Komatzu pc300-2

CEBM207041
SHOP
MANUAL
KOMAfhJ
PC3OOLG5
WITH KDC 614TA ENGINE
PC4OOLG5
WITH CUMMINS LTA-IOC ENGINE
EXCAVATORS
MACHINE MODEL SERIAL NUMBERS
PC3OOLC-5 A30001 and up

PC4OOLC-5 A40001 and up
This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used,
or disclosed except in accordance with written authorization from Komatsu Dresser Company.
It is our policy to improve our products whenever it is possible and practical to do so. We
reserve the right to make changes or add improvements at any time without incurring any
obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be
made to this publication. It is recommended that customers contact their distributor for
information on the latest revision.
AUG 95
Includes revision @ 00-l
0
00-2
The affected pages are indicated by the use of the Mark Indication Action
following marks. It is requested that necessary
actions be taken to these pages according to the 0 New page to be added Add
table below a Page to be replaced Replace
( ) Page to be deleted Discard

Pages
. having
.._ no marks are those previouslyrevised or
made additions
LIST OF REVISED PAGE
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#9
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CONTENTS
01 GENERAL ..................................... 01-I
10 STRUCTURE AND FUNCTION ....................... IO-I
20 TESTING AND ADJUSTMENT ....................... 20-I
30 DISASSEMBLY AND ASSEMBLY ..................... 30-I
40 MAINTENANCE STANDARD ........................ 40-I
99 OTHER METRIC CONVERSIONS ..................... 99-1
00-7
A
Proper service and repair is extremely
IMPORTANT
important
SAFETY NOTICE
for the safe operation of your machine. The

service and repair techniques recommended and described in this manual are both effective and
safe methods of operation. Some of these operations require the use of tools specially designed
for the purpose.
To prevent injury to workers, the symbols A and *q are used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the necessary
actions to deal with the situation.
A SAFETY
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operators Manual carefully BEFORE Always keep the work area clean and make
operating the machine. sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
1. Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine. PREPARATIONS FOR WORK
2. When carrying out any operation, always 7. Before adding oil or making repairs, park the
wear safety shoes and helmet. Do not wear machine on hard, level ground, and block the
loose work clothes, or clothes with buttons wheels or tracks to prevent the machine from
missing. moving.
l Always wear safety glasses when hitting
parts with a hammer. 8. Before starting work, lower blade, ripper,
l Always wear safety glasses when grinding bucket or any other work equipment to the
parts with a grinder, etc. ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure to
3. If welding repairs are needed, always have a
lock all the control levers and hang warning
trained, experienced welder carry out the
signs on them.
work. When carrying out welding work, al-
ways wear welding gloves, apron, glasses,
cap and other clothes suited for welding 9. When disassembling or assembling, support
work. the machine with blocks, jacks or stands
before starting work.
4. When carrying out any operation with two or

more workers, always agree on the operating 10. Remove all mud and oil from the steps or
procedure before starting. Always inform your other places used to get on and off the
fellow workers before starting any step of the machine. Always use the handrails, ladders or
operation. Before starting work, hang UNDER steps when getting on or off the machine.
REPAIR signs on the controls in the opera- Never jump on or off the machine. If it is
tors compartment. impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
5. Keep all tools in good condition and learn the

correct way to use them.
00-8
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged part with new parts.
or hydraulic pressure measuring plugs, loos- l When installing hoses and wires, be sure
en them slowly to prevent the oil from spurt- that they will not be damaged by contact
ing out. with other parts when the machine is
Before disconnecting or removing compo- being operated.
nents of the oil, water or air circuits, first
remove the pressure completely from the 20. When installing high pressure hoses, make
circuit. sure that they are not twisted. Damaged
tubes are dangerous, so be extremely careful
12. The water and oil in the circuits are hot when when installing tubes for high pressure cir-
the engine is stopped, so be careful not to cuits. Also check that connecting parts are
get burned. correctly installed.
Wait for the oil and water to cool before
carrying out any work on the oil or water 21. When assembling or installing parts, always
circuits. use the specified tightening torques. When
installing protective parts such as guards, or
13. Before starting work, remove the leads from parts which vibrate violently or rotate at high
the battery. Always remove the lead from the speed, be particularly careful to check that
negative (-) terminal first. they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
fingers caught in a hole.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has ample 23. When measuring hydraulic pressure, check
capacity. that the measuring tool is correctly assem-
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hitting 24. Take care when removing or installing the
any other part. Do not work with any part still tracks of track-type machines.
raised by the hoist or crane. When removing the track, the track separates
suddenly, so never let anyone stand at either
15. When removing covers which are under inter- end of the track.
nal pressure or under pressure from a spring,
always leave two bolts in position on oppo-
site sides. Slowly release the pressure, then
slowly loosen the bolts to remove.
16. When removing components, be careful not

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

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

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-9
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop.
For ease of understanding, the manual is divided into the following sections. These sections are further
divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights,
and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
I I
NOTICE
The specifications contained in this shop manual are subject to change at any time and without
any advance notice. Contact your distributor for the latest information.
I I
00-l 0
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISIONS
Shop manuals are issued as a guide to Revised pages are shown at the LIST OF RE-
carrying out repairs. They are two manuals for VISED PAGES between the title page and
each machine, Chassis volume and Engine SAFETY page.
volume.
SYMBOLS
These volumes are designed to avoid duplica-
tion of information. Therefore to deal with all So that the shop manual can be of ample
repairs for any model, both chassis and engine practical use, important places for safety and
volumes are needed. quality are marked with the following symbols.
DISTRIBUTION AND UPDATING Item Remarks

Symbol
A
Special safety precautions
Any additions, amendments or other changes
are necessary when per-
will be sent to your distributors. Get the most up- forming the work
to-date information before you start any work.
Safety Extra special safety pre-
Mb? cautions are necessary
FILING METHOD when performing the work
e because it is under inter-
1. See the page number on the bottom of the
nal pressure.
page.
File the pages in correct order. Special technical precau-
tions or other precautions
2. Following examples show how to read the Caution for preserving standards
*
page number: are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts or sys-
terns. Caution necessary
Weight when selecting hoisting
6 kg
wire or when working
Item number (10. Struc-
posture is important, etc.
ture and Function)
Places that require special
Consecutive page number Tightening
attention for tightening
for each item torque
torque during assembly.
Places to be coated with
Example 2 (Engine volume): Coat adhesives and lubricants
Refer to the pertinent engine manual. etc.
Places where oil, water or
3. Additional pages: Additional pages are indi- Oil, water fuel must be added, and
cated by a hyphen (-) and numbered after the Q
the capacity.
page number. File as in the example.
Example: Places where oil or water
20-4 Drain must be drained, and
20-4-l quantity to be drained.
Added pages
20-4-2
20-5
REVISED EDITION MARK (0 @ @ . ...)
When a manual is revised, an edition mark is

recorded on the bottom outside corner of the
pages.
00-l1
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
A
,
Heavy parts (25 kg or more) must
be lifted with a hoist etc. In the
Disassembly and Assembly sec-
tion, every part weighing 25 kg or
:
264
more is indicated clearly with the Ko% 88% 79% 71% 41%
symbol
FSoO64
Do not sling a heavy load with one rope

1. If a part cannot be smoothly removed from
alone, but sling with two or more ropes
the machine by hoisting, the following checks
symmetrically wound on to the load.
should be made:
l Check for removal of all bolts fastening
the part to the relative parts. Slinging with one rope may cause turn-
ing of the load during hoisting, untwist-
ing of the rope, or slipping of the rope
l Check for existence of another part caus-
from its original winding position on
ing interface with the part to be removed.
the load, which can result in a dan-
gerous accident.
2. Wire ropes
1) Use adequate ropes depending on the Do not sling a heavy load with ropes
weight of parts to be hoisted, referring to forming a wide hanging angle from the
the table below: hook.
Wire ropes When hoisting a load with two or more
(Standard 2 or s twist ropes without galvanizing) ropes, the force subjected to each rope
Rope diameter (mm) Allowable load (tons) will increase with the hanging angles. The
10.0 1.0 table below shows the variation of allow-
11.2 1.4 able load (kg) when hoisting is made with
12.5 1.6 two ropes, each of which is allowed to
14.0 2.2 sling up to 1000 kg vertically, at various
16.0 2.8 hanging angles.
18.0 3.6 When two ropes sling a load vertically, up
20.0 4.4 to 2000 kg of total weight can be sus-
22.4 5.6 pended. This weight becomes 1000 kg
30.0 10.0 when two ropes make a 120 hanging
40.0 18.0 angle. On the other hand, two ropes are
50.0 28.0
subject to an excessive force as large as
60.0 40.0
4000 kg if they sling a 2000 kg load at a
lifting angle of 150.
P
The allowable load value is estimated to
/2 %kg
be one-sixth or one-seventh of the
breaking strength of the rope used. 2c00 1900
1700
a
2) Sling wire ropes from the middle portion 0

* @J
of the hook.
i!yy-h
Slinging near the edge of the hook may
\
cause the rope to slip off the hook during
hoisting, and a serious accident can 30 w 90. 120 t 50
result. Hooks have maximum strength at Lifting angle : a
the middle portion. Fsocms
00-12
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in
sections of Disassembly and Assembly.
Thread diameter
of bolt
(mm)
Width
across flat
(mm)
8
cl
kgm I Nm
6 10 1.35+0.15 13.221.4
8 13 3.220.3 31.4t2.9
10 17 6.750.7 65.7k6.8
12 19 11.5+1.0 11229.8
14 22 18.022.0 177219
16 24 28.5?3 279229
18 27 39+4 383 + 39
20 30 56?6 549258
22 32 7628 745 f 78
24 94.5+ 10 927+98
27 41 135215 1320+140
30 46 175+20 1720+-190
33 50 225 fi 25 2210+240
36 55 280 + 30 2750 2 290
39 60 335 f 35 3280 + 340
This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal
washers are to be used, or which require tightening to otherwise specified torque.
t Nm (newton meter): 1Nm & 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter Width Tightening torque

of bolt across flats
(mm) kgm Nm
(mm)
10 14 6.720.7 65.726.8
12 17 I 11.5+1 I 11229.8
16 22 I 28.523 279 f 29
00-l 3
3. TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS
Use these torques for nut part of flared.
Thread diameter Width across flats I Tighteni i torque

of nut part of nut part
kgm Nm
(mm) (mm)
14 19 2.5kO.5 24.5 f 4.9
18 24 5+2 49k19.6
22 27 8+2 78.5k19.6
24 32 14*3 137.3k29.4
30 36 1823 176.5 + 29.4
41 2025 196.1 249
:: 46 25+5 245.2+49
42 I 55 I 30+5 I 294.2 2 49
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
-
Nomenclature Code 1 Aoolications
LT-1 A Used to apply rubber pads, rubber gaskets, and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts
LT-1 B
when a fast. strona seal is needed.
Preventing bolts, nuts, and plugs from loosening and leaking
LT-2*
Adhesives oil.
Provides an airtight, electrically insulating seal.
LT-3
Used for aluminum surfaces.
Used to coat plugs (plate shaped, bowl shaped) and holes,
LT -4
and mating portion of shaft.
LG-1 Used with gaskets and packings to increase sealing effect.
Heat-resistant gasket for precombustion chambers and ex-
LG-3
haust piping.
Used by itself on mounting surfaces on the final drive and
LG-4 transmission cases. (Thickness after tightening: 0.07 - 0.08
Liquid gasket mm).
Used by itself to seal grease fittings, tapered screw fittings and
LG-5 tapered screw fittings in hydraulic circuits of less than 50 mm
in diameter.
LG-6 Silicon base type used in combination with LG-1 and LG-4.
LG-7 Has shorter curina time than LG-6. and is easier to oeel off.
Antifriction com-
pound (Lubricant Applied to bearings and taper shafts to facilitate press-fitting
LM-P
including molybde- and to prevent sticking, burning or rusting.
num disulfide)
Grease (Lithium Applied to bearings, sliding parts and oils seals for lubrication,
G2-LI
areasel rust prevention and facilitation of assembling work.
Heat resistance and long life type. Applied to bearings, sliding
Grease (Lithium
G2-LI-S parts and oils seals for lubrication, rust prevention and
synthetic grease)
facilitation of assembling work.
Grease (Lithium with Abrasion at lubrication areas is decreased. Applied to
Molybdenum MPG bearinas, slidina parts and oils seals for lubrication, rust
Disulfide) preveniion and &iIitation of assembling work.
Vaseline ___ Used for protecting battery electrode terminals from corrosion.
-
*LT-2 is also called LOCTITE in the shop manuals.
00-14
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black
stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
* Old numbers
CLASSIFICATION BY COLOR AND CODE
Signal
G Y L
Green Yellow Blue
GW YR LW
Green & Yellow & Blue &
White Red White
GR YB LR
Red Black Red
GY YG LY
Yellow Green Yellow
GB YL LB
Black Blue Black
GL YW
~ Green & Yellow &
Blue White
00-l 5
00-l 6
01 GENERAL
GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
MACHINE DIMENSIONS - PC3OOLC-5 . . . . . . . . . . . . . . 01-4
WORKING RANGE DIMENSIONS - PC3OOLC-5 . . . . . . . . 01-5
MACHINE SPECIFICATIONS - PC3OOLC-5 . . . . . . . . . . . 01-6
MACHINE DIMENSIONS - PC400LC-5 . . . . . . . . . . . . . . 01-8
WORKING RANGE DIMENSIONS - PC4OOLC-5 . . . . . . . . 01-9
MACHINE SPECIFICATIONS - PC4OOLC-5 . . . . . . . . . . 01-10
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
REFILL SPECIFICATIONS AND CAPACITIES

PC3OOLC-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l 4
PC4OOLC-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-l 5
01-l
01-2
GENERAL VIEW
PC3OOLG5, PC4OOLG5
Boom
Arm cylinder I Boom cylinder
Right
a
Rear
tlucxel cylrnaer 11
Front
Bucket Idler
XOlAD029
If directions are indicated in this manual, they refer to the directions shown by the arrows in the diagram
above.
01-3
MACHINE DIMENSIONS
PC3OOLG5
v 7
-J t
4 B .
OlAD0007
ARM
2.2 m (73) 2.55 m (84) 3.19 m (105) 4.02 m (132)
A Overall length 10950 mm 10855 mm 10810 mm 10840 mm

(3511,,) (357) (356) (357)
E Length on ground 7728 mm 6850 mm 5405 mm 5390 mm

(transport) (254) (226) (17'9") (17'8")
c Overall height 3370 mm 3425 mm 3200 mm 3650 mm

(to top of boom) (1 l'l") (11'3") (10'6") (12'0")
PC3OOLC-5
D Overall width 3290 mm (1010)
E Overall height (to top of cab) 3060 mm (100)
F Ground clearance, counterweight 1180 mm (310)
I G IMin. around clearance I 498 mm (1'8")
H Tail swina radius I 3225 mm (10'7")

I I I
I Length of track on ground 3945 mm (12'11")
J Track length 4855 mm (1511)
K Track gauge 2590 mm (86)
L Width of crawler 3290 mm (1010)
M Shoe width 700 mm (28")
N Grouser height 31 mm (1.2)
1 0 IMachine cab heiaht I 2495 mm (82)
P Machine cab width 2960 mm (99)
Q Distance, swing center to rear end 3150 mm (104)
01-4
WORKING RANGE DIMENSIONS
PC3OOLC-5
ARMS
PC3OOLG5
A MAXIMUM DIGGING HEIGHT
B MAXIMUM DUMPING HEIGHT
I I C MAXIMUM DIGGING DEPTH

6355 mm
(2010)
6705 mm
(22) I
7380 mm
(243) I
8180 mm
(2610)
I I F MAXIMUM DIGGING REACH

(334)
9950 mm
(347)
10355 mm
! (365)
10920 mm
! (391)
11730 mm
(328) I (34) I (3510) I (386)
4330 mm 4345 mm 4260 mm 4280 mm
(142) (143) (14) (141)
18800 kg 18800 kg 18800 kg 18800 kg
BUCKET DIGGING FORCE
(41,450 Ib) (41,450 I b) (41,450 lb) (41,450 I b)
I ARM CROWD FORCE

19100 kg
(42,110 lb)
16700 kg
(36,830 I b)
14100 kg
(31,080 lb)
12100 kg
(26,680 I b)
01-f
MACHINE SPECIFICATIONS
PC3OOLG5
Machine Model PC3OOLC5
Serial Numbers A30001 and up
Operating Weight (with operator) (kg) 31200
Bucket Capacity (m3) 1.25
Maximum digging depth (mm) 7380

%
Vertical wall depth (mm) 6480
3
Maximum digging reach (mm) 11100
g
E Maximum digging reach at ground level (mm) 10920
ti 8 Maximum digging height (mm) 10210
a *
z Maximum dumping height (mm) 7110
B
Maximum digging force (when using power max.)(kg) 17500 (18800)
%
Continued swing speed (rpm) 10
Swing maximum slope angle (deg.) 20
Travel speed WV-0 Lo: 3.4, Hi: 5.5
Gradeability (deg.) 35
Ground pressure (standard triple-shoe) (kg/cm*) 0.52 (700mm)
Overall length (at transportation) (mm) 10810

Overall width (mm) 3290
Track width (mm) 3290
Overall height (at transportation) (mm) 3200
Height of cab (mm) 3060
x Ground clearance of counterweight (mm) 1180
m
Minimum ground clearance (mm) 498
g
E Tail swing radius (mm) 3225
Minimum swing radius at front end (mm) 4260
Arm height at minimum swing radius (mm) 8445
Length of track on ground (mm) 3945
Track gauge (mm) 2590
Machine cab height (mm) 2495
01-6
Machine Model PC3OOLC-5
Engine model KDC 614TA
Type 4-cycle, in-line, water cooled, direct injection

type diesel engine with turbocharger and
aftercooler
No. of cylinder - bore x stroke (mm) 6 - 114 x 135
Total displacement (cc) 8270
Flywheel horsepower (HP/rpm) 207/2000

Y
B Maximum torque 94.7/l 500
(kgm/rpm)
z
High idling speed (rpm) 2200
Low idling speed (rpm) 725 f 25
Starting motor 24V
Alternator 24V, 45A
Battery 12V170Ahx2
Type of radiator core cwx-3
A! Carrier roller (one side) 8

g:L 8
33 Track roller (one side)
Track shoe Built-up triple grouser
L Type, number Variable displacement piston type x 2

z Gear type x 1
u
5 Delivery (P/min) Piston type: 250 x 2
d Gear type: 90
: Set pressure (kg/cm*) Piston type: 325 (350)

Gear type: 30
d Type, number 4-spool type and 5-spool type

3
EL!
6 5 Control lever operation Hydraulic assist type
& 09
U
3
d 0 Travel motor Piston type (with brake valve, parking brake)
+ x2
: Z8
Swing motor
E$
Piston type (with safety valve, parking brake) x
1
Hydraulic cylinder Double acting piston
Hydraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler Air cooled
01-7
MACHINE DIMENSIONS
PC4OOLC-5
P *
- H.g -
t-
I- i -I Ii+
II -J t
I- B -I 01A00007
PC4OOLG5 2.4 m 3.38 m _ 4.0 m 4.8 m

2.9 m (96)
(710) (111) (131) (159)
A Overall length 11765 mm 11750 mm 11700 mm 11705 mm 11560 mm

(387) (387) (385) (385) (3711)
B Length on ground 8428 mm 7418 mm 6680 mm 6268 mm 5978 mm

(transport) (278) (244) (203) (207) (197)
G Overall height 3660 mm 3680 mm 3450 mm 3805 mm 4365 mm

(to top of boom) (12) (121) (1 14) (126) (144)
PC4OOLC-5 Std. Undercarriage
L Width of crawler 3480 mm (115) 3200 mm (106) 3685 mm (121)
M Shoe width 750 mm (29.5) 750 mm (29.5) 750 mm (29.5)
N Grouser height 26 mm (1) 26 mm (1) 26 mm (1)
0 Machine cab height 2695 mm (810) 2695 mm (810) 2695 mm (810)
P Machine cab width 2960 mm (99) 2960 mm (99) 2960 mm (99)
Q Distance, swing center to rear 3360 mm (11) 3360 mm (11) 3360 mm (11)
end
01-8
WORKING RANGE DIMENSIONS
PC4OOLC-5
xo1*Do34
ARM
PC4OOLG5 2.4 m 2.9 m 3.38 m 4.0 m 4.8 m
(710) (96) (111) (131) (159)
10295 mm 10305 mm 10920 mm 11045 mm 11505 mm
A Maximum digging height
(339) (3310) (3510) (363) (379)
7055 mm 7095 mm 7570 mm 7725 mm 8155 mm
B Maximum dumping height
(232) (233) (2410) (254) (264)
6785 mm 7285 mm 7760 mm 8385 mm 9195 mm
C Maximum digging depth
(223) (2311) (256) (276) (302)
f, Maximum vertical wall 5335 mm 5680 mm 6850 mm 7280 mm 8215 mm
digging depth (176) (188) (226) (2311) (2611)
E Maximum digging depth of 6585 mm 7095 mm 7620 mm 8255 mm 9080 mm
cut for 8 level (2 17) (233) (25,) (271) (299)
11055 mm 11435 mm 12020 mm 12550 mm 13350 mm
F Maximum digging reach
(363) (376) (395) (412) (4310)
C Maximum digging reach at 10830 mm 11220 mm 11810 mm 12355 mm 13165 mm
ground (356) (3610) (389) (406) (432)
4750 mm 4730 mm 4660 mm 4710 mm 4785 mm
H Minimum swing radius
(157) (156) (153) (155) (158)
22500 kg 22400 kg 22600 kg 22400 kg 22300 kg
Bucket digging force
(49,600 lb) (49,380 lb) (49,820 lb) (49,380 lb) (49,160 lb)
25800 kg 22900 kg 19300 kg 17300 kg 15200 kg
Arm crowd force
(56,880 lb) (50,490 lb) (42,550 lb) (38,140 lb) (33,510 lb)
01-9
MACHINE SPECIFICATIONS
PC4OOLC-5
Machine Model PC4OOLC-5
Operating Weight (with operator) (kg) 42550
Bucket Capacity (m3) 1.63
Maximum digging depth (mm) 7760

g
Vertical wall depth (mm) 6850
3
Maximum digging reach (mm) 12020
4
E Maximum digging reach at ground level (mm) 11810
; 5 Maximum digging height 10920
3 (mm)
% Maximum dumping height (mm) 7570
i Maximum digging force (when using power max.)(kg) 21000 (22600)

n
Continued swing speed (rpm) 9.3
Swing maximum slope angle (deg.) 19
Travel speed (km/h) Lo: 3.1, Hi: 5.5
Gradeability (deg.) 35
Ground pressure (standard triple-shoe) (kg/cm*) 0.6 (750mm)
Overall length (at transportation) (mm) 11700

Overall width (mm) 3480
Track width (mm) 3480
Overall height (at transportation) (mm) 3450
Height of cab (mm) 3195
x Ground clearance of counterweight (mm) 1315
E
Minimum ground clearance (mm) 555
3
6 Tail swing radius (mm) 3430
Minimum swing radius at front end (mm) 4660
Arm height at minimum swing radius (mm) 9220
Length of track on ground (mm) 4340
Track gauge (mm) 2740
Machine cab height (mm) 2695
01-10
Machine Model PC4OOLC5
Engine model CUMMINS LTA 10
Type 4-cycle, in-line, water cooled, direct injection

type diesel engine with turbocharger and
aftercooler
No. of cylinder - bore x stroke (mm) 6 - 125 x 136
Total displacement (cc) 10000

Flywheel horsepower (HP/rpm) 276/2000
Y
B Maximum torque (kgm/rpm) 121/1400
3
High idling speed (rpm) 2200
Low idling speed (rpm) 750 + 50
Starting motor 24V
Alternator 24V, 55A
Battery 12V 170Ah x 2

Type of radiator core cwx-4
$ Carrier roller (one side) 8
n9 Track roller (one side) 8

20
Track shoe Built-up triple grouser
% Type, number Variable displacement piston type x 2

z Gear type x 1
0
2 Delivery (P/min) Piston type: 315 x 2
d Gear type: 92
: Set pressure (kg/cm*) Piston type: 325 (350)
Gear type: 30
d Type, number 4-spool type and 5-spool type

3
%
E Control lever operation Hydraulic assist type
t; 8g
u
i
2
%
0 Travel motor Piston type (with brake valve, parking brake)
z! x2
% 68 Swing motor
% Piston type (with safety valve, parking brake) x
1
Hydraulic cylinder Double acting piston
Hydraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler Air cooled
01-11
WEIGHT TABLE
A
This weight table is a guide for use when transporting or handling components.
Machine Model PC3OOLC-5 PC4OOLC-5
Serial Numbers A30001 and up A40001 and up
Engine assembly 1060 1470

l Engine 760 1170
l Damper 20 20
l Hydraulic pump 280 280
Radiator and oil cooler assembly 152 180
Hydraulic tank assembly (without hydraulic oil) 224 290
Fuel tank (without fuel) 175 190
Revolving frame 2540 3090
Operators cab 238 238
Operators seat 35 35
Counterweight 5420 8470
Swing machinery 440 620
Control valve assembly 236 240
Swing motor assembly 125.5 130
Travel motor assembly 239x2 290x2
Center swivel joint 43 43
Track frame assembly 7230 10560

l Track frame 4312 6600
l Swing circle assembly 430 585
l Idler 166x2 235x2
l Idler cushion 257x2 365x2
0 Carrier roller 31x4 31x4
l Track roller 52x16 73x16
l Final drive 426x2 560x2
01-12
Machine Model PC3OOLC-5 PC4OOLC-5
1
Serial Numbers A30001 and up A40001 and up
Track shoe assembly

Triple shoe (600 mm) 3730 4760
Wide triple-shoe (800 mm) 4455 5600
Wide triple-shoe (850 mm) 4635
Wide triple-shoe (900 mm) 6110
Boom assembly 2357 2990
Arm assembly 981 1234
Bucket assembly 1014 1300
Boom cylinder assembly 293x2 400x2
Arm cylinder assembly 425 580
Bucket cylinder assembly 263 345
Link (large) assembly 320 397
Boom pin 76+15x2+56+17+42 93+20x2+73+24+54
Arm pin 13+17 17+24
Bucket pin 30x2 34x2
Link pin 27x2 38x2
01-13
PC3OOLC
It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of
quality of the lubricant must remain with the supplier of the lubricant. When in doubt, consult your
Distributor.
The lubricants specified for this machine are shown below.
AMBIENT TEMPERATURE CAPACITY

(IND OF
RESERVOIR .22 -4 14 32 50 68 86 104F
FLUID Specified Refill
.30 -20 -10 0 10 20 30 40C
18.9 4 18.9 P
I
5.0 US gal 5.0 US gal
Engine oil pan 4.2 UK gal 4.2 UK gal
23 4 22.5 4
Swing machinery case 5.1 UK gal 4.9 UK gal
8.OP 7.4 Q
2.1 US gal 2 US gal
Final drive case 1.8 UK gal 1.6 UK gal
(each)
ingine oil
1.24 0
Damper case 0.33 US gal
0.27 UK gal
370 P 195 P
Hydraulic system 81.4 UK gal 42.9 UK gal
1 ,I\
0.2 Multi-purpose lithium grease with
All lubrication fittings Grease Fill as instructed
3% molybdenum disulfide
Fuel tank jiesel fue F
30 Q
7.9 US gal
Cooling system Coolant See COOLANT SPECIFICATIONS
6.6 UK gal
g ASTM D975 No. 1
01-14
PC4OOLC
It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of
quality of the lubricant must remain with the supplier of the lubricant. When in doubt, consult your
Distributor.
The lubricants specified for this machine are shown below.
AMBIENT TEMPERATURE CAPACITY

(IND OF
RESERVOIR 22 -4 14 32 50 68 86 104F
FLUID gpecified Refill
30 -20 -10 0 10 20 30 40C
T
38 P 38 4
1IO US gal 10 US gal
Engine oil pan and ai.3 UK gal 8.3 UK gal
filters
24 4 22 Q
i.3 US gal 5.8 US gal
Swing machinery casQ I.3 UK gal 4.8 UK gal
11.5 P 11 P
i.0US gal 2.9 US gal
Final drive case 1.5 UK gal 2.4 UK gal
(each)
ngine oil
1.07 Q
28 US gal
Damper case
23 UK gal
4604 255 Q
22 US gal 67.4 US gal
Hydraulic system 02 UK gal 56.2 UK gal
Grease
0.4 Multi-purpose lithium grease with
Fill as instructed
All lubrication fittings
3% molybdenum disulfide
550 Q
I
Fuel tank riesel fue 145 US gal
121 UK gal
34 4
9 US gal
Cooling system Coolant See COOLANT SPECIFICATIONS 7.5 UK gal
g ASTM D975 No. 1
01-15
ENGINE OIL SPECIFICATIONS
Normal Operation
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are
critical factors in maintaining engine performance and durability.
SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance
classification of CE or CF-4 is recommended.
NOTE: CD or CD/SF oils may be used in areas where CE or CF-4 oil is not yet available.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil
consumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of
1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine.
Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the
appropriate oil categories; the lower half may contain words to describe oil energy conserving
features. The center section identifies the SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and
improve engine cranking in cold temperatures while maintaining lubrication at high operating
temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the
previous chart for oil viscosity recommendations for extreme climates.
Limited use of low viscosity oils, such as SAE low-30 may be used for easier starting and providing
sufficient oil flow at ambient temperatures below -5C (+23F). However, continuous use of low
viscosity oils can decrease engine life due to wear.
Special break-in lubricating oils are not recommended for a new or rebuilt engine. Use the same type
of oil during the break-in as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the
E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines. The data book
may be ordered from the Engine Manufacturers Association, 401 North Michigan, Chicago, IL U.S.A.
60611. The telephone number is (312) 644-6610.
Arctic Operation
If an engine is operated in ambient temperatures consistently below -23C (-10F) and there are no
provisions to keep the engine warm when it is not in operation, use a synthetic API performance
classification CE or CF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-
30.
The oil supplier must be responsible for meeting the performance service specifications.
NOTICE:
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil
change intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
GREASE SPECIFICATIONS
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
01-16
DIESEL FUEL SPECIFICATIONS
A WARNING
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
NOTICE:
Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel
be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to
both the injection pump and nozzles.
For normal service above -12C (+lOF), the use of ASTM Grade No. 2-D diesel fuel with a minimum
Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine
performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed
in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke.
At operating temperatures below -12C (+iOF), use ASTM Grade No. 1-D diesel fuel. The use of lighter
fuels can reduce fuel economy.
Where a winterized blend of Grade No. 2-D and No. 1 -D fuels is available, it may be substituted for Grade
No. 1-D fuel. However, it is the suppliers responsibility to provide the fuel for the anticipated ambient
temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected
fuel temperature. Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
COOLANT SPECIFICATIONS
General
Selection and maintenance of the engine coolant is important to long engine life. The following information
provides recommendations for selecting the engine coolant and maintaining the coolant inhibitors.
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental
coolant additives. Supplemental coolant additive recommendations are included in the section entitled
Inhibitors/Conditioners. The coolant mixture must be drained and replaced at the specified service
interval shown in 23. SCHEDULED MAINTENANCE GUIDE on page 3-28 of the Operators Manual, or
every two years of operation, whichever comes first.
Water
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and
inhibited water must meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale
deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness)
above the specified amount will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize
sludge deposits, scale deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To
determine if local water supplies meet these standards, water samples can be tested by water treatment
laboratories. Softened water that is prepared using common salt (sodium chloride) contains excessive
amounts of chlorides and should not be used.
01-17
NOTICE:
Never use water alone in the cooling system because corrosion will occur.
Antifreeze
In climates where the temperature is above -37C (-34F), use a coolant mixture that contains 50 percent
antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by
lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent
antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent
antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates.
Antifreeze concentrations between 68% and 100% actually have a higher freezing point than a 68%
antifreeze concentration and should not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1%
anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel
(hydro-gel). This gel formation can occur when the cooling system contains an over concentration of high
silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze
because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be
added to maintain corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
NOTICE:
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the
protection against freezing. Antifreeze containing sealer or anti-leak additives should NOT be
used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling
system.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has
sufficient protection against freezing.
The following table shows the approximate percentage of antifreeze solution required for various
temperatures.
Percentage of
Approximate Antifreeze Specific
Freezing Concentration Gravity at
Point by Volume 16 C (SO F)
0C 0 1 .ooo
-7C [+;;I;{ 15 1.025
-12C (:: (;I;/ 25 1.040
-18C 33 1.053
-23C [-;;I ;; 40 1.062
-29C - 45 1.070
-34C 48 1.074
-40C If;:;]
- 53 1.080
-46C [-;;I;/ 56 1.083
-51C - 59 1.088
-57C 62 1.092
-62C [-;$;I
- 65 1.095
67 1.097
68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor DCA4, to protect
the engine cooling system.
01-18
inhibitors/Conditioners
1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal
operation. If the inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes
corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat
transfer. Cooling system conditioners which contain these inhibitors must be added to maintain
corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned
water is still the best coolant.
4. DCA4 is recommended to inhibit corrosion in the cooling system for the following reasons:
l Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over
concentration occurs.
l Provides engine protection in the following areas:

- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE OF COOLING SYSTEM INHIBITORS
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits
and corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in
the Operators Manual with a service DCA4 filter.
Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant
can be correctly charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate
listed in the table entitled, DCA4 Unit Guide.
If coolant is added between drain intervals, additional DCA4 will be required.
COOLANT TESTING FOR CONDITIONER CONCENTRATION
When the cooling system is maintained as recommended, the conditioner concentration should be
satisfactory. The DCA4 concentration must not fall below 1.0 unit per 3.8 P (1 US gal) or exceed 2 units
per 3.8 P (1 US gal) of coolant. The only accurate method for testing chemical concentrations in coolant
with mixed chemical compounds is a laboratory analysis. For this reason, the coolant inhibitor should be
maintained.
NOTICE:
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling
system components. Over concentration can cause formation of gel that can cause restriction,
plugging of passages and overheating.
REPLENISHING COOLANT CONDITIONER
Install a precharge DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss
occurs. Install a service DCA4 filter as specified in 23. MAINTENANCE SCHEDULE CHART on page 3-28
of the Operators Manual. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 P
(1 US gal) of antifreeze.
NOTICE:
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is
currently no test kit available to measure concentration levels with mixed chemical solutions.
01-19
DCA4 UNIT MAINTENANCE GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from
corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine.
Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant
additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter [one
unit per U.S. gallon] of coolant (initial charge). Maintain the correct DCA4 concentration by changing the
service coolant filter at each engine oil and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant
additives. Use the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be
drained and replaced as defined under General.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling
system capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4.
If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA
concentration level anytime make-up coolant is added to the system. The DCA4 concentration must not
fall below 0.13 units per liter or exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per
U.S. gallon].
DCA4 Unit Guide
Fleetguard DCA4
Part No. Units
DCA4 Coolant Filter

WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCAGOL 4 (1 Pint)
DCA80L 1760 (55 US gal)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters
System Capacity Precharge Filter Service Filter

(See NOTE 1) (See NOTE 3)
Liters Gallons
19-26 5-7 WF-2072 WF-2070
30-38 8-10 WF-2073 WF-2071
42-57 11-15 WF-2074 WF-2071
61-76 16-20 WF-2075 WF-2071
80-l 14 21-30 WF-2076 WF-2072
118-190 31-50 (See NOTE 2) WF-2073
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the
DCA4 concentration between 1.0 and 2.0 units per 3.8 0 (1 US gal).
01-20
NOTICE:
When performing service which requires draining the cooling system, discard the coolant.
Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in
premature failure of cooling system components.
NOTE 2 - To precharge cooling systems larger than 114 Q(30 gal) do the following:
0 Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 Q) cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units
l The answer represents the additional units required to precharge the cooling system. Four
bottles of powder, part number DCA95, will provide a sufficient amount of DCA4 units (80) to
precharge the example cooling system.
0 Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling
system.
Maintain a nominal concentration of 1 .O DCA4 unit per 3.8 Q(1 US gal) of coolant in the system. Less than
0.5 unit per 3.8 Q(1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8
Q (1 US gal) indicates an over-concentrated coolant solution.
To check the DCA4 concentration level, use the Fleetguard coolant test kit, CC2626. Instructions are
included with the test kit.
DCA4 Unit Concentration Guide

Number of Solution A Drops Coolant Condition Action Required
to Cause Color Change
0 - 10 Drops Extremely under-concentrated - Initially charge the system to a
less than 0.4 DCA4 units per minimum of 1.0 DCA4 unit per
3.8 Q (1 US gal) 3.8 Q (1 US gal).
11 - 16 Drops Marginally under-concentrated Add DCA4 liquid units to

- 0.45 to 0.8 DCA4 units per 3.8 maintain 1 .O DCA4 unit per 3.8
Q (1 US gal) 4 (1 US gal) minimum or
change the DCA 4 coolant
filter.
17 - 25 Drops Acceptable - 0.85 to 1.3 DCA4 None.

units per 3.8 Q (1 US gal)
26 - 35 Drops Highly acceptable - 1.35 to 2.0 None.

DCA4 units per 3.8 Q (1 US gal)
36 - 55 Drops Marginally over-concentrated - Review maintenance practice.

2.1 to 3.3 DCA4 units per 3.8 Q
(1 US gal)
Over 55 Drops Extremely over-concentrated Drain 50% of the coolant and

replace with water antifreeze
mixture. Retest the system for
correct DCA4 unit
concentration.
01-21
Co-22
10 STRUCTURE AND FUNCTION
ENGINE RELATED PARTS AND ENGINE TRACK FRAME AND RECOIL SPRING
MOUNT PC4OOLC . . . . . . . . . . . . . . . . . . . . . . lo-18
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 1o-4
IDLER
ENGINE RELATED PARTS AND ENGINE PCBOOLC . . . . . . . , . . . . . . . . . . . . . . 10-19
MOUNT
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . . I o-5 IDLER
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1O-20
RADIATOR AND OIL COOLER
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 1O-6 TRACKROLLER . . . . . . . . . . . . . . . . . 10-21
RADIATOR AND OIL COOLER CARRIER ROLLER . . . . . . . . . . . . . . . . 10-21

PC4OOLC . . . . . . . . . . . . . . . . . . * . . . * 10-7
TRACK SHOE
FUEL TANK AND PIPING PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-22
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 1O-8
TRACK SHOE
FUEL TANK AND PIPING PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1O-23
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . . 1o-9
HYDRAULIC PIPING . . . . . . . . . . . . . . 1O-25
POWER TRAIN . . . . . . . . . . . . . . . . . . lo-10
HYDRAULIC CIRCUIT DIAGRAM . . . . . . 1O-27
FINAL DRIVE
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 1 HYDRAULIC TANK
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-29
FINAL DRIVE
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 2 HYDRAULIC TANK
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1O-30
SWING CIRCLE
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 10-l 3 OLSS
(Open Center Load Sensing System) . . 10-31
SWING CIRCLE
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 10-14 HYDRAULIC PUMP . . . . . . . . . . . . . . . 1o-33
SWING MACHINERY LINE OIL FILTER . . . . . . . . . . . . . . . . . 1O-52

PC3OOLC . . . . . . . . . . . . . . . . . . . . . 10-15
CONTROL VALVE . . . . . . . . . . . . . . . . 1o-54
SWING MACHINERY
PC4OOLC . . . . . . . . . . . . . . . . . . . . . lo-16 SWING MOTOR . . . . . . . . . . . . . . . . . . 1O-66
TRACK FRAME AND RECOIL SPRING CENTER SWIVEL JOINT. . . . . . . . . . . . 1O-69

PC300LC . . . . . . . . . . . . . . . . . . . . . 10-17
10-I
TRAVEL MOTOR
PC300LC . . . . . . . . . . . . . . . . . . . . . . 1 O-70
TRAVEL MOTOR
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1 O-72
VALVE CONTROL . . . . . . . . . . . . . . . . lo-79
PPC VALVE . . . . . . . . . . . . . . . . . . . . . 1 O-80
ACCUMULATOR . . . . . . . . . . . . . . . . . 1 O-86
SAFETY LOCK VALVE . . . . . . . . . . . . . lo-86
SOLENOID VALVE ASSEMBLY . . . . . . . lo-87
SHUTTLE VALVE . . . . . . . . . . . . . . . . . lo-91
BOOM HOLDING VALVE . . . . . . . . . . . lo-92
HYDRAULIC CYLINDER . . . . . . . . . . . . lo-95
WORK EQUIPMENT . . . . . . . . . . . . . . . lo-98
ELECTRICAL WIRING DIAGRAM

PC3OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 00

PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 02
ELECTRICAL CIRCUIT DIAGRAM

PC300LC . . . . . . . . . . . . . . . . . . . . . . 1o-1 05

PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 1o-1 09
ENGINE CONTROL SYSTEM

PC300LC (S/N A30001 THRU A301 10, A301 12
ANDA30114THRUA30116 . . . . . . . . . . . . . . 10-113

PC300LC (S/N A30111, A30113 AND
A30117AND UP . . . . . . . . . . . . . . . . . 10-113-l

PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 10-l 14
PEMC SYSTEM . . . . . . . . . . . . . . . . . . lo-124
EMACC (ELECTRONIC MONITOR

AND CONTROL CONSOLE) . . . . . . . . . 1O-l 53
1 o-2
0
1 o-3
ENGINE RELATED PARTS AND ENGINE MOUNT
PC3OOLC
r-1
-.
T-----
-7
:II
I
II
B-B
6 c-c
A-A
12ADOOll
1. Front engine mount 4. Air cleaner

2. Engine 5. Muffler
3. Rear engine mount 6. Damper
1 o-4
ENGINE RELATED PARTS AND ENGINE MOUNT
PC4OOLC
I
1
I
3
B-B
View2 u
12Amo12
1. Front engine mount 4. Air cleaner

2. Engine 5. Muffler
3. Rear engine mount 6. Damper
1 o-5
PC3OOLC
J
06AH0014
1. Oil cooler 4. Sub-tank SPECIFICATIONS

2. Radiator 5. Radiator outlet hose Radiator: CWX-3
3. Radiator inlet hose 6. Fan guard Oil cooler: SF-3
1 O-6
PC4OOLC
___kI ji 11, __ 1 ,(A

- . - -
06AHOOlS
1. Oil cooler 4. Sub-tank SPECIFICATIONS

2. Radiator 5. Radiator outlet hose Radiator: CWX-4
3. Radiator inlet hose 6. Fan guard Oil cooler: SF-4
1o-7
FUEL TANK AND PIPING
PC3OOLC
1 2
(--
-,
> \. I,
12BD0003
1. Drain valve 4. Cap

2. Fuel level sensor 5. Sight gauge
3. Tank
1 O-8
FUEL TANK AND PIPING
PC4OOLC
/
6
1. Drain valve 4. Cap

2. Fuel level sensor 5. Sight gauge
3. Tank 6. Fuel filter
1 o-9
POWER TRAIN
1'2 205FO5008
1. Idler 7. Hydraulic pump

2. Center swivel joint 8. Swing brake solenoid valve
3. Control valve assembly 9. Travel speed solenoid valve
4. Final drive 10. Swing motor
5. Travel motor 11. Swing machinery
6. Engine 12. Swing circle
IO-10
FINAL DRIVE
PC3OOLC
k 1. Level plug
2. Drain plug
3. No. 1 sun gear (13 teeth)
5. Cover
6. No. 2 plant gear (30 teeth)
7. No. 2 ring gear (80 teeth)
a. Spacer
9. No. 1 ring gear (80 teeth)
10. No.1 planet gear (33 teeth)
11. Sprocket
12. Floating seal
13. Travel motor
14. Hub
15. Retainer
16. No. 1 planetary carrier
SPECIFICATIONS
Reduction ratio:
_ (?!$?) x (y) + l= -36.275
,13
Section A - A 207FO5008
IO-11
FINAL DRIVE
PC4OOLC
1. Level plug
2. Drain plug
3. No. 2 planet gear (34 teeth)
,1 6. No. 2 planetary carrier
7. Cover
9. Retainer
10. Sprocket
11. Floating seal
12. Travel motor
13. Hub
14. No. 1 plant gear (32 teeth)
16. Spacer
SPECIFICATIONS
Reduction ratio:
- (9) x (J!z$) + l= -44.588
8 9 lo 11
Section A - A 208FO5008
SWING CIRCLE
PC3OOLC
Section A - A
207FO5009
1. Swing circle outer race SPECIFICATIONS

2. Ball bearing Reduction ratio:
3. Swing circle inner race (90 teeth)
a. Outer race soft zone S 90 = 6 923
b. Inner race soft zone S 13 .
Grease volume: 354
IO-13
SWING CIRCLE
PC4OOLC
Section B - B
Section A - A
208FO5009
1. Swing circle outer race SPECIFICATIONS

2. Ball bearing Reduction ratio:
3. Swing circle inner race (84 teeth)
a. Outer race soft zone S 84 = 6 462
13 .
b. Inner race soft zone S
Grease volume: 351
IO-14
SWING MACHINERY
PC3OOLC
1.Swing pinion (13 teeth)

2.Cover
3.Case
4.Planetary carrier
5Ring gear (79 teeth)
G.Bearing holder
7.Drive gear (17 teeth)
8.Swing motor
S.Bearing holder
1O.Cover
ll.Driven gear (63 teeth)
12.Planet gear (32 teeth)
13Sun gear (14 teeth)
14.Drain valve
15Breather
16.Level gauge
SPECIFICATIONS
Reduction ratio:
63
24.618
17
9
8
16
Section B - B
Section A- A 207FO5010
10-15
SWING MACHINERY
PC4OOLC
1.Swing pinion (13 teeth)

2.Cover
3.Case
4.Planetary carrier
5.Ring gear (84 teeth)
G.Bearing holder
7.Drive gear (17 teeth)
8.Swing motor
S.Bearing holder
1O.Cover
11 .Driven gear (86 teeth)
7A 12.Planet gear (34 teeth)

13.Sun gear (15 teeth)
14.Drain valve
15Breather
16.Level gauge
SPECIFICATIONS
Reduction ratio:
86 x (84+15
7) = 35.475
16
18
Section B - B
208FO50
Section A - A
lo-16
TRACK FRAME AND RECOIL SPRING
PC3OOLC
207FO5011
1. Idler Depending on the model, the dimensions and

2. Track frame number of track rollers and center guards is
3. Carrier roller different, but the basic structure is the same. The
4. Final drive above diagram is typical
5. Track roller f Number of track rollers
6. Track shoe
PC3OOLC: 8 (each side)
7. Center guard
8. Recoil spring * Number of center guards
9. Front guard PCBOOLC 3 (each side)
IO-17
PC400LC
208FO5011
1. Idler Depending on the model, the dimensions and

2. Track frame number of track rollers and center guards is
3. Carrier roller different, but the basic structure is the same. The
4. Final drive above diagram is typical
5. Track roller * Number of track rollers
6. Track shoe
PC4OOLC: 8 (each side)
7. Center guard
8. Recoil spring * Number of center guards
9. Front guard PC4OOLC 3 (each side)
IO-18
IDLER
PC3OOLC
---
'6
_A-1-A
VII ---7
I Ii
-
I
207FO5012
1. Lubricating plug 4. Floating seal

2. Support 5. Idler shaft
3. Idler 6. Bushing
10-19
IDLER
PC4OOLC
---~~--------_______7
-------------------
1
208FO5012
1. Lubricating plug 4. Floating seal

2. Support 5. Idler shaft
3. Idler 6. Bushing
1 O-20
TRACK ROLLER
1 2 3 4 5
1. Lubricating plug
2. Collar
3. Floating seal
4. Track roller
5. Bushing
6. Shaft
_- -
I- -1
I- - - _I
208FO5013
CARRIER ROLLER
.I
I. Shaft
2. Collar
n
a. Floating seal
4. Carrier roller
5. Ring
6. Cover
7. Lubricating plug
I-
208FO5014
IO-21
TRACK SHOE
PC3OOLC
1. Shoe 8. Link
2. Regular pin 9. Shoe bolt
3. Regular dust seal 10. Shoe nut
4. Regular bushing STANDARD SHOE SPECIFICATIONS
5. Master pin l 700mm triple-shoe
6. Master dust seal
l Link pitch: 203mm
7. Master bushing
l Number of shoes: 100
1 o-22
TRACK SHOE
PCIQOOLC
208FO5015
1. Shoe 8. Link
2. Master bushing 9. Shoe bolt
3. Master dust seal 10. Shoe nut
4. Master pin STANDARD SHOE SPECIFICATIONS
5. Regular bushing
l 700mm triple-shoe
6. Regular dust seal
7. Regular pin l Link pitch: 216mm
l Number of shoes: 104
1 O-23
SELECTION OF TRACK SHOE
l Select the most suitable track shoe from the following table
PC3OOLC PC4OOLC
Specification Category Specification Category
600 mm 600 mm
A A
triple shoe triple shoe
700 mm 700 mm
B B
triple shoe triple shoe
800 mm
triple shoe
l Category
Cate- Use Precautions when using

gory
A Rocky ground, l Travel in Lo when traveling on rough ground with obstacles such
normal river soil as large boulders and fallen trees.
B Normal soil, soft l Cannot be used on rough ground where there are large obsta-
land cles such as boulders and fallen trees.
l Travel in Hi speed only on flat ground and when it is impossible
to avoid traveling over obstacles. Lower the travel speed to
approx. half of Lo speed.
C Extremely soft l Use only for ground where A and B sink and are impossible
ground (swampy to use.
ground) l Cannot be used on rough ground where there are large obsta-
cles such as boulders and fallen trees.
l Travel in Hi speed only on flat ground and when it is impossible
to avoid traveling over obstacles. Lower the travel speed to
approx. half of Lo speed.
D Paved surface l The shoes are flat, so they have low gradeability.
* Categories B and C are wide shoe, so * When selecting the shoe width, select the
there are restrictions on their use. Therefore, narrowest shoe possible within the range that
before using, check the restrictions and con- will give no problem with flotation and ground
sider carefully the conditions of use before pressure.
recommending a suitable shoe width. If nec- If a wider shoe than necessary is used, there
essary, give the customer guidance in their will be a large load on the shoe and this may
use. lead to bending of the shoe, cracking of the
links, breakage of the pins, loosening of the
shoe bolts or other problems.
1 O-24
Foldout 1
HYDRAULIC PIPING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Accumulator
6. R.H. travel motor
7. Control valve
a. Oil cooler
9. Hydraulic filter
(PC3OOLC, 1: PC4OOLC, 2)
10. Hydraulic tank
11. Hydraulic pump
.12 12. Line oil filter
13. L.H. travel motor
14. Solenoid valve assembly
15. Arm shuttle valve
16. Swing shuttle valve
17. Boom, bucket shuttle valve
la. Arm half flow solenoid valve :
19. Safety lock valve I
20. Travel shuttle valve
21. L.H. PPC valve
22. Travel PPC valve
23. R.H. PPC valve
24. Center swivel joint i
25. Boom holding valve
i6
207FO5015
1 o-25
1 O-26
HYDRAULIC CIRCUIT DIAGRAM Foldout 2
i I
I
Arm Cylinder
] (pcmo~c
$160 x $110 - 1685)
i/ (PC~OOLC $185 x 4120 - 1820)
J
I
I
I'
I
I
I
I
I
I
I
1;
II
II
I
I
I
I
I
I R.H. travel motor
I
I PC3OOLC: HMV280ADT 175/26Occ/rev
PC4OOLC: HMV355ADT 1911355cclrev
-
Regulator switching
I pressure: 8 kg/cm
I
1
Iili
Ill
I I,
III
)lII
,111
Work equipment
(II . swing oil
pressure switch
fil!
Cracking
pressure: KMF160AB2 160.7 cc/rev
4.3 kg/cm2 (R.H. swingl-TL]
1
\
< <
I
----- j-_--__---__---___--_---_
__---------
1 O-27
1 O-28
HYDRAULIC TANK
PC3OOLC
Section B - B
Section A - A
2OJFO5017
1. Bypass valve SPECIFICATIONS

2. Bypass filter Tank capacity: 3150
3. Filter element Oil amount: 1954
4. Check valve
Breather
5. Breather
6. Cap Relief set pressure: 0.420.07 kg/cm2
7. Hydraulic tank Suction set pressure:0.04*0.01 kg/cm2
8. Hydraulic oil level sensor Bypass valve set pressure: 1.05 20.2 kg/cm2
9. Suction strainer Check valve pressure: 1.75 kg/cm2
10. Sight gauge
11. Filter case
1 o-29
HYDRAULIC TANK
PC4OOLC
Section B - B
Section A - A
-10
208FO5016
1. Bypass valve SPECIFICATIONS

2. Bypass filter Tank capacity: 3586
3. Filter element
Oil amount: 2558
4. Check valve
Breather
5. Breather
6. Cap Relief set pressure: 0.420.07 kg/cm2
7. Hydraulic oil level sensor Suction set pressure:0.04t0.01 kg/cm2
8. Suction strainer Bypass valve set pressure: 1.0520.2 kg/cm2
9. Hydraulic tank
Check valve pressure: 2.50 kg/cm2
10. Sight gauge
11. Filter case
10-30
OLSS (Open Center Load Sensing System)
Motor
Cylinder
I
0
F205C5006-1
OLSS (Open Center Load Sensing System) is an

energy-saved system to reduce the fuel con-
sumption by means of the swash plate angle
(delivery) of the variable-displacement swash-
plate type piston pump.
Therefore this system acts to reduce the hydrau-
lic loss during operation, to increase the fine
control and to control the pump delivery.
1 o-31
1. EFFECTIVE USE OF ENGINE
HORSEPOWER
IN H mode, the set speed of the engine and
the actual speed of the engine are always
detected. As a result, even if the load chang- Main pump delivery
es during operation, the discharge amount
(swash plate angle) of the pump is controlled
so that the load on the engine (engine speed)
is always maintained constant, thus ensuring
effective use of engine horsepower. (Engine
speed, oil pressure sensing control)
Pump delivery volume Q
205F05121A
(Note) H.0: Heavy duty operation mode,

G.0: General operation mode.
F.0: Finishing operation mode,
L.0: Lifting operation mode
2. CUT-OFF CONTROL
0 The cut-off control is a function to reduce Loss when there is no cut-off
relief loss during operations. If the load
-(\I
increases, the discharge pressure of the main
pump is increased; if the load comes close to
the relief pressure, the discharge volume is cut-off
decreased.
l This function is carried out with the CO valve.
For details of the operation of the CO valve,
see HYDRAULIC PUMP.
1
Pump discharge volume (Q/min.)

