Both left and right One direction only Both left and riaht I or swing speed is slow E Excessive overrun 1 Swing speed is faster than specified swing speed Troubleshooting Troubleshootinq r:This l :This f :This 3 :This shows shows shows shows code when service code is displayed code when there is abnormality in monitoring check at ront or rear) applicable item for service code (simultaneous abnormality applicable item for service code item that needs only checking with monitoring item to check with monitoring or machine monitor 20-462 0 PC300. PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS JUDGEMENT TABLE FOR GOVERNOR. 350-6 .TROUBLESHOOTING JUDGEMENT TABLE FOR GOVERNOR. F/O modes. oumo controller (E2:XX svsteml f . $ -? z s. PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS Governor. s i 5 Auto-deceleration does not work Fine control ability is poor or response is poor Boom is slow or lacks power Arm is slow or lacks power Bucket is slow or lacks power Boom does not move Arm does not move Bucket does not move Excessive hydraulic drift Excessive time lag (engine at low idling) Other equipment moves when single circuit is relieved In L/O. _ _ _ _ I 1 .TROUBLESHOOTING JUDGEMENT TABLE FOR GOVERNOR.1 . ‘24225 226227 I 0 /III/ 20 21 I 221 c: III 23 -_ In7llnlllIl7llnll~ll~ -. PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS * If service code E218 (abnormality in network system) is displayed.I.1. 350-6 20-463 0 .~F-l~F-2~F-3~F-4~F-5~F-6~F-7~F-E~F-S~F-lO~F-11~ -1 .1 - PC300. go to troubleshooting for N mode. TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE ELECTRICAL CIRCUIT DIAGRAM FOR C MODE TVC MONITOR PANEL III I I I I 55 TWP01415 20-464 0 PC300. 350-6 . 350-6 20-465 0 .TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE MACHINE PUSH UP SWITCH SWING LOCK SWITCH PUMP REDUNDANCY CIRCUIT SWITCH EOS(SWP141 - E07 (X21 ENGINE SENSOR 3!zBzm SPEED TWP01416 PC300. ) Cause Remedy YES 1 I Defective governor.TROUBLESHOOTING C-l C-l Abnormality OFF) in controller power source system (controller LED is This troubleshooting is carried out when there is still an abnormality. Always connect any disconnected connectors before going on the next step. Check that fuse 1 is not blown. or disconnection in wiring harness between fuse 1 H15(2)-M14(2)(1)banery relay M Replace Repair or replace * Turn starting switch ON. *20-30V NO Repair or replace C-l Related electric circuit diagram Governor. pump controller COl(MIC13) H14(M6) Fuse 1 @ H15(L2) I PGND PGND 0 @ 4. or disconnection in wiring harness between fuse 1 and CO1 (female) (7) (13) Defective contact. pump controller Defective contact. so when disconnecting the connector and inserting the T-adapter. Before carrying out troubleshooting. if an E service code is not displayed. When the starting motor rotates normally. (If the starting motor also does not rotate. m C02(MIC21) Battery relay Fusible link BKPOO186 20-466 0 PC300. check that all the related connectors are properly inserted. the problem has been removed. or when removing the T-adapter and returning the connector to its original position. 350-6 . go to E-8. * Turn starting switch OFF.chassis Resistance value CO5 (male) (1) . Before carrying out troubleshooting. 4 (3) .(female) (8) and (18).(31. 5 . (1) and chassis as Disconnect C02. * Turn TVC prolix switch OFF. 1 MR PC300.CO5 (female) cl). If the starting switch is turned OFF after an abnormality occurs. if an E service code is not displayed. (8) and chassis as shown in Table l? NO (male) (I) and (2). + Turn starting switch ON. (2) . check that all the related connectors are properly inserted. * Disconnect C05. the problem has been removed.chassis CO5 (female) (3) . (If it is not displayed. 1 MR value Cl3 (male) (1) . 1 f2 Min.(4) (l)(2)(3)(4) Max. or short circuit with power source in wiring harness between CO5 (female) (4) -H12 (4) -Cl3 (female) (2) starting switch OFF.(18) Troubleshooting Between Between CO5 (female) No. 1 hIO Replace * Turn starting switch OFF. Replace * Turn 1 NO “W I Is resistance 4 I Is resistance Repair or replace . or short circuit with power source in wiring harness between CO2 (female) (18) H12 (7) -CO5 (female) (2) Defective NC prolix switch (internal short circuit with ground or short circuit with power source) Short circuit with ground or short circuit with power source in wiring harness between CO5 (female) (3) .chassis Troubleshooting Between CO2 (female) No.chassis Table 2 Troubleshooting Between Between CO5 (male) No. 350-6 20-467 0 . Cause Remedy 3 YES Is resistance YES between CO2 2 . or when removing the T-adapter and returning the connector to its original position.TROUBLESHOOTING c-2 C-2 [E232] Short circuit in front pump WC displayed solenoid system is This troubleshooting is carried out when there is still an abnormality. * Disconnect C05.H 12 (3) Cl3 (female) (1). 3 (8) . Disconnect C13.) Always turn the n/C prolix switch OFF. Always connect any disconnected connectors before going on the next step. Repair or replace Table Between Between 1 Troubleshooting Cl3 (male) No. 2 (I) . .(4) Resistance IO-22R Min. Turn starting switch OFF.(2) Between CO2 (female) (8) .Interchange CO4 with C13. shown in Table l Defective governor. so when disconnecting the connector and inserting the T-adapter. the problem has been removed. turn the starting switch ON and check if an E service code is displayed. . pump controller Replace - GotoA connector with NO Defective front pump TVC solenoid (internal short circuit or short circuit with ground) Short circuit with ground or short circuit with power source in wiring harness between CO2 (female) (8) H12 (5) . 350-6 .TROUBLESHOOTING c-2 C-2 Related electric circuit diagram TVC prolix switch BKPO0187 20-468 a PC300. 1 C2 Min. if an E service code is not displayed. 4 (3) . or short circuit wth ground) Defective contact or disconnectio in wiring harness between CO5 (female) (3) . Is LE2331displayed? * Interchange CO4 with C13. defective contact.(4) (4) -chassis Resistance IO-22n Min. Before carrying out troubleshooting. Defective front pump WC solenoid (internal disconnection or defective contact) Defective contact or disconnection in wiring larness between CO2(female) :8). the problem has been removed. * Disconnect C05.(18) Troubleshooting Between Between CO5 (female) CO5 (female) No. Table I? * Disconnect C02. (2) .eplace Yr 4 Is resistance between CO5 (female ) (3) and (4). * Disconnect C05.H12 (4) -Cl3 (female) (2) qeplace -- YES ?epair or . turn the starting switch ON and check if an E service code is displayed. If the No.(2) Troubleshooting Between CO2 (female) No. * Disconnect 03. * Turn starting NO switch OFF.chassis Table 2 Troubleshooting Between Between No.H12 (3) . * Turn TVC prolix switch OFF. 1 MD PC300. the current (approx. or disconnection in wiring harness between CO5 (female) (4) . so when disconnecting the connector and inserting the T-adapter. the problem has been removed. If the starting switch is turned OFF after an abnormality occurs. Jr defective contact. Cause Remedy 3 YES Is resistance YES between CO2 .TROUBLESHOOTING c-3 C-3 [E2331 Disconnection displayed * in front pump WC solenoid svstem is * * * * * This troubleshooting is carried out when there is still an abnormality. 5 .) If there is a disconnection in the solenoid or wiring harness. Always connect any disconnected connectors before going on the next step. 350-6 20-469 0 . Always turn the TVC prolix switch OFF. * Replace From A -i *Turn starting switch OFF. (4) and chassis as shown in Table l? * Turn starting switch OFF. (If it is not displayed. 2 (I) . 1 A) continues to flow to the solenoid.Cl3 (female) (l). 2 pin of the solenoid is short circuiting with the ground.chassis Resistance value CO5 (male) (1) .(3). pump controller Replace NO Go to A 1 Interchange connector with rear pump TVC soleoid. + Turn starting switch ON.HI2 (7) -CO5 (female) (2) Defective TVC prolix switch (internal disconnection. check that all the related connectors are properly inserted.H12 (5) -CO5 (female)(l). no current flows to the solenoid. I NO Defective governor. r (female) (8) and YES Is resistance L between Cl3 (male) (1) and (2). IO Repair or replace Table Between Between 1 Troubleshooting Cl3 (male) No. (2) and * Turn starting chassis as shown in switch OFF.chassis Between CO2 (female) (18) . or when removing the T-adapter and returning the connector to its original position. or lisconnection in wiring aarness between CO2(female’ (18) . short :ircuit with grond. 3 (8) .(41 CO5 (male) (l)(2)(3)(4) 1 1 Max. 1 MR value Cl3 (male) (2) . pump controller C02(MIC21) r \ I H12(Sl6) CO5(SlO) @ I 0 0 04 05 6 3 I II F-WC(+) FTVCH @ @- 3 -@) 3 3 I L @ /=\ -I-- C13(X2) II BKFO0187 20-470 0 PC300. 350-6 .TROUBLESHOOTING c-3 C-3 Related electric circuit diagram TVC prolix switch Governor. . pump controller C02(MIC21) H12(S16) CO5(SlO) I 3 -3 A CO4(X2) Rear TVC valve _ $J @ I 2 BKP00188 20-472 0 PC300.TROUBLESHOOTING c-4 C-4 Related electric circuit diagram TVC prolix switch Governor. 350-6 . * Disconnect C05. If the starting switch is turned OFF after an abnormality occurs. so when disconnecting the connector and inserting the T-adapter. connector with -Turn starting switch OFF. 2 (I) . -Turn TVC prolix switch OFF. 1 MR PC300. Cause Remedy 3 Is resistance YES between CO2 2 r (female) 19) and (19). if an E service code is not displayed. * Turn starting switch ON.CO5 female) (7) Defective TVC prolix switch internal disconnection. Always turn the TVC prolix switch OFF.(81.H12 (8) . 1 A) continues to flow to the solenoid. check that all the related connectors are properly inserted. (6) (7) (8) (9) 4 and chassis as shown in Table 2? NO *Turn starting switch OFF. the problem has been removed.CO5(female) (6). Is fE2371 . Before carrying out troubleshooting.(9) CO5 (male) (6)(7)(8)(9) . o defective contact. or when removing the T-adapter and returning the connector to its original position. or disconnection n wiring harness between CO5 female) f91. 3 (9) . If the No.(6) and (8). (9) and chassis as shwon in Table l? starting switch OFF.(2) Troubleshooting Between CO2 (female) No.TROUBLESHOOTING C-5 C-5 [E237] Disconnection displayed * in rear pump WC solenoid system is t Ir t * * This troubleshooting is carried out when there is still an abnormality. or short :ircuit with ground) Iefective contact or disconnectionin wiring harness letween CO5Ifemale) (8) .CO4(female) (l). (2) and .H12 1) .chassis Resistance IO-22a Min. t NO YES Defective governor. turn the starting switch ON and check if an E service code is displayed. Disconnect C04.(19) Troubleshooting Between Between CO5 (female) CO5 (female) No.chassis Max. 1 MR value CO4 (male) (2) . (If it is not displayed. short circuit Nith ground. front Pump TVC NO solenoid. 2 pin of the solenoid is short circuiting with the ground. 350-6 20-473 0 . or disconnection n wiring harness between CO2 female) (19) . (7) . the problem has been removed. Table l? lnteiEhange * Disconnect C02. short circuit vith ground.chassis Between CO2 (female) (19) -chassis Table 2 Troubleshooting Between Between No. no current flows to the solenoid.* Turn starting 1 chassis as shown in switch OFF. NO Repair or replace From A = Is resistance between CO5 (female) (8) and (9).(I) and (21. displayed? * Interchange Cl3 with C04. 4 (8) . * Disconnect C05. Replace * Turn Repair or replace Table Between Between 1 Troubleshooting CO4 (male) No. defective contact. 1 L2 Min. Always connect any disconnected connectors before going on the next step. or defectivecontact. the current (approx.H12(2) -CO4 female) (21 Replace YES 5p Is resistance YES between CO5 (male) . pump controller Replace Defective rear pump TVC solenoid (internal disconnection or defective Iefective contact or disconnection in wiring larness between CO2Ifemale) 9) H12 (6) . Is resistance YES between CO4 (male) . (7) and (9).) If there is a disconnection in the solenoid or wiring harness. 5 Resistance value CO5 (male) (6) .(9) (9) . 350-6 . pump controller C02(MIC21) RNC(+) RNCk) H12(S16) r-B-l-& CO5(SlO) \ I 1 Rear NC valve -L : BKP00188 20-474 0 PC300.TROUBLESHOOTING c-5 C-5 Related electric circuit diagram Governor. If the starting switch is turned OFF after an abnormality occurs. NO Defective LS select solenoid (internal short circuit or short circuit with ground) Replace Table Between Between 1 V02 (male) (I) . 350-6 20-475 0 . Always connect any disconnected connectors before going on the next step. turn the starting switch ON and check if an E service code is displayed. the problem has been removed.(2) V02 (male) (2) . 60 R 1 MR C-6 Related Ens electric i ne throttle circuit diagram controller Active mode (boom) solenoid valve co1 (MIC13) TWPOl417 PC300. (If it is not displayed. pump controller Replace Short circuit with chassis ground in wiring harness between CO1 (female) (8) and V02 (female) (2) Repair or replace --with * Interchange V02 other connector. * Start engine. check that all the related connectors are properly inserted. or when removing the T-adapter and returning the connector to its original position. the problem has been removed. Cause Remedy 3 YES 2 r Is resistance between CO1 (female) (8) and YES Defective governor.) Before carrying out troubleshooting. if an E service code is not displayed.TROUBLESHOOTING C-6 C-6 [E207] Short circuit in active mode (boom) solenoid system is displayed This troubleshooting is carried out when there is still an abnormality.chassis 120 1Min. so when disconnecting the connector and inserting the T-adapter. * Active mode switch OFF. If the starting switch is turned OFF after an abnormality occurs. * Disconnect COl. the problem has been removed..resistance betweenCO1 3 Ife. * Max.fe. the problem has been removed. check that all the related connectors are properly inserted. is . if an E service code is not displayed.TROUBLESHOOTING c-7 C-7 [E208] Disconnection displayed * -k * * in active mode (boom) solenoid system is This troubleshooting is carried out when there is still an abnormality. * Turn starting switch ON.) Before carrying out troubleshooting. * Disconnect V02. Remedy Cause 4YE: WhenVO2 (female)(21is YES groundedto chassis. * Disconnect V02. Defective LS select solenoid (internal disconnection) Replace Defective gavernor. vo2. or when removing the T-adapter and returning the connector to its original position. IV N( Short circuit with power source in wiring harness between CO1 (female) (8) and V02 (female) (2) Repair or replace C-7 Related Enain electric e throttle circuit diagram controller co1 (MIC13) v(I3 (X2) a aActive mode (boom) solenoid valve ~03 (KES~ 2) -3 3 TWPO1417 20-476 0 PC300.Max. turn the starting switch ON and check if an E service code is displayed. 1 R NO NC - GotoA _ YES 2 Is resistance between V02 (male) (1) and (2) normal? Turn starting switch OFF. 181 and chassis _ * Turn starting switch OFF. (If it is not displayed. . * Max. 350-6 . Always connect any disconnected connectors before going on the next step. 1 n Short circuit with power ground.J Interchange V02 with other I NO * Turn starfing switch ON. *20-60R l Is resistance between V02 (female) (I) and chassis normal? *Turn starting switch OFF. so when disconnecting the connector and inserting the T-adapter. defective contact. pump controller From A Replace * Disconnect COI. or disconnection in wiring harness between CO1 (female) (8) and V02 (female) (2) Defective contact or disconnection in wiring harness between V02 (female) (1) and chassis. Repair or replace YES Repair or replace I _ IIE2081 displayed? l No . if an E service code is not displayed. the problem has been removed. or when removing the T-adapter and returning the connector to its original position. X05. *Turn swing lock switch OFF. the problem has been removed. Is LE2031 displayed? * Interchange V04 with other connector. so when disconnecting the connector and inserting the T-adapter. * Start engine. * Operate swing lever. NO - GotoA Defective swing holding brake solenoid (internal short circuit or short circuit Nith ground) Short circuit with chassi ground in wiring harness cetween CO1 (female) (3) 126 (l)(2).(2) ( 20 . 350-6 20-477 0 . Always turn the swing lock prolix switch OFF. _ 1 pInterchange connector with other solenoid. 1 MR PC300. 1 MD switch OFF.chassis Min. *20-60R . (If it is not displayed. then turn the swing lock switch OFF before checking. pump controller Replace Is resistance YES between V04 _ (male) (T) and (2).TROUBLESHOOTING C-8 C-8 [E203] Short circuit in swing brake solenoid system is displayed This troubleshooting is carried out when there is still an abnormality. *20-60R NO I NO YES Defective governor. turn the starting switch ON and check if an E service code is displayed.Disconnect NO Table Between Between 1 V04 (male) (1) .60 R V04 (male) (2) . check that all the related connectors are properly inserted. Cause Remedy 3 Is resistance YES between CO1 2 (female) (3) and chassis normal? *Turn starting switch OFF.) Before carrying out troubleshooting. If the starting switch is turned OFF after an abnormality occurs.H13 (I) -X01 (7) -X05 (male) (3) Short circuit with chassis ground in wiring harness between X05 (male) (4) -X01 (7) . . Always connect any disconnected connectors before going on the next step.H13 (7) -VO4 (female) (2) Defective swing lock sitch (internal short circuit with ground) xeplace 5 Is resistance YES between X05 4 r (male) (4) and YES sepair or ‘eplace Repair or replace chassis normlal? * Turn starting switch OFF.Disconnect X05. (2) and chassi nornal? P * Turn starting switch OFF. * Disconnect COl. * Min. * Disconnect V04. * Turn swing lock switch OFF. 350-6 .TROUBLESHOOTING C-8 C-8 Related electric circuit diagram Swing redundancy switch I I Engine throttle controller co1 (MIC13) ~26 (KES~ 2) H13 (S16) X01 (MIC21) g @ x05 (M4) I D05(~w a @ m \ I 2) L vo4 (X2) brake solenoid TWP01418 20-478 0 PC300. 350-6 20-479 0 . so when disconnecting the connector and inserting the T-adapter. Before carrying out troubleshooting.TROUBLESHOOTING c-9 C-9 [E213] Disconnection in swing brake solenoid system is displayed This troubleshooting is carried out when there is still an abnormality. 1 R Is resistance between X05 (male) (4) and chassis normal? * Turn starting switch OFF. or when removing the T-adapter and returning the connector to its original position. * Disconnect X05. turn the starting switch ON and check if an E service code is displayed. check that all the related connectors are properly inserted.chassis after all levers are returned lever operated (operated lever or work equipment PC300. * Turn starting switch ON. but it does not indicate a failure. defective contact. if an E service code is not displayed. * Disconnect V04. . then turn the swing lock switch OFF before checking. Note: When the swing prolix switch is operated. . Always connect any disconnected connectors before going on the next step.X01 (7) -X05 (male) (3) Short circuit with power source.HI3 . * Turn starting switch OFF.V04 (female) (2) Defective swing lock switch (internal disconnection or short circuit with power source) Repair or replace From A = Repair or replace Replace NO Table 1 No. If the swing prolix switch is operated. If the starting switch is turned OFF after an abnormality occurs.20-600 I Defective swing holding brake solenoid (internal disconnection or short circuit with power source) Replace YES 5 YES 4 P Is resistance between X05 (female) (3) and (4) normal? * Turn starting switch OFF.) Always turn the swing lock prolix switch OFF. * MAX.20-60R NO Defective contact or disconnection in wiring harness between D26 (female) (2) . the problem has been removed. (If it is not displayed.5 seconds Measurement condition to neutral in small movements) Troubleshooting Between D26 (1) .30 v Swing 4 . this error 12131 is detected. Is fE2131 displayed? * Interchange V04 with other connector. carry out troubleshooting (F-9) for the swing lock signal input system. pump controller Replace I connector with other solenoid. if error 12131 occurs. Note: Cause Remedy YE Defective governor. or disconnection in wiring harness between X05 (male) (4) -X01 (6) HI3 (7) . the problem has been removed. * Disconnect x05. 3 Voltage o-IOV 20 . 350-6 .TROUBLESHOOTING c-9 C-9 Related electric circuit diagram Swing redundancy switch Swing lock switch Engine ~26 (KES~ 2) I X01 (MIC21) @ a x05 hI4) H13 (S16) -3 -3 DO5 (KESl 21 e TWP01418 20-480 a PC300. If the starting switch is turned OFF after an abnormality occurs.(2) V03 (male) (2) . if an E service code is not displayed. Cause Remedy 3 Is resistance YES between CO1 2 . the problem has been removed. check that all the related connectors are properly inserted.) Before carrying out troubleshooting. (2) and .60 R 1Min. Is NO * Disconnect V03.*Turn starting switch OFF.(female) (2) and chassis normal? Is resistance YES betweenVO3knale) p . Table I? Interchange . or when removing the T-adapter and returning the connector to its original position. 1 MR C-IO Related electric circuit diagram Ensin e throttle controller CO1 (MIC131 TWPOl419 PC300. the problem has been removed. so when disconnecting the connector and inserting the T-adapter. pump controller Replace ~ NO Short circuit with chassis ground in wiring harness between CO1 (female ) (2) and V03 (female) (2) Repair or replace . * Operate travel independently. other solenoid.TROUBLESHOOTING C-IO C-IO [E204] Short circuit in pump merge/divider displayed Ir * * * solenoid system is This troubleshooting is carried out when there is still an abnormality.20-60R * Turn starting connector with switch OFF. [E2041 displayed? V03 with other connector.(I) and (21. chassis as shown in 1 * Disconnect COI. 350-6 20-48 1 0 . (If it is not displayed. * Start engine.chassis 20 . YES Defective governor.Interchange v NO Defective pump merge/divider soleoid (internal short circuit or short circuit with ground) Replace Table Between Between 1 V03 (male) (1) . turn the starting switch ON and check if an E service code is displayed. Always connect any disconnected connectors before going on the next step. * Turn starting switch ON. Max. * Disconnect COl. . so when disconnecting the connector and inserting the T-adapter. (If it is not displayed.) Before carrying out troubleshooting. * Turn starting switch ON. 1 V NC C-11 Related Engine electric throttle circuit diagram controller co1 (MIC13) vo3 (x21 a @ Meree/flow divider solenoid valve TWP01419 20-482 0 PC300. 350-6 . or when removing the T-adapter and returning the connector to its original position. If the starting switch is turned OFF after an abnormality occurs. Always connect any disconnected connectors before going on the next step. the problem has been removed.TROUBLESHOOTING C-II C-11 E2141 Disconnection displayed in pump merge/divider solenoid system is This troubleshooting is carried out when there is still an abnormality. if an E service code is not displayed. starting switch OFF. the problem has been removed. 1 R NO Repair or replace * Turn NO t Defective pump merge/divider solenoid (internal disconnection) Replace 5YE5 Defective governor. * Disconnect ~03. Is IE2141 displayed? * Interchange V03 with other connector. * Max. turn the starting switch ON and check if an E service code is displayed. *20-60R 1 NO * Turn starting switch OFF. Remedy 1When V03 (female) (2) i: FS resistance between CO1 (fern&l (2) and chassis I IL *Turn starting H NO r - GotoA Defective contact or disconnection in wirina harness between CO1 _ (female) (2) and V02 (female) (2) Defective contact or disconnection in wiring harness between V03 (female) (1) and chassis Repair or replace p Is resistance YES between V03 (male) (1) and (2) 1 normal? Interchange connector with _ other solenoid. pump controller Replace From A{=[’ Short circuit with power source in wiring harness between CO1 (female) (2) and V03 (female) (2) Repair or replace * Disconnect CO1 and V03. check that all the related connectors are properly inserted. 350-6 20-483 0 . Defective travel speed solenoid (internal short circuit or short circuit with ground) Reolace Table Between Between 1 V06 (male) (I) . if an E service code is not displayed.Operate the lever slightly not enough to move the machine. pump controller Replace Short circuit with chassis ground in wiring harness between CO1 (femle) (8) and VO2 (female) (2) Repair or replace --with * Interchange V06 other NO connector. so when disconnecting the connector and inserting the T-adapter. Cause Remedy 3 YES Is resistance YES 2 r between (female) CO1 (9) and Defective governor. a Travel solenoid va I ve speed TWP01420 PC300.TROUBLESHOOTING c-12 C-12 [E206] Short circuit in travel speed solenoid system is displayed This troubleshooting is carried out when there is still an abnormality. * Travel speed switch at Mi or Hi .. the problem has been removed. * Start engine.(2) V06 (male) (2) . I I _ lli\. turn the starting switch ON and check if an E service code is displayed. If the starting switch is turned OFF after an abnormality occurs. the problem has been removed.chassis 120 1Min. 60 R 1 ML2 C-12 Related electric throttle circuit diagram controller Ens i ne I”” \AL.) Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. or when removing the T-adapter and returning the connector to its original position. (If it is not displayed. check that all the related connectors are properly inserted. * Disconnect V06. * Max. 1 R NO 4YES is 1 r YES grounded to chassis. so when disconnecting the connector and inserting the T-adapter. Is ~ Is resistance between V06 (male) (I) and (2) normal? * Turn starting switch OFF. the problem has been removed. 1 hl I.1 I - I Do7 (KES~ 2) -3 3 TWPOI420 20-484 0 PC300. the problem has been removed. or when removing the T-adapter and returning the connector to its original position.* Disconnect CO1 and V06. * Disconnect V06. if an E service code is not displayed.20-60R Is resistance YES between V06 (female) (1) and 2 chassis normal? *Turn starting switch OFF. check that all the related connectors are properly inserted.) Before carrying out troubleshooting. * Disconnect CO1 and V06.TROUBLESHOOTING c-13 C-13 [E216] Disconnection displayed in travel speed selector solenoid svstem is . Cause Remedy p Yf 1 connector with other solenoid. turn the starting switch ON and check if an E service code is displayed. is . * Turn starting switch ON. 350-6 . . 1 V NC Short circuit with power source in wiring harness between CO1 (female) (9) and V06 (female) (2) Repair or replace C-13 Related electric circuit diagram Engine throttle controller CO1 (MIC13) 1 Travel speed solenoid _ V06 (X2) Travel solenoid valve m speed )(9. * Max. * Max. pump controller Replace From A * Turn starting switch OFF. Always connect any disconnected connectors before going on the next step. 1 R 1When VO6 lfemalel (2) - GotoA Defective contact or disconnection in wiring harness between CO1 (female) (9) and V06 (female) (2) Defective contact or disconnection in wiring harness between V06 (female) (1) and chassis Repair or replace NO Repair or replace * Interchange V06 with other connecror. (If it is not displayed.V Defective pump merge/divider solenoid (internal disconnection) 5 YES 1-H Defective governor. This troubleshooting is carried out when there is still an abnormality.resistance between CO1 3 (female1 (91 and chassis normal? NC * Turn starting switch OFF. If the starting switch is turned OFF after an abnormality occurs. check that all the related connectors are properly inserted. * Swing lock switch OFF. (If it is not displayed. pump controller Replace YE 1 connector with other solenoid. * Operate swing + boom raise lever slightly at the same time. the problem has been removed.) Before carrying out troubleshooting.I I solenolo valve I TWPOl421 PC300. if an E service code is not displayed. the problem has been removed. Interchange V07 I with other NO connector. * Active mode switch ON.(2) 120 . or when removing the T-adapter and returning the connector to its original position. * Disconnect V07. * Start engine. 1 MR C-14 Related electric circuit diagram Ene i ne throttle Ml controller h4lf?l?1 ... *Turn starting switch OFF. (2) and 1 7 l-l NO Short circuit with chassis ground in wiring harness between CO1 (female) (IO) and V07 (female) (2) Repair or replace (female) (IO) and chassis normal? * Turn starting switch OFF.60 R V07 (male) (2) . a @ 7 ~02 (KES~ 21 -3 -3 \ \ Active I \ Imode wIna.chassis Min. . Cause Remedy 3 YES YES- Defective governor.” I \n.TROUBLESHOOTING c-14 C-14 [E2311 Short circuit in active mode (swing) solenoid system is displayed * * + * This troubleshooting is carried out when there is still an abnormality. 350-6 20-485 0 . Is [E2311 displayed? between V07 (male) (1) and (Z). Always connect any disconnected connectors before going on the next step. If the starting switch is turned OFF after an abnormality occurs. * Disconnect COI. *20-60R . 1 NO Defective LS select solenoid (internal short circuit or short circuit with ground) Replace Table Between Between 1 V07 (male) (1) . turn the starting switch ON and check if an E service code is displayed. so when disconnecting the connector and inserting the T-adapter. * Turn starting switch ON. Always connect any disconnected connectors before going on the next step. or when removing the T-adapter and returning the connector to its original position. the problem has been removed. the problem has been removed. Remedy c ToA Defective contact or disconnection in wiring harness between CO1 (female) (10) and V07 (female) (2) Is resrstance YES between V07 (male) (1) and (2) Repair or replace r-l *Turn starting switch OFF. 1 V NO Short circuit with power source in wiring harness between CO1 (female) (10) and V07 (female) (2) Repair or replace C-15 Related Ena electric in e throttle circuit diagram controller Active mode (sw i ns) solenoid valve co1 (MIC13) Do2 (KEY -3 3 2) TWP01421 20-486 0 PC300. * Disconnect COI. if an E service code is not displayed.) Before carrying out troubleshooting. * Max. 350-6 . Disconnect V07. * Turn starting switch ON. . check that all the related connectors are properly inserted. 1 R +Max. switch OFF. NO 1R Defective contact or disconnection in wiring harness between V07 (female) (1) and chassis Repair or replace connector with other solenoid.solenoid system is This troubleshooting is carried out when there is still an abnormality.TROUBLESHOOTING c-15 C-15 [E2351 Disconnection displayed in active mode (swing) . (If it is not displayed. -l NO 5YES From A{=[ 11 NO Defective active mode (swing) solenoid (intern: disconnection) Replace Defective governor. so when disconnecting the connector and inserting the T-adapter. * Max. Is fE2351 displayed? * Interchange V07 with other connector. pump controller Replace * Disconnect CO1 and V07. If the starting switch is turned OFF after an abnormality occurs. turn the starting switch ON and check if an E service code is displayed. or when removing the T-adapter and returning the connector to its original position. short circuit with ground. NO Defective model selection connector. if an E service code is not displayed. 221.chassis . (If it is not displayed. Ir * * Cause Remedy YES 1 1Is monitoring I mode disolav as shown in Table Defective governor.chassis 20 . Always connect any disconnected connectors before going on the next step. Max. or short circuti in witing harness where voltage is defective Repair or replace Table 1 Monitoring Model Monitoring code display Model Monitoring code 21 selection signal input display Monitoring code 22 code display codes 02. 1 V 20 .chassis Between (13) . so when disconnecting the connector and inserting the T-adapter. If the starting switch is turned OFF after an abnormality occurs.30 v Max. the problem has been removed.chassis Between (14) . Table 2 Voltage Cl? Voltage of wiring harness Between (6) chassis 1V Between (7) Between (5) .~ t I’? * Turn starting N switch ON. turn the starting switch ON and check if an E service code is displayed.TROUBLESHOOTING C-16 C-16 [E2171Model selection input error is displayed * This troubleshooting is carried out when there is still an abnormality. Check the bit pattern display marked with t. * Turn si:arting switch ON.) Before carrying out troubleshooting. check that all the related connectors are properly inserted.30 v PC300. 350-6 20-487 0 . 031 and I21. pump controller I “~l-l 1 1 ~~yff&. * Set to monitorir 19 codes 102. 1 V Max. 03 3 BKP00193 1t ( _---_ PP_ + BKP00194 BKP00195 Ir The diagram shows monitoring code 02. the problem has been removed. or disconnection. TROUBLESHOOTING C-16 C-16 Related electric circuit diagram Engine throttle controller Cl7 (04016) I I ?a co9 1 2 3 4 TWP01422 Machine select connector H14 (M6) TfT- 20-488 0 PC300.350-6 . (female) (7) and (17). 1 (71and chassisas shown in Table I? * Turn starting switch OFF. turn the starting switch ON and check if an E service code is displayed. Always connect any disconnected connectors before going on the next step. If the starting switch is turned OFF after an abnormality occurs. pump controller Short circuit with ground or short circuit with power source in wiring harness between CO2 (female) (7) .) Before carrying out troubleshooting. if an E service code is not displayed. the problem has been removed. or when removing the T-adapter and returning the connector to its original position. so when disconnecting the connector and inserting the T-adapter.Cl0 (female) (2) Defective LS-EPC solenoid (internal short circuit with ground or short circuit with power source) Is resistance between Cl0 (male) (1) and (2). check that all the related connectors are properly inserted. or short circuit with power source in wiring harness between CO2 (female) (17) . the problem has been removed. pump controller C02(MIC21) LS-EPC solenoid valve BKP00251 PC300. (1) and chassis as shown in Table I? _ * Turn starting switch OFF.chassis Between CO2 (female) (7) . 2 Resistance value 7-14R Troubleshooting Between Cl0 (male) (I) .Cl0 (female) (I). 350-6 20-489 0 . (If it is not displayed.(17) Between CO2 (female) (7) .(2) Between Cl0 (male) (1) . * * * I 2 YES Cause Remedy Is resistance YES between CO2 .TROUBLESHOOTING c-17 C-17 [E2221 Short circuit in LS-EPC solenoid system is displayed * This troubleshooting is carried out when there is still an abnormality. 1 Troubleshooting No. * Disconnect CIO. NO Repair or replace l NO Table 1 No. Disconnect CO2 I Defective governor.chassis Min. 1 MR C-17 Related electric circuit diagram Governor. Ir Always connect any disconnected connectors before going on the next step. so when disconnecting the connector and inserting the T-adapter. 350-6 . turn the starting switch ON and check if an E service code is displayed.chassis 1 Resistance I 7-14R value 1 I Between Between Cl0 (male) (1) . short circuit with ground.(17) (17) . 1 I 1Betieen Between Troubleshootina CO2 (female) CO2 (female) No. check that all the related connectors are properly inserted. I switch OFF. Replace NO Table 1 Troubleshootinq No. the problem has been removed. pump controller Defect contact or short circuit with chassis ground in wiring harness between CO2 (female) 171and Cl0 (female) (1).chassis Min. or short circuit with ground) Repair or replace * Turn starting switch OFF. 2 (7) . 1 M!Z C-18 Related electric circuit diagram Governor. defective contact. or disconnection in wiring harness between CO2 (female) (17) .) Sr Before carrying out troubleshooting. (If it is not displayed. * If the starting switch is turned OFF after an abnormality occurs. or when removing the T-adapter and returning the connector to its original position. if an E service code is not displayed.TROUBLESHOOTING C-18 C-18 [E223] Disconnection * in LS-EPC solenoid system is displayed This troubleshooting is carried out when there is still an abnormality. * Disconnect COZ.(2) Cl0 (male) (2) . or defective contact. DumD controller COiiMICil) ClO(X2) cg @ BKPO0251 20-490 0 PC300. * Disconnect ClO. Cause Remedy 2 YES II I Is resistance Defective governor.Cl0 (female) (2) Defective LS-EPS solenoid (internal disconnection. the problem has been removed. defective contact.5 v 4 YES Is voltage between CO8 (2) NO and chassis normal? I 1 I Repair or replace Repair or replace *Turn starting switch OFF. or short circuit with ground) Replace - P Is voltage between CO8 (2) and (1) normal? * Turn starting switch ON. If the starting switch is turned OFF after an abnormality occurs. pump controller Short circuit with powe source. lever NEUTRAL.5 .) Before carrying out troubleshooting. Always connect any disconnected connectors before going on the next step. *18-28V *Engine at high NO ilding _ * Operate repeatedly arm IN reliefe. check that all the related connectors are properly inserted.I 16)and CO8(female) (2) Defective front pump pressure sensor (internal disconnection. the problem has been removed. or disconnection in wiring harness between CO3 (female) (16) and CO8 (female) (1) Short circuit with ground. defective contact. * 0. turn the starting switch ON and check if an E service code is displayed. or when removing the T-adapter and returning the connector to its original position. if an E service code is not displayed. Interchange CO7 with C08.CO8 (female) (3) Short circuit with ground.4. I 3 YES YES 2-p Is voltage between CO3 (3) and (16) normal? Cause Remedy Defective governor. *18-28V NO Repair or replace IO Replace I C-19 Related electric circuit diagram Governor. the problem has been removed. or disconnection in wiring harness between CO3(female. pump controller CO3(04020) Front pump pressur sensor SIG Pressure sensor power source Pressure sensor GN CO8(XO2) ($ a a Front pump pressure sensor PC300. * Engine at high idling l * Disconnect C08. * Turn starting switch ON. defective contact. defective contact. 350-6 20-491 0 . (If it is not displayed. or disconnection in wiring harness between CO3 (female) (3) . so when disconnecting the connector and inserting the T-adapter.TROUBLESHOOTING Cl9 C-19 [E224] Abnormality displayed * in front pump pressure sensor system is * * * This troubleshooting is carried out when there is still an abnormality. short circuit. short circuit. or disconnection in wiring harness bewtween CO3 (female) 116)and CO7(female] 11) Short circuit with ground. Cause Remedy 3 YES YE pHp Defective governor. the problem has been removed.5 . so when disconnecting the connector and inserting the T-adapter. Always connect any disconnected connectors before going on the next step.CO7 (female) (3) Short circuit with ground. defective contact. or short circuit with ground) Replace 2 YE bwtween CO7 (2) and (1) normal? I I connector with *Turn starting switch ON. If the starting switch is turned OFF after an abnormality occurs. * Engine at high idling * Disconnect CO7. . pump controller Short circuit with power source. turn the starting switch ON and check if an E service code is displayed.) Before carrying out troubleshooting. *18-28V N NO * Engine at high idling * Operate repeatedly arm IN relief-lever NEUTRAL. or disconnection in wirino harness between CO3fiemalel (61and CO7(female) (2) Defective rear pump pressure sensor (internal disconnection.5 v 4 YES Repair or replace Repair or replace . defective contact. * 18-28V NO Repair or replace Replace C-20 Related electric circuit diagram Governor.TROUBLESHOOTING c-20 C-20 [E225] Abnormality displayed in rear pump pressure sensor system is This troubleshooting is carried out when there is still an abnormality. 350-6 . (If it is not displayed. Turn starting switch ON. check that all the related connectors are properly inserted. defective contact. if an E service code is not displayed. or disconnection in wiring harness between CO3 (female) (13) . pump controller CO3(04020) Pressure sensor power source Rear pump pressure sensor SIG CO7(XO3) a a Rear pump pressure sensor I I @ 20-492 0 PC300. Interchange CO8 with C07. or when removing the T-adapter and returning the connector to its original position. defective / contact.4.pH- * Turn starting swtich OFF. . the problem has been removed. * 0. 350-6 20-493 0 .18-28V - Replace Turn starting switch OFF. so when disconnecting the connector and inserting the T-adapter. pump controller Replace ~ Replace - * Turn starting switch ON. the problem has been removed. * Min.) Before carrying out troubleshooting. 