F205C5008
3. FLOW CONTROL
PNC (pump neutral control)
l When the control levers are at neutral, the
pump discharge volume is kept to the mini-
mum to reduce the wasteful flow of oil when
the control valve is at neutral.
PFC (pump fine control)
l When the lever is operated, the neccesary
flow is ordered to the pump based on the
flow command that corresponds with the
lever travel. This reduces the wasteful flow of
Lever travel (mm)
oil that occurs during fine control.
205FO5 145
l At the same time, by increasing the pump
discharge pressure to the optimum value
according to the lever travel, the fine control
performance is improve.
l This function is carried out with the NC valve
and jet sensor.
For details of the operation of the NC valve
and jet sensor, see HYDRAULIC PUMP.
1 O-32
HYDRAULIC PUMP
View Z
a. Jet sensor output pressure Pd IN port 1. TVC valve

b. CO cancel pressure PSO IN port 2. Front CO*NC valve
c. Jet sensor output pressure Pt IN port 3. Front servo valve
d. Jet sensor output pressure Pd IN port 4. Rear CO*NC valve
e. CO cancel pressure PSO IN port 5. Rear servo valve
f. Jet sensor output pressure Pt IN port 6. Rear main pump
7. Charging pump
8. Front main pump
9. Charging pump relief valve
1 o-33
1. FRONT MAIN PUMP AND REAR MAIN PUMP (HPV 160+160)
b C d
View Z
I m n
\ I I /
View X View Y
207FO5019
a. Suction PS port i. Front main pump output pressure Ppl port

b. Front main pump drain Pdl port j- Charging pump pressure PCI port
c.. Charging pump pressure k. Servo valve output pressure PclB port
- . - PC IN port
d. Rear main pump dram Pd2 port I. Servo valve output pressure Pc2B port
e. Front main pump discharge Ppl port m. Charging pump pressure Pc2 port
f. Rear main pump discharge Pp2 port n. Rear main pump output pressure Pp2 port
g. Servo valve output pressure PclA port 0. Servo valve output pressure Pc2A port
h. Rear main pump output pressure Pp2 port
1 o-34
Section C - C
Section B - B
207FO5020
1. Drive gear (61 teeth) 9. Front piston 17. Rear cylinder

2. Driven gear (42 teeth) 10. Front cylinder 18. Rear piston
3. Shaft 11. Front valve plate 19. Rear rocker cam
4. Coupling 12. Front end cap 20. Rear pump case
5. Front drive shaft 13. Impeller pump 21. Rear cradle
6. Front cradle 14. Coupling 22. Rear drive shaft
7. Front pump case 15. Rear end cap 23. Servo piston
8. Front rocker cam 16. Rear valve plate
1 o-35
2. SERVO VALVE
f The drawing shows the servo valve for front main pump
Section A- A
Section B- B Section C - C
Section D- D Section E- E Section F- F Section G - G

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

b. Servo actuator port i. CO@NC valve output pressure Pin IN port
c. Servo actuator port j. Charging pump pressure Ppo OUT port
d. NC valve output pressure Pi pick-up port k. Rear main pump output pressure Pp2 OUT
e. Servo valve drain Pdr OUT port Port
f. Rear main pump output pressure Pp2 IN port I. Front main pump output pressure Ppi OUT
g. Front main pump output pressure Ppl IN port port
1 O-36
19
/iI/ 18 17 16
Section A - A
\:I\
15 14 13 12
205FO5021
1. Lock nut 8. Pin 15. Guide spool

2. Cover 9. Control piston 16. Spring
3. Plug 10. Lock nut 17. Plug
4. Spring 11. Plug 18. Cover
5. Body 12. Lock nut 19. Lock nut
6. Spring 13. Cover
7. Arm 14. Sleeve
FUNCTION
u
E
Discharge volumes Ql and Q2 of main pumps
PPI and PP~ are controlled individually by their
own servo valve.
The relationship between pump discharge volume
Q and input signal Pi sent to the servo valve is %
as shown in the graph on the right. Q changes in
z
proportion to Pi.
I? /
/
kc/rev) /
CO-NC valve output pressure PI (kg/cm)
OZCHOOOI
IO-37
OPERATION
1) Operation for increasing pump discharges (rocker cam angle changes to the large)
I I
I nn ; PC
205F05023A
l Charging pump pressure PC is sent to port l The movement of guide spool (15) closes
a. port a and port d and connects port d with
Signal pressure Pi from the NC valve is sent drain chamber e. As a result, servo piston
from port b to chamber c. chamber f is also connected to chamber e
l As signal pressure Pi rises, the pressure in through port g and port d.
chamber C pushes control piston (9) to the At the same time, port a and port h are con-
left, in the direction of the arrow. The piston nected and the flow passes through port i to
stops in a position where it is balanced with servo piston chamber j to push servo piston
the force of springs (4) and (6). (20) to the left in the direction of the arrow.
At the same time, arm (7) uses servo piston The rocker cam angle of the main piston
(20) as a fulcrum and moves to the left in the pump becomes larger and the pump dis-
same way as control piston (9) while fluctuat- charge volume increases.
ing moves guide spool (15) to the left. l Because of the movement of servo piston
(20), arm (7) rotates clockwise around pin
(8), moves guide spool (15) to the right and
closes port a, port d and port h so the dis-
charge volume increases only by an amount
corresponding to signal pressure Pi.
1 O-38
2) Operation for decreasing pump discharges (rocker cam angle changes to the small)
jig
II
.:::::::
..\.. Pi
j:;.j:j
:.:.:.:.
::::::
c II::::::: I NC valve
205F05024A
l When signal pressure Pi drops, control piston At the same time, port a and port d are
(9) moves to the right in the direction of the connected and the flow passes through port
arrow to a point where the hydraulic pressure g to servo piston chamber f to push servo
of chamber c is in balance with the force of piston (20) to the right in the direction of the
springs (4) and (6). arrow. The rocker cam angle of the main
At the same time, arm (7) uses servo piston piston pump becomes smaller and the pump
(20) as a fulcrum, moves to the right in the discharge volume decreases.
same way as control piston (9) and while 0 Because of the movement of servo piston
fluctuating, moves guide spool (15) to the (20), arm (7) rotates counterclockwise around
right. pin (8), moves guide spool (15) to the left
0 The movement of guide spool (15) closes and closes port a, port d, and port h so the
port a and port h and connects port h with discharge volume decreases only by an
drain chamber e. As a result, servo piston amount corresponding to signal pressure Pi.
chamber j is also connected to chamber e
through port i and port h.
1 o-39
3. TVC VALVE a b C
e d
C4 q4
34567 8
Section B - B
Section A - A
D4
Section C - C Section D - D Section E - E Section F - F
205FO5025
a. Charging pump pressure Ppo IN port 1. Spring
b. Front main DurnD outwt wessure PPI IN Dart 2. Spool
c. Rear main dumb outbut bressure Pi2 IN port 3. Piston
d. TVC valve drain Pdr OUT port 4. Piston
e. TVC valve output pressure Pe OUT port 5. Sleeve
6. Piston
7. Body
8. Solenoid
1 O-40
FUNCTION AND OPERATION
1) When command current from pump controller is small (when pump controller is normal)
TVC valve
co
valve
Servo valve
Servo piston
Dec!erease
Discharge
PPI
Resistor 205F05026A
FUNCTION OPERATION
l When the pump controller is normal, the main l Because of the command current sent from
pump discharge volume can be controlled as the controller, solenoid push pin (9) moves
desired over a wide range according to the and piston (2) also moves. It stops at a point
command current from the pump controller to where the sum of the force of spring (1) and
carry out the power mode function. the force of push pin (9) and the force of TVC
l When the pump controller is abnormal, hy- output pressure Pt2 acting on piston (3) is in
draulic sensing is carried out to control the balance. When this happens, the command
main pump discharge volume according to current is small, so piston (2) balances at the
the load (pump discharge pressure) to carry bottom.
out the constant torque control function As a result, port a and port b are almost
(prolix function). completely open and almost all the pres-
l For details, see PEMC SYSTEM. surized oil from the charging pump is output
as TVC output pressure Pts. Because of this,
the pump discharge volume is maximum.
10-41
2) When command current from pump controller is large (when pump controller is normal)
TVC valve
....,........
:::::,
:.:.:.
.:.:.
.:.::::
....
::::::
:::.:.
Servo valve
.A......
.:.:.:.:.:.:
:.:.:.:.::::::::::,::::::::::::::::::::::::
pi
.. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .
NC
va,ve
l--l
c0
valve
j:j:j:j:j:
Deer ett!zLe
Discharge
I
Resistor 205F05027A
Because of the command current sent from
the controller, solenoid push pin (9) moves
and the piston (2) also moves. It stops at the
point where it is balanced with the force of
spring (1). When this happens, the command
current is large, so piston (2) is balanced at
the top. As a result, the flow of oil sent from
the charging pump is throttled at port a and
port b and the area of the opening at port b
and port c (drain port) becomes larger.
Because of this, TVC valve output pressure
Pt2 drops and the pump discharge volume is
reduced.
1 O-42
3) Main pump under light load (pump controller abnormal and TVC prolix switch ON)
TVC valve
!
Pi
NC
valve
Servo valve
l-----i
Servo piston
Discharge
Resistor 205F05028A
0 Main pump discharge pressures PPI and PP~
are low, so spool (2) is pushed down by
spring (1). As a result, charging pump dis-
charge pressure PC and TVC valve output
pressure Pt2 are equal.
When this happens, TVC valve output pres-
sure Pt2 is maximum and the main pump dis-
charge volume is also maximum.
1 o-43
4) Main pump under heavy load (pump controller abnormal and TVC prolix switch ON)
TVC valve
.,.,
:.:,:
Pi
,,,,,,NC
I::::::::::::::::::i:::::;:::::::::
y::::::::::::::::::::::
:.:.:,
l-
co
.:.:. valve valve
:::::
:.:.:
:::::
jj{jj
;g
j:::
:;:i:
:::::
:.:.:
.:.:.
:j::
:.:.:
1
~j&
Discharge
C Pump OFF1
It-41 I
controller
- ON
@, 1 TVC prolix switch
Resistor
205F05029A
l When main pump discharge pressure PPI (or
PP~) increases, spool (2) is moved up by pis-
ton (4) or piston (6). As a result, the flow at
port a and port b is throttled by the notch in
the spool, and the area of the opening at port
b and port c (drain port) becomes larger.
Because of this, TVC valve output pressure
Pt2 drops and the main pump discharge vol-
ume is reduced.
1 o-44
4. CO l NC Valve
*The diagram shows the CO*NC valve for the front pump.
a
d 9
i
e h
b
Section A - A
205FO5030
a. Charging pump pressure PRO OUT port co VALVE NC VALVE

b. Main pump output pressure Ppi (Pp2) OUT 1. Plug 7. Plug
port 2. Piston 8. Sleeve
c. Main pump output pressure Pp2 (Ppi) OUT 3. Spring 9. Piston
port 4. Spool 10. Spool
d. TVC valve output pressure Pt2 IN port 5. Piston 11. Spring
e. TVC valve drain Pdr port 6. Plug 12. Plug
f. CO cancel pressure Per (PC,) IN port
g. TVC valve output pressure Pt2 F-R connec-
tion port *c ) For servo valve
h. Jet sensor output pressure Pd IN port
i. Jet sensor output pressure Pt IN port
1o-45
FUNCTION AND OPERATION OF CO VALVE
1) When main pump discharge pressure is below relief pressure
NC
valve
PC0
Discharge
rlx__l >c/- 205F05031A
FUNCTION OPERATION
If the load increases during operation and the l Spool (4) is pushed down by spring (3). As a
main pump discharge pressure increases result, port a and port b are completely open
when it becomes nearly the relief pressure, and TVC valve output pressure Pi are equal.
the CO valve carries out the cut-off function Because of this, CO valve output pressure Pi
to reduce the discharge amount of the pump becomes maximum and the discharge volume
and reduce the relief loss. of the main pump is also maximum.
At the same time, the pilot pressure of the
CO function cancel solenoid valve also has
the function of canceling the cut-off.
The CO valve is controlled by balancing the
spring with the sum of main pump discharge
pressure Pp and CO valve output pressure Pi.
1 O-46
2) When the main pump discharge pressure is higher than the main relief pressure
Servo valve
l-----i
uecrease
Servo piston
- l+l
Discharge
Increase
PP
205F05032A
l When main pump discharge pressure PP

comes close to the relief pressure owing to
an increase in the load, piston (5) is pushed
by main pump discharge pressure PP and at
the same time piston (5) is pushed by CO
valve output pressure PCO. When the force of
spring (3) is overcome by the pressing force
of the pistons, spool (4) moves upward.
As a result, the spool land restricts the oil
flow from port a to port b and at the same
time the opening areas of port b and port c
(drain port) are made larger.
With angle reduced by the operation of the
servo valve, the main pump discharge is
reduced.
1 o-47
3) When cut-off function is canceled by CO cancel solenoid valve
10 cancel
;olenoid valve
I I
Decrease L+ - Increase
Disch,arge
I
- /- 205F05033A
l When the CO cancel solenoid valve is

switched, pilot pressure is taken to port PSO
and piston (2) is pushed down.
As a result, the setting of spring (3) becomes
larger, so even when main pump discharge
PP rises and reaches the relief pressure,
spool (4) is not actuated and CO valve output
pressure Pco remains at the maximum.
1 O-48
FUNCTION AND OPERATION OF NC VALVE
1) Control valve at neutral
nsor
Control valve
205FO5034A
FUNCTION OPERATION
l The NC valve controls the main pump dis- l The differential pressure (Pt - Pd) of the jet
charge volume according to the amount of sensor reaches the maximum and jet sensor
operation of the control valve spool, and output pressure Pt acting on piston (10)
carries out the function of controlling the oil becomes greater than the sum of the force of
flow to reduce the neutral loss and fine con- spring (12) and jet sensor output pressure Pd
trol loss. acting on the lower end of spool (11).
l The NC valve is controlled by balancing the As a result, spool (11) is pushed downward
sum of jet sensor output pressure Pt and NC causing a restriction of the oil flow between
valve output pressure Pi with the sum of the port c and port b and in turn opening port b
force of NC valve spring (12) and jet sensor and port a (drain port).
output pressure Pd. Output pressure Pt of the NC valve is then
l The jet sensor detects the flow of return oil reduced to the minimum and the main pump
passing through the control valve and re- discharge is also reduced to the minimum
turning to the tank, and takes it as NC valve with the swash plate angle minimized through
Pt and Pd. the operation of the servo valve.
1o-49
2) When the control valve is operated
205F05035A
l With the jet sensor differential pressure (Pt -

Pd) reduced according to the operation of
the control valve spool (11) is pushed up-
ward, fully opening port c and port b.
Thus, the NC valve output pressure increas-
es. Together with the increase in the main
pump swash plate angle through the servo
valve operation, the main pump discharge is
also increased. That is to say, the pump
discharge increases as the stroke of the lever
increases.
10-50
5. CHARGING PUMP
Suction
0
l-
Discharge
Section A - A
207FO5021
SPECIFICATIONS
1. Filter Theoretical delivery: 32.3 cc/rev
2. Relief valve Operating pressure: 30 kg/cm2
3. Collar
4. Body
5. Housing
6. Drive gear
7. Driven gear
1 o-51
LINE OIL FILTER
From pump - _F To control valve
207FO5022
1. Bracket
2. Cartridge
3. Element
4. Drain plug
1 o-52
1 o-53
CONTROL VALVE
X Y
ee dd cc bb aa
nm. mn
kk
207FQ5023
1 o-54
1. Travel shuttle valve OUTLINE
2. Four-spool valve (Built-in straight-travel valve, l This control valve consists of a four-spool
arm throttle valve) valve and a five-spool valve. In addition, it
3. Five-spool valve (Built-in swing priority valve) also has a travel shuttle valve.
It has a built-in straight-travel valve, arm
P3 port (From arm PPC valve)
throttle valve and swing priority valve.
:: PL port (From rear main pump)
PR port (From front main pump) l The four-spool valve and the five-spool valve
dc: B3L port (To bucket cylinder bottom side) are connected by bolts to form one unit. The
e. B2L port (To boom cylinder head side) oil flow merges inside the valve, so the valve
f. BlL port (To L.H. travel motor PB port) is compact and provides excellent ease of
P5 port (From swing PPC shuttle valve) maintenance.
R: P4 port (From boom bucket PPC shuttle
valve)
i. P6 port (To work equipment oil pressure
switch)
AlL port (To L.H. travel motor PA port)
d: A2L port (To boom cylinder bottom side)
I. A3L port (To bucket cylinder head side)
m. P4AL port (From arm PPC valve)
n. PBAL port (From bucket PPC valve)
0. PSAL port (From boom PPC valve)
PlAL port (From L.H. travel PPC valve)
;: PRL port (From 2-stage relief solenoid valve)
r. PRR port (From 2-stage relief solenoid valve)
S. PlAR port (From 2-stage relief solenoid
valve)
t. P3AR port (Service)
U. P4AR port (From arm PPC valve)
V. P5AR port (From R.H. travel PPC valve)
w. A3R port (Service)
X. AlR port (To swing motor MA port)
Y. BlR port (To swing motor port MB)
2. B3R port (Service)
aa. B4R port (To arm cylinder bottom side)

bb. B5R port (To R.H. travel motor PA port)
cc. T port (To tank)
dd. A5R port (To R.H. travel motor PB port)
ee. A4R port (To arm cylinder head side)
ff. PtL port (To rear NC valve)
gg. PdL port (To rear NC valve)
hh. PtR port (To front NC valve)
ii. PdR port (To front NC valve)
jj. PlBL port (From L.H. travel PPC valve)
kk. PSBL port (From boom PPC valve)
II. P3BL port (From bucket PPC valve)
mmTs port (To tank)
nn. PSBR port (From R.H. travel PPC valve)
00. P4BR port (From arm PPC valve)
pp. PBBR port (Service)
qq. PiBR port (From swing PPC valve)
1 o-55
Section A - A
Section B - B
207FO5024
1. Spool return spring 6. Jet sensor orifice

2. Spool (L.H. travel) 7. Jet sensor relief valve
3. Spool (Boom-Lo) 8. Main relief valve
4. Spool (Bucket) 9. Spool (Straight-travel)
5. Spool (Arm-Hi) 10. Spool (Arm throttle valve)
1 O-56
Section C - C
10
Section D - D
207FO5025
1. Spool return spring 6. Spool (R.H. travel)

2. Spool (Swing) 7. Jet sensor relief valve
3. Spool (Boom-Hi) 8. Jet sensor orifice
4. Spool (Service) 9. Main relief valve (five-spool)
5. Spool (Arm-Lo) 10. Spool (Swing priority)
1 o-57
/
'2
Section E - E
Section F - F
3 4 5 6 7 6 9 10
Section G - G Section H - H
207FO5026
1. Check valve 7. Suction valve

2. Check valve spring 8. Spool (Boom-Lo)
3. Spool (L.H. travel) 9. Check valve
4. Spool (Straight-travel) 10. Spool (Boom-Hi)
5. Spool (Swing priority) 11. Safety-suction valve.
6. Spool (Swing)
IO-58
Section J - J
Section L - L
2OJFO5027
1. Safety-suction valve 6. Check valve
2. Spool (Bucket) 7. Spool (Arm-Lo)
3. Spool (Arm throttle) 8. Safety-suction valve
4. Spool (Service) 9. Check valve
5. Spool (Arm-Hi) 10. Spool (R.H. travel)
1 o-59
TRAVEL SHUTTLE VALVE
a
/
b
d C
I
j
Section A - A
Section C - C Section D - D
Section B - B 207FO5028
a. Ps port (Work equipment* e. P4a port (To arm throttle j. P2 port (From L.H. travel
swing switch) valve) control valve)
b. P4 port (From boom l f. P6a port (To swing priority
bucket shuttle valve) valve) 1. Cover
c. Ps port (From swing shut- g. PT port (To tank) 2. Spool return spring
tle valve) h. PO port (To straight-travel 3. Body
d. P3 port (From arm shuttle valve) 4. Spool
valve) i. PI port (From L.H. travel
control valve)
1 O-60
FUNCTIONS
l The travel shuttle valve is installed to the top
of the four-spool valve control valve. It takes
the PPC valve pressures from the left travel,
work equipment, and swing and sends pilot
pressure to the straight-travel valve when the
travel and work equipment or swing are
operated at the same time.
OPERATION
Travel lever at FORWARD (other levers at
NEUTRAL)
l Pilot pressure oil flows to Pl port from the
To arm
left travel circuit and pushes the spool to the E+ throttle valve
right.
Therefore, ports P3, P4, P5 and PO are con-
nected through the groove in the spool and
are also connected to the straight-travel
valve. However, there is no flow of pilot
pressure oil from the shuttle valves of the
PPC valves, so the straight-travel valve is not
actuated.
(When operating in REVERSE, pressure oil
From shu&le valve From shut& pressure switch
is sent to port P2 and pushes the spool to
of arm PPC valve valve of boom From shuttle
the left.) valve of swing
bucket PPC
valve PPC valve
205F2032-2
During simultaneous operation
When the arm and travel FORWARD are oper-
ated at the same time, pilot pressure oil flows
from the left travel circuit to port Pl and
pushes the spool to the right.
At the same time, when the arm is operated,
pilot pressure oil flows to port P3 from the
shuttle valve of the arm PPC valve. This
passes through the groove in the spool and
port PO and then flows to the straight-travel
valve.
The pilot pressure oil from the shuttle valve
of the swing PPC valve flows port P5 -+ port
PO - straight-travel valve and the pilot pres- e throttle valve
sure oil from the shuttle valve of the boom
and bucket PPC valves flows port P4 - port
PO - straight-travel valve.
arm PPC valve valve of From shuttle valve of

boom, bucket swing PPC valve
PPC valve
205F2033-2
lo-61
STRAIGHT-TRAVEL VALVE
FUNCTION
l While operating the swing, boom, arm or
bucket when traveling, the pressure oil flow-
ing to the R.H. and L.H. travel circuit branch-
es into the swing, boom, arm, or bucket
circuit.
Since the supply of pressure oil in a
branched travel circuit is less than that in the
circuit before the branch, the motor naturally
slows down, resulting in a turn.
l When the straight-travel valve is switched
over to establish continuity between the R.H.
and L.H. travel circuits, this undesired turning
is prevented by equalizing the supply of pres-
sure oil to the R.H. and L.H. travel motors so
that they rotate at the same speed.
OPERATION
When traveling only
l Since no pilot hydraulic oil flows from the
shuttle valve in the PPC valve, no hydraulic
oil flows from the travel shuttle valve to the
straight-travel valve.
l Therefore, the circuit between port PR (R.H.
travel circuit) and port PL (L.H. travel circuit)
remains closed and both circuits remain
independent.
205FO5042
While operating the swing, boom, arm or
bucket when traveling
l Spool (1) of the straight-travel valve is
pushed to the right by the pilot pressure from
the travel shuttle valve.
l Port PR and port PL then become connected
to each other and an equal amount of pres-
sure oil is supplied to the R.H. and L.H. travel
motors, allowing both motors to rotate at the
same speed. The machine travels thus in a
straight line.
205FO5043
1 O-62
SWING PRIORITY VALVE
FUNCTION
l When operating the swing and arm at the
same time, most of the oil flows to the arm,
which has less load. The flow of oil to the
swing circuit is reduced so the arm speed is
faster than the swing speed. This makes com-
bined operations difficult.
l To prevent this, the swing priority valve is
switched to restrict the flow of pressure oil to
the arm-Lo control valve. This restricts the
arm speed and makes it easier to operate the
arm and swing at the same time.
OPERATION
When swing is at neutral
l No pilot pressure oil flows from the travel
shuttle valve, so the swing priority valve is
not switched. Because of this, the pressure
oil from the front main pump passes through
port PR and all the oil flows to the arm-Lo
control valve.
205FO5044
When swing is operated

l When the swing is operated, spool (1) of the
swing priority valve is pushed to the left by
the pilot pressure from the travel shuttle
valve.
Because of this, the pressurized oil flowing
from front main pump - port PR to the arm-Lo
control valve is throttled and the arm speed
is controlled, so the simultaneous operation
performance is improved.
205FO5045
1 O-63
ARM THROTTLE VALVE
FUNCTION l The arm is actuated by the merged oil flow

l When the arm control lever and boom control from two pumps, and the bucket is actuated
lever are operated at the same time, most of by the flow from one pump.
the pressure oil flows to the arm circuit, For this reason, when the arm and bucket are
where the load is less. The amount of oil operated together, the flow of oil to the arm
flowing to the boom circuit drops, so the arm circuit is greater, so the arm moves much
speed is faster than boom speed. This makes faster than the bucket. This makes combined
combined operations difficult. (Particularly operations difficult. (Particularly when using
when using ARM OUT and BOOM RAISE at ARM OUT and BUCKET CURL at the same
the same time.) time.)
When this happens, the arm throttle valve is When this happens, the arm throttle valve is
switched and the flow of oil to the arm-Hi switched and the flow of oil to the arm-Hi
control valve is restricted. This regulates the control valve is restricted. This regulates the
arm speed and makes combined operations arm speed and makes combined operations
easier. easier.
Arm-Hi
OPERATION
When arm is operated independently
0 The pilot pressure does not flow from the
travel shuttle valve, so the arm throttle valve
is not actuated and the pressure oil from the
rear pump passes through port PL and all
flows to the arm Hi control valve.
205FO5046
1 Arm-Hi /
Simultaneous operation
l When the arm is operated together with the
boom or bucket, the pilot pressure from the
travel shuttle valve pushes spool (1) of the
arm throttle valve to the left. When this hap-
pens, the flow of pressure oil from the rear
pump to the arm-Hi control valve is throttled,
and the arm speed is controlled to improve
the ease of simultaneous operation.
205FO5047
1 O-64
1 O-65
SWING MOTOR
View 2
e
207FO5029
a. T2 port (To tank) SPECIFICATIONS

b. S port Type: KMF160AB-2
c. MA port (From control valve) Theoretical delivery: 160.7 cc/rev
d. MB port (From control valve)
Safety valve set pressure:
e. C port (From swing brake solenoid valve)
PC3OOLC: 275+: kg/cm* at 244 P/min
PC4OOLC: 260+: kg/cm* at 300 P/min
Rated speed:
PC3OOLC: 1,560 rpm
PC4OOLC: 1,925 rpm
Brake release pressure: 16.5+2 kg/cm*
1 O-66
LL_JJ I-LU
Section A - A
Section B - B
Section C - C
207FO5030
1. Safety valve 10. Cylinder

2. End cover 11. Center spring
3. Brake spring 12. Piston
4. Brake piston 13. Plug
5. Plate 14. Valve plate
6. Disc 15. Center shaft
7. Housing 16. Check valve spring
8. Cover 17. Check valve
9. Drive shaft
1 O-67
SWING HOLDING BRAKE
OPERATION
1) When swing brake solenoid valve is
deactivated
When the swing brake solenoid valve is
deactivated, the pressurized oil from the
charging pump is shut-off and port B is
connected to the tank circuit.
Because of this, brake piston (4) is pushed
down in the direction of the arrow by brake
spring (3), so disc (6) and plate (5) are
pushed together and the brake is applied.
205F05050K
2) When swing brake solenoid valve is

excited
When the swing brake solenoid valve is
excited, the valve is switched and the pres-
surized oil from the charging pump enters
port B and flows to brake chamber a.
The pressurized oil entering chamber a over-
comes the force of brake spring (3), and pump
brake piston (4) is pushed up in the direction
of the arrow. Because of this, disc (6) and
plate (5) separate, and the brake is released.
U
205FO5051 K
1 O-68
CENTER SWIVEL JOINT
.A1
Cl
.F2
Section A - A
TI T2 DP
View Z
r-77
62 A2 CZ
207FO5031
1. Cover Al : From control valve AIR port Dl: From control valve AIL port
2. Plate A2: To R.H. travel motor PB port D2: To L.H. travel motor PA port
3. Body Bl: From control valve PIL port Fl: From travel speed solenoid valve
4. Slipper seal
82: To R.H. travel motor PB port F2: To L.H. and R.H. travel motor P port
5. Oil seal
6. Shaft Cl: From control valve BAR port Tl: To tank
c2: To R.H. travel motor PA port T2: From L.H. and R.H. travel motor T
port
1O-69
TRAVEL MOTOR
PC300LC
\e
I _
207FO5032

b. PB port (From control valve) Type: HMV280ADT
c. P port (From travel speed solenoid valve) Theoretical delivery: Min. 175.1 cc/rev
d. PA port (From control valve)
Max. 280.0 cc/rev
e. TI port (To tank)
Rated pressure: 325 kg/cm2
Rated speed: Min. 1,430 rpm
Max. 895 rpm
Brake releasing pressure: 1353 kg/cm2
Hi-Lo switching pressure: 87; kg/cm2
IO-70
Section C - C \
26
Section D - D
Section B - 6
207FQ.5033
1. Output shaft 10. Check valve 19. Regulator piston

2. Motor case 11. Check valve spring 20. Spring
3. Regulator piston 12. Regulator valve 21. Check valve spring
4. Cradle 13. Spring 22. Check valve
5. Rocker cam 14. Air bleeder 23. Counterbalance valve
6. Piston 15. Brake spring 24. Spool return spring
7. Cylinder 16. Brake piston 25. Piston
8. Valve plate 17. Plate 26. Safety valve
9. End cover 18. Disc 27. Check valve
IO-71
TRAVEL MOTOR
PC4OOLC
View 2
208FO5017

b. PB port (From control valve) Type: HMV355ADT
c. P port (From travel speed solenoid valve) Theoretical delivery: Min. 191.3 cc/rev
d. PA port (From control valve)
Max. 355.4 cc/rev
e. TI port (To tank)
Rated pressure: 355 kg/cm2
Rated speed: Min. 1,620 rpm
Max. 870 rpm
Brake releasing pressure: 13 + 3 kg/cm*
Hi-Lo switching pressure: 8:: kg/cm2
1 O-72
1 2 3 4 5 6 7 8 9
Section c - c 26
/I rYI \\
20 19 18 17 16 15 14
Section A - A
27
Section D - D
Section B - B 208FO5010
1. Output shaft 10. Check valve 19. Regulator piston

2. Motor case 11. Check valve spring 20. Spring
3. Regulator piston 12. Regulator valve 21. Check valve spring
4. Cradle 13. Spring 22. Check valve
5. Rocker cam 14. Air bleeder 23. Counterbalance valve
6. Piston 15. Brake spring 24. Spool return spring
7. Cylinder 16. Brake piston 25. Piston
a. Valve plate 17. Plate 26. Safety valve
9. End cover la. Disc 27. Check valve
1 o-73
MOTOR
OPERATION
1) At Lo speed (motor rocker cam angle at maximum)
205F05059K
l The solenoid valve is deactivated, so the pilot 0 At the same time, the pressurized oil at regu-
pressure oil from the charging pump does lator piston (3b) at the bottom passes
not flow to port P. through orifice b in regulator valve (9) and is
For this reason, regulator valve (12) is drained to the motor case.
pushed to the right in the direction of the l As a result, rocker cam (5) moves in the max-
arrow by spring (13). imum rocker cam angle direction, the motor
l Because of this, it pushes check valve (27) capacity becomes maximum and the system
and the main pressure oil from the control is set to Lo speed.
valve to end cover (9) passes through pass-
age a in regulator valve (12), enters regulator
piston (3a) at the top, and pushes regulator
piston (3a) to the right in the direction of the
arrow.
1 o-74
2) At Hi speed (motor rocker cam angle at minimum)
Traveling speed
solenoid v
205F05060K
The solenoid valve is excited, so the pilot l At the same time, the pressurized oil at regu-
pressure oil from the charging pump flows to lator piston (3a) at the top passes through
port P, and pushes regulator valve (12) to the orifice d in regulator valve (12) and is drained
left in the direction of the arrow. to the motor case.
Because of this, the main pressure oil from l As a result, rocker cam (5) moves in the
the control valve passes through passage c minimum rocker cam angle direction, the
in regulator valve (12), enters regulator piston motor capacity becomes minimum and the
(3b) at the bottom, and pushes regulator system is set to Hi speed.
piston (3b) to the right in the direction of the
arrow.
1 o-75
PARKING BRAKE
OPERATION
1) When starting to travel

l When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool (23), the circuit to the
parking brake is opened and the oil flows into
chamber a of brake piston (16), overcomes
the force of spring (15), and pushes piston
(16) to the right in the direction of the arrow.
When this happens, the force pushing plate
(17) and disc (18) together is lost, so plate
(17) and disc (18) separate and the brake is
released.
205FO5061 K
18 17
2) When stopping travel
l When the travel lever is placed in neutral,
counterbalance valve spool (23) returns to
the neutral position and the circuit to the
parking brake is closed. The pressurized oil
in chamber a of brake piston (16) is drained
to the case from the orifice in the brake pis-
ton and brake piston (16) is pushed to the
left in the direction of the arrow by spring
(15).
As a result, plate (17) and disc (18) are
pushed together and the brake is applied.
Travel
control valve
205F05062K
1 O-76
BRAKE VALVE
Control valve
l The brake valve consists of a check valve,

counterbalance valve and safety valve in a
circuit as shown in the diagram on the right
(Fig. 1).
l The function and operation of each com-
ponent is as given below.
(Fig. 1) 205FO5063
1. COUNTERBALANCE VALVE, CHECK VALVE I I
FUNCTION Control valve

l When traveling down a slope, the weight of
the machine makes it try to travel faster than
the speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
EI
without load and will run away, which is
extremely dangerous.
To prevent this, these valves act to make the
machine travel according to the engine speed
(pump discharge volume). S,-
OPERATION WHEN PRESSURE IS SUPPLIED
l When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port PA. It pushes open check valve (22a)
and flows from motor inlet port MA to motor (gi 205F05064A
outlet port MB. However, the motor outlet
port is closed by check valve (22b) and spool
Control valve
(23), so the pressure at the supply side rises
(Fig. 2).
l The pressurized oil at the supply side slows
from orifice El in spool (23) to chamber Sl,
and when the pressure in chamber Sl goes
above the spool switching pressure, spool
(23) is pushed to the right in the direction of EI
the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened and the motor starts to rotate S,-
(Fig. 3).
(Fig. 3) 205FO5065
1 o-77
OPERATION OF BRAKE WHEN TRAVELING
DOWNHILL
l If the machine tries to run away when travel-
ing downhill, the motor will turn under no
load, so the pressure at the motor inlet port
will drop and the pressure in chamber Sl
through orifice El will also drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(23) is returned to the left in the direction of
the arrow by spring (24) and outlet port MB
is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the
rotation of the motor and this prevents run-
ning away.
In other words, the spool is moved to a (Fig. 4)
position where the pressure at outlet port MB 205FO5066
balances the pressure at the inlet port and

the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the speed according to the
discharge volume of the pump (Fig. 4).
2. SAFETY VALVE
FUNCTION
l When travel is stopped (or when traveling
downhill), the circuit at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated by
inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the inlet port side of the motor to
prevent damage to the equipment.
OPERATION
l When stopping travel (or when traveling
downhill), chamber E in the outlet port circuit
is closed by the check valve of the counter-
balance valve, but the pressure at the outlet (Fig. 5) 205F2044
port rises because of inertia (Fig. 5).
l If the pressure goes above the set pressure,
the force produced by the difference in area
between Dl and D2 [x/4 (D: - DE) x pres-
sure] overcomes the force of the spring and
moves the poppet to the right, so the oil DI
flows to chamber F in the circuit on the
opposite side (Fig. 6).
(Fig. 6) 205F2045
1 O-78
VALVE CONTROL
Boom raise
Bucket dump _ /
Boom low& y&y,: ___
4---
1'
i6
207FO5035
1. L.H. travel control lever 9. Arm shuttle valve

2. R.H. travel control lever 10. Swing shuttle valve
3. R.H. PPC valve 11. Boom*bucket shuttle valve
4. R.H. work equipment control lever 12. Travel shuttle valve
5. Accumulator 13. Safety lock valve
6. Control valve 14. L.H. work equipment control lever
7. Hydraulic pump 15. L.H. PPC valve
8. Arm half flow solenoid valve 16. Travel PPC valve
1 o-79
PPC VALVE
FOR WORK EQUIPMENT AND SWING
\
a
c d
e
View 2 205FO5068
a. P port (From charging pump)

b. T port (To tank)
c. P3 port (L.H.: arm in/RH.: bucket dump)
d. P2 port (L.H.: R.H.: swing/RH.: boom lower)
e. P4 (L.H.: arm out/R.H.: bucket curl)
f. PI (L.H.: L.H. swing/R.H.: boom raise)
1 O-80
Section A - A Section B - B
Section D - D
Section C - C
1. Spool 7. Disc
2. Metering spring 8. LWer
3. Centering spring 9. Joint
4. Pilot piston 10. Plate
5. Pilot spring 11. Collar
6. Piston 12. Body
IO-81
FOR TRAVEL
I I
, I
\
a
207FO5036
a. P port (From charging pump)

b. T port (To tank)
c. P2 port (L.H. reverse)
d. P4 port (R.H. reverse)
e. PI port (L.H. forward)
f. P3 port (R.H. forward)
1 O-82
1 Section A - A Section B - B
Section D - D
Section C - C
207FO5037
1. Spool 5. Bolt
2. Metering spring 6. Plate
3. Centering spring 7. Collar
4. Piston 8. Body
1 O-83
OPERATION * The operation depends on the work equip-
1) At neutral ment and swing PPC valve.
Ports Pl and P2 of the PPC valves in circuits
A and B of the control valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
2) Control lever operated slightly (fine con-

trol)
When piston (4) starts to be pushed by disc
(2), retainer (7) is pushed. Valve (10) is also
pushed by spring (9) and moves down.
When this happens, fine control hole f is
shut-off from drain chamber D. At almost the
same time it is connected to pump pressure
chamber Pp, and the pilot pressure of the Control valve
control valve is sent through fine control hole
f to port Pl. When the pressure at port Pl (Fig. I) 205FC
rises, valve (10) is pushed back. Fine control

hole f is shut-off from pump pressure cham-
ber Pp. At almost the same time it is con-
nected to drain chamber D, so the pressure
at port Pl escapes to drain chamber D.
Valve (10) moves up and down until the force
of spring (9) is balanced with the pressure of
port Pl.
The relationship of the positions of spool (1)
and body (12) (fine control hole f is in the
middle between drain hole D and pump
pressure chamber Pp), does not change until
damper piston (4) contacts piston (6).
Therefore, spring (2) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port Pl also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a position
where the pressure of port A (same as pres-
sure at port Pl) and the force of the return
spring of the control valve are balanced
(Fig. 2).
(Fig. 2) 205FO5073
1 O-84
3) During fine control (control lever returned)
iiL
wt
When disc (7) starts to be returned, spool (1)
is pushed up by the force of centering spring 1
(3) and the pressure at port Pl. \
Because of this, fine control hole f is con- 8
nected to drain chamber D, and the pressur-
ized oil at port Pl is released. 4
If the pressure at port Pl drops too much, a
spool (1) is pushed down by metering spring
(2), so fine control hole f is shut-off from 3, :j
drain chamber D. At almost the same time it
is connected to pump pressure chamber Pp,
so the pressure at port Pi supplies the pump
pressure until the pressure recovers to a
pressure equivalent to the position of the
lever.
When the control valve spool returns, oil in
drain chamber D from fine control hole f of
the valve on the side that is not moving flows
through port P2 and goes to chamber B, so
the oil is charged (Fig. 3).
205FO5074
4) At full stroke
Disc (7) pushes down piston (6), but damper
piston (4) also follows this and pushes down
spool (1). Fine control hole f is shut-off from
\I
drain chamber D, and is connected to pump
pressure chamber Pp. Therefore, the pilot
pressure oil from the charging pump passes
through fine control hole f and flows to
chamber A from port Pl to push the control
valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f and
flows to drain chamber D.
With damper piston (4) that was following
piston (6), the pressurized oil in the spring
chamber flows out from orifice a, and damper
piston (4) and spool (1) are pushed back by
the force of metering spring (2) and the
hydraulic pressure at port Pl.
The time lag when the lever is suddenly
operated is prevented by damper piston (4).
(During fine control, damper piston (4) does
not follow piston (6), so the fine control
performance is maintained.) (Fig. 4).
(Fig. 4) 205FO5075
1 O-85
ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATION
Gas capacity:
PC300LC: 300 cc
PC4OOLC: 500 cc
205FO5076
SAFETY LOCK VALVE
3.
4.
2.
1. Seat
Ball
Body
Lever
5. End cap
2 3 4 5
207FO5038
1 O-86
SOLENOID VALVE ASSEMBLY
FOR 2-STAGE RELIEF, CO CANCEL, SWING BRAKE AND TRAVEL SPEED
i
a b
a. T port (To tank) 1. CO cancel solenoid valve

b. P port (From charging pump) 2. 2-stage relief solenoid valve
c. To front and rear NC valve 3. Travel speed solenoid valve
d. To main relief valve 4. Swing brake solenoid valve
e. To L.H. and R.H. travel motor
f. To swing motor
1 O-87
1. FOR P-STAGE RELIEF, CO CANCEL AND TRAVEL SPEED
1 2 3 4 5 6 7
1. Connector
2. Plunger
3. Coil
4. Push pin
5. Spool
6. Spring
7. Bracket
205FO5079
OPERATION
Solenoid deactivated
l No signal current flows from the controller,
so solenoid is deactivated.
Because of this, port A is closed, and the
pressurized oil from the charging pump does
notflow to the actuator.
At the same time, the oil from the actuator
flows from port B to port C and is drained to
the tank.
205FO5080-1
Solenoid excited
l When the signal current flows from the con-
troller to solenoid, solenoid is excited. As a
result, the pressurized oil from the charging
pump flows from port A to port B, and to the
actuator.
At the same time, port C is closed, and the
not flow to the tank.
205FO5081-1
1 O-88
2. FOR SWING BRAKE
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5082
OPERATION
so coil is deactivated.
Because of this, port P is closed, and the
not flow to the swing motor.
At the same time, the oil from the swing
motor flows from port A to port T and is
drained to the tank.
205FO5083-1
Solenoid excited
0 When the signal current flows from the con-
troller, coil is excited.
Because of this, port P and port A are inter-
connected, and the pressurized oil from the Exci
charging pump flows to the swing motor.
At the same time, port T is closed, so the oil
does not flow to the tank.
205FO5084-1
1 O-89
FOR ARM HALF FLOW
1. Connector
2. Plunger
3. Coil
4. Spring
5. Spool
6. Body
7. Plug
205FO5085
OPERATION
so coil is deactivated.
Because of this, port P and port S are inter-
connected, so the pressurized oil from the
PPC valve flows to the control valve.
205FO5086-1
Solenoid excited
l When the signal current flows from the con-
troller, coil is excited.
Because of this, port P is closed, and the
pressurized oil from the PPC valve does not
flow to the control valve.
At the same time, port S and port T are inter-
connected, so the pressurized oil from the Exci
control valve is drained to the tank.
205FO5087-1
1 O-90
SHUTTLE VALVE
FOR BOOM . BUCKET AND TRAVEL
e 1. lug
2. 3all
3. 3ody
4. lug
a. 1~ port (Bucket dump)
j3.H. reverse]
b. 3~ port (Bucket curl)
1R.H. forward]
C. 4~ port (Boom raise)
1L.H. forward]
d. 2~ port (Boom lower)
I
I
i x 1L.H. reverse]
e. 3s port (Travel shuttle valve)
? /3 :Travel oil pressure switch]
f. 238 port (Bucket curl)
1R.H. forward]
g. 1~ port (Bucket dump)
1R.H. reverse]
h. 28 port (Boom lower)
1L.H. reverse]
i. 4~ port (Boom raise)
1L.H. forward]
( ): For boom*bucket
[ 1: For travel
Section A - A Section B - B
207FO5039
FOR ARM AND SWING
a b c
1. Ball
2. Body
3. Plug
Pin port (Arm out) [L.H. swing]

:: P3 port (Travel shuttle valve)
[Blind plug]
Psn port (Arm in) [R.H. swing]
d: Pie port (Arm out) [L.H. swing]
e. PUB port (Arm in) [R.H. swing]
( ): For arm, [ 1: For swing
Section A - A
d
I \
e
207FO5040
1 o-91
BOOM HOLDING VALVE
a b
Section A - A
207FO5041
a. T port (To tank) 1. Safety-suction valve

b. Pi port (From boom PPC valve) 2. Pilot spring
c. Cy port (To boom cylinder) 3. Pilot spool
d. V port (From boom control valve) 4. Poppet spring
5. Poppet
1 o-92
OPERATION
1) At boom RAISE
When the boom is raised, the main pressure
from the control valve pushes up poppet (5)
in the direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
205FO5091
2) Boom lever at NEUTRAL

When the boom is raised and the control
lever is returned to NEUTRAL, the circuit for
the holding pressure at the bottom end of the
boom cylinder is closed by poppet (5) in the
direction of the arrow.
Because of this, the main pressure oil from
the control valve passes through the valve
and flows to the bottom end of the boom
cylinder.
A 1 BOOT-LO 1
205FO5092
1 o-93
3) Boom LOWER
When the boom is lowered, the pilot pressure
from the PPC valve pushes pilot spool (3)
and the pressurized oil in chamber b inside
the poppet is drained.
When the pressure at port Cy rises because
of the pressurized oil from the bottom end of
the boom cylinder, the pressure of the pres-
surized oil in chamber b is lowered because
of orifice a.
If the pressure in chamber b drops below the
pressure at port V, poppet (5) opens, the
pressurized oil flows from port Cy to port V,
and then flows to the control valve. If any
abnormal pressure is generated in the circuit
at the bottom end of the boom cylinder
safety valve (1) is actuated.
205FO5093
1 o-94
HYDRAULIC CYLINDER
1. BOOM CYLINDER
PC3OOLC
\
i6 207FO5042
PC4OOLC
16 208FO5019
2. ARM CYLINDER
PC3OOLC
1 2 3 4 5 6 7 8 9 10 11 12 13 17 14 15
19 18
207FO5043
1 o-95
PC4OOLC
1 2 3 4 5 6 7 8 9 10 11 12 13 14
19 18
3. BUCKET CYLINDER 208FO5020
PC3OOLC
207FO5044
PC4OOLC
208FO5021
1. Bottom side bushing 8. Head side cushion plunger 15. Bottom side bushing
2. Piston 9. Piston 16. Head side tube
3. Cylinder head 10. Piston ring 17. Spacer
4. Rod packing 11. Wear ring 18. Bottom side cushion
5. Buffer ring 12. Ring plunger
6. Wear ring 13. Spacer 19. Ball
7. Cylinder 14. Bottom side tube
1 O-96
SPECIFICATIONS
Unit: mm
Cylinder
Boom Arm Bucket

I
Item
1 o-97
WORK EQUIPMENT
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
1 O-98
1 o-99
PC3OOLC
19
/
18 /'
l7 I
16
15
08DD0012
1. Monitor panel 12. Pump controller

2. Swing lock switch 13. Engine throttle controller
3. Horn switch 14. TVC prolix resistor
4. Starting switch 15. Power maximizing switch
5. Fuel control dial 16. Light relay
6. Cigarette lighter 17. Heater Hi relay
7. Buzzer 18. Heater Low relay
8. Service meter 19. Speaker
9. Radio 20. Wiper relay
10. TVC prolix switch 21. Fuse box
11. Swing lock prolix switch 22. Ether injector switch
10-100
08DD0030
23. Working lamp 40. Starting motor

24. Head lamp 41. Engine speed sensor
25. Battery 42. TVC valve
26. Battery relay 43. Engine oil pressure switch
27. Fuel level sensor 44. Engine oil level sensor
28. Horn (Low tone) 45. Hydraulic oil lever sensor
29. Horn (High tone) 46. Arm half flow solenoid valve
30. Ether injector 47. Swing brake solenoid valve
31. Room lamp 48. Travel speed solenoid valve
32. Front pump pressure sensor 49. 2-stage relief solenoid valve
33. Rear pump pressure sensor 50. CO cancel solenoid valve
34. Work equipment lswing oil pressureswitch 51. Travel oil pressure switch
35. Alternator 52. Wiper motor
36. Coolant level sensor 53. Washer motor
37. Coolant temperature sensor
38. Governor motor
39. Shut off valve
1 O-l01
PC4OOLC
08DD0034
1. Monitor panel 12. Pump controller

2. Swing lock switch 13. Engine throttle controller
3. Horn switch 14. TVC prolix resistor
4. Starting switch 15. Power maximizing switch
5. Fuel control dial 16. Light relay
6. Cigarette lighter 17. Heater Hi relay
7. Buzzer 18. Heater Low relay
8. Service meter 19. Speaker
9. Radio 20. Wiper relay
10. TVC prolix switch 21. Fuse box
11. Swing lock prolix switch 22. Ether injector switch
23. Service meter relay
IO-102
36 37
08DD0035
24. Working lamp 41. Starting motor

25. Head lamp 42. Engine speed sensor
26. Battery 43. TVC valve
27. Battery relay 44. Engine oil pressure switch
28. Fuel level sensor 45. Engine oil level sensor
29. Horn (High tone) 46. Hydraulic oil lever sensor.
30. Horn (Low tone) 47. Arm half flow solenoid valve
31. Ether injector 48. Swing brake solenoid valve
32. Room lamp 49. Travel speed solenoid valve
33. Front pump pressure sensor 50. 2-stage relief solenoid valve
34. Rear pump pressure sensor 51. CO cancel solenoid valve
35. Work equipment*swing oil pressure switch 52. Travel oil pressure switch
36. Alternator 53. Wiper motor
37. Coolant level sensor 54. Washer motor
38. Shut off valve
39. Governor motor
40. Coolant temperature sensor
10-103
10-104
PC3OOLC
Please remove this page and insert Foldout 3 from rear of book
IO-105
IO-106
ELECTRICAL CIRCUIT DIAGRAM - Continued
PC3OOLC
1 O-l 07
IO-108
PC4OOLC
10-109
10-110
ELECTRICAL CIRCUIT DIAGRAM - Continued
PC4OOLC
10-111
IO-112
PCSOOLC
S/N A30001 THRU A30110, A30112 AND A30114 THRU A30116
View Z
1. Battery relay OUTLINE

2. Battery l The engine can be started and stopped
3. Fuel control dial simply by using the starting switch.
4. Starting switch
l The engine speed can be controlled using a
5. Starting motor
dial control system for the fuel control.
6. Engine throttle controller
7. Fuel injection pump l The engine throttle controller also controls
8. Governor motor the engine speed at the same time using
9. Fuel shut off valve signals from the pump controller.
* For details, see PEMC SYSTEM.
IO-113
0
PC3OOLC
S/N A30111, A30113 AND A30117 AND UP
View Z
X12BVO72

4. Starting switch l The engine speed can be controlled using a
5. Starting motor dial control system for the fuel control.
0 The engine throttle controller also controls
7. Fuel injection pump
the engine speed at the same time using
8. Governor motor
1 O-l 13-1
0
1 O-l 13-2
0
PC4OOLC
12BVOO28

4. Starting switch
l The engine speed can be controlled using a
5. Starting motor
dial control system for the fuel control.
l The engine throttle controller also controls
7. Fuel injection pump
8. Governor motor the engine speed at the same time using
IO-114
GOVERNOR MOTOR LINKAGE - PC3OOLC
S/N A30001 THRU A30110, A30112 AND A30114 THRU A30116
FULL SPEED
ANGLE ORIGIN
(MOTOR STOP
POSITION)
/
12BV0029 g
1. Governor actuator
2. Engine governor
3. Spring assembly
4. Yoke
5. Lock nut
6. Pin
10-115
0
GOVERNOR MOTOR LINKAGE - PC300LC
S/N A30111, 30113 AND 30117 AND UP
FULL SPEED
I, LOW IDLE
ANGLE ORIGIN
tMnTOR STOP
\.I._
POSITION)
SPEED
LOW
b-
IDLE
X12BV073
2. Engine governor
3. Spring assembly
4. Ball joint
5. Lock nut
6. Lock nut
1 O-l 15-I
0
1 O-l 15-2
0
GOVERNOR MOTOR LINKAGE - PC4OOLC
FULL SPEED
XlZBV070
2. Engine governor
3. Spring assembly
4. Yoke
5. Lock nut
6. Pin
IO-116
OPERATION OF SYSTEM
STARTING ENGINE
0 When the starting switch is turned to the START position, the start signal flows to the starting motor
and the starting motor turns to start the engine. Power also flows from the starting switch to the
engine shutoff valve, energizing the valve and allowing fuel to flow to the engine.
When this happens, the engine throttle controller checks the signal voltage from the fuel control dial
and sets the engine speed to the set speed.
e--
*-- (Power source)
(Throttle signal) controller 12BVOOll
ENGINE SPEED CONTROL

l The fuel control dial sends a signal voltage to the engine throttle controller according to the position
of the dial.
The engine throttle controller calculates the angle of the governor motor according to this signal
voltage and drives the governor motor so that it is set to that position.
When this happens, it detects the operating angle of the governor motor using a potentiometer and
observes the governor motor.
12BV0012
IO-117
STOPPING ENGINE
l When the starting switch is placed at the OFF position, the shut-off valve closed so the supply of fuel
to the engine is shut off and the engine stops.
r
Starting
1 e,,;,
a Starting motor
switch-
II
C3
I
Engine throttle
(Throttle signal) Control kr
12BV0013
IO-118
COMPONENT EQUIPMENT OF SYSTEM
1. ENGINE THROTTLE CONTROLLER
I
@ @ @
= II IJ
Z CN - El
View 2 i
1. Self-diagnostic display LEDs
nwt and output signals

Pin
No. I
Name of signal Name of signal
IInput/
output I
Ipower source + VB 1 Input 1 12 IPower source ground GND I Input I
2 13
3 Motor drive A A output 14 Motor drive A A output
4 Motor drive B B output 15 Motor drive B B output
5 IPotentiometer signal APSiG 1Output 1 16 IPotentiometer GND AP - 1Output 1
Potentiometer power
6 AP + output 17 Model selection SEL Input
source +
7 Fuel dial power source + SP + output 18 Fuel dial GND SP - output
8 Fuel dial signal SPSiG Input 19 No. 2 throttle - PC - Input
9 INo. 2 throttle PC + I Input I 20 IThrottle - SA - 1Output 1
10 Throttle + SA + output 21 Warming-up signal TL
11 Auto-deceleration signal PAD Input
IO-119
(Input signal) (Output signal)
Control function of controller Pump controller
(Throttle signal)
0 The engine throttle controller receives the b
input signals shown in the diagram on the Fuel control dial
%
-z
(Throttle slgnall
right, processes these internally and sends
E
output signals to the pump controller and Pump controller a Governor motor
governor motor.
(Auto-deceleration sIgnal) - E
(No. 2 throttle signal)
2
Monitor panel 5
(Engine warming-up signal)
.-E
?
Governor potent,ometer w
(Potentiometer signal)
Controller output
1) Engine speed set function using fuel con- characteristics
trol dial
An output signal that matches input voltage
a corresponding to the position of the fuel
control dial is sent so that the governor
motor is set to turning angle b.
Turning angle b is fed back to the controller
by the potentiometer signal and the operation
of the governor motor is always observed. Fuel control dial output
Fuel cktrol dial output
205FO5110
2) Engine speed control by No. 2 throttle

signal from pump controller
The pump controller controls the engine
speed directly using the No. 2 throttle signal
in order to carry out the PEMC system.
The engine throttle controller controls the
engine using the lower signal (higher voltage)
of the throttle signal from the fuel control dial
and the No. 2 throttle signal from the pump
controller.
Example:
Even if the fuel control dial is set to the MAX.
position, if [finishing operation mode and S
mode] is selected for the working mode and
power mode, the engine speed will automa-
tically be set to partial speed.
* For details, s.ee PEMC SYSTEM.
IO-120
3) Auto-deceleration function using autode- INTERNAL STRUCTURE OF CONTROLLER
celeration signal from pump controller The inside of the controller consists of the
When the pump controller detects that all input circuit, microcomputer and drive circuit
levers are at neutral, it sends the autode- shown in the diagram, these have the various
celeration signal to the engine throttle con- functions described below.
troller. When this signal is received, the
engine throttle controller reduces the engine Input circuits
speed to the deceleration position. These receive the signals from the fuel con-
* For details, see PEMC SYSTEM. trol dial (throttle signal), pump controller (No.
2 throttle signal, auto-deceleration signal)
4) Automatic warming-up function using and monitor (warming-up signal) and send
warming-up signal from monitor them to the microcomputer. In this portion,
After the engine is started, if the engine water the noise in the signal is removed and the
temperature is low, the monitor sends the wave pattern of the signal is regulated.
warming-up signal to the engine throttle In addition, it makes the power source (ap-
controller. prox. 5V) for the governor motor potenti-
When this signal is received, the engine ometer and fuel control dial.
throttle controller raises the engine speed to
carry out warming-up.
7-v
5) Self-diagnostic function
Three LEDs (red, green and red) light up and
go out to indicate that the machine is normal
or to indicate the location of any failure when
any abnormality occurs.
* For details, see TROUBLESHOOTING.
2) Microcomputer
The angle of the governor motor is calculated
from the input signals sent from the input
circuits, and the pulse signal to drive the
governor motor is sent to the drive circuit.
3) Drive circuit
The pulse signal sent from the microcom-
puter is used to switch the direction of the
current flowing to the governor motor to
rotate the motor clockwise or counterclock-
wise.
IO-121
2. FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
4. Ball
Machine 5. Potentiometer
forward 6. Connector
MIN. A
--I
Section A - A
Composition of circuit
2
0 c3
a
3
205FO5113
FUNCTION
l This is installed under the monitor panel. A (%) Hi
potentiometer is installed under the knob, 100
and when the knob is turned, it rotates the
potentiometer shaft
D
This rotation changes the resistance of the
?
variable resistor inside the potentiometer, and m
sends the desired throttle signal to the en- 1
n
gine throttle controller. The shaded area in
the graph on the right shows the abnormal
detection area and the engine speed is set to 0 0.25 1 4 4.75 5
low idling. Throttle voltage
characteristics (VI
205FO5114
IO-122
3. GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
Section A - A
\
I- 8
205FO5115
FUNCTION OPERATION
l The motor is rotated and the governor lever Motor stationary
of the fuel injection pump is controlled by the l Both A phase and B phase of the motor are
drive signal from the engine throttle con- continuous.
troller. Motor rotating
l A stepping motor is used for the motor which l A pulse current is applied to the A phase and
provides the motive power. B phase by the engine throttle controller to
In addition, a potentiometer to give feedback give synchronous rotation with the pulse.
is installed to allow observation of the opera-
tion of the motor.
The rotation of the motor is transmitted to the
potentiometer through a gear.
IO-123
PEMC SYSTEM
Working mode selection function

Pump & engine mutual control system
Power set selection function
Pump flow control (PFC, PNC) function
<~~ZEi~[~/lIZLn
Power maximizing system

1
Auto-deceleration system
PEMC system
Engine automatic warming-up function

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

Swing control system
I Swing holding brake function
(Pump control function

When machine is traveling)
-Automatic Hi-Lo travel speed shift

function
I Self-diagnostic function
1
205FO5116
* PEMC system: Pump and Engine Mutual Control System

l The PEMC system is a system of total control to give a high level of both power and fuel economy
by controlling both the pump and engine.
IO-124
Travel motor
I-
i I
PPC shuttle valve
I Controlvalve ____ __$___L+,
IJet 1 i !
i I
I!-=
, L
L :
;
:
Swing
Zharginl lock
,urllp switch
Enginethrottle I jwing
Power max. ock
switch volix
#witch
(Front oil pressure sensor signal),, I
(Drive signal)
I (Work equlpment.swing lever sIgnal)

(Travel lever signal)
(Drive signal
(Swing lock switch signal)
(Engine mode signal)
(Swing lock switch signal1
IO-125
PUMP AND ENGINE MUTUAL CONTROL SYSTEM (WORKING MODE SELECTION
AND POWER SET SELECTION)
Engine
Travel control lever
NCvalve 1 I
PPC shuttle valve
m
IEn* IPWd my? pnell
2
-
(Travel lever signal)
Engine throttle (Throttle
sIgnal
- Pump controller -
controller 2Engine
,NO fhroftlecontrall~r,
4
H.0 G.0 F.0 LO
Fuel control dial A ! _; 0000
hutch sqnal) WORKING MODE @
(Switch signal) 8 8 b
205FO5 118A
OUTLINE The combination of the 4-level working mode

0 The changes in the engine speed caused by and 3-level power set makes it possible to
the pump load are detected by the engine choose a pump absorption torque corres-
speed sensor and fuel control dial output ponding to the nature of the work, so it is
signal. The pump controller calculates these possible to use the engine more effectively
signals and sends the results to the TVC while also reducing fuel consumption.
valve as a signal to control the pump dis- Normally, the combination of the working
charge volume. In this way, it can always mode and power mode takes the working
give the optimum matching of the engine mode as the basic mode and the power
torque and pump absorption torque. mode is automatically set according to the
selection of the working mode.
Engine torque Engine horsepower Main pump delivery

L.0 + L G.O. F.O. L.0 + S L.0 + L H
t- H.O+S 3
s
e
B
aY
.E
0,
5
Engine speed N 205FO5,, 9A Engine speed N

205FO5120A
Pump delivery volume 0
Note) H.0: Heavy duty operation mode, G.0: General operation mode,
F.0: Finishing operation mode, L.0: Lifting operation mode.
IO-126
CONTROL OF H MODE l Engine torque
When using H.0, G.0, F.0 or L.O. mode and H
mode
l Working mode: Same for any mode
0 Power set: H
0 CO function: Actuated
l Pump absorption: At rated output
horsepower: point
PCBOOLC I PC4OOLC
207 HP/2,000 rpm 276 HP/2,000 rpm
Engine speed N
205FO5 122
l Engine horsepower
When the pump controller receives the power
set [H] signal from the monitor, it sends out
an electric command for the H mode output
setting to the engine throttle controller.
The engine throttle controller receives this
and uses the governor motor to set the
engine governor lever to the FULL position.
If the pump load becomes too high and the
engine speed drops, the engine speed sensor
reduces the pump discharge amount, and
momentarily resets the engine speed to the
V I
rated point. In this way, the engine torque
Engine speed N
and pump absorption torque are always 205FO5123
matched at the rated point and the engine
horsepower can be used to the maximum.
l Main pump delivery
The CO (Cut-off) function is actuated and
when it reaches near the relief pressure, the
pump discharge amount is reduced to reduce
hydraulic loss and power loss.

205FO5124
IO-127
CONTROL OF S MODE Engine torque l Engine horsepower
When using H.O. mode and S mode n
I
l Working mode: H.O. b

B
0 Power set: S 0
0 CO function: Actuated 0
z
l Pump absorption At 85% partial 2
horsepower: output point E
._
Engine speed N
W
P Engine speed N
PC3OOLC PC4oOLC 205FO5125 205FO5126
177.5 HP/2400 rpm 236.6 HP/2,000 rpm

Main pump delivery
L
l When the pump controller receives the work-
ing mode [H.O.] and power set [S] signal
from the monitor, it sends out an electric
command for the S mode output setting to
the engine throttle controller.
and uses the governor motor to set the gov-
ernor lever to the FULL position.
l The pump absorption horsepower and engine
speed are different, but the control is basical- Pump delivery volume Q
ly the same as for [H] mode (engine speed 205FO5133
sensing at the matching point).
When using G.O., F.O. or L.O. mode and S

mode
l
0
Working
Power set:
mode: G.O., F.O. or L.O.
S +
Engine torque l
% _.-
Engine horsepower
ml
0 CO function: Actuated J .., hi
3
P
l Pump absorption At 85% partial B -2
horsepower: output point ii! s
5
8
L
L5: E
PC3OOLC PC4oOLC 6
Engine speed N Engine speed N
177.5 HP/l ,860 rpm 236.6 HP/l,800 rpm 15
205FO5128 205FO5129

0 When the pump controller receives the work-
ing mode [G.O.] (or [F.O.] [L.O.]) and power
set [S] signal from the monitor, it sends out
an electric command for the S mode output
governor lever to the partial position.
speed are different, but the control is basical-
ly the same as for [H] mode (engine speed
sensing at the matching point). Pump delivery volume Q
205FO5136
lo-128
CONTROL OF L MODE l Engine torque Engine horsepower
When using H.O. mode and L mode cl
l Working mode: H.O.
0 Power set: L
l Pump absorption At 70% partial
horsepower: output point
I I I
Engine speed N Engine speed N
PC3OOLC. PC4OOLC 205FO5131 205FO5132
147.9 HP/2,000 rpm 192.3 HP/2,000 rpm

0 When the pump controller receives the work- o- I

ing mode [H.O.] and power set [L] signal
command for the L mode output setting to
governor lever to the FULL position.
l The pump absorption horsepower and engine ai
speed are different, but the control is basical- Pump delivery volume Q
ly the same as for [H] mode (engine speed 205FO5127
When using G.O. or F.O. mode and L mode

l Working mode: G.O. or F.O. l Engine torque l Engine horsepower
0 Power set: L
l Pump absorption At 70% partial
horsepower: output point
PC3OOLC PC400LC
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm
205FO5134 UJ 205FO5135
l When the pump controller receives the work-

ing mode [G.O.] (or [F.O.]) and power set [L], l Main pump delivery
signal from the monitor, it sends out an
electric command for the L mode output
governor lever to the partial position.
speed and different, but the control is
basically the same as for [H] mode (engine
speed sensing at the matching point).
205FO5130
IO-129
When using L.O. mode and L mode l Engine torque
l Working mode: L.O.
0 Power set: L
0 Pump absorption At 62% partial
horsepower: output point.
PC3OOLC I PC46OLC
128.2 HP/l,400 rpm 1 172.5 HP/l,400 rpm
When the pump controller receives the work- Engine speed N

205FO5137
ing mode [L.O.] and power set [L] signal
l Engine horsepower
command for the L mode output setting to
and sets the governor lever to the partial
position.
The pump absorption horsepower and engine
speed are different, but the control is basical-
ly the same as for [H] mode (engine speed
The area around the matching point is a
highly efficient area for engine fuel consump-
tion, so the fuel reduction effect is extremely Engine speed N
large. 205FO5138
At the same time, by throttling the pump
output, it is possible to obtain a high level of
fine control performance to match fine con-
trol operation.

205FO5139
1 o-1 30
CONTROL OF POWER MAXIMIZING FUNCTION l Engine torque
l When the power max. switch is OFF.
l Working mode: H.O. or G.O.

0 Power set: Same for any mode
l Pump absorption Depends on the setting
horsepower: for working mode and
power set.
u
Engine speed N
205FO5122
l When power maximizing switch ON.
l Engine horsepower
l Working mode: H.O.
0 Power set: H
0 CO function: Cancel
l Pump absorption At rated output point
horsepower:
0 Operation time: Even if the switch is
kept ON, it is automa-
tically canceled after
8.5 seconds.
l When the working mode switch is at [H.O.] or Y I
[G.O.] and the power max. switch is pushed Engine speed N

ON, the following functions are actuated 205FO5 123
while the switch is being pressed.
1. If either of the working modes and any of
the power sets is selected, the system
will switch to [H.O.] and [HI.
2. The CO (cut-off) function is canceled and
the flow at near relief pressure is in-
creased.
* l=ysTc$ails see, PUMP CONTROL
* Even if the switch is kept pressed, the

above function is automatically canceled
after 8.5 seconds and the system is reset
to the condition before the switch was
pressed.
205FO5 140
* This function does not work when the
working mode switch is at _[F.O.] - or
[L.O.]. -
1 o-1 31
CONTROL FUNCTIONS WHEN TRAVELING l Engine torque
l When the travel is operated, even if any

working mode or power set is selected, the
, working mode and engine speed will stay as
they are, and only the power set is switched
to the equivalent of H mode to increase the
pump absorption torque.
Engine speed N
205FO5141
l Engine horsepower
CONTROL FUNCTION WHEN TVC PROLIX Engine speed N

207FO5053
SWITCH IS ON
l If any abnormality occurs in the controller or
sensors, a constant current flows form the l Main pump delivery
battery to the TVC valve so that the function
can be maintained through a pump absorp-
tion torque more or less equivalent to S
mode
In this condition, only hydraulic sensing using
the TVC valve is used.

207FO5079
1 o-1 32
SELECTION OF MODE
Foldout 7
Power maximizing switch OFF Power maximizing switch ON

g
g Manual selection mode Auto-selection function Manual selection mode Auto-selection function
P
z Power set Half Level of achievement Power set Half Level of achievement
Auto CO Auto CO
flow flow
4 decel cnacel decel cancel
PC3OOLC PC4OOLC mode PC3OOLC PC4OOLC mode
H 1. Full power used by engine speed 1. Full power used by engine speed
ON sensing sensing
207 HP/2,000 rpm 276 HP/2,000 rpm 2. Power increased by cancellation of
S
,9 ON/ ON
OFF (Operation) (Cancel)
OFF I_ ~~ _ H ON KZrtZelJ KZelI !\ i\-
z 177.5 HP/2,000 rpm 236.6 HP/2,000 rpm
L 207 HP/2,000 rpm 276 HP/2,000 rpm

ON/ Eng.PwdN Pump
a#,rary
YOlUrnC
0 P
Engine speed N Pump d*hwv lOlYme 0
OFF 205FO5172 205FO5173
147.9 HP/2,000 rpm 192.3 HP/2,000 rpm 205FO5180 205FO5181
H 1. Fuel consumption improved by 1. Full power used by engine speed

ON/ sensing
partial use of engine power
207 HP/2,000 rpm 276 HP/2,000 rpm OFF 2. Power increased by cancellation of
S
9
ON (Operation)
ON KZzt!Zel) 1;: in H ON CCYrZelI KZ!elI I:::-: pi\-.
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm
L 207 HP/2,000 rpm 276 HP/2,000 rpm

ON/ Ef?+w
Ipeed
N Pump
WV YOlunl~
a d
Engtne sped N Pump d*llvery YOlUme Q
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm OFF 205FO5174 205FO5175
205FO5180 205FO5181
I
H 1. Ease of operation improved by half

ON/ flow mode function
207 HP/2,00O rpm 276 HP/2,000 rpm OFF
S
+ Same control as when power max. switch is OFF
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm OFF = (Operation)
ON (Operation)
L
ON/
147.9 HP/l ,800 rpm 192.3 HP/l ,800 rpm OFF
H 1. Increase of fine control range

ON/ 2. Improvement in efficiency by
207 HP/2,000rpm 276 HP/2,000rpm OFF lowering engine speed
,0 S
ON/ ON * Same control as when power max. switch is OFF.
i OFF (Operation) (Operation) f :
177.5 HP/l ,800 rpm 236.6 HP/l ,800 rpm ON :I~...--.-..- I\:.._.~~
L
1 OFF En*,ns
rpes6
N Pump
dollvely
OlYrnL
Q
128.2 HP/l ,400 rpm 172.5 HP/l ,400 rpm 205FO5178 205FO5179
* The thick lines mark the modes and functions that are automatically selected according to
selection of the working mode.
* When the starting switch is turned ON, working mode LG.01 and the default modes and
functions are automatically set. IO-133
1 o-1 34
PUMP CONTROL SYSTEM
1 (S$ch signal), ,- 1
I (Drive signal)
(Switch signal)
- Pump ;jDrive signal!,
controller (Drive signal)
I (Travel lever signal)
205FO5144
OUTLINE
l By controlling the main pump discharge
volume according to the stroke of the control
lever, it is possible to reduce the neutral loss
and fine control loss.
l The half flow mode function that is automati-
cally set by the working mode produces
excellent fine control performance.
l The cut-off function and cut-off cancel func-
tion, together with the 2-stage relief function
provide both reduction of relief loss and
increase of digging power.
IO-135
1) FLOW CONTROL FUNCTION
PNC (Pump Neutral Control)
l When the control levers are at neutral,
the pump discharge volume is controlled
to the minimum to reduce the wasted oil
flow that occurs when the control valve is
at neutral. I
PFC (Pump Fine Control) Lever stroke L

205FO5145
l When the lever is operated, the control
for the necessary oil flow is sent to the
pump based on the flow command corre-
sponding to the stroke of the lever. In this
way, the wasted oil flow that occurs
during fine control is reduced.
l At the same time, by increasing the pump
discharge volume by a suitable amount to
correspond to the stroke of the lever, the I cut off
fine control performance is improved.
* For details see, HYDRAULIC PUMP.
2) CUT-OFF (CO) FUNCTION

0 When the load increases during oper-
ations and the main pump discharge
pressure rises, it reduces the pump dis-
charge volume when the pressure is near
the relief pressure and acts to reduce
relief loss.
Pump discharge volume 0
* For details see, HYDRAULIC PUMP.
205FO5146
3) CUT-OFF CANCEL FUNCTION

l When the load increases during oper- Pump discharge volume is
ations and the main pump discharge
pressure rises, the pump discharge vol-
ume is not cut-off even when the pres-
sure is near the relief pressure. This
ensures the flow of oil and prevents any
drop in speed.
l Actuation and cancellation of the cut-off
function is automatically determined by
the position of the power max. switch,
travel lever and swing lock switch.
l Operation of switches and cut-off function.

Pump discharge volume Q
Power maximum Swing lock switch
Travel lever 205FO5147
switch (Note 1)
ON OFF Operated Neutral ON OFF

CO function Canceled Actuated Canceled Actuated Canceled Actuated
Note 1) This is only effective when the working mode switch

is at [H.O] or [G.O].
IO-136
Quick warming up of hydraulic oil when
swing lock switch is ON. When the
swing lock switch is turned ON, the CO
function is canceled.
In this condition, if the work equipment is
relieved, the hydraulic oil temperature
can be raised quickly to reduce the time
taken for warming up.
4) HALF FLOW MODE FUNCTION

When [F.O.] or [L.O.] is selected with the
working mode switch the operation of the
control valve for the arm Hi (acceleration) is
stopped. The pumps actuating the boom and
arm are separated, so the digging (finishing)
operation is not affected by the load on the
other circuit. This improves the fine control
and finishing precision.
l Relationship between working mode and
pump discharge volume (during indepen-
dent operation).
* The portion for one pump is taken as

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

When the power max. switch is pushed ON 1Power max. switch (Note 1) 1
(Note l), the P-stage relief solenoid valve
pilot pressure raises the set pressure of the
ON I OFF
main relief valve from 325 kg/cm2 to 350 Main relief valve set
350 325
kg/cm2 to increase the digging power. pressure (kg/cm2)
Note 1) This is only effective when the

working mode switch is at [H.O.]
or [G.O.].
IO-137
POWER MAXIMIZING FUNCTION
Control valve
[Jet -/
sensor
,
R.H. travel E Arm-Hi 3
E Arm-Lo 3 E Arm throttle 3
E Service E Bucket 3
E Swing priority 3 Boom-Lo 3
Boom-Hi 3 Straight-travel
Swing L.H. travel

I
Engine
Fuel Governor
injection motor
1 (Swim: signal) ,
t (Engine speed signal)

(Drive signal)
Engine throttle (Throttle signal) _ Rump controller (Drive,signal)
controller
[Tq
sET @
,;, I I =, [o]
(Switch signal) (Switch signal) woaklNc MODE@
OUTLINE 205FO5 148
l By pressing the switch on the left work equip-

ment lever knob, the maximum digging power
is increased to give superior production.
1 O-138
0 When the working mode is switched to [H.O.]
or [G.O.], and the power max. switch is
switched ON, the following functions are
actuated.
Power max. switch

Mode function
OFF i ON
H.O. or
Working mode Go H.O.
. .
Power set Any mode H
ICO function 1 Actuated 1 Canceled I
I
Main relief
valve pressure 1 ks3/2c5m21 350 kg/cm2 1
Even when pressed
Length of
continuously, it is can-
operation
celed after 8.5 sec.
* This function does not work if the working

mode switch is at [F.O.] or [L.O.].
10-139
AUTO DECELERATION SYSTEM
Engine
_. . . .. . I I
fuel control alal
HI n I Governor
Fuel injection mntnr
(Throttle signal) Enaine throttle

-_
controller
L.H. control R.H. control
PPC shuttle valve

c,
Oil pres.
switch (Work equipment +
swing lever signal)
-
I* ~..L_L_:--_I\
207FO5054
OUTLINE
l This is a fully electronic control type and
when all the work equipment, swing and
travel levers are at neutral, and the pump
controller receives the signal, it sends a
command to the engine throttle controller.
When this is received, the engine throttle Fuel control dial setting rpm
controller drives the governor motor to re-
mm
duce the engine speed, thereby reducing fuel
consumption and noise.
Control lever Neutral Control lever Operation
205FO5 150
1 O-l 40
OPERATION
When auto-deceleration switch ON
1. If the fuel control dial is set at a position
higher than 1500 rpm, and all control levers
are at neutral, the pump controller receives
the neutral signal and sends the auto-decel-
eration signal to the engine throttle
controller.
When the engine throttle controller receives
the signal, it sends the drive signal to the
governor motor to drive the governor motor
and pull back the injection pump governor
lever to the No. 1 deceleration position. It
holds it at this position for approximately 4
seconds. When this happens, the engine
speed is lowered by about 100 rpm from the
dial setting.
2. After the levers have been at neutral for more

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

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

l The engine speed can be set as desired
using the fuel control dial and even if all the
levers are at neutral, the engine speed is not
reduced.
FO20705003
IO-141
ENGINE AUTOMATIC WARMING-UP AND OVERHEAT PREVENTION FUNCTION
4 Engine
nD Coolant temp. sensor

Governor
1 Monitor panel / Fuel control dial

Hi
f
Lo
Engine throttle
1 (Warming-up signal) controller
-
(Working mode signal) Pump controller

c
(Power set signal)
e
205FO5154
OUTLINE
0 After the engine is started, this raises the
engine speed automatically to warm-up the
engine. (Automatic warming-up function.)
In addition, to protect the engine, if the
coolant temperature rises too high, it lowers
the pump load and engine speed to prevent
overheating of the engine. (Overheat preven-
tion function.)
1 O-l 42
1) AUTOMATIC WARMING-UP FUNCTION
0 Actuation table
Conditions Action
\_
Coolant temperature: Less than 30C
Fuel control dial: Below set speed
[set speed: 1450 rpm]
Engine speed: 1,450 r 100 rpm
sr If all the above conditions are satisfied,
the automatic warming-up function
is actuated.
Coolant temperature: Above 30C

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

0 Actuation table
r T Conditions Action
Power set:
Selected mode Action mode
H.0 and H,S mode H.0 and L mode

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

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

Power set: Default mode
than 102C. return fuel control
Engine speed: Fuel control dial set speed
dial to low idling position.
(as desired)
* Manual reset
IO-143
0
SWING CONTROL SYSTEM
L.H. control lever
Swing motor
Swing holding brake

Swing
I I
PPC shutlle
valve Oil pres.
switch
I
A (Swina lock sianal)
1 Pump controller
1_- Eying lever sign-$)
205FO51558
OUTLINE
l The swing is controlled comprehensively both
when stopping and when operating the swing
or work equipment, by the swing lock, swing
holding brake and swing priority function.
1 O-l 44
1) SWING LOCK AND AUTOMATIC SWING l Relationship between swing lock lamp and
HOLDING BRAKE SYSTEM the brake.
The swing lock (manual) and swing holding
brake (automatic) are employed to lock the Lock lamp Actuation
swing in the desired position and to prevent
hydraulic drift after stopping the swing. OFF (Switch OFF) The swing brake is applied ap-
(Swing holding prox. 4 seconds after the
brake applied) swing or work equipment con-
Swing lock prolix switch function trol lever is placed at neutral.
* When the pump controller is abnormal When the swing or work
and the swing holding brake function equipment control lever is
does not work normally, the swing lock operated, the swing brake is
prolix switch cancels the swing brake and released and the upper struc-
operates the swing. ture can swing freely.
* Even when the swing lock prolix switch is ON (switch ON) The upper structure is held in
turned ON, the swing lock switch stays (Swing lock ap- place by the swing brake and
ON and the swing brake is not canceled. plied) even if the swing or work
* When the swing brake is canceled, the equipment control lever is
swing has only a hydraulic brake operat- operated, the swing brake is
ed by the safety valve, so if the swing is not canceled, so the upper
stopped on a slope, there may be hydrau- structure does not swing.
lic drift.
Actuation table
Swing lock pro- ON OFF
lix switch I (when controller is abnormal) I (when controller is normal)
Swing lock
ON OFF ON OFF
switch
Swing lock ap- Swing holding
Swing brake Swing lock applied fzfdg lock can-
plied brake applied
2) HYDRAULIC OIL QUICK WARM-UP FUNC-

TION WHEN SWING LOCK SWITCH IS ON.
* For details see, PUMP CONTROL
SYSTEM
IO-145
TRAVEL CONTROL SYSTEM

Travel motor
Fuel control dial ,.,
[yiyjing signal, ) Pump controller

4 I
(Drive signal)
205FO5 156
OUTLINE
l This increases the pump absorption torque
and drawbar pull when traveling.
l The travel performance is improved by
switching the travel speed manually or auto-
matically.
1 O-l 46
1) PUMP CONTROL FUNCTION WHEN TRAV-
ELING
When traveling, the following functions are
actuated.
l If any of the working mode and power set
are selected, the working mode and
engine speed stay as they are and the
power set only is switched to the equiva-
lent of H mode.
* For details see, ENGINE AND PUMP
MUTUAL CONTROL SYSTEM.
2) TRAVEL SPEED SWITCHING FUNCTION
The switching of the travel speed can be
carried out manually or automatically, and
has the following functions.
0 When the travel speed switch is
switched, the solenoid valve is
switched. The action of the pilot pres-
sure then changes the motor rocker
cam angle and changes the travel
speed.
ii) If the speed setting of the fuel control
dial is set to less than approx. 1200
rpm:
l When traveling in Lo, even if it is
switched to Hi, the transmission is
not shifted.
l When traveling in Hi, the trans-
mission is automatically shifted to
Lo.
iii) Automatic switching between Hi and
Lo according to pump discharge
pressure. When traveling with the High speed
Uphill slope
travel speed switch at Hi, if the ma- travel I-I I
I 1 I I
chine travels up a slope and the pres- (Travel speed (Travel pressure
sure in the travel circuit goes above switch at Hi) continues at
310 kg/cm2 for more than 1 .O second more than 3 10
for the PC3OOLC, or 2.0 seconds for kg/cm2 for
the PC4OOLC, the solenoid valve is more than 1 .O
deactivated (closed) and the travel (FC3OOLC), 2.0
speed is switched to Lo. If the ma- (PC4OOLC) seconds)
chine continues to travel at Lo (with
the travel speed switch still at Hi) and
it comes again to flat ground or trav-
els downhill, and the pressure in the
travel circuit drops below 210 kg/cm2
for more than 1.0 second, the sole- (Travel pressure (Travel speed
noid is excited (opened) and the continues at switch at Hi)
speed is switched again to high less than 210
speed. kg/cm2 for
* Detection of the pressure in the more than 1 .O
travel circuit when only the travel seconds)
is being operated is made by
sensing the pressure for both the
front pump and the rear pump,
and taking the higher value; for
compound operations, only the
sensor for the rear pump pressure
is used.
IO-147
SYSTEM COMPONENT EQUIPMENT
1. PUMP CONTROLLER
CN-C3 CN-C2 CN-Cl
1. Self-diagnostic
display window
l----A Section A- A
205FO5157
IO-148
nput and output signal
:N-Cl CN-C
No Signal name In or Out Signal name In or Out
Travel oil pressure switch input
Service oil pressure switch 1 Input
Travel speed Input
Swing lock 1 Input
Power set (a) I Input 1

6 Arm half flow solenoid 1 output Power set (b) I Input 1
CO cancel solenoid output I
Auto-deceleration I
I
Input I
Swing brake solenoid output 8 GND
I
TVC valve (+) 1 output I 9 I Model selection I Input I
10 ]NC I I IO I Throttle (t) I Input I
11 NC I II I No. 2 throttle (t) I output I
12 GND I 12 ( Power maximizing I Input I
13 IGND I 13 I Service oil pressure switch 2 I Input I
14 INC I I 14 I Working mode (a) I Input I
15 I 2-stage relief solenoid I output I 15 I Working mode (b) I Input I
16 I Travel speed solenoid I output I 16 I Engine mode I Input I
17 I NC valve (-) I output I 17 I Coolant temperature 1020 I Input I
I 18 I Coolant temperature 105* I Input I
19
k 20
21
CN-C3
Signal name I In or Out I
10-149
2. ENGINE SPEED SENSOR
205FO51588
1. Magnet FUNCTION
2. Terminal l The engine speed sensor is installed to the
3. Case ring gear of the engine flywheel and acts to
4. Boot count electrically the number of gear teeth
5. Connector that pass in front of the sensor. This detec-
tion is carried out magnetically and the sen-
sor contains a magnet and detection coil.
3. ENGINE THROTTLE CONTROLLER, FUEL

CONTROL DIAL AND GOVERNOR MOTOR
* For detail see, ENGINE CONTROL SYS-
TEM.
4. MONITOR PANEL
* For detail see, EMACC.
5. TVC VALVE
j, For detail see, HYDRAULIC PUMP.
6. 2-STAGE RELIEF SOLENOID VALVE CO
CANCEL SOLENOID VALVE TRAVEL
SPEED SOLENOID VALVE ARM HALF
FLOW SOLENOID VALVE
* For detail see, SOLENOID VALVE
ASSEMBLY.
IO-150
7. PUMP PRESSURE SENSOR
2 3
1. Amplifier
1 2. Cord
3. Connector
4. Flange
5. Detect module of oil pressure
6. Introduction pipe of oil pressure
'6
Amplifier
205FO5159A
OUTLINE OPERATION
l The pump discharge pressure is converted to
a voltage and the signal is sent to the pump
Isolation
controller. To amplifier seam
FUNCTION
l The voltage output is proportional to the
pressure.
Oil pressure 205FO5 160
l When the pressurized oil entering from pres-

sure introduction pipe (6) is pressurized by
the diaphragm of pressure sensor module (5),
the diaphragm shape changes. A bridge is
formed on the opposite face of this dia-
phragm by a strain gauge and the deflection
Oil pressure P (kg/cm21 of the diaphragm is converted from a resis-
205FO5161 tance value of the strain gauge to the bridge
output voltage and is sent to the voltage
amplifier (amp).
l Relationship between output voltage V (v)
and pressure P(kg/cm).
V = 0.008 x Pt1.0. l The voltage is further amplified by the amplifi-
er and is output to the controller.
10-151
8. WORK EQUIPMENT*SWING OIL PRESSURE SWITCH, TRAVEL OIL PRESSURE SWITCH
ap--* I -21
202FO5 I65
1. Plug SPECIFICATIONS
2. Diaphragm Actuation pressure: 5.0 + 1 .O kg/cm*
3. Back up spring Reset pressure: 3.0 f 0.5 kg/cm*
4. Pin
5. Guide pin
6. Movable contacts
7. Connector
IO-152
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)
Monitor panel Relay Electrical parts
Sensor signal Engine throttle controller
Warming-up signal
I=7
Pump controller
-:
Sensor Power
source Buzzer signal
I
Coolant temp. signal
Buzzer
Battery
205FO5162
0 The Electronic Monitor And Control Console l Various modes selector switches are built
(EMACC) observes the condition of the ma- into the monitor panel and it acts as the
chine through the sensors installed to various control portion of the machine control sys-
parts of the machine and processes this tern.
information quickly. The system informs the
operator of the condition on the panel.
The content of the panel displays can be
broadly divided into the following.
1. Monitor portion that gives warnings when any
abnormality occurs in the machine.
2. The gauge portion (coolant temperature, fuel
level) that always informs the condition of the
machine.
IO-153
MONITOR PANEL
WORKING MODE
205FO5 163
CN-Pl CN-PP
l The monitor panel has the switch functions

for the electrical parts, mode selection and
monitor display functions.
It has a built-in Central Processing Unit
(CPU) and processes the data and outputs
the display.
The monitor display uses a Liquid Crystal
Display (LCD). The switches are flat sheet
switches.
1 O-l 54
Input and output signal
CN-P2
No Signal name In or Out
3 Swing lock Input
4 Travel speed output
5 Power set (a) output
6 Power set (b) output
7 Auto-deceleration output
1 8 1 Working mode (a) I output ~1
9 Working mode (b) output

I I
I II I Engine warming-up I output I

I 12 I Coolant Temperature IONIC I output I
1 13 1Coolant temperature 105*C I Output I
I 14 I
1 16 1GND
CN-Pl
INOI Signal name I In or Out I
1 Power source +24V
2 Power source +24V
I 3 IGND I I
I 5 I Fuel level I Input I

6 I Coolant temperature I Input I
7 I Charge level I Input I
8 I Starting signal I Input I
10 I Hydraulic oil level I Input I

11 I Buzzer I output I
12 I Heater Fan Lo I output I
13 I Heater Fan Hi I output I
14 I Lamp I output I
15 1Wiper I output I
16 I Engine oil pressure Input I
17 I Coolant level I Input I
18 I Engine oil level I Input I
19 I (PPC oil pressure) I Input I
20 I (Over-load warning) I Input I
IO-155
1. MONITOR
12345 1. Coolant temperature gauge

2. Engine oil level caution lamp
3. Coolant level lamp
4. Coolant temperature caution lamp
5. Coolant level caution lamp
6. Engine oil pressure caution lamp
7. Fuel level caution lamp
8. Charge level caution lamp
9. Hydraulic oil level caution lamp
10. Fuel level gauge
9 8 7 6
llAJ0050
Classifi-
Condition for displaying
cation of Symbol Item Description
abnormalities
indication
Q Coolant level Below low level Indicates when placing the starting
Eswitch to ON before starting the
cengine.
Engine oil level Below low level If it is normal, the lamp goes off.
- If it is an abnormality, the lamp
1flashes.
Hydraulic oil level Below low level
43
b Engine oil pressure 0.5 kg/cm* max. Indicates while the engine is tunning
and the starting switch is set to ON.
Coolant level Below low level If it is normal, the lamp goes off.
8
If it is an abnormality, the lamp
iFlashes and the buzzer sounds.
Coolant temperature 107C min.
9
Indicates when the engine is running
m Charge level When charging system fails. and the starting switch is set to ON.
If it is normal, the lamp goes off.
If it is an abnormality, the lamp
Fuel level Below low level
flashes.
67 76 83 90 $7 102 107C
Appropriate place (one place)

Coolant temperature
8 lights up.
All light up below appropriate

level
IO-156
2. SWITCH
8. Wiper switch
5 9. Swing lock lamp
205FO5 165
l The switches consist of four mode selector Switch actuation table

switches and four electrical component Item Action
switches; every time the switch is pressed,
the condition of the machine changes. The Working mode G.O. - H.O. - L.O. - F.O.
present condition is displayed by the lighting Power set S-H-L
1
up of the LED above the switch.
Auto decel ON - OFF
Travel speed Lo - Hi
Fan OFF - Lo - Hi
Wiper OFF - Lo 4 Hi
Lamp OFF-1 -2
Buzzer cancel 1 OFF - ON
* The bold letters indicated the default values

when the starting switch is turned ON.
10-157
SENSOR
l The signals from the sensors are input direct-
ly to the monitor panel.
One of the contact points of the sensors with
contacts is always connected to the chassis
GND.
Classification of
Type of sensor Sensing type Normal Abnormal
indication
Coolant level Contact type ON (close) OFF (open)
CHECK
Electrostatic
MONITOR Engine oil level ON (close) OFF (open)
capacity method
GROUP
Hydraulic oil level Contact type ON (close) OFF (open)
CAUTION Engine oil pressure Contact type OFF (open) ON (close)
Coolant temperature Resistance type
GAUGEGROUP
Fuel level Resistance type
1. COOLANT LEVEL SENSOR

PC3OOLC PC4OOLC
0
0
X08CD044
1. Sub-tank 1. Connector
205FO5166
2. Float 2. Plug
3. Sensor 3. Switch
4. Connector 4. Float
1O-158
2. ENGINE OIL LEVEL SENSOR
1. Coil
2. Plug
J-1 3. Connector
t+ BATTERY)
l_I_rTE1
IO-32v
A (TEST1 0 CSIGNALI
3. HYDRAULIC OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch
&-=+
205F05167A
IO-159
4. ENGINE OIL PRESSURE SENSOR
1. Plug
2. Connector
5. COOLANT TEMPERATURE SENSOR
1 2 3 1. Thermistor
2. Plug
3. Connector
IO-160
6. FUEL LEVEL SENSOR
1. Float
2. Connector
3. Cover
4. Variable resistance
2------E
pJ P
FEy
Section A - A
205FO5171
lo-161
IO-162
20 TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE ...................................... 20-2
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ............................... 20-27
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ......................... 20-39
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER ............................... 20-40
ADJUSTING ENGINE SPEED SENSOR .......................................... 20-41
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,

SWING AND TRAVEL CIRCUIT ................................................ 20-42
TESTING AND ADJUSTING CHARGING PUMP PRESSURE ............................ 20-45
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE ........................ 20-47
TESTING AND ADJUSTING TRAVEL DEVIATION ................................... 20-54
MEASURING STROKE OF SERVO PISTON ....................................... 20-57
MEASURING OUTPUT PRESSURE OF PPC VALVE .................................. 20-58
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE ............................ 20-59
TESTING PPC SHUTTLE VALVE ............................................... 20-60
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE ........................... 20-61
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ............... 20-62
BLEEDING AIR ......................................................... ..20-6 4
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................... 20-66
A
Before performing inspection, adjustment or faultfinding, park the machine on level ground and
check the safety pin and chock.
A
When performing joint work, make appropriate signals and allow only authorized personnel near
the machine.
A
When checking the water level, allow the engine to cool down before removing the radiator cap
to prevent the risk of being scalded by hot water which may spurt out if the engine is hot.
Take great care to avoid getting caught in rotating parts such as the fan, etc.
A
20-I
TABLE OF JUDGEMENT STANDARD VALUE
l FOR ENGINE
Machine Model PC3OOLC PC4OOLC
Engine KDC 614TA CUM LTAlO

f
Measurement Standard ermissible Standard Permissible

Item Unit
conditions valve value value value
High idling vm 2225 240 __ 2200 250

Engine speed Low idling wm 750 250 __ 750 250 __
Rated speed vm 2000 __ 2000 __
At sudden acceleration Bosch index __ __ __ __

* Exhaust gas color
At high idling Bosch index
__ __ -_ __
Intake valve mm 0.30 __ 0.36 __

* Valve clearance
(normal temperature)
Exhaust valve mm 0.61 __ 0.69 __
f Blowby pressure (Coolant temperature:

(SAE oil) Operating range)
At high idling mmH20 __ __
(Coolant temperature:
* Oil pressure Operating range)
4t rated speed (15W-40) 3.5 2.1 3.5 2.1
kg/cm2
At low idling (15W-40) 2.1 0.7 2.1 0.7
Whole speed range __

* Oil temperature C _- __
(inside oil pan)
* Fuel injection B.T.D.C. __

22
timing
Alternator __
Using
* Belt tension -_ __
gauge Between kg
(ST-l 293) fan and __ __
water
pump
t
* Refer to Engine Service Manual.
20-2
. FOR CHASSIS (PC3OOLC)
* The standard values and permissible values shown in this table are all values for H.0 (heavy-duty
operation) and H mode.
Mac hi ne model
T Pc3ooLc
Classifi
cation
Item
I Measurement conditions
I . Hydraulic oil temperature: 45 _ 55C

Unit Standard value Permissible value
At l-pump relief . Engine oil pressure:

Within operating range
2,100 f 100 -
Speed when auto-

. Fuel control dial at MAX.
deceleration is 1,4QO* 120
Control lever at neutral
actuated
Boom-Lo control
valve P a b a b
Boom-Hi control
valve
Arm-Lo control valve
Arm-Hi control valve mm 1 f 0. 5 11 f 0.5
202F2302
Travel control valve
. Center of lever knob Max. 75

Boom control lever 65?10 Min. 55
. Read max. value to end of travel
. Engine stopped
Max. 75
Arm control lever . Except for neutral play 65+10
Min. 55
Max. 75
Bucket control lever 65~10
Min. 55
mm
Max. 75
65+10
Min. 55
Max. 121
110f11
Min. 99
Play of travel lever Max. 15 Max. 20

I
Boom control lever Engine at high idling 2.3tO.3 Max. 3.1

1 _. Oil temperature: 45-55C
. Fit push-pull scale to center of
control lever knob to measure 1.ato.3 Max. 2.6
. Measure max. value to end of
1.8tO.3 Max. 2.6
Swing control lever 2.3tO.4 Max. 3.1

I
Lever 3.0 f 0.75 Max. 4.8

Pedal 8.4 f 2.1 Max. 13.4
20-3
I Machine model I PC3OOLC I
Classifica- Permissible
Measurement conditions Unit Standard value
tion value
325? 10 Max. 345

Min. 310
Arm Max.38
t350::3 ( Min.335 4
Oil temperature: 45-55C
Relief pressure with engine at high
idling.
H.O. and H mode
Bucket ( ): When using power maximizing
(reference)
At outlet of pump
Oil pressure when travel is relieved
on one side. 285 +I; Max. 310
Swing Min. 258
Max. 370
Travel Min. 335
32;; Max. 38
Charging pump Min. 28
Control lever at
2621 18 - 38
neutral
l-pump relief rg/cm2

Oil temperature: [2-pump aver-
TVC valve output 45-55C age oil press-
pressure Engine at high ure]
H.O. and H mode
I --pt+p2_ 1921
Max. 20
Min. 17
2
o-5 0 - 5.5
Oil temperature 45-

55C
Engine at high full track rotat-
CO*NC valve out- idling
put pressure H.O. and H mode 18 - 38 17 - 38
Measure at NC valve both not
valve outlet port
o-5 0 - 5.5
valve not actu-
ated]
Lever at Oil temperature: 4555C Max. 24
-F
Jet Engine at high idling 21*3 Min. 18
sensor neutral
Control lever at neutral
differ-
ential Oil temperature: 45-55C
Lever at Engine at high idling
pres-
end of Control lever at end of travel 0 - 2.5
sure 0 - 2.5
travel (Pump discharge pressure as de-
sired)
20-4
Classifi
Machine model
r Pc3ool_c
cati on Measurement conditions Unit Standard value Permissible value
Working equipment Max. reach
2cQF2323 Deg.
Swing brake angle . Engine at high idling Max. 78 Max. 88
mm)
Hydraulic oil temperature: 45 - 55C
Stop after swinging one turn
and measure distance that swing
circle moves
( I: Distance of movement on
outside circumference of
swins circle
Work equipment Max. reach 1
3.4 + 0.3 Max. 4.0
Time taken to start sec.

swing . Engine at high idling
. Hydraulic oil temperature:
45 - 55C
H.0 and H mode 180 5.0 f 0.5 Max. 6.0
Time taken from starting
position to swing 90 and
180
Work equipment Max. reach

posture
Time taken to swing sec. 30 * 2 Max. 36
. Engine at high idling 202F2323

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

Leakage from swing * Hydraulic oil temperature:
45 - 55Oc llmin Max. 5 Max. 10
motor
- Swing lock switch ON
* Relieve swing circuit.
20-5
Machine model PC300LC
Classifi- Standard value Permissible value

Item Measurement conditions Unit
cations
-
PC300 PC3OOLC PC300 PC3OOLC
Lo
Max. 56.6 Max. 59.8
50.6 f 3 53.8 k 3
Vlin. 47.6 Min. 50.8
Travel speed (1)
Engine at high idling

Hydraulic oil temperature:
45-555c
H.0 and H mode Max. 35.3 Max. 37.3
Hi 31.3 * 2. 33.3 * 2
Raise track on one side Min. 29.3 Min. 31.3
at a time, rotate one turn,
then measure time taken
for next 5 turns.
Max. 25.2 Max. 25.2

Lo 21.2 f 2
Min. 19.2 Min. 19.2
205F2409
-
Travel speed (2)
. Engine at high idling
45 - 55Oc Max. 17.1
Hi Max. 17.1
. H.O and H mode 13.1 It 2
Min. 11.1 Min. 11 .l
. Run up for at least 10 m,
and measure time taken to
travel next 20 m on flat
around.
205F2409

45-555=c
Travel deviation Run up for at leats lOm, and mm Max. 200 Max. 220
measure deviation when travel-
ing next 20 m on flat ground.
* Use a hard horizontal surface
I 20 m
205F240:
t Measure dimension x
20-6
Machine model PC3OOLC
_~
Classifi
Item Unit Standard value Permissible value
cation
Hydraulic drift of
mm 0 0
travel
. Engine stopped
45-555Oc
. Stop machine on 12 slope
with sprocket facing straight
up the slope.
Measure the distance the
machine moves in 5 minutes.
Leakage of travel Lockpin Urnin Max. 20 Max. 40

motor F20703008

- Hydraulic oil temperature:
45-555Oc
* Lock shoes and relieve travel
circuit.
Work equipment posture
Total work equip-

ment (hydraulic
drift at tip of Max. 450 Max. 675
bucket teeth)
Boom cylinder
(amount of
retraction of Max. 25 Max. 38
cylinder)
Place in above posture and
measure extension or retraction
of cylinder and downward
mm
movement at tip of bucket teeth.
. Bucket: Rated load
Arm cylinder . Horizontal,flat ground
(amount of . Levers at neutral Max. 135 Max. 203
extension of . Engine stopped
cylinder) Hydraulic oil temperature:
45 - 55Oc
. Start measuring immediately
after setting.
. Measure hydraulic drift for each
Bucket cylinder 5 minutes, and judge from results
(amount of for 15 minutes.
retraction of Max. 20 Max. 30
cylinder)
20-7
Machine model PCBOOLC
Classifi-
cati on
Item
r Measurement conditions Jn it Standard value Permissible value
Boom
3.5 f 0.4 Max. 4.3
Bucket teeth in
contact with
ground
cylinder fully . Engine at high idling

3.1 f 0.3 Max. 3.7
?xtended . Hydraulic oil temperature:
45-55Oc
. H.0 and H mode
Arm 4.1 f 0.4 Max. 4.9

Cylinder fully
retracted
205F2422
fully extended . Engine at high idling
3.1 f 0.3 Max. 3.8
45-555Oc
. H.O and H mode
4.8 i 0.5 Max. 5.8

But ket
Cylinder fully
retracted
Sec.

2.8 f 0.3 Max. 3.4
45 - 5!.Fc
. H.0 and H mode
Boom Max: 3.0
. Lower bucket to ground and

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

for a moment.
45-555Oc
20-8
Machine modal PCBOOLC
._
Classif Permissible value

Item Measurement conditions Unit Stand value
cation
Bucket Max. 3.0

-
Sec.
Amount of time when bucket

stops for a moment.
Engine: Low idling
45 - 55Oc
Cylinders Max. 4.5 Max. 20

45- 55Oc c/mir
Relieve circuit to be measured
Center swivel
Max. 10 Max. 50
joint

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

45- 55C
. Measure with engine running at
Charging pump rated speed. Min. 82
Min. 90
. At relief valve set pressure
Simir
(32 kgfcm )
Piston pump See next page See next page
20-9
Classifi-
Discharge volume of PC3OOLC main piston pump (H mode)
cation
300
200
100
(1
PI + P2
Pump discharge pressure = 7 (kg/cm )
L
205FO5644A
Pump rated speed: 1,950 rpm
Standard value Judgement standard

Discharge pressure Discharge pressure Average Pressure
for discharge value
Check point of test pump of other pump
amount
(kg/cm*) Q (Q/min) Q (Q/min)
(kg/cm) (kg/cm*)
I I I
PI + P, See graph
As desired PI P* See graph (Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
The error is greatest around the area where the graph bends, so avoid measuring at these ponts.
* When measuring with the pump mounted on the machine, if it is not possible to set the engine
to the specified speed with the fuel control dial, use the engine speed and pump discharge
amount as a base to calculate the pump discharge amount at the specified speed.
20-I 0
Classifi-
Dischargevolume of PC3OOLCmain piston pump (S mode)
cation
200 I
Lower limit
200 300 4
Pl + P2 ^.
Pump discharge pressure = 7 tkg/cm 1
L 205F05645A
Discharge pressure Discharge pressure Average Pressure Standard value Judgement standard
of test pump of other pump for discharge value
Check point
amount
(kg/cm ) (kg/cm ) (kg/cm)
Cl (Q/min) Cl (Q/min)
I I I I I
PI + P* See graph
As desired PI P, See graph
2 (Lower limit)
* Bring discharge pressure P, and P2 for the pump as close as possible to the average pressure
when measuring.
20-11
Dischargevolume of PC3OOLCmain piston pump (L mode)
cation
Pl + P2
Pump discharge pressure = - (kg/cm )
2 205F05742A

I I I I I
for discharge value
amount
Q(Umin)
(kg/cm) (kg/cm ) (kg/cm* ) Q (Urnin)
P, + P, See graph
As desired PI P, See graph
2 (Lower limit)
when measuring.
20-12
TABLE OF SPEEDS FOR S, L MODES
* The values in this table are reference values for the speed of the work equipment, swing, and travel
when switching from H.0 and H mode to other modes
Classifi- PC3OOLC
Item Measurement condition Unit
cation
3.O+SjF.O+SIL.O+L
ii
Boom
(Bucket teeth in . Measure full stroke for each
cylinder (for boom only,
3
contact with
ground * cylinder measure time taken to lower -a:
fully extended) to the ground)
. Set the machine on a flat
horizontal surface. ;
J
No load in bucket -
. Engineat high idling

. Hydraulic oil temperature: z 4.5 I 8.0 I 10.0
Arm 45-55Oc f 0.5 f 0.8 i 1.0
SW.
(Cylinder fully . When measuring boom: arm, I
I I
retracted cf fully bucketcylinders fully retracted,
extended) When measuring arm: top 3.4 3.7
surface of boom horizontal * 0.3 + 0.3 f 0.4
bucket cylinder fully 3.4 1 I
Bucket
retaracted
When measuring bucket: top
surface of boom horizontal,
4.9
zt 0.5
I I 4.9
rt 0.5
6.2
* 0.6
(Cylinder fully arm cylinder fully retracted
retracted +
2.9
I I
fully extended) 3.0
* 0.3 f 0.3 * 0.3
2.9
. No load in bucket
.-F Time taken to . Swing one turn, then measure
Sec.
13.3 I 13.3 I 16.7
m swing time taken to swing next
two turns.
* 0.7 * 0.7 f 0.8
. Engine at high idling 23.6 I 23.6 I 29.3

Hydraulic oil temperature: Lo f 1.2 * 1.2 * 1.5
45 - 55Oc
Travel speed Raise track on oneside at a time, Sec. I I
I I
rotate one turn, then measure
14.9 14.9 18.8
time taken to rotate the next Hi
* 0.7 f 0.7 f 0.9
two turns.
Amount of deviation when

traveling 20 m as shown below
l Us a hard horizontal surface.
mm Max. 200
Travel deviation
205F2402
l Measure dimension x
20-I 3
20-14
l For Chassis PC4OOLC
_* The standard values and permissible values shown in this table are all values for H.0 (heavy-duty
operation) and H mode.
Machine model
T PC4OOLC
Classifi.
Item Measurement conditions Unit Standard value Permissible value
cation
Hydraulic oil temperature: 45 - 55C

At l-pump relief . Engine oil pressure:
Within operating range
. Coolant temperature: 2,100 It 100 _
Within opkrating range
At 2-pump relief . l-pump relief: Bucket relief rpm
2-pump relief: Arm relief
Speed when auto-
deceleration is
. Fuel control dial at MAX.
Control lever at neutral 1,600 t 120 1,600 + li0
actuated
-
Boom-Lo control
P
t-l-
valve b !2 a b
Boom-Hi control
valve
I
Arm-Lo control valve
1
Arm-Hi control valve mm - 11 io. II * 0.5 11 * 0.5 11 i 0.5
Bucket control valve
202F2302
A_-
Swing control valve
i
Travel control valve
. Center of lever knob Max. 75

Boom control lever 65+10 Min. 55
Read max. value to end of travel
. Engine stopped
Max. 75
Arm control lever Except for neutral play 65+10
Min. 55
Max. 75
Bucket control lever 65110
Min. 55
mm
Max. 75
Swing control lever 65210
Min. 55
Max. 131
Travel control lever 120t11
Min. 109
Play of travel lever Max. 15 Max. 20

I
2.3 k 0.6 Max. 3.8
1.8 f 0.5 Max. 3.0
BY/*l/yntroll
Measure max. value to end of
trave 1.8 -I 0.5 Max. 3.0
Swing control lever 2.3 jz 0.6 Max. 3.8

I
Lever 3.0 Max. 4.8

Pedal a.4 i 2.1 Max. 13.4
20-15
0
r Machine model
lassifica- Item Measurement conditions Unit Standard value
tion value
3255 10 Max. 345

Min. 310
Arm Max.37
Oil temperature: 45-55C
(35C$) ( Min.3354
Relief pressure with engine at high
idling.
(Relieve only circuit to be measured)
Bucket H.O. and H mode
( ): When using power maximizing
(reference)
At outlet of pump
Oil pressure when travel is relieved
on one side. 275 +A; Max. 300
Swing Min. 249
Max. 370
Travel Min. 325
32: Max. 38
Charging pump Min. 28
Control lever at 27~1 18 - 38

neutral
l-pump relief
[2-pump aver- rg/cm2
Oil temperature: age oil press-
TVC valve output 45-55 c u re]
pressure Engine at high Max. 21
H.O. and H mode 4% _ 2021 Min. 18
2
170-180
kg/cm2
-.
IControl lever a+
neutral
[CO valve not o-5 0 - 5.5
actuated, NC
. Oil temoerature valve actuated:
45-55+ Travel lever at
Engine at high full track rotat-
CO* NC valve out- idling ing freely
put pressure H.O. and H mode 18 - 38 17 - 38
[CO valve, NC
Measure at NC valve both not
valve outlet port Iactuated]
o-5 0 - 5.5
valve not actu-
. Oil temperature: 45-55C Max. 24

. Engine at high idling 2123 Min. 18
. Control lever at neutral
differ-
ential . Oil temperature: 45-55C
pres- . Engine at high idling
sure . Control lever at end of travel 0 - 2.5 0 - 2.5
(Pump discharge pressure as de-
sired)
20-16
Classifi
Item Measurement conditions Unit Standard value Permissible value
cation
Working equipment Max. reach
Swing brake angle Deg. Max. 120

. Engine at high idling Max. 90
(mm)
. Hydraulic oil temperature: 45 - 55C
Stop after swinging one turn
and measure distance that swing
circle moves
( 1: Distance of movement on
outside circumference of
swing circle
work equipment Max. reach
90 3.6 i 0.4 Max. 4.4
Time taken to start sec.

swing . Engine at high idling
45- 55Oc
. H.0 and H mode 180 5.3 * 0.5 Max. 6.3
. Time taken from starting
position to swing 90 and
180
Work equipment Max. reach

posture
Time taken to swing sec. 32 rt 2 Max. 38
Engine at high idling 202F2323

45 - 55C
. H.0 and H mode
Swing one turn, and measure time
taken to swing next 5 turns
4 F20703006
Hydraulic drift of
* Engine stopped
swing mm 0
+ Hydraulic oil temperature:
45-555Oc
+ Setmachine on 15 slope, and set
upper structure at 90 to the side.
* Make match marks on swing circle
outer race and track frame.
* Measure distance that match
- marks move apart after 5 minutes.
- Engine at high idling

Leakage from swing * Hydraulic oil temperature:
45 - 55C Qlmir Max. 5 Max. 10
motor
- Swing lock switch ON
1 Relieve swing circuit.
20-17
Machine model
T PC400LC
Classifi- Permissible value

Item Measurement conditions Unit Standard value
cations
PC400 PC4OOLC PC400 PC4OOLC
Lo Max. 67.5 Max. 71.2

61.5rt 3 65.2 k 3
Min. 58.5 Min. 62.2
Travel speed (I)

sec.
Engine at high idling
45 - 5!ic
H.0 and H mode Max. 38.6 Max. 40.8
Hi 34.6 zt 2 36.8 f 2
Raise track on one side Min. 32.6 Min. 34.8
at a time, rotate one turn,
then measure time taken
for next 5 turns.
Max. 27.2 Max. 27.2

Lo 23.2 * 2 23.2 k 2
Min. 21.2 Min. 21.2
Travel speed (2)

- sec.

45 - 55Oc
Hi Max. 17.1 Max. 17.1
H.0 and H mode 13.1 f 2 13.1 * 2
Min. 11.1 Min. 11.1
. Run up for at least IO m,
and measure time taken to
travel next 20 m on flat
ground.

45 - 55Oc
Travel deviation . Run up for at leats IOm, and mm Max. 200 Max. 220
measure deviation when travel-
ing next 20 m on flat ground.
* Use a hard horizontal surface
205F2402
l Measure dimension x
20-18
Classifi Unit Permissible value

Item Standard value
cation
Hydraulic drift of
mm 0 0
travel
. Engine stopped
45-55C
. Stop machine on 12 slope
with sprocket facing straight
up the slope.
. Measure the distance the
machine moves in 5 minutes.
Leakage of travel Lock/pin Zlmir Max. 20 Max. 40

motor F20703008

45-55C
. Lock shoes and relieve travel
circuit.
Work equipment posture
Total work equip-

ment (hydraulic
Max. 600 Max. 900
drift at tip of
bucket teeth)
Boom cylinder
200F1001
(amount of
Max. 25 Max. 38
retraction of
cylinder)
Place in above posture and
measure extension or retraction
of cylinder and downward mm
movement at tip of bucket teeth.
Bucket: Rated load
Arm cylinder Horizontal, flat ground
(amount of Levers at neutral
Max. 85 Max. 128
extension of Engine stopped
cylinder) Hydraulic oil temperature:
45- 55C
Start measuring immediately
after setting.
Measure hydraulic drift for each
Bucket cylinder 5 minutes, and judge from results
(amount of for 15 minutes.
Max. 30 Max. 45
retraction of
cylinder)
20-I 9
Classifi-
cation T Measurement conditions Jn it Standard value Permissible value
Boom
3.8 i 0.4 Max. 4.6
Bucket teeth in
contact with
ground
s
:ylinder fully . Engine at high idling
3.1 * 0.3 Max. 3.7
extended . Hydraulic oil temperature:
45- 5!ic
. H.0 and H mode
4.8 + 0.5 Max. 5.8

Arm
Cylinder fully
.etracted
$
ully extended . Engine at high idling 205F2422
3.9 * 0.4 Max. 4.7
45- 55C
H.0 and H mode
4.8 f 0.5 Max. 5.8

But ket
Cylinder fully
retracted
SW.
5
2.9 f 0.3 Max. 3.5
45 - 55Oc
. H.0 and H mode
Boom Max. 3.0 -
. Lower bucket to ground and

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

for a moment.
f Engine: Low idling
45-555C
20-20
Classif Permissible value

Item Measurement conditions Unit Stand value
cation!
Bucket Sec. Max. 3.0

-
Amount of time when bucket

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

45-55Oc c/min
Relieve circuit to be measured
Center swivel
Max. 10 Max. 50
joint

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

45-55OC
. Measure with engine running at
Charging pump rated speed. Min. 90 Min. 82
. At relief valve set pressure
Qimin
(32 kg/cm )
Piston pump See next page See next page
20-21
Classifi- Dischaige volume of PC4OOLC main piston pump (H mode)
cation
/ ::::;;
,.
Lower limit \ ,.,.II ::..
PI + P2
Pump discharge pressure = 2 (kg/cm )

Discharge pressure Discharge pressure Average Pressure for discharge
of test pump of other pump value
Check point amount
(kg/cm*) Q (Q/min)
(kg/cm* ) (kg/cm) Q (Q/min)
PI + P, See graph
As desired P, P* See graph
2 (Lower limit)
Sr Bring discharge pressure P, and Pz for the pump as close as possible to the average pressure
when measuring.
tr When measuring with the pump mounted on the machine, if it is not possible to set the engine
-amount as a base to calculate the pump discharge amount at the specified speed.
20-22
Classifi-
cation Dischargevolume of PC4CKrLC
main piston pump (S mode)
300
Pl + P2
Pump discharge pressure = - (kg/cm )
2 205F05647A

I I I I I
Discharge pressure Discharge pressure Average Pressure Standard value Judgement standard
of test pump of other pump for discharge value
Check point amount
(kg/cm ) (kg/cm 1 (kg/cm ) Q (Qlmin) Q (Q/min)
P, + P, See graph
As desired P, P* See graph
2 (Lower limit)
* Bring discharge pressure P, and P, for the pump as close as possible to the average pressure
when measuring.
20-23
Clanifi-
cation Dischargevolume of PC4OOLC main pi&n pump iL mode)
I-
I
1
Pl + P2
Pump discharge pressure = - (kg/cm*)
2 205F05648A

for discharge value
amount
(kg/cm) (kg/cm*) (kg/cm ) Q (Qlmin) Q Wmin)
See graph
As desired 1 PI j P, 1 p, j See graph
1 1 I L 1 (Lower limit)
when measuring.
t When measuring with the pump mounted on the machine, if it is not possible to set the engine
20-24
TABLE OF SPEEDS FOR S, L MODES
* The values in this table are reference values for the speed of the work equipment, swing, and travel
when switching from H.0 and H mode to other modes
Classifi-
Measurement condition Unit PC400LC
cation
Boom
(Bucket teeth in . Measure full stroke for each
contact with cylinder (for boom only,
ground *cylinder measure time taken to lower
fully extended) to the ground)
. Set the machine on a flat 3.2 I 3.2 I 3.4
horizontal surface. 2 0.3 * 0.3 * 0.4
. No load in bucket
. Engine at high idling I I
Hydraulic oil temperature: z 5.4 I 9.7 I 12.7
- f 0.5 * 1.0 * 1.3
Arm 45 - 55C SW.
(Cylinder fully . When measuring boom: arm, 1 I
retracted * fully bucket cylinders fully retracted
extended) . When measuring arm: top 4.1 4.4
surface of boom horizontal * 0.4 * 0.4 * 0.4
bucket cylinder fully 4.1 II II
retaracted
When measuring bucket: top
Bucket surface of boom horizontal,
(Cylinder fully arm cylinder fully retracted
retracted +
fully extended) 3.1 3.7
* 0.3
3.1 I f 0.3 I * 0.4
I I
. No load in bucket
Time taken to Swing one turn, then measure 14.6 14.6 18.4
Sec.
swing time taken to swing next * 0.7 * 0.7 f 0.9
two turns.

. Hydraulic oil temperature: LO
45 - 55Oc
Travel speed Raise track on one side at a time, Sec.
rotate one turn, then measure
time taken to rotate the next Hi
two turns.
. Amount of deviation when

traveling 20 m as shown below
* Us a hard horizontal surface.
I 20 m
mm Max. 200
Travel deviation
ZOSF2402
20-25
20-26
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
*Note 1: (Male) and (Female) in the Connector No. column indicates the mating at the terminal
(pin). (For details, see CONNECTION TABLE FOR CONNECTORS).
2: The figure in ( ) in the Judgement table column indicates the pin number.
Classifli- Measurement
No.
I
Connector Judgement table
cation! conditions
If the condition is as shown in the 1) Turn starting

table below, it is normal switch OFF.
2) Disconnect
Between (1) - (2) I 0.25 - 7kCl I connector.
Fuel control dial E6 (Male)
Between (2) - (3) j 0.25-7kS2 1
Between (1) - (3)

I 4-6K2
I

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

table below, it is normal switch OFF
2) Disconnect
Between (1) - (2) 4-9A-2
connector
Between (3) - (4) 4-9R

Motor E5 (Male)
Between (1) - (3) I No continuity I
(1) - chassis No continuity
(3) - chassis No continuity

table below, it is normal switch ON.
Power source 2) Insert

Between (1) - (12) 20 - 3ov T-adapter.
voltage
Between (2) - (121 20 - 3ov
1) Turn starting
switch ON.
2) Insert
Fuel control dial T-adapter.
(Throttle signal)
El

table below, it. is normal switch ON.
2) Insert
T-adapter.
Governor )I
Potentiometer
Between (6) - (16) 4.75 - 5.25V
20-27
CliaSifi Judgment table
Component Connector No.
conditions
cations

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

the table below, it is normal switch ON.
6 2) Insert
Warming-up
T-adapter.
signal

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

the table below, it is normal. switch ON.
2) Insert
El
Governor motor Between (3) - (14) 2.8 - 6.3V Tdapter
I
Between (4) - (15) 2.8 - 6.3V

switch ON.
table below, it is normal
2) Insert
Between (13) - (12) 20 - 3ov I T-adapter
Batterv relay
*This is only for 2.5 seconds after

turning the starting switch ON + OFF.
At other times, it is 0 V.

2) Disconnect
Model selection
Between connector
(17) - (12)
20-28
Classifi Measurement
cation Component Connector No. Judgment table
conditions

Throttle signal table below, it is normal. switch ON.
(engine throttle c2
controller) Between (20) - (10) 0.25 - 4.75 2) Insert
T-adapter

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

Engine speed sensor E7
2) Insert T-
adapter.
Between (1) - (2)
1) Screw in speed sensor until it contacts

ring gear, then turn back one turn.
2) Work normally after carrying out above

adjustment.
If the condition is as shown in the 1) Start engine.

table below, it is normal (Charge
accumulator)
For boom, arm, bucket and swing control levers
2) Disconnect
connector.
Work equipment .
swing oil pressure Sl (Male)
switch
Between (l), (2) - chassis Min. 1 MR I

table below, it is normal. (Charge accumu-
For travel control lever lator).
2) Disconnect
Lever at neutral Min. 1 Ma connector.
Travel oil pressure Between (1) - (2)
swicth S4 (Male)
Lever operated Max. 1.D
Between cl), (2) - chassis Min. 1 M.Q I
If the condition is as shown in the I) Start engine.

table below, it is normal.
2) Fuel control
dial at MAX.
Between (1) - (2)
I 18 - 28V
I
3) Insert
T-adapter.
C7 (Rear)
Pump pressure sensor I 1 I 1
C8 (Front)
IBetween
(,) _ (3)i 1o.5- 1.5v /
,4,:::;:,
ARM IN relief 3.1 - 4.5v
20-29
Inspec-
Classifi- Measurement
cat ions Component Connector No. tion hdgment table
conditions
method
8 If the condition is as shown in the 1) Turn start-

5 table below, it is normal. ing switch
z OFF.
E
Swing lock switch C2 (Female) i Switch OFF Min. 1 M.Q 2) Disconnect
Between (8) - (4) connector
2
Switch ON Max. 1 a c2.
z
1) Turn TVC
If the condition is as shown in the
prolix switch
table below, it is normal
OFF.
2) Turn start-
TVC solenoid valve C4 (Male) Between (1) - (2) IO-22.D
ing switch
OFF.
Between (2) -chassis Min. 1 MS2 3) Disconnect
connector C4.
k If the condition is as shown in the 1) Turn start-

Ei table below, it is normal. ing switch
OFF.
&I
= Swing brake 2) Disconnect
Vl (Male) Between (1) - (2) IO-335.Q
z solenoid valve 1 connector
E
Between (2) - chassis Vl .
8 Min. 1 Ma I
If the condition is as shown in the 1) Turn start-

table below, it is normal ing switch
OFF.
Travel speed
solenoid valve
V2 (Male) Between (1) - (2) 50 - looa 2) Disconnect
connector
Between (2) - chassis Min. 1 Ma v2.

table below, it is normal. ing switch
OFF.
CO cancel
V4 (Male) Between (1) - (2) 50 - loon 2) Disconnect
solenoid valve I I
connector
Between (2) - chassis Min. lMS1 v4.

OFF.
2-stage relief
solenoid valve
V7 (Male) Between (1) - (2) I 50 - 100Q I 2) Disconnect
connector
Between (2) - chassis v7
Min. 1MQ
I
I
Arm half flow OFF.
V5 (Male) Between (1) - (2) lo-35sL 2) Disconnect
solenoid valve
connector
Between (2) - chassis Min.1 Ma
I v5.
20-30
Classifi Measurement
aonent Connector No. Judgment table
cati ens conditions
If the condition is as shown in the I ) Turn start-

Pov\Er source OFF.
volt age Between (12). (13)-(31, (4) 20 - 3ov !) Insert
T-adapter.
If the condition is as shown in the 1) Turn start,

ON.
2) insert
T-adapter.
Wor king mode

c2
swit ch
If the condition is as shown in the 1) Turn start.

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

Powe r set switch c2
S mode
Between (8) - (6) 10 - 13V
Between (8) - (5) * 0 - IV

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

I I I I ON.
Auto- deceleration 2) Insert
switct 7 c2 Tdadapter.
I I / I

ON.
Tr; 3vel speed 2) Insert
SWitch c2 T-adapter.

ON.
Power 2) Insert
Switch OFF 20 - 28V
switch c2 Between Tadapter.
(8) - (12)
Switch ON o-1v
20-31
Classil Measurement
Component Connector No. Adgment table
cati on conditions

ON.
2) Insert
T-adapter.
3001ant temperatun
signal c2
(102C, 107OC)

ON.
Model
c2 2) Insert
selection
T-adapter.

table below, it is normal. 2) Insert
T-adapter.
Autodeceleration
c2 3) All levers
output signal
at neutral

ON.
Between
(21)-(11)
PCBOOLC PC4OOLC [Coolant
temperature
H.0 mode gauge is with-
0.75 - 1 .ov 0.75 - 1 .ov
or H mode in green range1
2) Insert
No. 2 throttle signal c2
1G.O. F.O. L.0
and S mode,
1 I I T-adapter.
1.23 - 1.53V 1.35 - 1.65V

G.0, F.0 and
L mode
L.0 and L mode 2.10 - 2.4OV 2.20 - 2.5OV

/ ,
When coolant 1
temperature is 4.0 - 4.25V 4.0 - 4.25V
above 10C

table below, it is normal. 2) Turn swing
lock switch
OFF.
Swing brake 3) Turn swing
Cl
solenoid lot k prolix
switch OFF.
4) Insert
T-adapter.
20-32
Classif
Ispee 1
Iti on Measurement
cation Component Connector No. Judgment table
conditions
lathoc

table below, it is normal. 2) Insert
Tadapter.
3) Fuel control
r----i
Travel speed
Travel speed 20 - 3ov dial at MAX.
switch at Lo
solenoid Cl
/I
Between
K5h)--(m o_3 4) Travel on

flat ground
If the condition is as shown in the 1 ) Turn start-

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

I I I I ON.
2) Insert
CO cancel
LI T-adapter.
solenoid

ON.
2) Insert
Arm half flow T+dapter.
solenoid
Cl
20-33
I nspec-
Classif
cation
onnector No.
I I
tion
method
Judgment table
Measurement
conditions
CHECK, CAUTION If the condition is as shown in Table 1, Table 2, and Table 3, the monitor I) Start engine
group pa nel is normal. 2) Insert T-adapter
Buzzer signal Ta ible 1 (CHECK, CAUTION group)
z -1
7 Monitor auxiliary signal input
The voltage for H and
L in the table are as
follows.
h
itg:_$ior Monitor
display
%I. Engine oil ii

pressure signal
H: 3.5 - 30V
Zoolant level
L: Approx. OV
1 (17)
1
12. Starting signal
H:7-30V ingine oil
eve1
L: Approx. OV
1 (18)
I
I I I
The starting signal is iydraulic oil ( I 1 H /I Flasing I
H once, but after that eve1 L
it becomes L. How- I (IO) L OFF
ever, until the starting
switch is turned OFF, reheat
the starting signal is I (9)
held in the memory
inside the monitor Flashing
panel as H.
OFF (
%3. Alternator
signal
H: 20- 30V
L: Max. 5V
%4. Sensor signal Iuel level

H:3.5-30V 1 (5)
L: Approx. OV
I
Flashing
Engine oil pressure signal

H and starting signal H
cressure
able 2 (Buzzer signal)

-
A Pl (4) Open (no connecting wiring)
P2 (I), (2), (14). (15)
-
B Pl (1) - (3) Starting switch ON
(+24V input) 20 - 3ov
Starting switch OFF

ov
c PI (II) (Alarm buzzer output) - (3) Remove connector, and

Disconnect P8 (coolant level sensor) buzzer sounds, or the follow-
ing cycle is repeated.
5
Connect short connector to P8 Over 2OV: 0.8 set
3V: 0.8 set
When short connector is

connected, buzzer stops or
voltage is OV.
20-34
I nspec-
Classil Measurement
Connector No. tion Judgment table
cation conditions
GAUGE group Table 3 (GAUGE group) I) Turn starting

switch OFF,
insert dummy
Position of Display level resistance (kS1) resistance, or
gauge display (Monitor panel input resistance) measure resist-
ance (kn)
Starting switch Starting switch OFF (Monitor panel
ON input resistance)
\jjj_\\\
2) Turn starting
Measure reslst- Min. - Max. switch ON, and
ante between check display.
coolant tempera- I 0 -0.7 I 3) Connect socket.
ture gauge Pl
(female)
I 0.5 - 3.245 I
(6) - (3) 3.015 - 3.665
Dis- 3.419 - 4.222

plav
posi- I 3.946 5.092 - I
tion
I 4.764 - 6.248 I
5.844 - 7.713
7.086 - 10.17
Left
ride I 9.455 - Disconnection I
Right
Measure
side
resistance be-
tween fuel level
gauge Pl (female)
t
I 17.51 - 27.32 I
(5) - (3)
I 23.52 - 34.07 I
Iis- I 29.98 - 39.55 I
Ilay
losi- I 35.15 - 44.38 1
:ion
Left
ride I 611.82 - Disconnection 1
If the condition is as shown in the table below, I) Turn starting

it is normal. switch ON.
2) Insert T-adapter.
Coolant Between (12) - (16) 10 - 13V
temperature
below 102C Between (13) - (16) 10 - 13V
Coolant temperature Coolant

P2 above1020C
temperature
~ Between(12)-(16) ~ O-1 /
signal
below 107eC Between (13) - (16) 10 - 13V
Coolant Between (12) - (16) o- 1v

temperature
above 107C Between (13) - (16) o- 1v
If the condition is as shown in the table below, I) Trun starting

Coolant temperature Max. 1 V
Warming-up signal P2
below IOC Between
Coolant temperature (ll)-(16)
8-12V
above 50 C
20-35
Classif Measurement
Connector No. Judgment table
cation conditions
If the condition is as shown in the table below. 1) Turn starting

switch ON.
Working mode
P2
switch
1 F.0 mode -1
1 LO mode -1
If the condition is as shown in the table below, 1) Turn starting

Between (5) - (16) IO-13v

H mode
Between (6) - (16) 10 - l3V
Power set switch P2

Ismode -1
~ Lmode -1
l 10 - 13V when working mode if L.0 mode

Auto-deceleration I 1 I 1
P2 ON Max. 1 V
switch Between
(7) - (16)
OFF 8-12v
If the condition isas shown in the table below, 1) Turn starting

Travel speed switch P2

it is normal. switch OFF.
2) Disconnect
connector P8.
Coolant level sensor P8 (Male) Coolant level normal Continuity
Coolant level abnormal No. continuity

2) Disconnect
Continuity connector P5.
Engine oil level sensor P5 (Male) Engine oil level.normal
Engine oil level abnormal No continuity
-.
20-36
Inspec-
Classif
cation
Component Connector NO. tion
method
Judgment table
I Measurement
conditions

2) Pisconnect
Hydraulic oil level sensor P9 (Male)

21 connector pg.

it is normal. switch OFF
2) Disconnect
Coolant temperature connector PJ.
sensor P7 (Male)
If the condition isas shown in the table below, 1) Start engine.

it is normal. 2) Disconnect
wiring.
Engine oil pressure
sensor
)
2) Disconnect
Fuel level sensor P6 (Male) connector P6.
When engine is running (l/2 throttle or above): 1) Start engine.