1 MD l * Disconnect C07. Always connect any disconnected connectors before going on the next step. check that all the related connectors are properly inserted. C07. pump controller CO3(04020) Front pump pressure sensor SIG Pressure sensor power source Rear pump pressure sensor SIG Pressure sensor GNC Front pump pressure sensor . * Turn starting switch ON. If the starting switch is turned OFF after an abnormality occurs. or when removing the T-adapter and returning the connector to its original position. * Disconnect C08. and C08. turn the starting switch ON and check if an E service code is displayed.TROUBLESHOOTING c-21 C-21 [E226] Abnormality displayed in pressure sensor power source system is This troubleshooting is carried out when there is still an abnormality. the problem has been removed. * Disconnect C03. (If it is not displayed. Rear pump pressure sensor BKPW1254 PC300. . if an E service code is not displayed. *18-28V NO NO Short circuit or short circuit with ground in wiring harness of system where resistance value is defective Repair or replace C-21 Related electric circuit diagram CO8(X3) Governor. YES 2 Is voltage YES between CO3 (6) and (16) normal? Is voltage between CO3 (6) NO and (16) normal? Defective front pump pressure sensor (internal short circuit or short circuit with ground) 3 YES Defective rear pump pressure sensor (internal short circuit or short circuit with ground) Defective governor. E07 (female) (2). check that all the related connectors are properly inserted. * Disconnect C16.) Before carrying out troubleshooting. the problem has been removed. pump controller Short circuit with ground. *500-lOOOR l Repair or replace Replace C-22 Related electric circuit diagram Governor.E08 (9) . or disconnection in wiring harness between Cl6 (female) (1) .E07 (female) (1) Defective engine speed sensor (internal disconnection. defective contact. or short circuit with ground) Replace - I Is resistance between E07 (male) (1) and (2) normal? Turn starting switch OFF. the problem has been removed. pump controller C16(MIC17) E08(SWP14) E07iX2) BKPCO255 20-494 a PC300. so when disconnecting the connector and inserting the T-adapter.TROUBLESHOOTING c-22 C-22 [E227] Abnormality in engine speed sensor system is displayed This troubleshooting is carried out when there is still an abnormality. turn the starting switch ON and check if an E service code is displayed. Cause Remedy 2 YES I r Is resistance between Cl6 (female) (I) and (2) normal? -k * Turn starting switch OFF. 350-6 . *500-lOOOR NO YES Defective governor.E08 (IO) . or when removing the T-adapter and returning the connector to its original position. * Disconnect E07. if an E service code is not displayed. defective contact. Always connect any disconnected connectors before going on the next step. If the starting switch is turned OFF after an abnormality occurs. or between Cl6 (female) (2) . (If it is not displayed. * Disconnect V05.X01 (16)-H13 (3 . defective contact. *20-60R NO Defective machine push-up solenoid (internal disconnection or defective contact) 4 YES Short circuit with ground. the service code is not displayed on the monitor panel. * 20 . * Carry out troubleshooting with the machine tion. Switch NO OFF: Min. defective contact. machine push-up switch is set to low-pressure push-up switch at the low-pressure setting posi- Cause Remedy YI Defective contact or disconnection in wiring harness between V05 (female) (I) and chassis ground I I I Repair or replace 1 Is voltage between V05 (2) and chassis normal? * Turn starting switch ON. *20-3ov .V05 (female) (2) Defective machine push-up switch (internal disconnection.31 2) L=Dl H 13 (S 161 . 2 is not blown. If solenoid is not actuated (turned ON) when setting * Check that fuse No.30 v * Turn starting switch OFF. 350-6 20-495 0 .TROUBLESHOOTING C-23 C-23 Abnormality in machine push-up solenoid system (no service code displayed) * * * a) Even if any abnormality occurs in the machine push-up solenoid system.- a a Machine push UP solenoid valve TWPO1423 PC300. Always connect any disconnected connectors before going on the next step. defective contact. check that all the related connectors are properly inserted. or short circuit with ground) Replace 17 Repair or replace Replace h * Turn starting switch ON. or disconnection in wiring harness between fuse 2 X01 (12) -M38 (male) (2) Repair or replace C-23 Related electric circuit diagram Fuse Do6 (~5.. or disconnection in wiring harness between M38 (male) fl). Before carrying out troubleshooting. 1MR Defective fuse 2 or short circuit with ground. * Max. 350-6 .TROUBLESHOOTING C-23 b) If solenoid is not canceled (turned OFF1 when setting * Carry out troubleshooting with the machine tion. and chassis N normal? * Turn starting switch ON.V05 (female) (2) Repair or replace C-23 Related electric circuit diagram Fuse D~~(KEs~ 2) TWP01423 20-496 0 PC300. * Max. 1 V NO Replace * Turn starting switch ON. 1 V Short circuit with power source in wiring harness between M38 (male) (1) X01 (16) . machine push-up push-up switch is set to high-pressure setting posi- switch at the high-pressure Cause Remedy YES Defective machine push-up solenoid (internal short circuit with power source) Defective machine push-up switch (internal short circuit with power source) Replace between V05 (2) 2 YES Is voltage between M38 (1) .HI3 (3) . ...................... switch does not light up ...... ......9 F-IO F-II circuit diagram 20-(l) for F mode.20-513 .........20-505 20-506 20-507 ...............................20-508 ......4 F...................................................TROUBLESHOOTING OF GOVERNOR........................ Kerosene L. .......1 F..................... switch does not light up ........... Swing oil pressure oil pressure switch does not light up ...........20-514 Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern Bit pattern 20-(2) Travel 20-(3) Boom 20-(4) Boom LOWER oil pressure RAISE oil pressure 20-(5) Arm IN oil pressure switch does not light up ... switch switch does not light up............20-509 20-510 20-51 1 .......... PC300.. ............. 350-6 20-501 0 .......................8 F.... .20-504 ................ switch does not light up........................2 F.....7 F....................... ...................................................... switch does not light up.............H............. PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE) Electrical F......5 F................................ .................. knob switch does not light up .....3 F............... 20-(6) Arm OUT oil pressure 21-(l) 21-(2) Bucket CURL oil pressure Bucket DUMP oil pressure 21-(3) Swing 22-(5) 22-(6) lock switch does not light up......... does not light up .................6 F...... mode connection does not light up........20-512 .. 20-502 .............. 350-6 .TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE ELECTRICAL CIRCUIT DIAGRAM STARTING SWITCH SWING FOR F MODE REDUNDANCY SWITCH TVC RESISTER coti IMZI L_---___-_I M45043) NETWORK !!I ’ I 1 BUS r PC300. TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE E08ISWPl4) E07 1x2) ENGINE SENSOR IzIIz@D SPEED E THROTTLE :oI lWIC13) CONTR_OA :R TWP01416 PC300. 350-6 20-503 0 . Turn the swing lock switch ON before operating the swing lever. 1 R * Between wiring harness and chassis: Min. check that all the related connectors are properly inserted. or disconnection in wiring harness between Cl6 (female) (5) and SO8 (female) (2) Defective swing oil pressure switch (If the condition does not return to normal even when the switch is replaced.) Before carrying out troubleshooting. check the voltage between Cl6 (5) and the chassis. 350-6 . pump controller C16tMIC17) SO8(X2) Swing oil pressure switch BKPCiJ257 20-504 0 PC300. or when removing the T-adapter and returning the connector to its original position. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO F-l Related electric circuit diagram Governor. 1 R * See Note 1. * Disconnect Cl6 and S08. (See H-5) (When measuring with the engine stopped. If there is no display when the lever is operated on one side. the problem has been removed. pump controller Defective contact. In this case. 1 MR Replace Note 1: It is also possible to fit a short connector and judge the condition. 1 MR Swing lever operated: Max. A * + * Cause Remedy YES Defective governor. IV l Repair or replace SO8{male) D) and (2) l l Disconnect SOS. if the monitor code c. so when disconnecting the connector and inserting the T-adapter. Start engine. the PPC shuttle valve is defective. or disconnection in wiring harness between SO8 (female) (1) and chassis ground Defective contact.lisplay returns to normal. * Swing lever at IO neutral : Min. * Swing lever at neutral :20-3ov Swing lever opereated : Max. l * Turn starting switch OFF. * Between Cl6 and SO8 Max. Always connect any disconnected connectors before going on the next step. short circuit with ground. charge the accumulator first. go to H-5.TROUBLESHOOTING F-l F-l Ir Bit pattern 20-(l) Swing oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality. between Cl6 (51 Yi Repair or replace * Start engine. check that all the related connectors are properly inserted. 1MR * Travel lever operated : Max: 1 R * See Note 1. (See H-5) (When measuring with the engine stopped. YES Defective contact. or disconnection in wiring harness between SO1 (female) (1) and chassis ground Defective contact. if the monitor code display returns to normal. In this case. Always connect any disconnected connectors before going on the next step. the PPC shuttle valve is defective. 1 V *Turn starting switch *Disconnect C16and l NO Repair or replace * Disconnect SO1 * Start engine. so when disconnecting the connector and inserting the T-adapter. pump controller 1 1s voltage between Cl6 and chassis normal? l r (13) YES r 2 1s resrstance between SO1 (male) (1) and (2) . pump controller C16(MIC17) Travel oil pressure switch PC300. charge the accumulator first. 1 n -Between wiring harnessand chassis: Min. Between Cl6 and Sol: Max.) Replace Note 1: It is also posibble to fit a short connector and judge the condition. 350-6 20-505 0 . or disconnection in wiring harness between Cl6 (female) (13) and SO1 (female) (2) Repair or replace Start engine. 1 MQ Defective travel oil pressure switch (If the condition does not returen to normal even when the switch is replaced. or when removing the T-adapter and returning the connector to its original position. * Travel lever at neutral : 20-30V * Travel lever operated : Max.) Before carrying out troubleshooting. go to H-5. a Ir * * Cause YES Defective governor. Sol. check the voltage between Cl6 (13) and the chassis. Before operating the travel lever.normal. short circuit with ground. check that the surrounding area is safe. and is circuit NO insulated from chassis? 3 Is resistance between Cl6 (female) (131 and SO1 (female) (2) normal. the problem has been removed. and is circuit insulated from chassis? OFF. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO F-2 Related electric circuit diagram Governor.TROUBLESHOOTING F-2 F-2 Bit pattern * 2042) Travel oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality. * Travel lever at NO neutral : Min. If there is no display when the travel lever is operated on one side. 350-6 .) Replace Note 1: It is also possible to fit a short connector condition. * Disconnect Cl7 and S04. short circuit with ground. and judge the between Cl7 Turn starting switch OFF.TROUBLESHOOTING F-3 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality.30V * Boom lever operated to LOWER: Max. 1 Ma * Boom lever operated to LOWER: Max. 1 MR l Defective boom LOWER oil pressure switch (If the condition does not return to normal even when the switch is replaced. Ir * Cause Remedy YES Defective governor. pump controller Replace H 1 Is voltage between Cl7 (IO) and chassis normal? YE Defective contact. pump controller C17(04016) oil m+ BKP00259 20-506 a PC300. * Boom lever at neutral: 20 . Always connect any disconnected connectors before going on the next step. go to H-5. *Ifitis20-30V:GotoYES * If it is less than 1 V: Go to NO F-3 Related electric circuit diagram SO4(X2) Boom LOWER pressure switch Govermor. * Between Cl7 and S04: Max. and is circuit + Disconnect S04. g When measuring with the engine running. or disconnection in wiring harness between Cl7 (female) (10) H13 illi -SO4 (female] (21 Repair or replace * Stan engine. charge the accumulator first.) Before carrying out troubleshooting. or when removing the T-adapter and returning the connector to its original position. (When measuring with the engine stopped. 1 42 * See Note 1. or disconnection in wiring harness between SO4(female) (1) and chassis ground Defective contact. so when disconnecting the connector and inserting the T-adapter. check the voltage (IO) and the chassis. * Boom lever at No neutral : Min. * Start engine. IV Repair or replace normal. 1 R * Between wiring harness and chassis : Min. the problem has been removed. check that all the related connectors are properly inserted. if the monitor code display returns to normal. In this case. operate the lever slightly and make sure that the work equipment does not move. ) Before carrying out troubleshooting. * See Note 1. pump controller C17(04016) BKF’OOZSO PC300. 1 R. short circuit with ground. * Boom lever NO normal. When measuring with the engine running. check that all the related connectors are properly inserted. chassis? * Boom lever at is resistance between p NO . 350-6 20-507 0 . 1 MR * Start engine. or when removing the T-adapter and returning the connector to its original position. * If it is 20 . go to H-5. 1 V * Between wiring harness and chassis * Disconnect S02. if the monitor code display returns to normal. In this case.Turn starting switch neutral: 20 . or disconnection in wiring harness between SO2 (female) (I) and chassis ground Defective contact. (When measuring with the engine stopped.TROUBLESHOOTING F-4 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up * This troubleshooting is carried out when there is still an abnormality.H13 (9) . * Boom lever at NO neutral: Min. l Repair or replace Repair or replace Replace Note 1: It is also possible to fit a short connector and judge the condition. operated to RAISE insulatedfrom chassis? d * Between Cl7 and SO2 : Max.30V _ SO2 (male)11)and (21 OFF. 1 L! : Max. pump controller Defective contact. 1 MR * Boom lever operated to RAISE : Max. g Ir * Cause Remedy YES Defective governor. the problem has been removed. : Min. so when disconnecting the connector and inserting the T-adapter.and is circuit * Disconnect Cl7 and S02. check the voltage between C17 (2) and the chassis.30V: Go to YES + If it is less than 1V: Go to NO F-4 Related electric circuit diagram SO2(X2) H13(S16) @ m ($ @ Boom RAISE oil pressure switch Governor.SO2 (female) (2) Defective boom RAISE oil pressure switch (If the condition does not return to normal even when the switch is replaced.) Replace 3 between Cl7 (2) ____ Is resistancebetween YES Cl7 (female) I21and YES SO2(female) (21 normal. and is circuit insulated from 2 Start engine. charge the accumulator first. Always connect any disconnected connectors before going on the next step. operate the lever slightly and make sure that the work equipment does not move. or disconnection in wiring harness between Cl7 (female) f21. eplace qepair or . and is circuit * Arm lever NO insulated from * Disconnect Cl7 and S05. pump controller Defective contact.H13(IO) .TROUBLESHOOTING F-5 F-5 Bit pattern 2045) Arm IN oil pressure switch does not light up * This troubleshooting is carried out when there is still an abnormality. pump controller C17(04016) Arm IN oil pressure switch 8 BKPoo261 20-508 0 PC300. 1 V * Between wiring harness and chassis * Disconnect S05. 1 MR Start engine.SO5 ifemale) 12) Defective arm IN oil pressure switch (If the condition does not return to normal even when the switch is reolaced.) Before carrying out troubleshooting.) Is voltage between Cl7 (3) and chassis normal? qepair or . operate the lever slightly and make sure that the work equipment does not move. * If it is 20 . or when removing the T-adapter and returning the connector to its original position. check the voltage between Cl7 (3) and the chassis. short circuit with ground. Always connect any disconnected connectors before going on the next step. 1 R * See Note 1. or disconnection in wiring harness between SO5 (female) (1) and chassis ground Defective contact. 1 MQ * Arm lever operated to IN: Max. l Defective governor. check that all the related connectors are properly inserted. if the monitor code display returns to normal.3OV: Go to YES * If it is less than 1V: Go to NO F-5 Related electric circuit diagram SO5(X2) H13(S16) @ m @ a Arm IN oil pressure switch Governor. When measuring with the engine running.30V switch OFF. and is circuit insulated from 2 * Start engine. In this case. operated to IN chassis? * Between C17 and S05: Max. 1 R : Max.eplace Replace * Arm lever at NO neutral : Min. : Min. 350-6 . or disconnection in wiring harness between Cl7 (female) (3) . go to H-5. chassis7 Is * Arm lever at NO SO5(male) (1) and (2) * Turn starting neutral: 20 . the problem has been removed. L normal. A * * Cause Remedy YES 1 Is resistance betwe$ YES _ Cl7 (female) 13)and YES SO5(female) (2) r normal. charge the accumulator first. so when disconnecting the connector and inserting the T-adapter. (When measuring with the engine stopped. Note 1: It is also possible to fit a short connector and judge the condition. (When measuring with the engine stopped. if the monitor code display returns to normal. Arm lever ND insulatedfrom * Disconnect Cl7 and S03. : Min. In this case. Always connect any disconnected connectors before going on the next step. check that all the related connectors are properly inserted. * If it is 20 .30V normal. 1 V * Between wiring harness and chassis * Disconnect S03. . 350-6 20-509 0 . 1 R * See Note 1. the problem has been removed. * Between Cl7 and S03: Max. or disconnection in wiring harness between SO3 Eo. 1 MD * Arm lever operated to OUT: Max. and is circuit insulated from 2 * Start engine. Cause Remedy YES Defective governor. charge the accumulator first.l$ (1) and chassis Defective contact.Arm lever at NO neutral : Min. When measuring with the engine running.. operate the lever slightly and make sure that the work equipment does not move. pump controller C17(04016) BKPoo262 PC300.TROUBLESHOOTING F-6 F-6 Bit pattern 2046) Arm OUT oil pressure switch does not light up a * * This troubleshooting is carried out when there is still an abnormality. 1 MR * Start engine. so when disconnecting the connector and inserting the T-adapter. or disconnection in wiring harness between Cl7 (female) (11) . go to H-5. chassis? resistance between ~ * Arm lever at NO SO3Imale) 11)and (2) * Turn starting neutral: 20 .HI3 (12) SO3 (female) (2) Defective arm OUT oil pressure switch (If the condition does not return to normal even when the switch is replaced. - 3 - Repair or replace Repair or replace l Note 1: It is also possible to fit a short connector and judge the condition. check the voltage between Cl7 (11) and the chassis.3OV: Go to YES . 1 R OUT: Max. or when removing the T-adapter and returning the connector to its original position. pump controller Defective contact.If it is less than 1V: Go to NO F-6 Related electric circuit diagram SO3(X2) H13(S16) @ 77-T @ g Arm OUT oil pressure switch Governor.and is circuit switch OFF. short circuit with ground.) 1 between Cl7 (II) YES Is resistance between Cl7 (female) 111) and YES SO3 (female) (2) normal. operated to chassis? .) Before carrying out troubleshooting. if the monitor code display returns to normal. Bucket lever NO insulated from * Disconnect Cl6 and S06. 350-6 . Note 1: It is also possible to fit a short connector condition.normal. the problem has been removed. and is circuit normal? insulated from 2 Start engine. charge the accumulator first.30V: Go to YES * If it is less than 1V: Go to NO and judge the between Cl6 Replace F-7 Related electric circuit diagram Governor. operate the lever slightly and make sure that the work equipment does not move. check that all the related connectors are properly inserted. 1 fi + See Note 1. When measuring with the engine running. check the voltage (11) and the chassis. or when removing the T-adapter and returning the connector to its original position. 1 MD * Start engine.Bucket lever operated to CURL: Max. (When measuring with the engine stopped. and is circuit switch OFF. g Ir * Cause Remedy VFS Defective governor.) Before carrying out troubleshooting. * If it is 20 . l l 1 Repair or replace Repair or replace * Bucket lever at NCl neutral: Min. short circuit with ground. In this case. Always connect any disconnected connectors before going on the next step. pump controller C16(MIC17) SO6IX2) Bucket CURL oil pressure switch BKP00263 20-510 0 PC300. go to H-5.30V . or disconnection in wiring harness between SO6 (female) (1) and chassis ground Defective contact.) Replace 3 YES Is voltage Is resistance between P between Cl6 (11) Cl6 (female) (11) and and chassis YES SO6(female) 12) normal. so when disconnecting the connector and inserting the T-adapter. pump controller Defective contact. operated to chassis? * Between Cl6 and S06: Max.TROUBLESHOOTING F-7 F-7 Bit pattern 21-(I) Bucket CURL oil pressure switch does not light up * This troubleshooting is carried out when there is still an abnormality. 1 ‘_MQ . 1 V * Between wiring harness and chassis * Disconnect SO6 : Min. Is chassis? * Bucket lever at NO SO6(male) 11)and 12) -Turn starting neutral: 20 . 1 R CURL: Max. or disconnection in wiring harness between Cl6 (female) (11) and SO6 (female) (2) Defective bucket CURL oil pressure switch (If the condition does not return to normal even when the switch is replaced. 1 V l Defective contact or disconnection in wiring harness between SO7(female) (21and chassis ground Defective contact. pump controller Replace 1 Is voltage between Cl6 (12) and chassis normal? * Start engine.) Repair or replace Repair or replace * Disconnect S07. (When measuring with the engine stopped.) Ir Before carrying out troubleshooting. * If it is 20 . * Cause Remedy YES Defective governor. check that all the related connectors are properly inserted. check the voltage (12) and the chassis. 1 R * See Note 1. or when removing the T-adapter and returning the connector to its original position. Bucket lever at neutral: 20 . or disconnection in wiring harness between Cl6 (female) (12) and SO7 (female) (2) Defective bucket DUMP oil pressure switch (If the condition does not return to normal even when the switch is replaced. + Bucket lever at IO neutral : Min. short circuit with ground.30V: Go to YES * If it is less than 1V: Go to NO F-8 Related electric circuit diagram SO7(X2) g @ Bucket DUMP oil Governor. In this case. pump controller C16(MIC17) pressure switch BKP00264 PC300. 1 MR * Bucket lever operated to DUMP: Max. 1 MR Replace Note 1: It is also possible to fit a short connector condition. . * Disconnect Cl6 and S07. charge the accumulator first. the problem has been removed. Sr Always connect any disconnected connectors before going on the next step. and judge the between Cl6 *Turn starting switch OFF. * Between Cl6 and S07: Max. if the monitor code display returns to normal. so when disconnecting the connector and inserting the T-adapter. 350-6 20-511 0 . 1 52 * Between wiring harness and chassis: Min. When measuring with the engine running. operate the lever slightly and make sure that the work A equipment does not move. * Start engine.TROUBLESHOOTING F-8 F-8 Bit pattern 2%(2) Bucket DUMP oil pressure switch does not light up This troubleshooting is carried out when there is still an abnormality. go to H-5.30V * Bucket lever operated to DUMP: Max. 350-6 .normal. Always connect any disconnected connectors before going on the next step. * * Cause Remedy Defective governor. or disconnection in wiring harness between X05 (female) (2) -X01 (51. or disconnection in wiring harness between Cl7 (female) (16) -X01 (4) X05 (male) (I) Repair or replace Repair or replace Defective switch swing lock Replace F-9 Related electric circuit diagram Swing lock switch XOl(MIC21) @ I g X05(M4) -3 -3 Governor. IV OFF: 20 .) Before carrying out troubleshooting. If the panel display is normal. or when removing the T-adapter and returning the connector to its original position.(2) normal. 1 MR Defective contact. NO * Swing lock switch ON: Max. so when disconnecting the connector and inserting the T-adapter.H14 (61. if the monitor code display returns to normal. (If the swing lock lamp does not light up. 1 R *Turn starting . and is switch OFF. This troubleshooting is carried out when there is still an abnormality. 1 MQ * Disconnect X05. j. short circuit with ground. ND circuit insulated from * Disconnect Cl7 and X05. pump controller C17(04016) Monitor panel PO1(04020) H14(M6) 20-512 0 PC300.30V Is resistance between YES Cl7 (female) (161and YES X05 (female) (1) .TROUBLESHOOTING F-9 F-9 Bit pattern 2143) Swing lock switch does not light up j. * Swing lock switch ON: Max. chassis? * Between Cl7 and X05 : Max. check that all the related connectors are properly inserted. chassis ground Defective contact. the problem has been removed. short circuit with ground. and is circuit insulated from 2 Is chassis7 P NO X05 (female) (1) and * Turn starting . :Min. 1 R OFF: Min. go to M-21. Between wirina harness and chassis switch OFF. pump controller 1 Is voltage between Cl7 (16) and chassis normal? l 3 Turn starting switch ON. Before carrying out troubleshooting.TROUBLESHOOTING F-IO F-10 Bit pattern 2245) Kerosene mode connection * does not light up * * This troubleshooting is carried out when there is still an abnormality. or disconnection in wiring harness between M36 (male) (1) and chassis ground Defective contact or disconnection in wiring harness between Cl7 (female) (15) and M36 (female) (1) Replace Repair or replace Connected : Max.. Cause Remedy YES Defective governor. NO Repair or replace * Disconnect and M36. 1V Open: 20 . so when disconnecting the connector and inserting the T-adapter. Always connect any disconnected connectors before going on the next step. if the monitor code display returns to normal. check that all the related connectors are properly inserted.--$J~~~ l (connected) Diesel oil mode (open) PC300. l Cl7 Max.30V * Turn starting switch OFF. or when removing the T-adapter and returning the connector to its original position. the problem has been removed. C17(04016) circuit diagram pump controller Kerosene mode connector ~j. 350-6 20-5 13 0 . pump controller Defective contact. 1 R F-IO Related electric Governor. Always connect any disconnected connectors before going on the next step. and chassis *Turn starting switch ON. 5 . check that all the related connectors are properly inserted.H. . so when disconnecting the connector and inserting the T-adapter. the problem has been removed. 1 V 3 Is resistance YES between terminals of knob 2 switch normal? Is voltagebetween _ _ knobswitchinlet NO tyi.H12 (16) . * Knob switch ON: 20 .TROUBLESHOOTING F-II F-II Ir Bit pattern 2246) L.H.M23 (2) M22 (2) . knob switch M22IM2) a a M23(M2) I. 350-6 . or disconnection in wiring harness between knob switch outlet .CO3 (female) (9) Defective L. 1 R OFF: Min. aa.30V OFF: Max. or when removing the T-adapter and returning the connector to its original position. or disconnection in wiring harness between fuse No. 1 MD l YES Repair wiring harness Replace NO Repair wiring harness F-II Related electric circuit diagram H12(S16) Fuse Governor. knob switch does not light up * * * This troubleshooting is carried out when there is still an abnormality. I FY EKPW267 PC300. pump controller CO3(040) L. knob switch Defective contact.H. * YES Defective governor. if the monitor code display returns to normal. Knob switch ON: Max.H23 (1) -knob switch Replace 1 Isvoltage between CO3 (9) and chassis normal? * Turn starting switch ON. pump controller Defective contact. 5 is not blown. * Disconnect switch terminal..20-30V NO * Turn starting switch OFF.M22 (I) . Before carrying out troubleshooting. When fuse No. ...................................... ....................... swing (around No work equipment....................................................... is excessive 20-558 ................. Work equipment (but travel H-l 1 H-12 H-13 H-14 H-15 Excessive Excessive (boom....................................................................................................................................... Steering Travel Travel system speed does not switch does not move (one side only)....................................... lag (engine at low idling) .......................... ...................................... work equipment with larger load is slow ............................. ............................................... .................................. .............. 350-6 20-551 0 ........ All work equipment.......................................................... ...... Other equipment In L/O......... Compound H-16 H-17 H-18 H-19 Travel H-20 operations operations............................... 20-580 20-580 (both left and right...................... swing swing.................................................. bucket) does not move ...... In swing + travel................ ability is poor or response Work equipment H-7 H-8 H-9 H-10 Boom is slow or lacks power .. Abnormal move .................20-569 20-570 20-570 20-571 .............................................................. .............. arm.... ................................................................... ....................................... bucket) ........... 20-573 20-573 20-573 20-574 .................................................................................... or engine stalls .............. noise generated Auto-deceleration Fine control does not work (when PPC shuttle valve is cause) ............................ single circuit is relieved ........20-576 20-578 20-578 When there is deviation travel deviation Excessive starting H-21 H-22 H-23 H-24 Swing H-25 Travel speed is slow.. PC300.......... MECHANICAL SYSTEM (H MODE) Pump merge/divider Table of failure logic..................... or is faster than specified speed .................20-572 In compound In swing + boom RAISE........... solenoid actuation table...................................................... .................... arm is slow........... .................. boom RAISE is slow. In swing + arm................................................ does not turn easily or lacks power....... travel speed drops excessively system Travel a) b) deviation.................................... .............. 20-579 20-579 20-579 in one direction H-26 Swing is poor or swing speed is slow only) ................................................... 20-564 20-566 20-568 arm........................... one direction a) Swing accelerations is poor....................... speed is faster than specified function............................................... a) b) Does not swing to either Does not swing acceleration left or right ............................... ..................................................... .20-561 20-562 20-562 drop in engine travel............................................................. travel................................................................... F/O modes.......... Bucket is slow or lacks power......................................................20-560 20-561 ............... H-l H-2 H-3 H-4 H-5 H-6 Speeds There of all work equipment...................................................... pump) ....... speed.. 20-553 20-554 modes and causes .................................................... 20-569 ............... in normal when travel ....................TROUBLESHOOTING OF HYDRAULIC........................ Does not swing ........................... travel are slow or lack power..... speed............................................................. 20-571 20-572 20-572 ...........................20-571 and swing are normal) hydraulic time drift (boom.................................................................................................................... Arm is slow or lacks power........................................................................................ is poor.............. . .................................... Defective actuation moves when work equipment of machine push-up ................................................................... .................... 20-552 0 PC300...............H-27 Excessive a) b) overrun when stopping swing ............ .............................................................................. .......... shock when abnormal hydraulic swing H-28 H-29 H-30 Excessive Excessive Excessive a) b) When When noise when stopping ....... holding brake is released................ 20-582 20-582 20-582 ................................................... swing holding H-31 Swing speed is faster than specified speed ........................................ brake is applied ...............................................................20-583 ................ ................................................................................................ 350-6 ... drift of swing ...................................................... Both directions.............................................................................................................................................. stopping swing (one direction swing only).............................20-583 20-584 20-584 20-584 20-585 One direction only ......................................... (See diagram) ON _____ _. Travel + work equipment (any one of boom.______ OFF IIIIE 14. arm. LS SELECT LOGIC.7 MPa I150 kg/cm*) or above when lowered.6 MPa 1200 kg/ cm*) or above when raised or 14. bucket. SOLENOID Swing Travel Active holding speed ACTUATION brake TABLE ON (energized) OFF Brake applied Travel motor swash plate angle at MAX Active mode Merged I Name of solenoid Brake released Travel motor swash plate angle at MIN STD mode valve 1 mode (boom) Pump merge/divider Machine Active push-up Divided flow flow Low pressure Active mode High pressure STD mode mode (swing) PC300. SOLENOID ACTUATION TABLE PUMP MERGE/DIVIDER Divide (pump 1. swing. 2.7 (150) 19. solenoid Travel operated independently. merge/divider LOGIC ON) Merge (pump merge/divider solenoid OFF) All operations except those on left.TROUBLESHOOTING PUMP MERGE/DIVIDER LOGIC. or service) + front or rear pump oil pressure 19.6 (200) BKP00221 Pressure MPa(kg/cm2) 3. 350-6 20-553 0 . Breaker mode + service (breaker) valve pressure switch ON. . modes for compound L: When there is an abnormality operations are used when independent operations are normal 0 - 0 0 0 - for both front and rear 20-554 0 PC300.- e2 0 0 0 0 0 5 0 0 0 0 0 - 5 t In the failure modes. 350-6 .TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES TABLE OF FAILURE MODES AND CAUSES Parts causing failure (l/Z) Piston pump - s 9 F s - E & E ij - r & 0” f2 . 5 P E 9 z Troubleshooting code AAAA H-l H-10 0 0 0 H-30 H-31 PC300. 350-6 20-555 0 .TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES Control valve Pump merge/ divider valve Regeneration valve Front pump Rear pump 5 2. : p 5 . 350-6 . modes for compound A: When there is an abnormality operations are used when independent operations are normal for both front and rear 20-556 0 PC300.TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES TABLE OF FAILURE MODES AND CAUSES (2/2) xcesswe overrun * In the failure modes. ._ 2 t I z 5 u 6 ..i ......? P l- - 5 +Y x al 1” 2 i? s d P 2 5 $ -0 h I J 2 is 2 :: % > +6 :: I T 2 0 e E i-2 .....3 7 7 i G I- 2 3 - --c -3 1 31 =_ - 2 T 1 0 F .......I(01 - I I H-28 H-29 H-30 PC300....z ii - z ci ...5 ii 6 IL - s s $ -0 E 8 m 0 G - 1” 5 z f 9 2 7 Boom Pressure switch Arm Bucket T Troubleshooting code 5 2 z h :: 5 6 . 350-6 20-557 a ........z E ....- G G I C ii - 7 - - ) C - $ - H-l H-2 H-3 H-4 H-5 H-6 H-7 L 5Y 7 - H-l 1 H-12 I I H-13 H-14 H-15 H-16 H-17 I I I I H-18 H-19 H-20 H-21 H-22 H-23 H-24 1 1 7 7 I I 7 .b z % ..TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES Travel motor - - - - - - - - P ..... ) carrying out YES 51 Does condition YES become normal when TVC valve is adjusted? * See TESTING AND ADJUSTING.2 5 0. travel are slow or lack Carry out troubleshooting in the H/O mode. 350-6 . the pressure at the large diameter end is approx. Measuring servo piston inlet port pressure in Item No.74 MPa (130 kg/cm?) Basically. see TESTING AND ADJUSTING.0 MPa NO .77 MPa (330 . approx.92 k 1. mode. 4 . (If there is any abnormal noise. see TESTING AND ADJUSTING. Arm IN relief - L NO % Ir The oil pressure in the control circuit is reduced by the self-pressure reducing valve. power swing.35. knob switch ON *Arm IN relief 7 YES FH_ bJO NO * Distribution of servo (LS valve) and piston pump (servo plstonj 2 YE I Is main pump relief pressure normal? IO 1 Is control circuit pressure normal? i * Check and measure circuit oil pressure. Engine at high idling * Arm IN relief * Engine at high idling . Check that no abnormal noise is being generated from the main pump before troubleshooting. 2/5 of main BYES _ Does condition become normal when ND servo assembly is replaced? NO 3 YI Is output pressure of LSEPC valve nnrmal7 * 0. ~32.34 .H.2 MPa I2 2 2 kg/cm*) .365 kg/cm*} NO replaced in order from + Engine at high left to right? idling * 3.77 MPa _ unload valves are I339 .)] 20-558 0 PC300.TROUBLESHOOTING H-l H-l + Sr Speeds of all work equipment. (Approx.34 . Measure the input pressure to the large diameter end of the servo piston when the arm is relieved in the power max.Power max. 12. 2/5 of the small diameter end. mode * L.Arm IN relief (40 ‘-_10 kg/cm’} * Engine at high idling .365 kg/cm? * Engine at high idling * Arm IN relief P YES 8 Does condmon become normal when left to right? . main relief valves are 1adjusted in order from 9 YES Does condmon become normal when ~32.35. For details. (For details. carry out troubleshooting for H-4. TROUBLESHOOTING H-l ( Cause Remedy Defective adjustment of TVC valve Adjust Defective servo assembly (defective TVC valve) Repair or replace Defective piston pump Repair or replace Defective servo assembly (defective LS valve) Repair or replace Defective piston pump (servo piston) Repair or replace Defective operation of LS-EPC solenoid valve Defective operation of main relief assembly (valve which becomes normal when adjusted) Defective operation of unload valve (valve which becomes normal when replaced) Defective operation of main relief valve Adjust Replace Replace Defective self-reducing valve Repair or replace PC300. 350-6 20-559 0 . at arm IN relief NO normal? 3 YES Doescondrtron YES becomenormalwhen .TROUBLESHOOTING H-2 H-2 There is excessive drop in engine speed. Cause Remedy YES Clogged throttle inside servo or clogged filter inside servo Defective TVC valve or defective operation of LS valve Clean 1 Is throttle inside servo or filter inside servo clogged? P Is engine speed . Check that the main relief pressure is normal. it can be judged that the TVC valve (servo valve assembly) is defective. or engine stalls * * Carry out troubleshooting in the H/O mode. * Engine speed (reference) at arm IN relief when engine and pump are normal 20-560 0 PC300. carry out troubleshooting for S mode (engine).TVCvalve (servo 2 valveassembly) is replaced? _ NO Adjust or replace servo valve assembly Replace (piston pump assembly) Defective servo piston * See Note 1. so replace it. 350-6 . and if the engine speed is lower than the reference value below. If it is higher. See troubleshooting engine (S mode) for - N_ Note 1:Replace the servo valve assembly on the defective side with a new part. TROUBLESHOOTING H-3. 350-6 20-56 0 1 . NO Defective self-reducing valve.) Remove tefect inside pump Repair or reolace Inspect again (depending on changes in symptoms) rperate for a short time nd watch for any hange in symptoms 0 ack of hydraulic oil 4dd hydraulic oil PC300. swing move Cause 2 YES When main pump YES pressure pickup 1 . etc. does oil come out? Is safety lock valve working properly? _ * Crank with starting motor. 5 Is suction strainel clogged with metal particles or Nc are metal particles stuck to drain plug? Iogged by external lbject (cloth. travel. H-4 H-3 No work equipment. or defective main piston pump Replace Defective damper Replace NO Defective operation of safety lock valve or safety linkage Adjust H-4 Abnormal noise generated (around pump) Cause Remedy 3 YES Goto4 YE j=y2 stopped? I I NO YES nproper hydraulic oil Change hydraulic oil bubbles inside 4 Is suction strainer clogged by NO external object? Is hydraulic tank oil level normal? * External object: Cloth.plug is removed. defective control circuit. etc. 350-6 . Cause Remedy 1 YES Does condition become normal when oressure switch is replaced? NO Defective pressure switch Defective operation of PPC shuttle valve in applicable system (swing or travel) Replace Repair or replace H-6 Fine control ability is poor or response is poor Remedy 2 YES Is throttle in LS circuit clogged? 1 Is output pressure of LSEPC normal? * Output pressure: 2.TROUBLESHOOTING H-5. H-6 H-5 Auto-deceleration cause) * does not work (when PPC shuttle valve is the PPC shuttle valve and is supplied The control pressure for the travel and swing passes through to the pressure switch. or defective servo piston Replace Defective LS-EPC valve NO Repair or replace 20-562 0 PC300.2 MPa (30 t 2 kg/cm3 YES Clogged throttle in LS circuit Clean - NO Defective servo valve assembly (LS valve).94 t 0. . (Bit pattern 20 (3)(4)) * See Note 1.365 kg/cm? I NO * Engine at high idling Does control YES valve spool for boom move smoothly? 2 . do not forget to return the interchanged valves to the original position. Note 2: After inspection.TROUBLESHOOTING H-7 H-7 Boom is slow or lacks power Ir Sr When travel and swing speeds are normal.H. YES ls output . system normal. travel NO and bucket I Is relief oressure when boom RAISE I (330 . - * It is also possible to interchange with other compensation valve. is 20-564 0 PC300. * See Note 2. .pressure of PPC valve normal? 1 Is pressure switch for boom RAISE. 350-6 . (50 + 30 kg/cm21 * Engine at high idling NO NO - NO NO Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated. YES YEiS 5 Does LS shuttle valve move smoothly? * Check LS shuttle L for R. Min. Carry out troubleshooting in the H/O mode. 2.74 MPa (28 kg/cm21 * Engine at high idling * Operate boom. LOWER normal? * See Judgement Table. check boom Hi spool also) Defective PPC valve Repair or replace Repair or replace Replace Defective boom RAISE or boom LOWER pressure switch Replace PC300. 350-6 20-565 0 .H. check boom Hi also) Defective operation of control valve spool (for boom RAISE end. travel or bucket) Defective boom lock valve or suction valve for boom in control valve Repair or replace Replace Defective operation boom lock valve of Repair or replace Defective operation boom regeneration of valve Repair or replace Defective operation of boom pressure compensation valve 01 pressure compensation piston (for boom RAISEend.TROUBLESHOOTING H-7 P Remedy Defective operation boom lock valve of Repair or replace Defective boom cylinder piston packing Repair or replace Defective operation of LS shuttle valve (LS shuttle for R. R. boom. * Carry out troubleshooting in the H/O mode. (6)) * See Table 1.365 kg/cm*) * Engine at high idling *Check LS shuttle i-4’ for L. Note 1: If the auto-deceleration is canceled when arm IN or arm OUT is operated. YES 6 S Does LS shuttle valve move smoothly? YE 4 IS pressure YES compensrrtion valve for - _ Does control YES valve spool for arm move 3 arm normal. 350-6 .74 MPa (28 kg/cm? * Engine at high idling * Operate arm. * See Note 2. is 20-566 0 PC300. 32. do not forget to return the interchanged valves to the original position.TROUBLESHOOTING H-8 H-8 Arm is slow or lacks power Sr When travel and swing speeds are normal. NO NO NO * See Judgement Table.H. 2. or does pressure compensation piston move smoothly? .34 . travel and bucket uo NO _ YI Is output pressure of PPC valve normal? .77 MPa I330 . Min. (Bit pattern 20 (5).H.35. Note 2: After inspection. - * It is also possible to interchange with other compensation valve. travel. the system normal. travel or bucket) Defective operation of arm oressure Remedy Repair or replace Repair or replace Repair or replace I Defective PPC valve Replace Defective arm IN or arm OUT pressure switch Replace PC300. travel. boom.H.TROUBLESHOOTING H-8 Y=Is leakage from .arm cylinder normal? * Max. 350-6 20-567 0 . R.H. 20 cc/min * Engine at high idling NO Defective operation of arm regeneration valve Defective arm cylinder piston packing Defective operation of LS shuttle valve (LS shuttle for L. TROUBLESHOOTING H-9 H-9 Bucket is slow or lacks power Sr When travel and swing speeds are normal. position. * Min.See Note 1. (2)) . Note 2: After inspection. 350-6 . do not forget to return the interchanged or bucket DUMP is operated. I NO --_ qepair or *eplace Note 1: If the auto-deceleration is canceled when bucket CURL system is normal. (Bit pattern 21 (1).~ I Defective bucket cylinder piston packing Defective operation of compensation valve for bucket or pressure compensation I piston I Ipressure Repair or replace rncve smoothly? * It is also possible to interchange with other compensation valve. Cause Remedy Defective operation of control valve spool for bucket Repair or replace switch for bucket I -----I I valve normal? II Defective PPC valve Replace * See Judgement Table. NO NO Defective bucket CURL or bucket DUMP pressure switch Defective operation of safety-suction valve for bucket Replace 5YE! 5 Repair or replace From A. * See Note 2. the valves to the original 20-568 0 PC300. 2.74 MPa (28 kg/ems) * Engine at high idling * Operate bucket. 74 MPa I28 kg/cm? . arm.It is also possible to measure leakage of cylinder. bucket) does not move (but travel and swing are normal) arm. H-II H-10 * Work equipment (boom. 2. . 20 cc/min * At relief .Max. bucket) hydraulic drift of boom 1) Excessive YES 1 Doesspeedof downwardmovement becomefasterwhen lever is operated? * See TESTING N~ AND ADJUSTING. N . and bucket are each operated indeCause -7 Remedy When boom.Engine at high idling I Cause Remedy Defective hydraulic cylinder piston packing Replace 2 Does condition become normal when safety-suction valveis Interchanged? YES Defective operation of safety-suction valve Replace NO Defective operation of boom lock valve Repair or replace 2) Excessive hydraulic drift of arm or bucket Cause Remedy ‘ES Defective hydraulic cylinder piston packing downward movement become faster when * See TESTING AND ADJUSTING. do not forget to return the interchanged valves to the original position.Engine at high idling output pressure of Is Defective PPC valve NO Replace H-11 Excessive hydraulic drift (boom. 20 cclmin f At relief * Engine at high idling YES Defective operation of safety-suction valve 1Does condition Defective control valve spool Damaged slipper seal of pressure compensation valve. PC300.TROUBLESHOOTING H-10. 1 YES Defective control valve spool Repair or replace PPC valve normal? * Min. or defective operation of pressure compensation piston Replace Repair or replace * It is also possible to interchange with other compensation valve * See Note I. pendently. * Max. arm. . Note 1: After inspection.It is also possible to measure leakage of cylinder. 350-6 20-569 0 . or does pressure compensation piston move smoothly? arm Cause Remedy Defective safety-suction valve.TROUBLESHOOTING H-12. l H-13 Other equipment moves when single circuit is relieved Cause Defective operation of pressure compensation valve slipper seal (The slipper seal in the pressure compensation valve of the circuit that moved is defective.S compensationvalve normal.) Remedy Replace 20-570 0 PC300. Note 2: After inspection. H-13 H-12 Excessive time lag (engine at low idling) I YES 2 Is YE. i * It is also possible to interchange NO with other compensation valve. Defective operation of pressure compensation valve or pressure compensation piston Defective operation of LS-EPC solenoid valve Repair or replace N0 Repair or replace Note 1: Output pressure of LS-EPC solenoid 2. do not forget to return the interchanged valves to the original position. or defective regeneration valve Replace Bucket Defective valve safety-suction Replace Is output pressure of LSEPC solenoid valve normal? . 350-6 .2 MPa 130 f 2 kg/cm*) is output from the LS-EPC solenoid when the all lever are at neutral. * See Note 2.See Note 1.94 + 0. l when the all lever are at H-15 * When Defective electrical actuation is normal.2 MPa I30 + 2 kg/cm21 is output from the LS-EPC solenoid neutral. Repair or replace Table 1 push-up switch setting setting (Oil pressure (MPa {kg/cm?) 1 1 Machine @ Low pressure @ High pressure H-16 In compound operations. 350-6 .TROUBLESHOOTING H-14. work equipment specified speed speed is faster than Cause Remedy 1 YES Is output pressure of LSEPC solenoid valve normal? Defective LS valve Repair or replace . H-16 H-14 In L/O.See Note 1. For details of the measurement procedure. F/O modes. see TESTING AND ADJUSTING. of machine push-up function Cause Remedy system 1 YES 1soutput oressure I I of machine pushup solenoid valve as shown in Table Defective safety valve Replace H Defective operation of solenoid valve NO * Engine at high idling . work equipment with larger load is slow Cause Remedy Replace (replace pressure compensation valve on side where load is lower) operation Defective operation of pressure compensation valve 1 Combination 1 2 3 I 4 1 5 of compound 1 Side where load is larger 1 Boom RAISE + arm IN Boom RAISE + arm OUT Boom RAISE + bucket CURL Boom RAISE Arm OUT Boom RAISE I 1 Arm OUT + bucket CURL Boom LOWER + arm OUT I I Arm OUT Arm OUT I 20-57 1 0 PC300. NO Defective operation of LS-EPC solenoid valve Repair or replace Note 1: Output pressure of LS control EPC solenoid (travel OFF) 2. H-15.94 + 0. LS select) Repair or replace H-18 + In swing + arm.) 20-572 0 PC300. If the Cause column shows that there is defective operation of the LS shuttle valve. H-18. If the Cause column shows that there is defective operation of the PPC shuttle valve. arm is slow See H-17. the cause is in the shuttle valve for the arm OUT. boom RAISE is slow RAISE work normally when operated independently. 2.) H-19 * In swing + travel. IN and LS select. (If the operation is normal when the swing and travel are operated independently.74 MPa _ YES 128 kg/cm’) * Boom lever operated fully to RAISE 2 Does valve select move PPC shuttle for LS circuit smoothly? NO YES Defective operation of active (swing) solenoid valve Repair or replace Defective operation select valve of LS Repair or replace Defective operation of PPC shuttle valve for LS select circuit (PPC shuttle for boom RAISE. 350-6 . * (I) If swing and boom In active mode NO 1 Is output pressure of active (swing) solenoid valve normal? ~ * Min. (If the operation is normal when the swing and arm are operated independently.TROUBLESHOOTING H-17. travel speed drops excessively See H-17. H-19 H-17 In swing + boom RAISE. LS select) Repair or replace (2) In other mode 1 YES I Does valve select move PPC shuttle for LS circuit smoothly? NO Defective operation select valve of LS Repair or replace Defective operation of PPC shuttle valve for LS select circuit (PPC shuttle for boom RAISE. the cause is in the shuttle valve for the LS select. there is deviation in normal travel Cause a) When 3 Does control YES valve spool for 2 travel move smoothly? YES Does junction . and check operation.39 MPa t4 kg/cm2 ) * Engine at high idling * Travel relief * Same conditions as for Item 1 * See Note 1 Replace NO Note 1: l l Remove the PPC shuttle block inlet hose. interchange the travel PPC hoses with the PPC hoses for the bucket (CURL.TROUBLESHOOTING H-20 H-20 * * Travel deviation Carry out troubleshooting in the H/O mode. boom (LOWER). When swing and work equipment speeds are normal. If the adapter for blocking the circuit is not available. fit an adapter. or arm (IN) at both the inlet and outlet ports of the shuttle block.valve move smoothly? lIs difference in output pressure betweenleft and rightPPC valves YES Defective travel motor assembly Repair or replace NO Defective operation of control valve spool Repair or replace . DUMP). and block the tip.Check as an individual part NO Defective operation of travel junction valve Repair or replace Defective PPC shuttle Repair or replace Defective PPC valve between FORWARD and REVERSE : Within 0. bl Excessive travel deviation when starting Cause Defective operation of travel counterbalance valve Clogging of throttle inside servo of front or rear pump I Remedy Correct or replace I Correct or replace PC300. 350-6 20-573 0 . ‘.2 I2.Same NO Measure the travel speed under no load or measure the time taken to travel 20 m.39 MPa (4 kg/cm*) * Output pressure: Min. Carry out troubleshooting in the H/O mode.pressure compensation piston 6 move smoothly? + It is also possible to interchange NO with other compensation valve. and measure travel speed in Lo and Hi.2 * 0. _ ~~~~“.8 + 0. or is Is Is pressure .TROUBLESHOOTING H-21 H-21 * * * Travel speed is slow the full stroke before carrying out trouble- Check that the spool of the travel PPC valve is moving shooting. p Does control YES valve spool for travel move 5 smoothly? p YES Does junction valve move smoothly? * Check as individual compensation valve YES normal.2 f 0. or is output pressure * Difference in _ 9 YES Is output pressure _ (shuttle block inlet ~0 end) of PPC valve normal? conditions as for Item 4 * See Note 4.0) LS-EPC output pressure Remarks l Engine at high idling Operate travel lever slightly (auto-deceleration cancel position) 20-574 0 PC300.0 + 2.0 * 2.74 MPa (28 kg/cm? * Engine at high idling * Travel relief . NO NO YES 7I1 speed slow m both FORWARD and REVERSE. 350-6 .) . 3 Is output YES pressure of LS2 EPC solenoid valve normal? Slow in both FORWARD and REVERSE I YES _ Is pressure switch normal? _ * See Note 2.2 i18.4 + 2. When measuring the speed of the travel motor under no load + Remove connector of LS control EPC solenoid.01 Hi 0.2 {2. NO 1 Slow in one direction only (FORWARD or REVERSE) _ Is difference in output pressure between left and right PPC valves normal. When swing and work equipment speeds are normal.01 l Mi 1. Note 2: Output pressure of LS-EPC solenoid Unit: MPa {kg/cm21 Note 1: l Travel speed Lo 0.‘““““‘” FORWARD and REVERSE : Within 0. (See MAINTENANCE STANDARD FOR CHASSIS RELATED PARTS.See Note 1. NO 4 part. or does . 2.“. * See Note 3. DUMP).when travel suction valve for control valve is replaced? * See Note 1. YES Defective operation of travel suction valve for control valve Repair or replace Defective travel motor assembly NO Defective pressure compensation valve. do not forget to return the interchanged valves to the original position. interchange the travel PPC hoses with the PPC hoses for the bucket (CURL. l l PC300. If the adapter for blocking the circuit is not available. and check operation. fit an adapter. Note 4: Remove the PPC shuttle block inlet hose. boom (LOWER). or arm (IN) at both the inlet and outlet ports of the shuttle block. and block the tip. 350-6 20-575 0 .TROUBLESHOOTING H-21 Cause Remedy f Defective operation of LS shuttle valve (for bucket) Repair or replace Defective operation of LS-EPC solenoid valve Repair or replace Defective travel pressure switch Replace a Does condition become normal . or defective operation of pressure compensation piston Defective operation of travel spool for control valve Repair or replace Repair or replace Repair or replace Defective operation of iunction valve Repair or replace Defective PPC shuttle Repair or replace Defective PPC valve Replace Note 3: After inspection. system is normal. 350-6 .TROUBLESHOOTING H-22 H-22 * Steering does not turn easily or lacks power in the H/O mode. (Bit pattern 20 (2)) If autodeceleration is canceled when travel is operated. drive side is low tnoo~~~$te side is l l See Judgement Table. Does not turn to left only L 0 Ni 20-576 0 PC300. or is it difficult to turn in one direction only? L One direction only pump when relieved Does not turn to left or right - pressure switch When steering.being relieved (oil pressure is normal) Both front and rear high jFZ$$%r$H NO when relieved 2 Is it difficult to turn to Y ES both left and right. Carry out troubleshooting 4YES _ Both front and rear high Both left and right pressure of front on Pressure high only on side . TROUBLESHOOTING H-22 Cause Remedy Defective operation of pump merge/divider valve or LS pump merge/divider valve Defective operation of main pump merge/divider solenoid valve Defective operation of travel junction valve spool Repair or replace Repair or replace Repair or replace Defective operation of LS circuit check valve Repair or replace YES 11 Defective control valve suction valve Replace r-J YES Doescondrtion becomenormalwhen .suction valveof controlvalveis interchanged? + Interchange left and right s~ools.NO 8 Does condition become normal _ when suction valve of motor is interchanged? _ YES Defective travel motor check valve Repair or replace NO Defective travel motor safety valve Replace NO Defective operation of LS shuttle valve for bucket Repair or replace Defective travel pressure switch Replace PC300. 350-6 20-577 0 . 8 f 0. (Bit No pattern 20 (2)) * If autodeceleration is canceled when travel is operated. Travel speed selector switch: Mi. Defective travel pressure switch Replace Table 1. Output pressure of LS-EPC solenoid Lo 0.2 12. Hi * Turn travel switch ON.0 f 2. Engine at high idling -At travel relief NO Defective travel motor Replace 20-578 0 PC300.TROUBLESHOOTING H-23. _ Is output pressure of travel speed selector solenoid valve normal? NO * Min.01 Mi 1. 350-6 .2 (2.Max.0 * 2. i Defective operation of travel speed selector servo piston in travel motor Defective operation of travel speed selector solenoid valve Replace Repair or replace Is travel pressure switch normal? NO Defective operation of LS-EPC solenoid valve Repair or replace * See Judgement Table. : 30 -- e /min .74 MPa {28 kg/cm21 . 2.2 i18.4 f 2.2 f 0. Cause Carry out troubleshooting 3 YES YES 2 I Is output YES pressure of LSEPC solenoid 1 valve normal? * See Table 1. H-24 H-23 * Travel speed does not switch or is faster than specified speed in the H/O mode.2 f 0.0} Unit: MPa {kg/cm21 Hi 0. system is normal.0) Travel speed LS-EPC output pressure Remarks l l Engine at high idling Operate travel lever slightly (auto-deceleration cancel position) H-24 Travel does not move (one side only) YES ti Defective final drive Repair or replace 3 nne~trom final drive7 YES 11 II 1Doescondition II v~sl become normal when 1 1 If control valve I Defective operation of suction valve of control valve Defective operation of counterbalance valve or travel motor safety valve Replace I Replace . 2. 350-6 20-579 0 .TROUBLESHOOTING H-25 H-25 Does not swing to either left or right a) Does not swing Cause Remedy 3 YES YES 2 r Is output pressure YE 1 Is swing pressure switch normal? * Min. Operate swing lever for operate work equipment lever). (Bit NO pattern 20 (1 )I * If autodeceleration is canceled when swing is operated. system is normal.74 MPa I28 kg/cm? NO . 2.74 MPa (28 kg/cm*} * Operate swing lever for operate work equipment lever). Defective swing pressure switch Replace b) Does not swing in one direction Cause Remedy i YES 1 Is PPC valve output pressure normal? I J YES Does control valve spool for swing move smoothly? Defective swing motor safety valve or suction valve - NO Defective operation of control valve spool for swing Repair or replace * Min. Is any foreign material found in oil drained from swing machinery? Defective swing machinery Repair or replace - NO Defective swing holding brake or swing motor Repair or replace Defective operation of holding brake solenoid valve Repair or replace * See Judgement Table. Defective PPC valve NO PC300. l l Note 1: 20-580 0 PC300. Carry out troubleshooting in the H/O mode.TROUBLESHOOTING H-26 H-26 * * Swing acceleration is poor or swing speed is slow is operated independently.or does pressure 5 compensation piston move smoothlv? _ NO interchange with other compensation valve. 0 See Note 2. interchange the swing PPC hoses with the PPC hoses for the bucket (CURL. 4 Does control valve spool for swing move smoothly? p * It is also possible to NO l Remove the PPC shuttle block inlet hose. fit an adapter. 350-6 . DUMP).74 MPa (28 kg/cm2) * Engine at high idling Operate swing 4 II - p Is output pressure (at shuttle block end) of PPC valve normal? * Same conditions as for ltem 6 * See Note 1. If the adapter for blocking the circuit is not available. Note 2: After inspection. and check operation. NO II acceleration poor in both directions YES YES r - One direction only (left or right) - Is PPC valve output pressure normal? * Min. at both the inlet and outlet ports of the shuttle block. and block the tip. If condition is normal when work equipment acceleration is poor al Swing 2 Both left and right Does LS shuttle valve move smoothly? I YES - - I I NO 6 YES Is pressure compensation valve YES for swing Norman. do not forget to return the interchanged valves to the original position. 2. 350-6 20-581 0 .TROUBLESHOOTING H-26 . F= Defective swing motor assembly Defective operation of LS shuttle valve (all LS shuttles) Defective operation of swing motor safetysuction valve Defective operation of pressure compensation valve or compensation piston Defective operation of control valve spool for swing Remedy Replace Repair or replace Repair or replace Repair or replace Repair or replace Defective operation of PPC shuttle valve Repair or replace Defective PPC valve Replace PC300. YES 2 _ Is problem reversed YES when left and right .TROUBLESHOOTING H-27 H-27 Excessive overrun when stopping only swing a) One direction Cause Remedy I. 350-6 .output hoses of PPC valves are 1 3 problem reversed when left and right swing PPC slow return valves are interchanged? IS I YES Defective swing PPC slow return valve Repair or replace Defective NO PPC valve Replace p ~ Does control valve spool for swing move smoothly? NO Defective swing motor safety valve Replace Defective operation of control valve spool for swing Repair or replace b) Both directions Cause Defective swing motor Remedy Repair or replace 20-582 0 PC300. TROUBLESHOOTING H-28. 350-6 20-583 0 . H-29 H-28 Excessive shock when stopping swing (one direction only) Cause Remedy 1 YES 1Does condition become 11 normal when leftand right swine PPCslowreturn 1valve-sare interchanged? 1 Y I Defective swing PPC slow return valve (check valve) Repair or replace I NO Defective PPC valve Replace H-29 Excessive abnormal noise when stopping swing Cause Remedy 1 Doescondition become 1 normal when swing motor safety-suction valve is cleaned? t Defective operation of swing motor safetysuction valve Clean YES 2 Does conditionbecome normalwhenswing motorsafetysuction valveis replaced? No Defective swing motor safety-suction valve Replace h 3 Is foreign material found swing machinery? in YES Defective swing machinery Repair or replace NO Defective valve back pressure Repair or replace PC300. 2 f 0. or defective operation of pressure compensation piston Defective control valve spool for swing Repair or replace 1 I -One direction only i~H~ Is hydraulic drift excessive in both directions or one direction only? NO Repair or replace 3 YES Replace i IBoth left and right {FHP Defective swing motor -11 elmin * Engine at high idling .TROUBLESHOOTING H-30 H-30 a) When Excessive hydraulic drift of swing swing holding brake is released Cause Remedy 2 YES Defective swing motor safety-suction valve Defective pressure compensation valve for swing.2 MPa (2 * 2 kg/cm*) -When 5 seconds havepassed after all swing and work equipment control levers have been returned to neutral. NO Defective operation of swing holding brake Repair or replace Defective operation of swing holding brake solenoid valve Repair or replace 20-584 0 PC300. 350-6 .At swing relief NO Repair or replace b) When swing holding brake is applied Cause Remedy 1 YES Is output pressure of swing holding brake solenoid valve normal? * 0. TROUBLESHOOTING H-31 H-31 Swing speed is faster than specified swing speed Cause Remedy Replace servo assembly Defective operation of LS valve Is output pressure of LSEPC solenoid valve normal? .2 * 0.0 f 2.2 i15.0 + 2.0) l Engine at high idling Travel OFF PC300. Output pressure of LS-EPC solenoid valve unit: MPa {kg/cm*} H/O mode 0.2 + 0.0 f 2.2 (2.0) L/O mode 2. 350-6 20-585 0 .17 +I 0.2 (2.0) F/O mode 1.2 (22. J 1 NO Defective LS-EPC solenoid Repair or replace Table 1.01 l G/O mode 0.4 f 2.51 + 0.See Table 1. . ............................................................................................. ................ . ...........................................................TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) Action taken by monitor and problems Electrical M-l panel when abnormality occurs 20-604 on machine ................. ............... ....................... ......... is turned ON and engine is started................ . ON........... ...... oil pressure) level) flashes charge) flashes flashes .................... ... is turned ON (engine stopped).................... 20-621 20-621 20-622 Alternator Engine oil pressure switch When starting emergency stop items flash ............................ circuit diagram for M mode system ...... ...................... ............................. ............................. ................................................ ...................................................................... ..................... ................................................ panel do not light up... ........................................... . .. basic check items flash ................... .... .............. PC300.............. ......... . ........ detected ........... M-8 When starting switch is turned ON.....20-612 None of lamp on monitor Some of lamps on monitor switch is turned When starting and do not go out............. oil pressure switch When starting emergency a) b) M-13 stop items flash .................................. .............. .................. items lighted (model) up on monitor panel are 20-614 different M-9 When a) b) c) M-10 from actual machine switch is turned ........................... ............... ..... panel light up..................... 350-6 20-601 0 ................. ....... .................. ...................................................................... .............................................................................. .............. (fuel level) flashes............. ......... 20-606 in error data is displayed .. ....... ....................... ........ ....... ............. caution items.......................... ......20-610 ..................... ................ ......... ...................... ............. ................................... (air cleaner clogging) flashes ................................ .. .......... 20-619 20-619 20-620 Alternator Engine system .................. oil level) flashes.......................... panel is displayed Hi detected Drop in engine oil pressure is displayed is displayed [El081 Engine water temperature When starting switch is turned 105’C detected ON...... monitor panel lamps all stay lighted up 20-612 20-612 ....... stopped)........................................... .......... ................. .. 20-623 20-623 20-623 20-623 20-624 20-624 20-625 a) b) c) d) e) f) (engine (coolant (battery (coolant temperature) flashes........................... basic check items flash ................. oil level) flashes .............................................. caution items...................... ......................... 20-614 20-615 20-615 20-616 20-617 ......... .......................................................... ..................................... ...... .......... ............ ............................... none of lamps on monitor light up for 3 seconds a) b) M-7 ............................................................. .................................................. ....... ..... .......... ............................... .................. ................................. .....20-610 20-61 1 20-608 [El011 Abnormality [El021 Error in clock data is displayed M-2 [El031 Short circuit in buzzer output with buzzer drive harness M-3 M-4 M-5 M-6 [El041 Air cleaner [El061 clogging is displayed..................................20-618 starting ON (engine (coolant (engine level) flashes .............. .. .............. ..................................... monitor) lights up ............................................................ .......... ..................... system ..................._......... ....... ................... (hydraulic Preheating is not being used but (preheating switch is turned ON and engine M-l 1 When a) b) M-12 starting is started. ....................... ............... .................... ...................... sensor system....... system .............................. .......... .................. . ............. .... ............. or contact of 24V wiring harness 20-609 ............................ .............................................................................. switch is at OFF and time switch are not displayed................... FULL.......... ................... 350-6 ............................................................................................... 20-630 20-631 prolix switch but (swing lock monitor) meter does not advance starting engine is running ........................................................................................................ El 13)................... is pressed............. time and service meter M-25 M-26 M-27 M-28 M-29 M-30 Defective Defective Defective Defective Defective Wiper ................................... is turned is turned ON (LOCK) but (swing ON (prolix)..20-628 ......20-628 ........................................... .................................... switch is not being operated but wiper is actuated .................................................................................................................................. 20-602 0 PC300....... 20-631 20-632 20-633 20-634 20-635 20-636 fuel level sensor system...................................20-642 Washer motor does not work...20-629 20-629 but buzzer does not sound ............... while lock monitor) does not light up ........ or switch is not being used but washer is actuated a) b) M-32 Washer Switch (include motor E114) ........................... 20-627 .. does not work.............................. is not being used but wiper is actuated does not work or switch (include a) b) M-31 Wiper Wiper E112. 20-643 20-643 20-644 20-645 is not being operated Electric grease gun does not work....................................... oil level sensor system ........................... does not work ....................................... .......... level sensor system ......... but washer is actuated ..................................... on monitor but buzzer sounds................................................ ...................... ..................................................................................... .. does not give any display. oil level sensor system ........................... ....................................................... coolant engine coolant hydraulic temperature sensor system..... is normal) M-15 M-16 M-17 M-18 M-19 M-20 M-21 M-22 M-23 M-24 No abnormality Night lighting Coolant Coolant is displayed on monitor gauge gauge panel does not light up (liquid crystal display temperature temperature does not rise .......................... 20-630 does not flash ...................................................................................... .............. motor 20-638 20-638 ............................ Caution item flashes buzzer does not sound for 1 second ..................................M-14 When starting switch is turned ON (engine stopped).............................................................................................................................................................20-626 20-626 ................... Fuel level gauge Fuel level gauge Swing Swing Service When lock switch always displays does not give display ......... . Short circuit with power source in wiring harness between monitor PO2 (2). Short circuit inside washer motor 2. short ground. Short circuit with 3. 4. or between W08 (16) and M28 (1) - El14 Short circuit in window washer drive system 20-604 0 PC300. Short circuit with ground. Short circuit inside buzzer 2. short and relay box (3) circuit inside wiper motor circuit inside relay box circuit in wiring harness between W08 (21. short circuit in wiring harness between monitor PO2 (3) and relay box W08 (31. Nature of abnormality - El01 Abnormality data in error Abnormality in internal memory Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Connector has separated Abnormality in internal clock function Excess voltage (more than 36V) has occurred Low voltage (less than 12V) has occurred Connector has separated /- - El02 Abnormality in clock data - El03 Short circuit in buzzer output system 1.TROUBLESHOOTING ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE User zode Service code Abnormal system 1. or between W08 (7) and wiper motor W04 (1) 1. 2. 3. Air cleaner clogging sensor has detected clogging - ~106 Drop in engine oil Hi pressure detected is displayed 1. or between W08 (6) and - El13 Short circuit in wiper motor drive reverse rotation system 1. Short circuit with ground. Short circuit with monitor PO2 (11) wiper motor W04 ground. Short circuit inside relay box 3. 2. short circuit inside wiper motor 2. Abnormality in monitor panel - El04 Air cleaner clogging detected is displayed 1. short ground. 350-6 . Coolant temperature 105°C gauge has detected water temperature of - El12 Short circuit in wiper motor drive nOrmal rotation system 1. short circuit inside relay box 3. 1. Short circuit with 2. 3.(10) and relay box W08 (171. Power line in contact with wiring harness between monitor (PO1 (7) pin) and buzzer 3. 4. Short circuit with ground. Engine oil pressure Hi sensor has detected drop in oil pressure - El08 Engine water temperature 105’C detected is displayed 1. Buzzer does not sound Resistance between PI1 (male) .(2): Min. engine speed is reduced to low idling l Voltage and (5) between W04 (3) 1. engine oil pressure caution lamp flashes and buzzer sounds Resistance (1) . Clock does not advance. keep time switch pressed for 5 seconds to actuate clear function - 1. 1 R (engine started) Resistance between sensor terminal . 3 V z 20 . Operation of wiper stops : Max. resistance) Action by controller abnormality when is detected Problem that appears on machine when there is abnormality - 1. If abnormality detection continues.chassis 1 MR (engine at midrange speed or above) - 1. Sets output to relay box to 0 1.30 v in regular cycle * Repeats D Resistance of motor : 1. Service code cannot be cleared 2. 350-6 20-605 0 .PI2 (male): Min. El03 is not displayed and the buzzer does not sound - 1. air cleaner clogging caution lamp flashes and buzzer sounds - 1. Time becomes 0O:OO. 3 V 5 20 .156 started) between PO7 - kR (engine 1.chassis Buzzer ON: Max. t Voltage between PO1 (7) . If abnormality detection continues. IV Buzzer OFF: 20 . 3. Time becomes 0O:OO. Sets output to washer motor to 0 1. . When starting switch is turned ON. If abnormality detection continues. current.TROUBLESHOOTING ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE Condition when normal voltage. coolant temperature caution lamp flashes and buzzer sounds 2.30 v in regular cycle * Repeats - Voltage and (5) between W04 (1) Same as El12 Same as El12 : Max. 3. Operation stops of window washer PC300.30V When there is a disconnection. If abnormality detection continues. Service code cannot be cleared 2. 350-6 . RADIATOR WATER LEVEL FUEL LEVEL SENSOR SENSOR OIL LEVEL SENSOR TWP01424 20-606 0 PC300.H) FOR M MODE SYSTEM WORKING LAMP (BOOM) MONITOR PANEL L I!! ! I I Ir NETWORK ALARM BUZZER PO4 (M2) BUS PO9 (Xl) AIR CLEANER CLOGGING SENSOR nl.TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM STARTING SWITCH HEADLAMP (R. TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM LAMP SWITCH SWING LOCK SWITCH WIPEReWASHER SWITCH SWING REDUNDANCY SWITCH Ml8 (M4) I I L-4 RELAY BOX WO8 (07018) WI PER MOTOR ENGINE THROTTLE CONTROLLER r-------1 UL a-__ a. ENGINE OIL LEVEL SENSOR II lEX0 Sll ENGINE WATER LEVEL SENSOR ENGINE OIL PRESSURE SWITCH TWP01425 PC300.L-L- B___ uL__ L_______. 350-6 20407 0 . battery relay terminal B. all the service codes in the internal memory are erased. fuse No. connector Mll. (With this operation. Before carrying out troubleshooting.battery relay B-Ml1 (l)(Z)-HI4 (I)-fuseNo. check that all the related connectors are properly inserted. carry out troubleshooting as follows.TROUBLESHOOTING M-l M-l [El011 Abnormality in error data is displayed [El021 Error in clock data is displayed * This is not an abnormality.) NO Normal - Note 1: Resetting operation: Turn the starting switch OFF. connector M14. 13. short circuit with ground in wiring harness between battery . defective contact. Then keep the time switch at the back of the monitor depressed. switch the starting switch ON again. BKW0272 20-608 0 PC300. 350-6 . (See Note 1.) panel for 5 M-l Related electric circuit diagram Monitor panel GND PO2(04016) I I Fuse 14(M6) Mll(L2) I I Power source (+24V) GND Power source (+24V) : Fusible link 11 (I-11 11. * * * Cause Remedy 2 II YES Defective monitor panel Disconnection. It occurs during troubleshooting when disconnecting and connecting connector PO2 (for the monitor panel electrical system). or the battery terminal.13-PO2 (female) (8)(14) Replace Repair or replace * After resetting system. carry out normal operations for a short time and watch the condition.) If the service code display appears again after the system has been reset. (When the monitor panel power source circuit is shut off with the starting switch turned OFF. and keep the time switch depressed seconds to return the system to normal. Always connect any disconnected connectors before going on the next step. 1 V * Buzzer OFF: 20 . Always connect any disconnected connectors before going on the next step. * Buzzer ON: Max. in the table? .TROUBLESHOOTING M-2 M-2 [El031 Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed * t * If the starting switch is turned OFF after an abnormality occurs.30 V *Turn starting l Repair or replace Replace switch OFF. check that all the related connectors are properly inserted.) Before carrying out troubleshooting.12). the system has been reset. Disconnect P04. NO Table M-2 Related electric circuit diagram P04(M2) Monitor panel POl(O4020) a Buzzer I I Buzzer @ I @ I Dl l(KES) BKPW273 PC300. Cause 2 YES Defective monitor panel Short circuit with power source in wiring harness between PO1 (female)(7) and PO4 (female)(Z) or short circuit in wiring harness between PO4 (1) and (2) Defective buzzer Replace I Remedy Is voltage _ YES between ~04 (2) 1’ and chassis normal? Is resistance between NO PO4(male)(1) . (If it is not displayed. turn the starting switch ON and check if an E service code is displayed. 350-6 20-609 0 . _ * Turn starting (2) -chassis as shown switch ON. NO Failure in engine system (See Note 1) YES Defective monitor panel Replace - Note 1: The monitor panel display has returned to normal. but the air cleaner clogging sensor has detected symptoms of clogging in the past. NO Failure in engine system (See Note 1) - Note 1: The monitor panel display has returned to normal. M-4 M-3 [El041 Air cleaner clogging detected is displayed k YES 1 Is air cleaner clogging caution lamp on monitor flashing? See M-13 f) - I 2 Is “E” service NO code displayed? * Turn starting switch ON. 20-6 10 PC300. so carry out troubleshooting of the engine to remove the problem.TROUBLESHOOTING M-3.Turn starting switch ON. so carry out troubleshooting of the engine to remove the problem. but the engine oil pressure Hi sensor has detected symptoms of a drop in the oil pressure in the past. 350-6 . M-4 [EI~G] Drop in engine oil Hi pressure detected is displayed Remedy YES 1 Is engine oil pressure caution lamp on monitor flashing? Is “E’ service NO code displayed? See M-13 a) - 2 YES Defective monitor panel Replace . TROUBLESHOOTING M-5 M-5 [El081 Engine water temperature 105°C detected is displayed Cause Remedy See M-13 d) - Defective monitor panel Replace ‘Turn starting switch ON. NO Failure in engine system (See Note 1) Note 1: The monitor panel display has returned to normal. but the coolant temperature sensor has detected symptoms of the coolant temperature reaching 105’C in the past. so carry out troubleshooting of the engine to remove the problem. PC300. 350-6 20-611 0 . check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Before carrying out troubleshooting. 350-6 . Repair or replace 1 Is voltage between PO2 (8)(14) . none of lamps on monitor panel light up for 3 seconds Ir * Ir a) Check that fuses No. None of lamps on monitor panel light up inserted.TROUBLESHOOTING M-6 M-6 When starting switch is turned ON.Ml4 (2)(l) .short circuitwith ground in wiring harness between fuse No. short circuit with ground in wiring harness between PO1 (female) (9) and fuse No. *20-30V Defective monitor panel Disconnection. defective contact. *20-30V 4 YES NO . 10 and 13 are not blown. Cause Remedy YES 2 YE Is voltage between PO1 (9) and chassis normal? * Turn starting switch ON. *20-30V Repair or replace I NO . short circuit with ground in wiring harness between PO2 (female) (8)(14) and fuse No. defective contact. 13 and chassis normal? starting switch ON. 10 . NO 10 and chassis normal? * Turn starting switch ON.(l)(9) normal? * Turn starting switch ON.Turn Repair or replace b) Some of lamps on monitor panel do not light up Cause Remedy Defective monitor panel Replace 20-612 0 PC300. 10 Disconnection.battery relay M Disconnection. 13 . 13 Disconnection. defective contact. defective contact. short circuit with ground in wiring harness between fuse No.HO5(2) .H14 (2)-M11(2)(1)-battery relay B Replace 3 YES Is voltage between fuse No. *20-30V Repair or replace N Is voltage between fuse No. HO5 (L2) GND Power SUPPIY I (+24V) I GND Power SUPP IY (+24V) I I PO2 (04016) Battery relay TWP01426 PC300.TROUBLESHOOTING M-6 M-6 a) Related electric circuit diagram Monitor oanel Starting ON signal PO1 (04020) \ I switch FIISC ly4.(L2). 