27.5 - 29.5V
Between
alternator * If the battery is old, or after starting in cold
Alternator
terminal R areas, the voltage may not rise for some time.
- chassis
20-37
20-38
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or
Symbol Part Number Part Name Remarks
measurement item
I I I
Multi- Digital display: L: 60-2,000 rpm

Engine speed A 799-203-8000
tachometer H: 60-19,999 rpm
Water and oil Digital tempera- _50 _ 1 2oooc

B 799-l 01-l 500
temperatures ture gauge
I I 799-l 01-5002 Hydraulic tester

Pressure gauge
25, 60, 400, 600 kg/cm2
Hydraulic pressure
II 790-261-l 203
Digital hydraulic
tester
Pressure gauge 700 kg/cm2
.790-261-l 310
2 *790-261-l 320 Adapter
l790-261-1330
Blow-by pressure E 799-201-l 504 Blow-by checker O-500 mmH20
Commercially
Valve clearance F Feeler gauge
available
Exhaust color
Commercially (Discoloration %x1 /lO =
Smoke meter Bosch index)
available
Operating force H 1 79A-264-0020 1 Push-pull scale 1
Stroke hydraulic drift I 1 790-301-1410 1 Scale

I
Work equipment
J 799-201-l 120 Stop watch
speed
Pump performance K 1 790-303-1003 1 Flowmeter kit

I
1 799-601-2600 T-adapter box
Troubleshooting of 2 799-601-7000 Adapter assy *Kit Part Number

wiring harness and L . T-adapter kit
sensors 799-60 l-2730 799-60 l-71 00
3 Adapter
799-601-2740
Troubleshooting of
voltage and resistance M Tester
79A-264-0210
values
20-39
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER
ADJUSTING
Pc3OOLC
1. Turn the starting switch OFF. FULL SPEED
2. Pull out pin (6), then disconnect spring rod

(3) from governor motor lever (2).
3. Adjust the length of spring rod (3) and yoke

(4) and temporarily assemble so that gover-
nor motor lever (1) and governor lever (2) are ANOE
IYOTOR
ORlow
STOF
at the FULL position (stopper position).
PC3OOLC
4. After temporarily assembling, loosen yoke (4)

P-turns, then secure it with locknut (5).
l The distance between the pins will in-

crease by 2.5 mm.
Pc4OOLC
PC4OOLC
4. After temporarily assembling, tighten yoke (4)

4-turns, then secure it with locknut (5).
l The distance between the pins will de-

crease by 5mm.
20-40
ADJUSTING ENGINE SPEED SENSOR
PC3oOLC
1. Screw in so that tip of sensor (1) contacts
gear (2).
2. When sensor (1) contacts gear (2), turn it
back one turn.
3. Tighten locknut (3).
* When connecting the wiring, be careful to
prevent any excessive force from bearing
on the wiring of the sensor.
* Be careful not to scratch the top of the
sensor or to get any metal powder stuck
to it.
OBCDDD27
Pc4OOLC
205FO5661
2 Clearance
205FO5222
20-41
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
EQUIPMENT, SWING AND TRAVEL CIRCUIT
1) Measuring
* Oil temperature when measuring: 45-55C.
S
A4Y Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the re-
maining pressure in the hydraulic piping.
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
Put the safety lock lever in the LOCK
position. - Y 305FO!i662
1. Remove pressure pick-up plug (1) or (2)

(Thread dia. = 1Omm Pitch = 1.25mm) from the
1
circuit to be measured, then install oil pres-
sure gauge Cl (600 kg/cm2).
2. Start the engine, set to the H.O. and H mode
and measure the main relief pressure with the
engine at high idling.
l Condition of actuator to be measured:
0 For the work equipment, set each
cylinder to the end of its stroke.
ii) For swing, turn the swing lock switch
ON.
iii) For travel, fit block @ under the // 205FO5224
track shoe grouser. Or fit block @
between the sprocket and frame to
lock the track shoe. Measure one side
at a time.
Table1
Actuator controlled
l Arm cylinder
l Boom cylinder
l Swing motor*
l R.H. travel motor
l Arm cylinder
l Boom cylinder*
2 Rear pump l Bucket cylinder
l L.H. travel motor
205F05225 FO20705006
* The set pressure of safety valve for the boom

head end and swing motor is lower than the
set pressure of the main relief valve, so be
careful.
20-42
2) Adjusting
For front pump For rear pump
Main relief valve
\ /
1 Adjusting high set pressure:
i) Loosen locknut (3) and turn holder
(4) to adjust.
j, Adjust the holder as follows:
To INCREASE pressure, turn
CLOCKWISE.
0 To DECREASE pressure, turn
COUNTERCLOCKWISE.
1 iii-\
u Locknut: 11.5+ 1 .O kgm
2051 :05663
* When the high set pressure is adjusted,
the low set pressure also changes so
always adjust the low set pressure also.
2. Adjusting low set pressure:
i) Loosen locknut (5).
3 4 PR 5 6
* Check that elbow (6) moves.
ii) Loosen locknut (7) and turn holder
(8) to adjust.
l To INCREASE pressure, turn
CLOCKWISE.
l To DECREASE pressure, turn
COUNTERCLOCKWISE.
*Amount of adjustment for one 7 8
turn of holder: 128 kg/cm2 I 205FO5664
J
w Locknut: 4.5kO.5 kgm
* Normally, the pressure applied to port PR
is approx. 13 kg/cm2 or less and at high
set pressure, is approx. 30 kg/cm2.
Swing
1 Loosen
motor safety valve
locknut (9) and turn adjustment
I R.H. swing L.H. swing
screw (10) to adjust.

* Adjust the adjustment screw as follows.
CLOCKWISE.
COUNTERCLOCKWISE.
* Amount of adjustment for one turn of the
adjustment screw: 48.6 kg/cm2
u Locknut: 4+1 kgm 205FO5665
* After adjusting, repeat the procedure in
Step 1 to check again.
* Adjustment of the safety valve set pressure is
9 10
only for the swing motor. Do not try to adjust
\ /
the safety valve set pressure for any other I \ /
part.
205FO5666
20-43
PRECAUTIONS WHEN MEASURING HYDRAU-
LIC PRESSURE
1. Measuring hydraulic pressure under normal

operation.
Relieve the boom, arm and bucket cylinders
when measuring.
* Do not operate the power max. switch.
2 Measuring hydraulic pressure when P-stage
relief is actuated.
Push the power max. switch when measuring.
* If the power max. switch is pressed, the
CO cancel solenoid valve are actuated.
* When the CO valve is canceled, the relief
pressure is different when one side is
relieved and when both sides are
relieved.
Reference
Set pressure of safety valve
1. The set pressure of the safety valves in the Table 2 Set pressure of safety valves for each
swing motor and at the boom cylinder head actuator.
end is lower than the main relief set pressure, Set pressure
so for these two, the safety valve relief pres- Actuator
(kg/cm*)
sure is measured.
Head end 290
2. The set pressure of the actuators other than
Boom cylinder Bottom end 365
these is higher than the main relief set pres-
sure, so it is impossible to measure them Head end 365
directly. However, it is possible to judge if Arm cylinder Bottom end 365
they are correct or not as follows.
Head end 365
l When measuring the main relief pressure
Bucket cylinder Bottom end 365
at two or more actuators, if any actuator
is lower than the main relief pressure, the 275
Swing motor
set pressure of the safety valve for that (260)
actuator has dropped.
l If all of the actuators have low pressure,
the set pressure of the main relief valve
I Travel motor
I 335
(355) I
has dropped.
l ( ): Value for PC4OOLC
20-44
TESTING AND ADJUSTING CHARGING PUMP PRESSURE
1. MEASURING
* Oil temperature when measuring: 4555C.
1. Remove pressure pick-up plug (1) (Thread
dia: 14mm, Pitch: 15mm) and install hydrau-
lic pressure gauge Cl (60 kg/cm2).
2. Start the engine and measure with the engine
running at high idling.
* When measuring for internal leakage from
equipment in the charging circuit, use the
parts given below to shut off the following
parts of the circuit when measuring the relief 205FO5667
pressure.
No Selection of hydraulic Equipment that can
circuit shut off be inspected
1 Piston pump inlet port Piston pump
2 Charging pump outlet Charging pump
POfl
3 Solenoid valve inlet
Solenoid valve
Port
4 Travel PPC valve inlet Travel ppc va,ve
POfl
5 L.H. PPC valve inlet
L.H. PPC valve
POfl
I
6 R.H. PPC valve inlet ----h-t 205FO5668
R.H. PPC valve
Port
* Items No. 2 and below can be checked
Plug
/
* Items No. 2 and below can be checked if
the equipment in the previous number is
normal.
* Use the parts given below to shut off the
circuit.
l For elbow:
Sleeve nut: // 205FO5669
07221-20315, 07221-20422,
07221-20520
Plug: Travel PPC valve
Piston Pump Solenoid valve
07222-50325, 07222-00414
07222-00515 r-I-l=
L 1
tiharging
. For hose: >a :@ R.H. PPC valve
pump
Plug: 2 5
n ::
07376-50315, 07376-50422, T-^-u
I- - I Safety lock 1
07376-50522
L.H. PPC valve
rY?J
205FO5234
20-45
2. ADJUSTING
1. Loosen locknut (2) and turn adjustment
* Adjust the adjustment screw as follows.
CLOCKWISE.
COUNTERCLOCKWISE.
j, Amount of adjustment for one turn of
adjustment screw: 5.4 kg/cm2.
u Locknut: 6.5rt 1 .O kgm.
205FO5235 1
* After completion of adjustment, repeat

the procedure in Step 1 to check the set
pressure again.
20-46
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE
1) TVC valve output pressure

Measuring
* Oil temperature when measuring:
45-55C.
* Measure the relief pressure of the charg-
ing pump first and check that it is normal.
* The TVC valve output pressure for the
pump discharge pressure
(Pf+P2- average pressure), so

2 205FO5670
before measuring always adjust the main

relief pressure to the specified pressure.
1. Remove pressure pick-up plug (1) (Thread
dia. = lOmm, Pitch= 1.25mm) and install oil
pressure gauge Cl (60 kg/cm2).
2. Set to H.O. and H mode, run the engine at
high idling and measure the hydraulic pres-
sure with the control lever at neutral and at
pump relief.
[Reference] Graph 1
1. The average pressure at one pump relief is
approx. 175 kg/cm2. (The discharge pressure
of the pump being relieved is 325 kg/cm2
and the discharge pressure of the pump not
being relieved is approx. 20 kg/cm2.)
2. For the relationship between the change in
the TVC valve output pressure and the pump
discharge amount, see graphs 1 and 2.
100 200 300
Pump discharge pressure - + = Average pressure (kg/cm*)

2
205FO5231 3
Graph 2
V
TVC valve control area
When CO function is canceled
control area co valve

control area
Pump discharge pressure v = Average pressure (kg/cm*)
205FO5239
20-47
r
Adjusting
* If the results of the measurements show that
the hydraulic pressure is not within the stan-
dard, adjust as follows.
1. Loosen locknut (2).
2. Turn adjustment screw (3) to adjust.
* If the adjustment screw is stiff, do not use
excessive force. If excessive force is used
to then the screw, the tip may break.
3. Adjust the adjustment screw as follows.
0 To INCREASE pressure, turn CLOCK-
WISE.
l To DECREASE pressure, turn COUNTER-
CLOCKWISE.
* Amount of adjustment for one turn of
adjustment screw: Approx. 3.5 kg.cm2.
* After adjusting with the adjustment screw,
repeat the procedure in measuring to check
the output pressure. 3
* If the adjustment screw is stiff and excessive
force is used to turn it, the tip may break, so
in this case, remove the TVC valve assembly,
remove the cover assembly and put lubricant
on the screw before trying to move it.
L 205FO5241
20-48
2) Output pressure of CO valve and NC valve
[Reference]
The output pressure of the NC valve controls
the discharge amount of the piston pump
flowing to the servo valve.
The oil flows TVC valve - CO valve - NC valve
- servo valve and the output pressure chang-
es as follows according to the movement of
the control lever of work equipment.
* Control levers at neutral.
The NC valve is actuated by the differen-
tial pressure of the jet sensor and the
output pressure drops below 5.5 kg/cm2.
* When hydraulic cylinder is relieved.
The CO valve is actuated and lowers the
pressure of the oil entering the NC valve
to below 5.5 kg/cm2. The NC valve sup-
plied this pressure as it is to the servo
valve. (The pump discharge amount in
this case is the minimum.)
* Work equipment, swing and travel actuat-
ed.
The output pressure of the TVC valve is
not affected by the CO valve and NC
valve and is supplied as it is to the servo
valve. 205FO567; ,
(The discharge amount of the pump
varies between the maximum and the
point where the CO valve is actuated.)
Measuring
* Oil temperature when measuring: 45-55C.
l Remove pressure pick-up plug (4) (Thread
dia. = 1Omm, Pitch = 1.25mm) and install oil
pressure gauge Cl (60 kg/cm2).
* This is at the body side of the servo
valve.
4
I. Pressure when NC valve is actuated.
Set to H.O. and H mode, run the engine at
high idling and measure the pressure when
all control levers are at neutral.
* Turn the auto-deceleration switch OFF.
* If the output pressure is more than 5.5
kg/cm2, measure the differential pressure
of the jet sensor.
20-49
2. Pressure when CO valve is actuated.
Run the engine at high idling and measure
the hydraulic pressure when any of the boom
(except LOWER) arm or bucket are relieved.
3. Pressure when work equipment or swing are
actuated.
A
The work equipment is actuated when
the pressure is measured, so be care-
ful of the surrounding area.
Measure the hydraulic pressure when reliev-
ing the swing (F pump) and when rotating the
track under no load (F, R pump) at the same
time as measuring the output pressure of the
TVC valve.
* If there is a big difference from the TVC
valve output pressure, the operation of
the CO valve or NC valve is probably
defective.
* The CO valve is canceled when the travel
is operated.
Adjusting
1. CO valve.
* If the set pressure of the CO valve is
high, the discharge amount is not re-
duced when the circuit is relieved, so the
relief pressure becomes high. For this
reason, always adjust the pressure to the
specified pressure.
i) Loosen locknut (5) and turn adjust-
ment screw (6) to adjust.
* Adjust the adjustment screw as
follows. 205FO5673
0 To INCREASE pressure, turn
CLOCKWISE.
COUNTERCLOCKWISE.
* Amount of adjustment for one
turn of adjustment screw:
41.25 kg/cm2.
* If the hydraulic pressure does not
drop even when the adjustment 6
screw is adjusted, there is proba-
bly a defect inside the CO valve.
ii) After adjusting, repeat the procedure
in measuring to check the set pres-
205FO5246
sure again.
20-50
2. NC Valve.
j, The NC valve is actuated by the differen- NCnvalve
tial pressure of the jet sensor, so when
adjusting it, always check first that the
differential pressure of the jet sensor is
correct.
i) Loosen locknut (7) and turn adjust-
ment screw (8) to adjust.
* Adjust the adjdstment screw as
follows.
0 To INCREASE pressure, turn
CLOCKWISE. 205FO5674

COUNTERCLOCKWISE.
* Amount of adjustment for one
turn of holder:
Approx. 4.3kg/cm2.
20-51
3) Differential pressure of jet sensor Relationship between travel of
r
[Reference] control lever and differential
High pressure and low pressure (high pres- pressure of jet sensor
sure - low pressure = differential pressure) is
formed at the outlet port of the control valve
\
and this differential pressure controls the NC
valve.
The differential pressure is at its maximum
when the control levers are at neutral and is
at its minimum when the control levers are
operated to the end of their travel. O Control lever travel (mm)
205FO5249
Measuring
Y
AY Loosen the oil filler
the pressure inside
cap slowly to release
the hydraulic tank.
k40il temperature when measuring: 4555C.
1. Remove pressure pick-up plugs (9) (high
pressure side) and (10) (low pressure side)
(PT l/8).
* For both front and rear sides, the plug
farthest from the engine is the high-pres-
sure side.
2. Install oil pressure gauge Cl 60 kg/cm2 at
1
high pressure side, 25 kg/cm at low pres-
sure side). 205FO5675
3. Set to H.O. and H mode, run the engine at

high idling and measure the differential pres-
sure with the control levers at neutral.
* High pressure (Pt) - low pressure (Pd) =
Differential pressure.
4. Using the work equipment, raise the track
frame on one side and measure the differen-
tial pressure with the track rotating freely
(control lever operated to the end of its
travel).
* Any actuator can be measured but it is
easiest to measure the free rotation of the
track because the measurement time can
be chosen as desired.
* The differential pressure is the minimum
(below 2.5 kg/cm2).
20-52
Adjusting
* If the results of the measurement show that
the differential pressure is not within the
standard value, adjust as follows.
1. Loosen locknut (11) and turn adjustment
i) Adjust the adjustment screw as fol-
lows. Jet sensor relief valves
CLOCKWISE.
205FO5676
COUNTERCLOCKWISE.
ii) Amount of adjustment for one turn of
the adjustment screw:
Approx. 16.6 kg/cm*
a Locknut: 7.0? 1 .O kgm.
* After adjusting the adjustment screw,

repeat the procedure in measuring to
check the differential pressure again.
I F20505398
20-53
TESTING AND ADJUSTING TRAVEL DEVIATION
Travel posture
1) Measuring when traveling
1. Set the machine in the travel posture.
* For the travel posture, extend the bucket
and arm cylinder rods fully and hold the
boom angel at 45.
2. Travel for lOm, then measure the deviation
when traveling for the next 20m.
j, Set to H.O.+H mode and measure with
the engine at high idling.
* Install the hydraulic pressure gauge and
measure the pump discharge pressure at
the same time.
20m 0 RunupforlOm
I
Do not stop; continue
to travel for the whole
distance
Make a mark Make a mark at the Make a mark

10 m midway point
Lay out a string

20 m point \
\
Mark
Measure the amount of __
dimension a at this point Mark
202F5258
2) Adjusting
If the results of the measurements are not
within the standard value, adjust as follows.
* Measurement pressure and adjustment
procedure.
Condition of 1 Pressure when measuring

deviation 1Deviates to riaht 1Deviates to left
Discharge pres- Remove shim at Remove shim
sure: 100 kg/cm2 rear pump to at front pump
adjust (a). to adjust (b).
Discharge pres- Screw in at rear Screw in at
sure: 180 kg/cm2 pump to adjust front pump to
(c). adjust (d). u 205FO5678
l If the travel deviation does not come

within the standard value even when
adjusted, go to Troubleshooting item
Travel deviation is excessive.
20-54
1. Shim adjustment procedure.
i) Loosen 4 bolts (1).
* Split shims are used so it is not
necessary to remove the bolts.
ii) Remove the appropriate thickness of
shim (2) to match the amount of devi-
ation, then tighten bolts (1).
* Amount of deviation and amount
of shim to remove.
PC3OOLC
,679
2 5-z
E
8a
c- 10 ' 200 ;$z
: SB
=z
z 5
-0 loo $ .E
3 I rJ
ri
h0 0 0.1 0.2 0.3 0.4 0.5 + u
Amount of shim to remove (mm)
205FO5680
PC4OOLC
20
z
,< 15 300
Z"
Q)
& 10 200
z=
.-
u
3 5 100
0
ii
0 0.1 0.2 0.3 0.4 0.5

Amount of shim to remove (mm)
205FO5681
* Do not remove more than 0.4mm of shim.

u Mounting bolt: 5.5?2 kgm.
2. Screw adjustment procedure.

i) Loosen locknut (4) of servo valve (3).
ii) Screw in adjustment screw (5) the
appropriate amount to match the
deviation, then tighten locknut (4).
Amount of travel deviation and
amount to screw in.
20-55
PC3OOLC
25 500
TE
BE 20 400
5
8 15 300
b
0
= 10 200
Is
ii
O 5 100
0 20 40 60 80 100 120
Angle to screw in (deg)
205FO5682
_
PC4OOLC
0 20 40 60 80 100 120
Angle to screw in (deg)

205FO5683
* Do not screw in more than 100.

u Locknut: 0.820.2 kgm.
* The travel deviation is an estimated value
and will change according to the type of
soil and travel surface condition, so use
the value as a guide and travel the ma-
chine again after adjusting to check the
deviation.
20-56
MEASURING STROKE OF SERVO PISTON
* If the output pressure of the NC valve is

normal and it is considered that the pump
performance is defective, inspect as follows
to determine if the servo valve is defective or
not.
1. PREPARE THE TOOL.

Make up gauge @ from the following parts.
1. Servo piston cap (side which has spring).
2. Dump truck brake wear measurement
gauge (566-98-41120).
3. Tap PT l/4 threads in the center of the 205FO5254
cap and install the gauge.
2. MEASURING
1. Remove the cap (with the spring) from
the side to be measured.
2. Fit the shims that were removed and
install gauge @ .
* Do not let the shims catch on the
threaded portion of the bolt.
3. Stop the engine, push the rod in fully,
then measure the dimension of the rod.
205FO5677
4. Raise the track shoe on the side where
the gauge is installed and measure the
dimension of the rod when the engine is
run at high idling and the track is rotated
freely.
* Standard stroke:
PCBOOLC: Approx. 8.9mm
PC4OOLC: Approx. 11.2mm
* When the track shoe is rotated freely,
push the rod by hand and check at
the same time that the rod moves
smoothly in accordance with the
travel of the control lever.
20-57
MEASURING OUTPUT PRESSURE OF PPC VALVE
* Oil temperature when measuring: 4555C.

1. Disconnect the hose (see diagram below)
from the circuit to be measured.
2. install adapter C2 between the hose and
elbow.
3. Install oil pressure gauge Cl (60 kg/cm2) to
adapter C2.
4. Run the engine at high idling, operate the
control lever for the circuit to be measured
and measure the hydraulic pressure.
Travel PPC valve 1 ml
R.H.
I \!4.P
I r
1 I L-a(y)
J-P-cy
(R)
L.H. PPC
1-1
205F05685A
* Color code:
6: Black, Br: Brown, W: White, Y: Yellow
Bu: Blue, G: Green, R: Red
20-58
ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE
* If there is excessive play in the work equip-

ment or swing lever, adjust as follows.
*
A
4
Y Lower the work equipment to the ground
levers several times to release the re-
maining pressure in the hydraulic piping.
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
Set the safety lock lever to the LOCK
position.
1. Remove the boot, loosen the lever mounting

bolt, then remove the lever.
2. Hold down disc (1) and loosen locknut (2).
3. Turn disc (1) and adjust the clearance.
* Adjust the clearance with the disc as
follows.
l To DECREASE clearance, turn
CLOCKWISE.
l To INCREASE clearance, turn
COUNTERCLOCKWISE.
0 When adjusting the clearance, adjust 0.3 - 0.5 mm 1
four pistons (3) separately. (Two
pistons in the front-to-rear direction
(A-a) and two pistons in the left-to- 3
right direction (B-b).)
ii) Set disc (1) so that it contacts one of
the pistons in the front-to-rear direc-
tion (A-a), then adjust the clearance
between disc (1) and piston (3) on
the opposite side to 0.3-05mm.
iii) After adjusting in the front-to-rear
direction, adjust in the left-to-right
direction (B-b).
iv) If the clearance exceeds 0.5mm,
change the position of disc (1) or
change the mounting position of pis-
ton (3), then check again. 205FO5257
L
m Locknut: 11.5t1.5 kgm.
* If no clearance is made, even when the
lever is at neutral, the work equipment
will move or the hydraulic drift will in-
crease, so always provide a clearance.
20-59
TESTING PPC SHUTTLE VALVE
f If the auto-deceleration does not work, the

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

to be tested.
l Work equipment*swing pressure switch i 205FO5256
(1).
l Travel pressure switch (2).
2. Install pressure gauge Cl (60 kg/cm*).
3. Run the engine at high idling, operate the fol-
lowing control lever and measure the hydrau-
lic pressure.
In the case of switch (l), operate the work
equipment or swing lever.
In the case of switch (2), operate the travel
lever.
I 2 205FO5686
20-60
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE
l Measure each solenoid valve at the following

place.
1 No. 1 Solenoid 1Measurement location
205FO5687
205 iFO5688
1. Disconnect the hose and install adapter C2 4. CO cancel solenoid valve.

between the measurement point and the Turn the swing lock switch ON.
hose. 5. 2-stage relief solenoid valve
Push the power max. switch ON.
-k Adapter
Size 1 Part No.
02 790-261-l 310
03 790-261-l 320
I 04 1 790-261-l 330
2. Install oil pressure gauge Cl (60 kg/cm2) to

the adapter.
3. Run the engine at high idle and measure the
hydraulic pressure under the following condi-
tions. r
1. Arm half flow solenoid valve.
If the working mode switch is set to heavy-
duty or general mode and the arm is operat-
ed, the PPC valve output pressure is sup-
plied; if the working mode switch is set to fin-
ishing or lifting mode, the pressure should be
0 kg/cm2.
2. Swing brake solenoid valve.
Operate the swing.
3. Travel speed solenoid valve.
Set the travel speed switch to Hi. L 205FO5263
20-61
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF
WORK EQUIPMENT
If there is any hydraulic drift in the work

equipment (cylinders), check as follows to
determine if the cause is in the cylinder pack-
ing or in the control valve.
1. CHECKING FOR DEFECTIVE CYLINDER

PACKING
1. Checking boom and bucket cylinders.
PC3OOLC: 2,160 kg \.
i) Set in the same posture as when PC4OOLC: 2,880 kg c \
measuring hydraulic drift and stop the
engine.
ii) Operate the boom control lever to I 205FO5264
RAISE or the bucket control lever to
CURL.
l If the lowering speed increases,
the packing is defective.
l If there is no change, the holding
valve (boom) or the control valve
(bucket) is defective.
2. Checking arm cylinder.
i) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the arm control lever to IN.
l If the lowering speed increases,
the packing is defective.
205FO5265
l If there is no change, the control
valve is defective.
* If the pressure in the accumulator has
been lost, run the engine for approx. 10
seconds to change the accumulator again
before operating.
[Reference]
If the cause of the hydraulic drift is in the 2. When the internal pressure at the head end
packing and the above operation is carried increases, the balance is maintained by a
out, the downward movement becomes faster certain pressure (this differs according to the
because of the following reasons. amount of leakage) in proportion to it.
1. If the work equipment is set to the above 3. When the pressure is balanced, the down-
posture (holding pressure applied to the ward movement becomes slower. If the lever
bottom end), the oil at the bottom end leaks is then operated according to the procedure
to the head end. However, the volume at the given above, the circuit of the head end is
head end is smaller than the volume at the opened to the drain circuit (the bottom end is
bottom end by the volume of the rod, so the closed by the check valve), so the oil at the
internal pressure at the head end increases head end flows to the drain circuit and the
because of the oil flowing in from the bottom downward movement becomes faster.
end.
20-62
2. CHECKING BOOM HOLDING VALVE
*
A4Y Set the work equipment at the maximum
reach and the top of the boom horizontal,
then stop the engine.
Lock the work equipment control levers
and release the pressure inside the hy-
draulic tank.
1. Disconnect pilot hose (1) of the boom hold-
ing valve and install a blind plug in the hose.
* Blind plug: 07376-50315
* Leave the holding valve end open.
205FO5690
2. Start the engine, charge the accumulator,
then stop the engine.
3. Operate the boom control lever to the
LOWER position.
* If any oil leaks from the port that is left
open, the holding valve is defective.
3. CHECKING PPC VALVE

If the hydraulic drift differs when the safety
lock lever is in the LOCK or FREE position
(engine running) the PPC valve is defective.
4. MEASURING THE INTERNAL LEAKAGE OF

THE CYLINDERS
l If the hydraulic drift of any cylinder ex-
ceeds specification, see if the cause of
the hydraulic drift is in the cylinder or in
the control valve by performing the fol-
lowing.
* Oil temperature at time of measure-
ment: 45-55 C.
i) Fully extend the rod of the cylin- lOBR0023
der to be tested and stop the
engine.
ii) Disconnect the piping on the
head side and plug the piping on
the machine body side with a
plate.
A
Do not disconnect the piping on
the bottom side.
iii)Start the engine and run it at full

throttle to apply the relief pres-
sure to the bottom side.
iv) After 30 seconds, measure the
leakage during one minute.
20-63
BLEEDING AIR
ORDER FOR OPERATIONS AND PROCEDURE FOR BLEEDING AIR
Air bleeding procedure
1 6
Bleed
Start
Nature of work air from
operation
pump
l Change hydraulic oil 0 0
l Clean strainer
l Replace return filter 0
element
l Replace repair pump
l
l
Change clean line filter
element
Remove suction piping
Replace,
valve
Replace
repair
cylinder
control
0
d-A-l--
0 0 0 0
0
0
l Remove
ing
cylinder pip-
OI O I
l Replace swing motor
l Remove swing motor 0 0 0
piping
l Replace travel motor
swivel 0 0 0
l Remove travel motor
swivel piping
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has
been drained.
1. BLEEDING AIR FROM PUMP

1. Loosen bleeder @ and check that oil oozes
out from the bleeder.
2. When oil oozes out, tighten bleeder @ .
a Bleeder: 0.920.1 kgm.
* If no oil oozes out from the bleeder:
3. Leave bleeder@loosened and remove plug@
4. Pour in oil through the plug hole until oil

oozes out from the bleeder.
5. Tighten plug 0.
u Plug: 7.02 1 .O kgm.
6. Tighten bleeder @ .
* Precautions when starting the engine.
After completing the above procedure
and starting the engine, run the engine at
low idle for 10 minutes.
-k If the coolant temperature is low and
automatic warming-up is carried out,
cancel it by using the fuel control dial
after starting the engine.
20-64
2. BLEEDING AIR FROM HYDRAULIC CYLIN-
DERS
1. Start the engine and run at low idling for 4. Repeat steps 2 and 3 to bleed the air from
approx. 5 minutes. the arm and bucket cylinders.
2. Run the engine at low idling, then raise and * If the hydraulic cylinder has been
lower the boom 4-5 times in succession. replaced, it is better to bleed the air
* Operate the piston rod to approx. 100mm before connecting the work equipment
before the end of its stroke. again.
Do not relieve the circuit under any cir- (In particular, for the LOWER end of the
cumstances. boom cylinder, if it contacts the boom,
3. Run the engine at high idling and repeat step the cylinder cannot be operated to the
(2). After that, run the engine at low idling end of its stroke.)
and operate the piston rod to the end of its
stroke to relieve the circuit.
3. BLEEDING AIR FROM SWING MOTOR

1. Run the engine at low idling, loosen air bleed
plug (3) and check that oil oozes out.
* If no oil oozes out from the air bleed
plug:
2. Stop the engine and pour oil into the motor
case from plug (3).
3. Tighten air bleed plug (3).
u Plug: 14.Ok2.0 kgm.
205FO5692 1
4. BLEEDING AIR FROM TRAVEL MOTOR
1. Run the engine at low idling, loosen air
bleeder (4) when oil oozes out, tighten again.
u Bleeder: 0.9kO.l
20-65
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
* If the piping between the hydraulic cylinder

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

pressure inside the tank.
2. Operate the control levers.
-k When the levers are operated 2-3 times,
the pressure stored in the accumulator is
removed.
3. Start engine, run at low idling for approx. 5
minutes, then stop the engine and operate
the control levers.
* Repeat the above operation 2-3 times to
release all the remaining pressure.
20-66
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING ............................... 20-69
SEQUENCE OF EVENTS IN TROUBLESHOOTING .................................. 20-70
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE .............................. 20-71
HANDLING YAZAKI CONNECTORS ............................................. 20-76
HANDLING PACKARD CONNECTORS ........................................... 20-77
CHECKS BEFORE TROUBLESHOOTING ......................................... 20-80
ELECTRICAL CIRCUIT DIAGRAM, ENGINE THROTTLE CONTROLLER SYSTEM (PC3OOLC) ..... 20-81
ELECTRICAL CIRCUIT DIAGRAM, ENGINE THROTTLE CONTROLLER SYSTEM (PC4OOLC) ..... 20-82
PUMP CONTROLLER SYSTEM (PC3OOLC) ........................................ 20-83
PUMP CONTROLLER SYSTEM (PC4OOLC) ........................................ 20-84
MONITOR SYSTEM (PC3OOLC) ................................................ 20-85
MONITOR SYSTEM (PC4OOLC) ................................................ 20-86
POSITION OF CONNECTORS FOR TROUBLESHOOTING TABLE - PCBOOLC ............... 20-87
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC3OOLC ..................... 20-89
POSITION OF CONNECTORS FOR TROUBLESHOOTING TABLE - PC4OOLC ............... 20-91
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC4OOLC ..................... 20-93
CONNECTION TABLE FOR CONNECTOR (N-SLC TYPE) ............................. 20-95
CONNECTION TABLE FOR CONNECTOR (M TYPE) ................................. 20-96
CONNECTION TABLE FOR CONNECTOR (S TYPE) ................................. 20-98
CONNECTION TABLE FOR CONNECTOR (AMP040) ................................. 20-99
CONNECTION TABLE FOR CONNECTOR (SWP TYPE) .............................. 20-100
CONNECTION TABLE FOR CONNECTOR (MIC TYPE) .............................. 20-101
CONNECTION TABLE FOR CONNECTOR (X TYPE) ................................ 20-102
CONNECTION TABLE FOR CONNECTOR ....................................... 20-103
EXPLANATION OF THE FUNCTIONS OF THE CONTROL MECHANISM OF

THE ELECTRICALSYSTEM ................................................. 20-104
20-67
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND
ENGINE THROTTLE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ _ . _ . _ . . 20-107
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTONS ON MACHINE

ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 11
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE

PUMP CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 13
METHOD OF USING JUDGEMENT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 19
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM, E-MODE . . . . . . . . . . . . . . . . . . . . 20-121
TROUBLESHOOTING OF PUMP SYSTEM, C-MODE ................................ 20-149
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM, F-MODE .......... 20-181
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM, H-MODE . . . . . . . . . . . . . 20-191
TROUBLESHOOTING OF MONITOR SYSTEM, P-MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-223
20-68
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A
l Stop the machine ina level place and check that the safety pin, blocks and parking brake are
securely fitted.
l When carrying out the operation with two or more workers, keep strictly to the agreed signals
and do not allow any unauthorized person to come near.
l Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
l When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
*
A4 Y l When removing the plug from a location which is under pressure from oil, water or air always
release the internal pressure first. When installing measuring equipment be sure to connect it
properly.
l The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs
swiftly and to prevent reoccurrence of the failure.
When carrying out troubleshooting and important point is of course to understand the structure
and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible cases of the failure that would produce the reported
symptoms.
1. When carrying out troubleshooting, do not * Check the travel of the control levers.
hurry to disassemble the components. * Check the stroke of the control valve
If components are disassembled immediately spool.
any failure occurs: * Other maintenance items can be checked
l Parts that have no connection with the externally, so check any item that is con-
failure or other unnecessary parts will be sidered to be necessary.
disassembled. 4. Confirming failure:
l It will become impossible to find the l Confirm the extent of the failure yourself
cause of the failure. and judge whether to handle it as a real
It will also cause a waste of manhours, parts failure or as a problem with the method
or oil or grease and at the same time will also of operation, etc.
lose the confidence of the user or operator. * When operating the machine to
For this reason, when carrying out trouble- reenact, do not carry out any
shooting, it is necessary to carry out investigation or measurement that
thorough prior investigation and to carry out may make the problem worse.
troubleshooting in accordance with the fixed 5. Troubleshooting:
procedure. l Use the results of the investigation and
2. Points to ask user or operator: inspection in items 2-4 to narrow down
* Have any other problems occurred apart the causes of failure, then use the trou-
from the problem that has been reported? bleshooting flowchart to locate the posi-
* Was there anything strange about the ma- tion of the failure exactly.
chine before the failure occurred? * The basic procedure for trouble-
* Did the failure occur suddenly or were shooting is as follows.
there problems with the machine condi- i) Start from the simple points.
tion before this? ii) Start from the most likely
* Under what conditions did the failure oc- points.
cur? iii) Investigate other related parts
* Had any repairs been carried out before or information.
the failure? 6. Measures to remove root cause of failure.
When were these repairs carried out? l Even if the failure is repaired, if the root
* Has the same kind of failure occurred cause of the failure is not repaired, the
before? same failure will occur again.
3. Check before troubleshooting: To prevent this, always investigate why
* Check the oil level. the problem occurred. Then, remove the
* Check for any external leakage of oil from root cause.
the piping or hydraulic equipment.
20-69
SEQUENCE OF EVENTS IN TROUBLESHOOTING
a Jobsite
\
Step 1
1Examination, confirmation of symptoms 1
1) When a request for repavs is received. 1f Ring! Ring1
first ask the following points. --------
. Name of customer
---- -- -- 3
Type, serial number of machine
* Details of jobsite, etc.
2) Ask questions to gain an outline of the
problem.
Condition of failure
Work bemg carried out at the time
of the failure
* Operating environment
. Past history, details of maintenance,
etc.
Step 2
Determining probable location of cause
1) Look at the troubleshootmg section of the

,---fi
shop manual to find locations of possible
causes
Step 3
1Preparation of troubleshootmg tools
1) Look at the table of troubleshooting tools

in the shop manual and prepare the
necessary tools.
. T-adapter
. Hydraulic pressure gauge kit, etc.
troubleshooting)
2) Look I the parts book and prepare the
* Decide action to take
necessary replacement parts. I
I
1) Before starting troubleshootlng. locate and
r repair simple failures
* Check before starting items
* Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshooting
flowchart that matches the symptoms. and
carry out troubleshooting.
* Drive and operate the machlne to conflrm

1
the condltlon and judge if there is really a
failure.
/
,
Step 4 I I Step 5
/I r\ . 1-y / Ask operator questions to confirm details of 1 -
I
Was there anything strange about the
machine before the failure occurred
Did the failure occur suddenly?
20-70
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over

a long period and to prevent failures or other
troubles before they occur, correct operation,
maintenance and inspection, troubleshooting and
repairs must be carried out. This section deals
particularly with correct repair procedures for
mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives
sections on Handling electric equipment and
Handling hydraulic equipment (particularly
hydraulic oil).
1. PRECAUTIONS WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harness and connectors.

Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnect-
ing one wire from another wire and protector
or tubes used for protecting the wiring.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct ef-
fects of rain, water, heat or vibration. Further-
more, during inspection and repair operations
they are frequently removed and installed
again, so they are likely to suffer deformation
or damage. For this reason, it is necessary to
be extremely careful when handling wiring
harnesses.
F20505201
Main failures occurring in wiring harness

1. Defective contact of connectors (defective Improper insertion
contact between male and female).
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector
or because one or both of the connectors is
deformed or the position is not correctly
aligned or because there is corrosion or
oxidization of the contact surfaces. F20505202
20-71
2. Defective compression or soldering of con- Improper compressio
nectors.
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion but there is excessive force
on the wiring and the plating peels to cause
improper correction or breakage. F56103079
3. Disconnections in wiring.
If the wiring is held and the connectors are
pulled apart or components are lifted with a
crane with the wiring still connected or a
heavy object hits the wiring, the compression
of the connector may be lost or the soldering
may be damaged or the wiring may be bro-
ken.
F20505204
4. High pressure water entering connector.

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow
dry with air and spray it with a contact
restorer.
* When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
I F20505206
20-72
-k If there is water or oil in the air, it
will increase the contamination of
the points, so clean with air from
which all the water and oil has
been removed.
2) Removing, installing and drying connec-

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

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil or
water from getting in the connector portion.
F2050520E
Connecting connectors
1. Check the connector visually for the follow-
ing:
l Check that there is no oil, dirt or water
stuck to the connector pins (mating por-
tion).
l Check that there is no deformation, de-
fective contact, corrosion or damage to
the connector pins.
l Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water or dirt stuck to
the connector wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dryer
but be careful not to make it too hot as
this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
20-73
2. Fix the connector securely.
Align the position of the connector correctly,
Clicks into
then insert it securely.
For connectors with lock stopper:
Push in the connector until the stopper clicks
into position.
II F20505209
3. Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the
wiring harness is misaligned or the clamp is
out of position, adjust it to its correct posi-
tion.
j, When blowing with dry air, there is dan-
ger that the oil in the air may cause im-
proper contact, so clean with air from II F20505210
which all the water and oil has been
removed.
Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid wash-
ing it in water or using steam. If the connec-
tor must be washed in water, do not use high
pressure water or steam directly on the
wiring harness. If water gets directly on the
connector, do as follows.
F20505211
1. Disconnect the connector and wipe off the
water with a dry cloth.
-k If the connector is blown dry with air,
there is the risk that oil in the air may
cause defective contact, so avoid blowing
with air.
2. Dry the inside of the connector with a dryer.
If water gets inside the connector, use a
dryer to dry the connector.
* Hot air from the dryer can be used but be
careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
F20505212
20-74
3. Carry out a continuity test on the connector.
After drying, leave the wiring harness discon-
nected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas- T-adapter
semble.
F20505213
3) Handling control box

1. The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2. Do not open the cover of the control box
unless necessary. F20505214
3. Do not place objects on top of the control

box.
4. Cover the control connectors with tape or a
vinyl bag.
5. During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6. Do not place the control box on oil, water or
soil or in any hot place, even for a short time.
(Place it on a suitable dry stand.)
7. Precautions when carrying out arc welding.
When carrying out arc welding on the body,
disconnect all wiring harness connectors
F20505215
connected to the control box. Fit an arc
welding ground close to the welding point.
F20505216
20-75
HANDLING CONNECTORS
YAZAKI TYPE CONNECTOR
r
1 When removing the connectors from the
clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left and
right or up and down, the housing may
break.
205FO5609
2. When disconnecting male and female con- /

nectars, release the lock and pull in parallel
with both hands.
* Never try to pull out with one hand.
205FO5611
3. When the wiring harness clamp of the con-

nector has been removed, always return it to
its original condition and check that there is
no looseness of the clamp.
205FO5612
20-76
HANDLING CONNECTORS
PACKARD COMPANY CONNECTOR
1. When removing the connectors from the

clips, pull the connector in a parallel direc-
tion to the clip.
* If the connector is twisted to the left and
right or up and down, the housing may
break.
08CD0024
I 08CD0025
2. When disconnecting male and female con-

nectors, release the lock and pull in parallel
with both hands.
j, Never try to pull out with one hand.
08CD0026
20-77
1. POINTS TO REMEMBER WHEN
HANDLING HYDRAULIC
EQUIPMENT
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil
orwhen disassembling or assembling hydrau-
lic equipment, it is necessary to be particular-
ly careful.
1) Be careful of the operating environment.

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

field.
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there
is danger of dust entering the equipment. It is
also difficult to confirm the performance after
repairs, so it is desirable to use unit
exchange. Disassembly and maintenance of
hydraulic equipment should be carried out in
a specially prepared dustproof workshop and F20505217
the performance should be confirmed with

special test equipment.
3 ) Sealing openings.
After any piping or equipment is removed, the
openings should be sealed with caps, tapes
or vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil, so never do this.
Do not dimply drain oil out on to the ground,
F20505218
collect it and ask the customer to dispose of
it or take it back with you for disposal.
4) Do not let any dirt or dust get in during

refilling operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean and
also use clean pumps and oil containers. If
an oil cleaning device is used, it is possible
to filter out the dirt that has collected during
storage, so this is an even more effective F20505219
method.
20-78
5) Change hydraulic oil when the temperature
is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be drained out easily from the circuit togeth-
er with the oil, so it is best to change the oil
when it is still warm. When changing the oil,
as much as possible of the old hydraulic oil
must be drained out. (Do not drain the oil
from the hydraulic tank; also drain the oil
from the filter and from the drain plug in the
circuit.) If any old oil is left, the contaminants
and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment or changing the oil, use flushing
oil to remove the contaminants, sludge and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri
mary flushing is carried out with flushing oil
and secondary flushing is carried out with the
specified hydraulic oil.
F20505220
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to remove
the sludge or contaminants in the hydraulic
oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 34 particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
20-79
Other check items Check before starting items
Hydraulic, Electrical
Electrical components mechanical Lubricating oil, cooling water
eaubments equipments
-.
3
0-.
-
x2
I I I I I I I I I I I I I I
ENGINE THROTTLE CONTROLLER SYSTEM
Starting switch Ml 1 (L2)
Battery
M7(L2)
r
Governor motor
Enginethrottle
controller
El (MlC21)
___._
+ 0.58
Fuel dial (-1
Fuel control dial
L
No. 2-Tthrottle (-)
0.5BW E6 (M3)
Throttle (-)
20 0.56 1
Warming-up 21 p5Ly
r Y
0.858 0
08DD0024
20-81
PC4OOLC
E-10
-TQay m
1
6
ii
Starting switch Ml 1 (L2)
$3
,-a
Alternator
Battery
1.25L 24V
45A
Fuse
E-9
3mm
cc,3 21 5WR
NZZ
dd
10A
0.85GY
-2
20A
2WR _ 9
M7(L2)
II
II 0.85BW
I
I Governor motor
Fuel control dial
.JL I
eleratlon 1
lection
\ 7g 0.5B I
/ ,. n0.5w
it.,-
0.5G
i [ Work
*n
08DD0025
20-82
PUMP CONTROLLER SYSTEM
PC3OOLC
Work equipment
Battery relay Battery - swing oil
Swing lock
TVC prolix switch Ml1 (LZ) I G-Hi
Swing lock switch
Arm half flow
L-2
TVC prolix TVC
resistor solenoid
er
C2(MlC21P) 1
Power
maximlzlng
switch
Engine
I speed
sensor
08DD0026,
20-83
PUMP CONTROLLER SYSTEM
PC4OOLC
Swing lock
prolix switch
Battery relay Battery
Work equipment
- swing oil
Travel oil
pressure
switch
service
rpressure
switch 2
011 -sa
pressure
switch 1
pressure switch
Swing lock switch I M34 II llt
Arm half flow

solenoid valve
mfl
TVC crolix
resistor
TVC
solenoid
solenoid valve
--
Cl (MlC17P) 1
1 i Engine throttle controller

fi1-C21P)
Power
maximizing
switch
Engine
speed
sensor
I I
I II
1 Lm
c-9 08DD0027
20-84
MONITOR SYSTEM
PC3OOLC
Service meter
Fuse M7 (L2) Ml1 (L2)
A
A ,_A__
Wiper motor (KES4) M4(KES4) M5(M4)
Light
relay
Heater
Hi relay
Heater
Lo relay
Wiper
relay
MI
1-d
P9 (X2) M3 (S16)
Starting switch I I
IL 125R
E R.H. heqp
:
08DD0028
20-85
MONITOR SYSTEM
PC4OOLC
D20
-I
e
SWVlCe
meter
relay
A
$5
00
u
Sewce meter D19
v&&motor (KES4) M4CKES4) M5iM4) I Ir-l
Light
relay
Heater
HI relay
Heater
Lo relay
Wiper
relay
1 Pl (AMP20P) 1
P2 cAMPlGP) l
L-1
P9 (X2) M3 CS161 IIIII I
II
Frame
ground
I
Starting switch I I Wlndow washer
M291(M2) Switch]
Ml0 M9 Boom lamp
Ma R H head lamp
08DD0029
20-86
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC3OOLC
CN No. of No.
I I
ELECTRICAL COMPONENT Type CN
No. pin ELECTRICAL COMPONENT Type of
No.
pin
M21 IRadio 1 KES 1 4 j

I I I
MPPjPower max. button 1 M 12

M23 Horn switch M 2
M25 Power Max. Switch M 2
C5 jTVC prolix switch I M 161
C6 TVC prolix resistor M 2 M26 Power source for cooler or
Iair conditioner I KES I 4 I
c7 Rear pump oil pressure
sensor
x 3 M27jlntermediate connector I M PI
M28 Windshield wiper motor KES 2
GIm~oil pressure 1 x 1 3 1
M29 Washer switch M 1
controller,
controller
governor
(Model selection) I MI31 M31 Intermediate
M34jFree swing unit
connector
I
M
- 141
2
ID15jEther injector (Diode) I - 121

El Engine throttle controller MIC 21
M44 Ether injector
E2 Intermediate connector S 12 qi
E4 Governor potentiometer x 3
Pl IMonitor panel 1 AMP 1201
E5 IGovernor motor I x 141 P2 /Monitor panel 1 AMP 1 16 1
E6 IFuel control dial I M 131 P4 IWarning buzzer 1 M 121
E7 Engine speed sensor x 2
P5 Engine oil level sensor Packard 4
E8 Intermediate connector SWP 8
P6 Fuel level sensor x 1
E9 jlntermediate connector I SW I 6 I P7 Coolant temperature sensor Packard 2
El0
Fl
Shut-off
Intermediate
Ml IStarting
valve
switch
connector
Packard
I M 161
3
4
11
Pl 0 IService meter I KES I 2 I
M2 IStarting motor I x 121
M3 Intermediate connector S 16
M4 Wiper motor KES 4
M5 jlntermediate connector I M 141 R3 IHeater Hi relay I I51
R4 jLight relay I I 5
M7 Intermediate connector L 2
s1 Work equipment l swing oil x 2
M8 IHeadlight I M Ill I pressure switch
I-
I
I
I
I
M9 IWorking light 1 M 111 S2 ISwing oil pressure switch j X I 2

Ml0 Intermediate connector KES 2 S4 ITravel oil pressure switch l x 12
Ml 1 Fusible link L 2
Ml2 Heater KES 3
Ml3 Speaker KES 2
Ml4 Intermediate connector S 8 V2 ITravel speed solenoid valve l x 12
MlGjHorn (High tone) I KES I 1 I
Ml7 Horn (Low tone)
Ml8 Swing
M20 Intermediate
lock prolix
connector
switch
1
KES
M
M 14
1
2 1
V5 Arm half flow solenoid valve
20-87
20-88
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC3OOLC Foldout 8
M3
M21 E2
PlO I I M36 P8
P7
_- c7 \ I 64. E5. ES
P4
M29
w3 \ \\ I
E6
P2 \ ti .
M4
Mi3 / / I I \ s2, s4, ss, SlO

M7
M5 II M27
// / /
M31\ \ \ \ - \ Ml2 Mli

Ai6 \ /
Ml4 \\ Ml8 /i /
d4 \
R3
08DD0033
08DD0017A
20-89
20-90
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC4OOLC
CN No. of
CN ELECTRICAL COMPONENT
I No. I ELECTRICAL COMPONENT 1 Type 1;it No.
I
M17jHorn (High
- tone)
I
1 KES
Type
I
1 1
Din
Cl Pump controller MIC 17

Ml8 Swing lock prolix switch M 2
C2 Pump controller MIC 21
M20 Intermediate connector M 4
C3 Pump controller MIC 9
M21 Radio KES 4
C4 TVC valve x 2
M22 Power max. button M 2
C5 TVC prolix switch M 6
M23 Horn switch M 2
C6 TVC prolix resistor M 2
M26 Power source for cooler or
I I
c7 Rear pump oil pressure
sensor I
x
I
3 air conditioner
M27 Intermediate connector
KES
M
4
2
I I
c8
I
Front pump
sensor
oil pressure
I
x
I
3
I
M28jMotor
MPOlWasher switch
I
1 KES
1 M
I
1 2
12
cg Pump controller, governor M 3
I controller (Model selection) I I M36jEnaine
I
mode connector II M jlI
ID15jEther iniector
, (Diode)
. I
I - 12 M44jEther injector 1 KES 1 1
D16 Shut-off valve (Diode) 2 M46 Ether injector switch M 2
D19 Monitor panel (Diode) 2 Pl I Monitor panel I AMP I
20
D20 Service meter (Diode) 2 1 P2 IMonitor oanel I AMP I 16 1
El Engine throttle controller MIC 21 P4 Warning buzzer M 2
E2 Intermediate connector S 12 P5 Engine oil level sensor Packard 4
E4 Governor potentiometer x 3 P6 Fuel level sensor x 1
E5 Governor motor x 4 P7 Coolant temperature sensor Packard 2
E6 Fuel control dial M 3 P8 Coolant level sensor x 2
P9 Hydraulic oil level sensor x 1
PlO Service meter KES 2
Pll Engine pressure switch Packard 3
Rl Wiper relay 5
Fl Intermediate connector M 4 R2 Heater Lo relay 5
Ml Starting switch M 6 R3 Heater Hi relay 5
M2 Starting motor x 2 R4 Light relay 5
M3 Intermediate connector S 16 I RlO IService meter relav I I 5
M4 Wioer motor KES 4 2
M5 Intermediate connector M 4 I I
s1
S2 Swing
Work equipment
pressure switch
oil pressure
l swing
switch
oil
I
x
x
I
2
M7 Intermediate connector L 2 S4 Travel oil pressure switch x 2
M8 Headlight M 1 S9 Service oil pressure switch X 2
SlO Service oil pressure switch X 2
Vl Swing brake solenoid valve X 2
V2 Travel speed solenoid valve X 2
V4 CO cancel solenoid valve x 2
V5 Arm half flow solenoid valve X 2
Ml4 Intermediate connector S 8 v7 2-stage relief l CO cancel
x 2
KES 1 solenoid valve
Ml6 Horn (Low tone)
20-91
20-92
POSITION OF CONNECTORS FOR TROUBLESHOOTING - PC4OOLC Foldout 9
M3
E2
PlO M2
D20 \ / M36 ;;; E4, ES, ES
M44 \ P8
.c2
-Ml8
M46
Ml3 /
M7 \\\\\ I I G/i \
A \ ti22
M5
I
\\\\\ I I I
M27 \ \ \ \ \ v/Y I lbh6
M.31 \ \ \ \ \ \ Mi2
hi6 \
Mb5
Ml4 \\\
d4 \
R3 \
RlO
08DD0037
08DD0036
20-93
20-94
CONNECTION TABLE FOR CONNECTOR
* Display of male and female connectors.

All the displays of male and female show the mating portion at the terminal (pin) end. therefore, the
diagram does not always match the male and female at the housing mating end.
In the circuit diagrams, the pointed side (the part inside the pointed line) as shown in the diagram
below is the male side.
r
Female side of terminal Male side of terminal
I
2 Governor potentiometer
3
2x6
F20505399
No. 0 FT N-SLC CONNECTOR

pins Female connector Male connector
423F349 423F350
423F351 423F352
423F353 423F354
20-95
No. 01 M TYPE CONNECTOR

pins
Male connector Female connector
205FO5317 205FO5318
\
1 i
205FO5319 205FO5320
205FO5321 205FO5322
205FO5323 205FO5324
20-96
T
No. o F M TYPE CONNECTOR
pins Male connector Female connector
\
3/ 6 6 3
205FO5325 205FO5326
20-97
No. o fT S TYPE CONNECTOR

pins
8 4
205FO5327 205FO5328
1 6 6 1
10
10 5
205FO5329
6 1
12
12 5
205FO5331 205FO5332
16 7 8 1
0
16
8 1 16 i
205FO5333 205FO5 334
20-98
No.
pins
-r
oiF AMP040 TYPE CONNECTOR
16
i
205FO5335 205FO5336
20
/ \
i 1
1 11 1
2c 15FO5337 205FO5338
20-99
T
No. oiF SW/P TYPE CONNECTOR
pins Male connector Female connector
1 4 1
\ /
6
H
6
II
3
w 0
3 6
205FO5339 205FO5340
205FO5341 205FO5342
20-100
No. 0 fT MIC CONNECTOR

pins Female connector Male connector
205FO5343 205FO5344
ouooLloLloolJo
17
1 I
142F414 142F415
1 11
nun 0 olJolJo 0 ouo
21
142F416 142F417
20-101
No. of X TYPE CONNECTOR

pins Female connector
Male connector
205FO5309 205FO5310
205FO5311 205FO5312
205FO5313 205FO5314
1 3
GEII
205FO5315 205FO5316
20-102
No. of l- PACKARD COMPANY CONNECTOR

pins Male Connector Female Connector
,B
(Coolant temperature sensor)
08cD0011
(Engine oil pressure sensor1
OBCOOO18 oncooo19
D
C
08CDOO22 00c00023
20-103
EXPLANATION OF THE FUNCTIONS OF THE CONTROL MECHANISM OF
THE ELECTRICAL SYSTEM
This section gives the functions and details of checks for the monitor panel, pump controller and engine
throttle controller needed to carry out troubleshooting of the electrical system.
1) Explanation of functions
The control mechanism for the electrical system consists of the monitor panel, pump controller and
engine throttle controller. It carries out control by changing the absorption torque of the pump (power
set) or by changing the output of the engine (working mode).
Monitor panel and both the controllers each input the necessary signals and combine the signals
selected by the monitor panel. The controllers input and output the necessary signals to control the
absorption torque of the pump and the engine output.
l Input and output signal system of monitor panel and both controllers (Fig. 1).
Monitor panel
Work eauipment .
ipeed swtch slgnal
D controller
Pump K
Fuel control dial signal

-a
205FO5714
20-104
The pump controller and engine throttle controller have a self-diagnostic function and if any electrical
abnormality (disconnection, contact with ground, internal short circuit or short circuit between wires)
occurs in the output signals (input signal for the receiving controller) for numbers @ - @ in Fig. 1, the
content of the abnormality is displayed.
l If 01 - 09 or 25 are displayed (if a short circuit or other fault causes a current above the specified level to flow
to the controller, the controller stops the operation of that system).
l If 11 - 28 are displayed, there is a disconnection (the operation of that system stops) or there is contact of the
No. 2 pin of the solenoid with the ground (the solenoid continues to operate).
Even if there is any abnormality in the input signal system for @ - 0, the abnormality is not displayed
in the display area but the pump controller has a built-in monitor function to check the input signals.
The controller starts to work only when there is an input signal and it gives a display on the display panel.
Therefore, when investigating if the cause is in the electrical system or in the hydraulic or mechanical
system in the case of There is no abnormality display on the display panel but there is an abnormality
in the movement of the unit, the first step when carrying out troubleshooting is to use the method of
checking the operation of the electrical system in Item 2 to check if the necessary signal is being output
to the pump controller correctly.
20-105
2) Checking operation of electrical system
When the set of operations given below is carried out in the order given and the action of the monitor
panel, pump controller and engine throttle controller are as given in the table, the monitor panel
(EMACC) and both the controller are normal.
0 The IH.1.1 display and other displays given in the table are the monitor displays given by the
controller if the input and output signals are normal.
0 The monitor display of the pump controller is displayed for 1.5 seconds after the signal is input
and after that the operation mode is displayed.
0 For items @ ,a, and 0, the system automatically enters the auto-deceleration mode, so set the
auto-deceleration switch on the monitor panel OFF.
Operation procedure.and condition of Items for confirmation (when normal)
machine Monitor panel Pump controller Engine throttle controller
..
l Turn starting switch OFF.
All lamps OFF
D l Turn fuel control di& t&IN.
- .AlllampsOFF All lamps OFF
Display lamps light UP

3 Turn starting switch ON. b G.0 and S mode is m is displayed FEzE ~~~~~~~~&~d
display for 5 set)
Start engine - -1
.zt .r_
If coolant temperature is below 30C. After 5 sec. normal display
+ &I is displayed
B carry out automatic warming up and m is displayed
[Operating model
increase engine speed.
Decimal point flashes
l Turn fuel control dial to MAX.

Engine speed rises (fuel
Raise engine speed in FULL speed of
9 control dial, governor
G.0 mode.
potentiometer systems normal)
. Set auto-deceleration switch OFF.
* Set working mode to H.0 mode

Engine speed rise (No. 2
Raise engine speed from FULL speed of H.0 and H mode
I;-:.[ is displayed throttle signal system
B G.0 mode to FULL speed of H 0 mode. is displayed
normal1
* Set auto-deceleration switch OFF.
* Set working mode to L.0 mode Engine speed drops (No. 2

L.0 and L mode is
Lower engine speed from FULL speed -W j:_.-:] is displayed throttle signal system
B displayed
of H.0 mode to FULL speed of L.0 mode. normal)
* Set working mode to G.0 mode

Engine speed rises again (No.
Raise engine speed from FULL speed of
3 - :$ldvSsTode m is displayed Z?;;g;le signal system
L.0 mode to FULL speed of G.0 mode.
l Set auto-deceleration switch OFF.
is displayed
a Press power maximizing switch -
-I:::j- [l - 1.5 secl
- Travel speed
pm_ Hi -Lo
3 Switch travel speed switch between Hi and LO -)
is displayed [l - 1.5 secl
Operate work equipment or swing

Cancel deceleration and raise engine - Ip.21 1; ~~lagy~~cl
IzJ
speed.
Switch auto-deceleration switch ON.

Deceleration is
Engine speed drops to deceleration mi ;: py;;,,
0 -) displayed
speed after a few seconds.
Swing lock lamp OFF

Q Switch swing lock switch ON and OFF. -
-=I:and ON is displayed
@ Operate travel lever slightly. + pm_
Return fuel control dial to MIN. Engine speed drops (fuel

-_)
@ Engine speed drops to low idling. control dial system normal)
Engine stops
Turn starting switch OFF.
0 r (battery relay system normal)
20-106
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND
ENGINE THROTTLE CONTROLLER
1. MONITOR PANEL l Model code display.

Approximately 2 seconds after the starting
switch is turned ON, all monitor and gauge 1 LEDs (Light Emitting Diodes)
Model
lamps light up and the buzzer sounds for
approximately 1 second. This is the self- Red Green Red
diagnostic function of the monitor panel. PC3OOLC
After this, the display returns to normal. OYF O?F ON
Red Green Red
PC400LC
OFF o\l OFF
2. ENGINE THROTTLE CONTROLLER

1 Model code display function (normal display)
When the starting switch is turned ON, the
model code is displayed for approximately 5
u
seconds on the controller display panel.
* After 5 seconds, the model code display Red Green Red
changes to the normal display or the Normal display
abnormal display (self-diagnostic dis- OFF o\l O?F
play).
2. Self-diagnostic display (abnormal display). l Self-diagnostic display

l The abnormal display consists of 3 LEDs
Order of
I LEDs
and the ON/OFF combination of these priority (Light Emitting Diodes) Abnormal system
displays the type of abnormality (abnor-
mal system). Red Green Red Power source
1 0 0 system or con-
l If two or more abnormalities occur at the
OFF OFF OFF troller system
same time, the abnormalities are dis-
played in the order of priority shown in Red Green Red Short circuit in
the table on the right. 2 0 0 governor motor
l Once the starting switch is turned OFF, & OFF ON system
the self-diagnostic display is reset.
Check the abnormal display with the
starting switch ON.
l When the abnormality is removed, the
display is automatically reset, so if the
abnormality occurs intermittently, the
abnormal display and normal display will
appear alternately and the display may Red Green Red
appear to be flashing. 5
OFF $ & system or motor
Red Green Red

6 fuel control dial
o\l & $4
Red Green Red Abnormality in
7 No. 2 throttle
& ON OFF signal system
20-I 07
l Model code display
3. PUMP CONTROLLER
1. Model code display function (normal display). Model Code Display
When the starting switch is turned ON, the
model code is displayed for approximately
0.5 seconds on the controller display panel.
2. Operation mode display function (normal

display). l Operation mode display
The operation mode is displayed unless there
Power mode
is any change or abnormality in the input or
selection system Working mode selection system
output system for the pump controller on
controller. Mode Code Display
\
Heavy-duty 1 \
General 2 -\
\Z
Finishing 3 -\
3
\ ) Lifting 1 4 1 \-\ 1
Power source Engine speed signal monitor

monitor
When engine speed signal is
Lights up when
input
power is ON
Flashes
(At 2,000 rpm, approx.
20 times/ 10 set)
3. Input signal display function (normal display). 0 Input signal display ;

.:
When the input signal to the controller is
switched, the input signal is displayed for
approx. 1 - 1.5 second.
Ir If it is not displayed, there is an abnor-
mality in the input signal system.
* After the input signal is displayed for
1 - 1.5 seconds, the display changes to
the operation mode display.
20-I 08
T
Abnormality system Code G$Q

C
jhort circuit in 2-stage

4. Self-diagnostic display function (abnormal 01
,elief solenoid system
display).
l If there is any abnormality in the control- jhort circuit in arm half flow
03
ler output signal system and sensor sys- ;olenoid system
tem, the abnormal display and operation jhort circuit in swing brake
04
mode are shown alternately. ;olenoid system
* If two or more abnormalities occur at the jhort cirucit in travel speed
05
same time, all of the abnormality displays ;olenoid system
-I-
and operation mode display are shown in Short circuit in CO
07
turn. cancel solenoid system
l If 01 - 09, 25 are displayed, there is Short circuit in TVC solenoid
danger that the controller may be broken, 08
system (I )
so the controller automatically stops the Short circuit in TVC solenoid
output to the system where the abnor- 09
system (2)
mality has occurred.
Xsconnection in 2-stage
l Once the starting switch is turned OFF, 11
*elief solenoid system
the abnormal display is reset, so check
Disconnection in arm half flow
with the starting switch ON.
:.s
- n
-l-i
13 .
solenoid system
If the starting switch is turned OFF, re-
\\-\
. \\ \
*
Disconnection in swing brake
enact the abnormal display as follows. 14
solenoid system 1.7 H
n System I
I I
Disconnection in travel speed
Turn the starting switch ON. 15 .q /
u
solenoid system
17 System --
Disconnection in CO
Turn starting switch ON (Engine 17 H
. \. \
cancel solenoid system
stopped) and operate the control
lever. Disconnection in TVC solenoic n
i- 18 \\-\
system . \.a
A Start the engine and operate the
control lever. No. 2 throttle signal system 21
4 If no signal comes from the engine speed
sensor (engine stopped, defective Throttle signal System 22
clearance at sensor, etc.), the central
decimal point does not flash. Front pump pressure sensor
23
% Example of display. system
i) H.O. and H mode when normal. Rear pump pressure sensor
24
system
\\ 1
.\-\. \ Pressure sensor power source
25
ii) Same as i) above but throttle signal svstem
system abnormal
Engine speed sensor system 26
\\ \
.\-\. \ Auto-deceleration output
and flashes in turn with 28
svstem
Overheat system 29
Dot
Controller
only
Power source system

I All OFF H
20-l 09
20-110
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE Foldout IO
o ENGINE THROTTLE CONTROLLER SYSTEM * This table shows how the controller reacts and what symptoms the machine displays if any abnormality should occur in the
lFnr thnca \nrhn havn nnnri I Inricarctanriinn nf mnrhatmnirc trnllhlnchnntinn qut using this table.)
between El (1) and fuse (2)

Red Green Red Disconnection i harness between El (2) - M20 (3) - M20 (4)
Cannot control
OFF OFF OFF ing harness between Ml (12) and chassis
1. Short circuit inside governor motor Makes motor drive current 0.