350-6 20-613 0 . * Set to monitoring code 01. then turn it ON again and check. 350-6 . Cause Remedy 1 YES Is display of monitoring code 01 as shown in table? starting switch ON. M-8 M-7 When starting switch is turned ON. _ Defective monitor panel I NO * Turn Go to troubleshooting C mode (See C-14) for - Table 3cc BKPGO275 20-614 0 PC300. turn the starting switch OFF. items lighted up on monitor panel are different from actual machine (model) + immediately after replacing the monitor panel. monitor lighted up and do not go out panel lamps all stay Cause Remedy Defective monitor panel Replace M-8 When starting switch is turned ON.TROUBLESHOOTING M-7. TROUBLESHOOTING M-9 M-9 When starting switch is turned ON (engine stopped).(female j(8) and chassis as shown 2 in table? YES IS bit (3) of . . or disconnection in wiring harness between Cl6 (female) (8) . .chassis ground - . Before carrying out troubleshooting. P08. N( Defective monitor panel Defective contact. items flash Ir * a) basic check inserted. pump controller Coolant level sensor BKFW277 PC300. 350-6 20-6 15 0 . NO * Disconnect C16.* Turn starting * Set switch ON. Disconnect P08. Cause Remedy Check that the coolant Defective coolant level sensor system (see M-261 - 4 YE out when short connected to PO8 + Disconnect P08. starting switch OFF.Turn Repair or replace Repair or replace Table M-9 a1 Related electric circuit diagram Governor. Turn starting switch ON. _ Is there continuity between PO8 NIO (female) (2) and chassis? p Is continuity YES between Cl6 . to monitoring code 24. NO . Connect ++ disconnect short connector to PO8 (female). or disconnection in wiring harness between PO8 (female) (2) . pump controller . a )c) SAP00519 Ir (coolant level) flashes is at the specified level before carrying out troubleshooting.PO8 (female) (I) Defective contact. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.monitoring code 3 24 lighted up? - Defective governor.Turn - starting switch OFF. TROUBLESHOOTING M-9 bl SAP00523 Ir 0 6 (engine oil level) flashes oil is at the specified level before carrying out troubleshooting. PO5(Xl) Engine oil level sensor BKPOO278 20-616 0 PC300. or disconnection in wiring harness between Cl6 (female) (16) . Iefective monitor panel . * Disconnect C16.E08 (5) PO5 (female) (1) Repair or replace Table 1Chassis ground 1Continuity 1 M-9 b) Related electric circuit diagram Governor. 350-6 . PO5. * Connect++ disconnect short connector to PO5 (female) (I). Check that the engine Cause Remedy Y‘ES 3efective engine oil level sensor system (see M-27: - 3 when PO5(female)(1) III YES Iefective governor.3eplace * Turn starting I NO switch OFF. oump controller 3eplace * Disconnect PO5 -Turn starting switch ON. Defective contact. pump controller Monitor panel C16(MIC17) E08(SWP14) 3 . monitor panel Replace Defective contact.TROUBLESHOOTING M-9 cl SAP00524 * a 0 (hydraulic oil level) flashes oil is at the specified level before carrying out troubleshooting Check that the hydraulic Cause Remedy ‘ES Defective hydraulic oil level sensor system (see M-29) - when PO9(female) (1) 3 YES Defective governor.Connectdisconnect short connector PO9 (female) (1). * Turn starting switch ON. pump controller Replace * Disconnect PO9. NO .Disconnect C16. . 350-6 20-617 0 . pump controller C16(MIC17) Hydraulic oil level sensor PO9(Xl) &--- BKP00279 PC300. or disconnection in wiring harness between Cl6 (female) (9) and PO9 (female) (1) to Repair or replace M-9 c) Related electric circuit diagram Monitor panel Aetwork Governor. PO9. Defective h * Turn starting I switch OFF. HI3 (6) PO1 (femaleJ(l8) or El1 (female)(l) .E08 (3) H13 (female)(6) Defective starting switch Repair or replace Replace M-10 Related electric circuit diagram Starting switch B BR Rl R2 C ACC 0 x07 (MIC 1 Monitor Pane I PO1 (04020) 1 Heater H13 (S16) 3 E08 (SWP14) a El1 (X2) 3 3 - plug TWP01427 20-618 0 PC300. 1 V 1V Short circuit with power source in wiring harness between starting switch RI -X07 (3) . * Disconnect terminal RI.TROUBLESHOOTING M-IO M-10 Preheating lights up + is not being used but 0m SAP00526 (preheating monitor) inserted. *Turn starting switch ON. Cause - Remedy 2 YES Defective monitor panel Replace ~~ * Max. 350-6 . any disconnected check that all the related connectors are properly connectors before going on the next step. * Max. + Before Always carrying connect out troubleshooting. normal? .20-30V Start engine and rr. or disconnection in wiring harness between alternator terminal R E08 (2) . Before carrying out troubleshooting.d-range NO l Defective governor.TROUBLESHOOTING M-l 1 M-II Ir + * When starting switch is turned ON and engine is started. pump controller Replace Defective monitor panel Defective contact. Is voltage between * Set to monitoring code 43...i. Start engine and alternator terminal run at mid-range NO R and chassis or above.CO3 (female) (12) Defective alternator Replace Repair or replace Replace *20-30V M-II a) Related electric circuit diagram Monitor panel Governor. system a) Alternator 3 YES l Does monitoring YES code 43 show a _ 2 value of greater than IOO? Is voltage p YES between CO3 (12) _ *Start engine and NO and chassis run at mid-range 1 normal? or above. Check both the alternator system and the engine oil pressure system. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 350-6 20-6 19 0 . pump controller c03(04020) EOB(SWPl4) Alternator BKPC4282 PC300. check items flash basic inserted.. TROUBLESHOOTING M-11 b) Engine oil pressure system * When engine oil pressure I) Low-pressure sensor is normal. Defective oil pressure sensor (for low pressure) Contact of chassis ground with wiring harness beteen Cl6 (female) (15) - E08 (8) sensor Defective governor, pump controller Replace *Engine idling ’ zat row Ir Repair or repalce Is there continuity between Cl6 II * Turn starting switch OFF. * Disconnect sensor wiring harness C16. N Defective monitor oanel l Replace Engine at low idling *Set to monitoring code 24. NO 2) High-pressure sensor I Defective oil pressure sensor (for high pressure) Remedy YES 1r Replace When engine is runningat high idling and wiring harness of oil pressuresensor is removed,does displaygo out? . Engine at high idling 2 Is there continuity YES ,_ between Cl6 NO (female) (7) and chassis? * Turn starting switch OFF. * Disconnect sensor wiring harness Cl6 Is bit (2) of No monitoring code 24 lighted up? Contact of chassis ground with wiring harness between Cl6 (female) (7) - E08 (7) sensor 3 YES Defective governor, pump controller Repair or replace Replace Defective monitor panel Replace Engine at high idling * Set to monitoring code 24. l NO M-II b) Related electric circuit diagram Governor, pump controller E08(SWP14) Engine oil pressure sensor (high pressure) Engine oil pressure sensor (low pressure) BKPOO283 20-620 0 PC300, 350-6 TROUBLESHOOTING M-12 M-12 When starting switch is turned ON (engine stopped), items, emergency items flash (battery, engine oil pressure lamps do not light up) caution Sr * j, Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Check both the alternator system and the engine oil pressure system. system inserted. a) Alternator 3 Does monitoring YES code 43 show a 2 value of greater than lOO? _ YES Defective governor, pump controller YES 1 _ Is voltage between alternator terminal R and chassis normal? * Disconnect terminal R. * Turn starting switch ON. * Max. 1 V Is voltage between Co3 (female) (12) and chassis normal? + Disconnect C03. *Turn starting switch ON. * Max. 1V Defective monitor panel Replace , ‘Startengineand NO run at mid-range speed or above. * Set to monitoring code 43. NO Short circuit with power source in wiring harness between CO3 (femaleHl2) - E08 (2) alternator R Defective alternator Repair or replace I NO Replace M-12 a) Related electric circuit diagram Monitor panel Governor, pump controller CO3(04020) E08(SWP14) PC300, 350-6 20-621 0 TROUBLESHOOTING M-12 b) Engine oil pressure sensor system * When engine oil pressure is normal. 1) Low-pressure sensor Cause Remedy Defective governor, pump controller Defective monitor panel Is there continuity bstweensensor terminal and chassis? * Turn starting switch OFF. Remove sensor wiring hanrness. l * Turn starting switch OFF. * Disconnect Cl6 and sensor wiring harness. 1 NO 24. Defective contact, or disconnection in wiring harness between Cl6 (female) (15) - E08 (8) sensor Defective oil pressure sensor (low pressure) Repair or replace NO Replace 2) High-pressure sensor Cause I Remedy 1 3 III YES * Turn starting switch OFF. * Remove sensor wiring harness. Is 1 YE 1 L NO switch OFF. * Disconnect Cl6 and sensor wiring harness. UO NO Defective governor, pump controller Replace Defective monitor panel Replace there continuity between sensor terminal and chassis? Defective contact, or disconnection in wiring harness between Cl6 (female) (7) - E08 (7) sensor Defective oil pressure sensor (high pressure) Repair or replace Replace M-12 b) Related electric circuit diagram Governor, pump controller C16(04017) Engine oil pressure sensor (high pressure) Monitor panel Engine oil pressure sensor (low pressure) BKF’O0283 20-622 0 PC300, 350-6 TROUBLESHOOTING M-13 M-13 When starting switch is turned ON and engine is started, _ caution items, emergency items flash (when there is no abnormality in engine or items to check before troubleshooting) inserted. * * Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. (engine oil pressure) flashes is normal before Cause a) 0 6 SAP00520 * Check that the engine oil pressure carrying out troubleshooting. Remedy See M-II b) - b1 a SAPW519 (coolant level) flashes level is normal before carrying Ir Check that the coolant out troubleshooting. I Cause Remedy See M-9 a) - (battery SAP00522 charge) flashes Cause Remedy See M-l 1 a) - PC300, 350-6 20-623 0 TROUBLESHOOTING M-13 d) * 01 SAP00527 (coolant temperature) flashes is normal before carRemedy Check that the coolant temperature rying out troubleshooting. Cause Defective coolant temperature sensor system (see M-26) 2When PO7 is YI3 disconnected, . does only level 1 (left end) of gauge 1 display light up? * Start engine. _ 3 Is resistance between CO3 (female) (1) -(16), (1) (16) -chassis normal? - YES - Defective governor, pump controller Short circuit of wiring harness between CO3 (female) (1) - E08 (6) PO7 (female) (1) and wiring harness between CO3 (female) (16) - EO8 (11) -PO7 (female) (2) Defective monitor panel Replace NO * Start engine and run at mid-range or above. I NO * Turn starting switch OFF. * Disconnect CO3 and P07. * Max. 1 MR NO Repair or replace Replace M-13 dl Related electric circuit diagram Governor, pump controller CO3(04020) Coolant temperature GND G @ BKPOO284 E08(SWP14) PO7(X2) Coolant temperature sensor dletwork e) SAP00528 * !EB (fuel level) flashes is fuel before YES 2 WhenPO6 (female) (1) to chassis YEiS is connected ground, do alllamps to level14 (right end)of gauge display light up? 1 p * Start engine. * Wait for aPProx. NO 2 minutes. (The fuel level may vary, so the display is given a time delay.) Cause carrying out troubleDefective fuel level sensor system (see M25) Remedy Check that there shooting. - 3 Is voltage between CO3 (2) and (16) normal? YES Defective governor, pump controller Defective contact or disconnection in wiring harness between CO3 (female) (2) and PO6 (female) (1) Defective monitor panel Replace - l Start engine. * Connect PO6(female) NO (I) to chassis ground. *Turn startingswitchON. - Max. 0.3 V Repair or replace Replace NO M-13 e) Related electric circuit diagram Governor, pump controller CO3(04020) /Vlonitor p;nel hetwork I \ PO6(Xl) Fuel level sensor BKPO0285 20-624 0 PC300, 350-6 TROUBLESHOOTING M-13 fl w * c__~ a SAP00521 (air cleaner clogging) flashes is not clogged before carrying out troubleshooting. Check that the air cleaner Cause Remedy Defective air cleaner clogging sensor when PI 1 (female) is connected to PI2 * Start engine. h 4 YE Ir YES Is bit (6) of - monitoring code _ 3 24 lighted up? Is continuity between YES Cl6 (female)(17) and _ * Start engine. NI chassis as shownin * Set to monitoring 2 table? code 24. Is there continuity p . Turn starting between PI2 NO switch OFF. (male) and Disconnect C16, Pll, and P12. chassis? * Connectc*disconnect Pll (female) to * Turn starting P12 (male). ___ switch OFF. ..a IYU Disconnect P12. l l Defective governor, pump controller Defective monitor panel Defective contact or disconnection in wiring harness between Cl6 (female) (17) and Pll (female) Defective contact or disconnection in wiring harness between P12 (male) and chassis ground Repair or replace Repair or replace M-13 f) Related electric circuit diagram Monitor panel Governor, pump controller C16(MIC17) Pll Air cleaner clogging P12 Air cleaner clogging sensor PC300, 350-6 20425 0 TROUBLESHOOTING M-14, M-15 M-14 When starting switch is turned ON (engine stopped), does not sound for ‘l second Caution item flashes but buzzer does not sound buzzer * * * Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge or fuel level. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. I YES 2 When PO1(female) YES (7) and chassis are connected, does buzzer sound? , * Defective monitor panel Defective contact or disconnection in wiring harness between PO1 (female) (7) and PO4 (female) (2) Disconnection, defective contact, short circuit with ground in wiring harness between PO4 (female) (I 1 and fuse No. 13 Defective buzzer Replace 3 Is voltage _ between PO4 NO (female) (1) and chassis normal? * Disconnect ~04. * Turn starting switch ON. *20-30V YES I Repair or replace ~ Is resistance between PO4 _ ‘(male) (1) and (2) normal? * Turn starting switch OFF. * Disconnect P04. *200-300 R *Disconnect POI. * Turn starting switch ON. NO Repair or replace Replace NO M-15 f No abnormality is displayed on monitor but buzzer sounds * * When the buzzer sounds continuously. If the buzzer sounds intermittently, carry out troubleshooting M-14.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 1 YES When PO1 is disconnected, does buzzer sound? Cause Contact of chassis ground with wiring harness between PO1 (female) (7) and PO4 (female) (2), or defective buzzer Defective monitor panel Remedy Repair or replace Replace * Disconnect POI. * Turn starting switch ON. NO M-14, 15 Related electric circuit diagram Buzzer TWP01428 20-626 0 PC300, 350-6 TROUBLESHOOTING M-16 M-16 Night lighting on monitor panel does not light up (liquid crystal display is normal) * When the front lamp and working lamp light up normally. Cause Remedy YES Blown bulb or defective contact of bulb Replace bulb, or clean (defective contact) is there defective Defective monitor panel Replace * Remove bulb. . Check visually h for blown bulb. Defective contact, or disconnection in wiring harness between PO1 (female) (8) -X01 (1) MO7 (female) (I) code 49. * Turn starting switch ON. . Turn light switch ON. l20-30V NO Repair or replace M-16 Related electric circuit diagram Monitor panel Light switch PO1(04020) I Light \ @ I XOl(MIC21) a @ M07(M2) (OFF/ ON/ 01 2 Fuse BKPOO287 PC300, 350-6 20-627 0 TROUBLESHOOTING M-17. M-18 M-17 * * * Coolant temperature gauge does not rise If the coolant temperature actually does not rise, check the engine system. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. YES Defective coolant temperature sensor system (see M-26) Remedy Id When short connector is connected to PO7 3 YES Does monitoring YES _ _ code 41 show a value of less than 2 50? Is therecontinuity betweenCO3 (female) - (1) and (1s)when short connector is connected to PO7 . Connect short connector to PO7 (female). ~0 Defective monitor panel Replace (female), do level lamps on gauge go up in turn and then all lamps go out? * Disconnect P07. - Turn starting switch ON. Defective governor, pump controller Defective contact, or disconnection in wiring harness between CO3 (female) (16) - E08 (11) PO7 (female) (2) Defective contact or disconnection in wiring harness between CO3 (female) (1) - E08 (6) PO7 (female) (1) Replace NO *Turnstarting switch ON. *Set to monitoring code 41. 4 YES Is there continuity between CO3 NO (female) (1) and PO7 (female) fl)? * Turn starting switch NO OFF. * Disconnect CO3 and PO7. * Turn starting switch OFF. * Disconnect CO3 and P07. Repair or replace Repair or replace M-18 * * Coolant temperature gauge does not give any display (none of gauge lamps light up during operation) Cause Remedy Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. YES 1 When PO7is disconnected,does coolanttemperature gauge display appear? Is there continuity . Disconnect P07. between CO3 Turn starting NO (female) (I) and switch ON. chassis? * Turn starting switch OFF. * Disconnect C03, PO7. Iefective coolant emperature sensor system (see M-26) Iontact of chassis rround with wiring rarness between CO3 female) (I) - E08 (6) ‘07 (female) (1) YES 2 Xepair or .eplace l 3 YES Does monitoring code 41 show a NO value of less than 50? * Turn starting switch ON. * Set to monitoring code 41. NO Defective governor, pump controller Replace Defective monitor panel Replace M-17, 18 Related electric circuit diagram Monitor panel Governor, pump controller CO3(04020) I 1 I Coolant @ temperature GND @ E08(SWP14) PO7(X2) I/ I I I \I I Coolant temperature sensor BKP00284 20-628 0 PC300, 350-6 TROUBLESHOOTING M-19, M-20 M-19 Jc Fuel level gauge always displays FULL Check that there is actually remaining fuel before carrying out troubleshooting. * Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on the next step. YES Cause Defective fuel level sensor system (see M-25) Contact of chassis ground with wiring harness between CO3 (female) (2) and PO6 (female) (I) Defective monitor panel 2 *Turn starting switch ON. N *Wait for approx. 2 minutes. (The fuel level may vary, so the display is given a time delay.) Is there continuity r YES Repair or replace chassis? . Turn starting switch OFF. - Disconnect C03, P06. H * Turn starting switch ON. * Set to monitoring code 42. Replace NO Defective governor, pump controller M-20 j, * * Fuel level gauge does not give display Check that there is actually remaining fuel before carrying out troubleshooting. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Cause Remedy Defective fuel level sensor system (see M25) 1 3 when PO6Ifemale) YES Does monitoring YES code 42 show a 2 value of less than Is there conttnurty 408? between co3 (femaleI A 1 (21and chassiswhen _ * Turn starting switch ND ’ PO6(female)(l) and ON. chassisground are connected7 , * Set to monitoring code 42. *Turn starting NO switch OFF. * Disconnect C03, P06. Defective governor, pump controller - Replace * Disconnect P06. *Turn starting switch ON. Defective monitor panel Defective contact, or disconnection in wiring harness between CO3 (female) (2) and PO6 (female) (1) Replace F Repair or replace M-19, 20 Related electric circuit diagram Governor, oumo controller C03id4026) r-----T 2 Fuel level 2 Monitor r----T anel /Newark PO6(Xl) II Fuel level sensor BKP00285 PC300, 350-6 20-629 0 TROUBLESHOOTING M-21, M-22 M-21 * * * Swing lock switch is turned ON (LOCK) but monitor) does not light up 8 (swing lock SAT00098 Carry out this troubleshooting only if the swing lock is actually Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. I I being actuated. Defective monitor panel Is voltage betweenP05and chassis as shown in table? * Turn starting switch ON. NO Replace Defective contact disconnection in harness between (female) (5) -X01 X05 (male) or wiring PO1 (4) - Repair or replace M-21 Related electric circuit diagram Swing lock switch -775 M-22 * * * - BKFQ0288 Swinq prolix switch is turned ON (prolix), but moniio;) does not flash Cause 8 (swing lock SAT00098 Carry out this troubleshooting only if the swing prolix is actually being actuated. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. 2 YES Remedy I II - Defective monitor panel Replace YI 1 between Cl7 (8) and chassis as shown in table? * Turn starting switch ON. . Is bit (6) of monitoring code 21 lighted up? NO Turn starting switch ON. * Set to monitoring code 21. l Defective governor, pump controller Replace NO Defective contact or disconnection in wiring harness between Cl7 (female) (8) and prolix switch (4) Repair or replace Table Swing Swing prolix switch ON Max. 1 V M-22 Related prolix switch OFF 20 - 30 V electric circuit diagram Swing prolix switch BKPW289 20-630 0 PC300, 350-6 TROUBLESHOOTING M-23, M24 M-23 Service meter does not advance while engine is running Cause Remedy YES 1 Does battery charge caution lamp flash? See M-13 d) - - 2 YES Defective monitor panel Replace Does monitoring . Start engine and _ code 43 show a NO value of greater run at midthan IOO? range or above. * Start engine and NO run at mid-range or above. - Set to monitoring code 43. Defective governor, pump controller Replace M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed Cause Remedy 1 YES When starting switch is ON, is panel display normal? * Turn starting switch ON. _ Replace NO See M-6 - PC300, 350-6 20-63 1 0 TROUBLESHOOTING M-25 M-25 Sr Defective fuel level sensor system the fuel level sensor when carrying out the troubleshooting. Remove Cause Remedy 3 YES Interference with sensor inside tank Replace (See Note 2) YES Is there any large 2 YES Does arm move smoothly? 1 When float - crack, chip, or damage to float? Defective contact of connector Clean connector or replace NO is NO moved up and down, is resistance between connector (1) and flange as shown in table? Defective sensor (See Note 2) Replace 4 YES - Check wiring - harness visually. NO Is it broken? Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied) Replace sensor Defective sensor NO Replace Table Top (FULL) stopper Bottom (EMPTY) position position Approx. Approx. 12 Q or below 85 - 110 Q stopper r: p$p~.; TOPFULL) Bottom (EMPTY) ELPOO290 Note 1: Difference between fuel level and gauge display For gauge display position 14 (FULL), the amount of fuel is 78-100%; and for display position 1 (EMPTY) it is below 14.5%. If the chassis is at an angle, the displayed amount of fuel will be different from the actual amount. Therefore, when checking, stop the machine at a horizontal place and wait for at least 2 minutes before checking the gauge. (The display is given a time delay so that the gauge can deal with sudden changes in the fuel level.) Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be careful when installing. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. 20-632 a PC300, 350-6 TROUBLESHOOTING M-26 M-26 Defective coolant temperature sensor system I Cause I Remedy Defective contact of connector (See Note 1) temperature sensor Clean connector or replace sensor 2 YES Check wiring - harness visually. NO IS it broken? - Disconnection in wiring harness (See Note 2) (defective clamp) (external force applied) Replace sensor NO Defective sensor Replace Table Normal temperature 100°C (25°C) Approx. Approx. 37 - 50 kR 3.5 - 4.0 kR Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. PC300, 350-6 20-633 0 TROUBLESHOOTING M-27 M-27 * Defective engine oil level sensor system the engine oil level sensor when carrying out troubleshooting. Remove Cause Remedy YES 2 Is any foreign YES material (dirt) stuck to moving part of float? 1 When float is moved up anddown,is resistance between connector (1) andflangeasshown in Table l? _ 3 YES Is there any large - crack, chip, or NO damage to float? NO Defective movement float due to dirt of Clean Resonance of mount (See Note 2) Replace senso (See Note 4) Defective contact of connector (See Note 2) Clean connector or replace 4 YES Check wiring - harness visually. (r ) Is it broken? - Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied) Defective sensor Replace senso Replace NO Table Float UP Float DOWN Max. 1 Q Min. 1 MQ UP I Note 1: Variations in oil level The oil level may change according to the angle of the machine, the engine speed, or the temperature of the oil, so if there is any display, check the oil level again with the machine at a horizontal place. Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check the connector and wiring harness at the chassis end. Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action. Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for any vibration of the mount, and if there is excessive vibration, take the appropriate action. 20-634 0 PC300, 350-6 If there is excessive vibration. Cause Remedy YES 2 Is any foreign material (dirt) stuck to moving Defective movement float due to dirt of Clean YES 3 YES Resonance of mount (See Note 2) Replace sensor (See Note 4) 1 crack. and if there is excessive vibration. PC300. Note 3: Check for vibration at the connector mount. 350-6 20-635 0 . take the appropriate action. chio.TROUBLESHOOTING M-28 M-28 Defective coolant level sensor system * Remove the coolant level sensor when carrying out troubleshooting. so check the connector and wiring harness at the chassis end. Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied) Replace sensor Defective sensor NO Replace Table -1 BLP00293 Note 1: Variations in coolant level The coolant level may change according to the angle of the machine. so be careful when installing. take the appropriate action. or NO[damage to’float? resistance between connector (1)and(2)as shown inTablel? 4 YES 11 NO Defective contact of connector (See Note 2) Clean connector or replace harness visually. so if there is any display. check for any vibration of the mount. Note 4: Defective installation is a possible cause. If the problem occurs again. or the swaying of the machine. check the coolant level again with the machine at a horizontal place. Note 2: If the problem occurs again. the connector (female) at the chassis end is probably defective. . check for any vibration of the mount. and if there is excessive vibration. kUI Is it broken? H Disconnection in wiring harness (See Note 3) (defective clamp) (external force applied) Replace sensor 11 Defective sensor Replace NO UP t 1 DOWN BLFOO292 Note 1: Variations in hydraulic oil level The hydraulic oil level may change according to the angle of the machine. so be careful when installing. the connector (female) at the chassis end is probably defective. Note 3: Check for vibration at the connector mount. Note 2: If the problem occurs again. 350-6 . take the appropriate action. or the swaying of the machine. check the hydraulic oil level again with the machine at a horizontal place. so if there is any display.TROUBLESHOOTING M-29 M-29 Ir Defective hydraulic oil level sensor system oil level sensor when carrying out troubleshooting.I harness visually. so check the connector and wiring harness at the chassis end. If there is excessive vibration. If the problem occurs again. Note 4: Defective installation is a possible cause. take the appropriate action. 20-636 0 PC300. Remove the hydraulic Cause Remedy Defective movement float due to dirt of Clean YE ~ 1 Resonance of mount (See Note 2) Replace sensor (See Note 4) resistance between NO Defective contact of connector (See Note 2) Clean connector or replace 4 YES lCheckwiring= . . WOA NO ‘NO * Front window: Closed position * Turn starting switch ON. W04. P02. Disconnect P02. l * Turn starting switch OFF. YE. * Set to monitoring code I481. Set to monitoring code 1481. Always connect any disconnected connectors before going on to the next step. 11 YES Is resistance between YES wtc k”&) (31. * Turn wiper switch OFF. Turn wiper switch to ON or INT. * Disconnect P02.* Disconnect M 18. 20-638 a PC300. * Set to service code display mode.tfemaleli13l. WlOImale 10 (4). YES 6 I - Is service code [El 121 or [El 131 hIO being displayed? p *Turn starting switch ON. check that all the related connectors are properly inserted.of monitoring _ code f4CI light up _ NO when wiper switch is turned OFF? * Turn starting switchN$N.PO2 (fern&J Ill pprmat? Is resistance NO * Turn starting between WlO switch OFF. 9 YES Is resistance between YES pins of PO2 (female1 and W04 (male) as 8r shown in Table 2? *Turn starting switch OFF. El131 Before carrying out troubleshooting. W08.S Do bits (31or (4) of ES monitoringcode I471 liaht UDunder same c&dit/ons as Item Z? 1 Do bits (I) and (2) of monitoring YES code 1481 go out Iwhen wiper monitoring code I l I .~~~ switch * Turn starting switch OFF. a) Wiper does not work + * Check that fuse 7 is normal. Same as Item 2. 350-6 . * Set to monitoring code [4Cl.TROUBLESHOOTING M-30 M-30 * * Wiper does not work. NO * Disconnect WlO. or switch is not being used but wiper is actuated (include E112. II YES pDo bits (2) or (3) ’ . Max. 1 R *Turn starting switch OFF. Carry out this troubleshooting if service code [El121 or [El131 is displayed. NO (female) (3) and * Disconnect W04. .p02 . * Turn starting switch ON. (4) normal? . I - Iurns . or between WlO (male) (4) . or between PO2 (female) (11) and W08 (female) (2) Defective contact or disconnection in above wiring harness Repair or replace Repair or replace Repair or replace Defective monitor panel Replace Defective monitor panel Replace Defective contact or disconnection in wiring harness with defective resistance Defective wiper.H14 (2) chassis.H15 (1) chassis Defective rear limit switch. or between PO2 (female) (1) . washer switch Repair or replace Defective monitor panel Defective contact or disconnection in wiring harness between PO2 (female) (13) and WlO (male) (3). 350-6 20-639 0 .TROUBLESHOOTING M-30 Cause tReplace Defective relay box Defective contact or disconnection in wiring harness with defective resistance Short circuit with power source in wiring harness between PO2 (female) (3) and W08 (female) (3). or front window is open Replace Repair or replace Inspect or replace PC300. 3 V ON: 20 .(12) Between (4) .(4).yc Between (1) .(4) 1 Between 1 Between Between (1) .(2) Between Between (1) .(12) Between (4) .ti0n ON R%% OFF rotltion 08 ON OFF: Max. 350-6 .(4) ) feRe.(4) (2) . 1 R Table 3 W. 1 MR Between (1) ON mode - (2) - (4) Between W08 (female) (2) and PO2 (female) (11) Between W08 (female) (3) and PO2 (female) (3) Between (1) .. rot. 1 MR Max.(4) Between (2) .Itech ( Ml8 (female) 1 PO2 (female) Between (1) .(4) Between (1) .(12) (4) .(12) Between (1) Min. 1 MR Between (1) OFF mode Between 1Between - (2) - (4) Min..(5).(4) (2) .y.(4) Between (1) .TROUBLESHOOTING M-30 Table 1 Timing chat-t when wiper switch is at ON Item Length of pause until next actuation Safety circuit during operation of wiper [safety + function (l)l Length of pause when Symbol Tla Set time Tsa 1.(12) (1) 1 Max. 1 M&2 (1) .30 V ------- TI1 ----_______ 1 Safety circuit during stowing of wiper [safety function (2)I I TSP I 1Osec I TKP00828 Table 2 Resistance value Between W04 (female) (1) and W08 (female) (7) Between W04 (female) (3) and W08 (female) (6) Between W04 (female) (4) and PO2 (female) (5) Between W04 (female) (5) and PO2 (female) (1) Between W04 (female) (6) and PO2 (female) (6) Between W04 (female) (l).(3).. 1 R Min.5sec Safety circuit during stowing of wiper [safety function (2)I TKP00827 1Osec Timing Actuation of wiper snitch chart when wiper ON OFF switch is at INT Item Symbol Set time ____________________--__--------_____________ Length of pause until next actuation Safety circuit during operation of wiper [safety function (l)] ----I Tlr[ I Tla I 4sec Tsa 1 Osec NO. 1 R Max..(6) and GND Min.(12) 20-640 0 PC300.i. WASHER SWITCH RELAY BOX TWP01429 PC300.TROUBLESHOOTING M-30 M-30 Related electric circuit diagram MOTOR DRIVE (REVERSE) WIPER SWITCH (ON) WIPER SWITCH (WASHER) LIMIT SWITCH (WI POWER SUPPLY WASHER DRIVE MOTOR DRIVE (NORMAL) WIPER SWITCH (INT) LIMIT SWITCH (WINDOW) POWER SUPPLY LIMIT SWITCH (P) HI2 616) WIPER. 350-6 20-641 0 . NO code [4CI light 7 YES . * Disconnect M18. Turn starting switch OFF. * Disconnect P02.(12) Between (1) .TROUBLESHOOTING M-30 b) Wiper switch is not being operated but wiper is actuated Cause Remedy 4YEI I IS resistance between YE I Is resistance between pins of Ml8 (female) (1).or between (1) switch ON.(4) (1) . * Max.(4) Between (2l(4) Between (1) .Set to up? Is voltage between monitoring code W06 (female) (1) and * Turn starting 1471.(12) 20-642 0 PC300. 1 V Defective monitor panel Replace Short circuit with ground in wiring harness between PO2 (female) (3) and W08 (female) (3).Q OFF mode -1 Between Between (1) . 1 MR Between W08 (female) (2) and PO2 (female) (11) Between W08 (female) (3) and PO2 (female) (3) Between (1) .(12) Between (1) - (2) - (4) Min. (2). 1 R Min. and (7) normal? * Set to monitoring code * Disconnect W06.(41 Min. or between PO2 (female) (11) and W08 (female) (2) Defective relay box Repair or replace Replace Short circuit with power source in wiring harness between W08 (female) (6) and W04 (male) (l). rt Do bits (1) or (2) of monitoring code 1481 go out? * Turn starting switch ON. 1 a INT mode Between (1) . Ir Defective monitor panel Replace YE 2 .(6) and GND 1 1 1 Max. washer Repair or replace Replace 1 Does bit (4) of monitoring code f481 light up? r * Turn starting switch ON.(4) (1) Between (1) . or between W08 (female) (71 and W04 (male) (3) Repair or replace Table 2 Resistance value Table Wiper 3 switch Ml8 (female) Between (1) PO2 (female) (2) Between (1) Resistance (4) Min.1M.(4) (2) . NE (61. 1 MD Max. YES 5 IDo bits (3) or (4) 1 1 of monitoring YES . (4) as shown in Table l? .(12) Between (4) .(2) Between (1) . * Set to monitoring code 1481. NC [4Cl.(12) Between (4) . * Turn starting switch ON. W04 W08. NC * Turn starting switch OFF.(3).(4L(5). 1 R Between Max.(12) Between (4) . 1 R Min. 350-6 . 1 MR - - 1 Between W04 (female) (I) and W08 (female) (7) 1 Between W04 (female) (3) and W08 (female) (6) 1 Between W04 (female) (4) and PO2 (female) (5) Between W04 (female) (5) and PO2 (female) (1) Between W04 (female) (6) and PO2 (female) (6) Between W04 (female) (1).(4) Between Between (2) . code I471 light 6 up? ~ Do bits (2) or (3) * Turn starting of monitoring switch ON. NO Defective contact or disconnection in wiring harness with defective resistance Defective switch wiper. 1 MD ON mode Max. * Set to monitorin< code 1481. NO NO * Disconnect M28. 1 V l - Short circuit in wiring harness between PO2 (female) (2). Check as nindividual part. *5-20R Defective monitor panel Replace NO Defective washer motor (internal short circuit) Replace * Turn starting switch OFF. * Turn starting switch ON. -Wiper washer switch at [WASH II or [WASH III: Max. . Remedy Cause Before carrying out troubleshooting. 350-6 20-643 0 . Max. a) Washer motor does not work Ir Check that fuse 5 is normal. * Disconnect M18. No M28. *Wiper washer switch at [WASH I] or [WASH III: Max.Ml8 (3) Disconnection in wiring harness between Ml8 (male) -X01 (21) chassis ground Repair or replace . (10) and M28 (I) Short circuit with ground or disconnection in wiring harness between fuse 5 and M28 (16) Defective relay box (internal disconnection) Short circuit with power source or defective contact in wiring harness between PO2 (5) -X01 (IO) . * Disconnect P02. * Connect T-adapter. check that all the related Always connect any disconnected connectors before going on to the next step. . *20-30V l Repair or replace Replace 5YE Repair or replace From A jGJ%&q[ N Turn starting switch OFF. * Turn starting switch ON. * Insert T-adapter in P02. 1 Ma YES l 2 (female) (21. Turn starting switch ON. * Disconnect W28. * Insert T-adapter in P02. * Max. * Check as individual part. Disconnect W08. a)-1 When El14 is displayed * 2 YES YES 1 Is voltage between PO2 (female) (2). * Max. *Wiper washer switch at [WASH II or [WASH III: Max. * Turn starting switch to ON or OFF. 1 V *Wiper washer switch at [OFF]: 20-30V Defective switch wiper washer Replace 6 box W08 (16) and * Turn starting switch OFF. M28 (female) (1) and chassis normal? Is resistance of washer motor normal? p * Turn starting switch OFF. (IO) and (9) normal? * Turn starting switch OFF. 1 R Wiper washer switch at [OFF]: Min. 1 !J I EH_ Short circuit with ground or disconnection in wiring harness between PO2 (female) (21. or switch is not being used but washer motor is actuated (include El141 connectors are properly inserted. 1 V *Wiper washer switch at [OFF]: 20-30V * Turn starting switch OFF. 1 Q l Repair or replace PC300. (9) and M28 (female) (I) Replace Cause Remedy a)-2 When El 14 is not displayed YES 3 Is voltage between PO2 (female) (5) and (9) normal? Defective monitor panel Replace Y 4 To1 _ Is resistance between Ml8 NO (female) (1) and (3) normal? * Turn starting switch OFF. (10).TROUBLESHOOTING M-31 M-31 * Washer motor does not work. * Connect T-adapter to PO2 (female) or M28 (female). Disconnect M18. . WASHER SWITCH RELAY BOX TWP01429 20-644 0 PC300. Defective monitor panel Replace YES Is resistance PO2 (female) (3).TROUBLESHOOTING M-31 b) Switch + is not being operated mode.WO8 (13) and chassis normal? between starting NO switch OFF.Min. Ml8 (male) (3).. .DisconnectP02. El14 but washer is actuated Cause Remedy For this failure 1 is not displayed.1 MR CauseRemedy *Turn Short circuit with ground inwiring harness between PO2 (female)(5) -M18(male)-W08 (female)(13) Repair or replace M-31 Related electric circuit diagram CONNECTOR FOR CHECK M46 CM31 MOTOR DRIVE (REVERSE) WIPER SWITCH (ON) WIPER SWITCH (WASHER) LIMIT SWITCH (WI POWER SUPPLY WASHER DRIVE MOTOR DRIVE (NORMAL) WIPER SWITCH (INT) LIMITSWITCH (WINDOW) POWER SUPPLY MIT SWITCH (PI H12 LSI 61 DOI HI5 (LZI (KESI WASHER MOTOR WIPER.W08.M18. 350-6 . 350-6 20-645 a .TROUBLESHOOTING M-32 M-32 * Ir * 1: Electric grease gun does not work inserted. . Cause 2 YES YES 1 Is voltage between electric grease gun _ connector CN (I) and chassis normal? * Turn starting switch ON. *20-28V Is resistance between electricgrease gun connector CN (female1 (2)andchassis normal? l Defective gun electric grease Repair or replace Turn starting switch OFF. Check that fuse No. Repair or replace NO Repair or replace M-32 Related electric circuit diagram Battery Cable Special fuse (20A) for electric grease gunA Electric grease gun (Inside battery case) PC300. Disconnect CN. Check that there is grease before starting troubleshooting. 1R l NO Defective contact or disconnection in wiring harness between CN (female) (2) and chassis Defective contact or disconnection in wiring harness between CN (female) (1) and fuse No. Before carrying out troubleshooting. check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. 1 for the electric grease gun is normal. Max. . ............ TURBOCHARGER ASSEMBLY Removal and Installation ......... ENGINE OIL COOLER ASSEMBLY Removal and Installation ............... SPECIAL TOOL LIST................... Installation ......... SWING CIRCLE ASSEMBLY Removal and Installation ........... FINAL DRIVE ASSEMBLY Removal and Installation ................ CYLINDER HEAD ASSEMBLY Removal . ....................... ............................. SPROCKET Removal and Installation ................................... GOVERNOR MOTOR ASSEMBLY Removal and Installation ........................ Assembly .......................................................... Disassembly ........................................ Disassembly ............ IDLER ASSEMBLY Disassembly ................................. ENGINE.. TRACK SHOE ASSEMBLY Removal and Installation ....................................... FUEL INJECTION PUMP ASSEMBLY Removal .......................................................................... Disassembly . Assembly ................ CARRIER ROLLER ASSEMBLY Removal and Installation ........... Assembly ................................................ Installation ............ 30-39 30-40 30-41 30-42 30-43 30-44 30-48 30-54 30-55 30-56 30-57 30-61 30-66 30-67 30-68 30-69 30-70 30-71 30-73 30-74 30-75 30-76 30-77 30-79 30-80 30-82 30-84 PC300........................................................................................... SWING MACHINERY ASSEMBLY Removal and Installation ......................................................................................................3 30............................. FUEL TANK ASSEMBLY Removal and Installation .5 30.. Disassembly and Assembly............................................ ENGINE FRONT SEAL Removal ................................................... Installation ............... THERMOSTAT ASSEMBLY Removal and Installation ................................................... Assembly .................. Installation .......................................... 350-6 30-l 0 ........................... MAIN PUMP ASSEMBLY Removal ........................................................................................................7 30-10 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-19 30-20 30-21 30-22 30-23 30-25 30-26 30-28 30-31 30-32 30-33 30-34 30-35 30-38 DAMPER ASSEMBLY Removal and Installation ......... HYDRAULIC COOLER ASSEMBLY Removal ....................................................... REVOLVING FRAME ASSEMBLY Removal .. Installation .......................... HYDRAULIC COOLER ASSEMBLY Removal ...................... ENGINE REAR SEAL Removal and Installation .. AFTERCOOLER ASSEMBLY Removal and Installation ............................................................................................ NOZZLE HOLDER ASSEMBLY Removal and Installation ... RECOIL SPRING ASSEMBLY Removal and Installation .............................. IDLER......... WATER PUMP ASSEMBLY Removal and Installation .. ALTERNATOR ASSEMBLY Removal and Installation ...... Assembly .... Installation .............. SKETCHES OF SPECIAL TOOLS ..................... SWING MOTOR ASSEMBLY Removal and Installation ............... Assembly ............ CENTER SWIVEL JOINT ASSEMBLY Removal and Installation .................... Disassembly ................................................... RADIATOR...................................... STARTING MOTOR ASSEMBLY Removal and Installation ............. TRACK ROLLER ASSEMBLY Removal and Installation ....................... 30................ RECOIL SPRING ASSEMBLY Disassembly ...........30 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL ................................... PRECAUTIONS WHEN CARRYING OUT OPERATION ............................................ ... 30-I 50 AIR CONDITIONER CONDENSER ASSEMBLY Removal and Installation . PUMP MERGE/DIVIDER VALVE ASSEMBLY Disassembly and Assembly .... . ......... . ....... . .. Installation ............ ........ ........... ..85 30.......... ....... ................. ...................... Disassembly and Assembly ... Disassembly ..... .... ... ............ 30...... Installation .......... ....... ........................ ................ 30-I 47 Installation .... ........ ......... ... ...... ....... ..... ..... .... . .. ...................... Installation ................. .. .... .......... 30-I 39 Installation ................... ..... 30-I 28 Installation ........ ........ ........... .......................... 30-129 HYDRAULIC CYLINDER ASSEMBLY Disassembly ..... . ................................ ...... .......................... .. ...... 30-137 Installation .. 30-I 57 Installation ......... ................ ....... . 30-I 41 Installation ....................... 30-145 Installation ...... ..... ...89 3030303090 92 93 99 30-106 30-107 30-I 08 30-109 30-I 10 30-I 11 30-I 12 30-l 13 30-l 14 30-I 15 30-I 16 30-I 17 30-I 18 30-I 19 30-120 30-121 30-122 30-123 30-124 30-125 ARM CYLINDER ASSEMBLY Removal ................. ...................... .. ...... .. ............._..... . ................... 30-I 53 Installation ....... ........ ................... Installation ........ ... ....... ............................................ ..... .................. 30-I 33 WORK EQUIPMENT ASSEMBLY Removal . . Assembly .. .......... ............ 30-I 26 Installation ....... Disassembly ....... .......................... ..... ............................................ ..... .... .... LS-EPC SOLENOID VALVE ASSEMBLY Removal and Installation ..... ...... ..... 30-I 58 30-2 0 PC300....... . ....... .. .... . Installation .. ..... ............... .......... ... .......... .... TRAVEL PPC VALVE ASSEMBLY Removal and Installation . 30-127 BUCKET CYLINDER ASSEMBLY Removal .......... .... . ................ . Assembly . .... .. ........88 30..... .......................... ........HYDRAULIC TANK ASSEMBLY Removal . . PRESSURE COMPENSATION VALVE ASSEMBLY Disassembly and Assembly ..... ........ ............. PUMP CONTROLLER ASSEMBLY Removal and Installation ... 30-I 54 GOVERNOR........... ............... ..................... 30-I 42 BUCKET... ... .. ................. SOLENOID VALVE ASSEMBLY Removal and Installation ...... ....... ................ .. . ................... ............ ... ............. . Assembly ......... .... ............... ARM ASSEMBLY Removal .. ......... ... ..... Disassembly . PPC SHUTTLE VALVE ASSEMBLY Removal .. .......................... ...... ........................... 350-6 . ............... ..... .... .. ........ 30-I 43 Installation .................... ........................ . ..... 30-130 Assembly ...... . .................... 30-I 48 COUNTERWEIGHT ASSEMBLY Removal and Installation ...... ............ ... BOOM LOCK VALVE ASSEMBLY Removal and Installation .......... .. ...... CONTROL VALVE ASSEMBLY Removal .. ............. ........ SERVO VALVE ASSEMBLY FOR FRONT PUMP Removal and Installation ...... WORK EQUIPMENT PPC VALVE ASSEMBLY Removal and Installation . .......... ......... Assembly .............................. .... ........ BOOM CYLINDER ASSEMBLY Removal . ..... 30-152 AIR CONDITIONER UNIT ASSEMBLY Removal ......... MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation . . ..... .................................................................................... .. ................... .. ...... SERVO VALVE ASSEMBLY FOR REAR PUMP Removal and Installation .... . 30-151 RECEIVER TANK ASSEMBLY Removal and Installation .. 30-I 56 CONTROL STAND CASE Removal ........ ..... ...................... .... . ...... .............. 30-155 MONITOR PANEL ASSEMBLY Removal and Installation ....... 30-I 40 ARM ASSEMBLY Removal ........86 30....... . ................ ...... ...... 30-I 44 BOOM ASSEMBLY Removal ...... 30-138 BUCKET ASSEMBLY Removal ..................................................... ..... . 30-I 49 AIR CONDITIONER COMPRESSOR ASSEMBLY Removal and Installation ......87 30...... .. ......... ........ ..... .. MAIN PUMP ASSEMBLY Removal .. ... ............... . .... ................. .... 30-146 OPERATOR’S CAB ASSEMBLY Removal ........ .................... ...... ..._. Disassembly .... ..... ......... .. Quantity of oil or water drained INSTALLATION OF 0 0 0 0 ASSEMBLY ........... .......... . 3..... ..... Technique used during installation * ....... .. Step in operation * ....................... and quantity of any tools (Al............................ ... ... .............. OF USING MANUAL When removing or installing unit assemblies @ When removing or installing a unit assembly... (Example) REMOVAL OF 0 0 0 0 ASSEMBLY .......... the order of work and techniques used are given for the removal operation.. 2. ........ .. a Indicates that a technique is listed for use during installation 3.. .. PC300........ ....DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL METHOD 1............... Technique or important point to remember when removing XXXX (1)............. ............. ...... XXXX(1) .. 0 0 0 0 assembly (3) 4 & ......... Title of operation g ........... ................... n n a a (2): ....... Adding water................ Point to remember when adding water or oil l ti 2.... Technique or important point to remember when installing a a a n (2)...................... .........*.. .. ... ............... part number... ........... ..... .................. ........ ..... see the SPECIAL TOOLS LIST given in this manual........ 350-6 30-3 0 ........ .................................. .. ... ........... ..... Step in operation * ............. .... m .. @ Any special techniques applying only to the installation procedure are marked a................. ......... etc.... so be sure to follow these precautions when carrying out the operation.... .. ........... the order of work for the installation operation is not given... ....... Quantity when filling with oil and water General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION.. Listing of special tools @ For details of the description.. .....*......... ....... ................) that appear in the operation procedure.. ..... ..Title of operation Carry out installation in the reverse order to removal.... and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to...... . . Precautions related to safety when carrying out the operation 1... oil .......... ...... Thread diameter mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats SAD00481 SAD00482 mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 kgm 1.3 + 29.7 11. tighten to the torque given in the table below. tighten to the torque given in the table below.4 196.5 f 10 135 175 225 280 335 f + + + 2 15 20 25 30 35 Seal Nm 13.9 49 f 19.5 -c 29.35 + 0.15 3.2 f 49 6.5 -c 0.7 65.9 -c 6. 3 20 + 5 25 + 5 30 f 5 torque Nm 24.7 f 0.0 28.6 78. 350-6 .5 * 1. 6.7 112 177 279 383 549 745 927 1320 1720 2210 2750 3280 surface + 1.3 6. Thread diameter mm 10 12 16 Width across flats mm 14 17 22 Tightening torque Nm kgm 6.2 31.7 & 0.2 + 0.1 + 49 245.4 176.4 + 2.4 65.5 5-c2 8&2 14 f 3 18 +.0 2 2. * General tightening torque table (when using torque wrench) In the case of metric nuts and bolts for which there is no special instruction.5 f 3 30-4 0 PC300.DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL 4.6 137. Ir Table of tightening torques for flared nuts In the case of flared nuts for which there is no special instruction. Thread diameter mm 14 18 22 24 30 33 36 42 F Width across flats mm 19 24 27 32 36 41 46 55 ----I Ti htenin kgm 2.5 -c 3 39 + 4 56 f 6 76 2 8 94.5 f 4.0 18. tighten to the torque given in the table below.2 + 49 294. * Table of tightening torques for split flange bolts In the case of split flange bolts for which there is no special instruction.8 112 r 9.5 -c 19.5 + 1 279 f 29 28.8 11.8 * 19 f + A f + 29 39 58 78 98 -c 140 k 190 + 240 + 290 2 340 SAD00483 5.8 + 9.7 +. After disconnecting hoses or tubes. be sure to follow the general precautions given below when carrying out the operation. .DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units. Confirm the match marks showing the installation position. * entering. Pre&tions when carrying out removal-w&k . . Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. (Nut). be sure to use lifting equipment of ample strength. . Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. To prevent any excessive force from being applied to the wiring. cover them or fit blind plugs to prevent dirt or dust from . (Nut). and keep in a safe place. When draining oil. When using forcing screws to remove any components. (Nut). 1) Hoses and tubes using sleeve nuts Nominal number 02 03 04 05 06 10 12 Plug (nut end) 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 Sleeve nut (elbow end) 07221-20210 07221-20315 07221-20422 07221-20522 07221-20628 07221-21034 07221-21234 (Nut). Do not pull the wires. . the following corks can be used. .] . . (Nut). tighten the forcing screws uniformly in turn. and make match marks in the necessary places before removal to prevent any mistake when assembling. Use the two items below as a set 07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219 (Plug) (Plug) (Plug) (Plug) (Plug) (Plug) (Plug) 2) Split flange type hoses and tubes Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 0737 I-30400 07371-30500 Nominal number 04 05 3) If the part is not under hydraulic pressure. Part Number A Taper l/8 I ‘0 a 1 L n a DEW00401 PC300. Check the number and thickness of the shims. Before removing any unit. (Nut). . When raising components. If the coolant contains antifreeze. . clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. prepare a container of adequate size to catch the oil. (Nut). 350-6 30-5 0 . always hold the connectors when disconnecting the connectors. dispose of it correctly. 1. always bleed the air from the system after reassembling the parts. cotter pins. 3. coat the surface with anti-friction compound (LM-PI. clean the part and remove all oil and grease. or rust. 2. When coating with gasket sealant. follow the same procedure. burrs. and align the direction of the hook. Bend the cotter pins and lock plates securely. Install the hoses without twisting or interference. and correct any damage. always bleed the air as follows: 1. Next.4 times to the end of its stroke. run the engine at normal speed. When press fitting parts. or water. Ir When using the machine for the first time after repair or long storage.5 times. and lock plates with new parts. When operating the hydraulic cylinders for the first time after reassembling cylinders. tighten uniformly in turn to prevent excessive tightening on one side. Bleeding air. 350-6 . then coat uniformly with gasket sealant. operate the hydraulic cylinder 3 . check that there is no deformation or deterioration. Then check the water level again. 30-6 0 PC300. Then check the oil level again. clean the surface and remove all oil and grease. then connect securely. clean the connector to remove all oil. O-rings. 4. dirt. and add water to the specified level. pumps and other hydraulic equipment removed for repair. check that there is no dirt or damage. Run the engine to circulate the water through the system. Coat rotating parts and sliding parts with engine oil. check that the snap ring is fitted securely in the ring groove. stopping the cylinder 100 mm from the end of its stroke. After fitting snap rings. Replace all gaskets. dents. Clean all parts. After doing this. Precautions when completing the operation If the coolant has been drained. When coating with adhesive.DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. When tightening split flanges. Run the engine to circulate the oil through the system. If the piping or hydraulic equipment have been removed. then coat the threaded portion with 2 . Operate the work equipment control lever to operate the hydraulic cylinder 4 . Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. Start the engine and run at low idling. screw them in fully. see TESTING AND ADJUSTING. When using eyebolts. If the hydraulic equipment has been removed and installed again. add engine oil to the specified level. tighten the drain valve. When connecting wiring connectors.3 drops of adhesive. * For details. remarks Tightening of cylinder head bolt Erasssftting of Removal. Component Engine assembly Swing machinery assembly I . 350-6 30-7 0 .1110 796-627-1210 796T-627. Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST SPECIAL TOOL LIST Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured). R: Tools with upgraded part numbers.104-3940 01580-I 1613 790-101-2570 01643-31645 790-105-2100 790-101-I 102 790-331-I 110 791-580-1510 796-570-1020 791-601-1000 796-670-1010 791-601-1000 790-302-I 500 l Part Name IQ’tyl . installation of round nut -c Final drive assembl) I 2 4 5 6 7 8 3 4 Disassembly. assembly Tightening of cover bolt Installation of Floating seal Installation of floating seal Charging with oil Installation of Floating seal Charging with oil Removal.gze. remodeled from items already available for other models. installation of nut installation of floating seal Press fitting of ring Track roller assembly 3 4 5 09003-05560 Carrier roller assembly 6 7 8 796-670-I 020 796T-630-1130 791-601-1000 791-685-8005 Oil oumo 1 Charging with oil Recoil spring assembly 791-635-3160 F 1 790-101-1600 790-101-1102 Oil pump Removal. assembly Pushing of bearing inner race Idler assembly 1 2 Installer Oil pump Installer Oil pump Wrench kit 1 1 1 1 1 Disassembly. T 790-331-I 110 F 1 1 2 3 796T-626. Blank: Tools already available for other models. assembly Disassembly. installation of recoil spring I 1 I PC300. used without any modification.ISketchI Nature of work. New/remodel: N: Tools with new part numbers.1230 790-101-2510 792. newly developed for this model. fitting of master tion pin 102 200 Oil stopper assembly l 1 1 1 1 1 N Shutting off Removal hydraulic oil installation 1 Hydraulic assembly pump l 796-460-1210 796-660-1210 2OY-60-21330 Oil stopper Rod Rod assembly l S l N l 790-20. ~790-201-1500 l Part Name 1Push tool kit l Q’ty 1 1 1 1 1 1 rez$el 1 I Sketch I Nature of work. press installa. 350-6 .DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST Component Recoil spring assembly I I Symbol Part No.-2700 2 l Push tool kit 790-201-2740 I l Soacer III I I Press fitting of shaft oil seal I79O-IOl-2501 I Push tool kit Ill I I c Center swivel joint assembly 1 Disconnection of shaft and rotor I*790-101-2630 1 Leg l I2 IrI 30-8 0 PC300. installer Cylinder Pump Removal Removal. remarks 790-201-1650 790-101-5021 01010-50816 Plate Grip Bolt 2 l l Disassembly Installation of assembly piston dust seal l l 791-646-3000 Track shoe assembl) R 790-101-1300 790-101-I 796-660-I l Remover. of coil bucket I 1 Hydraulic assembly cylinder I* 790-101-5021 1 01010-50816 l 1 Grip l I JIll I* Bolt ~790-201-1500 1Push tool kit l 1l I I I I Installation dust seal Boom.tting g Born.DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST Component 3 Symbol I l Part No. remarks I I assembh If assembli I shaft and rotor Dis- Center swivel joint assembly T l l I 2 2 I Disconnection of l l Adapter 1 790-502-1003 Cylinder repair stand 1 cvlinder Securing of Installation of piston ring U pF. I Sketch Nature of work. boom assembly I* 01803-13034 I* Nut Removal of boom foot pin III I 1 1 I 1 I I ~790-101-4000 ~790-101-1102 I799-703-1200 799-703-I 100 I Puller ( Pump Ill I I I Service toot kit III Vacuum pump (1OOV) I I I I Removal.J.1 of Arm U 5 I I* 01010-50816 1796-670-1100 l I* Bolt Ill I N I-1 I I 1 Remover assembly] 1 1 796-670-I I 10 1 Sleeve IIINI l 1 Work equipment assembly. 790-101-2570 790-101-2560 790-101-2650 I I l Part Name Plate Nut I Q’ty I41 I re$$e. 350-6 30-9 0 . installation 1 I 1 1 Components related to air conditioner I X 1 799-703-l 110 120 Vacuum pump (22OV) Vacuum pump l24OV) tCharging with 1 ireon gas (R134a) 799-703-I 799-703-1400 Gas leak detector 1 PC300. 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. 350-6 .5 70 100 co. F Push tool 1 / t 1 co.1110 J2-1 Push tool n -t---t ---M 140 HEAT TREATMENT -__ PART NAME PUSH TOOL -_-M MATERIAL STKMlBA cm 1 796T-627-1230 A 30-l 0 0 PC300.5 CDPOO506 - 796T-626. 350-6 30-H 0 .DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS L7 Push tool Cl -~- i HEAT TREATMENT -__ PART NAME PUSH TOOL MATERIAL STKM 13A QN 1 796T-630-1130 n PC300. motor wiring harness cover. CEP00301 (-1 ter- engine starting Disconnect starting motor harnesses and connector (3) EN-M2).DISASSEMBLY AND ASSEMBLY STARTING MOTOR REMOVAL OF STARTING MOTOR ASSEMBLY g 1. Open engine Remove Remove hood. 5. 2. (1) and (21. * The two mounting bolts at the top are also used for tightening the cover mounting bracket in Step 3. Remove 3 mounting bolts. 350-6 . then remove starting motor assembly (4). INSTALLATION OF STARTING MOTOR ASSEMBLY J l I I CEP00302 Carry out installation removal. in the reverse order to 30-l 2 0 PC300. 4. undercover. Disconnect the cable from the negative minal of the battery. 3. INSTALLATION OF ALTERNATOR ASSEMBLY l Carry out installation removal. PC300. Remove lock bolt (5) and mount remove alternator assembly (9). in the reverse order to Adjust the belt tension. 5. (21. 4. and (3). wiring (I). Open engine Disconnect Remove hood. For details. bolt (61. 350-6 30-l 3 0 . 3. bolt (6). Testing and adjusting of alternator belt tension. Disconnect the cable from the negative minal of the battery.DISASSEMBLY AND ASSEMBLY ALTERNATOR REMOVAL OF ALTERNATOR ASSEMBLY a 1. (-1 ter- alternator fan guard (4). 2. Loosen lock bolt (5) and mount I \ L ’ uuuuuuuuu~ I CEFUO303 Loosen tension adjustment bolt (71. then a \ \ // // 6. see TESTING AND ADJUSTING. then remove belt (8) from alternator pulley. oil cooler assembly oil cooler core (7) from cover (6). 7. 5.DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER REMOVAL OF ENGINE OIL COOLER ASSEMBLY 1. Drain coolant. wiring 3. 6.9 + 0. INSTALLATION OF ENGINE OIL COOLER ASSEMBLY l Carry out removal.5 kgm} I 7 I _ CEP00312 CEFO0313 30-14 0 PC300. 4. For details.68 + 4. Remove fuel injection pump assembly. Disconnect engine oil pressure sensor harnesses (I) and (2) from sensor. Remove oil filter (3) together bottom with bracket. (5). installation in the reverse order to 5 -4 CEFQO311 m Mounting bolt of oil filter marked with %: 18. 2. see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY. m 3 1 i CEW0310 Disconnect Remove Remove part of tube (4). 350-6 .9 Nm II. I IO CEPo0317 PC300. Remove mounting bolts.DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP REMOVAL OF FUEL INJECTION PUMP ASSEMBLY a Disconnect the cable from the negative (-1 terminal of the battery. a -n-n\ 7 II I 8 7. Disconnect governor motor spring rod (2). * Always disconnect governor motor connector CN-E05 before disconnecting the rod. 1. * Disconnect the hose at the injection pump m end. Disconnect governor motor wiring connector (I) (CN-E05). so stop the fuel. a * Do not rotate the shaft of the governor motor suddenly. Remove fuel filter (3) together with bracket and hose. 4. Open engine hood. Disconnect fuel supply hose (4) and return hose a (5). 350-6 30-15 0 . Disconnect 6 delivery tubes (8). 5. 9. Remove bracket (9). 2. then remove fuel inm jection pump assembly (IO). Remove boost compensation tube (6) and injec1141 tion pump lubrication tube (7). 8. 6. + Check the position of the lever hole. Ir There is no stop valve installed to the supply hose. 3. see TESTING AND ADJUSTING. then align the line on the fuel injection pump with the line on the gear case.05 t 0.5 + 1.8 12.5 Nm Il.2 t 2.0 .5 Nm (2.15 Nm kgm} Nm kgm} kgm} w Delivery tube sleeve nut: 22. For details.25 kgm) w w Boost compensation tube nut .3 t 2. and install the coupling. Adjust the injection timing.2 2 2.25 Lubrication tube joint bolt: 11. Adjusting governor motor lever stroke.3 f 1. Injection pump end: 10.15 t 0.5 (I.25 + 0. Adjusting fuel injection timing.751 t 0. 9. If w Joint bolt (width across flats: 22 mm): 17.5 t. For details. Connect the spring rod before connecting the connector (CN-E05). see TESTING AND ADJUSTING.DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY l Carry out installation removal.5 Nm Il.5 Nm Il.25 kgm} w Joint bolt (width across flats: 22 mm): 17. CDP00318 30-16 0 . Intake manifold end: 24.1 + 2.75 t 0.25 kgm} Align the spline notch. Bleed the air from the fuel circuit. in the reverse order to * Ir Adjust the spring rod. 3. l Refilling with water -k Add water through the water filler to the specified level. INSTALLATION OF WATER PUMP ASSEMBLY l Carry out installation removal. aeration tube (61. * Set one mounting bolt at the fan pulley end installed to the water pump (it will not go in later). see TESTING AND ADJUSTING. 350-6 . Testing and adjusting of water pump belt tension. Ir There is one mounting bolt at the cylinder block end. and clamps (8) and (9). Disconnect bypass hose (51. For details. 2. in the reverse order to a * Adjust the belt tension. Drain coolant. Remove mounting bolts. 5. Loosen adjustment bolt (2) and mount bolts (3) of tension pulley (I). Disconnect water pump inlet hose (IO). then remove water m pump assembly (II). CEFW322 PC300. * Check the angle of the clamps. and remove belt (4) from m water pump pulley. 4. 6. Run the engine to circulate the water through the system. heater hose (71. Then check the water level again.DISASSEMBLY AND ASSEMBLY WATER PUMP REMOVAL OF WATER PUMP ASSEMBLY 1. Open engine hood. Open engine hood.1 s 4. Disconnect spill hose (2). 5. 3. Disconnect delivery tube (I). 2. in the reverse order to Delivery tube sleeve nut: 22. INSTALLATION OF NOZZLE HOLDER ASSEMBLY . 4.1 + 2.9 Nm 14.25 z 0. Remove nozzle assembly (4). Remove bolder(3).5 kgm1 30-18 0 PC300.DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER REMOVAL OF NOZZLE HOLDER ASSEMBLY 1. 350-6 .5 Nm I2.5 + 0.25 kgm} CEPO0324 Nozzle holder mounting bolt : 44. Carry out installation removal. 8 + 7. 8.4 Nm I3. Remove intake hose (2). Remove clamp (7) and bolts and nuts of cona necting clamp (6) of exhaust pipe (5). Remove bottom adiabatic cover (4). ASSEMBLY Open engine hood. Remove turbocharger outlet hose (3). m CWPOGI 03 INSTALLATION OF TURBOCHARGER ASSEMBLY l Carry out installation removal.5 kgm} w m Turbocharger mounting nut: 36.7 Nm I8.75 + 0. 4. 6. Disconnect turbocharger lubrication return hose (9).5 z 1. Remove turbocharger lubrication inlet tube (8). Remove top adiabatic cover (I) together with stay. 7. Remove turbocharger assembly (IO) while pulling out exhaust pipe (5). 5.4 2 14.DISASSEMBLY AND ASSEMBLY TURBOCHARGER REMOVAL OF TURBOCHARGER 1. Replace it with a new part.75 kgm} PC300. 9. 350-6 30-l 9 0 . Exhaust pipe connection: Coat with thermosetting agent (Nihon Holt Fire Gum or equivalent) Tightening nut of connecting clamp (6): 83. 3. 2. in the reverse order to u Ir & Do not use the connection clamp again. Run the engine to circulate the water through the system. * The mounting bolts (inside bottom bolts) of the thermostat cover cannot be removed. 3. * There are two clamps. so check the mounting angle. INSTALLATION OF THERMOSTAT ASSEMBLY . 350-6 . 6. Carry out installation removal. Remove thermostat cover (3). Then check the water level again. Remove thermostat (4). 4. 30-20 0 PC300. Open engine hood. Drain engine coolant. 2. in the reverse order to . Refilling with water * Add water through the water filler to the specified level. Disconnect aeration tube (IL Disconnect water pump inlet hose (2). so disconnect the hose. -1 CEPoO328 5.DISASSEMBLY AND ASSEMBLY THERMOSTAT REMOVAL OF THERMOSTAT ASSEMBLY 1. tension pulley (4). HYDRAULIC COOLER ASSEMBLY.DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL REMOVAL SEAL 1. 7. (7). and air conditioner compressor (5). 350-6 30-21 0 . WATER PUMP. For details. and (8). remove front pulley (12). PC300. Remove front pulley washer (I 1). see REMOVAL OF ALTERNATOR. OF ENGINE FRONT Remove radiator and hydraulic cooler assembly. see REMOVAL OF RADIATOR. m Ir The compressor drive pulley will also come off at the same time. Ir The collar will also come off at the same time. CEPOO330 2. and remove belts (6). m * For details. mounting bolt (IO) and m 6. AIR CONDITIONER COMPRESSOR. Using puller 0. 3. Remove fan guard (2). m 4. Remove fan (I). 5. Remove damper (9). Loosen tension of alternator (3). Damper mounting bolt: 88. 2 cc. and air conditioner compressor belt tension. 350-6 . Remove front oil seal (12).2 t 2.25 kgm) Front pulley mounting bolt: 451.1 t 29.2 t 2.25 kgm} Adjust the belt tension.75 z 0.DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL 8.5 Nm 16. see TESTING AND ADJUSTING.5 Nm i6. water pump belt. in the reverse order to m Fan mounting bolt: 88. Lip of oil seal: Grease (G2-LI) (approx. CEPoo334 INSTALLATION OF ENGINE FRONT SEAL l Carry out installation removal. For details. Testing and adjusting alternator belt.) 30-z 0 PC300.75 + 0.4 Nm I46 t 3 kgm} Ir & Press fit the front seal until it is level with the surface of the front cover. the crankshaft INSTALLATION REAR SEAL 1. & Lip of oil seal : Grease (G2-LI) CWP06167 PC300. move rear seal approx. * Be careful not to damage when removing. Installation OF ENGINE of rear seal 1) Install rear seal with TOP mark facing up. Remove rear seal (3). Remove damper assembly (1). 2) Press fit 20 mm from end face of crankshaft. 3. Remove flywheel assembly (2). PUMP AS- 2. CWPO6165 4.1 mm). 3 mm to rear when assembling. see REMOVAL OF MAIN SEMBLY. OF ENGINE REAR Remove main pump assembly.DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL REMOVAL SEAL 1. For details. 350-6 30-23 0 . 3) If there is wear of lip contact face of crankshaft (fingernails catch: more than 0. 25 kgm} 30-24 0 PC300.20 mm Radial runout: Max.3 Nm (II.3 Nm I19 kgm} 3) Measurement of face runout. radial runout Face runout: Max. 0. w Mounting bolt : 1st step: 88. take the action given in the MAINTENANCE STANDARD. Installation of flywheel 1) Coat flywheel mounting bolts.3 Nm (9 kgm} 2nd step: 188. seat face. thread portion. bolt: 110 t 12. & Mounting bolt: Engine oil (EO#30) 2) Install mounting bolts in order shown in diagram on right. 350-6 .25 t 1.15 mm -k If the measurement is not within the standard value. Installation of damper w Damper mounting CWPO6188 3.DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL 2. and washer with engine oil. 0. Open engine hood. PC300. CEP00341 3. Disconnect spring rod (4). Testing and adjusting of governor motor lever stroke. Remove cover (3). Remove governor motor assembly (5).DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR REMOVAL OF GOVERNOR MOTOR ASSEMBLY A 1. in the reverse order to CEP00342 * Adjust the spring rod. For details. Disconnect wiring connectors (I) (CN-E04) and (2) KN-E051. 2. 350-6 30-25 0 . Disconnect the cable from the negative (-1 terminal of the battery. a INSTALLATION OF GOVERNOR MOTOR ASSEMBLY l Carry out installation removal. see TESTING AND ADJUSTING. 4. 5. a 15. 7. Disconnect turbocharger outlet hose (16) and remove inlet hose (171. 2. 4. Remove top adiabatic cover (18) and bottom adiabatic cover (19). 8. 9. Drain coolant. 6 cylinder. 16. * There is a wiring clamp at the bolt at the bottom of the No. then remove plate mounting bolt (15). 10. Remove boost compensation tube (12). 14. * Remove the top adiabatic cover together with the stay. Disconnect the cable from the negative (-) terminal of the battery. m 11. Disconnect wiring harness clamp (71. then return bolt to its original position. 12. 6. Disconnect oil filter bracket (11) from intake manifold. Disconnect both ends of delivery tube (13). Remove intake connector (2). 30-26 0 PC300. Disconnect fuel filter (5) at bracket end. 350-6 . Remove clamp (31.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD REMOVAL OF CYLINDER HEAD ASSEMBLY A 1. Disconnect block (10) from cylinder head. Loosen tension of alternator belt. and disconnect spill hose (4). Open engine hood. then move it towards counterweight. Ir One connector clamp and one wiring harness clamp are tightened together. Disconnect heater relay (6) at bracket end. 3. Disconnect bypass hose (8) and aeration tube (9). m /GJ 13. 5. Remove intake manifold (14). 22. m 11121 26. @ZJ then remove 6 nozzle holders (33). Disconnect spill hose (311. then move the inlet tube towards the control valve.3 turns. Remove 6 glow plugs (30). Remove mounting bolts and nuts of connecting clamp (23) of exhaust pipe (201. 19. Remove wiring harness (28) and lead (29I. Remove rocker arm assembly (36). 24.m a 23. 20. 18. Disconnect blow-by hose (341.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 17. Lift off turbocharger and exhaust manifold as116 sembly (26). Ir Loosen the nut at the bottom. * Loosen the locknut. Disconnect level gauge clamp (25). and remove head cover (35). then loosen the adjustment screw 2 . remove holder (321. m 21. PC300. then remove m clamp (24). Remove exhaust pipe (20). 350-6 . Disconnect turbocharger lubrication inlet tube (21) and outlet tube (22). 25. Injection pump end: 10. For details.5 t 1. Remove push rods (37). 29.5 t 9. Intake manifold end: 24. Remove cylinder head bolts (38).DISASSEMBLY AND ASSEMBLY CYLINDER HEAD 27. 30-28 0 f’C300.3 t 2.25 kgm} m Intake manifold mounting bolt: 24.8 Nm 12.5 t 9. Lift off cylinder head assembly (39). 28.1 t 2. Testing and adjusting alternator belt tension.5 Il. see TESTING AND ADJUSTING. in the reverse order to m Boost compensation tube nut.5 t 1.5 Nm I2.350-6 .25 t 0.25 Nm kgm} Nm kgm) m Delivery tube sleeve nut: 22.05 t 0. &I kg Cylinder head assembly: 65 kg INSTALLATION OF CYLINDER HEAD ASSEMBLY l Carry out installation removal.0 kgm} * Adjust the belt tension. .0 .8 I2. nut: 24.1 t 4.5 Nm IO.5 Nm II. m the nuts and bolts. Mounting bolt.75 z 0.9 Nm i2.25 kgm} * w Clean the mounting portion.5 + 1. Adjust the valve clearance.5 kgm} m Head cover mounting nut: 8. For details.2 + 2.1 + 9.7 Nm I8. start from the center and work towards the outside. m Connecting clamp (23) tightening nut: 83.05 kgm} w Glow plug: 17. 1. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod.0 kgm} w & Exhaust pipe connection: Coat with thermosetting agent m Wiring harness and lead mounting nut: 1.5 t.5 kgm} PC300.8 Nm 14.9 Nm (4.5 t 0. Adjusting valve clearance.5 t 0.5 kgm} w Exhaust manifold mounting bolt: 44. see TESTING AND ADJUSTING.8 + 1. Nozzle holder mounting bolt: 44. 350-6 30-29 0 .DISASSEMBLY AND ASSEMBLY CYLINDER HEAD m * Do not use the connection clamp again. Replace it with a new part.5 + 4.0 Nm IO.1 kgm1 11121 * When tightening * .5 t 0.15 t 0.4 + 14.9 t 0. 350-6 . Coat the thread and seat of the bolt.DISASSEMBLY AND ASSEMBLY CYLINDER HEAD & * If any rust of more than 5 mm square is found on the shaft or the thread of the bolt. Be careful to check that there is no dirt or dust on the mounting surface of the cylinder head or inside the cylinder. and run the en- ( Make mark with punch gine to circulate the water through the system. replace the head bolt with a new bolt. Tighten the cylinder head mounting bolts 2 . Mounting bolt: Anti-friction compound (LM-PI. Then check the water level again.1 2 4. l CEP00354 Cylinder head start mark Socket 1 start mark CI.1 + 9. 2) Make an end mark at a point 90’?from the start mark.8 Nm IlO t 1 kgm} Front Exhaust side CEPOO353 2nd pass: Tighten to 147. tighten bolt 90““8’. do not reuse it.3 turns by hand. When installing the gasket. make start marks on the cylinder head and socket. then tighten in the order given in the diagram. I. Using an angle tightening wrench. and the seat of the cylinder head holes completely with molybdenum disulphide (LM-P). I CErn0356 30-30 0 PC300. Replace it with a new bolt.5 kgm} 3rd pass: 1. check that the grommets have not come out. 3) Tighten so that the start mark on the socket is aligned with the end mark on the cylinder head at the 90”+? position. When not using tool A. When using tool A. End mark / Socket cylinder head start mark So\cket start mark After tightening. Refilling with water * Refill to the specified level. 2. make one punch mark on the bolt head to indicate the number of times it has been tightened. w Cylinder head mounting bolt: 1st pass: Tighten to 98. .9 Nm (15 t 0. If any bolt already has five punch marks. I) Using the angle of the bolt head as the base. INSTALLATION AFTERCOOLER l OF ASSEMBLY in the reverse order to Carry out installation removal.DISASSEMBLY AND ASSEMBLY AFTERCOOLER REMOVAL OF AFTERCOOLER ASSEMBLY 1. inlet hose (I) and Loosen clamps of aftercooler outlet hose (2). 2. PC300. pull out from hose. 3. 350-6 30-3 1 0 . Remove mounting bolts. and remove aftercooler assembly (3). Open aftercooler front cover. Drain oil from hydraulic tank. 200 !J Lift off engine hood (1). and open front cover. see REMOVAL OF AFTERCOOLER ASSEMBLY. INSTALLATION OF HYDRAULIC COOLER ASSEMBLY Carry out installation removal. Remove aftercooler assembly. : Hydraulic tank: Approx. in the reverse order to CEFOO361 Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. * Loosen the hinge mounting bolts before lifting. remove mounting bolts.DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER REMOVAL OF HYDRAULIC COOLER ASSEMBLY A Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 2. 1. * Set a container under the cooler assembly to catch the oil. 6. then lift off hydraulic cooler assem bly. Remove aftercooler top cover. 30-32 0 PC300. Run the engine to circulate the oil through the system. & kg Hydraulic cooler assembly: 90 kg 4. For details. 5. 350-6 . & kg Engine hood assembly: 85 kg 3. Disconnect hose (2) and tube (3). Then check the oil level again. Sling hydraulic cooler assembly (41. 5.DISASSEMBLY AND ASSEMBLY RADIATOR. Disconnect radiator outlet hose (5). 9. and open front cover. Ir The shroud mounting bolts cannot be removed. HYDRAULIC COOLER ASSEMBLY A Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. * Loosen the hinge mounting bolts before lifting. HYDRAULIC COOLER REMOVAL OF RADIATOR.: Hydraulic tank: Approx. Remove aftercooler top cover. Lift off engine hood (1). 10. 350-6 30-33 0 . 6. Drain coolant 3. see REMOVAL OF AFTERCOOLER ASSEMBLY. 1. 200 . Remove radiator undercover. . Remove 2 mounting 6 bolts of shroud (7) from below. Remove shroud left cover (4). Drain oil from hydraulic tank. Ir Set a container under the cooler assembly to catch the oil. For details. so remove the cover. 11. & kg Engine hood assembly: 85 kg CEW0359 4. Remove aftercooler assembly.Q 2. Disconnect sub-tank hose (6). Disconnect hydraulic cooler hose (2) and tube (3). * Disconnect the clamps at two places at the same time. PC300. 350-6 .3 Nm III. then lift off radiator and hydraulic cooler assemb1y. and move it towards engine. HYDRAULIC COOLER ASSEMBLY l Carry out installation removal.a Ir Check the direction of the holder plate at the bottom of the top mount.25 kgm} . Refilling with water Ir Add water through the water filler to the specified level. remove top and bottom mount bolts. I+ kg Radiator.3 t. Remove top 2 mounting bolts of shroud (71. Then check the water level again. 12. Then check the oil level again. Sling radiator and hydraulic cooler assembly (91.25 t 1. hydraulic cooler assembly: 160 kg 365 INSTALLATION OF RADIATOR. Run the engine to circulate the oil through the system. 13.DISASSEMBLY AND ASSEMBLY RADIATOR. Run the engine to circulate the water through the system. l 30-34 0 PC300. 14. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. HYDRAULIC COOLER 12. in the reverse order to w Mount bolt: 110. Disconnect radiator inlet hose (8). A Lower the work equipment completely to the qround and stoo the engine. 5. 1. Remove main pump top cover (II. 13. 17. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. * After disconnecting the hoses. 9. and partiand engine 6. stop oil. Drain coolant.DISASSEMBLY AND ASSEMBLY ENGINE. 8. Disconnect NC wiring clamp (13). 4. remove the drain plug.r? A CEP00268 2. Disconnect front pump LS pressure detection hose (14). Disconnect LS control hose (9). Ir Do not disconnect the branch hose. MAIN PUMP REMOVAL OF ENGINE. . 12. fit tags to distinguish them. tions (2) and (3). 16. Disconnect cooling hose (8). Disconnect front pump delivery pressure detection hose (15). Disconnect suction tube (7). Remove muffler drain tube (4). Disconnect chassis ground cable (5). Open engine hood. When not using tool Sl. Remove main pump undercover undercover. : Hydraulic tank : Approx. 15. MAIN PUMP ASSEMBLY Disconnect the cable from the negative (-1 terminal of the battery. 14). Disconnect TVC wiring connectors (12) (C13. and drain the oil from the hydraulic tank and inside the system. 350-6 . 14. PC300. 7. - II I / \\ CWPO6108 11. 3. 10. 200 . Disconnect rear pump LS pressure detection hose (IO). Remove hydraulic tank strainer. Disconnect rear pump delivery pressure detection hose (I 1). and using tool Sl. Remove bracket (6) of pump branch hose. 21. then disconnect spill hose (28).DISASSEMBLY AND ASSEMBLY ENGINE. 26. so stop the fuel. 29. Remove fan guard (301. Disconnect engine coolant outlet hose (29). 28. 350-6 . then remove fan (31). Disconnect spill hose clamp (22). Disconnect car heater hose (21). and (E04. Disconnect drain hose (18). Disconnect hose (16) going to self-reducing pressure valve. (261. Remove aftercooler joint tube (241 together with bracket. Disconnect governor motor wiring connectors (251. 26 _ 23 . 24. Remove clamps (27) (2 places). 05). 22. Ir There is no stop valve installed to the supply hose. 20. Disconnect hose (17) going to control valve. Disconnect water pump inlet hose (23). 19. CWPO61 I I 27. Disconnect fuel return hose (19) and supply hose m (20). MAIN PUMP 18.22 U CEW0370 25. m 30-36 0 PC300. 23. 37. MAIN PUMP 30. then lift off slowly. Engine and main pump assembly: 1062 kg / 7 CWPO6117 PC300. use tool Xl to collect the refrigerant (R134a).DISASSEMBLY AND ASSEMBLY ENGINE. Disconnect wiring connector (39) (E08) and clamp (40). 32. Disconnect hose (32) going to aftercooler. Lift off engine and main pump assembly (43). Remove air cleaner assembly (35) together with bracket. 33. Ir m Check that all wiring and piping has been disconnected.m 4L CWPO61 16 39. 350-6 30-37 0 . Disconnect wiring cable (38) from starting motor. 36. Remove hose (33) coming from air cleaner. m 35. *CWPO6114 CWPO6115 38. -f Before disconnecting the hose. -- / 32 co) \ 35 c9 CWP06113 34 34. Remove engine mount bolts (41) and (42I. Disconnect hose (34) going to dust indicator. Disconnect air conditioner hose (37). 31. Disconnect air conditioner compressor wiring connector (36) (M34). DISASSEMBLY AND ASSEMBLY ENGINE. MAIN PUMP INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY l Carry out installation removal. in the reverse order to w Joint bolt: 17.2 2 2.5 Nm t1.75 t 0.25 kgm} m Fan mounting bolt: 66.2 t 7.4 Nm (6.75 t 0.75 kgml m * Check that there is no damage or deterioration of the O-ring, then connect the hose. m Engine mount bolt (front): 384.9 L 41.7 Nm 139.25 t 4.25 kgm} (rear): 926.7 t 103.0 Nm (94.5 f 10.5 kgm) l Refilling with water * Add water up to the water filler port. Run the engine to circulate the water through the system. Then check the water level again at the reserve tank. Charging air conditioner with gas * Using tool Xl, charge the air conditioner circuit with refrigerant (R134a). Refilling with oil * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air * Bleed the air from the main pump. For details, see TESTING AND ADJUSTING, Bleeding air. l l l 30-38 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY DAMPER REMOVAL OF DAMPER ASSEMBLY 1. Remove main pump assembly. For details, see REMOVAL OF MAIN PUMP ASSEMBLY. Remove damper assembly (1). m 2. INSTALLATION ASSEMBLY l OF DAMPER Carry out installation removal. in the reverse order to w Damper mounting bolt: 110.3 2 12.3 Nm III.25 + 1.25 kgm) PC300, 350-6 30-39 0 DISASSEMBLY AND ASSEMBLY FUEL TANK REMOVAL OF FUEL TANK ASSEMBLY & 1. Disconnect the cable from the negative (-1 terminal of the battery. Open drain valve of fuel tank and drain fuel. - : Fuel tank: Approx. 