1. During operation
Red Green Red

2. Short circuit of wiring harness between El (3) - E2 (3) - E5 (1) with (Abnormal display disappears when startrng 1) Speed drops to low idling.
wiring harness between El (14) - E2 (4) - E5 (2) switch is turned OFF.)
Short circuit in 2) Engine does not stop.
3. Short circuit of wiring harness between El (4) - E2 (10) - E5 (2) with * If the failure location is reset during opera- 2. When engine stops
governor motor system
ON OFF ON wiring harness between El (15) - E2 (9) - E5 (4) 1) Engine starts, but stays at low idling.
4. Wiring harness in Item 2 or 3 in contact with ground 2) Engine does not stop after starting.
connection occurs simultaneously for

A phase and B phase, it is the same as
1. Disconnection inside governor motor short circuit in the governor motor
2. Disconnection in wiring harness between El (3) - E2 (3) - E5 (1)
Disconnection in 3. Disconnection in wiring harness between El (4) - E2 (I 0) - E5 (3)
governor motor system Same as short circuit for governor motor system No particular action is taken.
4. Disconnection in wiring harness between El (14) - E2 (4) - E5 (2) phase or B phase,
5. Disconnection in wiring harness between El (15) - E2 (9) - E5 (4) 1) Engine does not stop.
6. Defective contact of connectors El, E2, E5 2) Stops moving at position just before fail-
ure occurred, so engine speed cannot be
controlled.
ple, the following cases may

1. Short circuit in wiring harness between El (5) - (6). (6) - (I 6). (5) - (16).
2. Short circuit in wiring harness between E2 (1) -
(2). (2) - (7). (1) - 17).
(2). (2) - (3). (1) - (3).
(2), (2) - (3). (1) - (3).
Red Green Red 5. Short circuit in wiring harness between El (10) - (20). (C20 (10) - (20)). Controls by calculating the position of the
motor from the voltage value just before oc-
6. Shortcircuit in wiring harness between El (7) - (B), (8) - (18). (7) - (18). 3) Auto-deceleration or automatic
currence of the abnormality.
OFF ON ON
7. Disconnection in wiring harness between El (6) - E2 (1) -
E4 (1). warming-up speed are defective (too
8. Disconnection in wiring harness between El (5) - E2 (2) - E4 (2). high or too low).
9. Disconnection in wiring harness between El (16) - E2 (7) - E4 (3).
10. Defective governor potentiometer.
11. Defective contact of connectors El, E2, E5
Fuel control dial
Red Green Red Fuel control dial

Abnormality in fuel At MAX: 0.25 - 1 .OV Holds the engine speed at the fuel control dial
control dial system 1. Short circuit position just before the abnormality occurs.
At MIN: 4.0 - 4.75V
ON ON ON
* PEMC control impossible
5. Disconnection in wiring harness between El (8) - E6 (2).

6. Disconnection in wiring harness between El (18) - E6 (3).
7. Defective fuel control dial
8. Defective contact of connectors El, E6
1. Contact of wiring between harnesses between El (9) - (19) (C2 (11) - 21)). Actuated by the movement of the fuel control
Red Green Red 2. Disconnection in wiring harness between El (9) - C2 (1 1). When power set is set to S or L mode, engine
Abnormality in No. 2 Between El (9) - (19) (C2 (11) - (21)): dial.
3. Disconnection in wiring harness between El (19) - C2 (21). speed does not drop.
0 0 0 throttle signal system 0.25 - 4.75V * In the case of Item 2. the pump controller
4. Abnormality in pump controller signal * PEMC control impossible
ON ON OFF also displays.
5. Defective contact of connectors El, C2
20-I 12
. PUMP CONTROLLER SYSTEM * This table shows how the controller reacts and what symptoms the machine displays if any abnormality should occur in the
sensors or actuators. (For those who have good understanding of mechatronics, troubleshooting can be carried out using this table.)
Foldout 11
isplay System with Condition when normal
Details of abnormality Action of controller when abnormality is detected Symptoms shown by machine when there is abnormality
3de abnormality (voltage, current, resistance values)
2-stage relief Resistance value of solenoid: The relief pressure is not increased when using the power maximiz-
01 ing function, so there is lack of power
solenoid 50 - 100 R
Arm half flow Resistance value of solenoid: In F.0 mode, the Hi circuit is not cut, so the fine control is poor. (The
03 solenoid 10-350 digging speed is the same as in G.0 mode)
Short circuit inside solenoid or between

solenoid pins (I) - (2).
Swing brake Resistance value of solenoid: During swing operations, the motor brake is not released, SO the
04 (When resistance inside solenoid is ex-
solenoid 10-350 machine does not swing
tremely low) It makes the current to the solenoid 0.
Excessive current flows However, the abnormality is temporary (momentary short
circuit, etc.), so if the system returns to normal, the drive
Travel speed Resistance value of solenoid: current is output again when all control levers are returned Travel speed does not change (stays in Lo) when travel speed
05
solenoid 50- 1000 to neutral. switch is operated
t However, the display does not disappear (it disappears
when the power is turned OFF).
CO cancel * The above automatic reset is repeated up to three times. Action of CO valve does not stop when using the power maximizing
Resistancevalue of solenoid:
07 solenoid function, so the pump discharge amount is minimum. Therefore,
50- 1000
the speed is low in this pressure range.
TVC (+) line in contact with ground

08
(excessive current flows)
Current does not flow to the TVC solenoid. Therefore, when the
Resistance value of solenoid:
TVC solenoid load is high, the engine speed drops excessively, and the engine
IO-220
Short circuit or contact with ground may even stall. (All of H, S, and L modes)
09 inside TVC solenoid (excessive current
flows)
1. In cases 1) and 2). current stops flowing to the solenoid,

2-stage relief Resistance value of solenoid: so not particular action is carried out. Therefore, if abnor-
11 1. In cases 1) and 21, it is the same as display 0 1.
solenoid 50- 1000 mal places are reset by the vibration of the machine, they
become normal again.
* However, the display does not disappear (disappears
when power is turned OFF.) 1. In cases I) and 2). it is the same as display 03.
Arm half flow Resistance value of solenoid:
13 2. In case 31, electric current continues to flow to the sole- 2. In the case of 3). the Hi circuit remains cut, so the speed for
solenoid 1) Disconnection inside solenolu IO-35fl
noid, but the controller does not carry out any action. normal work is low.
(The resistance inside the solenoid
Therefore, if the abnormal places are reset, they return to 1. In cases 1) and 2). it is the same as display 04.
is extremely large)
Swing brake Resistance value of solenoid: normal. 2. In the case of 3). the brake stays released, so the brake has no
2) Disconnection in wiring harness be-
14 * However, the display does not disappear (disappears effect even when the lever is returned to neutral. (The upper
solenoid tween solenoid pin (2) and controller IO-350
when power is turned OFF.) structure will swing on slopes.)
3) Contact with ground at pin (2) of
* When the controller sends the command to turn the sole-
solenoid
noid current OFF, the voltage at portion @ should be 20 1. In cases I) and 21, it is the same as display 05.
Travel speed Resistance value of solenoid: - 30V; if there is any disconnection or contact with the
15 2. In the case of 3). the solenoid continues to be actuated and
solenoid 50- 1000 ground, the voltage at portion 0 is low (almost OV), so it stays at Hi.
can be judged that there is an abnormality.
CO cancel Resisistance value of solenoid: 1. In cases 1) and 21, it is the same as display 07.
17
solenoid 50-loon
205FO5348
Resistance value of solenoid:

10-220
1) Disconnection inside solenoid or dis- Value of current 1. In the cases 11, it is the same as display 08,09.
connection in wiring harness be- 2. In the cases 2). the same current (approx. 1 A) continues to flow
1. In the case of 11, it is the same as Item 1 above.
tween controller Cl (9). (17) - H mode 0.10 - 0.25A 2. In the case of 2). current continues to flow (approx. IA) to the TVC solenoid, so the TVC valve output pressure drops
18 TVC solenoid TVC solenoid S mode 0.59 - 0.89A to the solenoid and the total speed becomes slower.
2) Contact of wiring harness between L mode 0.80 - 1.03A (There is no change even when the power set is switched be-
3. Other items are the same as Item 2 above.
controller Cl (I 7) - TVC solenoid tween H, S, and L.)
C4 (2) with ground Engine at high idling, H.0 mode.
(Auto-deceleration OFF, levers at
neutral)
1. Voltage between Cl (1 I) and There is an abnormal display, but no particular action is
(12) taken. Therefore, if the places in contact wit!: the ground
Wiring harness between controller C2 Even when the fuel control dial is set to MAX and the auto-
21
No. 2 throttle
(1 1) - engine throttle controller El (9)
: 0.8 - 4.2V are reset by the vibration of the machine, the condition re-
deceleration is canceled, the high idling speed of the engine does
signal 2. Resistance value between Cl turns to normal.
in contact with ground not change for H.0 + H mode or G.0 + S mode.
(female) (1 1) and El (9) * However, the display does not disappear (disappears
: Min. 1 M n (Disconnect El) when power is turned OFF.)
20-114
rolaouI i12
w-m_._ .
Display System with Condition when normal

Details of abnormality Action of controller when abnormality is detected Symptoms shown by machine when there is abnormality
code abnormality (voltage, current, resistance values)
1) Disconnection in wiring harness (1).
2) Wiring harness (1) in contact with
ground
3) Disconnection in wiring harness (2).
4) Disconnection in wiring harness (3)
or contact with ground
lt acts when the fuel control dial is set to MAX. If it is reset, it 1. Inthecaseof l)or3),
5) Disconnection in wiring harness (4) 1. Between El (8) and (18) acts again in proportion to the movement of the fuel control i) Operates normally when the fuel control dial is set to MAX.
or contact with ground (MAX) 0.25 - 4.75 V (MIN) dial. ii) When the fuel control dial is set to partial, the power feels
6) Disconnection in wiring harness (5). 2. Between El (7) and (18) less than S mode although it is in H mode.
22 Throttle signal <*is,6,dI * However, the display does not disappear (disappears
Inmi!ir
Engine : 5 f 0.5v when power is turned OFF.) 2. In case of 2), 4). 5), or 6).
&a,
dldi ; (31
COl,Ol C0011B1C
t,v_: 3. Between C2 (10) and (20)
< 5 * In the case of 2). 4), 5). and 6). the engine throttle con- The engine speed does not change even when the fuel control
- 0,#,-1 : (MAX) 0.25 - 4.75 V (MIN)
(9,UC
-5%a.SP
2 -h-,,,< troller also shows abnormality. dial is turned.
Prn0 . i D,.,.
COfrOl*r 2)
!z%I .nre 2051053L9
* In the case of 2), 4), 5). and S), the
engine throttle controller also show
abnormality.

1) Defective pressure sensor
tween pressure sensor (3) pin and ii
controller, .or contact with ground
205FO5350 1. Cannot carry out PEMC control in S or L mode
1. Between C3 (6) a:d (1) Operate with pressure at 0 kg/cm*. If the abnormal place is (There is a horsepower difference between H, S, and L mode)
23 Pump pressure : 0.5 - 4.5v reset, it operates normally. 2. Travel speed does not change automatically (does not change
tween pressure sensor (1) pin and * However. the display does not disappear (disappears
24 sensor signal controller 2. Between C7 (1) and (2) from Hi to Lo)
: 18-28V when power is turned OFF.) * Can be changed manually.
tween pressure sensor (2) pin and 3. Resistance value between C3
controller, or contact with ground (female) (6) and (1). and be-
tween (6) and chassis
I) Defective pressure sensor : Min. 1 M R Operates with pressure at 0 kg/cm. When it detects an ab-
Pump pressure normality, it turns the output OFF; when all control levers
2) Wiring harness between pressure (Disconnect connector of pres- Same as display 23
25 sensor power
sensor (2) pin and controller in con- sure sensor and connector at
source
1) Disconnection inside speed sensor

(When the resistance inside the current to the TVC solenoid. If it is reset during operation,
Engine speed sensor has become extremely high) it returns to normal. The output pressure of the TVC valve drops, so the pump discharge
26 Resistance value: 500 - 1000 (1 * However, the display does not disappear (disappears Pressure drops (the engine load becomes lighter), and the total
sensor signal 2) Disconnection in wiring harness be-
tween speed sensor E7 (1) (2) pin when power is turned OFF.) speed becomes slower.
and controller 2. When the sensor function has been lost because of dis-
connection inside the speed sensor, the speed sensor
monitor on the controller does not flash.
tween controller C2 (19) and engine 1. Voltage between C2 (19) and When the auto-deceleration switch on the panel is ON
throttle controller El (1 1) chassis I) When the engine speed has dropped to deceleration speed, it be-
It does not carry out any particular action. Therefore, if it is comes FULL speed. Or, if the engine is running at FULL speed,
2) Wiring harness between C2 (14) l During deceleration: 0 - 1V
28
Auto-deceleration reset during operation, and all control levers are returned to the engine speed does not drop to deceleration speed even
and El (1 1) in contact with ground l When canceled: 8 - 12V
signal neutral, the output starts again. when the levers are placed in neutral.
3) When auto-deceleration is canceled, 2. Resistance value between C2
and voltage between C2 (19) and (19) and chassis: Min. 1 fl 2) Even when the levers are operated, deceleration is not canceled.
(21) drops below 7V.
1. Voltage between C2 (17) and 1. When 102C signal is input:
When voltage between controller C2
chassis, and between (1.8) and No. 2 throttle circuit outputs L mode speed command to 1. In the case of I), it becomes L mode (controller display also be-
(17). (18) - (8) is below IV (when engine throttle controller
chassis comes L)
29 Overheat signal engine is overheating and monitor
l When normal: 10 - 13V 2. When 107C signal is input: 2. In the casecf 2), the engine speed becomes low idling.
panel gives coolant temperature
l When overheat signal is No. 2 throttle circuit outputs low idling command to
warning) engine throttle controller.
given: 0 - 2V
1. Upper structure does not swing because swing brake is not
released.
1) Power source is not input All functions stop, but when the power source voltage be- 2. Current of TVC solenoid becomes 0.
JI off Power source 2) When voltage is more than 38V or Voltage: 20 - 30V comes normal, the functions return to normal. (If the load is high, the drop in engine speed is large, and the
less than 19V. * The display also becomes normal engine may stall)
3. Travel speed is not switched.
4. Engine speed does not go down to deceleration speed.
Except for swing brake circuit, all functions stop.
0
Self-diagnostic check inside controller * However, TVC solenoid only gives a fixed Output Of Apart from swing brake and TVC solenoid, same as above.
Only dot lights up
(cannot be measured from outside) approx. 0.7A.
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. The symptoms are
then used to decide which troubleshooting table (E-o-o, C-o-o, H-o-o) matches the symptoms.
The presence of any self-diagnostic display given in the judgement table indicates which troubleshooting
table to use.
* The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of the
vehicle (P-o-o).
(See the contents for troubleshooting of the vehicle monitor system.)
1) Judgement table for engine throttle controller, engine related parts.

0 If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (E-o) given
on the bottom line of the judgement table.
(There is a l given in the column where the failure mode and self-diagnostic display, go to the
troubleshooting code (E-o or engine shop manual) given in the column on the right of the judgement
table for that failure mode.
c Example> Failure mode Lack of output power.
[Procedure]
Check the three LEDs on the side face of the controller to see if their ON/OFF combination gives an
abnormal display for the self-diagnostic display.
[Judgementl
If there is an abnormal display (for example, VI) on the self-diagnostic display:
Go to troubleshooting E-2 of the electrical system
...........
Starting
motor
rotates:
If there is no abnormal display on the self-diagnostic display:
Go to troubleshooting of
r
mechanical system
(see engine shop manual)
l Check that the starting
motor rotates
l- Go to troubleshooting of
Starting motor does not rotate: ............
electrical system Fl , 2, or 6
20-117
2) Judgement table for pump controller, hydraulic related parts.
l If the self-diagnostic display gives an abnormal display, go to the troubleshooting code (C-o-o)
given on the bottom line of the judgement table.
(There is a l given in the column where the failure mode and self-diagnostic display come
together.)
l For any problem where there is no abnormal display given by the self-diagnostic display, check
the chart for the place where the failure mode and input signal display come together (place
marked 0).
If the display is normal, go to the troubleshooting code (H-o-o) given in the column on the right
of the judgement table.
If the input signal is not displayed, go to the troubleshooting code (F-o-o) given on the bottom
line.
c Example> Failure mode Auto-deceleration does not work.
[Procedure]
Check if an abnormal display is given by the self-diagnostic display or if the numbers on the side face
of the controller are flashing.
[Judgement]
If there is an abnormal display (for example, 28) on the self-diagnostic display:
Go to troubleshooting C-21 of the electrical system.
If there is no abnormal display on the self-diagnostic display, and the auto-deceleration does.not work:
Display given: ...................... Go to troubleshooting of

hydraulic system H-7
. Check the monitor for the pump .; ,1>
controller input signal .Go t& tr;&-l@fi&q$f
No display given:. ..... . . 1:.....
electrical system Fl , 2, 3, or 6
20-118
METHOD OF USING TROUBLESHOOTING CHARTS
1) Category of troubleshooting code number

Troubleshooting Component
Code No.
E-o-o Troubleshooting of engine throttle
controller system.
c-o-o Troubleshooting of pump controller
system.
F-o-o Troubleshooting of pump controller
input signal system.
H-o-o Troubleshooting of hydraulic and
mechanical system.
P-o-o Troubleshooting of monitor system.
2) Method of using troubleshooting table.

Troubleshooting code number and problem.
The top left of the troubleshooting chart gives the troubleshooting code number and the problem
with the machine.
Distinguishing condition.
Even with the same problem the method of troubleshooting may differ according to the model,
component or problem. In such cases, the troubleshooting chart is further divided into sections
marked with small letters (for example, a)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item.
Method of following troubleshooting chart.
Check or measure the item inside the box and according to the answer follow either the YES
line or the NO line to go to the next box. (Note: The number written at the top right corner of
the box is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy column
on the right.
Below the box there are the methods for inspection or measurement and the judgement values.
If the judgement values below the box are correct or the answer to the question inside the box
is YES, follow the YES line; if the judgement value is not correct or the answer to the question
is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement and the
judgement values. If this preparatory work is neglected or the method of operation or handling
is mistaken, there is danger that it may cause mistaken judgement or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully and start the work in order from item 1.
General precautions.
When using the troubleshooting chart, precautions that apply to all items are given at the top of
the page and marked with *. The precautions marked *are not given in the box but must always
be followed when carrying out the check inside the box.
Troubleshooting tools.
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details,
see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.
20-119
Installation position, pin number.
A diagram or chart is given for the connector type, installation position and connector pin number
connection table, so when carrying out troubleshooting, see this chart for details of the connector
pin number and location for details of the connector pin number and locations for inspection and
measurement of wiring connector number oo appearing in the troubleshooting flow chart.
-CExample >
[Short circuit in governor motor] is displayed.
(There are cases where the troubleshooting is divided into Sections a), b), etc.).
* If this happens during operation, because of the force of the spring:
l Engine speed changes to low idling.
It If the problem occurred when the engine was stopped:

l Engine starts but remains at low idling.
A
Stop the engine before carrying out any checks.
* Before carrying out teoubleshooting, check that all the related connectors are properly
inserted.
* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defecrive engine rhroffle

COI,Ollei
I El (female),and
Short circuit in wiring
Red Green Red
Is resistance be- harness for Problem
fween each pin of !
E5 (ma,e),ad pin NO. (berween El-
EZ- E5)
each pin-chassis * See Fig, 1
ON OFF ON wifch OFF.
as shown in Table
1, i Dirconnect El.
Defective governor
mo7or
20-120
TROUBLESHOOTING OF ENGINE CONTROLLER
SYSTEM (E-MODE)
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . 20-123
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON

ENGINE THROTTLE CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
E-l [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED

(ALL LAMPS OFF) .................................................. 20-126
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED. ..................... 20-128
E-3 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED. ... 20-129
E-4 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED. ............... 20-130
E-5 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED ...................... 20-132
E-6 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED. ................... 20-134
E-7 ENGINE DOES NOT START (PC3OOLC) ................................... 20-136
E-7 ENGINE DOES NOT START (PC4OOLC) ................................... 20-138
E-8 ENGINE ROTATION IS IRREGULAR ...................................... 20-142
E-9 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW) ................. 20-144
E-10 ENGINE DOES NOT STOP. ............................................ 20-146
E-l 1 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE ....................... 20-148
20-121
20-122
20-124
POINTS TO REMEMBER WHEN CARRYING OUTTROUBLESHOOTING ON
The engine on the PC3OOLC and PC4OOLC is controlled by an engine throttle controller.
The problems that may arise with this system are as follows.
1. Low idling speed in too high (low).

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

b motor linkage.
See TESTING AND ADJUSTING.
pump is disconnected I GO to troubleshooting of electrical

and pump governor l Set starting switch No system E-8 - E-10.
lever is operated at ON position and
by hand or is operate fuel control dial
secured with wire? and working mode switch.
See Engine Shop Manual
If the engine does

not stop, push the
governor lever to the
STOP position and
check if the engine
stops.
After disconnecting or adjusting the ,linkage as shown above, go to the troubleshooting flow chart for the
mechanical system or electrical system.
f For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
20-125
El mj [ABNORMALITY IN POWER SOURCE SYSTEM OR
CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)
* If fuses 2 and 9 are not blown.

If they are blown, check for a short circuit in the wiring harness between fuse - controller or starting
switch.
f If battery is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
4 YES
1s there continuitv
YES between El
- (female) (12) and -
battery relav
3 terminal E?
0 Turn starting NO
Is voltage between switch OFF.
Yl
. El (2).and El (12) - 0 Disconnect El.
normal?
5 YES
2 .20-30V
Is voltage between
0 Turn starting
starting switch
Is voltage between switch ON.
NO terminal 6R and
El (1) and El (12) chassis normal?
.20-30V NO
0 Turn starting
.20-30V
switch ON.
0 Turn starting
switch ON.
JO
*
YES
switch ON. 6 I
Is voltage between
battery relay
r terminal 6 R and 7 YES
chassis normal?
_ Is voltage between
.20-3ov starting switch
l Turn starting NE terminal BR and -
switch ON. chassis normal?
.20-30V NO
l Turn starting
switch ON.
Starting switch MI(M4) DIO
Engine throttle controller
F20505355A
20-126
CaL4S.e Remedy
Defective engine throttle

Replace
controller
Defective contact, or
disconnection in
Repair or
wiring harness
replace
between El (female)
(12) - Ml4 (8)
disconnection in wiring
Repair or
harness between El
replace
(female) (2) -starting
switch terminal ACC
Defective starting switch Replace
Repair or
harness between E1
replace
(female) (1) -fuse 2
outlet port
Defective battery relay Replace
harness between starting Repair or
switch terminal B R - M7 replaCe
(2) -battery relay

terminal 8R
Defective starting switch Replace
20-I 27
E2 li$ii [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED.
* If this happens during operation, because of the force of the spring:

1. Engine speed changes to low idling.
* If the problem occurred when the engine was stopped:
1. Engine starts but remains at low idling.
2. Engine starts but does not stop.
A
Stop the engine (Place the governor lever of the injection pump in the NO INJECTION position)
before carrying out any checks.
CaUSe Remedy
? YES Defective engine throttle

Replace
controller

harness for problem
Repair or
pin NO. (between El-
replace
E2-E5)
l See Fig. 1
Defective governor
Replace
motor
Table 1.
E5 (male) El (female) Resistance value
(1) - (2) (3) - (14) 4-90
(3) - (4) (4) - (15) 4-90
(2) - (3) (3) - (4) Min. 1Mn
(2) - (4) (3)~(15) Min. 1Mn
Between pins (l), (2), (3), (4) - chassis Between pin (3), (4), (14), (15) - chassis Min. 1 MQ
Fig. 1

E I (MIC21)
205FO5352-2
20-128
[DISCONNECTION IN WIRING HARNESS OF GOVERNOR
MOTOR] IS DISPLAYED.
* During operation:
1. If there is disconnection simultaneously in the A phase and B phase:
Engine speed changes to low idling.
Engine does not stop.
2. If there is a disconnection in either A phase or B phase:
The engines speed stays the same as immediately before the problem occurred.
* If the problem occurred when the engine was stopped:
1. Engine starts but remains at low idling.
A
Stop the engine (place the governor lever of the injection pump in the NO INJECTION position)
Remedy
2 YES Defective engine throttle Replace

15 resistance controller
between each
YES pin of El
I- (female). and
Red Green Red Is resistance harness for problem Pin
ND 3epair or
s .;,.,..,.
between each . ~~~,:: No. (between El - E2
,eplace
pin of E5 (male), * Turn starting switch OFF. -E5)
l See Fig. 1
chassis as shown
ON OFF OFF
in Table I?
~ . Turn starting Defective governor

Replace
switch OFF. motor
* Disconnect E5. No
Table 1.
E5 (male) El (female) Resistance value
(1) - (2) (3) - (14) 4-9n
(3) - (4) (4) - (15) 4-90
(2) - (3) (3) - (4) Min. 1MSl
(2) - (4) (3)-(15) Min. 1MQ
Between pins (l), (2), (3), (4) - chassis Between pin (3), (4), (14), (15) - chassis Min. 1 Mn
Fig 1
205FO5352-2
20-129
E4 ml [ABNORMALITY IN GOVERNOR POTENTIOMETER]
IS DISPLAYED.
* If the pump controller displays only 22, go to troubleshooting C-18.

f Always connect any disconnected connectors before going on the next step.
Is resistance bet-
YES ween El (female)
- (6) - (5). (5) - -
(16). (6) - (16) as
3 shown in Table l?
Is resistance
between E4 - Turn starting
YES _ switch OFF.
r
(male) (1) - (2).
(I) - (3). (2) - - - Disconnect El.
(3) as shown in
Table l?
Governor motor
. Turn starting
potentiometer
switch OFF.
display and pump
. Disconnect E4. ND
controller
display 1221 t -chassis normal?
I . Min. 100 k.Q I

. Between wiring
chtzz aMn;. 1 Ma NC
* Turn starting
switch OFF,
Disconnect El and C2.
a Turn starting NO
switch OFF.
* Disconnect El.
Table l? 1
. Turn startina
switch OFF.-
IO
. Disconnect E4.
E I (MIC21)
Pump controller
Fuel control dial
Governor potentiqmeter
F205F05357A
20-130
T .. Remedy -
I
.,- .
: .
.
6 YES . Defective engine throttle

Replace
Is resistance bet- controller
YES ween El (female)
5 - (7) - (8), (8) - -
(18), (7) - (18) as Wiring harness between
T shown in Table 17 ND El (female) (7) - E6
between E6 (female) (1) in contact
(male) (1) - (2). * Turn starting switch OFF. with ground, or Contact
(1) - (3). (2) - - * Disconnect El. with other wiring harness
(3) as shown in
switch OFF.
I NO
Defective
control
fuel
dial
Replace
. Disconnect E6.
i
Wiring harness between
El (female) (6)-E2 (1)
-E4 (female) (1) in Repair or
NO contact with ground, or replace
contact with other
wiring harness.
I
Defective governor
motor Replace

harness between El
Repair or
. (female) (10). (20) -
c2 (ft?inale) (10). (201, replace
or contact with ground
Defective engine
Recdace
throttle controller
Defective wiring
harness in system where Repair or
resistance value is reDlaCe
defective
Defective governor
Replace
motor
Table 1.
E4 (male) E6 (male) El (female) El (female) Resistance value (KQ)
Between (1) - (3) Between (1) - (3) Between (6) - (16) Between (7) - (18) 4-6
Between (3) - (2) Between (1) - (2) Between (6) - (5) Between (7) - (8) 0.25 - 7.0
Between (2) - (1) Between (2) - (3) Between (5) - (16) Between (8) - (18) 0.25 - 7.0
Between (6), (5), Between (7), (8),
Min. 1MQ
(16) - chassis (18) - chassis
20-131
[ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED
When the relevant abnormality is displayed, Pump controller abnormality display 22 is also displayed
at the same time.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause RWedY
3 YE Defective engine throttle

Replace
cOtrOller
YE
E[
2 harness between El Repair or
(female) (10). (20) - reolace
Is resistance bet- . Min. lOOka NI C2 (female) (10). (20),
YE
ween El (female) I . Between wiring or contact with ground
(7) - (S), (7) - harness - chassis:
(18), (8) - (18) as Min. 1 MS1
shown in Table I? t Turn starting
Red Green Red switch OFF.
Turn starting Defective wiring
between E6 * Disconnect El and C;
switch OFF. harness in system where Repair or
Disconnect El. resistance value is replace
(3) ar shown in defective
ON ON ON
u * Turn starting
switch OFF.
Defective fuel control
* Disconnect E6.
dial
Replace
Table 1.
I E5 (male) I El (female) 1 Resistance value (Kn) 1
. Between (1) - (3) Between (7) - (18) 4-6
Between (1) - (2) Between (7) - (8) 0.25 - 7.0
Between (2) - (3) Between (8) - (18) 0.25 - 7.0
I - IBetween (7), (8), (18) - chassis I Min. 1Mn I

Fig. 1
E I (tvlIC21)
1
C2(MIC21)
r-k IO
E6(M3)
\
Throttle (+)
Throttle (-)
Pump controller
I
I
Fuel control dial
0 r
,,
L
T e
Sensor power
source 5V
F2050.5358
20-132
E-6 mj [ABNORMALITY IN NO.2 THROTTLE SIGNAL]
IS DISPLAYED.
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
4 YES
Yl
. Switch working mode switch.
2
Is resistance I
berwee El * Turn starting
(female) (9). (19) s:i,h OFF. NO
- C2 (female) Disconnect El.
(11). (21) asshown
in Table l?
Red G We Red
Turn starting
0 0 0
between El switch OFF.
Disconnect El
ON ON OFF and C2.
M . Turn starting
switch OFF.
a Disconnect El. ND
Table 1.
Engine throttle controller Pump controller
El (female) -
El (female) Resistance value EI(MIC21) 132(YlC2 I)
C2 (female) 1
I I
Between (9) - (19) 1 Min. 1Mfi
Between (9) - chassis 1 - 1 Min. 1Mn
Between (19) - chassis 1 - I Min. 1MO
Between (9) - (11) Max. ln -J
Between (19) - (21) Max. lg

205FO5358
Table 2 Voltage (V
Condition when measuring PC3ooLC PC4ooLC
I11 I When overheatina 1 4.0-4.25 1 4.0-4.25
Engine speed (rpm)

205FO5359
20-134
CaUSe Remedy
. Defective engine throttle Replete

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

El (female) (9). (19)- Repair or
C2 (female) (11). (21) in replace
contact with ground
20-135
E-7 ENGINE DOES NOT START
When the cranking motor does not turn.

Check that fuse 9 is not blown before starting troubleshooting.
4
IS voltage betueen Yes

Yes starting motor
-terminal B -
chassis normal?
* Turn starting No
3 switch ON.
* Approximately 24'4. Yes
Is there any sound
.of a starting motor - 5
pinion moving out.
Is voltage between
* Turn starting starting motor
switch to START. i terminal C -
No chassis normal?
f Turn starting
witch to START.
* Approximately 24'4. No
Is any noise heard Is there continuity

Yes frcm the batterv Yes between battery
11 -terminal (-) -
- battery relay
Is resistance of terminal - b?
Yes wiring harness
* Turn starting switch -between starting -
switch BR - battery
relay BR normal
10
I 1 I * Between starting INo
switch BR- battery 1
between starting u relay BR: Max. 1 ohm.
gravity normal? . Bet&en wiring harness chassis: MIN. 111 ohm.
* Disconnect at both startifvg witch and
battery relay &_
Min. 24V I
* Specific gravity: Is voltage at start- switch ON. No
Min. 1.26 - ing switch terminal - * Remwe terminal 8.
No B normal?
* Connect (-) pole of

tester to (-) No
terminal of battery.
* 20 - 29V.
No
starting
switch
08DD0019
20-136
Defective starting motor Replace
Defective contact of
Miring harness batwen
battery terminal (+) - Repair
starting motor terminal B
Defective starting motor+; Replace

7 Yes
Defective safety relay Replace
Is voltage between
Yes safety relay Defective contact, or
-terminal R end disc-tion in wiring
6 chassis grow-d? harness between ~8(2)- Repair or
alternator terminal D, or replace
Is voltage between * Approximately 12V. NO defective alternator
safety relay . Turn starting
terminal S and - switch ON. Defective contact, or
chassis ground? a Yes discornaction in wiring
- Approximately 24V. Is voltage between switch terminal C-M(4)- replace
* Turn starting starting switch M14(1)-EBtl)-MZ(l)-
switch to START -terminal C and safety relay terminal S
position. NO chassis ground?
Defective starting switch Repair
* Approximately 24V. NO
. Turn starting Defective battery relay Replace
to START position.
Defective ccntact of
wiring harness between Repair or
battery terminal (-)- replace
battery relay terminal-b
disconnection in wiring Repair or
harness between starting replace
switch terminal BR-Ml
(21-117 (2Mattery
relay tensinal RR
Defective starting switch

(between terminal B-RR) Replace
harness between battery Repair or
terminal (+I-Ml-H7 replace
(1)-M (l)-starting switch
terminal B (including
fusible link)
VBattery capacity too 10~ Charge or replace
20-137
PC3OOLC
b) When the cranking motor is normal.

Cause
Yes
2, Defective shut-off valve Replace
tween El0 (female)

Defective contact or dis-
connection in wiring
harness between ElD(B)- Repair or replace
1 E9(4)-E8(7)- safety relay
l Turn starting terminal C.
Is voltage between switch OFF
ElD(A)- chassis l Disconnect El0 and safety
normal? relay terminal C.
l Max. In
l Turn starting
switch ON Defective contact or dis-
* Approximately 24V. Yes connection in wiring
3 -harness between ElO(A)- Repair or replace
E9(3)-M14(4)-M1(5)- start-
ing switch terminal (ACC).
starting switch
N~%!k:'n!!~~~ 1 Lo Defective starting switch. Replace
l Turn starting
switch ON.
l Approximately 24V.
Starting
Safety
M14CS83 Ml tM81 Switch
Relay
El0 E9tSWP81 1
Valve
08DD0020
20-I 38
PC4OOLC
b) When the cranking motor is normal.

Cause Remedy
Yes
Defective shut-off valve. !eplace.
1
Is voltage between
shut-off valve
terminal - chassis - Yes
normal? Defective contact or dis-
connection in wiring
1 harness between starting lepair or replace
l Turn starting Is voltage between switch terminal (Act)-M(5)
switch ON. starting switch -M14(4)-E8(3)- shut-off
l Approximately 24V. terminal (Act)- valve terminal.
l Turn starting Defective starting switch. leplace

switch ON. No
l Approximately 24V.
EBISWP61 M14(Si31
Starting
Shut-off valve
switch
08DD0021
20-l 39
E-8 ENGINE ROTATION IS IRREGULAR
a) Idling rotation is irregular.
* Before starting troubleshooting, check the model code.
Adjust linkage _ :
bet&e governor
YES motor and injec -
tion pump. Does
it become
orlal? NO
* See TESTING AND
ADJUSTING.
Warming-up signal 6 YES

,
1 Is voltage
YES between El
Is motor lever
- (21) -(12) -
at low idling Starting signal 5
normal and
position when -
Is voltage stable?
linkage is dis-
connected? YES between El * When warming-up VO
- (2) - (12) operating: Max. 1V
. Turn starting switch normal and
Potentiometer 4 * When warming-up
OFF. stable?
~ canceled: 8 - 12V
Is voltage.
* When operating:
YES between El (5) _ 20-30V NO
- - (16) normal
Fuel control dial 3 and stable?
Is voltage
between El *At low idling
- (8) - (18) _ PC3coLc: 2.6 - 2.9v
NO normal and PC4OOLC: 2.6 - 3.OV No
stable?
- At MIN.:
4.0 - 4.75v
- At MAX.:
NO
0.25 - l.OV
Engine throttle controller E6 (M3)

El (MIC21)
-0 3
E4 (X3)
1
.O
Governor potentiometer
P2 (MIC16)
7
.O
11
Monitor panel
@
08DD0022
20-140
I Cause Remedy
Defective adjustment
Adjust
of linkage
Defective injection ;ee Engine sho

Pump nanual
Defective governor
Replace
motor
SeeE_ll
Defective contact of wiring

switch BR - Ml (2) - M20 replace
(4), (3) - El (female) (21, or
defective starting switch
See E-4
20-I 41
E-8 ENGINE ROTATION IS IRREGULAR
b) There is hunting.
Ir Always connect any disconnected connectors before going on to the next step.
._
2 YES
Adjust linkage
between governor
ES motor and injec-
tion pump. Does
it become
flOrmal?
YES
Starting signal 7 -
Is voltage
YES between El
Deceleration r (2) - (12)
signal normal and
6
stable?
Is voltage
1 ~~~~~~;~is- between El
- When engine
iS
_ (11) _ (12) _ running: 20-30V NO
No. 2 throttle
- Turn starting
normal
stable?
and
switch ON.
* Move fuel Control * When auto-decele-
dial from MIN. to ration operating:
MAX. and stop on Max. 1V NO
tne way. . When auto-deceleration
canceled: 8 - 12V
YES between El
1
- (5) - (16)
normal and
Fuel control dial 3 stable?
Is voltage *At low idling:

between El 63ooLc: 2.6 - 2.9v
,- (8) - (18) - 64WLc: 2.5 - 3.ov
NO *At high idling: NO
normal and
stable? 0.5 - 0.9v
*When decelerating: 1.7 - 2.OV
At MIN.: *When warming-up: 63KILc: 1.8 - 2.2V
4.0 - 4.75v 64OOLc: 1.9 - 2.3V
At MAX.:
0.25 - 1.OV NO
Table 1 Voltage (V)

1 Condition when measurinrr 1 PC3OOLC 1PClOOLc]
1 (1) 1 When overheating 1 4.0-4.25 1 4.0-4.25 1
(2) L.O. and L mode 2.1 o-2.46 2.20-2.50

G.O., F.O. and S mode
(3) 1.23-l 53 1.35-l .65
G.O.. F.O. and L mode
l(4) 1 H.O. mode or H mode 1. 0.75-1.0 1 0.75-1.0 1
Engine speed (rpm)
205FO5362
20-142
CSSe Remedy
Defective adjustment tdj St

of linkage
Defective injection ee Engine shol

pump 1anual
Warming-up signal 6 YES Defective governor

3ePlaCe
Is VOItage motor
between El
- (21) - (12) -
normal and
stable?
See E-1;
. When warming-up NO
operating: Max. 1 V
- When warming-up Defective contact of
canceled: 8 - 12V wiring harness between
starting switch BR - Ml qepair or
(2) - M20 (4). 13) - ,eplaCe
El (female) (2) -
starting switch, or
defective starting switch
See-P-l?
See E-6
See E-5
Fuel control dial
20-143
E-9 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)
Before starting troubleshooting, check the model code.
NO. 2 throttle
Potentiometer
El (5) - (161
- start engine. Fuel control normat and stable? H
. Fuel control dial dial 3 I I NO
is at MAX. . At low idling:
. Heavy-duty Yes Is voltage batuaen 6300LC: 2.6-2.9V. No
+H mode. 6400LC: 2.6-3.OV. L
* At high idling: 6300LC. 6400LC: 0.5-0.9V.
* tien decelerating: 630O~C. 64OOLC: 1.7-2.OV.
. At MIN: * Uhen warming-up: 6300LC: 1.8-2.2V.
4.0-4.75V. 6400~~: 1.9-2.3V.
linkage between * At MAX: I
governor rotor * 0.25-l.OV. NO
No
l"J.ZCtlO" Pnp. DOeS

NO it become normal? NO
. See TESTING AND

AOJUSTING.
@
E 4.0 -
E
p 3.0 - Table 1 Voltage (V)
5
._
1
Enginespeed (rpm)
(4)( H.O. mode or H, mode 1 0.75-1.0 1 0.75-1.0
205FO5364
20-I 44
Defective injection pimp ;ee Engine Shop
lanua 1
Yarming-up signal 7 Yes

Defective governor motor eplace
Stertina Yes IS volt&x between
signal - 6
p
Is vottage between Refer to E-11
El (2) - (12) - * Uhen warming-up operating: Max. 1V.
normal and stable? * Uhen warming-up canceled: 8-12V.
~ No
* When engine 4Refer to P-19
rwing: 20 - 30V.
to E-6
to E-4
to E-5
Defective adjustment of djust

governor motor linkage
Defective injection pnp ee Engine Shop

anual
Fuel control dial
Pump controller
Monitor panel
20-145
E-l 0 ENGINE DOES NOT STOP.
A
~1
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
PCBOOLC
Cause Remedy
Yes
Repair or replace
[-IDefective shut-off valve. Replace

No I
Starting
@
Safety
M14CS83 Ml CM61 Switch
Relay
0
El-K 0 Act
El0 E9lSWP61 1
Valve
20-146
E-IO ENGINE DOES NOT STOP.
A
*I :
PC4OOLC
Cause Remedy
I
Yes
Defective starting switch
or wiring harness between
Does engine stop starting switch terminal Repair or replace
when wiring harness (Act)-M1(5)-M14(4)-E8(3)-
of shut-off valve - shut-off valve terminal in
terminal is removed contact with +24 volts.
GDefective shut-off valve. Replace

No
Fuse 9
MlfM63
EBISWPGI M141S81 0
Starting
Shut-off valve
switch
08DD0021
20-147
E-l 1 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE
f Warming-up is not carried out when the coolant temperature is under 30C or does not stop when the
coolant temperature goes above 30C.
(When it is canceled by the fuel control dial, there is no change in the voltage.)
* Conditions for carrying out warming-up:
1. Coolant temperature below 30C.
2. Fuel control dial set at about 50% or below (warming-up signal: Max. 1V).
* Conditions for canceling warming-up:
1. Coolant temperature above 30C.
2. Fuel control dial raised to above 70% and kept there for at least 3 seconds in power set switch H
or S mode (see Note 1).
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Note 1: When the fuel control dial is turned up to cancel warming-up, warming-up will not start again
unless the starting switch is turned OFF and then turned ON again.
Note 2: When the fuel control dial is turned up to cancel warming-up, the voltage of El (21) does not
change.
Remedy
YES Defective engine throttle

Reolace
(See Note 2) 2 7 controller
voltage
l--I
Warming-up Is
- operation is not between El (21)
canceled - (12) normal?
: See P-21
- When canceled:
1 a-12V Disconnection in wiring
Warming-up * Fuel control dial
operation is not at MIN. (female) (21)- P2
I canceled,
warmina-uo
or
t * Start engine. - Turn
OFF.
starting switch (female)
with
(11),
ground
or contact
replace
- Disconnect El and
4 YEg2 Defective engine throttle

Replace
-11 cOtrOller
Warming-up Is voltage between
operation does - ~1 (21) - (12) -
of start I normal?
NO
See P-21
* Warming-up: Max. 1V
- Fuel control dial at MIN.
- Start engine.
Table 1 Engine throttle controller

Wiring harness 1 Resistance value
EltMIC211
IBetween El (female)
(21) - chassis I
Min. 1MQ
I] P21040163
Between El (female)
Max. l!J Warming- @
(21) - P2 (female) (11) I UP
08DD0023
20-148
TROUBLESHOOTING OF PUMP SYSTEM (C MODE)
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR
IN HYDRAULIC RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
c-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP. ........ 20-153
c-2 [SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID VALVE SYSTEM] IS DISPLAYED .... 20-154
c-3 [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED ... 20-155
c-4 [SHORT CIRCUIT IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED ..... 20-156
C-5 [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED ..... 20-157
C-6 [SHORT CIRCUIT IN CO CANCEL SOLENOID VALVE SYSTEM IS DISPLAYED ........ 20-158
c-7 [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1)) IS DISPLAYED ................ 20-159
C-8 [SHORT CIRCUIT IN TVC SOLENOID VALVE SYSTEM (2)] IS DISPLAYED ........... 20-160
c-9 [DISCONNECTION IN 2-STAGE RELIEF SOLENOID VALVE SYSTEM] IS DISPLAYED ... 20-161
c-10 [DISCONNECTION IN ARM HALF FLOW SOLENOID VALVE SYSTEM] IS DISPLAYED . . 20-162
C-l 1 [DISCONNECTION IN SWING BRAKE SOLENOID VALVE SYSTEM] IS DISPLAYED .... 20-163
C-l 2 [DISCONNECTION IN TRAVEL SPEED SOLENOID VALVE SYSTEM] IS DISPLAYED .... 20-164
c-13 [DISCONNECTION IN CO CANCEL SOLENOID VALVE SYSTEM] IS DISPLAYED ...... 20-165
C-l 4 [DISCONNECTION IN TVC SOLENOID VALVE SYSTEM] IS DISPLAYED ............ 20-166
c-1 5 [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED ............. 20-167
C-1 6 [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED ................. 20-168
c-17 [ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SIGNAL SYSTEM]

ISDISPLAYED ................................................... ..20-17 0
C-l 8 [ABNORMALITY IN REAR PUMP PRESSURE SENSOR SIGNAL SYSTEM]

IS DISPLAYED ..................................................... 20-172
c-19 [ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED ... 20-174
c-20 [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED. ............ 20-176
c-21 [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED . . 20-177
c-22 [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED ................. 20-178
C-23 [CONTROLLER ABNORMAL SYSTEM1 IS DISPLAYED ......................... 20-179
20-149
20-150
20-I 52
C-l I!& ti2 1
(.yu.L!J
COFFl SELF-DIAGNOSTIC
J-
DISPLAY OF CONTROLLER DOES
NOT LIGHT UP.
Check if fuse 1 is blown. If the fuse is blown, check if the wiring harness between the fuse l-Cl (3)
and (4) is in contact with the ground.
Cause Remedy
YES Defective pump

I controller Replace
1
IS voltage Defective contact, or dis-

_ between Cl (3) _ connection in wiring Repair or
YES replace
(4) - (13) harness between fuse 1 -
normal? 2 M20 (2). (1) - M3 (3) - Cl
(female) (3). (4)
- 20-30V Is voltage at outlet
a Turn starting Defective contact,
h$ end of fuse 1
switch ON. normal? 3 YES or disconnection Repair or
in wiring harness
between Ml1 (female) replace
* Is voltage between cl)-MM7 (l)-fuse 1
* 20-30V - Ml1 (1) -chassis -
* Turn starting NO normai? Defective contact, or
switch ON.
disconnection in wiring Repair or
. 20- 30V NO harness between fusible replace
link or Ml 1 (female)
* Turn starting (2)-battery
switch ON.
Fusible link
v M20(M4) - Mll(L2)
(i)@ ($0
Pump controller
Cl (MICl7) M3(Sl6) M7(L2) Battery
205FO5369-1
20-153
c-2I._.
;\
1
\ [SHORT CIRCUIT IN 2-STAGE
SYSTEM] IS DISPLAYED
RELIEF SOLENOID VALVE
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then set
the power max. switch to ON and check that the display is [Ol]. (If it is not displayed, the system has
been reset.)
Cause Remedy
2 YES
Defective pump controller Replace
Is resistance bet-
\-\ \ ween Cl (female)
(31,(4) and (151,(15)
J-J. \ and chassis as
shown in Table l? . Power
ON
maximizing switch
. Turn starting switch

OFF
. Disconnect Cl
Contact between wiring
3 YES harness of power source Repair or
H
and wiring harness betweer replace
Is resistance bet- Cl (female) (15) and V7
ween V7 (male) (I) (female) (2)
A
and (2) as shown in
Table I?
-4 Defective 2-stage relief Replace
. Turn starting NO solenoid valve
switch OFF
. Disconnect V7
Table 1
1 Cl (female) I V7 (male) 1 Resistance value
Between (3), (4) and (15) Between (1) and (2) xl - 100a
Between (15) and chassis Between (2) and chassis Min. lM0
M20(M4)
Pump controller
Fuse
D9
205FO5370-1
20-154
c-3 I\:\ --\ ][SHORT CIRCUIT IN ARM
&. a-1 -
HALF FLOW SOLENOID VALVE
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the
working mode switch to F.O. mode and check that the display is 1031. (If it is not displayed, the
system has been reset.)
Remedy
, 2, YES Defective pump

I controller
Interchange with
YES wiring of CO
1 - cancel solenoid.
P Is [03] displayed?
Is resistance bet-
NO
ween Cl (female)
\-\ -\ _ (3), (4) and (6). (6) _ . interchange v5 andv4
. Turn starting switch ON
.\A 3 and chassis as
shown in Table l? . Set working mode
switch to F.0 mode
. Turn starting
switch OFF To A
. Disconnect Cl. NO

a YES Iarness of power source ant
Repair or
Niring harness between Cl
replace
I ISresistance bet- I I female) (6) and V5 (female)
:2)
1 I I Defective arm half flow

Replace
. Turn starting NO jolenoid valve
switch OFF.
. Disconnect V5
Table 1.
Cl (female) V5 (lamp) Resistance value
Between (3), (4) and (6) Between (1) and (2) 10-350
Between (6) and chassis Between (2) and chassis Min. 1MQ
M20(M4)
Pump controller
Fuse
Cl (MiCl71 I- I I I I I
V7(X2)
I, 1
I rly,Iy,
205FO5726
20-155
\J~,][~H~RT
c-4 [._. CIRCUIT IN SWING BRAKE SOLENOID VALVE
If the starting switch is turned OFF after the abnormality occurs, start the engine, operate the swing
and check that the display is [04]. (If it is not displayed, the system has been reset.)
Cause Remedy
2 YES Defective pump Replace

controller
YES
1 Is resistance bet- f
. St$eng&e and operate 1 _ To A
. Turn starting
switch OFF
. Disconnect Cl

YE larness of power source and Repair or
Is resistance bet- Niring harness between Cl replace
:female) (8) - M3 (female) (9
harness of power source and
Niring harness between M3 Repair or
jzmale) (I) and Vl (female) replace
YES ween M3 (male) (1) . Turn starting N(
and (9). (1) or (9) switch OFF.
and chassis normal? Disconnect M3. . Defective swing lock Replace
switch
Is resistance bet- Contact between wiring
ween VI (male) (1)
. BeWMyxn # - (9) : harness of power source Repair or
A- and wiring harness bet-
and (2) as shown in replace
Table l?
. (1) ;,p y--chassis: ween M3 (male) (1) - lock
switch - M3 (male) (9)
L
Y
. Turn
_. starting__^
switch OFF
. Turn starting 1 . usconnect MJ
switch OFF Defective swing brake Replace
. Disconnect Vl NO solenoid valve
Table 1
Cl (female) M3 (female) M3 (male) Vl (male) Resistance value
Between (3), (4) and (8) Between (3) and (1) Between (1) and (9) Between (1) and (2) lo-3!5n
Between (8) and chassis Between (1) and chassis Between (9) and chassis Between (2) and chassis Min. 1MQ
Swina lack prolix switch Swina lock switch
e+l
Pump controller 2 I 5
Cl (MICl7) r-l& 6 VI(X2)
4 I _ I I lZ71 _Swing
I
brake
M3El6)
I Eii t solenoid
valve
I-W
Swing brake S 1 I I%\ L D2
solenoid Id _
r!_!
r \I
Fuse
M20Uvl4)
205FO5727
20-156
C-5 [.z\_,] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID VALVE
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the
fuel control dial to MAX. and the travel speed switch to Hi and check that the display is [05].
(If it is not displayed, the system has been reset.)
Always connect any disconnected connectors before going on to the next step. _ _
CG3K.e Remedy
2 YES Defective Pump 3eplace

Interchange with controller
I^.
~H~~~~~ . Place travel speed switch at Hi.
* Turn starting
switch OFF. IT-...
NO
* Disconnect Cl.

3 YES harness of power Source
Repair or
, 1 1 and wiring harness
*eplace
Is resistance between Cl (female)
between V2 (16)-V2 (female) (2)
A - (male) (1) - (2) -
as shown in
Table 11 Defective travel speed Replace
- Turn starting solenoid valve
NO
switch OFF.
- Disconnect V2.
Table 1
Cl (female) V2 (male) Resistance value
Between (3), (4) - (16) Between (1) - (2) 50 - 1000
Between (16) - chassis Between (2) - chassis Min. 1MQ
V M20(M4)
(i)@
Pump controller M3(Sl6) Fuse
Cl (MICl7) I
205FO5373-1
20-l 57
r\ 7 1[SHORT CIRCUIT IN co CANCEL SOLENOID VALVE SYSTEM
C-6 [.-.
_IS DISPLAYED
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, then set
the power max. switch to ON and check that the display reads [07]. (If it is not displayed, the system
has been reset.)
It is also possible to operate the travel lever with the engine at high idling.
Remedy
YES lefective pump

:ontroller
Interchange with
._
r
YES wiring of 2-stage
1 relief solenoid.
. Interchange V4 and V3.