470 I? (when tank is full) 2. 3. Remove air conditioner condenser top cover. CEPUO112 Remove handrail (I 1, front cover (2), and battery case cover (3). Disconnect fuel level sensor connector (4) (CNPO6). Disconnect fuel supply hose (51, return hose (61, spill hose (71, and clamp (8). Remove mounting assembly (9). & kg bolts, and lift off fuel tank a 4. 5. 6. Fuel tank assembly: 210 kg I CEPO0113 INSTALLATION ASSEMBLY l OF FUEL TANK Carry out installation removal. in the reverse order to m Fuel tank mounting bolt: 277.0 + 31.9 Nm i28.25 + 3.25 kgm} CEPO0114 CEPOOllE 30-40 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY a Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Mark all the piping with tags to prevent mistakes in the mounting position when installing. Disconnect travel motor hoses (I) and (21. Disconnect speed selector hose (3). Disconnect drain hose (41, and remove elbow (5). + Install a blind plug in the drain hose. Disconnect drain hoses (7) and (8). * Install a blind plug in the drain hose. Disconnect travel hoses (9) and (IO), and speed selector hose (11). Pull out pin (121, and disconnect plate (13). Sling center swivel joint assembly (141, remove mounting bolts from below, then lift off. Center swivel joint assembly: 40 kg g + 1. 2. 3. 4. 5. 6. 7. INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY l Carry out installation removal. in the reverse order to m Sr Assemble the center swivel as shown in the diagram below. l Refilling with oil (hydraulic tank) li Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air li Bleed the air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air. . Sprocket B d D h CEPoo404 PC300, 350-6 30-41 0 DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. 2. 3. Remove cover (1). Remove snap ring (2). Using puller T, pull out swivel rotor (4) and ring (3) from swivel shaft (5). Remove O-ring (6) and slipper seal (7) from swivel rotor. 4. ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1. Assemble slipper seal (7) and O-ring (6) to swivel rotor. Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. & Contact surface of rotor, shaft: Grease (G2-LI) Ir When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring. Install ring (3) and secure with snap ring (2). Fit O-ring and install cover (I). m Mounting bolt: 31.4 t 2.9 Nm f3.2 t 0.3 kgm} CEP00381 2. 3. 4. 30-42 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE REMOVAL OF FINAL DRIVE 1. 2. a 3. 4. 5. 6. 7. Remove the track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. Using work equipment, push up track frame and set block between track frame and link. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove sprocket. For details, see REMOVAL OF SPROCKET. Remove cover (1). Disconnect drain hose (2). * Set a container to catch the oil, then disconnect the hose and install a blind plug. Disconnect speed selector hose (3) and motor hoses (4) and (5). Sling final drive assembly (61, and remove mounting bolts, then remove. m & kg Final drive assembly: 550 kg INSTALLATION OF FINAL DRIVE ASSEMBLY l Carry out installation removal. in the reverse order to w Final drive mounting bolt: 549.1 + 58.8 Nm I56 + 6 kgm} . Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified 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 (hydraulic tank). For details, see TESTING AND ADJUSTING, Bleeding air. . PC300,350-6 30-43 0 DISASSEMBLY AND ASSEMBLY FINAL DRIVE DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Draining oil Remove drain plug and drain oil from final drive case. - : 2. Cover Final drive case: Approx. 11 t 1) Remove mounting bolts, then use forcing screws @ to disconnect cover (I) from ring gear. 204 2) Use eyebolts @ to remove cover (1). CEFU0472 3. Spacer Remove spacer (2). 4. No. 1 carrier assembly I) Remove No. 1 carrier assembly (3). 30-44 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 2) Disassemble No. 1 carrier assembly as fol- lows. i) Push in pin (41, and knock out shaft (5) from carrier (6). + After removing (4). ii) shaft (51, remove pin 8 4 7 6 Remove thrust washer (71, gear (81, bearing (91, and thrust washer (IO). 5. No. 1 sun gear shaft Remove No. 1 sun gear shaft (11). No. 2 sun gear Remove No. 2 sun gear (12). 6. CWPO6120 CWPO6121 I 7. Thrust washer Remove thrust washer (13). 8. Ring gear Using eyebolts 0, remove ring gear (14). PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 9. No. 2 carrier assembly, I) Remove No. 2 carrier assembly (15). 2) Disassemble No. 2 carrier assembly as follows. i) Push in pin (16) and pull out shaft (17) from carrier (18). After removing the shaft, remove pin * (16). ii) Remove thrust washer (19), gear (20), bearing (21), and thrust washer (22). 20 \ I,’ 19 / 18 I 2i 16 22 CEfO0481 10. Nut 1) Remove lock plate (23). 2) Using tool Jl, remove nut (24). 30-46 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 11. Hub assembly I) Using eyebolts @, remove hub assembly (25) from travel motor. 2) Disassemble hub assemblv as follows. i) Remove floating seal (iSI. I CWPO6125 ii) Remove bearings (27) and (28) from hub (29). 3) Remove floating seal (30) from travel motor (31). PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY ASSEMBLY -k OF FINAL DRIVE Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Hub assembly 1) Assemble i) hub assembly as follows. Using push tool, press fit bearings and (29) to hub. (28) ii) Using tool 54, install floating seal (26). * Remove all oil and grease from the O-ring and O-ring contact surface, and dry the parts before installing the floating seal. Ir 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 oil. ‘J4 CUP06128 2) Using tool J4, install floating seal (30) to travel motor (31). * The procedure for installation is the same as in Step II-ii) above. J4 3) Using eyebolts 0, set hub assembly (25) to travel motor, then using push tool, tap to press fit bearing portion. 30-48 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 2. Nut 1) Using tool 52, push inner race portion of bearing (27). Ir Pushing force: 14.7 - 18.6 kN (1.5 - 1.9 ton) Ir Rotate the hub 2 - 3 times before applying the pushing force to the bearing inner race. 2) Measure dimension a in the condition in Step 1) above. 27 a CEFUO491 Measure thickness b of nut (24) as an individual part. 4) Calculate a - b = c 5) Using tool Jl, tighten nut (24) until c portion dimension is as follows. c portion dimension = c _y mm 3) 24 “b CEFUO492 6) Using push-pull scale 0, measure tangential force in direction of rotation of hub in relation to motor case. * Tangential force: Max. 490 N (50 kg) + The tangential force is the maximum force when starting rotation. CEP00493 PC300, 350-6 30-49 0 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 7) Install lock plate (23). Ir & m Install the lock plate as shown in the diagram on the right. Thread of mounting bolt: Thread tightener (LT-2) * Do not coat the threaded portion of the nut with thread tightener (LT-2). Mounting bolt: 66.2 f 7.4 Nm (6.75 + 0.75 kgm) Casting notch Install to place where there is no casting notch. Bring lock plate and spline of motor into tight contact. \ CEW0494 3. No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. -)r There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so 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). 20 19 18 21 h 22 CEPO0495 of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (17). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iii) Insert pin (16). * After inserting the pin, caulk the pin portion of the carrier. * After assembling the carrier assembly, check that gear (20) rotates smoothly. ii) Align with position 20 16 CEP00496 30-50 0 PC300, 350-6 DISASSEMBLY AND ASSEMBLY FINAL DRIVE 2) Install No. 2 carrier assembly (15). * Align the position so that the three tips of the gear shafts of carrier assembly (15) enter the three hollows in the end face of the motor case, then install. 4. Ring gear Fit O-ring to hub end, then using eyebolts 0, install ring gear (14). Ir Install so that the side with two grooves machined in the outside circumference of the ring gear is at the top (cover end). Ir Remove all grease and oil from the mating surface of the ring gear and hub. * Do not put any gasket sealant on the mating surface of the ring gear and hub under any circumstances. 5. Thrust washer Install thrust washer (13). 6. No. 2 sun gear Install No. 2 sun gear (12). CWPO6122 CWPO6121 7. No. 1 carrier assembly 1) Assemble No. 1 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (9) to gear (81, fit top and bottom thrust washers (7) and (IO) and set gear assembly to carrier (6). 8 h 7 6 CEW0499 PC300, 350-6 30-51 0 DISASSEMBLY AND ASSEMBLY FINAL DRIVE Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (5). Ir When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iii) Insert pin (4). After inserting the pin, caulk the pin * portion of the carrier. * After assembling the carrier assembly, check that gear (8) rotates smoothly. ii) 8 5 CEW0499 2) Install No. 1 carrier assembly (3). 8. No. 1 carrier assembly I) Assemble No. 1 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so 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 (IO) and set gear assembly to carrier (6). 8 h 7 6 9 10 CEFO04998 9. No. 1 sun gear shaft Install No. 1 sun gear shaft (11). CEW0501 30-52 0 PC300, 350-6 and add engine oil Final drive case: Approx.110” I J3 . & Mounting surface of cover: Gasket sealant (LG-6) CEPOO472 2) Using tool 53. Cover 1) Using eyebolts 0.DISASSEMBLY AND ASSEMBLY FINAL DRIVE IO. Refilling with oil Ir Tighten drain plug through oil filler. install cover (I). %9 * Carry out a final check of the oil level at the determined position after installing the final drive assembly to the chassis. 350-6 30-53 0 . PC300. 11. 11 !?.1 Nm {lo kgm1 Additional tightening angle: 100 . Spacer Install spacer (2). tighten mounting bolts. m Mounting bolt: Initial torque: 98. i CEP00050 2. then lift off sprocket )I . For details. in the reverse order to & w Thread of sprocket mounting bolt: Thread tightener (LT-21 Sprocket mounting bolt: 637. see REMOVAL OF TRACK SHOE ASSEMBLY. Remove track shoe assembly.1 Nm I65 r 5 kgm) 30-54 0 PC300. I+ kg bolts. then push up chassis with work equipment and set block 0 between track frame and track shoe. Sprocket : 70 kg INSTALLATION OF SPROCKET l Carry out installation removal. 350-6 .DISASSEMBLY AND ASSEMBLY SPROCKET REMOVAL OF SPROCKET 1. Swing work equipment SO”. 3.4 t 49. Remove mounting (I). installation in the reverse order to l Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Disconnect swing hoses (2). 5. Bleeding air * Bleed the air from the swing motor. Disconnect swing holding brake hose (5). see TESTING Bleeding air. 4. Fit blind plugs in the disconnected hoses and tubes. 2. Run the engine to circulate the oil through the system.DISASSEMBLY AND ASSEMBLY SWING MOTOR REMOVAL OF SWING ASSEMBLY A MOTOR A * 1. Remove mounting bolts. Then check the oil level again. For details. Disconnect suction hose (I). Release the remaining pressure in the hydraulic circuit. PC300. For details. . and lift off swing motor assembly (6). Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. AND ADJUSTING. Releasing remaining pressure from hydraulic circuit. el kg Swing motor assembly: 110 kg INSTALLATION OF SWING MOTOR ASSEMBLY l Carry out removal. 3. 350-6 30-55 0 . Disconnect drain hoses (3) and (4). see TESTING AND ADJUSTING. in the reverse order to w Swing machinery case mounting bolt: 927 t 103 Nm t94. For details. 3. I+ kg Swing machinery assembly: 331 kg INSTALLATION OF SWING MACHINERY ASSEMBLY l Carry out installation removal. m 2. 350-6 . then lift off.5 t 10. Sling swing machinery assembly (21.5 kgm1 30-56 0 PC300. screw in forcing screws @ to separate swing machinery from frame. Remove swing motor assembly. Remove mounting bolts (1).DISASSEMBLY AND ASSEMBLY SWING MACHINERY REMOVAL OF SWING MACHINERY ASSEMBLY 1. see REMOVAL OF SWING MOTOR ASSEMBLY. 1 carrier assembly as follows. Draining oil Loosen drain plug and drain oil from swing machinery. 4. 2. 1 carrier assembly. bearing (IO). 12. Ir After removing the shaft. then lift off cover (1). and knock out shaft (6) from carrier (7). No. 350-6 . remove pin (5). I) 2) Remove thrust washer (2). 3. 2) Remove thrust washer (81. 1 sun gear (3). : Swing machinery case: Approx. gear (91. 9 11 6 CEPOOZOS PC300.DISASSEMBLY AND ASSEMBLY SWING MACHINERY DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1. 1) Push in pin (5). Disassemble No. Remove No. 1 carrier assembly (4).5 rJ Cover Remove mounting bolts. and thrust washer (II). 3) Remove No. * Remove No. 7. 1 sun gear I) Remove thrust washer (13) and collar (14). 30-58 0 PC300. 350-6 . 1 sun gear (15).DISASSEMBLY AND ASSEMBLY SWING MACHINERY 5. No. No. 2 carrier assembly Lift off No. CWPO6136 6. 2) Remove No. Ring gear Lift off ring gear (12). 2 carrier assembly (17). 2 carrier assembly (17) before removing the thrust washer. 31 Remove thrust washer (16). 350-6 . 2) Remove gear (26). 2 carrier assembly as follows. I) Push in pin (181. then remove mounting bolts (28) of cover assembly (27). gear (21). CEPOO216 CEFOOZl. * Set a wooden block under the press. remove pinion shaft assembly (30) with press. * After removing the shaft. then remove holder (25). 2) Remove thrust washer (201. 19 22 17 21 -------23 18 CEP00213 9. and thrust washer (23). and be careful not to damage the pinion shaft assembly when removing it. and knock out shaft (19) from carrier (17). Disassemble No. 1) Remove bolt (241. remove pin (18). and set on press stand. 27 28 CEPO0215 4) Turn over case and pinion assembly (29). PC300. 3) Turn over case and pinion assembly. then using push tool 0. bearing (221. Pinion shaft assembly.DISASSEMBLY AND ASSEMBLY SWING MACHINERY 8. 3 27 CEP00219 11. 2) Remove oil seal (33) from cover (27). 350-6 . Disassemble pinion shaft assembly as follows.DISASSEMBLY AND ASSEMBLY SWING MACHINERY 10. Bearing Using push tool. bearing (34) from case 35 34 CEFOo220 30-60 0 PC300. remove cover assembly (27) and bearing (31) from shaft (32). remove (35). 1) Using push tool 0. then using push tool 0. * When setting the case assembly to the shaft. Coat the sliding surfaces of all parts with engine oil before installing. & Cover mounting surface: Gasket sealant (LG-61 m Mounting bolt: 66. and tighten mounting bolts (28). 1. CEW0221 2. 350-6 30-61 0 . 27 CWPO6140 2) Fit cover assembly (27) to case (351. press fit bearing (31) to case (35). Cover assembly 1) Using push tool 0. & Outside circumference of oil seal: Gasket sealant (LG-61 * Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting. press fit bearing inner race portion.2 + 7. and check for dirt or damage.75 kgm} a Lip of oil seal: Grease (G2-LII 27 35 CWPO6141 3. 35’ I I -32 CWPO6142 PC300.4 Nm 16. be extremely careful not to damage the oil seal. Case assembly 1) Set case assembly (35) to shaft (321. press fit oil seal (33) to cover (27).75 t 0. Bearing Using push tool 0.DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY OF SWING MACHINERY ASSEMBLY * Clean all parts. * Be careful not to let the gasket sealant (LG-6) get on the oil seal lip when press fitting. check that the case rotates smoothly. Insert pin (18). -k After assembling the carrier assembly. 2 carrier assembly as follows * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier. then fit holder (25) and tighten bolt (24). 1) Assemble bearing (22) to gear (211. Jr Press the bearing inner race and outer race at the same time when press fitting. Do not press only the inner race when press fitting. press fit bearing (34). holder Assemble gear (261.75 + 4. rotate the planetary gear. then tap with a plastic hammer to install shaft (19). + After press fitting the bearing. Ir When installing the shaft. - - CWP06143 3) Gear. f After inserting the pin. 22 20 21 23 I 17 / h CEP00226 2) Align with position of pin holes of shaft and carrier.6 Nm (38.DISASSEMBLY AND ASSEMBLY SWING MACHINERY 2) Bearing Using tool F. so remove the caulked metal from the inside diameter of the hole before starting to assemble. check that gear (21) rotates smoothly. 350-6 . and be careful not to damage the thrust washer. fit top and bottom thrust washers (23) and (20) and set gear assembly to carrier (17).75 kgm} 4. & Mounting bolt: Thread tightener (LT-2) m Mounting bolt: 380 t: 46. I 3) 18 CEPO0227 I 30-62 0 PC300. caulk the pin portion of the carrier. Assemble No. 2 carrier assembly (17). 6. then install. 2) Install No. * Align the position so that the tip of the gear shaft enters at 4 places. 2 sun gear (15) to No. * Align with the drain hole and assemble. * Assemble thrust washer (16) before installing No. No. & Mating surface of ring gear and case: Gasket sealant (LG-6) CUP06136 PC300. 7. 350-6 . 2 carrier assembly Raise No. then install collar (14) and thrust washer (13).DISASSEMBLY AND ASSEMBLY SWING MACHINERY 5. 2 carrier. 2 carrier assembly (17) and install. Ring gear Raise ring gear (12) and install. 2 sun gear I) Assemble thrust washer (16). No. rotate the planetary gear. Insert pin (5). h 10 7 2) Align position of pin holes of shaft and carrier. Ir After inserting the pin. No. 1 carrier assembly (4). 1 sun gear (3) to carrier assem bly. 1 carrier assembly Install No. caulk the pin portion of the carrier. and be careful not to damage the thrust washer. 2) Install thrust washer (2). fit top and bottom thrust washers (8) and (11) and set gear assembly to carrier (7). * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier. Ir When installing the shaft. check that gear (9) rotates smoothly. 30-64 0 PC300. then tap with a plastic hammer to install shaft (6). 10. 3) 9 6 9.DISASSEMBLY AND ASSEMBLY SWING MACHINERY 8. 11 Assemble bearing (IO) to gear (91. Assemble No. 1 sun gear I) Assemble No. 350-6 . No. so remove the caulked metal from the inside diameter of the hole before starting to assemble. 1 carrier assembly as follows. * After assembling the carrier assembly. Cover Install cover (I). 12. 350-6 30-65 0 . Refilling with oil Tighten drain plug and add engine oil through oil filler. & Cover mounting surface: Gasket sealant (LG-6) w Wlounting bolt: 1st pass: 98 Nm II0 kgm) 2nd pass: 80 .5 I? PC300.DISASSEMBLY AND ASSEMBLY SWING MACHINERY 11. Q Swing machinery case: Approx.90” 12. DISASSEMBLY AND ASSEMBLY REVOLVING FRAME REMOVAL OF REVOLVING FRAME ASSEMBLY 1. and disconnect plate (13) from swivel joint. and frame (6). Leave 3 mounting bolts each at front and rear of revolving frame. When disconnecting the hydraulic hoses. 3. For details. Disconnect drain hoses (7) and (8). 8. For details. 6. see REMOVAL OF COUNTERWEIGHT ASSEMBLY. release the remaining pressure in the hydraulic circuit. 350-6 . see REMOVAL OF HYDRAULIC COOLER ASSEMBLY. cover (51. Raise boom cylinder assembly (21. For details. Disconnect travel hoses (9) and (IO). Remove engine hood (41. * Fit blind plugs in the hoses and make it possible to swing the upper structure. then pull out foot pin (3) and lift off. g 2. 30-66 0 PC300. Remove work equipment assembly. see REMOVAL OF WORK EQUIPMENT ASSEMBLY. Boom cylinder assembly: 300 kg kg &I Remove counterweight assembly. Ir Install blind plugs in the drain hoses. and speed selector hose (I I). 4. 6 CEFfJo393 7. Pull out pin (12). 1: Swing the upper structure and set to a position where it is easy to remove the mounting bolts. see TESTING AND ADJUSTING. 9. 5. + For details of the method of removing the engine hood. and remove other mounting bolts. Disconnect boom cylinder hoses (I). -f Remove the right cylinder assembly in the same way. Releasing remaining pressure from hydraulic circuit. DISASSEMBLY AND ASSEMBLY REVOLVING FRAME IO.5 kgml & PC300. Ir Use 2 lever blocks. Sling revolving frame assembly (141.7 + 103 Nm (94.5 t 10. 350-6 30-67 0 . in the reverse order to pJ Mating surface of swing circle: Gasket sealant (LG-41 & Thread of revolving frame mounting bolt: Thread tightener (LT-2) -Revolving frame mounting bolt: 926. * Loosen the mounting bolts remaining at the front and rear and adjust the center of gravity with the lever block while lifting off. Revolving frame assembly: 7000 kg A kg INSTALLATION OF REVOLVING FRAME ASSEMBLY l Carry out installation removal. then remove mounting bolts. and lift off revolving frame assembly. 5 kgm} Set the soft zone S mark on the inside ring of the inner race facing the right side of the machine as shown in the diagram. For details.5 t 10. and lift off swing circle assembly. then install to the track frame. Swing circle: Grease (G2-LI) 33 e 30-68 0 PC300. 350-6 . CIRCLE Remove revolving frame assembly. installation in the reverse order to Front of machine + a Thread Swing of swing circle mounting bolt: Thread tightener w * (LT-2) & circle mounting bolt: 926.7 * 103 Nm 194. then remove mounting bolts. INSTALLATION OF SWING 3 CIRCLE ASSEMBLY l Inner race Carry out removal. Sling swing circle assembly (I) at three points. & kg Swing circle assembly: 500 kg 2. see REMOVAL OF REVOLVING FRAME ASSEMBLY.DISASSEMBLY AND ASSEMBLY SWING CIRCLE REMOVAL OF SWING ASSEMBLY 1. in the reverse order to * When installing the idler assembly and recoil spring assembly. recoil spring assembly: 430 kg 3. For details. PC300. Remove track shoe assembly. Sling idler and recoil spring assembly (21. and pull out to the front to remove. * Remove lubricator (I). RECOIL SPRING REMOVAL OF IDLER. RECOIL SPRING ASSEMBLY 1. Disconnect recoil spring assembly (4) from idler assembly (3). & kg Idler. CEW0534 CEFWO 2. &I kg & kg Idler assembly: 170 kg Recoil spring assembly: 260 kg INSTALLATION OF IDLER. RECOIL SPRING ASSEMBLY l Carry out installation removal. * Fit wire to the idler and spring of the idler and recoil spring assembly. assemble so that the position of the greasing plug on the idler is on the outside for the right side of the machine and on the inside for the left side of the machine. see REMOVAL OF TRACK SHOE ASSEMBLY. and adjust the balance when removing. 350-6 30-69 0 .DISASSEMBLY AND ASSEMBLY IDLER. Remove pin (91. Remove bushing (12) from idler (5). 2. 230 cc. 350-6 . CEPo0066 6. Remove floating seal (7) on opposite side from idler (5) and shaft and support assembly (6).DISASSEMBLY AND ASSEMBLY IDLER DISASSEMBLY ASSEMBLY 1. CEPGQ540 4. I 5. Remove floating seal (4) from support (3) and idler (5). OF IDLER Remove pin (21. L CEP00069 9 CEPOO550 30-70 0 PC300. so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. + It is filled with approx. of oil. then remove support (10) from shaft (I 1). Pull out shaft and support assembly (6) from idler (5). 6 3. then remove support (3). * After inserting the pin. * Coat the sliding surface of the floating seal with oil. CEF-30073 PC300. and be careful not to let any dirt or dust get stuck to it. Assemble shaft and support assembly (6) to idler (5). 2. caulk the pin portion of the support. Press fit bushing (12) to idler (5). then install pin (9). 350-6 30-71 0 .DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY OF IDLER ASSEMBLY 1. Using tool Ll. 6 CEPO0063 I 4. install floating seal (7) to idler (5) and shaft and support assembly (6). * Remove all grease and oil from the contact surface of the O-ring and the floating seal. Fit O-ring and install support (10) to shaft (Ill. CEW0071 9 CEPOO550 3. and be careful not to let any dirt or dust get stuck to it.5 kgm} 7.5 I 2. CEP00080 6. * Coat the sliding surface of the floating seal with oil. Install O-ring. li After inserting the pin. Using tool Ll. * Remove all grease and oil from the contact surface of the O-ring and the floating seal.DISASSEMBLY AND ASSEMBLY IDLER 5. caulk the pin portion of the support. Oil: Approx.5 Nm 115. 24. then assemble support (3) and install pin (2). install floating seal (4) to idler (5) and support (3). Add oil and tighten plug. 350-6 . 230 cc IEOSO-CD) Plug: 152 t. 30-72 0 PC300. 1 Ml 2. of piston assembly g I CEFOOO55 4. * Installed load of spring: 173.DISASSEMBLY AND ASSEMBLY RECOIL SPRING DISASSEMBLY OF RECOIL SPRING ASSEMBLY 1. snap ring (121. 2) 3) The recoil spring is under large installed load. Remove piston assembly (2) from recoil spring assembly (II. * Compress the spring to a point where the nut becomes loose.3 kN (17.680 kg) Apply hydraulic pressure slowly to compress spring. so be sure to set the tool properly. * Free length of spring: 795 mm Remove yoke (61. cylinder (71. PC300. then remove lock plate (31. Failure to do this is dangerous. and remove nut (4). 350-6 30-73 0 . then valve (I I). and dust seal (8) from spring (5). Disassembly of recoil spring assembly 1) Set tool Ml to recoil spring assembly (1). Disassembly 1) 2) Remove remove Remove ing (13) lock plate (IO) from piston (91. then remove U-packand ring (14). Ir Fill the inside of the cylinder with approx. and tighten nut (4) so that installed length of spring is dimension “a”. & Sliding portion of cylinder: Grease (G2-LI) 3) Apply hydraulic pressure slowly to compress spring. 2) Tighten valve (11) temporarily. and secure with lock plate (IO). and secure with snap ring (12). /8 ‘7 2. 6 Piston sliding portion and wear ring: Grease IG2-Ll) * Assemble the cylinder assembly so that the mounting position of the valve is 90” to the side. CEPOO062 3.DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY ASSEMBLY 1. then bleed the air and check that grease comes out of the grease hole. OF RECOIL SPRING M2 Assembly of piston assembly I) Assemble ring (14) and U-packing (13) to piston (9). Assembly of recoil spring assembly 11 Using tool M2. 350-6 . assemble dust seal (8) to cylinder (7). then secure with lock plate (3) Ir Installed length “a” of spring: 648 mm 4) Remove recoil spring assembly (I) from tool Ml. Assemble piston assembly (2) to recoil spring assembly (I). 200 cc of grease (G2-LI). 2) Assemble cylinder (7) and yoke (6) to spring (51. 1 CEP00063 30-74 0 PC300. and set in tool Ml. a & kg Track roller assembly: 55 kg INSTALLATION OF TRACK ROLLER ASSEMBLY l Carry out installation removal. and remove track roller assembly (3) to outside of machine. jack up machine with work equipment.DISASSEMBLY AND ASSEMBLY TRACK ROLLER REMOVAL OF TRACK ROLLER ASSEMBLY 1. remove mounting bolts of track roller assembly (3). then swing work equipment 90”. and relieve track tension.6 Nm I20 + 2 kgmj 2nd pass: Tighten an additional 105 + 5” PC300. Track roller guard: 35 kg 2.5 kgm} & m Track roller mounting bolt: Thread tightener (LT-2) Track roller mounting bolt: 1st pass: 196. If the grease does not come out easily. 350-6 30-75 0 .7 t 103 Nm f94. then jack up machine with work equipment. move the machine backwards and forwards.5 t 10. CEP00534 CEPOOOB Lower chassis completely.m &I kg 3. For details. Testing and adjusting track tension. m g The adjustment cylinder is under extremely high pressure. in the reverse order to * Adjust the track tension. then loosen lubricator (I). so never loosen the lubricator more than one turn. Lower work equipment to ground. and remove track roller guard (2) towards outside of machine.1 2 19. Remove mounting bolts of track roller guard (2). see TESTING AND ADJUSTING. CEPOOQ83 6 m Roller guard mounting bolt: Thread tightener (LT-21 Roller guard mounting bolt: 926. so drain the oil at this point or lay a cloth to prevent the area from becoming dirty. Remove floating seal (6) on opposite side from roller (4) and collar (8). then remove collar (8) from shaft (5).DISASSEMBLY AND ASSEMBLY TRACK ROLLER DISASSEMBLY OF TRACK ROLLER ASSEMBLY 785 I 1 CEPOooRd 1. Remove pin (71. Remove floating seal (3) from collar (2) and roller (4). 350-6 . of oil. Remove pin (I). 3. CEP00087 CEPOOOE9 5. Remove bushings (9) and (IO) from roller (4). * It is filled with 250 . CEPOOa95 4. then remove collar (2). 2. Pull out roller (4) from shaft (5). 7 CEFUO090 30-76 0 PC300.280 cc. 6 6. * When assembling the floating seal. check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 . Using tool L3. see the precautions marked * for Step 3. install floating seal (3) to collar (2). Assemble (7). (IO) to roller (4). collar press fit bushings (9) and 2. Ir For details of the precautions when installing floating seals (3a) and (3c). OF TRACK ROLLER Using push tool 0. Ir For details of the precautions when installing floating seals (6b) and (6d). clean the contact surface of O-ring (6~) and floating seal (6a). * After inserting the floating seal. CEFOOOSl CEPOO092 Remove all oil and grease from hatched portion. 3 CEPOO095 CEPOcm6 6. and (3b) and (3d). install floating seals (6) and (3) to roller (4). Assemble shaft (5) to roller (4). Using tool L3. Make sure that no dirt or dust sticks to the contact surface of the floating seal. CEPOO093 Protrusion of seal 5-7mm -i 1 CEWOO94 4. and install pin 3. Turn over roller (4) and shaft (5) assembly. install floating seal (6) to shaft 6 (5). remove all grease and oil. 7. a.7 mm. 350-6 .DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY ASSEMBLY 1. I b dI 5. Using tool L3. CEPO0097 CEFUW96 PC300. see the precautions marked * for Step 3. (8) to shaft (5). and dry it. 5 kgml i To oil pump To vacuum tank CEPO0201 r” CEFO0202 30-78 0 PC300.1 MPa (1 kg/cm21 * Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down. * Standard pressure: 0. then tighten plug (II).7 t 4. Using tool L4.9 Nm U. fill track roller assembly with oil. and install pin (1).280 cc (E030-CD) w Plug: 14. Track roller oil: 250 . 350-6 . apply standard pressure to roller oil filler port.5 + 0. 9. and check for leakage of air from seal. Assemble collar (2) to shaft (5). CEPOOlOO 10. Using tool L4.DISASSEMBLY AND ASSEMBLY TRACK ROLLER 8. in the reverse order to * Adjust the track tension. If the grease does not come out. then remove carrier roller assembly (2). so never loosen the lubricator more than one turn. For details. m kg r&I Carrier roller assembly: 35 kg 2 CEPO0203 INSTALLATION OF CARRIER ROLLER ASSEMBLY . Lower work equipment to ground. Testing and adjusting track tension. then loosen lubricator (11. CEP00534 CEPO0051 2. push up track to a position where carrier roller assembly can be removed. and relieve track tension. Using hydraulic jacks 0. see TESTING AND ADJUSTING. PC300.DISASSEMBLY AND ASSEMBLY CARRIER ROLLER REMOVAL OF CARRIER ROLLER ASSEMBLY 1. 350-6 30-79 0 . move the machine backwards and forwards. a A The adjustment cylinder is under extremely high pressure. Carry out installation removal. Using tool L5. pull out shaft assembly (5) from roller (6) with press. Carrier roller assembly: 450 . Remove : plug (I) and drain oil. 3. Using push tool 0. I) Using puller 0.500 cc 2. 8. remove nut (4). 350-6 .DISASSEMBLY AND ASSEMBLY CARRIER ROLLER DISASSEMBLY OF CARRIER ROLLER ASSEMBLY CEP00231 1. Set carrier roller assembly on stand 0. 6. 6 8 Disassembly of shaft assembly. CEP00234 CEPO0235 7. Remove ring (3). I 1 CEW0236 CEFW237 30-80 0 PC300. 4. remove inner race (IO). Remove cover (2). Remove outer races (8) and (9) from roller (6). then remove inner race (7). CEP00233 5. 350-6 30-81 0 . remove shaft (13).DISASSEMBLY AND ASSEMBLY CARRIER ROLLER 2) 3) Remove floating seals (11). collar (12) from CEPO0238 L-l o 4 13 - 12 +- CEP00239 PC300. Using push tool 0. Using tool L5. assemble floating seals (11). be careful that there is no scuffing. 5. Assemble floating seals (I I). and press fit to a point where the rotation becomes slightly heavier. f When press fitting. I 30-82 0 PC300. tighten nut (4) to a point where drill hole in shaft is aligned with drill hole in nut.P CEFWJ093 CEPOO094 CEPOO244 CEPOO234 3. rotate the roller. press fit inner race (IO).DISASSEMBLY AND ASSEMBLY CARRIER ROLLER ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1. Ir For details of the precautions when installing floating seals (I 1b) and (I Id). and dry it. 1) Using tool L7. press fit inner race (7). see the precautions marked * for Step 2). * After inserting the floating seal. press fit collar (12) to shaft (13). * When press fitting the bearing. 350-6 . press fit outer races (8) and 0 L7 2. 4. check that the angle of the seal is less than 1 mm and that the protrusion of the seal is within a range of 5 . then using push tool 8. Protrusion of seal 5-7mm Jc!J . * When assembling the floating seal. Using push tool 0. Assemble roller (6) to shaft assembly (5). Assembly of shaft assembly. (9) to roller (6). Using push tool 0. & Fitting portion of shaft: Engine oil (E030-CD] 2) Using tool L6. clean the contact surface of O-ring (11~) and floating seal Illa).7 mm. Make sure that no dirt or dust sticks to the contact surface of the floating seal. 12 13 8 E+d CEW0240 ’ CEP00241 3) CEP00242 CEP00243 Remove all oil and grease from hatched portion. remove all grease and oil. Install ring (3). I 10. Using tool L8. apply standard pressure to roller oil filler port.599 cc (E030CD) Plug: 14. * Standard pressure: 0. 7.350-6 . fill carrier roller assembly with CEPO0249 oil. then tighten plug (1).DISASSEMBLY AND ASSEMBLY CARRIER ROLLER 6. I& m Carrier roller oil: 450 . scale 8.9 Nm il. Using tool L8. check that roller ro- CEPO0233 CEW0247 8. CEP00249 9.5 kgm) t To oil pump To vacuum pump CEPU0250 PC300.1 MPa {I kg/cm21 * Method of checking The standard pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.7 + 4. Using push-pull tates smoothly.5 + 0. and check for leakage of air from seal. Fit O-ring and install cover (2). a I I II CDPOOZ30 30-84 0 PC300. Protrusion “a” of master pin: 4. 350-6 .2 f 2 mm CEPO0297 & When assembling the dust seal. Using tool R. and remove dust seal. (12( CEP00534 CEPO0051 2.coat the bushing contact surface with grease IG2-LI). then remove temporary pin 0. and relieve the m track tension. Lay out track as follows. then loosen lubricator (I). so never loosen the lubricator more than one turn. move the machine backwards and forwards.DISASSEMBLY AND ASSEMBLY TRACK SHOE REMOVAL OF TRACK SHOE ASSEMBLY 1. in the reverse order to Adjust the track tension. Positioning track shoe * Stop the machine at a point where it is easy to set master pin removal tool R. pull out master pin (2). For details. g The adjustment cylinder is under extremely high pressure. see TESTING AND ADJUSTING. INSTALLATION OF TRACK SHOE ASSEMBLY l Carry out installation removal. set block @ in position. m 2) Drive machine in reverse to lay out track. If the grease does not come out. 1) Move machine forward so that position of temporary pin is at front of id!er. m * Use tool R and press fit so that the protrusion of the master pin is dimension “a”. Testing and adjusting track tension. and where master pin is in the middle of the track frame. 3. 200 e 3. Disconnect drain hoses (61.: 2. 5. PC300. then remove partitions (II and (2). 8. CEFO0406 7. Disconnect hydraulic oil filter inlet hose (9) and outlet hose (IO). Remove operator’s cab assembly. and main pump undercover. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Remove air conditioner air suction port (5).DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK REMOVAL OF HYDRAULIC TANK ASSEMBLY l A Swing the upper structure to set the position of the hydraulic tank drain and mounting bolt outside the track. 1. (71. hydraulic tank undercover. Remove covers (3) and (4). 350-6 30-85 0 . . see REMOVAL OF OPERATOR’S CAB ASSEMBLY. Drain oil from hydraulic tank. Remove control valve top cover. and (8). For details. Hydraulic tank: Approx. Open main pump side cover. 4. 6. DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK 9. 30-86 0 PC300. For details.9 Nm 128. . I CEFO0410 13.25 kgm} Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified . Then check the oil level again. Remove mounting bolts. Ir A box wrench cannot be fitted on the center rear mount bolt. 11. 12. &I kg Hydraulic tank assembly: 230 kg INSTALLATION OF HYDRAULIC TANK ASSEMBLY l Carry out installation removal. in the reverse order to w l Hydraulic tank mounting bolt: 277 t 31. level. Run the engine to circulate the oil through the system. and (14). and lift off hydraulic m tank assembly (17). Remove main pump suction tube (16). Disconnect hydraulic oil level sensor connector (15) (CN-PO9). 350-6 . Bleeding air + Bleed the air. IO. Bleeding air. see TESTING AND ADJUSTING.25 f 3. Disconnect hydraulic oil cooler return hose (1 I). so disconnect both sides of tube (16) and offset them. (131. Disconnect drain hoses (121. Disconnect cooling hose (8). Disconnect LS control hose (9). remove the drain plug. Disconnect suction tube (7). 12. 14. Disconnect front pump delivery pressure detection hose (15). 16. * When not using tool Sl. Disconnect chassis ground cable (5). 5. - II I / CWPO6106 detection hose (IO). Disconnect TVC wiring connectors (12) (C13.DISASSEMBLY AND ASSEMBLY MAIN PUMP REMOVAL OF MAIN PUMP ASSEMBLY -G Disconnect the cable from the negative (-1 terminal of the battery. Remove bracket (6) of pump branch hose. 16. Remove muffler drain tube (4). and partiundercover and engine 6. Open engine hood. Disconnect TVC wiring clamp (13). 13. fit tags to distinguish them. Remove hydraulic tank strainer. Drain coolant. stop oil. 9. Disconnect rear pump LS pressure PC300. . 14). 1. 15. and drain the oil from the hydraulic tank and inside the system. 3. Remove main pump top cover (I). * After disconnecting the hoses. 11. A Lower the work equipment completely to the ground and stop the engine. Disconnect rear pump delivery pressure detection hose (I I).: Hydraulic tank: Approx. tions (2) and (3). Remove main pump undercover. 200 e g -kid!- CEP00268 2. 17. 8. Ir Do not disconnect the branch hose. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 7. and using tool Sl. 4. 350-6 30-87 0 . Disconnect front pump LS pressure detection hose (14). 21. remove mounting bolts. wait for 15 minutes. see TESTING Bleeding air. l Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Disconnect hose (17) going to control valve.DISASSEMBLY AND ASSEMBLY MAIN PUMP hose (16) going to self-reducing pressure valve. Disconnect drain hose (18). For details. and check the oil level again. Run the engine to circulate the oil through the system. Disconnect INSTALLATION OF MAIN PUMP ASSEMBLY l Carry out installation removal. 350-6 . Run the engine. then lift off. Sling main pump assembly (191. 20. l Bleeding air Ir Bleed the air. AND ADJUSTING. 30-88 0 PC300. Then check the oil level again. then stop the engine. &I kg Main pump assembly: 250 kg 18. in the reverse order to & Involute Mating spline of main pump: Anti-friction 6 compound (LM-G) surface of main pump case: Gasket sealant (LG-6) l Refilling with oil (damper case) * Add oil through the oil filler to the specified level. 19. see REMOVAL OF MAIN PUMP ASSEMBLY. then remove spacer (2). Carry out installation removal. be extremely careful not to damage the shaft. press fit oil seal (3). CEPOO400 INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL . Remove snap ring (I). * When removing the oil seal. Using tool S2.DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL 1. CEP00401 * PC300. in the reverse order to & 6 Lip of oil seal: Grease (G2-LI) Coat the outside circumference of the oil seal with grease (G2-LI) thinly. then press fit. Lever up oil seal (3) with a screwdriver to rem move. F 2. Remove main pump assembly. 350-6 30-89 0 . 3. For details. Disconnect 9 bottom PPC hoses (7). Disconnect pump merge/divider solenoid hose (8). Disconnect main pump outlet hoses (11) and (12). 2. Make match marks before disconnecting the PPC circuit hoses. Disconnect pressure sensor connectors (9) and (IO) (CN-CO8 and CN-C07). Disconnect turbocharger outlet port hose (I). 1. 8. 6. Release the remaining pressure in the hydraulic circuit. g * * 7. Open engine hood. 30-90 0 PC300. 7 8 fi CEFO0129 9. Disconnect air cleaner clogging sensor hose (3). Remove control valve top cover. Releasing pressure in hydraulic circuit. 10. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. For details. see TESTING AND ADJUSTING. Fit blind plugs in the disconnected hoses and tubes. 350-6 . and remove partition (6). 4. Disconnect wiring harness (51.DISASSEMBLY AND ASSEMBLY CONTROL VALVE REMOVAL OF CONTROL VALVE ASSEMBLY a Lower the work equipment completely to the ground and stop the engine. 3. 5. and remove inlet port hose (2). Disconnect air cleaner assembly (4) together with bracket. Remove elbows (211. * Hose (13): For arm boost PPC Hoses (14) and (15): For R. and (23). Disconnect hoses (131. + Hose (19): For drain circuit Hose (20): For high-pressure circuit 13.I4 12. I CEPO0134 PC300. Disconnect control valve return hose (26). (151. 15. 350-6 30-91 0 . and (18). straight travel Hoses (16) and (17): For L. (141. Disconnect hoses (19) and (20). Disconnect safety valve hose (29). 18. Disconnect high-pressure circuit hose (30) and LS pressure hoses (31). 14. straight travel Hose (18): For drain circuit I 17 . 17.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 11. Set hose mounts of elbows (24) and (25) facing down. (171. (16). Disconnect 10 top PPC hoses (28).H. 16. (221. Disconnect drain hose (27).H. 19. 22.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 20. Disconnect L. Run the engine to circulate the oil through the system. &I kg Control valve assembly: 260 kg INSTALLATION OF CONTROL VALVE ASSEMBLY l Carry out installation removal. 