Turn starting switch ON.
Set power max. switch to ON.
. Turn starting
switch OFF
. Disconnect Cl
Contact between
wiring harness of power qepair or
source and wiring harness .eplace
letween Cl (female) (7) and
Is resistance bet-
/4 (female) (2)
ween V4 (male) (1) _
A =
and (2) as shown in
Table I?
Defective CO cancel Replace
solenoid valve
. Turn startina NO
switch OFF -
. Disconnect V4
Table 1
Between (3), (4) and (7) Between (1) and (2) 50 - loon
Between (7) and chassis Between (2) and chassis Min. 1MO
I
M20(M4)
Pump controller Fuse
Cl fMICl7)
1 \ _I
I \ I
V4(X2)
CO cancel
solenoid
_ valve
205FO5374-1
20-158
C-7 [_@,\[SHORT CIRCUIT IN TVC SOLENOID SYSTEM (I)]
IS DISPLAYED
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check
that the display reads [08]. (If it is not displayed, the system has been reset.)
* Turn the TVC prolix switch OFF.
: Always connect any disconnected connectors before going on to the next step.
cause Remedy
!
YES
Defective pump Controller Replace
1I
~~ToA
Defective TVC solenoid Repke
- Turn startina NO
switch OFF- Wiring harness between
. Disconnect C4. Cl (female) (9)-C5
(female) (1) in contact
{ES with ground, or in COntaCt Repair or
with GND wiring replace
* Wiring harness between

C5 (male) (l)-prolix
switch-C5 (male) (3)
in contact with ground, Repair or
NO or in contact with GND replace
wiring
- Defective TVC prolix
I
. Disconnect C5.
switch
* Turn starting Wiring harness between Repair or
switch OFF. C5 (female) (3)- C4 reDlaCe
NO
. Disconnect C5. (female) (1) in contact
with ground, or in contacl
with GND wiring
Table 1
Cl (female) C5 (female) C4 (male) Resistance value
I
Between (9) - (17) Between (3) - (4) Between (1) - (2) 10 - 22n
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1MQ
Between C5 (male) (1) - (3), (2) - (4) Max. 10
TVC prolix switch
ON
Resistor
205FO5375-1
Pump controller
20-I 59
C-8 [.I._
;\,$][SHORT CIRCUIT IN TVC SOLENOID VALVE SYSTEM (2)]
IS DISPLAYED
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check
Turn the TVC prolix switch OFF.
Defective pump controller ReDlaCe
* Turn starting
switch OFF. I Defective TVC solenoid ReDlaCe
* Disconnect ~4. NO
Cl (female) (9)-C5
4 YES with ground, or in contact Repair or
with GND wiring replace
. Wiring harness between

F[
C5 (male) (l)--prolix
switch- C5 (male) (3)
in contact with ground, Repair or
* Turn starting switch or in contact with GND replaCe
OFF. wiring
* Disconnect C5. * Defective TVC prolix
switch
* Turn starting switch
airing harness between Repair or
OFF.
10 C5 (male) (3)-C4 (female replace
* Disconnect C5.
(I) in contact with ground
3r in contact with GND
Niring
Table 1
I Cl (female) C5 /female) I C4 (male) I Resistance value I
1 Between (9) - (17) 1 Between (3) - (4) 1 Between (1) - (2) 1 10-229 I
Between (17) - chassis Between (4) - chassis Between (2) - chassis Min. 1Mn
Between C5 (male) (1) - (3), (2) - (4) Max. ln
lVC prolix switch
ON
CSM6)
Resistor
205FO5375.1
Pump controller
20-160
C-9 [. \ . \l[DISCONNECTION IN 2-STAGE RELIEF SOLENOID VALVE
* If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.
If pin (2) of the solenoid is short circulating with the ground, the solenoid stays actuated.
that the display reads [ll]. (If it is not displayed, the system has been reset.)
* If [l l] is displayed, start the engine and press the power max. switch. If there is no difference in the
digging force between when the switch is pressed and when it is not pressed, start troubleshooting
from Item 4 in the flow chart below.
z Before carrying out troubleshooting,

Always connect any disconnected
check that all the related connectors
connectors
are properly inserted.
before going on to the next step.
Cause Remedy
2 YES Defective pump
HI
Replace
controller
In same conditions
YE as when measuring
Item 1, is [l l]
displayed?
1 Already reset
. Turn starting switch NO
ON.
YES
_-I
3
. Turn starting
switch ON. Is resisiance bet-
. Power max. ween Cl (female)
harness between Cl (female
switch: h
- (3) (4) and (15). (15) -
4 YES (3), (4). (15) - V7 (female) Repair or
ON: 0 - 3V and chassis as
(1) (2), or wiring harness replace
(8.5 set) .~shown in Table l? Is resistance bet- between Cl (female) (15) -
OFF: 20 - 30V . Turn starting L ween V7 (male) (1) V3 (female) (2) in contact
switch OFF ND and (2) as shown with ground
. Disconnect Cl in Table l?
Defective 2-stage relief Replace
. Turn starting NC solenoid valve
switch OFF.
. Disconnect V7.
Table 1
Between (3), (4) and (15) Between (1) and (2) 50 - 1OOR
Between (15) and chassis Between (2) and chassis Min. ln
205FO5370-1
20-161
c-10 [. \ .-31 1DISCONNECTION IN ARM HALF FLOW SOLENOID VALVE
If pin (2) of the solenoid is short circuiting with the ground, the solenoid stays actuated.
* Always turn the swing lock prolix switch OFF and set the swing lock switch at OFF before starting to
check.
* If [14] is displayed, start the engine. If the swing brake is not released when the swing is operated,
start troubleshooting from Item 4 in the flow chart below.
Cause Remedy
Defective pump
Controller
YE
Already reset
NO 3 ;ES 1
. Turn starting switch I IS resistance
H
ON.
. Finishing, lifting bewee Cl
.
mode:
mode:
Max.
Heavy-duty.
20 -
3v
general
30V
I (female) I31 (4)
- (6). I61 -
chassi* as shown
in Table l?
ILTToA
Disconnection
harness between
(female) (3)(4)-M3
in wiring
Cl
OFF. (female) (3)(51, or
. Disconnect Cl. wiring harness between
Cl (female) (6)-M3
(female) (5) in contact 3epair or
6 YES
with ground eDlace
YES between M3
(male) (3) -
Disconnection
harness between
in wirina
M3 -
(5).(5)- chassis
5 - ar (male) (3)(51-~6
showin (male) (7)(61, or wiring 9epair or
Is
resistance bet- Table 1 Y( J
harness between M6 eplace
YE5
-
ween M6 (female)
(7) - (6). (6) - -
. Turn starting switch (female) (51-M6 (male)
OFF. (6) in contact with
chassis es shown in . Disconnect M3.
4 ground
F Table 17
Is resistance bet- Disconnection in wiring
ween V5 (male) . Turn starting switch Repair or
?aress between M6
--c (1) - (2). (2) - - OFF. eplace
NO :female) (7) (6) - V5
chassis es shown in * Disconnect M6. Ifemale) (1) 12). or wiring
Table l? harness between M6
Ifemale) (7) - V5 (female
2) in contact with grounc
OFF.
. Disconnect v5. ND Defective arm half =teplace
flow solenoid valve
Table 1
Cl (female) M3 (male) V5 (male) M6 (female) Resistance value
Between (3), (4) - (6) Between (3) - (5) Between (1) - (2) Between (7) - (6) 10 - 359
Between (6) - chassis Between (5) - chassis Between (2) - chassis Between (6) - chassis Min. 1MSi
Pump controller
w 205FO5371-1
20-162
C-II 1. \J,]
. [ DISCONNECTION IN SWING BRAKE SOLENOID VALVE
* If there is a disconnection in the solenoid or wiring harness, the circuit up to the solenoid is not
actuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
* Always turn the swing lock prolix switch OFF and set the swing lock switch at OFF before starting to
check.
* If [14] is displayed, start the engine. If the swing brake is not released when the swing is operated,
start troubleshooting from Item 4 in the flow chart below.
Cause Remedy
2, YES Iefective pump 7eplace

:ontroller
jIZ$@ZHT
Already reset
Turn starting NW
switch ON
Is voltage bet-
u L_ ween Cl (8) and -
. Turn swing lock
switch OFF
chassis normal?
YES
. 1:\
3
. Lever at neutral: Max. 3V p
. Lever operated: 20 - 30V Is resistance bet-
. Turn swing lock switch ween Cl (female)
OFF. L (3) (4) and (8), (8) -
. Turn starting switch ON. ND and chassis as 4 YEE
To A
shown in Table l? Is resistance bet-
ween Vl (male) (1)
. Disconnect Cl.
N$ and (21, (21 and -
chassis as shown
in Table l? Iefective swing brake Replace
. Turn starting N( solenoid valve
switch OFF.
. Disconnect Vl. Disconnection in wiring
harness between Cl (female)
(8) - M3 (female) (9). or
6 YE:
contact with ground
Repair or
reolace
Defective swing lock
switch
harnes between M3 (male)
(1) - lock switch - M3 Repair or
(male) (9). or contact with replace
ground
narness between M3 (female
. Turn starting (1) (3) - Vl (female) (I) (2) 01 Repair or
switch OFF. wiring harness between M3 replace
Disconnect M3. (female) (1) and Vl (female)
(2) in contact with ground
Table 1
I Cl (female) M3 (female) I M3 (male) I Vl (male) 1Resistance value
Between (3), (4) and (8) Between (3) and (1) Between (1) and (9) Between (1) and (2) lo-35n
Between (8) and chassis Between (1) and chassis Between (9) and chassis Between (2) and chassis Min. 1MQ
Swing lock Swing lock

prolix switch switch
Swing brake
solenoid
valve
C-J 205FD5727
20-163
c-12 [* \-,I [DISCONNECTION IN TRAVEL SPEED SOLENOID VALVE
.-
actuated. If pin (2) of the solenoid is short circuiting with the ground, the circuit up to the solenoid
stays actuated.
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, set the
travel speed switch to Lo and check that the display reads [15]. (If it is not displayed, the system has
been reset.)
* If [15] is displayed, start the engine and if the speed does not become Hi when the travel speed switch
is set to Hi and the engine is at high idling, start troubleshooting from A in the flow chart below.
Cause Remedy
1
controller
Already reset
* Turn starting switch \
Is voltage between ON.
\ \- _ Cl (16) -chassis -
nromal?
. 1.11 3 YES
* At Lo: ZO-30V Is resistance

* At Hi: Max. 3V between
(female)
Cl
(3) (4)
* Switch travel
speed switch. NO- -116),(16)- -
chassis as show
. Turn starting switch in Table I? NO
ON. To A
OFF. Disconnection in wiring
* Disconnect Cl, harness between Cl
(female) (3) (4) (16) -
4 YE! v2 (female) (1) (2). or
wiring harness between
Cl (female) (16) - V2
with ground
Defective travel speed

* Turn starting switch solenoid valve
OFF.
a Disconnect V2.
Table 1
Cl (female) I V2 (male) Resistance value
Between (3), (4) - (16) 1 Between (1) - (2) 1 50 - loon
Between (16) - chassis Between (2) - chassis Min. 1MfI
n
Pump controller
Cl (MICl7)
205FO5373-1
20-164
c-13[. \ .71 [DISCONNECTION IN CO CANCEL SOLENOID VALVE
If pin (2) of the solenoid is short circuiting with the ground, the solenoid stays actuated.
* If the starting switch is turned OFF after the abnormality occurs, turn the stating switch ON, then turn
the swing lock switch ON and check that the display reads [17]. (If it is not displayed, the system has
been reset.)
f If [17] is displayed, start the engine and if there is no difference in the digging force between when
the swing lock switch is ON and when the swing lock switch is OFF, start troubleshooting from A in
the flow chart below.
Cause Remedy
2 YES Iefective pump

:ontroller
+JG&$qt
4lready reset
NO
\-\I
. Turn starting
\_ Is voltage between
Cl (71 and chassis l-l switch ON
I
switch OFF
. Disconnect Cl Xsconnection in wirinq
?arness between Cl (female
4 YE 31 (41. (71 - V4 lfemalel 111 Repair or
jZj,or&ring harness be< replace
Neen Cl (female) (7) and V4
:female) (2) in contact with
~---~H ground
Defective CO cancel Replace

. Turn starting N solenoid valve
switch OFF
. Disconnect V4
Table 1
Between (3), (4) and (7) Between (1) and (2) 50 - 1ooa
Between (7) and chassis Between (2) and chassis Min. 1MQ
M20fM4)
Pump controller Fuse
co
cancel
solenoid
205FO5374-1
20-165
c-14 1.\wj
.--, 1DISCONNECTION IN TVC SOLENOID VALVE SYSTEM]
IS DISPLAYED
actuated. If pin (2) of the solenoid is short circuiting with the ground, the current (approx. IA)
continues to flow to the solenoid.
* Turn the TVC prolix switch OFF.
2 Always connect any disconnected connectors before going on to the next step.
I CaUSe Remedy
YES Defective pump

r) I- I Replace
controller
Is resistance
befwee Cl
(female) (9) -
(17). (17) - 3 YES
chassis as show - TO A
in Table I? Is resistance
between C5
* Turn starting switch _ {Fjmp;;)-(3) - _ Disconnection in wiring
OFF. harness between C5
NO
. Disconnect Cl. chdssis as show (female) (3). [4)-C4
in Table l? NO (female) (1). (21, or Repair or
wiring harness between replace
C5 (female) (4)-C4
OFF.
* Turn starting switch . Disconnect C5.
with ground
OFF.
. Disconnect C4.
Defective TVC solenoid Replace
harness between C5
(female) (1). (2kCl
4 YES (female) (9). (17). or Repair Or
.A replace
C5 (female) (2)-Cl
with ground
Defective TVC prolix Repair or

* Turn starting switch switch, or defective replace
OFF. wirina harness between
. Disconnect C5. switch-C5
Table 1
Cl (female)
I C5 (female) C4 (male) 1Resistance value (Q)
Between (9) - (17) 1 Between (3) - (4) 1 Between (1) - (2) 1 10 - 22
Between (17) - chassis 1 Between (4) - chassis Between (2) - chassis Min. 1MO
Between C5 (male) (1) - (3), (2) - (4) - Max. 1
n
TVC prolix watch
205FO5375-1
Pump controller
20-166
c-15p ._. \] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM]
IS DISPLAYED
If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check
that the display reads [21]. (if it is not displayed, the system has been reset.)
CZllSe Remedy
Al ready reset
Is same condition
Defective Pump
3eDlace
controller
ES
I Defective engine
I I 4 YE throttle controller
See E-6 :
* Switch working El (f&ale) (19)
mode switch. - (9) as shown in
Table l? l-l h
Defective pump controller
- Turn starting switch
ON.
. Switch working
. Min. IMa mode switch.
* ~;,onnect C2 and * Disconnect El.
- Turn starting Switclh Disconnectionin wiring har-

OFF. ness between C2 (female) Repair or
1
NO (11). (21) - El (female) (9). replace
(19). or contact with ground
Pump controller Engine throttle controller
C2(MIC21) E I (MIC21)
205F05383-K
Table 1
Engine speed (rpm)
Condition when measuring Pc3ooLC Pc4ooLC
(1) When overheating 4.0-4.25 4.0-4.25
(2) L.O. and L mode 2.10-2.40 2.20-2.50
(3) G.O., F.O., L.O. and S mode
1.23-l 53 1.3!5-1.65
G.O., F.O. and L mode
(4) H.O. mode or H mode 0.75-l .o 0.751 .o
20-167
C-l6[7~1
_-_-
\_-_-,
[ABNORMALITY IN THROTTLE SIGNAL SYSTEM]
IS DISPLAYED
If an abnormality is displayed for the engine throttle controller, go first to troubleshooting E-6.
2 If the starting switch is turned OFF after the abnormality
that the display reads [22]. (If it is not displayed,
occurs, turn the starting switch ON and check
the system has been reset.)
** Before carrying out troubleshooting,
connectors
are properly inserted.
before going on to the next step.
CalSe Remedy

I , controller
3eplwa
Already reset
ON.
harness between C2 (female
3 YES (10). (20) - El (female) (10). Repair or
(20). or wiring harness bet- replace
ween C2 (female) (IO) - El
* Turn starting switch ON. (female) (IO) in contact with
- Fuel control dial FH_ ground
MIN.-MAX. h
See E-6
* 0.25-4.75V NO
ON.
* Fuel control dial
MIN. -MAX.
C2(MICl7) EI(MIC21)
205F05385A
20-168
20-169
c-17 [;3
.-.- a] [ABNORMALITY IN FRONT PUMP PRESSURE SENSOR
SIGNAL SYSTEM] IS DISPLAYED
2 YES
In same condition
YES as when measuring
- Item 1, is [231 -
displayed?
NO
ON.
1
5 YES
IS voltage
-\ -\
YES IS voltage
\- -\ - be;y)y:,crn/; -
4 - between C8 (3) -
.a.- - (I) normal?
. 0.5-4.5v
YES IS voltage
a Start engine. * 0.5-4.5v NO
- between C8 (2) -
(High idling) * Start engine.(High idling)
3 - (1) normal?
+ +
. Repeat bucket p . Repeat bucket
Is resistance
relief. + 18-2au relief.
between C3
_ (female) (6) _ _ . z&n starting SwitchNO
No (I), (6) -
chassis normal?
* Min. IMCZ
- Turn starting
switch OFF. NO
- Disconnect C3
and C8.
Pump controller
C3(MIC9) C8(X3)
F) Pressure sensor(-)
Front pump
R) Pressure sensor( -)
pressure sensor
24V(+)
lzl I Rear pump

iFl pressure sensor (SIG)
pressure sensor
-I
205FO5386-1
20-170
Remedy
Defective pump Reulace

controller
Already reset
disconnection in Repair or
replace
C3 (female) cl)-C8
(female) (1)
Defective front pump

Replace
pressure sensor
disconnection in wirinq
Repair or
harness between C3 _
replace
(female) (3)-C8 (female)
(2)

harness between C3
Repair or
(female) (61, (l)-C7. C8
reDlace
(female) (3). (1). or
contact with ground
20-171
C-18 [3-\]
.-. [ABNORMALITY IN REAR PUMP PRESSURE SENSOR
SIGNAL SYSTEM] IS DISPLAYED
2 YES
In same conditions
r Item 1. is 1241
displayed?
NO

ON.
1
5 YES
7 \ \ _ IS voltage
between C3 (7) -
YES 1s voltage
- (2) normal?
\- -1 - between C7 (3) -
0-o _ 4 - (1) normal?
* 0.5-4.5v
* Start engine. YES Is voltage between f 0.5-4.511 NO
(High idling) - c7 (2) - (1) - . Start engine.
normal?
* Repeat
+
arm relief. P
3 (High idling)
+
Is resistance
* 18-28V
- * Repeat arm relief.
between C3
_ . ;:.I- starting switch NO
- (female) (7)
NO
- (2). (7) -
chassis normal?
- Min. 1M.l-2
- Turn starting
switch OFF. NO
- Disconnect C3
and C7.
Pump controller
C3(MIC9) C8(X3)
Front pump
pressure sensor
Rear pump
,F, pressure sensor (SIG) pressure sensor
205FO5386-1
20-172
CaUSe Remedy
t--Defective Pump
Replace
Controller
Al ready reset
disconnection in Repair or
wiring harness replace
between C3 (female)
(2) - C7 (female) (1)
Defective rear pump

Replace
pressure sensor
disconnection in
Repair or
repliX.5
c3 (female) (3)- c7
(female) (2)

Repair or
harness between C3
replace
(female) (71. (2) -
C7 C8 (female) (3).
(1). or contact with
ground
20-I 73
c-19 pq
.-.a [ABNORMALITY IN PRESSURE SENSOR POWER SOURCE
j, If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON and check
Is same conditi-
ons as when
YES
- measuring
Item 1, is [251
displayed?
Is voltage between
-\ \-
\- -\ - :,,::,7 ()
e-o-
* 18-28V
ON.
r
I:
3
Disconnect C8.
IS voltage
NO between C3 (3)
- (1) normal?
* Disconnect C8.
. 18-28V
ON.
a Disconnect C7.
. 18-28V h ~~~
* ;;,n starting switct
N
OFF.
. Disconnect C3, C7.
and C8.
Pump controller
C3(MIC9) C8(X3)
I -
(F) Pressure sensor(-)
Front pump
(R)Pressure sensor( -) pressure sensor
Rear pump
(F) Pressure sensw (SIG)
pressure sensor
(RI pressure sensor (S(G)
I I 1
205FO5386-1
20-174
Remedy
Defective pump Seolace

controller
Already reset
Defective front pump 3eplace

pressure sensor
Defective rear pump

pressure sensor Replace
Defective pump
Replace
controller
harness or contact with
ground between
. C3 (female) (1) and Repair or
C8 (female) (1) reolace
. C3 (female) (3) and
C7, C8 (female) (2)
. C3 (female) (2) and
C7 (female) (I)
20-I 75
c-20[;3;,]
.-.- [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM]
IS DISPLAYED
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
NOTE: If the decimal point on the pump controller self-diagnostic monitor display
. _ does not flash when
the engine is started, go to troubleshooting F-8. -
3 YES
*
Defective pump
controller
YES When engine is
2 - started, is [261 -
displayed?
Is resistance Already reset
YES
_ between C3 . Start engine. NC (see Note)
(female) (8) - -
Note 1 (4) normal? Disconnectionin wiring
harness between C3
Is resistance * 500-l 0oo.Q NO (female) (8). (4) - M3 Repair or
between E7 . Turn starting switch (1 2). (4) - E2 (1 11. replace
(male) (1) - - OFF. (12) - E7 (female) (2).
(2) normal? - Disconnect C3. (1 i, or contact with
Replace
Pump controller
C3(MIC9) M3(S16) E2(Sl2) E7(X2)
Engine
speed
sensor
205FO5389-1
20-176
c-21 p-p,,]
._.I [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT
* When the auto-deceleration switch is ON.
* If the starting switch is turned OFF after the abnormality occurs, turn the starting switch ON, turn the
auto-deceleration switch ON, operate the control lever (Neutral-operated) and check that the display
reads 1281. (If it is not displayed, the system has been reset.)
C
Cause Remedy
2 YES IDefective pump Replace

I I c:ontroller
II same conditions1
YES es when measuring t
Item 1, is [281
displayed?
NO
1 Already reset
. Turn starting swtc
IS voltage ON.
between C2 (19)
- _ chassis es
show in
YES
Table I?
3
. Turn starting
switch ON. Disconnect C2.
Is voltage between
ND El (11) - (12)
normal?
4 YE SI 3efective engine
Replace
1throttle controller
/ IS reLilIlCe berwee
c2 (female) (19)--ET
L (ternale) (11). and _
ON.
Disconnection in
- ;yi2synnected: No ;~T~y$%%
JO wiring
r.
harness
C2 (female)
between
(19)--El
Repair or
replace
- Turn starting switch (female) (11). or
OFF. contact with ground
. &connect C2 and
Table 1
Operation Voltage between C2 (female) (19) - chassis
Auto-deceleration switch ON, lever at neutral o- 1v
Auto-deceleration switch OFF, lever at neutral 8- 12V
Table 2
Connector Resistance value
Between C2 (female) (19) - El (female) (11) Max. lfl
Between C2 (female) (19) - chassis Min. 1 MR
C2(MIC21) EI(MIC21)
205F05390A
20-177
c-22 [.-.-
7 $1 [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM]
IS DISPLAYED
If [29] is displayed again when engine is restarted.
: Before carrying out troubleshooting, check that all the related connectors are properly inserted.
CaLIS Remedy
YES See Engine shop

manual
17
Does monitor
-\ \-\ panel display YES Defective pump Replace
overheating? controller
\-
.-- -\ 2
_-t
. Turn starting
switch ON.
IS voltage between
& c2 (17). (18)--(S) - 3 YE Defective monitor
Replace
normal?
Is resistance bet- panel
4 wee P2 (female)
. When normal:
- (12). (13) - (16). -
lo-13v Disconnection in wiring
NO (12) (13) -
. When overheated: harness between c2
chassis normal? Repair or
O-IV (female) (17). (18)-
replace
- Start engine . Min. 1MSZ N P2 (female) (12). (13).
. Disconnect C2 and or contact with ground
P2.
Pump controller Monitor panel
C2(MIC21) P2(04016)
205FO5391-1
20-178
C-23 [tp!p\]
._.Q [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED
Remedy
Q-1 Q-Q_ Defective

controller
pump
ReDlace
.QZ!.QzQ
20-I 79
20-180
TROUBLESHOOTING OF PUMP CONTROLLER INPUT
SIGNAL SYSTEM (F MODE)
F-l PUMP CONTROLLER MONITOR DOES NOT DISPLAY
[WORK EQUIPMENT . SWING OIL PRESSURE SWITCH] . . . . . . . . . . . . . . . . . . . . . . . 20-182
F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY

[TRAVEL OIL PRESSURE SWITCH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-183
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [SWING LOCK SWITCH] . . . . . . . 20-184
F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY OR [TRAVEL SPEED SWITCH] . . 20-185

[AUTO-DECELERATION SWITCH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 86
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [POWER MAXIMIZING SWITCH] . 20-187

[DECIMAL POINT OF ENGINE SPEED SENSOR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-188
F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH . . . . . . . . . . . . . 20-189
F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH . . . . . . . . . . . . . . . . 20-190
20-181
Fl PUMP CONTROLLER MONITOR DOES NOT DISPLAY [> Iz\ 1
[WORK EQUIPMENT l SWING OIL PRESSURE SWIT&]-
After starting the engine and operating the work equipment lever or swing lever, it is displayed for ap-
prox. 1 second.
A
Before operating the swing lever, turn the swing lock switch ON.
Cause Remedy
2 YES Already reset

In same conditions
YE as when measuring _
Item 1, is [P21
displayed?
Iefective pump
:ontroller
. Start enaine NO
1 . 0peratelever
lefective contact, or
fisconnection in wiring qepair or
C3 (5) and chassis YES
larness between Sl (female) ,eolace
1) - Cl (female) (12), (13), 01
I J :ontact with ground
. Lever at neutral lefective contact,
: 20 - 3ov disconnection in wiring
. Lever operated ~~ Repair or
larness between C3 (female) replace
: Max. 1V (5) and Sl (female) (2). or
. Start engine. contact with ground
F . Between wiring harness ;t c;;;is:
Defective oil pressure switch
% If the condition does
. Lever operated: Reolace
not return to normal
Max. 1R LD
when the switch is
. Lever at neutral: replaced, go to H-7.
Min. 1MR
. Start engine
. Disconnect Sl
Work equipment.
Pump controller swing oil pressure switch
Cl fMICl7)
205FO5728
20-I 82
[TRAVEL OIL PRESSURE SWITCH]
I.\-\7 .\x
\-
1
* After starting the engine and operating the travel lever, it is displayed for approx 1 second.
Before operating the travel lever, check that the surrounding area is safe.
it is not displayed when operating the travel lever on one side, the PPC shuttle valve is defective.
ChJSe Remedy
2 YES
lready reset
In same conditi-
YE ons as when
measuring Item 1,
is [P61 displayed?
Defective pump
Replace
controller
. Start engine.
1 . Operate travel
Defective contact,
lever
Is voltage between harness between S4
C2 (1) - chassis (female) (1) - Cl
Repair or
,eplace
(female) (12). (13). or
I I contact with ground
- Lever at neutral :
20 - 3ov Defective contact,
- Travel lever disconmection in Wiring
Repair or
operated: Max. 1I harness between C2
replace
- Start engine. (female) (I) - M3 (13)
b * Between wiring harness and chassis: - S4 (female) (2). or
contact with ground
Lever operated: Defective travel oil

RC+DlaCe
Max. 1.Q pressure switch
NO
* Lever at neutral: * If the condition does
Min. 1Mn not become normal
* Start engine. even when the switch
* Disconnect S4. is replaced, go to H-7.
Travel oil
Pump controller
pressure switch
Cl (MICl7)
GND
I I I
C3( MIC9)
I \ I
205FO5394-1
20-183
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [ .-.-
\-,=,j
[SWING LOCK SWITCH]
f After starting the engine and turning the swing lock switch ON, it is displayed for approx. 1 second.
* If the panel display is normal (if the swing lock lamp on the panel lights up, go to P-21.)
Cause Remedy
2 YES
Already reset
In same conditions
item 1, is [b5]
displayed?
1 . Defective pump Replace
. Turn swing lock ND controller
Is voltage between switch ON * OFF.
W;Ia/d (8) - . Defective swing lock
switch
3 YES
harness between C2
Repair or
replace
. Swing lock switch:
Is there continuin/ (female) (8) and swing
ON: Max. 1V lock swith (2), or contact
_ between C2 (female) _
OFF: 18 - 28V with ground
NO (4) and swing lock
. Turn starting switch (l)? Disconnection in wiring Repair or
switch ON
harness between C2 replace
. Turn starting NO (female) (4) and lock
switch OFF switch (1)
Disconnect C2
Swing brake
solenoid valve
M20(M4)
Fuse
Pump controller cl(~lcl7p)
Swing brake
GND
switch ON (lock)
Pum
205FO5730
20-184
F-4 PUMP CONTROLLER MONITOR
DOES NOT DISPLAY (:-\ . ,]
OR[:
._.I \-\ ] [TRAVEL SPEED SWITCH]
* After starting the engine and switching the travel speed switch to Hi or Lo, it is displayed for approx.
1 second.
* If the monitor panel display is normal (if the panel display is not normal, go to P-19).
j, Always connect any disconnected connectors before going on the next step.
2 YES
Already reset
In same conditi-
YES ens as when
- measuring Item 1, -
is [Hi] or [LOI
1 displayed?
Defective pump
Replace
NO controller
Is volrage between
C2 (3) - (8) as -
shown in table 17
3 YES Defective monitor Repair or
. Turn starting Disconnect P2. Is panel reolace
switch ON. voltage between
* Travel speed switch - P2 (female) (4) - - Defective contact,
Hi-LO NO (16) as shown disconnection in
below? NO wiring harness Repair Or
between C2 (female) replace
(3) - P2 (female)
ON.
(4). or contact with
* P2 disconnected:
ground
10 - 13v
Table 1
Travel speed switch Lo 10 - 13V
Travel speed switch Hi Max. 1V
205FO5396
20-185
F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [!p, .-,-\I
[AUTO-DECELERATION SWITCH]
After starting the engine, set the auto-deceleration switch to ON. It is displayed for approx. 1 second.
If the monitor panel display is normal (if the auto-deceleration display on the panel does not change,
go to P-18).
Always connect any disconnected connectors before going on the next step.
Cause Remedy
2 YES
Already reset
In same conditi-
YES ons es when
measuring Item 1,
is [Ad] displayed?
1 Defective pump Replace
controller
Defective monitor
Replace
- Turn starting P.3el
harness between C2 Repair or
* Turn starting NO (female) (7) - P2 replace
switch ON. (female) (7)
* P2 disconnected:
10 - 13v
Table 1
Auto-deceleration switch ON Max. 1V
Auto-deceleration switch OFF 10 - 13V
P2 (04016)
205FO5397
20-186
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY I!!2 1
l.r,r.r J
[POWER MAXIMIZING SWITCH]
After starting the engine and pressing the power maximizing switch, it is displayed for approx. 1
second.
Always connect any disconnected connectors before going on the next step.
C.3US3 Remedy
Already reset
Defective Pump Replace

controller
Defective contact,
L I 3 YES or disconnection in
Repair or
replace
* When switch is ~2 (female) (12). (8)
not pressed: IS resistance - switch
20 - 3ov _ between switch
. When switch is NO (1) - (2)
pressed: Max. 1V nOrmal?
Defective power
3eplace
* When switch is not NO maximizing switch
pressed: Min. 1M0_
* When switch is
pressed: Max. 152
Pump controller
C2(MIC21)
Power maximizing switch
205FO5398
20-187
F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [lp\tp,]
[DECIMAL POINT OF ENGINE SPEED SENSOR] -*-
The display flashes when the engine is started.

2
* Before carrying out troubleshooting,
connectors
are properly
before going on the next step.
inserted.
CaUSe Remedy
Defective adjustment of =t(ewklce

engine speed sensor
YI IS
Defective pump
3eplaCe
controller
1
IS resirfance
El -e
between c3
(female) (8) - Defective engine speed
(4). (81 -chassis . Measure with sensor
norma and is
C,,Cif insulated AC range.
from charris? . 0.5 - 3v Defective contact,
- Start engine. disconnection in wiring
- 500 - 1oooc2
harness between C3
* Turn starting switc h 4 YES qepair or
(female) (8). (4) - M3
OFF. .eplaCe
Is resistance between I1 2). (4) - E2 (1 1). (12)
. Disconnect C3.
E7 (male) (I) -
(2). - E7 (female) (2). (1).
(2) - chassis normal - or contact with ground
UO
and is circuit insulated
from chassis NO
: Defective speed sensor qeplace
* Between (1) and (2):
500 - 100052
* Between (1) and
chassis: Min. 1 Ma
OFF.
- Disconnect E7.
Pump controller
C3(MIC9) M3(Sl6) E2 (Sl2) E7(X2)
Engine
speed
sensor
205FO5389-1
20-188
F-8 PUMP CONTROLLER WORKING MODE DISPLAY
DOES NOT SWITCH [ \ 2 z,-\]
* The working mode is displayed approx. 1 second after the starting switch is turned ON.
* If the monitor panel display is normal and the working mode does not switch, go to Troubleshooting
P-l 6.
Before carrying out troubleshooting, check that all the related connector are properly inserted.
Cause Remedy
t-
Already reset
YES measur,ng Irem

- l.doerwokrIg -
mode mDIfOr
di*pIaySWlfCh
1 D~ITT~IIY Defective pump
ReplaCe
controller
is voltage bet- . Switch working NO
ween c2 (14) mode on
(15) and (8) as - monitor Panel
$own in Table
3 YES
Defective monitor Panal Replace
. Turn starting When P2 IS dIs-
switch ON. connected. IS
voltage between
* Switch working -
P2 (female) (8)
Defective contact Or
mode on NO disconnection in wiring
191 and (16) as
monitor panel rhown below harness between C2
Repair or
(female) (14) - P2
replace
. Turn starting NO (female) (8). and
switch ON. between C2 (female)
. When P2 is (15) - P2 (female) 19).
disconnected:
10 - 13v
Table 1
Mode Between C2 Between C2
(14 - (8) (15) - (8)
H.O. lo- 13v o-iv
G.O. lo- 13v 10 - 13v
F.O. o- 1v 10 - 13v
L.O. o- 1v 0 - 1v
C2 (MIC21) P2 (04016)
I I I I
Working mode (a)
Working mode lb)
205FO5627
20-I 89
F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH
1\87\\-2 \\_ 1
The power set is displayed approx. 1 second after the starting switch is turned ON.
If the monitor panel display is normal and the power set does not switch, go to Troubleshooting P-17.
However, if the coolant temperature gauge on the monitor panel is showing the red range (over
102C), the pump controller displays L mode.
CFIUSS Remedy
Already reset
1
dlspla SWltC
1
Is voltage between
normally
. Switch
mode
power
on
L Defective
controller
pump
Replace
C2 (5). (6) and (8) _ monitor panel.

as shown in Table
17
3 YES
Defective monitor panel Replace
* Turn starting When P2 1sdir-
switch ON. connected, II
voltage between
* Switch power -
P2 if&ale1 (5)
mode on NO disconnection in
(6) and 116) as
monitor panel. Show below? wiring harness between
C2 (female) (5) - P2 Repair or
. Turn starting NO (female) (5), and bet- replace
switch ON. ween C2 (female) (6)
. When P2 is - P2 (female) (6).
disconnected:
lo-13v
Table 1
~!~.
C2 (MIC21) P2 (04016)
I \ 1 I I I
205FO5628
20-190
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
H-l SPEEDS OF WORK EQUIPMENT, TRAVEL AND SWING ARE ALL SLOW ............ 20-192
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED OR ENGINE STALLS ............. 20-194
H-3 WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE OR SPEED IS

EXTREMELYSLOW .................................................. 20-196
H-4 WORK EQUIPMENT, TRAVEL AND SWING LACK POWER ...................... 20-198
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH ....................... 20-198
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) ...................... 20-199
H-7 AUTO-DECELERATION DOES NOT WORK ................................. 20-199
H-8 BOOM AND ARM SPEED IS EXTREMELY SLOW ............................. 20-200
H-9 WORK EQUIPMENT (BOOM, ARM AND BUCKET) SPEED IS SLOW ............... 20-202
H-10 WHEN BOOM AND ARM IS OPERATED SIMULTANEOUSLY, BOOM IS SLOW. ........ 20-204
H-l 1 WORK EQUIPMENT (BOOM, ARM AND BUCKET) LACKS POWER ................ 20-204
H-12 EXCESSIVE HYDRAULIC DRIFT ......................................... 20-204
H-13 EXCESSIVE TIME LAG ............................................... 20-206
H-14 DOES NOT ENTER F.O. MODE (HALF FLOW FUNCTION) ...................... 20-206
H-15 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY, ARM IS SLOW ....... 20-206
H-16 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE .......... 20-208
H-17 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS .................... 20-211
H-18 EXCESSIVE DEVIATION WHEN STARTING ................................. 20-212
H-19 TRAVEL LACKS POWER (OR SPEED IS SLOW) .............................. 20-214
H-20 TRAVEL SPEED DOES NOT SWITCH ..................................... 20-214
H-21 MACHINE DOES NOT MOVE (ONE SIDE ONLY) ............................. 20-215
H-22 DOES NOT SWING .................................................. 20-216
H-23 SWING SPEED IS SLOW OR ACCELERATION IS POOR ........................ 20-218
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING ............................ 20-219
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING .............................. 20-219
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING ..................... 20-220
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING ................................ 20-220
H-28 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW ......... 20-220
TABLE OF FAILURE MODES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221
20-191
H-l SPEEDS OF WORK EQUIPMENT, TRAVEL AND SWING
ARE ALL SLOW
* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-16.
gg 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully
actuated.
x 2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.
4 YES
IS engine speed . When normal relieved:
YES normal when 2100 + 100 rpm
pump is relieved -
n with CO canceled?
L I I
*When CO cancelled:
PC300LC: 2050+ 100 mm PC4OOLC: 2040+100 rpm
I
lH.0. + H mode
*Engine at high idle
*Arm relieved s YES-
XXiwLc:19?+ kg/cm Does condition
become normal
Ptititi 20 :: kg/cmN when TVC valve
YEiS Is relief pressure
of F, R pump - H.0 + H mode
normal? - l-pump relief NO
*At normalrelief
1 PCKKJLC: 6 YES
310345 kg/cm*
PC4LMLc: Does condition
Is relief pressure 314-343 kg/cm* become nOrr73al
at charging pump *At *-stage relief
NO when main relief
PIXWLC: valve is adjusted?
345375 kg/cm*
PC4WLc:
* Engine at high NO
34%378 k&m*
idling -l-LO. and% mode
*Engine at high idling
* 30 zz kg/cm?
%2
%l
N0
20-192
II-l CG3.E.e Remedy
1 k_;ge inside Replace pump

assembly
Adjust
Defective TVC valve Replace
Defective adjustment 4djust

of main relief valve
qeplace
2I F;ztive main relief
(Go to H-3, Item 3)
20-I 93
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED
OR ENGINE STALLS
2
* output pres-
When pump is sure becomes
relieved, is YES
normal
output pressure of . Problem does
CO valve normal?
3.-I not change
* At normal relief: Does output . output pres-
Max. 5.5 kg/cm= pressure become sure becomes
* When CO canceled: _ normal when CO __ normal
Same pressure at NO valve is * Condition also
TVC pressure adjusted? becomes
. normal
* H.0 + H mode * output pres-
Is set pressure of
_ sure does not
TVC valve
NO become
n0rlel?
normal
set pressure
. PCBOOLC 30 ; kg/cm becomes
normal
l pc400Lc 20 t; kg/cm Problem does
not change I-
. 1 -pump relief
. H.0 + H mode Set pressure
* Engine at high becomes
become normal
normal
idling when TVC valve
set pressure is Condition also
becomes
normal
. set pressure
does not
become
NO
L[ normal
20-I 94
C?NJSG! Remedy
See Engine shop manual
Defective adjustment of Adjust

CO valve
Defective CO valve Replace
Defective adjustment of
4djust
TVC valve
20-I 95
H-3 WORK :QUIPMENT, TRAVEL AND SWING DO NOT MOVE OR
SPEED S EXTREMELY SLOW
* When there is a big difference from the permissible value.
* Auto-deceleration is normal.
Jc Mode selection is H.O. and H mode
I I
*Crank with cranking
1 motor.
lDisconnect
Do not move, or governor motor NO
speed is extremely
connector and set
slow?
governor lever to
NO INJECTION. YES
L TO Item 3 above
5
Speed is is set pressure of

extremelY slow - TVCvalve 6 YES
normal?
Does condition
lPCSOOLC: NO ~~fnrn~,n,O\~lve -
17-20 kg/cm2 is adjusted?
lPC4OOLC:
NO
18-21 kg/cm2
lH.O.+ mode
Fig. 1 Control circuit
Travel PPC valve
Solenoid valve
R.H. PPC valve
205FO5300
20-196
Cause Remedy
Excessive internal
leakage inside equipment Replace
in relevant system
Defective charging ReplaGS

Pump
Defective charging pump Replace relief

relief valve lalve
* Defective damper
(PTO)
3epair or
* Defective main pump
eplaCe
(broken shaft, etc.)
Defective set pressure

4djust
of TVC valve
Defective operation of
TVC valve
20-197
H-4 WORK EQUIPMENT, TRAVEL AND SWING LACK POWER
* Mode selection is H.O. and H mode
Cause Remedy
3 YE correct or
Defective CO valve
replace

_1-!Z&ZJ
n
Defective CO cancel
Replace
- See conditions for N( solenoid valve
When digging Item 4 below.
force is
maximized
4 YE! Drop in set pressure of Adjust or
main relief valve replace
l PCSOOLC:
345-375 ka/cm*
l Pc4ooLc: I
348-378 ka/cm Defective 2.stage
Replace
digging force is *Engine at-high . When digging force N( relief solenoid valve
maximized, or idling. is maximized:
during normal
27 - 35 kg/cm2
. During normal
operation: 0 kg/cm2
It is also possible to hold the solenoid

During normal valve outlet hose by hand to judge.
Drop in set pressure Adjust Or
operation replace
1 of main relief valve
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH
CZlUSX Remedy
I
IWhen TVC valve YES
I
solenoid is remov-
ed, and mode
selection switch is
operated with con
nectar still conne-
cted, does spool Defective TVC solenoid Replace
of solenoid move? NO
I) Turn starting
switch ON.
20-l 98
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
CWSe Remedy
Clogged strainer
Loose piping clamp Tighten
4 YE:
Replace
Defective pump
Is oil level in t
hydraulic tank FH
OVllal? N
Operate for a time Inspect again
and watch any Depending on
N( changes in symptoms changes
in symptoms)
Add hydraulic
Lack of oil
oil
H-7 AUTO-DECELERATION DOES NOT WORK
Cause Remedy
YES Defective travel shuttle

Is hydraulic Valve
pressure at inlet
port of travel
shuttle valve
OVllZll? Defective PPC shuttle
valve
.27 - 35 kg/cm2 NO
20-199
H-8 BOOM AND ARM SPEED IS EXTREMELY SLOW
l Mode selection is H.O. and H mode.

* When the travel, swing and bucket speeds are normal.
C.?NS.e Remedy
1 YES Defective operation Repair or

of straight-travel valve replaCe
Does travel shuttle

valve spool move -
smoothly?
Defective operation Of Repair or
- travel shuttle valve replace
*Valve on top of NO
control valve
20-200
20-201
H-9 WORK EQUIPMENT (BOOM, ARM AND BUCKET) SPEED IS SLOW
* When the travel and swing speeds are normal.

(However, if there is any travel deviation and the bucket or boom speed is slow when operated
individually, go first to H-14, When machine is traveling, it deviates naturally to one side.)
3 YES
Is operation of
Boom only ] - boom holding -
valve normal?
I INO
* Check movement of
valve with Your hand.
4 YES
Is hydraulic
pressure at outlet
YES
I Arm only - port of arm half
flow solenoid
-
valve normal? NO
rt
. Finishing or lifting mode: 0 kg/cm*
1 Normal operation: 27 - 35 kg/cm2
l It is also possible to hold the solenoid valve Outlet
YES IS output pressure
hose by hand to judge.
at PPC valve I
rl
normal? L[ Bucketonly ]
r-!
. 30 z kg/cm2
1 * Engine at high
I
idling
Is hydraulic drift NO
of slow cylinder
within standard
value?
YES
tic
YES
NO 6
Does condition
. See TESTING AND become normal
ADJUSTING.
* It is also possiole
.~ _.
10
when safety
(suction) valves
- -c Arm, bucket
measure the amount are inter-
of leakage fror- II lLII_
ha I, changed?
. For details of the
. 30 cclmin
type of safety
- When relieved valve, see NO 7 YES
Table 1.
c Is boom holding
1 Boom only
valve normal?
I1
. Check movement NO
of valve with your
hand.
Table 1 Table of locations and types of safety

valves used for each cylinder.
( ): Set pressure
Cylinder Bottom end (kg/cm) Head end (kg/cmL)
I
Boom 1 Safety - suction valve (365) 1 Safety - suction valve (290)
Arm Safety - suction valve (365) Safety valve (365)
Bucket Safety - suction valve (365) Safety - suction valve (365)
20-202
Remedy
Repair or
Defective operation of replace
control valve spool control valve
(boom) assembly
Defective operation Repair or

of boom holding valve replace
Repair or
replace
control valve spool (arm)
control valve
assembly
Defective arm half flow

Replace
solenoid valve
Repair or
Defective operation of replace
control valve spool control valve
(bucket) assembly
Defective PPC valve Replace
Defective cylinder piston ReplaCe

packing
Defective safety (suction) Replace

valve
Defective oil-tightness
Reolace
of control valve spool
Defective boom holding

Replace
valve
20-203
H-IO WHEP BOOM AND ARM IS OPERATED SIMULTANEOUSLY,
BOO\ IS SLOW.
0 When usual operation is normal.
Defective arm throttle Repair or

valve replaCe
H-l 1 WORK EQUIPMENT (BOOM, ARM AND BUCKET) LACKS POWER
* When the travel and swing speeds are normal.

* Mode selection is H.O. and H mode.
2 YES
Is main relief
YE:
When digging pressure normal
force is when digging
maximized l- force is maximi-
zed?
1
lPCSOOLC: NO
345 - 375 kg/cm2
Does this problem l PC4OOLC:
3
occur when digging 348 - 378 kg/cm
force is maximized, * Engine at high idling 4 YES
or during normal
operation?
jES r Both ends 1 j-HP
Is there lack of
power at both
During normal head end and . See Table 1. NO
operation bottom end, or
Nl
at one end
only?
c ( One end only ]

NO
Table 1
H-12 EXCESSIVE HYDRAULIC DRIFT

* Go to H-9, Item 5.
20-204
,
I CaUSe Remedy
Replace
2.stage relief solenoid Replace
valve
(Go to H-9, Item 2)
(Go to H-9, Item 5)
Defective safety
Replace
(suction) valve
20-205
H-13 EXCESSIVE TIME LAG
It If the work equipment speed is normal (if the speed is slow, go first to H-9, Item 2).
Time lag Sec.

C.NlSe Remedy
Boom Max. 3.0
Arm Max. 3.0
Bucket Max. 3.0
Defective operation
of suction valve Replace
H-14 DOES NOT ENTER F.O. MODE (HALF FLOW FUNCTION)
CaUSe Remedy
Defective operation
of arm half flow Replace
solenoid valve
H-15 WHEN ARM AND SWING ARE OPERATED SIMULTANEOUSLY,

ARM IS SLOW
If the operation of the auto-deceleration is normal (if the auto-deceleration is defective, go first to H-7).
Cause Remedy
Defective operation Of
swing priority valve
20-206
20-207
H-16 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO
ONE SIDE
* When the travel speed is normal.

a) Deviates in same direction both in forward and reverse.

YE
5 YES
YES Is servo piston

stroke normal?
Direction of 4-,
1
_ . For details, see NO
TESTING AND
Is output pressure
ADJUSTING.
of NC valve
* For details, see normal?
YES
TESTING AND
ADJUSTING. 6 -
. When track is rota- 1
ted freely or during
normal travel, Is differential
c
pressure must be Nc Pressure of jat -
sensor normal?
1
the same as
the TVC output
Is main relief
pressure.
NO pressure normal? * Lever at neutral:
. Lever at neutral:
18 - 24 kg/cm2
1 4
I Max. 5.5 kg/cm=
. Engine at high idling . SeeNote.
NO
*At travel relief:

PC3OOLC: 325-355 kg/cm2
*At work equipment
_
relief:
LNO
hoses are changed PC4OOLC: 314-343 kg/cm2
between F and R,
does direction of
*Engine at high
idling
YES
10
Are metal particles
YES found in oil
_ drained from final _ YES
drive on side
which deviates?
11
DOBS
dilecfio Of
deviafionchange when
_ left andrighthcses _
9 NO be,V,Be COT,D,
ad
an.3IWiWljoint are
inrsrchangedl
YES Does control valve
- spool move
smoothly? NO
Direction of
Is output pressure
deviation does
of PPC valve
not change
normal?
NO
I
30 +5
-3 kg/cm2
Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the output
pressure of the TVC valve, both the jet sensor and NC valve are normal.
20-208
l=
Remedy
See TESTING
Defective adjustment
AND
of pump
ADJUSTING
Leakage of inside
ReplaCe
pump
Defective operation
Replace
of servo valve
Defective OperatiO Adjust or

of NC valve replace
7 YES Drop in set pressure Adjust

Does condition of jet sensor relief Valve
become norm.9
when relief valve
of jet sensor is
interchanged or
adjusted? Defective jet Sensor Clean or
orifice replaCe
- Lever operated: NO
Max. 2.5 kg/cm*
- Engine at high idling
Drop in set pressure Of Adjust or

main relief Valve replace
1 ,;ztive final Repair 01

replace
Defective control
Ftepl.332
valve body
12 YES Defective Swivel

Replace
r joint
Does direction of
deviation change
when ,ef* and
rigtn hole* for SWiYd
joint OfbI port are
interchanged?
Defective travel Replace motor
NO motor assembly
Defective Operation Of
Replace
control valve spool
Replace
<I Defective PPC valve
20-209
b) Deviates in different direction in forward and reverse (See Fig. 1)
Ct%E.e Remedy
2 YES Defective swivel Repair or

joint packing replace
YES IS OUtpUt pressure
of PPC valve
1 normal?
Defective PPC valve Repair or
Is relief pressure replace
normal at travel . 30 ; kg/cm= No
relief?
H
PC30OLC: Drop in set pressure Replace safetv
l 1
of travel motor safety valve assemblr
325-355 kg/cm2 NO valve
l PC4OOLc:
340-370 kg/cm2
*Engine at high idling.
Location of defective swivel

Fig. 1 joint packing and direction
of deviation in travel
Drain
Right reverse OIllv
c Rear
right (A) Right reverse and
Front left left forward
Does not dewate c (6)
Front
right (C) Right forward and
Rear left reverse
Left reverse only left (D)
t,
I F I
20-210
H-17 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS
* If individual travel is normal.
Remedy
Defective operation Repair or

of straight-travel valve replace
Does spool of
YE travel shuttle
1 valve move
Defective operation Of Repair or

Is oil pressure at replaCe
travel shuttle valve
inlet port of travel
shuttle valve
normal?
. 27 - 35 kg/cm2 Defective operation of Repair or

10 PPC shuttle valve replace
f If the pressure in Item 1 is lost, the auto-deceleration also will not work.
20-211
H-18 EXCESSIVE DEVIATION WHEN STARTING
When the travel speed is normal.
If there is also deviation during normal travel, go to H-16 When machine is traveling, it deviates
naturally to one side.
For deviation during simultaneous operations with the work equipment, go first to H-17 Excessive
deviation during compound operations.
Bleed all air completely from the circuit.
YES
When pump outlet 4 YES

Deviates at _ hoses for F, R are _ When hoses at
full stroke interchanged, is swivel inlef
problem reversed? YES port are infer-
3 - changed, is
problem
When hoses at reversed?
swivel outlet
port are inter- NO
NO changed, is
problem
reversed?
Does machine
deviate at lever
full stroke, or
6 YES
1,
Machine deviates - Control lever at NO
when starting, pressure of jet neutral: Max.5.5 kg/cm2
sensor at fast * Track rotating freely: Min. 18 kg/cm
side (outside Of . Engine at high idling
N - Full stroke 7 YES
. Control lever at When relief valves

neutral of jet sensor are
18 - 24 kg/cm2
. Control lever at
full stroke problem reversed?
Max. 2.5 kg/cm2
NO
20-212
Cause Remedy
Defective operation Replace

of servo valve
Defective Control Replace

valve
Repair or
Defective SwiVel joint replace
Defective travel mOtOr Replace
Replace
servo valve
Defective adjustment of Repair or

NC valve rep lace
Defective jet Sensor Repair or

relief valve replace
Defective jet SensOr Replace

orifice
20-213
H-IQ TRAVEL LACKS POWER (OR SPEED IS SLOW)
-k The mode selected is H.O. mode (the power set is automatically set to H)
* When there is no travel deviation.
* If the main relief pressure has dropped, there is also lack of power for normal operations using the
work equipment.
If there are problems in the CO cancel system, there is lack of power when using the power max.
switch.
Cause Remedy
2 YES
Defective CO valve Replace
Is oil pressure at
YEiS outlet port of CO _
1 cancel solenoid
I
valve normal?
NO Defective CO cancel
Replace
At travel relief, is solenoid valve
main relief pressure
. At travelrelief and when using power maximizing:
27 - 35 kg/cm2
normal? . During normal operations:
0 kg/cm*
*At travel relief: Drop in set pressure of Idjust or replace
PCSOOLC: NIO main relief valve
% It is also possible to hold the
325-355 kg/cm2 solenoid valve outlet hose by
PC4OOLC: hand to judge.
340-370 kg/cm2
lEngine at high idling I
H-20 TRAVEL SPEED DOES NOT SWITCH

f When the travel speed is normal at Hi or Lo.
Remedy1
F= 1.
Cause
Defective travel motor

1 YES * Speed change servo Replace motor
Is hydraulic valve assy
pressure at
outlet port of -
travel speed
solenoid normal? Defective travel speed
solenoid valve Replace
. AtHi: NO
27 - 35 kg/cm*
At Lo: 0 kg/cm2
20-214
H-21 MACHINE DOES NOT MOVE (ONE SIDE ONLY)
Cause
2 YES Repair or
H
Defective final drive
replace
Is any foreign
Yl material found in
oil drained from
final drive?
Travel motor brake Replace motor
dragging assem b I Y
I 3 YES Defective travel Replace safety

motor safety valve valve
*At travel relief:
normal at motor
PCSOOLC: relief when safety
325-355 kg/cm2 b valves are
interchanged?
PC400LC: Defective travel Replace motor
340-370 kg/cm2 . For standard value, NO motor assembly
*Engine at high idling see Item 1.
20-215
H-22 DOES NOT SWING
l When other work equipment and travel speeds are normal.
* Turn swing lock switch OFF.
YES
4
Is any foreign
YES material found in
oil drained from 5 YES
swing machinery? _
3 - Does control
NO valve spool move
Is hydraulic
YES_ smoothly?
pressure at left _
and right relief .-[
normal? NO
2 _
Is hydraulic _ PC3OOLC:
pressure at swing 270-300 kg/cm2
brake solenoid -
valve outlet port
PC4OOLC: No
l-
normal? 255-285 kg/cm2
. Lever operated:
27 - 35 kg/cm2
Does not swing in . Lever at neutral: NO
either direction, Or 0 kg/cm2
in one direction *It is also possible to hold the solenoid valve outlet hose by hand to judge.
6 YES
When left and
l-
Does not swing right safety valves
in one direction are interchanged, -
is problem
reversed? NO
* It is also possible to
measure the hydraulic
pressure to judge.
PCSOOLC: 270-300 kg/cm2
20-216
CaUSe Remedy
Repair or
Defective swing machinerv rep,ace
Replace motor
Defective motor brake assembly
Defective operation of Repair or

control valve spool replaCe
Defective swing motor

Replace motor
assemblv
Defective operation Of
swing brake solenoid Replace
valve
- Defective safety valve Replace
q-1 Defective PPC valve Replace
20-217
H-23 SWING SPEED IS SLOW OR ACCELERATION IS POOR
f When other work equipment and travel speeds are normal. (If there is also deviation (to right) during
normal travel, go first to H-16 When machine is traveling, it deviates naturally to one side.)
C3X.e Remedy
Excessive leakage inside

3 YE: Replace motor
swing motor, or brake
assembly
dragging
YI Does spool move
smoothly when
operated?
n
Defective operation of Replace contrc
control valve spool valve
IS OUtpUt pressure
Y Both left and of co valve at
right swing relief
normal?
I
1
4 YE Drop in set pressure of
Adiust
. Must be the same a co valve
TVC valve output Does condition
become normal
pressure
- At relief: r
Max. 5.5 kg/cm= Defective operation Of
* Measure at NC valve. co valve
Replace
* For standard value, N
both left and see Item 2.
right, or in one
direction only?
6 YE Drop in set pressure of
Adjust
*Time taken to start safety valve
swing (set) (90):
PC3OOLC: Max. 4.0
PC4OOLC: Max. 4.4
*Time taken for Defective safety valve Replace
swing (set) (5 turns)
PC3OOLC: Max. 36
PC4OOLC: Max. 38 problem reversed?
*IS also possible to Defective PPC valve Replace
measure the hydraulic
pressure to judge.
lPCSOOLC: 270-300 kg/cm2
lPC4OOLC: 255-285 kg/cm2
20-218
ti-24 EXCESSIVE OVERRUN WHEN STOPPING SWING
A If the speed is slow or the acceleration is poor, go first to H-23.
Replace motor
1 YFS r Both left and
] 11 Leakage inside motor assembly
I HI
excessive to both
left and right, or
in one direction
Only? Replace or
IL 1 ~~,),?eydirectio ] ]_I Defective safety valve adjust
-Overturn when No
stopping swing:
lPC3QOLC: Max. 88
lPC4OOLC: Max. 120 I
*Engine at high idling.
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING

* When the swing speed is normal.
CAlE+Z Remedy
3 YES Defective swing

Repair
machinery
Is any foreign
YES ,material found in
2- oil drained from
V - swing machinery?
Is hydraulic Defective swing mot01 Replace
Y pressure at swing - - brake
Both left and NC
right brake solenoid -
31 valve Outlet port
1 normal?
---I
Is shock excessive . Lever operated: 27 - 35 kg/cm* ND Defective swing brake Replace
on both left and . Lever at neutral: 0 kg/cm* solenoid valve
right, or in one
* When the swing is operated and the lever
direction only?
is returned to neutral, the hydraulic
pressure becomes 0 after approx. 4 sec.
1
One direction Defective safety valve Replace
; OlY
20-219
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
* When the swing speed is normal.
CW.WS Remedy
2 YES Defective swing

Repair
machinery
Y
1
Defective lift check Replace
I
NO valve
on both left and

right, or in one
direction only?
Defective safety valve Repl.XC!
One direction
Only
Defective suction valve Replace
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING
CWSl? Remedy
Defective swing motor Replace motor

brake %sembly
Is hYdraulic
pressure at swing
brake solenoid -
valve outlet port
normal? Defective swing brake Replace
solenoid valve
. never at neutral: ND
0 kg/cm=
* Lever operated:
27 - 35 kg/cm2
H-28 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED

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

swing priority valve replace
20-220
TROUBLESHOOTING OF MONITOR SYSTEM (P-MODE)
P-l MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING
SWITCH IS TURNED ON .............................................. 20-225
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON
BUT DO NOT GO OUT ............................................... 20-226
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),

CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED) ........... 20-227
P-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,

CHECK ITEMS FLASH ................................................ 20-230

CAUTION ITEMS FLASH .............................................. 20-231
P-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS
FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE) ........ 20-232
P-7 (a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES
NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES
NOTSOUND ...................................................... 20-235
P-7 (b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR BUT THE

BUZZER SOUNDS .................................................. 20-235
P-8 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP

(LIQUID CRYSTAL DISPLAY IS NORMAL) .................................. 20-236
P-9 COOLANT TEMPERATURE SHOWS ABNORMALITY LOW TEMPERATURE ........... 20-237
P-10 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,

NO LEVEL OF GAUGE IS DISPLAYED) .................................... 20-237
P-l 1 FUEL GAUGE ALWAYS DISPLAYS FULL ................................... 20-238
P-12 FUEL GAUGE GIVES NO DISPLAY ....................................... 20-238
P-13 (a) LAMPS DO NOT LIGHT.UP .......................................... 20-240
P-l 3 (b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED. ............ 20-240
P-14 (a) WIPERS DO NOT WORK ........................................... 20-242
P-14 (b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED .............. 20-242
P-15 (a) FAN DOES NOT WORK ............................................ 20-244
P-15 (b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED ................. 20-244
P-16 WORKING MODE DOES NOT SWITCH .................................... 20-246
P-17 POWER SET DOES NOT SWITCH ....................................... 20-248
P-18 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION;

AUTO-DECELERATION IS NOT CANCELED) ................................ 20-248
P-19 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO. .................... 20-249
P-20 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 3OC, OR WARMING-UP

OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30C .... 20-250
20-223
P-21 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK),
SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP . . . . . . . . . . . . . . . . 20-251
P-22 FUEL LEVEL SENSOR SYSTEM DEFECTIVE ................................ 20-252
P-23 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE ...................... 20-253
P-24 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE ........................... 20-254
P-25 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE ............................ 20-255
P-26 HYDRAULIC OIL LEVEL SENSOR SYSTEM DEFECTIVE ........................ 20-256
20-224
P-l MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS
WHEN STARTING SWITCH IS TURNED ON
a) No monitor panel lamps light up.
Remedy
2 YES
)efective monitor panel 7eplace
YE Is voltage between
. Pl (female) (1) - - Iefective contact, or
1 (3) normal? lisconnection in wiring :iean
harness between fuse 3 - defective
1 (female) (I) or Pl :ontact) or
terminals of fuse * Voltage 20 - 30V NO
female) (3) - M6 (9) - eplace
3 - chassis ground * Turn starting switch
ON. :hassis ground
. Voltage 20 - 3ov eplace after

Iisconnectio in fuse lspecting cause
. Turn starting switcl
ON. f disconneCti
PI (040201
Id-1 Fuse
205FO5300
b) Some monitor panel lamps do not light up
Defective monitor panel replace
20-225
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH
IS TURNED ON BUT DO NOT GO OUT
Remedy
20-226
CHECK ITEMS FLASH (LEVELS
. FOR CHECK ITEMS ARE AS
SPECIFIED)
a) 8 (Coolant level) flashes
* Check that the coolant is at the specified lever before carrying out the troubleshooting.
Cause
Defective coolant level

YES -
sensor (reserve tank) systen
(See P-26)
YES leplace
off when short Defective monitor panel
Is continuity bet-
YES_ ween Pl (female) I
2 (17) and (3) as Defective contact, or
. Connect short - shown in table? disconnection in wiring :lean(defective
connector to P8 Is there continuity harness between P8 (femals :ontact) or
(female) between P8 (female) _ . Connect and dis- NO (1) - E8 (2) - M6 (1) - PI eplace
. Turn starting I 1 (2) and chassis connect short conne- (female) (17)
switch ON. ground? ctor to P8 (femalel.
1 . g; starting switch Defective contact, or
. Turn starting disconnection in wiring >lean (defectiv
switch OFF. harness between P8 (female ontact) or
(2) and chassis ground eDlaCe
Table
1 Short connector 1 Continuitv 1
Pl(O4020) E 8EWPl4) P8(X2)

Coolant level sensor
m
205FO5731
20-227
b) 6 (Engine oil level) flashes
* Use the dipstick to check that the engine oil is at the specified level before carrying out the
troubleshooting.
Yes
Cause Remedy
1
Defective engine oit level
Yes Is there continuity sensor system. (See P-24)
-between P5 (female) -
(B) - chassis Defective contact or dis- CLean (defective
ground connection in wiring har- contact) or
les Is voltage between ness between P5fB) - E8C3) replace.
-P5(C) and chassis - No or E9(1) - chassis.
ground normal?
Defective contact or dis- Clean (defective
Does display go off 020 - 3ov. connection in wiring har- contact) or
when PS (female) (1) *Turn starting ness between P5K) - E8(3) replace.
is connected to - switch ON. No or E9(3) - H14(4) - start-
chassis ground? ing switch terminal Act.
Yes
Defective monitor panel. Replace
*Connect PS (female)
to chassis ground.
*Turn starting switch (18) - (3) as Defective contact or dis- Clean (defective
ON. connection in wiring har- contact) or
ness between P5ffemale) (0) replace.
*Connect and dis- No E8(5) or E9(5) - Ml4 (5) -
connect P5 (female) Pl (female) (18).
to chassis ground.
Table
PltO40201
PC3OOLC
ESCSWPBI
Monitor Engine oil
PC4OOLC
oanel F-l-l@ hu4tsal Eatswa3 level sensor
X08DD054
20-228
c) @ (Hydraulic oil level) flashes
YES Defective hydraulic oil level

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

when P9 (female) _
(1) is connected to 2 YES
chassis ground? ) Defective monitor panel Replace
- Is continuiv bet-
. Turn starting _ ween Pl (female) _
switch ON. NO (10) and (3) as Defective contact, or
shown in table? disconnection in wiring Clean (defective
. harness between P9 (female contact) or
. Connect T-adapter NO (1) - M3 (7) - Pl replace
to Pl (female) (female) (10)
Pl(O40201 M3El6) P9(XI) Hydraulic oil

level sensor
-3
I @
205FO5733
20-229
P-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
STARTED, CHECK ITEMS FLASH
* Check both the alternator system and engine oil pressure system.
a) Alternator system cause Remedy
2 YES
Defective monitor panel ReDlace
Is voltage between
PI (female) (7) -
chassis ground Wective contact or dis-
normal? mnnection in wiring Clean (defectiv
tween alternator
iarness between alternator contact) or
. 26-30V NO replace
terminal R - * Start engine, and terminal D - E8(2) or E9(2)
chassis ground run at half 1 Ml4 (2) - Pl (female) (7)
throttle or above.
. 26 - 3QV Defective alternator Replace
* Start engine, and I\
IO
run at half
throttle or above.
b) Engine oil pressure system :heck that

* When the engine oil pressure is normal. erminal
lefective
is not
(con-
act, insertion),
:heck operation
)f sensor ac-
:ording to
standard Value
YES Defective engine Oil rable for elect-
pressure sensor ical
1
:omponets,
Does display go off
he replace
when wiring
harness terminal _ Contact of wirinCJ%Gess
of engine oil NO 2 YES between Pl 1 (C) - E9(2) or After inspectiol
pressure sensor is EB(2) - Ml4 (7) - Pl epair or replaC
removed7 Is there conti- (female) (16) with chassis
*Remove engine oil i wiry between
ground
Pl (female) (16) -
pressure sensor Pl 1.
chassis ground?
+ turn starting switch - NO
ON.
l Remove engine oil
pressure sensor Pl 1.
Pc3ooLc:
E9(SWP6)
PCQOOLC:
Pl(O4020) M14(S8) E8(SWP8)
Alternator
Monitor 0 D terminal
panel Pll
Pc3ooLc:
XOSDD055
20-230
CAUTION ITEMS FLASH
* When the engine oil pressure is normal.
Defective alternator. Replace

1
Is voltage between
YaS alternator terminal
D - chassis ground - Wiring harness between After inspection
20 - 3OV? 3 Yes alternator terminal D - repair or replace.
. -EM21 or E9(2) - M14(2) -
- Is voltage between Pl (female) (7) in contact
1 *Do not start engine. -P1(7) - chassis - with +24V.
*Remove alternator NO ground 20 - 3OV?
Is there continuity terminal D wiring. Defective monitor panel. Replace.
between Pl(female) *DO not start engine. No
(16) - chassis *Turn starting witch
ground? ON.
-4 Yes Disconnection in wiring Repair or replace.

wharness between Pl(16) -
Is there continuity Ml4(famaLe) (7) - E8(2) or
between Pl(female) between PllIA) - E8(1) or
-(A) - (C) terminal? - E9)l) - chassis growd.
NO
Defective engine oil Check that termi-
*Remove engine oil No pressure sensor. nal is not defec-
pressure sensor (Pll). tive (contact. in.
sertion), check
operation of sen-
sor according to
Standard Values
Table for electri.
cal corrponents,
the replace.
Pc3ooLc:
E9BWP6)
PC400LC:
PNO4020) Ml4(S8) EB(SWP8)
Alternator
D terminal
PI1
Engine oil
pressure
sensor
Pc3ooLc:
E9(SWP6)
Pc4ooLc:
20-231
P-6 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS
STARTED, CAUTION ITEMS FLASH
(WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)
a) & (Engine oil pressure) flashes

LJ
YES Defective engine oil

1 I pressure sensor
Contact of chassis
ground with wiring
Z YES
harness between Pll (C)-
E8(2) or E9(2) - M14(7)
HNC-I
l Remove engine oil - Pl(female) (16).
between Pl
pressure sensor
P(ll). chassis ground?
Defective monitor panel
OFF.
Pc3ooLc:
ZZ%? :
Pl(O4020) YWS) Pi1
Monitor Engine
) ++)
panel oil
pressure
sensor
20-232
c) $ (Coolant temperature) flashes
CXISEZ Remedy
2 YES Defective coolant tempe-

rature sensor system -
(See P-24)

~~
.-1 Start engine, and

PI (04020) Ml4lS8) E8WVPl4) P7(X2)
Monitor panel
205FO5738
d) m (Charge) flashes
Cause Remedy
2 YES
Is voltage be-
YES tween Pl
- (female) (7) - -
1 chassis ground
normal?
Is voltage be- Clean (defectiv e
harness between
tween alternator NO :ontact) or
*20-30V alternator terminal R
terminal R - - replace
a Start engine. - E8 (8) - Ml4 (2) - Pl
chassis ground
(female) (7)
normal?
* 20 -.3ov
* Start engine, and NO Defective alternator Replace
run at half throttle
Or above.
Pl(O4020) Ml4681 E86WP8)

\ 7
Monitor panel 3 , 0 Alternator R terminal
205FO5739
20-233
e) @ (Fuel level) flashes
* Check that there is fuel before carrying out troubleshooting.
CEASe Remedy
Defective fuel level

2 YES sensor system
(See P-23)
YES Does display go

off when P6 is -
1 removed?
- Remove P6. NO
IS fuel gauge with-
in red range? . Start engine.
. Wait for approx. 2 minutes
L----J
*
Start engine, and
l The
delay
surface of the fuel varies, so there is a
built into the display for the fuel level.
[
run at half throttle ND
or above.
PI (040201 M6 P6tXI)
Fuel level sensor
Monitor panel
205FO5309
20-234
P-7(a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),
BUZZER DOES NOT SOUND FOR 1 SECOND
CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND.
f Of the CAUTION item, the buzzer does not sound if there is any abnormality in the charge or fuel level.
?
Remedy
1 YES Defective monitor panel I

Does buzzer sound
when Pl (female)
(11) and chassis - Disconnection in Wiring
ground are con- harness between PI
netted? NO (female) (11) -
P4 (2)
- buzzer 1-j. or between
+24V - P4 (1) -buzzer
ON.
(+), or defective buzzer
P-7(b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR BUT

THE BUZZER SOUNDS
Cause Remedy
Contact of chassis ground After inspection

with wiring harness repair or
between Pl (female) replace
I -now-__ ----_
h1177G.T I I (11) - buzzer (-)
sound when Pl is -
removed?
- Defective monitor panel Replace

* Remove Pl. NO
ON.
+24V
P4tM3) Buzzer
fI(O4020) - .+
Monitor panel _-
205FO5310
20-235
P-8 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP
(LIQUID CRYSTAL DISPLAY IS NORMAL)
C.XSe Remedy
Seplace bulb, o
1 YES Bulb broken or defective
:lean (defective
contact :ontact)
Is bulb broken or
is there defective -
contact?
Defective monitor panel RePlace

* Remove bulb. NO
- Check condition of
bulb visually.
20-236
P-9 COOLANT TEMPERATURE SHOWS ABNORMALITY LOW
TEMPERATURE
* If the coolant temperature actually remains low, check the engine system.
CaUSe Remedy
Defective coolant
temperature sensor system
(See P-24)
gauge levels go
off? 2 YES
Defective monitor Panel ReDlace
Is there continuity
* Connect short
_ between Pl Defective contact, or dis-
connector
NO (female) (6) - connection in wiring
to P7 (male)
chassis ground? Clean (defective
. Turn starting switch NO harness between PI
(female) (6) - Ml4 (6) - :ontact) or
ON. . Connect short connector
E8 (5) - P7 (female) (I) replace
to P7 (male).
or P7 (female) (2) - E8
* Turn starting switch OFF. (6) - chassis ground
P-l 0 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING

OPERATION, NO LEVEL OF GAUGE IS DISPLAYED)
F
Cause
Defective coolant tempe-

YES
ratre sensor system
-
Gee P-24)
I
1C+act pf chassis ground
perature gauge with wmngharneSS oet-
appear when P7 ,fter inspection
ween P7 (female) (1) -
rpair,or replac
Is there continuity E8 (5) - Ml4 (6) - PI
* Remove P7 between PI (6) - (female) (6)
(female). - chassis ground -
* Turn starting switch when P7 is
ON. removed?
Defective monitor panel IepIC
- Remove P7. NO
OFF.
P-9, 10 RELATED ELECTRICAL CIRCUIT DIAGRAM
Pl(O4020) M14(S81 E8C3WPl4) P7(X2)

Coolant temperature sensor
Monitor panel 6
d7
205FO5738
20-237
P-l 1 FUEL GAUGE ALWAYS DISPLAYS FULL
* Check first if the fuel tank is actually full before carrying out troubleshooting.
CZlUSl? Remedy

YES
1 I
sensor system -
(See P-23)
Does display of
fuel gauge go off _
Contact of chassis ground
when P6 is NO 2 YES with wiring harness be- rfter inspection
removed? epair, or
tween P6 (female) (1) -
Is there continuity
M6 (4) - Pl (female) (5) eplace
- Remove P6 (male). between Pl (5) -
- Turn starting switch chassis ground -
ON. when P6 is
. Wait for approx. 2 removed?
minutes. Defective monitor panel 7eplace
- P6 is removed? NO
OFF.
. The surface of the fuel varies, so there is a delay built into

the display for the fuel level.
P-12 FUEL GAUGE GIVES NO DISPLAY

* Check if there is any fuel before carrying out troubleshooting.
C2aE.e Remedy

YES -
sensor- wster
1 I
(See P-23)
Defective monitor panel 7ePlace
Defective contact, Or
disconnection in wiring &an (defectiv
harness between P6 ontact) or
* Connectshort connector (female) (1) - M6 (4) - eplace
to P6 (female). Pl (female) (5)
OFF.
P-l 1 ,I 2 RELATED ELECTRICAL CIRCUIT DIAGRAM
Pl(O4020) P6(XII
Fuel level sensor
Monitor panel
205FO5309-1
20-238
20-239
P-l 3(a) LAMPS DO NOT LIGHT UP
YES
-
Does lamp light
when PI (female)
(14) and chassis
2 -
up
-
YES
ND
c
I
Clean (defecti\
ground are con- 3 _YES Disconnection,

contact in lamp
defective contact)
replace
or
netted?
l- Is there any dis- Defective contact, or dis-
p * Connect Pl (female) connection or connection in wiring
(14) and chassis - defective contact harness between Pl
Do LEDs on ground. (female) (14) - lamp
in lamp?
monitor
light up?
panel - * Turn
ON.
starting switch
- Check visually. NO
relay R4 (2). between
lamp relay
(5). between
R4 (1) -fuse
lamp relay
I
Clean
contact)
replace
(defecti\
or
* Turn starting switch R4 (5) - M6 (3) - M8

ON. cl), or between M6 (3)
* Turn lamp switch - Ml0 (1) - M9 (1)
ON. Defective monitor panel Replace
NO
P-13(b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS

NOT OPERATED
CX4Se Remedy
3 YES
with
ween
wiring harness
Pl (female)
bet-
(14) -
After inspec-
tion, repair or
Is there lamp relay R4 (2). or replace
YES continuity defective lamp relay
2 - between Pl
(female) (14) - Wiring harness between
chassis ground? M6 (female) (3) - M8 After inspec-
Does lamp light (female) (I) or M6 (male) tion, repair or
YES_ upwhen Pl * Turn starting switch (3) - Ml0 (1) - M9 replace
(female) is - OFF. (female) (I) in contact
1 removed? * Disconnect Pl. with +24V
* Remove Pl(female).
Are LEDs on Defective monitor panel Replace
. -&u;.n starting switch NO
monitor panel -
out?