28. Disconnect bucket hoses (331. Disconnect 2 R. and lift off control valve assembly. Disconnect arm hoses (35). 26. 21.4 25. 23.H. then remove mounting bolts. travel hoses (36). Ir Move slightly to the front and pass through the bracket to lift off. 30-92 0 PC300. :wPo614. Remove swing motor hoses (37). Disconnect swing motor suction hose (32).H. Remove boom tubes (38) and (39). Sling control valve assembly (411. Disconnect LS select valve hose (401. Then check the oil level again. 24. in the reverse order to l Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. 27. travel hoses (34). 350-6 . trave Arm-low ’ \ t Z 27 25 23 21 90 I! 17 X DWPOO716 PC300.106 Boom.H.DISASSEMBLY AND ASSEMBLY CONTROL VALVE DISASSEMBLY (l/3) OF CONTROL VALVE ASSEMBLY 89 W-J // 2 . arm-high Bucket R. 350-6 30-93 0 .H.travf Boom-low Swine L. H.travel Boom-low Swine L.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 15 13 II 9 7 5 3 2 A-A 16 Boom. arm-high Bucket R.H.travel Arm-low 14 I2 IO 0 6 4 I 23 21 26 24 ‘22 19 17 c-c 20 I8 ‘32 J-J 34 L-L K-K 37 EE-EE 35 36 DWP00717 30-94 0 PC300. 350-6 . DISASSEMBLY AND ASSEMBLY CONTROL VALVE N-N (For boom. 350-6 30-95 0 . arm-high) 60 (For F-F sw ins) 54 53 (For bucket) 87/ E-E (For travel) AA-AA (For travel) 74 75 if 76 \73 G-G (For boom) DWPOO718 PC300. bucket CURL pressure compensation valve (14). check and mark its mounting position. 1) Remove unload valve (1). 30-96 0 PC300. 1. travel FORWARD pressure compensation valve (12). R. Pressure compensation valves * Before removing any pressure compensa- tion valve. boom RAISE pressure compensation valve (9). Main relief valve 1) Remove main relief valve (2). 2) Remove boom Hi RAISE pressure compensation valve (16). remove check valve (88) from each pressure compensation valve mount. 3. boom LOWER pressure compensation valve (IO). 4. suction valve. travel FORWARD pressure compensation valve (6). LS select valve Remove LS select valve (29). travel REVERSE pressure compensation valve (II). 350-6 .H. 3) Remove suction valves (19). bucket DUMP pressure compensation valve (13). left swing pressure compensation valve (8). L. The set pressure of the safety valve cannot be adjusted when it is installed on the machine. 2) Remove safety-suction valves (17).DISASSEMBLY AND ASSEMBLY CONTROL VALVE * .H. and arm OUT pressure compensation valve (3). right swing pressure compensation valve (7). (23.H. and (26). * After removing the pressure compensation valves. L. so do not disassemble. 4) Remove plugs (27) and (28). and (24). (18). 1) Remove arm Hi IN pressure compensation valve (15). Unload valve. (22). The following procedure is for the 7-spool valve.H. safety-suction plug valve. and arm IN pressure compensation valve (4). (201. travel REVERSE pressure compensation valve (5). 2. R. Remove plug (581. and springs (36) and (39). * Do not disassemble spool assembly (49). Remove case (641. then remove spring (75) and retainer (76). Bucket control valve I) Remove case (781. Ir Do not disassemble spool assembly (67). and re2) tainer (66). 4) Remove block (87). 4) Remove spool assembly (77). Remove case (551. then remove spring (44) and retainer (45). PC300. Arm control valve 1) Remove plug (40). then remove remove remove remove spring piston spring piston (5% Remove spool assembly (60). then remove piston (42) and spring (41). then remove spring (82) and retainer (83). 2) Remove case (43). 11. 3) Remove case (46). 350-6 30-97 0 . LS shuttle valves. then remove spring (47) and retainer (48). travel control valve. pump merge/divider valve. Swing control valve 1) Remove case (501. * Do not disassemble spool assembly (60). 31 Remove spool assembly (84). 2) Remove pump merge/divider then remove boom regeneration spring (85) and boom regeneration valve (86). 4) Remove spool assembly (49). 6. then (51) and retainer (52). * Do not disassemble spool assembly (77). block I) Remove LS shuttle valves (30) and (31). Arm regeneration valve . then 3) 4) 5) (54). then (56) and retainer (57).H. spring (651. then remove spools (33) and (341. 2) Remove plug (531. then remove spring (62) and retainer (63). Remove plate (911. valve body (35) 3) Remove merge/divider and plugs (37) and (381. Ir Do not disassemble spool assembly (84). then remove piston (72) and spring (73). travel control valve 1) Remove case (61). 6. 10. valve (32). R. 9. then remove spring (69) and retainer (70). 3) Remove case (74). then remove arm regeneration spring (92) and arm regeneration valve (93). L. 2) Remove plug (711.H. 3) Remove spool assembly (67). 7. then remove spring (79) and retainer (80). Boom control valve I) Remove case (681.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 5. 2) Remove case (811. boom regeneration valve. 3) Remove case (1041. then disassemble into valve (IOI). arm Hi control valves Arm Hi control valve * Mark with tags to prevent mistakes in the mounting position when assembling the springs and spools. (90) and valve (106) 7a CWPO6153 O/ CWPO6154 30-98 0 PC300. Boom Hi control valve * Mark with tags to prevent mistakes in the mounting position when assembling the springs and spools. Boom Hi. 350-6 . hold position @ shown in diagram on right with a wrench (width across flats: 24mm). retainer (981. then disassemble into retainer (96). and spool (102). and spool (94).DISASSEMBLY AND ASSEMBLY CONTROL VALVE 12. 41 To prevent damage to spool assembly. then pull out spool assembly to position shown in diagram on right. plate (991. Remove covers (89) and from valve body. springs (97a) and (97b). hold position @ shown in diagram on right with a wrench (width across flats: 24mm). then remove spring (105) and plate (99). Remove case (1031. remove plug (IOO). 13. To prevent damage to spool assembly. remove plug (951. travel Arm-low 28 26 24 22 27 25 23 21 20 19 17 X DWP00716 PC300.DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY (l/3) OF CONTROL VALVE ASSEMBLY Swing L. H. 350-6 30-99 0 . 350-6 . H.100 0 PC300.DISASSEMBLY AND ASSEMBLY CONTROL VALVE (Z/3) 15 13 11 9 7 5 3 2 A-A 16 14 12 IO 8 6 4 I B-B Boom. travel Arm-low 23 21 26 . travel Boom-low Swing L. H.24 c-c J-J DWP00717 30. arm-hioh Bucket R. ket) (For E-E travel) 64 42 AA-AA (For travel) II 40 74 V-V 75 91 92 (For arm) 76 G-G (For boom) DWP00718 PC300. arm-high) 50 59 60 (For F-F swins) 54 53 / 25 87' (For-.buc. 350-6 30-101 0 .DISASSEMBLY AND ASSEMBLY CONTROL VALVE 103 55 56 57 N-N (For boom. and retainer (961. + Arm Hi control valve spool Check the mounting position of the spring and spool assembly carefully before installing.9 2 3. Hold spool (94) at position @ shown in diagram on right with a wrench (width across flats: 24mm). then fit Oring to case (103) and install. Covers Install valve (1061. w Cover mounting bolt: 166.4 Nm (3. Boom Hi.35 kgm} . Fit seal to spool (1021.8 Nm I17 + 1 kgm} AY++f D c& CDFfJo544 B 2.25 kgm} Push spool assembly into body.15 + 0. w Case mounting bolt: 30. and tighten plug 1) 2) (411.35 kgm) 1) 2) 7a 3) CWPOBl 30-102 0 PC300. and covers (89) and (90) to valve body. and tighten plug (32). then hold position @ shown in diagram on right with a wrench (width across flats: 24mm). Coat the sliding surfaces of all parts with engine oil before installing. install retainer (981.9 = 3. w Case mounting bolt: 30. * Check that there is no damage to the O-ring. damage. 350-6 .6 2 9.2 + 1.DISASSEMBLY AND ASSEMBLY CONTROL VALVE Ir Check the spools and valves for dirt. fit spring (105). Ir Tighten the mounting bolts of covers (89) and (90) in the order shown in the diagram on the right. then install plug (95).35 = 0.15 kgm} 3) Push spool assembly into body. 1. arm Hi control valve spools . Assemble spool (102) to position shown in diagram on right.2 2 2. w Plug: 13. then fit O-ring to case (104) and install. and install seal to valve (101). Assemble spool (94) to position shown in diagram on right.5 Nm {I.15 + 0.4 Nm 6. springs (97a) and (97b). w Plug: 17. install plate (99) and valve (101) to spool (1021.5 Nm Il. then install securely to the mating surface of the cover and valve. Boom Hi control valve spool * Check the mounting position of the spring and spool assembly carefully before installing.75 t 0. or burrs. 8 L 14.5 kgm) 4) Assemble retainer (70) and spring (69).35 kgm) Assemble retainer (63) and spring (62).15 = 0. w Case mounting bolt: 30.9 t 3.15 + 0.7 Nm Ill.15 t 0. then fit O-ring to case (74) and install. Assemble retainer (48) and spring (47).8 a 14. then fit O-ring to case (81) and install.9 + 3.15 +. then fit O-ring to case (64) and install. and install plug (53). Assemble retainer (66) and spring (65). then fit O-ring to case (55) and install. m Plug: 2) 107. body.35 kgm) Assemble retainer (80) and spring (79).15 z 0.15 + 0.35 kgm1 3) Assemble retainer (45) and spring (44).8 + 14.7 Nm III.15 2 0.5 kgm) 2) 3) body. 350-6 30-103 0 .7 Nm Ill.15 + 0. w Plug: 107. travel control valve. then fit O-ring to case (68) and install.4 Nm (3. w Plug: 107.35 kgm) 4) Assemble spring (41) and piston (42).4 Nm 13. and install plug (40).35 kgm) 4) Assemble piston (54).0 + 1.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 3.0 t 1.0 t 1. R. Bucket control I) Assemble valve 6. 2) Assemble retainer (83) and spring (82).4 Nm 13.9 2 3. w Case mounting bolt: 30.8 + 14. 0.5 kgm} 5) Assemble retainer (52) and spring (51). then fit O-ring to case (78) and install. w Case mounting bolt: 30.35 kgm) 3) Assemble spring (73) and piston (72). spool assembly (84) to valve Swing control valve I) Assemble spool assembly (60) to valve body.7 Nm Ill.4 Nm 13.35 kgm) 2) 5. Assemble retainer (76) and spring (75).9 t: 3. m Case mounting bolt: 30. then fit O-ring to case (61) and install.35 kgm) valve 2) Assemble piston (59).4 Nm (3.15 t 0.9 t 3.H.9 2 3. and install plug Plug: 107.4 Nm t3. Arm control valve (58). then fit O-ring to case (43) and install. then fit O-ring to case (50) and install.9 t 3.15 t 0.5 kgm) 3) Assemble retainer (57) and spring (56). m 3) 4.4 Nm (3. w Case mounting bolt: 30.4 Nm I3. L.H.9 t 3. m Case mounting bolt: 30.9 + 3. Q~EI Case mounting bolt: 30.35 kgm} 7.4 Nm 13.35 kgm1 PC300. Boom control 1) Assemble spool assembly (77) to valve body. travel control valve I) Assemble spool assembly (67) to valve 1) Assemble spool assembly (49) to valve body.9 + 3. and install plug (71). m Case mounting bolt: 30. then fit O-ring to case (46) and install.0 + 1. w Case mounting bolt: 30. w Case mounting bolt: 30.4 Nm 13. and boom Hi RAISE pressure compensation valve (16). and install in the correct position. 0. w Mounting bolt: 30. left swing pressure compensation valve (8). boom RAISE pressure compensation valve (91.5 Nm I4.6 Nm I40 r 2 kgm} 3) Fit O-rings and install arm OUT pressure compensation valve (31. travel FORWARD pressure compensation valve (121.6 t 9. and arm Hi IN pressure compensation valve (15). w Pressure compensation valve: 392 t 19.5 Nm (15. R. right swing pressure compensation valve (71. 7. boom LOWER pressure compensation valve (IO).0 +. w Mounting bolt: 66.35 kgm} CWPO6155 A+l-q+ D c& CDP00544 B 9.6 Nm 140 + 2 kgm} PC300.H.4 Nm I6. pressure compensation 11 Before installing valves below. travel FORWARD pressure compensation valve (61. m LS select valve: 127. 350-6 30-104 0 .H. LS select valve Install LS select valve (29). pump merge/divider boom regeneration valve.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 8. bucket CURL pressure compensation valve (141. Pressure compensation valves . install check valve (88). travel FORWARD pressure compensation valve (51.H.H.75 +10. LS shuttle valve. R. 2) Fit O-rings and install arm IN pressure compensation valve (41. Check the marks made on each pressure compensation valve during disassembly. then install plugs (37) and (38).2 + 4.5 kgm} m Plug (37): 151. block valve. L.75 kgm} Install block (87). bucket DUMP pressure compensation valve (131.9 = 24.15 2 0.9 + 3. L. 1) Assemble 2) 3) 4) springs (36) and (39) and spools (33) and (34) in merge/divider valve (351.4 + 19.4 Nm I3. * Tighten the mounting bolts in the order shown in the diagram on the right.8 Nm {I7 f 1 kgm} Install LS shuttle valves (30) and (31).2 +.6 Nm I13 = 2 kgm} 10. w Mounting bolt: 166.5 kgm} Assemble boom regeneration valve (86) and spring (85) in valve body. then install merge/ divider valve assembly (32). m Plug (38): 39. travel REVERSE pressure compensation valve (II). m Pressure compensation valve: 392 3 19.5 + 2. w Plate mounting bolt: 66. Fit O-ring and install main relief valve assembly (2).75 kgm} l 12. and (24). 350-6 30-105 0 . w Suction valve: 147 t 9. Main relief valve . Arm regeneration valve Assemble arm regeneration valve (93) and spring (921. (221.9 + 4.2 t 7. w Safety-suction valve assembly: 147 + 9. then install plate (91). safety-suction valve.8 Nm 115 t 1 kgm} Fit O-ring and install unload valve assembly (I). Sr Tighten the mounting bolts in the order shown in the diagram on the right. m Main relief valve assembly: 53.4 Nm I6.8 Nm I15 t 1 kgm} 3) Fit O-rings and install safety-suction valves (171.5 t 0.9 Nm (5. Unload valve. and (26).5 kgm} PC300. (20). (211. (231. suction valve I) Fit O-rings and install plugs (27) and (28). w Plug: 49 + 9. (181. w Unload valve assembly: 166.8 Nm (5 t 1 kgm} 2) Fit O-rings and install suction valve assemblies (191.DISASSEMBLY AND ASSEMBLY CONTROL VALVE 11.6 + lg.6 Nm I17 t 2 kgml CKP00820 4) 13.75 + 0. 5 Nm 115. 30-106 0 PC300.9 Nm I4. engine oil.DISASSEMBLY AND ASSEMBLY PUMP MERGE/DIVIDER VALVE DISASSEMBLY OF PUMP MERGE/DIVIDER VALVE ASSEMBLY CEFO0547 1. 350-6 .0 = 0. coat the sliding surface with 1. Remove plug (9).0 + 0. 3. w Plug (2): 152 f 24. * Remove plug (2) from valve body (II. 4.6 kgm} Fit O-ring to plate (5) and install valve body. w Plug (6): 39. Remove plug (61.2 + 5. if there is any abnormality in body (I 1 or spools (4) or (81. ASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY . 2.5 + 2. then fit Oring to plug (6) and install.5 kgm} 2. 4. 3. then remove spring (3) and spool (4). then fit Oring to plug (2) and install. Fit O-ring to plug (9) and install to valve body (1). m Plug (9): 39. Before assembling.6 kgm} Assemble spool (8) and spring (71.9 Nm I4. then remove spring (7) and spool (8). Remove plate (5). replace the whole pump merge/divider valve assembly. Assemble spool (4) and spring (31.2 t 5. After disassembling. Remove piston sub-assembly (2) and piston (3) from sleeve (I). Assemble spring (5). replace the whole pressure compensation valve assembly. bucket dump ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY Before assembling. Ir Sub-piston assembly (2) is assembled to pressure compensation valves A-C. * After disassembling. PC300. left swing. or piston (3).DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE DISASSEMBLY OF PRESSURE COMPENSATlOhi VALVE ASSEMBLY CEPOO548 l ‘I. and install to sleeve.I is the same. travel REVERSE R. Boom RAISE F: Arm OUT G: Bucket CURL H: Arm IN I: Right swing. 1. E-I. piston sub-assembly (21. then remove ring (6) and Orings (7) and (8) from sleeve (1). travel REVERSE. L. 350-6 30-107 0 . travel FORWARD E.H. coat the sliding surface with engine oil. Remove spring (51. The structure of the parts for pressure compensation valves A . then remove seal (4). if there is any abnormality in sleeve (I). seal (41. so be careful when assembling. . 2. Install O-rings (8) and (7) and ring (6) to sleeve (I). but the part numbers for the component parts is different. travel FORWARD. L. 2.H. Pressure compensation valves A: Arm IN Hi B: Boom RAISE Hi C: Boom LOWER D: R.H. and piston (3) is assembled to pressure compensation valves D. then assemble seal (4) to piston sub-assembly (2) and piston (3).H. Remove servo valve assembly (6) for front pump. I CEP00412 INSTALLATION OF SERVO VALVE ASSEMBLY FOR FRONT PUMP l Carry out installation removal.DISASSEMBLY AND ASSEMBLY SERVO VALVE FOR FRONT PUMP REMOVAL OF SERVO VALVE ASSEMBLY FOR FRONT PUMP g A 1. Then check the oil level again. m I 4. Disconnect LS-EPC hose (31. and pump circuit pressure hose (5).4 Nm 16. * Fit blind plugs in the disconnected hoses. Disconnect the cable from the negative (-1 terminal of the battery. l Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level.2 + 7. 3. 30-l 08 0 PC300.75 + 0. in the reverse order to * * m Ir Be careful not to let the O-ring or filter fall out when installing. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Run the engine to circulate the oil through the system. Tighten the mounting bolts gradually on opposite sides in turn. and swing. For details.75 kgm} Check the performance of the work equipment. Disconnect clamp (2). travel. see TESTING AND ADJUSTING. Disconnect TVC solenoid connector (I) (CN-C13). 350-6 . LS pressure hose (41. Servo valve mounting bolt: 66. 2. . . Disconnect wiring connector (CN-CIO). 6. Disconnect hose (3) coming from solenoid valve.DISASSEMBLY AND ASSEMBLY LS-EPC SOLENOID VALVE REMOVAL OF LS-EPC SOLENOID VALVE ASSEMBLY a g Disconnect the cable from the negative (-) terminal of the battery. INSTALLATION OF LS-EPC SOLENOID VALVE ASSEMBLY l Carry out installation removal. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Open main pump side cover. Disconnect hose (I) going to main pump. 4. Disconnect hose (2) going to hydraulic tank. Remove LS-EPC solenoid valve assembly (4). * Fit blind plugs in the disconnected hoses. 350-6 . 1. 3. 5. * It is installed at the bottom of the EPC solenoid valve mounting bracket. 2. in the reverse order to 30-l 10 0 PC300. When removing solenoid valve as an individual part I) Remove mounting bolts (91.DISASSEMBLY AND ASSEMBLY SOLENOID VALVE REMOVAL OF SOLENOID VALVE ASSEMBLY a A Disconnect the cable from the negative (-) terminal of the battery.4 Nm IO.92 t 0. Disconnect solenoid wiring connectors (I). 1. in the reverse order to m m Mounting bolt: 3. 06. 5. 3 . Disconnect drain hose (4). Disconnect outlet hoses (7) coming from each solenoid valve. Disconnect hose (2) coming from PPC. Remove mounting bolts. 8. 350-6 . and 07). Disconnect hose (6) coming from self-pressure reducing valve. 03.v/ CWPO6159 . 31 Remove sleeve (13) and spool (14). 4. 6. then remove solenoid valve assembly (8). and stopper (171.4 2 0. 2. * Make match marks on the hoses and connectors. 7. then clean valves. INSTALLATION OF SOLENOID VALVE ASSEMBLY l Carry out installation removal. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Disconnect hose (5) coming from accumulator. 4) Remove washer (151. spring (161. Disconnect hose (3) going to control valve. 05. 04. then remove coil m (10).04 kgm} CWPO6161 CWPOG 162 PC300. 2) Remove movable iron core (11) and O-ring (12). * Disconnect all connectors (VO2. 3. Disconnect wiring connector (I I.0 2 0. Remove joint bolt (21.4 3 4. ground and stop the engine.5 kgm} If there is excessive play in the control levers. and disconnect hose (3). Remove mounting bolts. then disconnect hoses (5) . and a remove. adjust the PPC valve. 350-6 . CEP00419 2. PPC VALVE ASSEMBLY l Carry out installation removal. Remove case. 1.and (61. . in the reverse order to w Hose mount joint bolt: 29.5 kgml w Hose mount joint bolt: 39. Ir 30-l 12 0 PC300.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY g Lower the work equipment completely to the .9 Nm (3. For details. see REMOVAL OF CONTROL STAND CASE. For details.0 + 0. 3.9 Nm (4. raise PPC valve assembly (41. m f Make match marks on the hoses.2 + 4. Adjusting PPC valve. 4. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. see TESTING AND ADJUSTING. . INSTALLATION OF WORK EQUIPMENT. springs (IO) and (II). Pull out valve (13) from body (14). Remove bolts. Pull out piston (8). 5.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1. 3. then remove plate (5). and remove retainer (91. then remove disc (2) and boot (3). cl---’ 2. 350-6 30-l 13 0 . * Do not remove joint (4) unless it is to be replaced. and shim (12). 8 U CEW0424 PC300. * Spring (IO) consists of two springs each of two types with different installed loads. Remove seal (6) and collar (7). Remove nut (I). 4. so check the mounting position (hydraulic port) and mark with tags to prevent mistakes when installing. Assemble valve (13) to body (14). Ir 4. see TESTING AND ADJUSTING.5 kgm} * After assembling the disc.5 Nm (I. Assemble boot (3) and disc (21. & Piston: Grease (G2-LI) Ir When assembling piston (81. adjust the height of the disc. 6. and tighten with nut (I). so be careful when installing.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY 1.1 + 4. retainer (9).7 Nm III. coat the outside of the piston and the inside of the hole in the body with grease. and piston (8).5 kgm} * Keep strictly to the tightening torque. 5. Assemble spring (IO). CEP00425 30-114 0 PC300. 2.5 t 0. then install seal (6). Ir When assembling spring (II). w Nut: 112.2 + 1.35 t 0. 7. Assemble shim (12) and spring (II) to valve (13). * The number of loops in the coil for spring (IO) is different for each of the hydraulic ports below. 350-6 . Position of port Free length of spring (mm) ~~ The position of each port is marked at the bottom of the valve body. & Sliding portion of joint: Grease (G2-LI) & Female thread of body: Thread tightener (LT-21 Ir Coat two places on the female thread with one drop of Loctite each as shown in the diagram on the right.5 + 1. Fit O-ring to collar (7) and assemble in body (141. Install plate (5). 3. For details.9 Nm (4. set the end with the small coil diameter (inside diameter) at shim (12) end. w Mounting bolt: 13. Adjusting PPC valve. w Joint: 44.15 kgm} Install joint (4).8 + 14. Remove pedals (I) and levers (2).0 + 0.2 kgm} m Hose mounting joint bolt (width across flats: 30mm): 39. m -‘“\--r_ INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY l Carry out installation removal.0 r 0.9 Nm I4. 2.0 Nm i2. 4. Remove cover (3). Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. then remove springs (5).2 t 4.4 d 4. Remove floor mat. Disconnect 6 PPC hoses (71. in the reverse order to w Cover mounting bolt: 19. 6.5 kgm} 8 w PC300. Remove travel PPC valve undercover.6 + 2. a 111 CEW0426 1. 3.5 kgm1 Hose mounting joint bolt (width across flats: 22mm): 29. 350-6 30-l 15 . Remove covers (41. 5.9 Nm 13.0 t 0.DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE REMOVAL OF TRAVEL PPC VALVE ASSEMBLY a Lower the work equipment completely to the ground and stop the engine. and remove travel PPC valve assembly (8). Remove seal (9) and collar (IO). Pull out valve (16) from body (17). and remove retainer (121. 7. 4. * Check the number and thickness of shims (15) for each mounting position. then remove lever (2). then remove case and shaft assembly (4). Remove mounting bolts (31. 6.DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1. Remove mounting bolts (81. * Check the thickness and mounting position of washer (18). 5. CEPOO533 30-l 16 0 PC300.5). Pull out piston (II). springs (13) and (141. then remove plate (6) together with damper assembly (7). then remove damper assembly (7) from plate (6). and keep in a safe place. and shims (1. Remove screw (I). 3. 2. 350-6 . Remove mounting bolts (51. then tighten mounting bolts (3). & Rocking portion of shaft. then tighten mounting bolts (5).3 mm. then tighten screw (I). m Mounting bolt: 30. Install damper assembly (7) to plate (61.6 mm) for washer (18).0 Nm (0. If the angle is greater than 0. measure the difference in the angle when the left and right levers are operated fully.4 Nm (2.4 t 0.0. body hole: Grease (G2. * Temporarily assemble standard washer (1. 6 Outside circumference of piston.DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY 1.7”. 6 Rocking portion of lever pin and plate: Grease (G2-LI) w Screw: 8. 350-6 30-117 0 . After completing the assembly. Assemble shim (15) and spring (14) to valve (16).3 mm * Spring (14) is not symmetrical at the top and bottom. then install seal (9).7”.85 + 0.35 kgm} Install lever (21.9 i 0. 8.8 t 1. and piston (II). retainer (121. 6.39” greater. the angle of the full stroke is 0.15 * 0. Ir Washer thickness: 1.6 mm * If the washer is thinner by 0. contact portion of lever and piston: Grease (G2-LII w Mounting bolt: 27. * Assemble the same number and thickness of shim (15) as was removed during disassembly. change the thickness of washer (18) to make the difference less than 0. 6 Mounting bolt: Thread tightener (LT-2) w Mounting bolt: 4. 1.LI) Fit O-ring to collar (IO) and assemble in body (171. 1. Assemble valve (16) in body (17). then tighten mounting bolts (8).3. 5.05 kgm} Install plate (6) and damper assembly (7) as one unit. Assemble spring (131.1 kgm) 3. 7.5 Nm (0.4 Nm i3.45 t 0.9 a 3. Standard shim thickness: 0.35 kgm1 Install case and shaft assembly (41. 2. 4. so assemble with the small coil diameter (inside diameter) at the shim end. CEPo0533 PC300.9 + 3. 3. Make match marks at the male and female ends of the oil pressure switch connectors. so hold the elbow with a wrench when disconnecting the hoses. 2. Before disconnecting any hoses. Ir The elbows on the front two hoses are long. Disconnect the cable from the negative (-1 terminal of the battery. Disconnect Disconnect 8 oil pressure switch connectors m (1). Disconnect 15 control valve hoses (3) (quick joint connection). 30-118 0 PC300. A * * 1. Jg 4. check the distinguishing tape stuck to the hose. Disconnect 4 straight-travel hoses (4). Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 350-6 . or make match marks. 12 PPC hoses (2).DISASSEMBLY AND ASSEMBLY PPC SHUlTLE VALVE REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY A Lower the work equipment completely to the ground and stop the engine. 350-6 30-119 0 . then remove PPC shuttle valve assembly (6). Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. INSTALLATION OF PPC SHUlTLE VALVE ASSEMBLY l Carry out installation removal. Then check the oil level again. in the reverse order to pg l Check that the quick joint does not come out when the hose is pulled.DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE 5. Disconnect clamp (5). 6. l PC300. Remove mounting bolts. Run the engine to circulate the oil through the system. 30-l 20 0 PC300. Disassembly of travel junction valve assembly 1) Remove 2 each of plug (IO). Disassembly of shuttle valve assembly I) Remove 8 oil pressure switches (5). 2) Remove 2 slow return valves (6). 3) Remove 2 plugs (14). 4) Remove plugs (81. travel junction valve assembly (3) and plate (4). 2. 3. then remove balls (9). and disconnect shuttle valve assembly (21. and retainer (12). Disconnection of valve Remove mounting bolts (I).DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE DISASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY 1. spring (II). * There are 6 plugs and 6 balls. 350-6 . 3) Remove shuttle valve (71. 2) Remove spool (13). 2 + 7. be careful of the direction of installation of the poppet when assembling. Install 8 oil pressure switches (5).3 t.DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE ASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY 1.25 kgm} 2) Assemble spool (131.2 * 2. 350-6 30-l 21 0 .9 Nm 13.7 Nm Ill. QECI Mounting bolt: 66.75 kgm) 2.5 2 0. 1) Fit O-ring and install 2 plugs (14). m Plug: 34.75 t 0. If the slow return valve has been dis* assembled.9 t 14. Assembly of travel junction valve assembly.5 kgm} 2) Fit O-ring and install shuttle valve (7).0 t 1. be careful of the direction of installation of the poppet when assembling. Ir If the shuttle valve has been disassembled. Connection of valve Fit O-ring and assemble shuttle valve assembly (21.5 kgm1 Assembly of shuttle valve assembly 1) Fit O-ring and assemble balls (91. 3) Fit O-ring and install 2 plugs (10). 4) 3. m Plug: 17. 3) Fit O-ring and install 2 slow return valves (6).4 Nm 16. then install plugs (8).5 Nm (1.75 + 0. Ir There are 6 plugs and 6 balls. w Plug: 107. 4. and install 2 retainers (12) and springs (II). travel junction valve assembly (3) and plate (41. PC300. then tighten mounting bolts (I). Drain hydraulic oil. l 30. * Install blind plugs in the disconnected hoses. then remove boom lock valve assembly (7). see TESTING AND ADJUSTING. Disconnect drain hose (I) and PPC hose (2). Bleeding air * Bleed the air. 200 e 1. Remove mounting bolts (6). 6.: Hydraulic oil: Approx. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove tube clamp (3). Run the engine to circulate the oil through the system. -kWPO6164 3. 350-6 . Disconnect tube (4) coming from control valve. 2. Disconnect tube (5) coming from boom cylinder. 4. Bleeding air. For details. . Then check the oil level again. Refilling with oil * Add oil through the oil filler to the specified level.122 0 PC300. 5. INSTALLATION OF BOOM LOCK VALVE ASSEMBLY l Carry out installation removal.DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE REMOVAL OF BOOM LOCK VALVE ASSEMBLY A Lower the work equipment completely to the ground and stop the engine. in the reverse order to . then remove spacer (6L spring (71. Ir The safety valve assembly cannot be adjusted when it is mounted on the machine. seat (81.5 t 9. seat (81. and washer (6) to body (21. parts with engine oil before 1. Remove safety valve assembly (I). 3. so do not disassemble it. Remove plug (51.2 + 4. Remove body (2). spring (71. then remove spring (3) and check valve (4). w Safety valve: 225.9 Nm (4.8 Nm I23 + 1 kgm) 2. 350-6 30. 3. then fit O-ring and install body (2).DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE OF BOOM LOCK VALVE ASSEMBLY DISASSEMBLY 1. ASSEMBLY OF BOOM LOCK VALVE ASSEMBLY * Coat the sliding assembling.123 0 . Fit O-ring and install safety valve assembly (I). then fit O-ring and install plug (5). Assemble spool (91.5 kgm1 Assemble check valve (4) and spring (3) to body (IO). 2. PC300. w Plug: 39. and spool (9).0 + 0. 350-6 . Start engine. For details. Disconnect grease hose (I). and remove m lock bolt (3). and remove boom cylinder assembly (2). CEPlW057 5. and keep in a safe place. and retract piston rod. I _ -. 3. Remove plate (41. Sling boom cylinder assembly (21. lower the work equipment completely to the ground.DISASSEMBLY AND ASSEMBLY BOOM CYLINDER REMOVAL OF BOOM CYLINDER ASSEMBLY a Extend the arm and bucket fully. Disconnect hoses (6). and keep in a safe place. then using forcing screws 0. g Release the remaining pressure in the hydraulic circuit.m * There are shims installed. so check the number and thickness. CEPO0056 4. remove bottom pin (71. a Ir There are shims installed. and put the safety lock lever in the LOCK position. so check the number and thickness. 6. then tie piston rod with wire to prevent it from coming out. + Set stand 0 under the cylinder assembly.124 0 PC300. and adjust the position for slinging the cylinder assembly. Remove plate. 30. & kg Boom cylinder assembly: 300 kg CEPO0056 1. see TESTING AND ADJUSTING. Releasing remaining pressure in hydraulic circuit. 2. then remove head pin (5j. DISASSEMBLY AND ASSEMBLY BOOM CYLINDER INSTALLATION OF BOOM CYLINDER ASSEMBLY l Carry out installation removal. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (2) and bracket (8) is less than 1. Standard shim thickness: 1.1. never insert your fingers in the pin hole.5 mm l . mm comoo6i Run the engine to circulate the oil through the system. Then check the oil level again.0 mm.5 .125 0 .5 mm. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1.0 mm.5 mm l CEWO059 * 4 2 / CDPoo060 & & g Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-G) * When aligning the position of the pin hole. 0 & & &When Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-G) aligning the position of the pin hole. 1.0 mm. Standard shim thickness: 1. tighten so that the clearance between the plate and nut is 0. never insert your fingers in the pin hole.0 mm. PC300. Bleeding air * Bleed the air. 350-6 30. R W’ . Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. .8 For details. Bleeding air. 1. see TESTING AND ADJUSTING. in the reverse order to u * When tightening the locknut. For details. Releasing remaining pressure in hydraulic circuit. then tie piston rod with wire to prevent it from coming out. so check the number and thickness. lower the work equipment completely to the ground. & Release the remaining pressure in the hydraulic circuit.DISASSEMBLY AND ASSEMBLY ARM CYLINDER REMOVAL OF ARM CYLINDER ASSEMBLY a Extend the arm cylinder piston rod to a point approx. remove plate (6). and keep in a safe place. then set the remaining safety lock lever to the LOCK position. 6. Disconnect hoses (3). Set block @ between arm cylinder and boom. then remove bottom pin (7). Raise arm cylinder assembly (51. see TESTING AND ADJUSTING. and remove arm cylinder assembly (5). Disconnect grease hose (4). 30. 1. 350-6 . 5. then remove head pin (2).126 0 PC300. and retract piston rod. m + There are shims installed. Remove plate (I). 4. 2. & kg Arm cylinder assembly: 430 kg (PC300) 440 kg (PC3501 3. 200 mm before the end of the IN stroke. m Start engine. Bun the engine to circulate the oil through the system. 350-6 30-127 0 . Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level.0 mm. Then check the oil level again. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (5) and bracket (8) is less than 1. in the reverse order to & & a Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-G) When aligning the position of the pin hole. see TESTING AND ADJUSTING. Standard shim thickness: 1. & & g * Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Greasing after assembling pin: Grease (LM-GI When aligning the position of the pin hole. For details. l PC300. Bleeding air. never insert your fingers in the pin hole.DISASSEMBLY AND ASSEMBLY ARM CYLINDER INSTALLATION OF ARM CYLINDER ASSEMBLY l Carry out installation removal.0 mm l .8 l Bleeding air * Bleed the air. never insert your fingers in the pin hole. and block @I between bucket cylinder and arm.DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER REMOVAL OF BUCKET CYLINDER ASSEMBLY g Extend the bucket cylinder piston rod to a point approx. A Release the remaining pressure in the hydraulic circuit. Releasing remaining pressure in hydraulic circuit. &I kg Bucket cylinder assembly: 270 kg 4. Set block @ under arm top. For details. 200 mm before the end of the DUMP stroke. and remove bucket cylinder assembly (5). then set the safety lock lever to the LOCK position. m 1. so check the number and thickness. m Start engine. and keep in a safe place. CEPOOO77 30. remove plate (61. Remove lock bolt (I).128 0 PC300. 350-6 . then remove bottom pin (71. see TESTING AND ADJUSTING. 5. then tie piston rod with wire to prevent it from coming out. B * There are shims installed. lower the work equipment completely to the ground. Raise bucket cylinder assembly (51. block @ between link and arm. and retract piston rod. then remove head pin (3). Disconnect hoses (4). Remove plate (21. 6. 3. 2. 1. Then check the oil level again.350-6 30-129 0 . in the reverse order to a * When tightening the locknut. Run the engine to circulate the oil through the system.0 mm . 0 CEPOO059 A * Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. 1 mm 6 & A * l Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the-.DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER INSTALLATION OF BUCKET CYLINDER ASSEMBLY l Carry out installation removal. Bleeding air. Standard shim thickness: 0. Adjust the shim thickness so that the clearance between link (8) and link (9) is less than 1. tighten so that the clearance between the plate and nut is 0.0 mm. position of the pin hole. see TESTING AND ADJUSTING. Bleeding air Ir Bleed the air. Adjust the shim thickness so that the clearance between the end face of the bottom of cylinder (5) and bracket (IO) is less than 1. PC300. Standard shim thickness: 1. For details.0 mm. never insert your fingers in the pin hole. .5 .5 mm. never insert your fingers in the pin hole. Refilling with oil (hydraulic tank) -k Add oil through the oil filler to the specified level.8 mm l Max. Bucket rlP03779 Ir If screw (3) has been caulked strongly be removed. Arm. to CLPO3941 4) Disassemble piston rod assembly as follows. Screw size: Ml2 x pitch 1. i) Set piston rod assembly (2) to tool Ul. then fit a tap to the thread and pull it out. and disconnect 3) head assembly (I).DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1. Piston rod assembly 1) Remove piping irom cylinder assembly. Pull out piston rod assembly (2). screw it in fully. and cannot Tao DKP00498 30-130 0 PC300. 2) Remove mounting bolts. CLP03179 ii) Remove piston assembly stopper screw (3). Ir Place a container under the cylinder catch the oil. 350-6 .75: Boom. and boom cylinder only head assembly (71. and boom cylinder only collar (6). and pull out 12 balls (9). remove piston assembly (4). piston ring (13). Arm cylinder only l J CWPO6166 2. DWP00715 iv) Remove . When not using tool U6. Arm v) Remove Arm vi) Remove l plunger (5). . use the drill holes ($10: 4 places) and loosen the piston assembly. O-ring and backup ring (14). 350-6 30431 0 . CLPO3762 vii) Remove cap (81.DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER iii) Using tool U6. I CLP03764 PC300. Disassembly 1) Remove 2) Remove 3) Remove 4) Remove of piston assembly ring (III. then remove cushion plunger (IO). wear ring (12). Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 19 II CLP02322 30-132 0 PC300. bushing (20). Remove Remove Remove snap ring (16).DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER 3. buffer ring (19). 350-6 . 2) 3) 4) 5) Remove seal (17). then remove dust 20 rod packing (18). Ir Set the piston ring on tool U2. and turn the handle 8 .DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY * * Be careful not to damage the packings. 31 Assemble rod packing (18). 2) Set tool U3 in position.133 0 . and secure with snap ring (16). Do not try to force the backup ring into position. 4) Using tool U5. Assembly of cylinder head assembly 1) Using tool U4. & Ring groove : Grease (G2-LII II 12 13 I1 12 CLPO3764 PC300. Assemble wear ring (12). press fit bushing (20). install dust seal (17). expand piston ring (13). Warm it in warm water (50 . CWPO6161 CWPO6162 20 I5 19 17 18 CLP02322 2. 1. and compress piston ring (13). 5) Install backup ring and O-ring (15). Assemble ring (11).60°C) before fitting it. CWPO6183 CWPO6164 3) 4) 5) Install backup ring and O-ring (14).10 times to expand the ring. Ir Be careful not to open the end gap of the ring too wide. 21 Assemble buffer ring (19). dust seals. 350-6 30. and O-rings. Assembly of piston assembly 1) Using tool U2. Boom and arm cylinder only Ir Check that there is a small amount of play at the tip of the plunger. Arm cylinder only Assemble piston assembly (4) as follows.DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER 3. 350-6 . Fit O-ring and backup ring to collar (6). ii) Tighten screw (3). then assemble 12 balls (9). When using rod and piston assembly (2) again Ir Wash thoroughly and remove all metal particles and dirt.75 kgm1 l .I0 6) I 30. * Remove all burrs and flashes with a file. Boom and arm cylinder only Assemble plunger (5). then assemble.2 2 7. CLPO3762 5) Set cushion plunger (IO) to piston rod.35 Nm (6. CLPO3179 2) 3) 4) . . m Screw (3): 66.134 0 DWP00715 PC300.75 t 0. and secure with cap (8). i) Screw in piston assembly (4). then use tool U6 to tighten piston assembly (2) so that position of screw thread hole matches. Piston rod assemblv I) Set piston rod assembly (2) to tool Ul. Assemble head assembly (7). check that there is play in plunger (51.2 t 7. w Piston assembly (4): 294 z 29. avoid the cushion plug position when machining.35 Nm 16. Arm cylinder only I i) Screw in until piston assembly (4) contacts end face of rod.4 Nm I30 t 3.75 t 0. . Ir For the cylinder with bottom cushion (arm cylinder). mark the cushion plug position on the end face of the rod. wash thoroughly to remove all metal particles and dust. 350-6 .75 kgml VI Caulk thread at 2 places with punch. Screw machining dimension (mm) Drill Bottom Tap Tap diameter hole depth I used I depth 10. iv) Tighten screw (3). m Screw (3): 99. then use tool U6 to tighten. Boom. * Align a drill horizontal with the V-groove of the thread of rod (2) and piston (41. arm cylinder only Machine one hole used to install screw (3).DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER l iii) Caulk thread at 2 places with punch. When using a new part for either or both of rod or piston assembly (2) * For the rod with bottom cushion. CLPO3779 PC300.75 20 DKP00500 ii) DKP00501 l CLPO3792 iii) After machining.0 kgml Ir After tightening the piston. .3 27 12x1. then carry out machining. 350-6 0 . & Seal portion: Grease (G2-LI) * Set the end gap of the ring at the horizontal (side) position.0 Nm (38. align the axial center of shaft and cylinder tube.0 * 5. * After inserting.5 kgml Arm Boom 9) Install piping.0 kgm) 373 t 54.0 t 8. then insert. w Mounting bolt : Cylinder Tightening torque Bucket 373 + 84.5 kgm} CLPO394 1 30-136 PC300. then push in fully. check that the ring is not broken and has not come out. 530 i 78.0 Nm t38.DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER 7) Assemble piston rod assembly (2).0 * 5.5 Nm I54. DLP00502 8) Tighten head assembly (I) with mounting bolts. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (71. 