ON. Replace
* Turn lamp switch NO
OFF
20-240
+24V
M6(SIO) M8lMI)
Monitor -3 R.H. head lamp
Lamp relay (R4
M9tMIl
Boom head lamp
A7 205FO5313-1
20-241
P-l 4 (a) WIPERS DO NOT WORK
.
CZil.Se Remedy
Defective monitor panel qeplace
4 YE
Defective wiper motor 3eo1ace
v
Is there
continuity
YES
3 r between M4
NO (female) (2) - Defective ConfaSt! or dis-
Connect Pl(female
chassis ground? h connection in wlrlng Yean (defective
(15) and chassis
Is voltage between harness between M4 :ontact) or
ground. . Turn starting switch
M4 (female) (1) _ (female) (2) - M5 (2) eplace
Turn starting switc, OFF. - chassis ground
Do LEDs on - chassis ground
ON. - Disconnect M4.
monitor panel normal?
1
Defective wiper relay,
light up? or defective contact,
* Turn starting switch or disconnection in :lean (defective
ON. wiring harness between :ontact) repair
Turn startina swit 1 NO
. Turn wiper switch wioer relav Rl (3) - ,r replace
ON. -
ON. M6 (1) - ti4 (female)
- Turn wiper switch
ON. (1)
Defective monitor Panel qeplace

NC
P-14(b) WIPERS WORK EVEN WHEN WIPER SWITCH IS

NOT OPERATED
Cause Remedy
Contact of chassis wound

with wiring harries; .iter inspection
between Pl (female) (15) wair or
Gyiper relay Rl (female) !place

wiper relay RI (3) - fter inspection
M5 (1) - M4 (1) in !pair or
contact with +24V, or !place
defective wiper relay
Defective monitor panel eplC3Ce
-Ehko Defective monitor panel ;epkXe
OFF
20-242
M 5lM4) M4(KES4) (KES4)
+24V
205FO5314
20-243
P-l 5 (a) FAN DOES NOT WORK
C3JS.e Remedy
H
Does fan work IS there con- S Defective
I
heater Replace
YE when Pl (female) tinuity between
. (12) (or (13)) - R2 (female) (3) Defective contact! or dis-
chassis ground YE - Ml 2 (female) connection in wlrlng
I_, Iharness between Pl
are connected? (2,. or between
Ifemale) (12) - heater
R3 (female) (3) Clean (defectiv
relay R2 (2). between PI
G)yl 2 (female) (female) (13) - heater contact) or
. connect ~1 0 relay R3 (2). between Ml: replace
(12) (or (13)) and R2 (female) (3)
(female) (2) - heater
. Turn starting swi tcl
1 chassis ground.
(Lo side) or R3
(female) (3) (Hi OFF.
relay R2 (3), or between
side) - chassis
Ml2 (female) (3) heater
ON. relay R3 (3)
Do LEDs on around normal? s Replace
Defective heater relay
monitor panel *o-1v
* Turn starting
Does heater work
switch ON. Disconnection in wiring
* Turn fan switch ON. harness between R2
* Turn starting switct
(female) (2) - Pl (12) Repair or
ON. IO
(female), or between R3
. Turn fan switch * Interchange lamp rela V
replace
(female) (2) - Pl (13)
ON. and heater relay.
(female)
ON.
f Turn heater switch 01 v.
Defective monitor panel Reolace
IO
P-15(b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED
CaUSe Remedy

with wiring harness
between Pl (female) (12) After inspec-
heater relay R2 (2). Or tion, repair or
3 YES
between Pl (female) (13) replace
Is there continuity - heater relay R3 (2)
YES between Pl
2 - (female) (12) (or - Contact of chassis
(13)) -chassis ground with wiring
r ground? harness between heater After inspec-
NO
- Ml2 (2) (of (3)) - tion, repair Or
Yl ES Does fan work
* Turn starting switch heater relay R2 (3) or R3
- when PI (female) - oFF. replace
(3). or defective heater
is removed?
1 relay R2 or R3
: Remove P!(fem$).[
Are LEDs on
monitor panel
* 0~: stamngswitch NO Defective monitor Panel Replace
* Turn starting switcl h

ON. L Defective monitor panel Replace
* Turn fan switch NO
OFF.
20-244
+ 24V M 12
PI (04020)
205FO5315
20-245
P-l 6 WORKING MODE DOES NOT SWITCH
Cause Remedy
a) Even when monitor panel switch is pressed, mode

display (LED) above switch does not change.
I 3eplace
3efective monitor panel
b) When monitor panel switch is pressed, mode

display (LED) above switch changes.
YFS jee troubleshooting Of

>ump controller system
,arness between C2
(14) - P2 (8) or Correct or
oetween c2 (15) - P2 replace
(9,hoC;;h;rt circuit

ON.
Table 1
Table 2
Between (8) - (16)
Note: If the voltage is not 12V and is unstable, take the answer as YES.
C2 (MIC21) P2 (04016)
205FO5627
20-246
P-l 7 POWER SET DOES NOT SWITCH
CaUSe Remedy
a) Even when monitor panel switch is pressed, mode

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

above switch changes.
YES See troubleshooting of

1 pump cOtrOller system
Is voltage between
C2 (5) - (8) and Disconnection in wiring
between (6) - (8) harness between C2 (5)
as shown in Table 2 YES - P2 (5) or between C2
Repair or
replace
I? Is voltage between (6) - P2 (6). or short
. Turn starting switc P2 (5) - (16) and circuit with GND
ON.
~i_e monitor panel Replace
Table 1 Table 2
Power set Between (5) - (8) Between (6) - (8) Power set Between (5) - (16) Between (6) - (16)
H 12V (Note) 12V (Note) H 12V (Note) 12V (Note)
S Max. IV 12V (Note) S Max. 1V 12V (Note)
L Max. IV Max. 1V L Max. 1V Max. 1V
Note: If the voltage is not 12V and is unstable, take Note: If the voltage is not 12V and is unstable, take
the answer as YES. the answer as YES.
205FO5628
20-247
P-l 8 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER
AUTO-DECELERATION: AUTO-DECELERATION IS
NOT CANCELED)
CaUSe Remedy
a) Even when monitor panel switch is pressed, ON-OFF display

(LED) above switch does not change.
I
- I3efective monitor panel 3eplaCZ
b) When monitor panel switch is pressed, ON-OFF display

(LED) above switch changes.

See troubleshooting of
YES
I,ulp Controller
iystem
14
Is voltagebetween [Iisconnection in wiring
C2 (7) - (8) as - t wness between C2
shown in Table l? _ 2 ~YES :orrect or
-( 7) - P2 (7). or
,epl.Xe
c:otact with chassis
p
Is voltage
p2 (7) _
between
(,6J as cUOUd
ON.
NO show in Table l?
I INO _I 3efective monitor panel Redace

ON.
Table 1
Note: If the voltage is not 12V and is un-

stable, take the answer as YES.
C2(MIC21) P2 (04016)
m_Ei
205FO5397
20-248
P-l 9 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO
C3.E.e Remedy
a) Even when monitor panel switch is pressed, Lo - Hi display

(LED) above switch does not change.
I
kfective monitor panel replace
b) When monitor panel switch is pressed, Lo - Hi display

(LED) above switch changes.
YES lee troubleshooting of
11 wmp controller system
Is voltage between
)isconnection in wiring
C2 (3) - (8) as -
2 YES ,arness between C2 (3)
:orrect
shown in Table l?
,r
- P2 (41. or contact
eplace
vith chassis ground
- Turn starting switch Is voltage between
ON. A- P2 (4) - (16) as -
NO shown in Table l?
NO
Iefective monitor panel 7eplace
a Turn starting switch
ON.
Note: If the voltage is not 12V

and is unstable, take
the answer as YES.

P2 (04016)
205FO5396
20-249
P-20 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 3OC,
OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN
TEMPERATURE GOES ABOVE 30C
* Carry out troubleshooting first for E-l 1 Automatic warming-up is defective.
Cause Remedy
See E-11
YES Defective coolant temper-

1 ) I ature sensor svstem
a
(See P-23)
~ ~..~ --.
Is voltage between Warming-up
I
P2 (11) and (16) as 6 operation Can warming-up Wiring harness between Pl
shown in Table l? cannot be (female) (6) - Ml4 (6) - E8
be carried out? 3 YE!
carried out (4) or E9 (4) - Pi(A) in Repair or
1 replace
. Turnstarting Is there continuity contact with chassis ground
switch ON. between Pl or other GND wiring
. Start engine. NC (female) (6) and
chassis ground?
H Defective monitor panel
. Remove P7. NC
~~_~__
Defective coolant temperature
YES
9 I sensor system

(See P-23)
H
Warming-up
operation is - Can warming-up Defective contact or dis-
be canceled? connection in wiring harness
not canceled 1 3 YE: Repair or
between Pl (female) (6) -
replace
M14 (6) - E8(4) or -
. Connect short E9 (4) - P7(A).
connector to P7 NC1-H
(female)
. Start engine. Defective monitor panel Replace
. Connect short NC
connector to P7
(female)
Table 1
Voltage
Auto warming-up (actuated) Max. 1V
Auto warming-up (not actuated) 12V (Note)
Note: If the voltage is not 12V and is unstable,

take the answer as YES.
Pc3ooLc:
E-8 (SWP8)
Coolant
Pc4ooLc: temperature
Pl(O4020) M14(S8) E-9 (SWPG) P7
XOSDD057
20-250
P-21 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK),
SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP
* Only carry out this troubleshooting if the swing lock is actually applied.
CFllK3e Remedy
1 YES
Defective monitor panel Flepke
Is voltage between
P2 (3) - (16) as -
shown in Table l?
NO
correct or
harness between swing
replaCe
. Turn starting switch lock switch (1) - P2 (3)
ON.
Table 1 Voltage
1 Swing lock switch ON Max. 1V
1 Swing lock switch OFF 1 20 - 30V 1
Swing lock switch
P2(04016)
Monitor panel
205FO5741
20-251
P-22 FUEL LEVEL SENSOR SYSTEM DEFECTIVE
Note 1: Difference between fuel level and gauge display.
If the gauge display position is lo, the fuel level display is 78% or 100%; if it is l, the fuel
level display is less than 14.5%. If the machine is on a slope, the display and the actual fuel
level will be different. Therefore, when checking, always stop the machine on level ground and
wait for at least two minutes before reading the gauge. (The fluid level changes when the
machine is moving, so a time delay is provided to give a stable display.)
f Remove the fuel level sensor when carrying out this troubleshooting.
C.SlSe Remedy
3 YES Interference with sensor (Note 2)

lnslde tank
YES IS the float badly
2 - cracked. chwped. or -
damaged,
Defect!ve contact of connector Clean COnnectOr

YES Does the arm move NO or replace
smoothly)
1
Move the float up Defectw sensor (Note 2) Re&ce
and down. Is the NO
resnstance between
I
Connector (1 and
flange as shown I
Table 1, D!sconnectlon I w,r,ng Repar w,r,ng
4 YES
harness (Note 3) harness or
Is wr,ng of w,r,ng ~
(Defective clamp) replace sensor
harness broken? Is
reswance between
~0 connector j
(1 and
sensor terminal
below 1 II? Defective sensor ReDlaCe
- NO
Table 1
FULL stopper position Approx. 1222 or less
EMPTY stopper position Approx. 85 - 1lOQ
F20205053
Note 2: There is probably interference with the sensor inside the tank or defective installation.
Install carefully when replacing.
Note 3: Check for any vibration at the connector mount and take the necessary action if the vibration
is excessive.
20-252
P-23 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE
CaUSe Remedy
YES
Defecwe contact of connector Clean connector
1I (Note 1) or replace sen*or
temperature sansor
connector (male) (A)
2
and (B) as shown in - YES
. Defectwe sensor Replace
IS wirmg of wring
harness broken? Is
resistance between
connector (male) -
and sensor termmal
below 1 f2? Dtsconnectmn I wnrng Repau wrmg
harness (Note 2) harness or
NO
(Defectwe clamp) replace sensor
Table 1
Normal temperature 25 C Approx. 37 - 50kQ
100C Approx. 3.5 - 4.0kQ
Connector
Sensor
--
F20205054
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so replace the connector (harness) at the chassis end.
is excessive.
20-253
P-24 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE
Note 1: Variations in oil level.
The oil level changes according to the angle of the machine, the engine speed and oil
temperature, so if any display is given, stop the machine on flat ground and check the oil level
before carrying out the check again.
Remove the engine level sensor when carrying out this troubleshooting.
: To check the performance of the sensor, prepare engine oil in a container.
* Prepare a power source giving lo-32V DC.
Cause Remedy
Yes
Defective contact of Clean connector or
connector. (See Note 2) replace sensor.
When sensor is
inserted in engine Yes
oil, is resistance - -Disconnection in wiring Repair wiring
between connector harness. (See Note 3) harness or replace
(D) and (B) as shown 2 (Defective clamp sensor.
in table?
Can any broken wires
*Connect power -be seen when check- -
source to (B) and No ing visually?
(0.
(C) is positive and
(B) is negative. -Defective sensor. Replace.
No
is excessive.
Table
In oil
In air
08DDOOll
20-254
P-25 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE
Note 1: Variation in coolant level.

The coolant level changes according to the angle and swaying of the machine, so if any
abnormal display is given, stop the machine on flat ground and check the coolant level before
carrying out the check again.
* Remove the coolant level sensor when carrying out this troubleshooting.
Callse RemedY
YES Defectw mOYemet of float Ck?afl

because of dirt
YES Is any dirt or dust

- stuck in float?
3 YES
Resonance of mount (Note 2) Replace sen?.or
L 1
IS float badly
1 - cracked, chipped, or _
NO damaged?
Move the float up
and down. Is the Clean COnnectOr
resistance between Defectwe contact or connector
NO or replace
Connector (1) and
flange as shown I
Table 1 ?
4
- YES Dlsconnectlon I wnng Repar wr,ng
Is wlrlng of wnng harness (Note 3) harness or
harness broken? Is (Defectwe clamp) replace sensor
L resstance between _
NO connector (1). (2)
and sensor below
1R?
FWplWX
NO
Table 1 PC3OOLC PC4OOLC

I Float UP Max. l!A A
I Float DOWN I Min. 1Mfl I
DOWN+ k+---- ~,oat

F20205056 F20505366
Note 2: There is a strong possibility that the mount is resonating, so check the mount of the subtank.
is excessive.
20-255
P-26 HYDRAULIC OIL LEVEL SENSOR SYSTEM DEFECTIVE
Note 1: Variations in hydraulic oil level.
The oil level changes according to the angle of the machine, the engine speed and oil
temperature, so if any display is given, stop the machine on flat ground and check the oil level
before carrying out the check again.
* Remove the engine level sensor when carrying out this troubleshooting.
Remedy
2 YES Excessive contamination

qeplace filter
zlement, change
of oil
)il
YES lS any dirt or dust
stuck in movable -
part of float?
1 Defective contact of
Clean connector
Move the float UP or replace
NO connector (Note 2)
sensor
-4 I
and down Is the
res~3ance berween
connector (1) and
-flange as shown I
Table 1) YES Asconnection in wiring Repair wiring
Is wiring of wiring harness (Note 3) harness or
harness broken? Is I (Defective clamp) replace sensor
L resistance between
NO connector (male)
and sensor terminal
below 1Q Replace
NO
Table 1
Float UP Max. 1fI
Float DOWN Min. 1MQ
F20205055
is excessive.
20-256
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . . . 30-5 INSTALLATION OF ENGINE,

HYDRAULIC PUMP ASSEMBLY.. . . . . . 30-28
PRECAUTIONS WHEN CARRYING OUT
OPERATION . . . . . . . . . . . . . . . . . . 30-6 REMOVAL OF ENGINE,
HYDRAULIC PUMP ASSEMBLY. . . ; . . . 30-30
SPECIAL TOOL LIST
PC3OOLC . . . . . . . . . . . . . . . . . . . . . . . 30-8 INSTALLATION OF ENGINE,
HYDRAULIC PUMP ASSEMBLY. . . . . . . 30-30
SPECIAL TOOL LIST
PC4OOLC . . . . . . . . . . . . . . . . . . . . . . 30-l 1 REMOVAL OF DAMPER
ASSEMBLY __. . __. ___. . . . . . . . . . . 30-32
WEIGHT TABLE . . . . . . . . . . . . . . . . . . 30-l 4
INSTALLATION OF DAMPER
TIGHTENING TORQUES AND STANDARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-32
VALUES TABLE . . . . . . . . . . . . . . . 30-l 5
REMOVAL OF CENTER SWIVEL
LUBRICANT AND COOLANT TABLE . . . 30-21 JOINT ASSEMBLY . . . . . . . . . . . . . . . . 30-34
REMOVAL OF GOVERNOR INSTALLATION OF CENTER

MOTOR ASSEMBLY . . . . . . . . . . . . . . . 30-22 SWIVEL JOINT ASSEMBLY. . . . . . . . . . 30-34
REMOVAL OF HYDRAULIC DISASSEMBLY OF CENTER

COOLER ASSEMBLY . . . . . . . . . . . . . . 30-24 SWIVEL JOINT ASSEMBLY . . . . . . . . . . 30-34
INSTALLATION OF HYDRAULIC ASSEMBLY OF CENTER

COOLER ASSEMBLY . . . . . . . . . . . . . . 30-24 SWIVEL JOINT ASSEMBLY . . . . . . . . . . 30-34
REMOVAL OF HYDRAULIC REMOVAL OF FINAL DRIVE

COOLER ASSEMBLY . . . . . . . . . . . . . . 30-24 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-36
INSTALLATION OF HYDRAULIC INSTALLATION OF FINAL

COOLER ASSEMBLY . . . . . . . . . . . . . . 30-24 DRIVE ASSEMBLY . . . . . . . . . . . . . . . . 30-36
REMOVAL OF RADIATOR, DISASSEMBLY OF FINAL

HYDRAULIC OIL COOLER . . . . . . . . . . 30-26 DRIVE ASSEMBLY . . . . . . . . . . . . . . . . 30-36
INSTALLATION OF RADIATOR, ASSEMBLY OF FINAL DRIVE

HYDRAULIC OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-26
DISASSEMBLY OF TRAVEL MOTOR
REMOVAL OF ENGINE, ASSEMBLY (HMV280ADT)(HMV355ADT) 30-44
HYDRAULIC PUMP ASSEMBLY.. . . . . . 30-28
30-I
ASSEMBLY OF TRAVEL MOTOR REMOVAL OF IDLER, RECOIL
ASSEMBLY (HMV280ADT) (HMV355ADT) 30-49 SPRING ASSEMBLY . . . . . . . . . . . . . . 30-80
REMOVAL OF SPROCKET . . . . . . . . . . 30-58 INSTALLATION OF IDLER,

RECOIL SPRING ASSEMBLY . . . . . . . . 30-80
INSTALLATION OF SPROCKET . . . . . . . 30-58
DISASSEMBLY OF RECOIL
REMOVAL OF SWING MOTOR SPRING ASSEMBLY . . . . . . . . . . . . . . 30-82
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-58
ASSEMBLY OF RECOIL SPRING
INSTALLATION OF SWING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-82
MOTOR ASSEMBLY . . . . . . . . . . . . . . . 30-58
REMOVAL OF TRACK ROLLER
DISASSEMBLY OF SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-84
ASSEMBLY (KMF160) . . . . . . . . . . . 30-60
INSTALLATION OF TRACK
ASSEMBLY OF SWING MOTOR ASSEMBLY ROLLER ASSEMBLY . . . . . . . . . . . . . 30-84
(KMF160) . . . . . . . . . . . . . . . . . . . 30-63
REMOVAL OF CARRIER
REMOVAL OF SWING ROLLER ASSEMBLY . . . . . . . . . . . . . 30-84
MACHINERY ASSEMBLY . . . . . . . . . . . 30-68
INSTALLATION OF CARRIER
INSTALLATION OF SWING ROLLER ASSEMBLY . . . . . . . . . . . . . 30-84
MACHINERY ASSEMBLY.. . . . . . . . . 30-68
REMOVAL OF TRACK SHOE
REMOVAL OF SWING ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-86
MACHINERY ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68 SHOE ASSEMBLY . . . . . . . . . . . . . . . 30-86
INSTALLATION OF SWING REMOVAL OF CHARGING

MACHINERY ASSEMBLY . . . . . . . . . . 30-68 PUMP ASSEMBLY . . . . . . . . . . . . . . . 30-86
DISASSEMBLY OF SWING INSTALLATION OF CHARGING

ASSEMBLY OF SWING REMOVAL OF HYDRAULIC

REMOVAL OF REVOLVING INSTALLATION OF HYDRAULIC

FRAME ASSEMBLY . . . . . . . . . . . . . . 30-78 PUMP ASSEMBLY . . . . . . . . . . . . . . . 30-88
INSTALLATION OF REVOLVING REMOVAL OF HYDRAULIC

FRAME ASSEMBLY . . . . . . . . . . . . . . . 30-78 PUMP ASSEMBLY . . . . . . . . . . . . . . . 30-88
REMOVAL OF SWING CIRCLE INSTALLATION OF HYDRAULIC

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-80 PUMP ASSEMBLY . . . . . . . . . . . . . . . . 30-88
INSTALLATION OF SWING DISASSEMBLY OF HYDRAULIC PUMP

CIRCLE ASSEMBLY . . . . . . . . . . . . . . . 30-80 ASSEMBLY (HPV160+160) . . . . . . . 30-91
ASSEMBLY OF HYDRAULIC PUMP

ASSEMBLY (HPV160 + 160) . . . . . . . 30-98
30-2
CHECKING CONTACT BETWEEN CYLINDER REMOVAL OF WORK
BLOCK AND VALVE PLATE, AND EQUIPMENT PPC VALVE
ROCKER CAM AND CRADLE . . . . . .30-112 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-127
REMOVAL OF HYDRAULIC INSTALLATION OF WORK

PUMP INPUT SHAFT OIL SEAL . . . . . . 30-115 EQUIPMENT PPC VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . .30-127
INSTALLATION OF HYDRAULIC
PUMP INPUT SHAFT OIL SEAL . . . . . . 30-115 DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE ASSEMBLY . . 30-l 27
REMOVAL OF CONTROL
VALVE ASSEMBLY . . . . . . . . . . . . . . .30-l 17 ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
INSTALLATION OF CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-l 27
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-l 17
REMOVAL OF TRAVEL PPC
DISASSEMBLY OF CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . 30-129
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-l 19
INSTALLATION OF TRAVEL PPC
ASSEMBLY OF CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . 30-l 29
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-121
DISASSEMBLY OF TRAVEL PPC
REMOVAL OF MAIN RELIEF VALVE ASSEMBLY . . . . . . . . . . . . . . 30-l 29
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-l 23
ASSEMBLY OF TRAVEL PPC
INSTALLATION OF MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-129
RELIEF VALVE ASSEMBLY . . . . . . . . . . 30-l 23
REMOVAL OF BOOM HOLDING
DISASSEMBLY OF MAIN VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-131
RELIEF VALVE ASSEMBLY . . . . . . . . . . 30-123
INSTALLATION OF BOOM
ASSEMBLY OF MAIN RELIEF HOLDING VALVE ASSEMBLY . . . . . . . . 30-131
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-l 23
DISASSEMBLY OF BOOM
REMOVAL OF TVC VALVE HOLDING VALVE ASSEMBLY . . . . . . . . 30-131
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-125
ASSEMBLY OF BOOM
INSTALLATION OF TVC VALVE HOLDING VALVE ASSEMBLY . . . . . . . . 30-131
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-125
REMOVAL OF PPC SHUTTLE
REMOVAL OF COoNC VALVE VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-133
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 25
INSTALLATION OF PPC
INSTALLATION OF CO.NC SHUTTLE VALVE ASSEMBLY . . . . . . . . 30-l 33
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-125
REMOVAL OF BOOM
REMOVAL OF SERVO VALVE CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-135
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 25
INSTALLATION OF SERVO CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-135
VALVE ASSEMBLY . . . . . . . . . . . . . . . 30-l 25
30-3
REMOVAL OF ARM CYLINDER INSTALLATION OF
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-137 COUNTERWEIGHT . . . . . . . . . . . . . . .30-153
INSTALLATION OF ARM REMOVAL OF ENGINE

CYLINDER ASSEMBLY . . . . . . . . . . . . .30-l 37 THROTTLE CONTROLLER . . . . . . . . . . 30-l 55
REMOVAL OF BUCKET CYLINDER INSTALLATION OF ENGINE

ASSEMBLY . . c . . . . . . . . . . . . . . . . . . 30-139 THROTTLE CONTROLLER . . . . . . . . . . 30-155
INSTALLATION OF BUCKET REMOVAL OF PUMP

CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-139 CONTROLLER ASSEMBLY . . . . . . . . . .30-155
DISASSEMBLY OF HYDRAULIC INSTALLATION OF PUMP

CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-141 CONTROLLER ASSEMBLY . . . . . . . . . . 30-155
ASSEMBLY OF HYDRAULIC REMOVAL OF MONITOR

CYLINDER ASSEMBLY. . . . . . . . . . . . . 30-143 PANEL ASSEMBLY . . . . . . . . . . . . . . . 30-155
REMOVAL OF WORK INSTALLATION OF

EQUIPMENT ASSEMBLY . . . . . . . . . . . 30-145 MONITOR PANEL
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-155
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY . . . . . . . . . . . 30-145 PROCEDURE FOR FLUSHING HYDRAULIC
CIRCUIT . . . . . . . . . . . . . . . . . . . . 30-l 57
REMOVAL OF BUCKET
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-147 PROCEDURE FOR FLUSHING HYDRAULIC
CIRCUIT . . . . . . . . . . . . . . . . . . . . 30-165
INSTALLATION OF BUCKET
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 47
REMOVAL OF ARM ASSEMBLY . . . . . . 30-147
INSTALLATION OF ARM
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-l 47
REMOVAL OF ARM, BUCKET

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 30-149
INSTALLATION OF ARM,
BUCKET ASSEMBLY . . . . . . . . . . . . . . 30-l 49
REMOVAL OF BOOM ASSEMBLY . . . . . 30-151
ASSEMBLY . . . . . . . . . _ . . . . . . . . . . . 30-151
REMOVAL OF OPERATORS
CAB ASSEMBLY . . . . . . . . . . . . . . . . . 30-153
INSTALLATION OF
OPERATORS CAB ASSEMBLY . . . . . . . 30-l 53
REMOVAL OF
COUNTERWEIGHT . . . . . . . . . . . . . . . 30-153
30-4
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for
the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying to the installation procedure are marked m, and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVALOFOOOASSEMBLY ........... Title of operation
............................
A
Precautions related to safety when
carrying out the operation
l.XXXX(l) . . . . . . . . . . . . . . . . . . . . . . . . Step in operation

* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to
remember when removing XXXX (1).
2. A A A (2) . . . . . . . . . . . . . . . . . . . . . . . . . . m Indicates that a technique is listed
for use during installation
3. q El 0 q assembly (3)
:
- . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 0 ASSEMBLY . . . . . . Title of operation

l Carry out installation in the reverse order to removal.
. . . . . . . . . . . . . . . . . . . . . . . . . . . Technique used during installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Technique or important point to
remember when installing A A A (2).
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these
precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A,) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. Listing of tightening torque, weight, refill amount for oil and water
(1) If symbols such as u, &, or @l appear in the operation procedure, see TIGHTENING
TORQUES AND STANDARD VALUES TABLE, MAINTENANCE STANDARD TABLE, WEIGHTTABLE,
and LUBRICANT AND COOLANT TABLE for details of the values.
30-5
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end)
number I I Usethetwo items below as a set
02 I 0737550210 1 07221-20210 (Nut),07222-00210 (Plug)

03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut),07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut),07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut),07222-00616 (Plug)
10 1 07376-51034 1 07221-21034 (Nut),07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut),07222-01219 (Plug)
Split flange type hoses and tubes

Nominal Sleeve head Splitflange
Flange (hose end)
number (tube end)
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
If the p art is not i nder hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part number
number
DdL
06 07049-00608 6 5 8 + -
A
08 07049-00811 8 6.5 11
10 Taperl/8
07049-01012 #10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18 t
r
16 07049-01620 #16 13.5 20
18 07049-01822 181 15 ) 22
20 07049-02025 20 17 25
202F2001
22 07049-02228 22 18.5 28
24 07049-02430 #24 20 30
27 07049-02734 27122.5 1 34
30-6
2. Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified torque.
Install the hoses without twisting or interference.
Replace all gaskets, o-rings, cotter pins and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
0 When coating with adhesive, clean the part and remove all oil and grease, check that there is no dirt
or damage, then coat uniformly with gasket sealant.
Clean all parts and correct any damage, dents, burrs or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt or water, then connect
securely.
l When using eyebolts, check that there is no deformation or deterioration, then screw them fully and
align the direction of the hook.
l When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations
l If the coolant has been drained, tighten the drain valve and add water to the specified level. Run the
engine to circulate the water through the system. Check the water level again.
l If the hydraulic equipment has been removed and installed again, add the engine oil to the specified
level. Run the engine to circulate the oil through the system. Check the oil level again.
l If the piping or hydraulic equipment, such as hydraulic cylinders, pumps or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
f For details, see TESTING AND ADJUSTING, bleeding air.
l Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related
parts.
30-7
SPECIAL TOOL LIST
PC3OOLC
Nature of work Symbol Part No. Part Name I QtY Remarks
Installation of floating
1 791-580-l 510 Installer
Disassembly, seal
assembly of final A
drive assembly Adjustment of clearance
2 796-570-l 110
of bearing
I
791-600-2001 Compressor A
791-6&8005 Compressor B
Disassembly,
assembly of recoil B 791-635-3160
spring assembly
790-l 01-l 600
790-l 01-l 102
791-630-3000 Remover & installer I 1

Disassembly,
Removal, press fitting of
assembly of track C 790-l 01-l 300 Cylinder (100 t) 1
---r-
I master pin
shoe assembly
790-l 01-l 102
l Removal,
installation of
charging pump
assembly D 796-760-l 310 Oil stopper 1
l Removal,
installation of main
pump assembly
I
1 790-720-l 000 Expander 1 Expansion of piston ring
Disassembly,
assembly of
E 796-720-l 680 Ring 1
hydraulic cylinder
2
assembly LJ%G&
07281-01589 Clamp 1
l Removal, 796-760-l 800 Remover 1

installation of boom
assembly Pulling out boom foot
l Removal, F 790-l 01-3800 Puller (50 t)
pin
installation of work
equipment
790-l 01-l 102
assembly
30-8
Nature of work Symbol Part No. Part Name QtY Remarks
790-501-5000
Repair stand 1
790-5oqr-5200
1
790-901-2110 Bracket 1
790-901-1361 Plate 1
-
2 799-301-1600 Oil leak tester 1 Removal of brake piston
-
796-765-1140 Bolt 1
01580-03024 Nut 1
Removal, installation of
3
spring of cylinder block
01643-33380 Washer 1
Disassembly, 796-765-1150 Washer 1

-
assembly of travel G
motor assembly Press fitting of bearing
4 790-201-2720 Push tool 1
inner race
-
Press fitting of bearing
5 796-765-1120 Push tool 1
inner race
-
6 796-765-1110 Push tool 1
outer race
-
790-101-5201 Push tool kit 1
7 790-101-5311 l Plate 1 Press fitting of oil seal

790-101-5221 l Grip 1
01010-51225 . Bolt 1
-
Press fitting of dowel
8 796-765-1130 Push tool 1
pin
-
790-501-5000
Repair stand 1
790-5oqr-5200
1
790-901-2110 Bracket 1
790-901-1470 Plate 1
-
796-730-2120 Screwdriver 1
2
retainer mounting screw
Disassembly, 796-720-2220 Socket 1
assembly of swing H -
3 790-201-2840 Push tool 1
inner race
-
4 796-766-1110 Guide 1 Assembly of drive shaft
-
5 790-201-2860 Push tool 1
outer race
-
796-720-3800 Wrench 1
Measurement of rotating
6
torque
795-630-1803 Torque wrench set 1
- A
30-9
Nature of work Symbol Part No. Part Name Remarks
790-501-5000
Repair stand
790-5::-5200
790-901-2110 Bracket 1
1
790-901-1450 Plate 1
790-901-1460 Spacer 1
790-767-1120 Plate 1
-
2 796-720-2270 Screwdriver 1 gear plate mounting
screw
-
796-720-2250 Screwdriver 1 impeller mounting
screw, shoe retainer
3
mounting screw and
796-720-2220 Socket 1 cam plate mounting
screw
-
Disassembly, Removal, installation of
assembly of J 4 796-767-1140 Wrench 1 strainer of charging
hydraulic pump pump
-
796-730-2120 Screwdriver 1 Removal, installation of
5 cam stopper mounting
796-720-2220 Socket 1 screw
-
Measurement of shoe
6 791-746-2770 Hook 1
clearance
-
796-767-1100 Gauge 1
Adjustment of stroke of
servo piston
7 796-767-1110 *Plate
796-720-4640 *Pin
(Max. angle side)
790-445-2921 *Bar
-
796-720-4681 Gauge 1
servo piston
a 796-720-4691 *Plate
796-720-4640 @Pin
(Min. angle side)
790-445-2921 *Bar
-
796-730-2300 Wrench 1
9
torque
795-630-l 803 Torque wrench set 1
-
30-10
SPECIAL TOOL LIST
PC4OOLC
Installation of floating
1 796-627-l 020 installer 1
Disassembly, seal
assembly of final A
drive assembly Adjustment of clearance
2 796-627-l 010 Plate 1
t of bearing
791-600-2001 Compressor A 1
791-6%8005 Compressor B 1
Disassembly,
assembly of recoil B 791-635-3 160 Extension 1
spring assembly
790-l 01-l 600 Cylinder (70 t) 1
790-l 01-l 102 Pump 1
791-630-3000 Remover & installer 1

Disassembly,
Removal, press fitting of
assembly of track C 790-l 01-l 300 Cylinder (100 t) 1
master pin
shoe assembly
790-l 01-l 102 Pump 1
l Removal,
installation of
charging pump
assembly D 796-760-l 310 Oil stopper 1
l Removal,
installation of main
pump assembly
1 790-720-l 000 Expander Expansion of piston ring
I
796-720-l 680 Ring
Disassembly,
assembly of
E 07281-o 1589 Clamp
hydraulic cylinder
2
assembly 1
796-720-l 690 Ring
07281-02 169 Clamp
l Removal, 796-760-l 800 Remover

installation of boon
assembly Pulling out boom foot
l Removal, F 790-l 01-3800 Puller (50 t) pin
installation of work
equipment
790-l 01-l 102 Pump
assembly
30-11
Nature of work Symbol Part No. Part Name Q~Y Remarks
790-501-5000
Repair stand 1
790-5001-5200
1
790-901-2110 Bracket 1
796-660-l 010 Plate 1
2 799-301-l 600 Oil leak tester 1 Removal of brake piston
796-765-l 140 Bolt 1
01580-03024 Nut 1
3 spring of cylinder block
01643-33380 Washer 1
Disassembly, 796-765-l 150 Washer 1

assembly of travel
4 790-201-2720 Push tool 1
inner race

5 796-765-l 120 Push tool 1
inner race

6 796-765-l 110 Push tool 1
outer race
790-l 01-5201 Push tool kit 1
7 790-l 01-5311 0 Plate 1 Press fitting of oil seal

790-l 01-5221 l Grip 1
01010-51225 l Bolt 1
Press fitting of dowel

8 796-765-l 130 Push tool 1
pin
790-501-5000
Repair stand 1
790-5oqr-5200
1
790-90 l-2 110 Bracket 1
790-901-l 470 Plate 1
796-730-2120 Screwdriver 1
2 retainer mounting screw
Disassembly, 796-720-2220 Socket 1
assembly of swing
3 790-201-2840 Push tool 1
inner race
4 796-766-l 110 Guide 1 Assembly of drive shaft

5 790-201-2860 Push tool 1
outer race
796-720-3800 Wrench 1
6
torque
30-12
790-501-5000
Repair stand 1
790-500:-5200
790-901-2110 Bracket 1
1
790-901-l 450 Plate 1
790-901-l 460 Spacer 1
790-767-l 120 Plate 1

-
2 796-720-2270 Screwdriver 1 gear plate mounting
screw
-
796-720-2250 Screwdriver 1 impeller mounting
screw, shoe retainer
3 mounting screw and
796-720-2220 Socket 1 cam plate mounting
screw
-
Disassembly, Removal, installation of
assembly of J 4 796-767-l 140 Wrench 1 strainer of charging
hydraulic pump pump
-
796-730-2120 Screwdriver 1 Removal, installation of
5 cam stopper mounting
796-720-2220 Socket 1 screw
-
Measurement of shoe
6 791-746-2770 Hook 1
clearance
-
796-660-l 100 Gauge 1
servo piston
7 790-445-2950 *Plate
790-720-4640 *Pin
(Max. angle side)
790-445-2921 *Bar
-
796-720-4681 Gauge 1
servo piston
8 796-720-4691 lPlate
796-720-4640 *Pin
(Min. angle side)
790-445-2921 @Bar
-
796-730-2300 Wrench 1
9
torque
-
30-13
WEIGHT TABLE
Unit:kg
Machine model PC3OOLC PC400LC
Serial No. f A30001 & up A40001 81 up
Cylinder head assembly 98

Hydraulic cooler assembly 70 90
Engine Radiator, hydraulic cooler assembly 152 180
Engine, hydraulic pump assembly 1060 1470
Turbocharger, exhaust manifold 26
Center swivel joint assembly 43 43
Final drive, travel motor assembly 665X2 850X2
Sprocket 50 75
Power train Swing motor assembly 125 130
Swing machinery assembly 440 620
Swing circle assembly 430 585
Revolving frame assembly 7850 8700
Idler, recoil spring assembly 430 600
Idler assembly 166 235
Undercarriage Recoil spring assembly 257X2 365X2
Track roller assembly 52X1 6 73X1 6
Carrier roller assembly 31x4 31x4
Hydraulic pump assembly 280 280

Control valve assembly 240 240
Hydraulic system Boom cylinder assembly 293x2 400X2
Arm cylinder assembly 425 580
Bucket cylinder assembly 263 345
Work equipment assembly 4352 5524
Bucket assembly 1014 1300
Arm assembly 981 1234
Arm, bucket assembly 1995 2534
Boom assembly 2357 2990
Work Equipment, Operators cab assembly 240 240

External Parts Operators seat assembly 35 35
Counterweight 5420 8470
Engine hood 110 150
Final drive cover 50 50
Battery upper cover 90 100
Side cover (hydraulic pump side) 35
30-14
TIGHTENING TORQUES AND STANDARD VALUES TABLE
Machine Model
Component Item Unit
PC300LC PC4OOLC
1 Engine, hydraulic pump mounting bolt

Engine Front kgm 39.25 k4.25 94.5 + 10.5
Rear 94.5 k10.5 94.5 k10.5
1 Damper assembly mounting bolt 11.25 k1.25 11.25 21.25

2 Final drive assembly mounting bolt 56 t6.0 56 26.0
3 Final drive assembly

@ Mounting bolt 73.5 24.5 91 +4
1 kgm
Power train @ Mounting bolt 39.25 f 4.25 76 28.5
@ Mounting bolt 6.75 +0.75 11.25 + 1.25
@ Mounting bolt 53 +5 53 +5
@ Mounting bolt 6.75 20.75 11.25 21.25
@ Starting force kg Max. 50 Max. 68
l Final Drive
205FO5512
30-15
Machine Model
Component Item Unit
PC3OOLC 1 PC4OOLC
Travel motor assembly
1. Cradle mounting bolt 28.25 +3.25
2. End cover assembly
@ Plug 5.4 20.6
I I 6.5 21.0 6.5 k1.0

@ Bleeder I I 0.9 +O.l 0.9 20.1
@ @ @ Plug I I 2.4 a0.4 2.4 20.4
@ Plug I I 11.25 21.25 11.25 f 1.25
@ End cover assembly mounting bolt 1 5825 58 &5
hj @ Mountmg plug of counterbalance valve 1% 26 +3

66.5 -+7.5
42.75 24.75
3. Plug of regulator piston I [ 37?4 37 a4
Power train 65 +5
0.5 20.1
1.35 51.5
2. Plug of check valve 1 1 5626 56 +6
3. Relief valve I I 3525 35 *5
4. Valve case mounting bolt 1 1 36+-2 36 +2
Swing machinery assembly mounting bolt I I 94.5 + 10.5 94.5 f 10.5
Swing machinery assembly
0 Carrier pin mounting bolt I I 18 +2 28.25 f 3.25
@ Carrier assembly plate mounting bolt I I 39.25 k4.25 39.25 k4.25
@ Bearing cage mounting bolt 6.75 +0.75 ~ 6.75 +0.75
Revolving frame assembly mounting bolt 94.5 + 10.5 ~ 94.5 +10.5
Swing circle mounting bolt 94.5 + 10.5 94.5 510.5
Recoil spring assembly
1. Installed load of spring kg 17,680 24,735
2. Free length of spring 795 857
Under-
carriage 3. Installed length of spring mm 648 707
Amount of slack for track 331 220 ~ 358 +20
Track roller assembly mounting bolt kgm 67 +7 ~ 91.5 28.5
30-16
l End Cover
F20705360
l Swing Machinery
30-I7
Machine Model
Component Item Unit
PC3OOLC 1 PC4OOLC
Main pump assembly

@ Plate mounting bolt 6.7 kO.7 6.7 20.7
@ Mounting bolt for hydraulic pump input

3.2 +0.3 3.2 20.3
shaft housing assembly
Main pump assembly
1. Rocker cam support mounting screw 3.2 2.03 3.2 kO.3
2. Plate mounting screw 3.2 +0.3 3.2 20.3
3. Bearing retainer mounting screw 3.2 20.3 3.2 +0.3
4. Rear pump mounting bolt 11.5 21.0 11.5 k1.0
5. Pump sub-assembly mounting bolt 18 22 18 22
6. Charging pump driven gear

Charging pump end 1 11.5 21.0 1 11.5 k1.0
Main shaft end 1 11.5 k1.0 I 11.5 21.0
7. End cap mounting bolt I 5.5 20.7 I 5.5 20.7
8. impeller mounting screw

Hydraulic
System 9. Servo piston cap mounting bolt 6.7 +0.7
10. Servo valve assembly mounting bolt 1 3.2 kO.3 1 3.2 rt0.3
11. TVC valve mounting bolt

12. CO l NC valve mounting bolt
13. Plug of strainer assembly
14. Sleeve nut of hose

CO l NC valve I 5 *2 I 5 +2
Charging pump I 23 23 I 23 +3
15. End cap mounting nut and bolt
Control valve assembly

@ Plug for check valve mount
@ Safety-suction valve I 19 21 I 19 +l
@ Jet sensor relief valve I 5.5 +0.5 I 5.5 +0.5
@ Main relief valve I 19 +l I 19 +l
30-18
l Main Pump
205FO5515
0 Control Valve
205FO55 I6
205F055 I7
205FO55 I8
205FO55 IS
30-19
Component item 1 Unit I+
7 Work equipment PPC valve assembly
@ Joint 11.25 21.25 11.25 21.25
@ Nut 11.5 k1.5 11.5 k1.5
5 Boom lock valve assembly

@ Safety valve 19 *l 19 21
@ Spool mounting plug 4 to.5 4 a0.5
@ Check valve body mounting bolt 11.25 + 1.25 11.25 f 1.25
s Hydraulic cylinder assembly

1. Bucket cylinder Head mounting bolt 38 25.5 54 28
2. Arm cylinder Head mounting bolt 54 +8 91 +14
Screw 6.75 20.75 16 +2
3. Boom cylinder Head mounting bolt 38 +5 54 r8
s
- Counterweight mounting bolt 185 210 390 a40
l Work Equipment PPC Valve l Boom Holding Valve
205FO552 I
205FO5520
30-20
LUBRICANT AND COOLANT TABLE
Unit: P
Machine Model PC3OOLC PC4OOLC
Remarks
Serial No. A30001 & up A40001 & up
Cooling water 30 4 34 P
Engine oil pan 18.9 Q 38 P
Swing machinery case 22.5 Q 22 0
Final drive case 7.4 P 11 4 I Each side
Hydraulic tank 195 P 255 P
PTO case 1.24 Q 1.07 e
Note: The values for oil volumes are the values for normal oil changes during inspection and maintenance.
30-21
REMOVAL OF GOVERNOR PC3OOLC
MOTOR ASSEMBLY
PC3OOLC PC4OOLC
A
Disconnect the cable from the negative
(-) terminal of the battery.
1. Remove control rod (1).

* Remove the pin at governor motor end.
2. Disconnect wiring connectors (2).
3. Remove governor motor assembly (3).
INSTALLATION OF GOVERNOR PC4OOLC

MOTOR ASSEMBLY
PC3OOLC PC4OOLC
l Carry out installation in the reverse order to

installation.
30-22
REMOVAL OF HYDRAULIC REMOVAL OF HYDRAULIC
COOLER ASSEMBLY COOLER ASSEMBLY
PCSOOLC PC4OOLC
YY Lower the work equipment to the ground Lower the work equipment to the ground
4 and stop the engine. Loosen the oil filler

cap slowly to release the pressure inside
the hydraulic tank.
and stop the engine. Loosen the oil filler
the hydraulic tank.
1. Remove hood.
1. Disconnect hose (1). (See Fl)
2. Remove net (2). (See Fl) YY Be careful when removing the hood,
* Loosen the mounting bolts and pull the A because it is under tension from the
4 spring.
net up to remove.
3. Remove the hydraulic oil cooler assembly (3). See Weight Table
(See F2)
* Sling the hydraulic oil cooler assembly, 2. Disconnect hose (1). (See Fl)
then remove the mounting bolts and 3. Remove net (2). (See Fl)
bracket, and pull the hydraulic oil cooler * Loosen the mounting bolts and pull the
assembly out from below. net up to remove.
* The bolts marked E are the mounting 4. Remove hydraulic oil cooler assembly (3).
bolts for the radiator and hydraulic oil (See F2)
cooler assembly, so do not remove * Sling the hydraulic oil cooler assembly,
them. (See F3) then remove the mounting bolts and
bracket, and pull the hydraulic oil cooler
See Weight Table
assembly out from below.
* The bolts marked B are the mounting
INSTALLATION OF HYDRAULIC bolts for the radiator and hydraulic oil
cooler assembly, so do not remove
COOLER ASSEMBLY them. (See F3)
See Weight Table

PC3OOLC
l Carry out installation in the reverse order to INSTALLATION OF HYDRAULIC

removal.
COOLER ASSEMBLY
l Refilling with oil
* Add engine oil to the specified level, and
run the engine to circulate the oil through PC4OOLC
the system. Then check the oil level l Carry out installation in the reverse order to
again. removal.
* Add engine oil to the specified level, and
run,the engine to circulate the oil through
the system. Then check the oil level
again.
30-24
Fl
F2070532E
F2
F3
5328
30-25
REMOVAL OF RADIATOR, Fl
HYDRAULIC OIL COOLER
A
3 Y
4
Lower the work equipment to the ground
and stop the engine. Loosen the oil filler
the hydraulic tank.
1. Drain cooling water.
2. Remove hood (1). (See Fl)
A4Y
Y Be careful when removing the hood,
because it is under tension from the
spring.
kg See Weight Table

EE?l
3. Remove hoses (2) and (3). (See F2)
4. Remove fan guard (4). (See F2)
5. Remove hoses (5). (See F3)
6. Remove radiator and hydraulic cooler
assembly (6). (See F4)
* Sling the radiator and hydraulic oil cooler
assembly, remove the upper mount
bracket and lower mount bolts, then
remove the radiator and hydraulic cooler
assembly.
See Weight Table
INSTALLATION OF RADIATOR,
HYDRAULIC OIL COOLER
ASSEMBLY

removal.
-k Add engine oil to the specified level, and
run the engine to circulate the oil through
the system. Then check the oil level
again.
205FO5552
l Refilling with water
-k Add water to specified level, and run the
engine to circulate the water through the F4
system. Then check the water level again.
205FO555:
30-26
30-27
REMOVAL OF ENGINE, INSTALLATION OF ENGINE,
HYDRAULIC PUMP ASSEMBLY HYDRAULIC PUMP ASSEMBLY
PC3OOLC PC3OOLC
A
Disconnect the cable from the negative e Carry out installation in the reverse order to
(-) terminal of the battery removal.
m
SLY Lower the work equipment to the ground
A and stop the engine. Loosen the oil filler u Mounting bolt:
4 cap slowly to release the pressure inside See Tightening Torques and
the hydraulic tank. Standard Values Table
Remove hydraulic tank strainer, and use tool l Refilling with oil and water
D to stop the oil. (See Fl) * Fill with oil and water to the specified
l When not using tool D, remove drain plug levels.
and drain the oil from hydraulic tank and
piping. See Lubricant and Coolant Table.
Q
:
- See Lubricant and Coolant Table l Bleeding air
* After removing the piping, mark with tags to * Bleed the air from the fuel system.
prevent mistakes when installing. * Bleed the air from the hydraulic pump.
1. Drain cooling water. For details, see TESTING AND
2. Remove hoses (1). (See P2) ADJUSTING, Bleeding air from all parts.
3. Disconnect wiring connector (2). (See P3) * After bleeding the air from the hydraulic
4. Remove sub-tank (3). (See P3) pump, check the hydraulic tank level and
* Remove the sub-tank together with the radiator (sub-tank) level.
bracket.
5. Remove tube (4). (See P2)
6. Remove air cleaner assembly (5). (See P2)
7. Disconnect wiring (6). (See P4)
a. Disconnect wiring connector (7). (See P4)
9. Disconnect ground connection (8). (See P4)
10. Disconnect fuel hoses (9). (See P5)
11. Disconnect wiring connectors (10). (See P5)
* Disconnect three connectors.
12. Remove fan guard (11). (See P5)
13. Remove fan (12). (See P5)
14. Disconnect wiring connector (13). (See P6)
15. Disconnect hoses (14). (See P7)
16. Remove hoses (15) and (16). (See F8)
17. Disconnect hoses (17). (See F8)
* Disconnect 5 pilot hoses.
18. Disconnect tubes (18). (See F8)
19. Disconnect wiring connector (19). (See F8)
20. Remove engine and hydraulic pump assembly
(20). (See F9) m
* When removing the engine and hydraulic
pump assembly, check that all the piping
and wiring has been removed, then
remove the assembly, taking care that
there is no interference.
el kg
See Weight Table
30-28
Fl
-D
I lOBV0032 I 12AD0016
P2 P7
F8
205FO5558
12ADO014 lZAD0020
F9
205F65559
REMOVAL OF ENGINE, 22. Remove engine and hydraulic pump assembly
(22). (See FlO) m
HYDRAULIC PUMP ASSEMBLY f When removing the engine and hydraulic
PC4OOLC pump assembly, check that all the piping
and wiring has been removed, then
A
Disconnect the cable from the negative remove the assembly, taking care there is
(-) terminal of the battery no interference.
*&S ee Weight Table

SLY Lower the work equipment to the ground
A and stop the engine. Loosen the oil filler
4 cap slowly to release the pressure inside INSTALLATION OF ENGINE,
the hydraulic tank.
HYDRAULIC PUMP ASSEMBLY
Remove hydraulic tank strainer, and use tool
D to stop the oil. (See Fl) PC4OOLC
l When not using tool D, remove drain plug
and drain the oil from hydraulic tank and 0 Carry out installation in the reverse order to
piping. removal.
: m
- See Lubricant and Coolant Table
* After removing the piping, mark with tags to u Mounting bolt:
prevent mistakes when installing. See Tightening Torques and
1. Drain cooling water. Standard Values Table
2. Disconnect hose (1). (See P2) l Refilling with oil and water
3. Disconnect wiring connector (2). (See P2) * Fill with oil and water to the specified
4. Remove hose (3). (See P2) levels.
5. Remove fan guard See Lubricant and Coolant Table.
6. Remove fan (4). (See P2) Q1
l Bleeding air
7. Disconnect fuel hoses (5) and (6) (See P3)
* Bleed the air from the fuel system.
* Bleed the air from the hydraulic pump.
* Disconnect three connectors
For details, see TESTING AND
9. Disconnect starting motor wiring (8).
ADJUSTING, Bleeding air from all parts.
(See P4)
* After bleeding the air from the hydraulic
pump, check the hydraulic tank level and
11. Remove heater hose (10). (See P5) radiator (sub-tank) level.
12. Remove sub-tank hose (11). (See P5)
13. Remove radiator inlet hose (12). (See P5) Fl
15. Remove side cover (14). (See P7)
* Sling the side cover together with the
frame, remove the mounting bolts, then
remove.
elkg See Weight Table

16. Remove frame (15). (See F7)
17. Disconnect ground connection (16). (See F8)
18. Disconnect hoses (17) and (18). (See F9)
19. Disconnect hoses (19). (See F9)
* Disconnect 5 pilot hoses lOBV0032
20. Disconnect tube (20). (See F9) m

30-30
P2 P7
12ADW18
2-a 12AD0024
P3
-16
12ADOO19
P4
12ADO021 12AD0026
P6 FlO
REMOVAL OF DAMPER
ASSEMBLY
1. Hydraulic pump assembly

l Remove hydraulic pump assembly.
For details, see REMOVAL OF
HYDRAULIC PUMP ASSEMBLY.
2. Remove damper assembly (1). (See Fl) m
INSTALLATION OF DAMPER
ASSEMBLY Xl 2AFOl

removal
m
& Damper spline:
Anti-friction compound (LM-P)
& Pump mounting bolt hole (2) only:
Liquid gasket (LG-6)
m Mounting bolt:
See Tightening Torques and
Standard Values Table
30-32
30-33
REMOVAL OF CENTER SWIVEL DISASSEMBLY OF CENTER
JOINT ASSEMBLY SWIVEL JOINT ASSEMBLY
A4Y
ZL Lower the work equipment to the ground
and release the remaining pressure in the
1. Remove cover (1). (See F4)
2. Remove snap ring (2). (See F4)
circuit. For details, see TESTING AND 3. Using push-puller @ , pull out swivel rotor (4)
ADJUSTING, Releasing pressure in and ring (3) from swivel shaft (5).
hydraulic circuit for machines with PPC (See F4, F5)
valve. 4. Remove snap ring (6), then remove oil seal
1. Disconnect hoses (l), (2), (3). (See Fl) (7) and slipper seal (8). (See F4)
2. Remove elbow (4). (See Fl)
3. Disconnect hose (5). (See F2)
4. Disconnect link (6). (See F2)
ASSEMBLY OF CENTER
5. Remove center swivel assembly (3). (See F4)
SWIVEL JOINT ASSEMBLY
f%ka See Weight Table
1. Assemble slipper seal (8) to swivel rotor (4).
(See F4)
2. Using push tool 0, press fit oil seal (7) to
INSTALLATION OF CENTER
swivel rotor (4), and install snap ring (6).
SWIVEL JOINT ASSEMBLY (See F4, F6)
l Carry out installation in the reverse order to e Lip of oil seal: Grease (G2-LI)
removal.
l Refilling with oil 3. Set swivel shaft (5) on block, then using push
f Run the engine to circulate the oil tool, tap swivel rotor (4) with a plastic
through the system. Then check the oil hammer and install. (See F4)
level again. -k When installing the rotor, be extremely
careful not to damage the lips of the
slipper seal and the oil seal.
4. Install ring (3), and secure with snap ring (2).
(See F4)
5. Fit O-ring and install cover (4). (See F4)
30-34
Fl F4
--- 205FO5567
..
5
205FO5568
J n
205FO542C
F3
205FO5569 205FO542 I
F6
205FO5422
30-35
REMOVAL OF FINAL DRIVE DISASSEMBLY OF FINAL
ASSEMBLY DRIVE ASSEMBLY
1. Sprocket 1. Draining oil

l Remove sprocket Remove drain plug and drain oil from final
*
A4Y Loosen the oil filler cap slowly to
release the pressure inside the
drive case.
:
hydraulic tank. - Final drive case:
2. Remove cover (1). (See Fl) See Lubricant and Coolant Table
* Using eyebolts, sling the cover, and 2. Cover
remove the mounting bolts. Using forcing screws and eyebolts , remove
See Weight Table cover (1). (See F4)
r5 kg 3. Thrust washer
3. Disconnect hose (2). (See F2) Remove thrust washer (2). (See F5)
4. Remove final drive assembly (3). (See F3) 4. No. 2 sun gear shaft
Remove sun gear shaft (3). (See F5)
f Sling the final drive assembly, then 5. No. 2 carrier assembly
remove the mounting bolts, and lift off the
1. Remove carrier assembly (4). (See F5)
final drive assembly.
2. Disassembly of carrier assembly
See Weight Table 0 Remove the mounting bolts (5), then
remove holder. (See F6)
ii) Set carrier assembly (4) in press, then
using push tool 0, pull out pin (6),
INSTALLATION OF FINAL and remove gear assembly (7).
DRIVE ASSEMBLY (See F7)
iii) Remove bearing (9) and spacer (10)
from gear (8). (See F8)
iv) Remove outer race (11). (See F8)
removal.
m
& Mounting bolt: Thread tightener (LT-2)
u Mounting bolt:
l Bleeding air
* Bleed the air from the motor
ADJUSTING, Bleeding air from travel
motor.
* After bleeding the air from the motor,
check the level of the hydraulic tank.
30-36
Fl F4
li 1
1.
205FO5570 205FO5425
F5
I
_ -I- II- -\ _\_
I 205FO557 I
F3
I LF-----
205FO5424 205FO5427 205FO542E
i 205FO5429
30-37
6. Ring gear
1. Remove ring gear (12). (See Fl)
2. Remove ring (10). (See Fl)
7. No. 1 sun gear
Remove sun gear (14). (See Fl)
8. Thrust washer
Remove thrust washer (15). (See F2)
9. No. 2 carrier assembly
1. Remove carrier assembly (16). (See F2)
i) Remove mounting bolts (17), then
ii) Set carrier assembly (16) in press,
then using push tool @ , pull out pin
(18), and remove gear assembly (19).
(See F4)
iii)Remove bearing (21) and spacer (22)
from gear (20). (See F5)
iv) Remove outer race (23). (See F5)
10. No. 1 ring gear
Remove ring gear (24). (See F6)
11. Gear coupling
Remove mounting bolts, then remove gear
coupling (25). (See F6)
12. Spacer
Remove spacer (26). (See F7)
13. Hub assembly
1. Using eyebolts @, remove hub assembly (27)
from travel motor. (See F8)
2. Remove floating seal (28). (See F9)
3. Remove cage (29), then remove floating seal
(30). (See FlO)
4. Remove bearings (31) and (32). (See FlO)
30-38
Fl F2 F8
I
1
15 16
27.
205FOS572 205FOSS73 I 205FO5437
F9 Fn
f
205FOS433 205FO5438 205FO5575
F
r
Y
23 21
205FOS434
:6 F7
24
25 I
2OSFOS574 205FO5436
30-39
ASSEMBLY OF FINAL DRIVE 2. Check adjustment of bearing clearance again.
Hook spring scale @ , in the tap hole for the
ASSEMBLY sprocket mounting bolt, pull to rotate the hub
on the shaft and measure the staring force.
1. Hub assembly (See F9)
1. Using push tool, press fit bearings (32) and * Starting force:
(31). (See Fl) See Tightening Torques and Standard
2. Using tool A,, install floating seal (30) to Values Table
cage, then install cage (29). (See Fl) * If the starting force is higher than the
& Cage mounting surface: standard value, there is a preload on the
Liquid gasket (LG-6) bearing, so adjust again.
u Mounting bolt: 4. No. 2 ring gear
See Tightening Torques and Fit ring gear (24). (See F8)
Standard Values Table & Ring gear mounting surface:
3. Using tool A,, install floating seal (28). Liquid gasket (LG-6)
(See F2, F3) * Coat liquid gasket only on ring gear upper
* When installing the floating seals, remove surface.
all oil and grease from the O-Ring and O-
ring contact surface, and dry completely
before installing.
* After installing the floating seals, coat the
sliding surfaces thinly with engine oil.
4. Using eyebolts @ , set hub assembly (27) on
travel motor, then using push tool, tap to
press fit bearing. (See F4)
2. Adjusting bearing clearance

1. Using tool A,, hold bearing, and temporarily
tighten 2 bolts. (See F5)
2. Rotate hub 2 - 3 turns to seat bearing.
3. Loosen bolts of tool A,, and then tighten
again to a torque of 2.0 kgm to 3.0 kgm.
(See F5)
4. Using a depth micrometer, measure stepped
difference a between end face and face of
shaft and inner race. (See F6)
* Measure two places and take the average
value.
5. Select a spacer to give a value of
a -0.1
-0.15 mm.
Ir Select the suitable thickness of spacer
from the 7 types of spacer.
6. Install the selected spacer (26). (See F7)
3. Gear coupling
1. Fit gear coupling (25), and tighten with
mounting bolts. (See F8)
& Mounting bolt:
Thread tightener (LT-2)
u Mounting bolt:
30-40
Fl :2 F6
A2
30 31 \
29 I
8
Inner
205FO5575 205FO5431 3 205FO5578
L
F7 F8
?------
24
25 /
205FO5509 205FO5436 205FO5574
F4 F9
\ I
I 205FO5437 205F2469A
F5
205FO5577
30-41
5. No. 1 carrier assembly (See F7)
1. Assembly of carrier assembly * When press fitting the pin, be
* The inner race, outer race, and spacer extremely careful of the angle of
form one set for the taper roller bearing, the pin, and rotate the gear while
so assemble the sets with the same press fitting.
marks. iv) Fit holder and tighten with mounting
0 Using push tool, press fit outer race bolts (5). (See F8)
(23) in gear (20). (See Fl) & Mounting bolt:
ii) Assemble spacer (22) and bearing Thread tightener (LT-2)
(21). (See Fl) u Mounting bolt:
iii) Set carrier assembly (16) in press, See Tightening Torques
assemble gear assembly (19), then and Standard Values
using push tool @ , press fit pin (18). Table
(See F2) 2. Align with teeth surface of ring gear, and
* When press fitting the pin, be install carrier assembly (4). (See F9)
extremely careful of the angle of
the pin, and rotate the gear while 10. No. 2 sun gear shaft
press fitting.
Assemble sun gear shaft (3). (See F9)
iv) Fit holder and tighten with mounting
bolts (17). (See F3)
11. Thrust washer
& Mounting bolt:
Assemble thrust washer (2). (See F9)
w Mounting bolt:
12. Cover
See Tightening Torques
Using eyebolts @ , install cover (1).
and Standard Values
(See FlO)
Table
a Cover mounting surface:
2. Install carrier assembly (16). (See F4)
a Mounting bolt:
6. Thrust washer
Assemble thrust washer (15). (See F4)
7. No. 1 sun gear

13. Refilling with oil
Assemble sun gear (14). (See F5)
Tighten drain plug and add engine oil
through oil filler to the specified level.
8. No. 2 ring gear
1
I. Install ring (13). (See F5) Final drive case:
& Mounting surface of ring: See Lubricant and Coolant Table
Liquid gasket (LG-6) * Carry out the final check of the oil level after
2. Align with teeth surface of carrier, and install installing the final drive assembly to the
ring gear (12). (See F5) machine. Check the level again at the
a Ring gear mounting surface: specified position.
9. No. 2 carrier assembly
1. Assembly of carrier assembly
* The inner race, outer race, and spacer
form one set for the taper roller bearing,
so assemble the sets with the same
marks.
0 Using push tool, press fit outer race
(11) in gear (8). (See F6)
ii) Assemble spacer (10) and bearing
(9). (See F6)
iii) Set carrier assembly (4) in press,
assemble gear assembly (7), then
using push tool @ , press fit pin (6).
30-42
Fl F6
23
205FO5434 205F05429
F7 F8
I
1
205FO544 I 205FO543i 205FO5442 205FO5427
J
F4 9
15 16
205FO5573 205F0542E j
5 Fl
205FO5579 205FO5425
30-43
DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT)
(HMV355ADT)
1. Motor assembly
Remove motor assembly from final drive
assembly.
f For details, see DISASSEMBLY OF FINAL
DRIVE ASSEMBLY.
2. Spring, pistons
Remove springs (1) and pistons (2).
f Mark match marks on the case, the
pistons and the springs.
3. Set motor assembly (3) in tool Gl. I F2070531 F20705362
4. End cover assembly, valve plate

1. Loosen plug (4) of checkvalve and mounting
plug (5) of counterbalance valve.
* If the end cover is an individual part, the
tightening torque is too large and it is
difficult to remove.
2. Remove safety valve assembly (6), then 6

remove end cover assembly (7).
j, Lift off using the mounting plug portion of
the counterbalance valve.
I 5 F20705363
A
The part to fit the lifting tool is small,
so be careful when lifting the
assembly.
3. Remove valve plate (8).