7. * Disconnect the boom cylinder on the opposite side in the same way. so check the number and thickness. then tie piston rod with wire to prevent it from coming out. Releasing remaining pressure in hydraulic circuit. and keep in a safe place.m * There are shims installed. I CDFOO280 f’C300. 5. 6. Start engine. Sling boom cylinder assembly (21. then remove boom foot pin (9) using tool V. r3 kg Work equipment assembly: 5700 kg 1. Disconnect grease hose (I). g Release the remaining pressure in the hydraulic circuit. and set the safety lock lever to the LOCK position. 3. and keep in a safe place. lower the work equipment to the ground. see TESTING AND ADJUSTING. 8. and secure to valve with rope. and remove m lock bolt (3). so check the number and thickness. 2.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT REMOVAL OF WORK EQUIPMENT ASSEMBLY g Extend the arm and bucket fully. and lower cylinder onto stand. If * There are shims installed. Disconnect wiring connector (8) for working lamp. For details. Remove plate (41. then remove head pin (5j. Raise work equipment assembly (IO). and set tool V to boom foot pin (9). 4. and remove work equipment assembly (IO). 350-6 . Remove plate. and retract piston rod. 5 .8 mm. 1. 350-6 . l 30-138 0 PC300.5 mm. tighten so that the clearance between the plate and nut is 0. Run the engine to circulate the oil through the system. Then check the oil level again.5 mm l l & Max. & & a * Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. I mm Bleeding air + Bleed the air. For details.0 mm. Bleeding air. in the reverse order to a * When tightening the locknut.5 mm l CEW0059 Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) &I& Grease after assembling pin: Grease (LM-G) A When aligning the position of the pin hole. see TESTING AND ADJUSTING. never insert your fingers in the pin hole. Standard shim thickness: 0. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level.0 mm. never insert your fingers in the pin hole.DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT INSTALLATION OF WORK EQUIPMENT ASSEMBLY l Carry out installation removal. 1. * Adjust the shim thickness so that the clearance between the end face of the foot of boom (11) and bracket (12) is less than 1. Standard shim thickness: 1. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1.1.0 mm. and keep in a safe place. Remove plate (41. 350-6 30. Start engine. 2. Remove connecting pin (2) between link and bucket. 6. then tie link to arm with wire to prevent piston rod from coming out. a 1. m * There are shims installed. 5. so check the number and thickness. Start engine. Remove lock bolt (3). a CEFU0285 3. and retract piston rod. lower the work equipment completely to the ground. kg r&I Bucket assembly: 1050 kg and 6 CEP00287 PC300.DISASSEMBLY AND ASSEMBLY BUCKET REMOVAL OF BUCKET ASSEMBLY A Set the back of the bucket facing down. so check the number and thickness. then raise work equipment swing to remove bucket assembly (6). a Ir There are shims installed. Remove lock bolt (1). 4. and set the safety lock lever to the LOCK position.139 0 . then remove connecting pin (5) between arm and bucket. and keep in a safe place. Adjusting bucket clearance. 350-6 . 1 mm CDP00288 a b 30.0 mm. It is easier to measure if the bucket * is moved to one side so that all the play is in one place.5 .1. Ir Standard shim thickness: 0. Insert the O-ring at the end face of the bucket boss securely. Standard shim thickness: 0.1. * E3j When tightening the locknut.5 mm. 1. in the reverse order to II. never insert your fingers in the pin hole.8 mm CEP00059 & & A * * Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. Adjust the shim thickness so that the clearance between the end face of the boss of bucket (6) and link (7) is less than 1.5 .DISASSEMBLY AND ASSEMBLY BUCKET INSTALLATION ASSEMBLY l OF BUCKET Carry out installation removal. 1) Measure clearance a between arm (8) and bushing (9). & 6 A * l Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole.0 mm 3) Install selected shim. then install plate (4). -!-Max.5 mm.0 mm. 2) Select shim thickness b so that clearance a is 0. tighten so that the clearance between the plate and nut is 0. never insert your fingers in the pin hole.140 0 PC300. 7. then lower the arm on to block @ and stand 0. If Start engine. Remove bucket assembly. Start engine. For details. 6. 200 mm before the end of the IN stroke. Releasing remaining pressure in hydraulic circuit. For details. see TESTING AND ADJUSTING. and keep in a safe place. 350-6 30-141 0 . Set block @ between arm cylinder and boom. then raise boom and swing to remove arm assembly (6). 3. m * There are shims installed. & kg Arm assembly: 1500 kg 2. 8. and set the safety lock lever to the LOCK position. see REMOVAL OF BUCKET ASSEMBLY. then remove connecting pin (5) between arm and boom. Disconnect 2 bucket cylinder hoses (3). a Extend the arm cylinder piston rod to a point approx. then remove arm cylinder head pin (2). then tie piston rod with wire to prevent it from coming out. g Release the remaining pressure in the hydraulic circuit. PC300. Secure link to arm with wire. so check the number and thickness. and retract piston rod. Remove plate (41. 4.DISASSEMBLY AND ASSEMBLY ARM REMOVAL OF ARM ASSEMBLY 1. Remove plate (11. 5. Bleeding air * Bleed the air. For details. 1 mm I l 30-142 0 PC300. * Adjust the shim thickness so that the clearance between the end face of the bottom of arm (6) and boom (7) is below 1. Then check the oil level again. Run the engine to circulate the oil through the system. 350-6 . never insert your fingers in the pin hole. Bleeding air. Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) && Grease after assembling pin: Grease (LM-G) a When aligning the position of the pin hole.0 mm.0 mm . Ir Standard shim thickness: 1. in the reverse order to & & g Inside surface of bushing when assembling pin: Anti-friction compound (LM-PI Grease after assembling pin: Grease (LM-GI When aligning the position of the pin hole. see TESTING AND ADJUSTING. never insert your fingers in the pin hole. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. & Max.DISASSEMBLY AND ASSEMBLY ARM INSTALLATION ASSEMBLY l OF ARM Carry out installation removal. arm assembly: 2600 kg CEP00294 1. a Ir There are shims installed. 350-6 30-143 0 . Then lower the work equipment completely to the ground. ARM REMOVAL OF BUCKET. A Release the remaining pressure in the hydraulic circuit. Releasing remaining pressure in hydraulic circuit. then remove arm cylinder head pin (2). and the arm cylinder piston rod to a point approx. ARM ASSEMBLY g Extend the bucket cylinder piston rod to the end of the CURL stroke. 6. &I kg Bucket. Disconnect 2 bucket cylinder hoses (3). For details. then raise boom and swing to remove bucket and arm assembly (6). then remove connecting pin (5) between arm and boom. and keep in a safe place. Remove plate (41. and retract piston rod. then tie piston rod with wire to prevent it from coming out. so check the number and thickness. Remove plate (I). m Start engine. 3. and set the safety lock lever to the LOCK position. 200 mm before the end of the IN stroke. 4. 5.DISASSEMBLY AND ASSEMBLY BUCKET. Set block @ to bucket cylinder bottom mounting boss portion of arm. CEPWZ95 PC300. Start engine. 2. see TESTING AND ADJUSTING. ARM INSTALLATION OF BUCKET. never insert your fingers in the pin hole. ARM ASSEMBLY . Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. never insert your fingers in the pin hole. in the reverse order to & & A Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole.DISASSEMBLY AND ASSEMBLY BUCKET.0 mm. Carry out installation removal. 350-6 . Standard shim thickness: 1. see TESTING AND ADJUSTING. Bleeding air.0 mm l Max. Run the engine to circulate the oil through the system. . For details. Then check the oil level again. 30-l 44 0 PC300. Adjust the shim thickness so that the clearance between the end face of the bottom of arm (6) and boom (7) is less than 1. 1 mm I l Bleeding air * Bleed the air. & & A + Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. 4. CEPO0299 PC300. Raise boom assembly (IO). so check the number and thickness. ARM ASSEMBLY. 7. then remove boom assembly (IO). 8. m Remove plate (41. and remove lock bolt (3). remove boom foot pin (9) using tool V. m * There are shims installed. 3. see REMOVAL OF BUCKET. r+ kg Boom assembly: 3000 kg CDPOO280 2. B * There are shims installed. and set tool V to boom foot pin (9). 350-6 . see TESTING AND ADJUSTING. Remove bucket and arm assembly For details. then tie piston rod with wire to prevent it from coming out. and retract piston rod. Releasing remaining pressure in hydraulic circuit. Disconnect wiring connector (8) for working lamp Remove plate. Ir Disconnect the boom cylinder on the opposite side in the same way. and set the safety lock lever to the LOCK position. Sling boom cylinder assembly (2). A Lower the boom assembly completely to the ground. 6. then remove head pin (5). 9. A Release the remaining pressure in the hydraulic circuit. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (71. For details. and keep in a safe place. 5. and lower it onto stand.DISASSEMBLY AND ASSEMBLY BOOM REMOVAL OF BOOM ASSEMBLY 1. and secure to valve with rope. so check the number and thickness. Start engine. and keep in a safe place. Disconnect grease hose (1). 8 mm. Adjust the shim thickness so that the clearance between the end face of the foot of boom (IO) and bracket (11) is less than 1. For details.1.0 mm. Bleeding air. 1. 30-l 46 0 Pc300. never insert your fingers in the pin hole.0 mm.5 .0 mm. 1 mm .5 mm 2 CDPOOO60 Max. Adjust the shim thickness so that the clearance between the end face of the rod of cylinder (2) and plate (4) is less than 1. never insert your fingers in the pin hole. 11 CDP00900 . Standard shim thickness: 1.5 mm l ’ II I I & & g * l Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. in the reverse order to m Ir When tightening the locknut. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. 1. Then check the oil level again. 350-6 . Run the engine to circulate the oil through the system. tighten so that the clearance between the plate and nut is 0. .5 + CEPOOO59 & & g * Inside surface of bushing when assembling pin: Anti-friction compound (LM-P) Grease after assembling pin: Grease (LM-G) When aligning the position of the pin hole. see TESTING AND ADJUSTING. 0. Bleeding air Ir Bleed the air. Standard shim thickness: 0.5 mm.DISASSEMBLY AND ASSEMBLY BOOM INSTALLATION OF BOOM ASSEMBLY l Carry out installation removal. Disconnect hose (8) and speaker wiring connector. Remove 4 bolts and 1 clip. 5. then remove left cover (7). Remove operator’s seat (I). * Lift up right cover (9) slightly before disconnecting the speaker wiring connector. then remove right cover (9). * Be careful not to damage the covers.147 0 .350-6 30. 1. Remove floor mat. Remove plate (61. 4. 2.DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB REMOVAL OF OPERATOR’S CAB ASSEMBLY a Disconnect the cable from the negative (-) terminal of the battery. 3. then remove panels (3) and (4). CEPOO440 CEFU0441 7. Remove knob (2). 442 Pc300. Disconnect window washer hose (5). 6. /GJ Operator’s cab assembly: 300 kg &I kg . 9. then lift off operator’s cab assembly (15). Disconnect 11 connectors (14). %: Nut A: Bolt * Check the length of the bolts. CEPO0443 12. Remove 4 mounting nuts and 6 mounting bolts. in the reverse order to w Mounting nut: 277.DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB 8.25 t 3. CEF’O0445 INSTALLATION OF OPERATOR’S CAB ASSEMBLY l Carry out installation removal. 350-6 .9 Nm 128.25 kgm) CEPC0446 30-148 0 Pc300. 10.0 t 31. Disconnect air conditioner cable (12). Remove cover (IO) and duct (II).Y\‘/ I ‘is 12. 11. Disconnect duct (13) at front. * Panel: CN-X07 (MIC211 Ir Controller: CN-CO1 (MIC13) : CN-CO2 (MIC21) : CN-CO3 (MIC20) : CN-Cl6 (MIC17) * Wiring harness intermediate : CN-HI2 (S16) White : CN-HI3 (S16) Blue : CN-HI4 (M6) : CN-HIS (L2) Ir Speaker: CM-Ml3 (KES-2) Ir Air conditioner: No connector No. m assembly: 5500 kg 1 CEPCO536 INSTALLATION OF COUNTERWEIGHT ASSEMBLY l Carry out installation removal. 350-6 30-149 0 . * Check the location of the shims. and sling. in the reverse order to & w Adjust the stepped difference (top and bottom clearance) from the bodywork with shims.1 + 98. 2.DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT REMOVAL OF COUNTERWEIGHT 1.1 Nm (185 t 10 kgm} PC300. 3. ASSEMBLY assem- Set lifting hook chains of counterweight bly in position. Lift off counterweight & kg Counterweight assembly (2). Thread of counterweight mounting bolt: Thread tightener (LT-2) Counterweight mounting bolt: 1814. Remove mounting bolts (I). Install so that the clearance between the door and counterweight and the clearance between the revolving frame and the counterweight are a uniform IO + 5 mm. charge the air conditioner circuit with refrigerant (R134a). 6. see TESTING AND ADJUSTING. 4. Loosen lock bolts (2) and (3). then connect the hoses. Disconnect hose (6). Adjust the belt tension. 3.150 0 PC300. Testing and adjusting belt tension for air conditioner compressor. then install tool Xl to portion @ of air cqnditioner compressor hose. so remove together with the bracket. * It is difficult to remove the compressor mounting bolts. Disconnect the cable from the negative (-1 terminal of the battery.DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY a 1. l Charging air conditioner with gas * Using tool Xl. CWPO6166 INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY l Carry out installation removal. in the reverse order to Check that the O-rings are not damaged or deteriorated. 5. Open engine hood. Remove lock bolts (2) and (3). and collect refrigerant (R134a). m a 2. 30. 350-6 . then remove air conditioner compressor assembly (7). For details. Remove fan guard (I). Remove drive belt (4) from pulley. charge the air conditioner circuit with refrigerant (R134a).DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY g a Disconnect the cable from the negative (-1 terminal of the battery. then connect the hoses. 2. 4. 1. Remove mounting bolts. 5. then remove air conditioner condenser assembly (4). l Charging air conditioner with gas * Using tool Xl. Collect refrigerant (R134a). PC300. INSTALLATION OF CONDENSER ASSEMBLY l Carry out installation removal. 350-6 30-l 51 0 . Open air conditioner condenser side cover.= Ir The connection at the condenser end breaks easily. in the reverse order to * Check that the O-rings are not damaged or deteriorated. Disconnect hose (3) going to receiver tank. 3. see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY. For details. Remove control valve top cover and disconnect condenser wiring connector (I 1 (M35). Disconnect hose (2) coming from air conditioner compressor. so always use 2 wrenches: one wrench to hold the connection and the other to loosen the hose. 3. in the reverse order to * Check that the O-rings are not damaged or deteriorated. Disconnect hose (I) coming from air conditioner condenser. Disconnect clamp (3) of hose (1). 5. l Charging air conditioner with gas * Using tool Xl. Remove 2 U-bolts (41.DISASSEMBLY AND ASSEMBLY RECEIVER TANK REMOVAL OF RECEIVER TANK ASSEMBLY a g Disconnect the cable from the negative (-) terminal of the battery. then remove receiver tank assembly (5). 1. 2. see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY. 350-6 . Open air conditioner condenser side cover. Disconnect hose (2) going to air conditioner unit. 4. Collect refrigerant (R134a). 30-l 52 0 PC300. then connect the hoses. INSTALLATION OF RECEIVER TANK ASSEMBLY l Carry out installation removal. For details. charge the air conditioner circuit with refrigerant (R134a). 8. Remove plate (I). * The speaker is installed to the cover. Remove cover (3). 6. 4. CEWOlO5 3.DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY g 1. Remove operator’s seat. Collect refrigerant (R134a). Close heater warm water outlet valve at engine end. see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY. Remove hose (4) from duct. 7. 5. For details.350-6 . Disconnect the cable from the negative (-1 terminal of the battery. 2. Remove duct (7). then remove cover (2). so disconnect the wiring connector (M73) of the speaker. PC300. Remove cover (5) and duct (6). 350-6 . Disconnect heater hose (II). IO. Charging air conditioner with gas Ir Using tool Xl. INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY l Carry out installation removal. 14. Disconnect air conditioner hose (12). charge the air conditioner circuit with refrigerant (R134a). 12. in the reverse order to l Refilling with water * Add water up to the water filler port. Remove air conditioner unit (13). l 30-154 0 PC300. Run the engine to circulate the water through the system. 11. Then check the water level again at the reserve tank. 13. Disconnect wiring connector (8) (M26).DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT 9. Disconnect cable (IO) from receiver. + Check that all the connectors have been disconnected. Disconnect wiring connector (9) (AC-I). 350-6 30-155 0 . 3. 03! 16. PC300. see TESTING AND ADJUSTING. PUMP CONTROLLER ASSEMBLY A Disconnect the cable from the negative (-1 terminal of the battery. 02. and swing. Ir The speaker is installed to the cover. then remove cover (2). For details. Slide operator’s seat fully forward. 1. PUMP CONTROLLER REMOVAL OF GOVERNOR. Remove plate (I). 17) Remove governor and pump controller assemm bly (6). * Connectors = (COI. PUMP CONTROLLER ASSEMBLY l Carry out installation removal. NSTALLATION OF GOVERNOR. in the reverse order to pJ l Check the performance of the work equipment. Disconnect 5 connectors (5). 5. Disconnect hose (4) from duct. travel. Remove cover (3). 4. 6. so disconnect the wiring connector (M73) of the speaker. 2.DISASSEMBLY AND ASSEMBLY GOVERNOR. and disconnect monitor panel assembly (2) from bracket. see TESTING. Disconnect connectors (31. ADJUSTING. For details. Remove 4 screws (I). AND TROUBLESHOOTING.DISASSEMBLY AND ASSEMBLY MONITOR PANEL REMOVAL OF MONITOR PANEL ASSEMBLY A Disconnect the cable from the negative (-) terminal of the battery. I - CEPO0437 30-156 0 PC300. 350-6 . 1. then remove monitor panel assembly (2). in the reverse order to m l Check the mode setting and display function. m CEP00436 INSTALLATION OF MONITOR PANEL ASSEMBLY l Carry out installation removal. 2. Disconnect wiring connector (7) from hole for removed tray. 2) Pull boot (3) to front to remove claw at rear jFJ of boot. Tray 1) Insert a thin flat-headed screwdriver into notch at rear of tray (I) and lever up lightly to release rear claw (2). remove bolt (81. then remove lever (9) and boot (3). 350-6 . Boot 1) Insert a thin flat-headed screwdriver between boot (3) and upper case (4). 1 II CEPOO607 9 (ry.DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE REMOVAL OF CONTROL STAND CASE 1. then raise front. remove claw (5) at front of boot from upper case. a I 2. Push boot up. * Check the direction of the lever. CEW0609 3) 4) $ 5 CEFQ0604 PC300. * The claw can only be released from the rear. L’ - \\ / CEPO608 2) Pull tray (I) to rear to remove. insert the claw at the rear first. CEP00421 CEW0422 2) Push bottom center of upper case (11) from both sides. CEWOW3 30-158 0 PC300. 350-6 . Upper case 1) Remove 4 upper case mounting screws (IO). insert the claws at the front first. in the reverse order to Jr When installing the boot. I 3) Use a screwdriver from front of upper case (11) to release claws (12) at front of case. Remove upper case (I I).DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE 3. m Ir When installing the tray and upper case. CEP00423 4) II INSTALLATION OF CONTROL STAND CASE l CEP00602 Carry out installation removal. and lift up to release claws at both sides. ........... Boom holding valve....................6 40.........40-46 PC300................................ Track roller............................................4 40... Hydraulic pump.......... Service PPC valve ....................... .................................................... Hydraulic cylinder ............. Carrier roller ................................... ......... Idler ........................ ........................................................................... Travel motor ........................................................................................ Self-reducing pressure valve ....2 40........................................................... Swing machinery ..... Track shoe...............................................40 MAINTENANCE STANDARD Engine mount .............. Center swivel joint .......... ............... ..8 40-10 40-12 40-14 40-15 40-16 40-20 40-22 40-29 40-30 40-31 40-32 40-33 40-34 40-35 40-36 40-37 40-38 40-40 40-41 40-42 40-44 .................... Work equipment....... Solenoid valve ........ Suction-safety valve........................ Swing motor............. Swing circle ........ ....... ........ l 40.................. LS-EPC valve.............. .. Track frame and recoil spring . Final drive ......................................... Dimensions of work equipment ..................................... Work equipment swing PPC valve ..... travel junction valve ................................................................................ Control valve ....... Travel PPC valve ......... 350-6 40-l .............................................. ..... PPC shuttle valve.......................................................... 350-6 . Free height of front mount rubber 84 Replace 2 Free height rubber of rear mount 126 - 40-2 PC300.MAINTENANCE STANDARD ENGINE MOUNT ENGINE MOUNT A-A B-B swP00401 Unit: mm No. Check item Standard size Criteria Repair limit Remedy . . MAINTENANCE STANDARD SWING MACHINERY SWING MACHINERY I III ’ m 927*103Nm f94. 350-6 .5koml --It=.5*10. -_ I SWPO4806 40-4 PC300. 23 - swing circle plate 0 . 1 planet gear and ring gear Backlash between No.00 10 0.0.66 1.100 0 I - limit Repair hard chrome plating or replace PC300.00 3 0.38 .0.0.0.25 - 5 0.49 I 0. 1 sur gear and No.0.57 1.57 1 . 2 sun gear Backlash between No.90 7 0.21 2.10 4 0.MAINTENANCE STANDARD SWING MACHINERY NO Check item Standard clearance Criteria Clearance limit Unit: Remedy mm 1 Backlash between swing motor shaft and No.82 Standard size - Reoair 11 - Wear of swing pinion seal contact surface oil I 4o -0. 2 sur gear and No.18 . 1 planet gear Backlash between No.0.0.17 .07 .38 .0.20 Replace 6 0.17 . 1 planet carrier and No. 350-6 40-5 .1. 2 planet gear and ring gear Backlash between and swing pinion Backlash between pinion and swing Clearance between and coupling coupling 0.0.49 I 1. 2 planet carrier and coupling Backlash between No.29 2 0.06 .oo 8 9 0. 1 sun gear Backlash between No.15 .15 . 2 planet gear Backlash between No. MAINTENANCE STANDARD SWING CIRCLE SWING CIRCLE -_ ---..5 . -__- L___i . Check item Clearance of bearing in axial direction (when mounted on machine) Standard clearance Criteria Clearance 3.2 limit Remedy 1 0.1. 350-6 .6 Replace 40-6 PC300._ __ I I I I I I Unit: mm No. . . 350-6 ._-. i z.K-_.MAINTENANCE STANDARD FINAL DRIVE FINAL DRIVE m \ Is 2n F’ 1 4 I-_-_ ____ -L-L& ______ 3:’ _’ ! / j 1 ‘.-._--.-_._.T-.-.._. _______-____________ SWPO4807 el 1 2 5 40-8 PC300.. 00 6 0. 1 planet gear Backlash between No. 2 planet carrier and motor Backlash between No. 1 sun gear and No.MAINTENANCE STANDARD FINAL DRIVE No Check item Backlash between No.50 2 0.0.15 qebuild or peplace I PC300.0.17 . 1 planet gear and ring gear Backlash between No.oo limit Remedy 1 0. 2 planet Standard clearance Unit: mm Criteria Clearance 1 .0. 2 sur aear End play of sprocket shaft I 8 Wear of sprocket teeth Standard 9 Sprocket tooth width size Repair limit: 6 Repair limit 0.52 1.24 .64 1. 2 planet gear and ring gear Backlash between No.21 .oo Replace gear 5 Backlash between No.24 - 4 0.0.oo 7 0. 1 planet carrier and No.10 .38 .0.06 .17 .64 1. 350-6 40-9 .0.78 1 .00 3 0.0. 2 sun gear and No. 350-6 . _____.MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING TRACK FRAME AND RECOIL SPRING + The diagram shows the PC300-6 _-__-_____-_____ __-_____________________ r---i--______ I _.__________ I I I 1 * SAP00409 Unit: mm No Check item I Criteria Standard size Tolerance Repair limit Remedy I 123 +2 -1 I I / 127 1 Top-to-bottom idler guide width of Track frame ! I idler support 120 1 ~0.5 118 Rebuild replace or Track frame Left-to-right 2 guide Idler support Standard I 266 width of idler 261 I +3 -1 I 271 259 Repair limit size 3 ‘lecoil spring Replace 40-10 PC300._____ __.. . 5Nm Ilk--L-4 llr 7 2 6 8 L_ _ _I SBP00411 40-12 PC300.0k24.MAINTENANCE STANDARD IDLER IDLER -I- 6 m 152. 350-6 . 68 .290 Hole +o.5 Clearance between and bushing shaft Standard size 80 Standard clearance 0.6 Standard +0.010 -0. 350-6 40-13 .087 +0.166 Clearance limit - Replace bushing 9 - Side clearance (both sides) of idler 0.225 -0.1.5 Clearance between and support shaft 80 - Replace 8 Interference between and bushing idler Standard size 87. Check item Outside diameter of proruding portion Outside diameter of tread 590 578 Rebuild replace or Width of protrusion 101 - Overall width 190 - Width of tread 44.195 50.215 0.22 I 2 I PC300.455 0.037 clearance -0.325 -0.MAINTENANCE STANDARD IDLER Unit: mm No.225 -0.079 0.064 0.03 .085 -0. 130 -0.0.205 1.5 Tolerance Shaft -0.027 -0. -A’ c **-\.. 350-6 .f ). -_ -....----- -. Y SBPOO415 Unit: mm iameter of flange PC300.MAINTENANCE STANDARD CARRIER ROLLER CARRIER ROLLER l--------I . f ‘J-7----_ ‘1 --__ :I li 3 __-__ ti t 2 1 I r ’ .+ I . 5 Replace bushing Standard Side clearance (both sides) of idler clearance Clearance 1.215 -0.501 Clearance limit 1.186 -0.MAINTENANCE STANDARD TRACK ROLLER TRACK ROLLER (6727kgm) _ I P-l-4 Unit: mm I No Check item Standard 1 Outside diameter (outside) of flange 216 Rebuild replace or size Criteria Repair limit Remedy Outside diameter of tread 180 I 168 Width of tread 49 55 Width of flange 27 Tolerance Shaft -0.41 .5 limit Replace 0. 350-6 40-l 5 .0.315 Hole +0.151 0.064 - Clearance between and bushing shaft Standard size 65 Standard clearance 0.95 PC300. 40-16 PC300.MAINTENANCE STANDARD TRACK SHOE TRACK SHOE TRIPLE GROUSER SHOE ’? ?I F 5 12 II 24 16 I 13 IL. 350-6 . I \ 2 18 7 17 25 I! \ 15 20a SWPO4808 Ir P portion shows the link of bushing press fitting end. 3 10.22 ton1 I Regular Master link I I PC300.6 4.6 pin 147 .2 5.8 42.215.4 Replace Shoe bolt pitch I 76.37 ton1 kN I10 .MAINTENANCE STANDARD TRACK SHOE No Check item Unit: mm I Standard size Criteria Repair limit Remedy 1 Link pitch 216.5 size Normal size load I 3 Link height Thickness of link metal (bushing press-fitting portion) Standard 116 I Repair limit 107 Repair or replace 4 5 6 7 30.27 ton1 kN {15 .8 Repair or replace Overall width pwidth of pin of length length regular bushing of pin of bushing metal Adjust or replace of bushing of spacer Bushing 98 .8 178.3 When turned Impact 61 load Reverse replace or Standard 2 Bushing outside diameter 66.2 19 I 8 9 10 11 12 13 14 15 16 17 18 x 19/ % : Dry type track Press-fitting force Protrusion Protrusion Overall Overall Thickness Thickness Link Inside width 102 47.6 98 .25 242 148.6 kN {IO . 350-6 40-17 .362.3 I 219.264. Master link I No.1k19.6 23 - Clearance between regular pin and bushing 24 % 25 nterference between master pin and link Clearance between naster pin and bushing track link Standard size 44.050 -0.5 44.273 .235 +0.915 +0.530 Hole -0.930 +0.485 Standard clearance 0.0.) 20 b.085 Tolerance Shaft +0.464 +0. interference 0.0.250 Hole +0.350 . 350-6: 45 PC300.03 0 Tolerance Shaft +0.180 .0.6 12OZ21 Additional tightening angle (deg.830 Standard.188 -0.MAINTENANCE STANDARD TRACK SHOE Unit: mm h.415 Hole +0.085 Tolerance Shaft +0.480 .6 Standard size 44.980 Adjust or replace 66. Regular link 196. NC - Check item Tightening torque (Nm {kgml) Triple shoe Shoe bolt Criteria Additional tightening angle (deg.280 Standard clearance 0.050 Hole +0.074 0 -0.464 0. 350-6 .0.6 Standard size 44.0. of shoes (each side) Tightening torque (Nm {kgm)) Retighten - PC300.3 % : Dry type 40-18 PC300.424 +0.) 120+10 Lower limit torque (Nm Ikgm)) Remedy a. 35OLC-6: 48 I I - 21 22 - Interference between bushing and link Interference between regular pin and link Standard size L Tolerance Shaft +0.188 .188 0 Standard interference 0.235 +0. Check item Standard size Criteria Repair 24 11 32 limit Remedy 1 Height 36 2 3 4 5 6 7 Thickness Length of base 26 24 .Rebuild replace or Length at tip 18 18 PC300. 350-6 40-19 .MAINTENANCE STANDARD TRACK SHOE TRIPLE GROUSER SHOE SDD01629 Unit: mm No. 350-6 .MAINTENANCE STANDARD HYDRAULIC PUMP HYDRAULIC HPVIGO + 160 PUMP 40-20 PC300. . always use 2 washers on top of each other. 166. see When tightening the bolts at the places marked *.MAINTENANCE STANDARD CONTROL VALVE CONTROL VALVE IO-spool valve (l/6) Ir For details of the 9. valves. and 7-spool IO-SPOOL VALVE. 350-6 .8Nm 17*lkml SWPO4810 40-22 PC300. 8.7*9. 1 49.1 kg} 287.5 358.3 x 37.2 N (4.3 kg} 40. 350-6 40-23 .1 kg) jpool return spring 40 x 12.1 - N (29.MAINTENANCE STANDARD CONTROL VALVE B-B SWPO481 I Unit: mm No Remedy 1 Spool return spring Spool return spring Replace spring if there is damage or / deformation Spool return spring 53.3 38 PC300.7 N l36.6 kg} 50 N 15. 350-6 .04*8.MAINTENANCE STANDARD CONTROL VALVE (316) 74.85koml K-K SWPO4812 40-24 PC300.55*0.34Nm ~7. 6Nm 140+2kaml LEI F-F w 147.3* 19.” 2knml E-E iNm F 392.1 * 9.8Nm ~l5~lkPml SWPO4813 PC300.3* 19.8Nm fI5*lkPml .MAINTENANCE STANDARD CONTROL VALVE 392. 350-6 40-25 .3+ 19.6Nm (40*2knmI (40*2k9ml w 147.4+9.6Nm (40~2ksm) .1 *9.8Nm Ikpml 392. 3* 19.6Nm (40*2koml NA-NA SWPO4814 Unit: mm No.MAINTENANCE STANDARD CONTROL VALVE E/6) 392.3* 19.6Nm (40*2koml 392. 350-6 . I Check item Criteria Remedy IA Regeneration valve spring 1B Regeneration Piston return valve spring spring 2 Replace spring if there is damage or deformation 3 Piston return spring 4 Piston return spring Piston return spring 40-26 PC300. 5 N IO.2 N IO.6 - Spool return spring 65.12 kg} 134.D.5 10 - PC300.55*3.5kamI 23.4kom) JJ-JJ SWPO4815 Unit: mm No Check item Standard size Criteria Repair limit Installed load 1.2 50 - Spool return spring 13.MAINTENANCE STANDARD CONTROL VALVE .kom23. 350-6 40-27 .6 x 5.7 kg} 1. 11.75Nm 15.4 f 0.1 kg} 2N IO.5 x 27.5 x Installed length 8.5*2.5 4.25*24.3 N i13.95Nm 1 f J-J 152.15 kg} 167.15 kg] Replace spring if there is damage or deformation Remedy 1 1 Check valve spring Free length x O.2 kg} Free length Installed load 1.95Nm 2.6 N i17.5 N IO.55i3. 350-6 . 40-28 PC300.MAINTENANCE STANDARD CONTROL VALVE VARIABLE PRESSURE COMPENSATION VALVE SDPOll24 Unit: mm No.8 N Remedy Installed length 20. Check item Standard size 1 Piston return spring FrT$.8 N 16.1 x 9 15.8 kg) 59.8 N 11.5 74.76 x 8.5 Criteria Repair limit installed load 9.1 kg) Replace spring if any damages or deformations are found.6 kg} - IO.5 N 17.0 kg) 2 Relief valve spring 17.5 Free length - Installed load 7.gth 32. 3 kg} Free length limit Installed load 17.6 N il.8 N 16 kg) Remedy 1 Spring.. bmcay.7 59 13.4 kg) 61.1 x 7. 19.7 N II.8 12.rng pressure valve.1 kg} 199.2 x 7. pilot) Spring Spring (safety valve) If%5 x 7.8 N 120.9 kg1 186.6 N {2 kg1 20. PC300. 350-6 40-29 . Free length x O.2 71 x 18 16.1 2 3 4 Spring (reducing pressure valve.6 N (2.2 Installed length 16.MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE SELF-REDUCING PRESSURE VALVE SWPO4816 Unit: mm No Check item Standard size Criteria Repair installed load 19.4 Replace spring if any damages or deformations are found.8 kg} 18.7 N 16.2 N 119 kg1 58.D. MAINTENANCE STANDARD SUCTION-SAFETY VALVE SUCTION-SAFETY FOR SERVICE VALVE VALVE No Check item Standard Criteria size Reoair limit Unit: mm Remedy 1 Suction valve spring 2 - Piston spring 40-30 PC300. 350-6 . 350-6 40-31 .28 kg} Replace spring if there . Check item Standard size 1 Check valve spring Free length x O. 46.6 N (1.2 Installed length 31 installed load 15 N {l.D.9 x 9. is damage or deformation Remedy - PC300.MAINTENANCE STANDARD SWING MOTOR SWING MOTOR KMFl60ABE-3 A - A SWPO4817 Unit: mm No.S kg1 Criteria Repair limit Free length Installed load 12. 7Nm .5bml 419*46.7komI swPo4818 Unit: mm NC Check item Standard size Criteria I Remedy ReDair limit 1 Spool return spring Free length x O.0 398.6 kg} 3 Regulator piston spring 40-32 PC300.MAINTENANCE STANDARD TRAVEL MOTOR TRAVEL MOTOR HMVl60ADT-2 14.7 kg} 319.2 30. 350-6 . Installed length Installed load Free length Installed load 2 Check valve spring 61.5 N I32.6*4.9 N 140.D.1 x 23.6Nm (42. 9Nm 0. P2) Metering spring 26.4 kg} 3 PC300.5 x 8.7 N (1.7 N Il.35*0. Check item Unit: mm ~ 1 Centering spring (for P3.2 16. P4) 2 Centering spring (for Pl.15kPml *4. 350-6 40-33 .7 kg1 13.2*1.5Nm 11.5koml A-A E-E SAP02751 No.MAINTENANCE STANDARD WORK EQUIPMENT l SWING PPC VALVE WORK EQUIPMENT l SWING PPC VALVE 13. 7 N Free length limit Installed load 13. Check item Standard size Criteria Repair Installed load 16.9 _ Replace if there is damage or deformation spring Il.3 N (8.15 Installed length 24.MAINTENANCE STANDARD TRAVEL PPC VALVE TRAVEL PPC VALVE SAP01255 Unit: mm No.4 kg} 86. 350-6 .5 32.8 kg} 2 Centering spring 48. 26.7 N Remedy 1 Metering spring Free length x O.5 - 40-34 PC300.1 x 15.7 kg} 108 N (11 kg1 - 0.D.5 x 8. MAINTENANCE STANDARD SERVICE PPC VALVE SERVICE PPC VALVE I J SBPO0436 Unit: mm No.5 kg1 Replace spring if any damages or deformations are found.1 N 14.8 x 16.6 kg} Criteria Repair limit Free length (62. Remedy 2 Metering spring 26.5 Installed load 46.5 kg1 24. 350-6 40-35 .0 x 10.9) Installed load 44.D.5 N 12.1 N 14. Check item Standard size 1 Centering spring Free length x O.2) PC300.7 kg} 25. 64.0 (25.6 Installed length 40.5 25.5 N t2. 2 kg) Remedy 1 Spool return spring Free length x O.8 N Il.9N m /~3. Check item Standard size Criteria Repair limit Installed load 14.6 x 13.9Nm SDP01353 Unit: mm No.3 f 4.5~0.3 Installed length 20 Replace spring if there is damage or deformation - 40-36 PC300.MAINTENANCE STANDARD PPC SHUTTLE VALVE. TRAVEL JUNCTION VALVE PPC SHUTTLE VALVE.5kml 34.3*4. TRAVEL JUNCTION VALVE 34.D.7 N (1. 350-6 . 23.5 kg} Free length Installed load 11. - PC300.32 kg} Criteria Repair limit Free length Installed load Remedy Replace EPC valve ass’y if any damages or deformations are found.4 Installed length 7. Check item Standard size 1 Return spring Free length x O. 350-6 .9 Installed load 3. 9.MAINTENANCE STANDARD LS-EPC VALVE LS-EPC VALVE SBPOO43S Unit: mm No.0 x 11.D.1 N (0. MAINTENANCE STANDARD SOLENOID VALVE SOLENOID VALVE SWP04676 40-38 PC300. 350-6 . . 111 . 350-6 .0. Check item Standard size Criteria Standard clearance 0.MAINTENANCE STANDARD CENTER SWIVEL JOINT CENTER SWIVEL JOINT \ - SBPOO439 Unit: mm No. Clearance between and shaft rotor 90 40-40 PC300.105 Remedy Clearance limit Replace 0.056 . Check item I Criteria Standard size Installed load 4.3 N I3.5 x 11. 26.6 kg} Repair limit Free length Installed load 3. 350-6 .2 x 16.9 kg1 I Remedy 1 Pilot valve spring Free length x O.48 kg} 35.0 Replace spring if there is damage or deformation 2 Check valve spring 37.7 N {o.D.2 30.4 N 12.MAINTENANCE STANDARD BOOM HOLDING VALVE BOOM HOLDING VALVE m I-* (15tl 147Lmmkgm) A-A Unit: mm I No.0 - PC300.7 N lo.38 kg1 28.2 Installed length 25. 4Nm (30*3.Okoml 3 40-42 PC300.MAINTENANCE STANDARD HYDRAULIC CYLINDER HYDRAULIC CYLINDER BOOM CYLINDER 2 3 ARM CYLINDER BUCKET CYLINDER 1 \ I 294*29. 350-6 . 457 +0.370 +0. 3ushing 3 Clearance between cylinder bottom support shaft and PC300. 350-6 40-43 .0 100 - - 1.MAINTENANCE STANDARD HYDRAULIC CYLINDER Unit: mm Nt - Check item Criteria Remedy 1 Clearance between piston rod Replace bushing 2 Clearance between piston rod support shaft and bushing Arm (for pc300) Arm (for PC3501 100 - +0.370 - 1.457 +0.0 - qeplace pin. MAINTENANCE STANDARD WORK EQUIPMENT WORK EQUIPMENT SBPO0443 D-D A-A I I b B-B E-E F-F G-G SAP00444 40-44 PC300. 350-6 . 338 +0.436 0.036 -0.MAINTENANCE STANDARD WORK EQUIPMENT Unit: mm C- No Check item Criteria Tolerance Remedy 1 2 Clearance between bushing and mounting pin of boom and revolving frame Clearance between bushing and mounting pin of boom and arm Clearance between bushing and mounting pin of boom and link Clearance between bushing and mounting pin of boom and bucket Clearance between bushing and mounting pin of link and bucket Clearance between bushing and mounting pin of link and link Bucket clearance (a) Standard size 110 1 Shaft -0.251 0.354 +0.036 -0.0 3 4 5 6 7 c 90 90 90 +0.5 .337 +0.311 0.346 +0.427 0.308 0.0 1.0 1.428 0.0 8 Bucket clearance (b) 2.0 1.311 0.0 Replace -0.1.110 0.307 0.346 +0.27 1 +0.090 1.090 1.036 -0.275 +0.444 0.090 -0.074 +0.0 -0.311 0.036 -0.275 0.275 Standard clearance 0. 350-6 40-45 .272 +0.090 Hole +0.0 1 Adjust shims PC300.161 +0.436 T Clearance limit 1. ARM OF WORK EQUIPMENT I 9 1 J I! t-A 18 x-x z-z SAP00446 40-46 PC300. 350-6 .MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT DIMENSIONS ‘I. 0 I 935.090 +0. PC300.036 -0.0 f 0.0 2 0.5 345 1990 3275 19 Max. 3304.2 728.0 f 0. 350-6 40-47 .090 I I 345. -0.5 Q go +0.l . -0.4 + 1.5/116 3 4 5 6 7 8 9 IO 11 12 13 14 15 16 17 Arm 18 as individual tJ go 2 1.0 3179 k 3 3095.2 320 +0.5 + 1.0 472.090 I 731.7 + 1.8 4J ‘IO 428.036 0 -0.0 219 + 0.3+.090 loo 0 320 +0.036 0 -0.6 1670 4 go +02 -0.3 0 Ll.5 490 +02 -0.5 345 1990 3275 3302.7 + 1.5 513.090 4 loo @l17.5 -0.036 0' '-0.036 0' Lo90 I I 345.2 $Jl17.3+.6 1670 +0 2 -0.5 468 f 1 234.3 0 '-0.5 513.1 /-0.0 5 0.2 728.5/l16 f 1.8 +O.l .2/-0.0 + 0.8 f 1.0 + 0.MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT Unit: mm PC300-6 1 @ PC350-6 +O.090 part When press fitting bushing Min.0 468 + 1 I 731.036 0 -0.036 0' '-0.0 f 0.5 -0.0 3179 f 3 3095.7 + 1.5 1022. MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT 2. BUCKET 2 . 350-6 . 5 I6 I6 I5 I5 ‘I l-J--A-A ’ ’ I SWPO4822 40-48 PC300. 0.5 37.5 2 0.5 93”12’ 513.5 @J 26 qI 170 I 42” c#l9o+y 346 +.6 I I RI15 RIO0 22 I 60 I 60 PC300. 350-6 40-49 .2 + 0.9 f 0. 68 138 525.5 f 0.9 f 0.2 f 0.6 1658 I PC350-6 512.2 346+:.1 137.0 RI15 RIO0 16 17 18 19 20 ! 4 200 146.6 1663 173 8 9 10 11 12 13 14 I 50” 0 90+.5 9 26 f#J 170 l#J 200 135.5 142.MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT Unit: mm PC300-6 512.5 94”19’ 513. 68 138 525.5 2 3 4 5 I 37. . ... 350-6 90-l .......90 OTHERS Hydraulic circuit diagram ...........90-5 ...............90-7 90-9 PC300.............................. Electric circuit diagram (2/3) .......... 90-3 ................. Electric circuit diagram (3/3) ......... Electric circuit diagram (l/3) ..... . . . . . use another sheet.A. If more space is needed.Komatsu America international Company 440 North Fairwav Drive I Vernon Hills.S. PMR 2 : : S E R DEPARTMENT: NAME: NAME OF COMPANY: LOCATION: PHONE NO: DATE: MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO: PROBLEM: Attach photo or sketch. IL 66061-8112 U.No. Attn: Technical Publications Fax No. (847) 970-4186 1 PROPOSAL FOR MANUAL REVlslON FOR INTERNAL USE ONLY -. 1 FOR INTERNAL USE ONLY CORRECTIVE ACTION: PFMRl 081696 . Documents Similar To Sm Pc300,350, Lc6Skip carouselcarousel previouscarousel nextSM PC300-350 LC 8uploaded by Cesar Ego-Aguirre CalderonPC35_PC45R-8_WEBM000300.pdfuploaded by Roberto PC200-8 SEN00084-03.pdfuploaded by andrapc450-7uploaded by IongornistuPC300-8uploaded by Manuel Santibañez ContrerasKomatsu PC45-1 Service Manualuploaded by masakpSEBDA2050508 SM PC220-5uploaded by César Augusto1_PDFS-1.PDFuploaded by humberto SEN01983-01 Shop Machine PC 300-8uploaded by jacklyn ade putraShop PC300-6.PDFuploaded by اشرينكيل مسونكيلKomatsu PC300uploaded by Yadie DoomeastvanKomatsu Manuals Electrical Diagram Pc300uploaded by SeaskybluesShop Manual Pc600-7uploaded by Jorge Zamora CernaParts Manual - PC400uploaded by leonidiooliveiraShop Manual PC300LC 7_SN40001and Upuploaded by Budi WaskitoZx450 3 Troubleshootuploaded by Khoai Sai GonPC100 & 120-6 SEBM010611uploaded by Budi WaskitoSebm024300(General s&f)uploaded by Joakim IndarnoPC240LC, 240NLC-6K _ K32001 and _ up PC210, 210LC-6K _K32001 and upEEBD001801uploaded by josephvanbackomatzu pc300-2uploaded by HarlintonKomatsu PC128UU-2 Shop Manual.pdfuploaded by John SimmondsTroubleshootinguploaded by ado_22Zx330 Workshop w1hh e 01uploaded by ElenaBaciuPC200-7_Noteuploaded by ĐộngCơÔTôPC130-7uploaded by Fernando SabinoExcavadora Kobelco SK170 Motor Hinouploaded by Juan Alfredo Guzmán Gómez10795750-DKP8P8EM-Download Komatsu Pc138us-8 Pc138uslc-8 Excavator Manualuploaded by Edison Leonardo Correa ZambranoPC130_S_SEBM036300_PC130-7_0404uploaded by SARAMQRKOMATSU GOLD BOOK.pdfuploaded by omni_partsPC78MR-6_SEBM030601uploaded by Augusto OliveiraFooter MenuBack To TopAboutAbout ScribdPressOur blogJoin our team!Contact UsJoin todayInvite FriendsGiftsSupportHelp / FAQAccessibilityPurchase helpAdChoicesPublishersLegalTermsPrivacyCopyrightSocial MediaCopyright © 2018 Scribd Inc. .Browse Books.Site Directory.Site Language: English中文EspañolالعربيةPortuguês日本語DeutschFrançaisTurkceРусский языкTiếng việtJęzyk polskiBahasa indonesiaYou're Reading a Free PreviewDownloadClose DialogAre you sure?This action might not be possible to undo. Are you sure you want to continue?CANCELOK