* If the valve plate is to be used again,
keep it in a safe place and be careful not
to damage the cylinder block mounting
surface.
e F20705364
F20705365
30-44
4. Disassemble end cover as follows. I
0 Remove bearing (9).

ii) Remove plug (4), then remove spring
(10) and valve (11).
iii) Remove plug (12), then remove
spring (13) and valve (14).
iv) Remove plug (15), then remove ball
(16).
v) Remove bleeder (17) and plug (18),
then remove spring (19) and spool
(20).
vi) Remove plug (21), then remove piston
(22).
vii) Remove plug (5), then remove spring
(23), ring (24) and spool (25).
viii) Remove dowel pin (26).
5. Spring
Remove parking brake spring (27).
10-S Q-24
8 fl
F20705367
1705366
6. Piston assembly
1. Set tool G2 to hole of brake piston.
2. Taking care that air does not leak from brake

piston hole, blow in air and remove brake
piston (28).
-k If the air is blown in at high pressure, the
brake piston may fly out.
7. Disc, plate
Remove plate (29), disc (30), and plate (31)
in order. I Tool settina bosition F2070536S
6. Cylinder block, piston assembly

1 Remove cylinder block (32) and piston
assembly (33).
28
F20205258
I 32
F2070537i
30-46
2. Disassembly cylinder block as follows.
i) Using tool G3, compress spring (34).
ii) Remove snap ring (35).
35
iii) Loosen nut of tool G3 gradually and
extend spring until tension is
removed. G3
iv) Remove seat (36), spring (34), seat
(37) and pin (38).
* Align the notched portion of the
washer (tool part number: 796-
36
765-1 150) with the head of the
snap ring. I
3d 3j F2070537:
3. Disassembly of piston assembly
i) Remove retainer guide (39).
ii) Remove piston (41) from shoe
retainer (40).
9. Rocker cam
Remove rocker cam (42).
10. Cradle
Remove 8 bolts (43) from final drive end,
then remove cradle (44).
40
F20705374
42
/
F20205264
11. Oil seal
1. Remove snap ring (45).
2. Using forcing screw (Dia. = 6 mm, Pitch =
l.O), remove cage (46).
3. Using push tool, remove oil seal (47).
12. Shaft assembly

1. Remove shaft assembly (48).
2. Remove outer race (49) and spacer (50) from
shaft.
3. Disassemble shaft assembly as follows.
i) Remove snap ring (51). FL20705377 II F20705371
ii) Remove ring (52)
iii)Using bearing puller, remove main
bearing (53).
iv) Using bearing puller, remove inner
race (54).
4. Outer race
Using push tool, remove outer race (55).
F20705380
F20705&1
30-48
ASSEMBLY OF TRAVEL MOTOR ASSEMBLY (HMV280ADT)
(HMV355ADT)
Precautions when assembling

1. Clean all parts, check for dirt or damage, and
repair any burrs.
2. Coat the rotating and sliding surfaces of all
parts with engine oil (EOlO-CD) before
installing.
f Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate.
iii) Main bearing and spacer
1. Set motor case (56) to tool Gl
2. Outer race
Using push tool, press fit outer race (55) to
case.
3. Shaft assembly
1. Assemble shaft assembly as follows.
i) Using tool G4, press fit inner race
(54) to shaft.
j, Press fit until it is in tight contact
with the end of the shaft.
ii) Using tool G5, press fit main bearing
55 F20705381
(53).
* Align the match marks on the
main bearing, and assemble.
* Press fit until the end face of the
main bearing inner race is in tight 54 G4
contact with the shaft.
F20705382
1
Front side Rear side

/Spacer
--t-
Outer race
Inner race
F20705385
30-49
iii) Install ring (52).
iv) Install snap ring (51).
52
2. Install spacer (50), and outer race (49) to
5
shaft assembly.
3. Using tool G6, press fit shaft assembly (48) in
case.
F2070538t
- F20705385
4. Oil seal
1. Using tool G7, press fit oil seal (47) in case.
* Use your fingertip to coat the
circumference of the lip portion with one
drop of grease at four places, then
F20705379
spread the grease uniformly around the
whole lip with your fingertip.
A Lip of oil seal: Grease (G2-LI-S)
I
2. Install case (46) to motor.
3. Secure with snap ring (45).
1 '7 F20705:611 F207053781
F20705377
30-50
5. Cradle
1. Align with dowel pin, set cradle (44) in
position, then tighten with 8 mounting bolts,
(43).
u Mounting bolt:
See Tightening Torques and Standard
Values Table
2 Fit dial gauge @ to motor case, move shaft
in axial direction, and measure amount of
movement (end play) of shaft in axial
direction.
* End play: 0.05 - 0.30 mm F20705375
j, If the end play is not within the standard

value, check the mounting condition of
the bearing in Step 2 and the mounting
condition of the cradle in Step 5-1.
6. Rocker cam
Install rocker cam (42).
* Install the flange of the rocker cam (thin
side) facing the small port hole side
(angle change piston side).
-k After installing the rocker cam, check that
the rocker cam moves smoothly by hand.
I
7. Cylinder block, piston assembly

I F20705387
1 Assemble piston assembly as follows.

i) Assemble piston (41) to shoe retainer
(40).
* The variation between the
thickness of the shoe lips must be
within 0.01 mm.
(Spare parts are supplied in a kit
within these dimensions.)
ii) Assemble retainer guide (39).
40
F20705374
30-51
2. Assemble cylinder block as follows.
i) Assemble pin (38), seat (37), spring
(34) and seat (36).
ii) Using tool G3, compress spring (34).
iii) Secure with snap ring (35).
3. Assemble cylinder block (32) and piston G3
assembly (33), align with shaft spline, then
install.
8. Disc, plate
Install plate (32), disc (30), and plate (29) in
order. $8 3j F20705373
da \ F20205262
32
II II
30-52
* The space between the cut teeth for the I
spline on the disc is uneven, so match
and fit on top then assembling.
* 6 plates and 5 discs.
9. Piston assembly
Assemble O-ring and backup ring, then install
brake piston assembly (28).
* Assemble so that the groove of the brake
piston is aligned with the end cover
dowel pin.
* Assemble the backup ring in the direction T F20705388
shown in the diagram.
10. Spring
Install parking brake spring (27).
* Assemble the spring so that the outside
circumference is facing in the closed
direction.
F20705389
Backup ring
O-rings
Backup ring
F20205298
11. End cover assembly l valve plate
1. Assemble end cover assembly as follows.
* Precautions when installing plug
Remove all grease from the plug, then
apply two drops of adhesive to the
thread (thread tightener: Loctite No.
638).
i) Using tool G8, install dowel pin (26).
* Install the dowel pin grooved side
facing the valve plate.
ii) Assemble spool (25), ring (24), and 16 f 0.3
spring (23) in order, then fit O-ring F20705390

and tighten plug (5) temporarily.
iii) Assemble piston (22) and fit O-ring.
Apply (2) drops Loctite 638 or 648 to
plug (21), then tighten.
u Plug:
iv) Assemble spool (20) and spring (19),

fit O-ring, then tighten plug (18) and
install bleeder (17).
Plug:
Bleeder:
v) Assemble ball (16) and fit O-ring.

Apply (2) drops Loctite 638 or 648 to
plug (15), then tighten.
F20705367
u Plug:
vi) Assemble valve (14) and spring (13),

then fit O-ring and tighten plug (12).
u Plug:
vii) Assemble valve (11) and spring (l),

then fit O-ring and tighten plug (4)
temporarily. 05366
viii) Install bearing (9).
30-54
2. Install end cover assembly as follows.
i) Install valve plate (8).
ii) Fit O-ring, then adjust valve plate so
that it matches dowel pin, then align
dowel pin with brake piston groove,
and install end cover assembly (7).
u Mounting bolt:
I
F2070536E
iii) Install safety valve assembly (6).
u Safety valve assembly:

iv) Apply (2) drops of Loctite 638 or 648

to plug (5) of counterbalance valve
and tighten. Apply (2) drops of Loctite
638 or 648 to plug (4) of check valve
and tighten.
Mounting plug of counterbalance

valve:
Plug of check valve:

12. Spring 0 Piston

Align match marks, assemble piston (2) and 6
spring (l), then fit O-ring and apply (2) drops
of Loctite 638 or 648 to plug and tighten.
u Plug: See Tightening Torques and I 5 F20705363

0 When storing or transporting the motor

assembly, your finger to coat the lip
use
surface of the oil seal thinly with engine oil
(EO-10).
F20705362 F20705361
30-55
CHECKING CONTACT BETWEEN
CYLINDER BLOCK AND VALVE PLATE,
AND ROCKER CAM AND CRADLE
1. Checking contact between cylinder block Cylinder block Centering tool
and valve plate.

1. Make a centering tool for the cylinder block
and valve plate.
* The tool can be made of a soft material
such as plastic or bakelite.
2. Remove grease from the parts to be checked
* Do not wipe with a cloth.
3. Set the tool in position, and coat the cylinder
block side with inspection paint.
* Apply the paint thinly.
4. Put the valve plate on top, push with a force
of 4 - 5 kg, and rotate 2 - 3 times.
5. Remove the valve plate, transfer the contact
surface to the tape, and check the contact 1
surface.
jr The standards for the contact surface are
as follows.
F20703037
Valve plate Cylinder block

F20705391
30-56
2. Checking contact between rocker cam and
cradle
1. Remove grease from the parts to be checked.
j, Do not wipe with a cloth.
2. Set the tool in position, and coat the cradle
side with inspection paint.
3. Put the rocker cam on top, push with a force
of 4 - 5 kg, and move 2 - 3 times from the
stopper contact position to the maximum
angle.
4. Remove the rocker cam, transfer the contact
surface to tape, and check the contact
surface.
* The standard for the contact surface shall
be a shown in the diagram below.
* If there is no contact at the center but
only at the outside, the contact is no
good.
Contact less
ontact 50% - 90%

ontact more
Contact 50% - 90%
Cradle
F20205290
Reference:
If the contact in not within the contact
standard value, when carrying out lapping,
always lap both parts together.
* Parts with scratches cannot be used.
30-57
REMOVAL OF SPROCKET REMOVAL OF SWING MOTOR
ASSEMBLY
1. Track shoe assembly
A4
l Remove track shoe assembly. % Y Lower the work equipment to the ground
For details, see REMOVAL OF TRACK and release the remaining pressure inside
SHOE ASSEMBLY. the circuit. For details, see TESTING AND
ADJUSTING, Releasing remaining
2. Jacking up machine pressure in hydraulic circuit for machines
with PPC valve.
-k Swing the work equipment 90 to jack up
the machine, then set block @ between 1. Disconnect hose (1). (See F2)
the track frame and the track shoe.
(See Fl) 2. Remove swing motor assembly (2). (See F3)
* Using eyebolts, sling the swing motor
3. Remove sprocket (1). (See Fl) assembly, then remove the mounting
* Sling the sprocket, then remove the bolts, and remove the swing motor
mounting bolts, and lift out the sprocket. assembly.
See Weight Table See Weight Table

& kg & kg
INSTALLATION OF SPROCKET INSTALLATION OF SWING

MOTOR ASSEMBLY
l Carry out the installation in the reverse order
to removal. l Carry out installation in the reverse order to
m removal.
a Mounting bolt: l Bleeding air
Thread Tightener (LT-2) * Bleed the air from the swing motor. For
u Mounting bolt: details. see TESTING AND ADJUSTING,
See Tightening Torques and Bleeding air from all parts.
Standard Values Table * After bleeding the air from the swing
motor, check the level in the hydraulic
tank.
30-58
Fl F2
I -
r ezz-7
- F20505315 F20705329
F3
F20705330
30-59
DISASSEMBLY OF SWING MOTOR ASSEMBLY (KMF160)
1. Motor assembly
Set swing motor assembly (1) on tool Hl.
2. Valve case assembly

1. Remove mounting bolts (2) of valve case
2. Using eyebolts @ (Thread dia. = 12 mm,
Pitch = 1.75 mm), lift off valve case (3).
3. Relief valve
Remove relief valve assembly (4).
4. Check valve
Remove plug (5), then remove spring (6) and
valve (7).
5. Belleville spring
Remove belleville spring (8).
6. Valve plate
Remove valve plate (9).
7. Cylinder block
Remove cylinder block (10).
F20703013
F20705391
F20705396
30-60
8. Spring
Remove spring (11) and center ring (12).
9. Retainer
Using tool H2, remove 7 mounting screws,
then remove retainer (13).
10. Shaft, piston

Remove center shaft (14) and 7 pistons (15).
11. Brake piston

1. Remove brake piston (16).
* Using an oil leak tester, supply air under
pressure through the oil port and remove
the brake piston.
* If the air pressure is too high, the piston
will fly out, so raise the air pressure
slowly.
2. Remove O-ring (17) and backup ring (18)
from piston.
12. Plate, disc

1. Remove plate (19) and disc (20).
2. Remove plate (21).
F20705399 F20705400
13. Cover
1. Remove case assembly from tool Hi and turn \
over.
2. Remove snap ring (22), then remove cover
(23).
1
14. Shaft assembly
1. Remove snap ring (24), then remove spacer
(25).
F20703014
F20705402
30-61
2. Set case assembly in press, then remove
shaft assembly (26) from case (27).
3. Remove bearing (28A) and (288) from shaft
(29).
15. Bearing, spacer, belleville spring

1. Remove bearing and outer race (30).
2. Remove spacer (31) and belleville spring
(32).
16. Outer race

Remove outer race (33A).
1F20705403 97
32 31
(i i
F2070540E, F20705406
wn7n54n7
30-62
ASSEMBLY OF SWING MOTOR
ASSEMBLY (KMFI 60)
Precautions when assembling

* Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with
engine oil before installing.
* Always use all the parts supplied in the kit.

Do not reuse the retainer mounting screw.
1. Shaft assembly
1. Install bearing outer race (33A). (Outside
diameter: 140 mm) to brake case (27).
2. Using tool H3, press fit bearing (28B) (Inside
diameter: 65 mm) to shaft (29).
f Press fit until the end face of the bearing
inner race is in tight contact with the
shaft.
3. Install outer race (338) and spacers (34) and
(35).
4. Using tool H3, press fit bearing (28A) (Inside
diameter: 65 mm).
* Do not use any bearing if it is uncertain
which set it belongs to.
5. To prevent the drive shaft from being at an
angle, set tool H4 in position, and install
shaft (29) to brake case (27). 35 F20705401
* Push in the outer race with a plastic bar
from groove @ . (Do not use a metal bar;
this will damage the outer race.)
H4
-31 Ia- F20705409
30-63
6. Assemble spring (33) and spacer (32), then I
using tool. H5, install outer race. (30).
(Outside diameter: 120 mm)
* Align the inside diameter (shaft end) to
install the spring. (With the outside
diameter open).
32
7. Support shaft (26) at both ends, then use tool
H3 to press fit bearing (28) (inside diameter:
65 mm).
* The press-fitting force is 400 - 2035 kg,
but up to 2200 kg is possible (when
coated with engineoil). _ IP I
F2070541C
* If the press-fitting force is less than 2200
kg, always push in at 2200 kg after press
fitting.
*Press fit until the spacer is in tight
contact.
a. Select thickness of 2 spacers (25) using
procedure and table below.
i) Measure dimension @ between seat
portion @ of shaft and end face of
inner race of bearing (28), then select
2 spacers from table below.
F20705411
F20705412]
Spacer selection table
r
Unit: mm
Necessary spacer Select 2 spacers marked o or o from table below.
Measured value of
No. dimension a
thickness of(possible
thickness as
2 spacers) Spacer thickness
1 2.3 2.5 2.7

1 1 12.250 - 12.449 4.6 00
I I
2 12.450 - 12.649 4.6 0 0
3 12.650 - 12.849 5.0 0 00 0
4 12.850 - 13.049 5.2 0 0
5 13.050 - 13.249 5.4 00
Spacer part number 706-77-42440 706-77-42450 706-77-42460
30-64
9. Assemble spacer (25), then install snap ring
(24).
* Check that the snap ring is fitted securely
in the groove.
10. Support motor case, push end face of shaft
(26) at 500 - 2200 kg in direction of arrow,
and check that movement when doing this is
0.1 - 0.4 mm.
* When doing this, check that the spacer
(25) cannot be moved by hand.
* If the movement of the shaft is not within
the standard valve, adjust the spacer so F207054 .13
-
that it comes within the standard valve.
11. Rotate shaft at a speed of 1 turn every
approx. 5 seconds and measure the rotating
torque.
* Rotating torque: 0.15 - 0.5 kgm
* Supply the bearing with ample oil when
500 - 2200 kg
measuring.
w
* If the rotating torque is not within the
standard valve, replace the bearing with
a new bearing.
2. Cover
1. Press fit oil seal and fit O-ring, then install
F20705414
cover (23).
2. Install snap ring (22).
3. Plate, disc
1. Set vase assembly on tool H 1.
2. Install plate (21).
3. Install disc (20) and plate (19).
F20705415
F20703014
30-65
4. Brake piston
1. install O-ring (17) and backup ring (18) to
piston.
* See illustration for direction of installation
of O-ring and backup ring.
2. Install brake piston (16).
5. Piston, shaft
1. Set 7 pistons (15) and center shaft (14).
2. Install retainer (13) and using tool H2, tighten
7 mounting screws.
& Mounting screw: Adhesive (LT-2) F20705400 F202052E
u Mounting screw:
Values Table
* Direction of installation may be clockwise
or counter-clockwise.
* After installing, check that the pistons
move smoothly and can fall under its own
weight. If the movement is not smooth,
loosen, then tighten again.
* The screws must not be used again.
3. After installing mounting screws, measure
clearance of piston ball.
i) Set dial gauge @ on ball. F20705399 F2070539Z
ii) Pull piston in axial direction of pump
sub assembly, and measure clearance
between ball and retainer. Play
* Ball clearance: Max. 0.25 mm
6. Spring
Fit center ring (12) and install spring (11).
7. Cylinder block
Install cylinder block (10).
I=2070301 1 F20703012
F20705396
30-66
6. Valve plate
install valve plate (9).
9. Belleville spring
Set belleville spring (8).
* See illustration for direction of installation
of belleville spring.
--
F20705394
F20705416
10. Check valve

Fit valve (7) and spring (6), fit O-ring, the
install plug (5).
u Plug: See Tightening Torques and
11. Relief valve

Fit O-ring and install relief valve assembly
(4).
u Relief valve: See Tightening Torques
and Standard Values Table F20703013 5
12. Valve case assembly

1. Fit O-ring and using eyebolts @ (Thread
dia. = 12 mm, Pitch = 1.75 mm), set valve
case (3).
Correctly match dowel pin and valve
plate.
2. Tighten mounting bolts (2).
m Mounting bolt:
Values Table
-2
13. Inspection of rotating torque of drive shaft
F20705417
1. From C port, apply more than 25 25 kg/cm*
pressure, then release brake.
2. Set tool H6 and rotate drive shaft at a speed
of 1 turn every approx. 5 seconds and
measure the rotating torque.
* Check that there is no uneven rotation in
the rotating torque.
Uneven width: Within 0.15 kgm
Rotating torque: 0.6 - 15.5 kgm range
-k If the uneven width is more, reassemble.
F2070541E
REMOVAL OF SWING REMOVAL OF SWING
MACHINERY ASSEMBLY MACHINERY ASSEMBLY
PC3OOLC PC4OOLC
1. Swing motor assembly

1. Swing motor assembly
l Remove swing motor assembly.
0 Remove swing motor assembly.
For details, see REMOVAL OF SWING
For details, see REMOVAL OF SWING
MOTOR ASSEMBLY
MOTOR ASSEMBLY
2. Remove swing machinery assembly (1).
2. Disconnect hoses (1) and (2). (See F2)
(See Fl) m
3. Remove bracket (3). (See F2)
* Sling the swing machinery assembly, then
4. Remove clamp (4). (See F2)
using the forcing screws, remove the
swing machinery assembly. 5. Remove swing machinery assembly (5).
(See F3) m
el kg See Weight Table * Sling the swing machinery assembly, then
using forcing screws, remove the swing
machinery assembly.
INSTALLATION OF SWING
See Weight Table
MACHINERY ASSEMBLY
PC3OOLC
INSTALLATION OF SWING
l Carry out installation in the reverse order to MACHINERY ASSEMBLY
removal.
m
PC4OOLC
u Mounting bolt:
removal.
m
* Run the engine to circulate the oil
through the system. Then check the oil u Mounting bolt:
level again. See Tightening Torques and
* Run the engine to circulate the oil
through the system. Then check the oil
level again.
30-68
Fl F2
I
F3
30-69
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Remove drain plug and drain oil from swing
machinery case.
:
- Swing machinery case:
See Lubricant and Coolant Table
2. Cover assembly
1. Remove mounting bolts, then using eyebolts
0, remove cover assembly (1). (See Fl)
* There are 9 mounting bolts at the top and
three mounting bolts at the bottom.
2. Disassembly of cover assembly
i) Remove cages (2) and (3). (See F2)
* Check the number and thickness
of the shims, and keep in a safe
place.
ii) Remove outer races (4) and (5) from
cage. (See F3, F4)
iii) Remove mounting bolts, then remove
cover (6). (See F5)
iv) Remove gear assemblies (7) and (8).
(See F6)
v) Remove bearings (9) and (10) from
gear. (See F7,F8)
vi) Remove inner races (12) and (13)
from case (11). (See F9)
3. Shaft
Remove shaft (14). (See FlO)
4. Ring gear
Remove ring gear (15). (See FlO)
5. Carrier assembly
1. Remove mounting bolts, then remove carrier
assembly (16). (See Fll)
i) Remove mounting bolts (17), then
ii) Set carrier assembly (16) in press,
and using push tool @ , remove pin
(18), then remove gear assembly (19).
(See F12,F13)
iii) Remove holder (20). (See F13)
30-70
Fl F2 F9
i
205FO5444 205FO5445 205FO5452
F3 F:4 FIO
I
205FO5446 205FO5447 205FO5453
F5 F6 31 F12
18 17
205FO5448 205FO5449 I 205FO5454 205FO5455
:7 F8 F13
1 10
205FO5450 205FO545 1 ia 205FO5456

iv) Remove bearing (22) and spacer (23)
ASSEMBLY OF SWING
from gear (21). (See Fl)
v) Remove inner race (24). (See Fl) MACHINERY ASSEMBLY
6. Shaft assembly 1. Case assembly

1. Loosen mounting bolts (25). (See F2) 1. Using push tool, press fit bearing (33).
2. Set shaft and case assembly (26) in press, (See F8)
and using push tool 0, remove shaft 2. Assemble spacer (29). (See F9)
assembly (27). (See F3) 3. Using push tool, press fit bearing (30).
3. Disassembly of shaft assembly (See F9)
i) Remove spacer (29) from shaft (28).
(See F4) 2. Shaft assembly
ii) Remove bearing (30). (See F4) 1. Assembly of shaft assembly
iii) Remove cover (31). (See F5) i) Using push tool @ , press fit oil seal
iv) Remove oil seal (32) from cover. (32). (See FlO,Fll)
(See F6) & Outer circumference of oil seal:
7. Case assembly ii) Assemble cover (31) to shaft (28).
Remove bearing (33). (See F7) (See F12)
& Grease (G2-LI)
iii)Set case assembly in press, and
press fit shaft assembly (27).
(See F13)
iv) Tighten mounting bolts (25). (See
F13)
x=Z& Cover mounting surface:
3. Carrier assembly
i) Using push tool, press fit inner race
(24). (See F14)
ii) Assemble spacer (23) and bearing
(22) to gear (21). (See F14)
30-72
Fl :g--
205FO5457 205FO5463 205FO546f
FlO '11
32
205FO5458 205FO5459 205FO5465 205FO5462
5 F12 F13
28 28
31
205FO5460 205FO5461 205FO5461 205FO546e
F6 17 F14
32
205FO5462 205FO5463 205FO5457
30-73
iii) Assemble holder (20). (See Fl) 7. Adjusting preload of bearing
iv) Set carrier assembly (16) in press, 1. Remove O-ring, and install cages (3) and (2).
then assemble gear assembly (19), (See F13)
and using push tool @ , press fit pin f Install 2 bolts each at a and b.
(18). (See F2) f Rotate the spline shaft for the motor 5 - 6
* Be careful to keep the pin straight turns, then tighten the bolts to the
and rotate the gear when press specified torque.
fitting the pin. u Bolt:
* After press fitting the pin, check See Tightening Torques and
that the gear rotates smoothly. Standard Values Table
v) Fit holder and tighten with mounting
bolts (17). (See F3)
K& Mounting bolt:
m Mounting bolt:
2. Fit carrier assembly (16), and tighten with
mounting bolts. (See F4)
&?&, Mounting bolt:
u Mounting bolt:
4. Ring gear
Install ring gear (15). (See F5)
Q Ring gear mounting surface:
5. Shaft
Assemble shaft (14). (See F5)
6. Cover assembly
1. Assembly of cover assembly
i) Using push tool, press fit inner races
(13) and (12) in case (11). (See F6)
ii) Using push tool @ , press fit bearing
(10) in gear. (See F7)
iii) Using push tool @ , Press fit bearing
(9) in gear. (See F8)
iv) Install gear assemblies (8) and (7).
(See F9)
v) Fit cover (6) and tighten with
mounting bolts. (See FlO)
& Cover mounting surface:
vi) Using push tool, press fit outer races
(5) and (4) in cage. (See Fl 1 ,F12)
30-74
Fl F2
205FO5467 II 205FO5468 1 205FO5469
F9 FlO
I Y
205FO5455 205FO5454 205FO5449 I/ 205F0544E
-5 :I1 F12
-r-----
205FO5453 205FO5447 II 205FO5446

L
F13
b
a .
205FO5452 205FO547
2. Selecting shims
Measure points c and cl with a feeler
gauge, then select shims from the table
below.
mm
Clearance Above 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4
at c, d Below 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6
Shim thickness 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7
* Types of shims:
t = 0.4, t = 0.5, t = 0.6
t = 0.7, t = 0.8
3. Remove cages (3) and (2). (See Fl)
4. Fit O-rings and install cages (3) and (2).
(See Fl)
a Mounting bolt:
* Check that the spline shaft for the motor
mount rotates smoothly by hand.
5. Using eyebolts 0 , install cover assembly
(1). (see Fl) -
e Cover assembly mounting surface:
Refilling with oil

Tighten drain plug and add engine oil
through oil filler.
Swing machinery case:
See Lubricant and Coolant Table
30-76
C
205FO5471
F2
I
w u 205FO544L
30-77
REMOVAL OF REVOLVING 13. Remove revolvina frame assemblv (9).
(See F5) m -
FRAME ASSEMBLY * For the mounting bolts marked 0, move
the control box assembly, remove the
1. Remove boom cylinder assembly. grommets, then remove the mounting
l For details, see REMOVAL OF BOOM bolts. (See F6)
CYLINDER ASSEMBLY. f Leave 2 bolts each at the front and rear,
2. Remove work equipment assembly. then use a lever lock to adjust the
l For details, see REMOVAL OF WORK balance of the revolving frame assembly
EQUIPMENT ASSEMBLY. to the front, rear, left, and right, then
3. Remove counterweight. remove the remaining bolts, and remove.
4. Remove cab. * When removing the revolving frame
assembly, be careful not to hit it against
l For details, see REMOVAL OF CAB
the center swivel joint assembly.
ASSEMBLY.
5. Remove hood (1). (See Fl)
* Y Be careful when removing the hood,
because it is under tension from the
Aka See Weight Table
+
spring.
See Weight Table

& kg
6. Disconnect hose (2) (See F2) INSTALLATION OF REVOLVING
7. Disconnect wiring connector (3). (See F2) FRAME ASSEMBLY
6. Remove frame (4). (See F2)
l Remove the frame together with the sub-
tank
removal.
* The length of the mounting bolts differs
10. Remove cover (6). (See F3) according to the mounting position, so
See Weight Table refer to the diagram when installing.
& kg (See F7)
11. Disconnect hoses (7). (See F4) Length of mounting bolts marked s
12. Remove link (8). (See F4) PC300LC :155mm
PC4OOLC :175mm
Length of other mounting bolts
PC3OOLC :140mm
PC4OOLC :165mm
e Swing circle mating surface:
&& Mounting bolt:
u Mounting bolt:
Values Table
30-78
Fl -5
205FO555C )
F2 F6
F
205FO5582
F3 F7
3% 205FO5586
205FO5584
205FO5585
30-79
REMOVAL OF SWING CIRCLE REMOVAL OF IDLER, RECOIL
ASSEMBLY SPRING ASSEMBLY
1. Remove revolving frame assembly. 1. Track shoe assembly

For details, see REMOVAL OF REVOLVING 0 Remove track shoe assembly.
FRAME ASSEMBLY. For details, see REMOVAL OF TRACK
2. Remove swing circle assembly (1). (See Fl) SHOE ASSEMBLY.
* Remove 36 mounting bolts. 2. Remove idler and recoil spring assembly (1).
(See F3)
See Weight Table
r5 kg * Sling the idler and recoil spring assembly,
and pull out to the front to remove.
See Weight Table
& kg
3. Disconnection of idler and recoil spring
INSTALLATION OF SWING assembly
CIRCLE ASSEMBLY Secure recoil spring with block @ , then sling
idler assembly, remove mounting bolts, and
0 Carry out installation in the reverse order to disconnect idler assembly (2) and recoil
removal. spring assembly (3). (See F4)
* Make match marks on the matching
* PC3OOLC surface of the idler and the recoil spring.
Install swing circle assembly (1) with the See Weight Table
inside soft zone (S) mark facing 90 to the
right.
* PC400LC
Align the positions of the (S) mark of the INSTALLATION OF IDLER,
inner circle soft zone and the outer circle soft
zone (plug) when installing the swing circle
RECOIL SPRING ASSEMBLY
assembly. (See F2)
Mounting bolt: l Carry out installation in the reverse order to
removal.
Mounting bolt:
Circle teeth surface:

Grease (MPG)
Amount of grease: 334 (PC300LC)
35e (PC400LC)
30-80
Fl F3
---LA F20505318 205FO5477
F2 F4
F20705331 205FO5478
30-81
DISASSEMBLY OF RECOIL ASSEMBLY OF RECOIL SPRING
SPRING ASSEMBLY ASSEMBLY
1. Remove piston assembly (2) from recoil 1. Assembly of piston assembly

spring assembly (1). (See Fl) 1. Assemble ring (14) and U-packing (13) to
2. Disassembly of recoil spring assembly piston (9), and secure with snap ring (12).
1. Set recoil spring assembly (1) to tool B. (See Fl)
(See F2) 2. Fit valve (11) and secure with lock plate (10).
*
A
4
Y The spring is under large installed
load, so be sure to set the tool
(See Fl)
2. Assembly of recoil spring assembly
properly. Failure to do this is 1. Assemble dust seal (8) to cylinder (7).
dangerous. (See Fl)
* Spring installed load: & Lip of dust seal: Grease (G2-LI)
See Tightening Torques and Standard 2. Assemble cylinder (7) and yoke (6) to spring
Values Table (5), and set in tool C. (See Fl)
2. Apply hydraulic pressure slowly to compress 3. Apply hydraulic pressure slowly to compress
spring, then remove lock plate (3), and spring. tighten nut (4) so that installed length
remove nut (4). (See Fl) of spring is dimension a, then secure with
* Compress the spring to a point where the lock plate (3). (See F3)
nut becomes loose. * Installed length of spring:
f Release the hydraulic pressure slowly and See Tightening Torques and Standard
release the tension of the spring. Values Table
* Free length of spring: 4. Remove recoil spring assembly (1) from tool
See Tightening Torques and Standard B. (See F2)
Values Table 3. Assemble piston assembly (2) to recoil spring
3. Remove yoke (6), cylinder (7), and dust seal assembly (1). (See Fl)
(8) from spring (5). (See Fl) JC& Piston: Grease (G2-LI)
3. Disassembly of piston assembly -k Assemble the cylinder assembly so that
1. Remove lock plate (10) from piston (9), then the mounting position of the valve is
remove valve (11). (See Fl) exactly at side.
2. Remove snap ring (12), then remove U-
packing (13) and ring (14). (See Fl)
30-82
Fl
1
205FOS479
2 F3
205FOS48 205FO5587
30-83
REMOVAL OF TRACK ROLLER REMOVAL OF CARRIER
ASSEMBLY ROLLER ASSEMBLY
1. Loosen lubricator (1). (See Fl) 1. Track shoe assembly

* Loosen the lubricator, and loosen the * Using hydraulic jack 0, push up the
track shoe tension. track to a position where the carrier roller
*
A4Y The adjustment
extremely high
cylinder
pressure.
is under
Never 2.
assembly can be
Remove carrier roller
removed. (See Fl)
loosen the lubricator more than one m
turn. If the track tension is not
relieved, move the machine See Weight Table
r5 kg
backwards and forwards.
2. Remove track roller assembly (2). (See F2)
m
* Remove the mounting bolts of the track
roller, then swing the work equipment
INSTALLATION OF CARRIER
90, jack up the machine, and remove ROLLER ASSEMBLY
the track roller assembly.
See Weight Table l Carry out installation in the reverse order to

removal.
m
AZ& Mounting bolt:
ROLLER ASSEMBLY

removal.
m
-k Set the track roller assembly to the
mounting position, then operate the
control levers to lower the machine
slowly, and tighten the mounting bolts
temporarily.
A Mounting bolt:
a Mounting bolt:
* Operate the control levers to lower the
machine completely to the ground, then
tighten the mounting bolts fully.
30-84
Fl F3
-__
__
3
F20505320 F20505322
'2
F20505321
30-85
REMOVAL OF TRACK SHOE REMOVAL OF CHARGING
ASSEMBLY PUMP ASSEMBLY
1. Positioning
Ir
track
Stop the machine in a position where the
A
Y Y
4
track can be laid out to the front and rear levers several times to release the
when the master pin is pulled, then remaining pressure in the hydraulic
loosen the lubricator (1) to relieve the piping. Then loosen the oil filler cap
track tension. (See Fl) slowly to release the pressure inside the
A
* Y The adjustment cylinder is under hydraulic tank.
4 extremely high
loosen the lubricator
pressure. Never
more than one
Remove hydraulic tank strainer, and use tool
D to stop the oil. (See F5)
turn. If the track tension is not * When not using tool D, remove drain plug
relieved, move the machine and drain the oil from the hydraulic tank
backwards and forwards. and piping.
2. Remove master pin (2) m :
-k Using tool C, pull out the master pin. u See Lubricant and Coolant Table
(See F2) 1. Disconnect hoses (1). (See F6)
3. Remove track shoe assembly (3) m 2. Disconnect tube (2). (See F6)
* Move the machine forward so that the 3. Remove charging pump assembly (3).
position of the temporary pin is at the (See F6)
front of the idler, then put block @ in
contact with the grouser, pull out
temporary pin @ , and remove the dust
seal. (See F3) INSTALLATION OF CHARGING
* Drive the machine in reverse to lay out PUMP ASSEMBLY
the track.
removal.
INSTALLATION OF TRACK l Refilling with oil
* Refill to the specified level, and run the
SHOE ASSEMBLY engine to circulate the oil through the
system. Then check the oil level again.
l
m
Carry out installation
removal.
in the reverse order to
%a 1 See Lubricant and Coolant Table
* Using tool C, press fit the master pin.

m
* Deflection of track a (See F4)
Values Table
30-86
Fl 5
I I
-D
F20505320 FI 1229 1
F2 6
F20505323
F3
F4
I I
Track frame
J
Track shoe
F9883
30-87
REMOVAL OF HYDRAULIC REMOVAL OF HYDRAULIC
PUMP ASSEMBLY PUMP ASSEMBLY
PC3OOLC PC4OOLC
and stop the engine. Operate the control A
% Y Lower the work equipment
4
to the ground
levers several times to release the levers several times to release the
remaining pressure in the hydraulic remaining pressure in the hydraulic
piping. Then loosen the oil filler cap piping. Then loosen the oil filler cap
slowly to release the pressure inside the slowly to release the pressure inside the
hydraulic tank. hydraulic tank.
Remove hydraulic tank stainer, and use tool a Remove hydraulic tank stainer, and use tool
D to stop the oil. (See Fl) D to stop the oil. (See F5)
* When not using tool D, remove drain plug * When not using tool D, remove drain plug
and drain the oil from the hydraulic tank and drain the oil from the hydraulic tank
and piping. and piping.
: :
- See Lubricant and Coolant Table u See Lubricant and Coolant Table
l Draining oil from damper chamber 0 Draining oil from damper chamber
: :
- See Lubricant and Coolant Table - See Lubricant and Coolant Table
1. Remove side cover (1). (See F2) 1. Remove side cover (1). (See F6)
* Sling the side cover and the frame as one * Sling the side cover and the frame as one
unit, remove the mounting bolts, then unit, remove the mounting bolts, then
remove. remove.
See Weight Table See Weight Table

& kg & kg
2. Remove tube (2). (See F3) 2. Remove frame (2). (See F6)
3. Disconnect hoses (3), (4), (5). and (6). 3. Disconnect tube (3). (See F7)
(See F3) * Disconnect 5 hoses (6). 4. Disconnect hoses (4), (5), (6), and (7).
4. Disconnect wiring connector (7). (See F3) (See F7)
5. Remove bracket (8). (See F3) * Disconnect 5 hoses (7).
6. Remove hydraulic pump assembly (9). 5. Disconnect wiring connector (8). (See F7)
(See F4) 6. Remove hydraulic pump assembly (9).
(See F8)
See Weight Table
See Weight Table
PUMP ASSEMBLY
PC3OOLC and PC4OOLC
removal.
& Pump mounting bolt hole (2) only:
* Refill to the specified level, and run the
engine to circulate the oil through the
system. Then check the oil level again. I Xli.AFOll
* Add oil to the damper chamber to the l Bleeding air

specified level. f Bleed the air from the hydraulic pump.
Q See Lubricant and Coolant Table For details,

ADJUSTING,
see TESTING AND
Bleeding air from all parts.
-k After bleeding the air from the hydraulic
pump, check the hydraulic tank level.
30-88
Fl :5
FI 1229 FI 1229
F2 6
Ti \\
205FO5589 205FO5592
F3 F7
3
205FO5593
F8
*I
+i4zLzA 1
T
205FO559I I4
:
30-89
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV160+160)
Note) The procedure for disassembly is

*\ Fz==?l
basically the same for both front and rear \ \\-
pumps, so this section describes the \
1
disassembly of the front pump only.
When there are differences, however,
\
they will be notes at the appropriate
place in the description.
1. Rear pump assembly

1. Set pump assembly (1) in tool Jl.
2. Remove hoses (2) and (3). 4
3. Remove 4 nuts (4) of front pump end, then lift -+. F20705419
off rear pump assembly (5).
* Separate end cap at center.
f Loosen 4 rear pump end cap mounting
bolts (Width across flats = 30 mm).
2. NC, CO*NC valve assembly

Remove TVC valve (6) and CO*NC valve
assembly (7) as a set.
* TVC valve installed only front pump.
3. Servo valve assembly

Remove servo valve assembly (8).
20705420
F20705421
30-90
4. Charging pump drive gear (Front pump
onW
1. Remove charging pump drive gear as follows.
i) Remove cover (9).
ii) Using tool 52, remove screw (lo),
then remove plate (11).
iii) Using puller @ , remove gear (12).
2. Remove charging pump driven gear as
follows.
i) Stop gear from turning, and remove
bolt (13) and plate (14).
ii) Using puller 0, remove gear (15). F20705422
5. End cap
1 Using puller 0, push shaft (16) to end cap
side, then hold tension of spring inside
cylinder block.
F20705425 F2070542
F20705427
* For rear pump, remove cover (17), bolt
(18), and
mounting
plate (19), then use the
holes of plate (19) and the
:919
cover to set puller @ in position.
2. Remove coupling (20).
3. Using tool 53, remove 4 screws (21).
4. Remove impeller (22).
5. Remove snap rings (23).
6. Remove spacers (24) and (25).
7. Remove thrust bearings (26).
* Impeller not installed on rear pump, so
remove plate (27), then remove end cap. F20705428
F207054
F20705432
30-92
8. Loosen 7 bolts gradually, and when spring in
cylinder block is fully extended, remove end
cap (28).
* Before removing end cap (28), remove
the puller @ installed in Step 5-1.
9. Remove bearing (29) from end cap (28).
10. Remove valve plate (30).
* When removing valve plate, be careful not
to damage valve plate and cylinder block
because valve plate adheres to cylinder
block.
6. Pump sub-assembly
1. Remove cradle mounting bolts.
2. Support shaft on front and rear, and remove
pump sub-assembly (31) from case.
7. Charging pump assembly

1. Remove charging pump assembly (32).
2. Remove plug (33A), then using tool J4,
remove strainer (33B).
F2070543!
F20705431
J4 333
F20705438
a. Charging pump drive shaft assembly (front
pump only)
1. Remove housing (34).
2. Using push tool, remove oil seal (35) from
housing (34).
3. Remove drive shaft assembly (36) by
knocking out from charging pump end.
4. Disassemble drive shaft assembly as follows.
i) Remove key, then push tool to
remove collar (38), bearing (39),
collar (40), and bearing (41) from
shaft (37). F20705439 F20705440
ii) Remove pin (42), then remove
coupling (43) from shaft (37).
iii) Remove snap ring (45) from case.
9. Servo piston assembly

1. Remove caps (46) and (47), and shims (48)
and (49) by using forcing screw.
2. Remove spring (50).
3. Remove servo piston (51).
F20705443
30-94
1. Cylinder, shaft
1. Set pump sub-assembly in a vice.
* Be careful not to damage the flange
surface of the cradle.
2. Remove slider (53) and cylinder block (54).
3. Disassembly of cylinder block
Remove snap ring (55), then remove retainer
(56), spring (57) and washer (58) from
cylinder block (54).
4. Using forcing screw, remove housing (59).
* Check the number and thickness of shims
and keep in a safe place. F20205329 F20705441
5. Using push tool, remove oil seal (60) from

housing (59).
6. Remove shaft assembly (61).
7. Disassembly of shaft
Using puller @ , remove collar (63) and inner
race (64) from shaft (62).
* Remove only the inner race for the rear
pump.
2. Piston
1. Using tool 53, remove 4 screws (65), then
remove bearing retainer (66), shoe retainer
(67) and piston (69).
I F20705445 F2070544E
~ F20705447 1 F20703036
F20703022-111 F20705448
2. Using tool 53, remove screws (70), then
remove plate (71). J3
3. Remove rocker cam (72).
4. Using tool 55, remove screws (73), then
remove rocker cam stopper (74).
3. Cradle
Using push tool, remove bearing (76) from
cradle (75).
l-f F20705449 F2070545C
h7ll F20705451
13 F20705452
30-96
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY (HPV160+160)
l Precautions when assembling

Always use all parts supplied in the kit. In
addition, always use the following parts as an
assembly.
1. Cradle and rocker cam
2. Cylinder block and valve plate.
Preparatory work
0 Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with 76
engine oil (EOlO-CD, new oil) before
installing. F20705452
ASSEMBLY OF PUMP SUB-ASSEMBLY
I-
1. Cradle and piston assembly 8-
1. Install bearing (76) (Outside diameter 110
mm) in cradle (75).
&Mounting surface of bearing:
r
Grease (G2-LI)
F2070301 E F20205351
2. Select shims to hold bearing as follows.
i) Measure distance @ between bearing
(76) and end face of cradle.
ii) Measure distance @ of housing (59).
* Measure distance @ of cover.
(Rear pump)
iii) Select shim thickness as follows.
Shim thickness = @ - @ - (0 to 0.1
mm)
* There are 3 kinds of shim
(thickness = 0.15, 0.1 and
0.05 mm).
3. Fit dowel pin, and using tool 55, install
rocker cam stopper (74) with screws (73). &7ll F20705451
& Stopper screw: Thread tightener

(LT-2) (Loctite #262)
Iz--] Stopper screw:

30-97
4. Fit dowel pin to cradle, set rocker cam (72) in
position, then using tool 53 install plate (71)
with screws (70).
* Install the grooved side of the rocker arm
facing the cradle oil hole.
H=C& Plate screw: Thread tightener (LT-2)

(Loctite #262)
u Plate screw:
and Standard Values
Table
f After tightening the bolts, check that the

rocker cam moves smoothly.
5. Select the spacer thickness as follows.
i) Assemble piston (69) to shoe retainer
(67), put on the level block, then
measure distance @ to top surface of
shoe retainer.
ii) Select spacer thickness as follows.
Spacer thickness = distance @ +
(0.03 to 0.07 mm).
-k There are three types of spacers.
6. Install spacer (68) selected in Step 5....i) and
5....ii), then install piston (69), shoe retainer
(67) and bearing retainer (66).
69
& Bearing retainer screw: 67
(Loctite #262)
u Bearing retainer screw:

7. Using tool 53, install screw (65).
65
F20705448 1
30-98
a. Hold rocker cam in position, using tool J6, Rocker cam
pull piston (69) with a force of 5 - 6 kg, and
measure clearance @ between piston shoe
and rocker cam.
* Measure the clearance with the rocker Bearing retainer
cam in position a or b, and measure for
all 9 pistons.
* Clearance: 0.03 - 0.07 mm
* If clearance @ is not within the standard
range, adjust the spacer again.
2. Cylinder block F20703021

Align piston and install cylinder block (54).
* Install the spring and washer inside the
cylinder after adjusting the preload of the Pull
bearing
* Always install the valve plate (which
forms a set with the cylinder) together
with the cylinder.
3. Shaft assembly J6
1. Using push tool, press fit inner race (64),
O-ring, collar (63) (inside diameter: 60 mm)
on shaft (62).
f0
* Be sure to install inner race in correct
direction. F20505442
* For the rear pump, use a push tool to
install inner race (78) to shaft (77), then
fit plate (19) and tighten with bolt (18).
& Mounting bolt: Thread tightener

(LT-2)
(Loctite #262)
m Mounting bolt:
F2070302:
2. Set cradle and piston assembly (79) in vice.

* Put a block under the cylinder.
3. Align shaft assembly (61) with cylinder, and
install.
4. Install housing as follows.
i) Install oil seal (60) (outside diameter:
95 mm) to housing (59).
Block
& Lip of oil seal: Grease (G2-LI)
ii) Fit shim selected in Step 1 - 2, and

install housing (59) to cradle.
F2070545E
ASSEMBLY OF PUMP ASSEMBLY
1. Charging pump drive shaft assembly (front

pump only)
1. Sub-assembly of shaft assembly.
i) Install coupling (43) in shaft (37), then
secure with pin (42).
ii) Using push tool, install bearing (41),
collar (40), bearing (39), collar (38)
(inside diameter: 35 mm) to shaft
(37).
F20705446 F20705445
42
F20703024 I F20705456
30-I 00
iii) Using push tool, install snap ring (45)
to case (44).
2. Install drive shaft assembly (36) to case.
f Check that shaft rotates smoothly.
3. Using push tool, install oil seal (35) to
.44
housing (34).
* When installing oil seal, be careful not to
deform it.
.45
4. Fit O-ring, install housing (34) to pump. F20705457
2. Servo piston
1. Install servo piston (51) in case.
* Servo piston is the same for front pump
and rear pump.
2. Adjust stroke of servo piston as follows.
i) Align tool 57 with dowel pin and
L
groove for servo valve arm of servo
piston, and set tool 57 in position.
* As seen from the rear of the
pump, the right side (the side with
35\
the spring) is the maximum swash
plate angle side. (maximum flow 34 F2070302E F20705439
side)
Note: For the rear pump, use the
same tool turned over.
51
F2050544C
J7
F20505450
30-101
ii) Measure distance @ between servo
piston and case.
iii) Measure distance @ of cap (46).
iv) Select shim thickness as follows.
@ - @ = @ k 0.05 mm
* After adjusting the shim, put it in
a set with the cap.
46
F20205356
Servo valve
mounting
surface
Pump case
Cleara
\
Servo piston
Clearance
0
_J F20703027

Clearance 0
F20703026
To adjust the minimum swash

plate angle, replace tool 58 with
the tool for the minimum angle,
and repeat the same procedure as
in Steps 2 . . . . i) - 2 . . . . iv).
Note that the case faces in the
opposite direction from the
maximum swash plate angle side.
3. Pump sub-assembly
1. Install slider (53) and O-rings.
* install O-rings on pilot bore and joint
portion.
2. Install joint to case.
* Install with small hole facing cradle side.
3. Align slider with servo piston, so it supports
the shaft and install pump sub-assembly (31).
* Be careful that O-ring is not caught.
30-I 02
4. Charging pump driven gear (front pump
only)
1 Fit key on shaft, then shrink fit gear (15).
(Charging pump end)
* Shrink-fitting temperature: 100C for 1
hour.
2. Fit plate (14) and tighten bolt (13).
D Bolt: See Tightening Torques and

3. Fit key, then shrink fit gear (12). (Main shaft F20705458 F2070542t5
end)
4. Using tool 52, install split plate (11) with
screw (10). r
* Push plate into bottom of groove of shaft
completely, then tighten screws
alternatively to prevent plate from
moving.
AX, Mounting bolt: Thread tightener

(LT-2)
(Loctite #262)
u Mounting bolt:
F20705459
Values Table
5. Select plate (11) as follows.

i) Install gear (12).
* When shrink fitting gear, install
gear after temperature becomes
low.
ii) Select proper plate from 5 kinds of
plate so that clearance @ becomes
the smallest.
* a = 0 - 0.1 (Best selection of plate is to
fit in position by knocking plate in
slightly.)
11
F20703029
30-103
5. End cap
1. Using push tool, install bearing (29) (outside
diameter: 54 mm) and ring (80) to end cap
(28) -
2. Coat with grease (G2-LI), align with dowel pin
and ring (80), then install valve plate (30).
* Check that the suction and discharge
ports of the valve plate are aligned with
the ports in the end cap.
6. Adjusting end play of front (rear) shaft

bearing F20705434 F20705461
1. Install joint to case end.
* Install with the small hole facing the
opposite side from the end cap.
2. Install end cap (28) to case.
u Mounting bolt:
3. Coat with grease (G2-LI), and install thrust
bearing (26).
* Install the thrust bearing with the outside
race (the side with the larger inside
_
diameter) surface facing the end cap. Pay
attention also to the direction of
installation of the ball (Grooved portion of
ball holder). (See diagram on right)
4. Install spacers (24) and (25), then install snap Outer race seat
Yi
ring (23).
End cap
Grooved
of ball holder
26
F20705461 F20705462
F20705432
30-104
5. Select spacer (24) as follows.
From the 5 thicknesses of spacers, select the Bearin
spacer (24) that gives the minimum clearance
from the snap ring (23).
6. Using tool 53, install impeller (22) with
screws (21).
7. Set dial gauge @ on case and measure axial
play of shaft.
* Axial play: 0.1 - 0.4 mm
Ir If axial play is not within specified range,
select plate from the five thicknesses of 24 Shaft
plate. F20705463
-
F20705431
_,__ Clearance
0.1 - 0.4 mm
F20703031
,464
8. Install selected plate, measure clearance
between impeller and end cap.
* Clearance: 0.65 f 0.18 mm
9. After completing measurements, remove
impeller and end cap.
* On the rear pump, plate (27) is used;
there is no impeller.
7. Washer, spring, snap ring

Assemble washer (59), spring (58) and
retainer (57) to cylinder block, then install
snap ring (56). F20705465
-k Be sure to install washer in correct

direction.
Clearance: 0.65 f 0.18
7-h
F20705466
F2070546;
F20703032 F20705468 II F20705469 I
30-106
8. Impeller
1. Secure shaft (16) with puller @ .
2. Fit O-ring, then install end cap.
* For details see step 5 and 6 - 1, 2.
3. Coat with grease (G2-LI), and install thrust
bearing (26).
* For details see Step 6 - 3, 4.

4. Install spacers (25) and (24), then install snap
ring (23).
* When doing this, press the shaft with a
force of 170 - 190 kg from the case side
to the end cap side.
5. Align bearing, and install impeller (22).
6. Using tool 53, tighten screw (21).
K& Screw: Adhesive (LT-2)

(Loctite #262)
u Screw: See Tightening Torques and

7. After tightening screws, remove puller @ .

8. Measure rotating torque of pump.
F20705432
i) Using tool J9, rotate pump shaft at 1
revolution every 3 - 5 seconds, then
measure rotating torque.
ii) There must be no variation
rotating torque
in the
(Range of variation:
l-l n
Max. 0.3 kgm) and the rotating torque
must be less than 2.0 kgm. (At
minimum swash plate angle.)
F20705431 I
F2Oi
30-107
9. Servo piston cap
1. Align servo piston, install spring (50).
f Install on left side when viewing pump
from rear.
2. Fit O-ring and shims (49) and (48) selected in
step 2, then install caps (47) and (46).
u Mounting bolt:
10. Servo valve assembly

Fit O-ring and align lever with groove of
servo piston, then install servo valve
assembly (8).
u Mounting bolt: >

and 48
6P
\
51
11. TVC, CO*NC valve assembly
d0
Fit O-ring and install TVC valve (6) and
CO*NC valve assembly (7) and a set.
u Mounting bolt: F20705443

* TVC valve is installed only on front pump.
F20705421
30-I 08
12. Charging pump assembly
1. Using tool 54, install strainer assembly (34),
then install plug.
u Plug: See Tightening Torques and

2. Fit O-ring, then install charging pump

assembly (32).
13. Rear pump assembly

1. Install coupling (20). F20705438
2. Fit O-ring to end cap, and raise rear pump

assembly (5), then tighten 4 nuts (4).
m End cap mounting nut and bolt:

* Also tighten 4 rear pump end cap

mounting bolts (Width across flats = 30
mm).
3. Install hoses (2) and (3).
u Sleeve nut of hose (2): 32 F20705472

u Sleeve nut of hose (3):

F20705420
F20705419
14. Cover
Install cover (9).
F2070542
30-110
CHECKING CONTACT BETWEEN CYLINDER BLOCKAND VALVE PLATE,
AND ROCKER CAM AND CRADLE
.........
.l---l&
...
....
1. Checking contact between cylinder block
and valve plate Cylinder block Centering tool
1. Make a centering tool for the cylinder block

and valve plate.
* The tool can be made of a soft material ............... ... . . .
.............
:.:.:.: ..........................
..........................................................
such as plastic or bakelite. ::::~:~.:.:.:.:.:.:.:.:.
:.:.:.:.:
.....................................
............
........................
I
.......................
7.y.: ......................
2. Remove grease from the parts to be checked :.:.:.:

.................................
..........................
.......................................
..................... .

3. Set the tool in position, and coat the cylinder
block side with inspection paint.
-k Apply the paint thinly.
4. Put the valve plate on top, push with a force
of 4 - 5 kg, and rotate 2 - 3 times.
5. Remove the valve plate, transfer the contact
surface to the tape, and check the contact
surface.
* The standards for the contact surface are
as follows.
1 Valve plate 1 a. Seal 1 Min. 80% 1

Cylinder block a. Seal Min. 80% F20703037
Valve plate Cylinder block
F20703038
30-111
2. Checking contact between rocker cam and
cradle
1. Remove grease from the parts to be checked.
2. Set the tool in position, and coat the cradle
side with inspection paint.
3. Put the rocker cam on top, push with a force
of 4-5 kg, and move 2 - 3 times from the
stopper contact position to the maximum
angle.
4. Remove the rocker cam, transfer the contact
surface to tape, and check the contact
surface.
* The standard for the contact surface are
as follows.
Pump a Contact Contact b

model Dimension surface from a to
(mm) outside
HPVl60 70 Min. 90% Min. 60%
* If there is no contact at the center but

only at the outside, the contact is no
good.
Reference
If the contact is not within the contact
standard value, when carrying out lapping,
always lap both parts together.
* Parts with scratches cannot be used.
30-112
30-113
REMOVAL OF HYDRAULIC
PUMP INPUT SHAFT OIL SEAL
1. Remove hydraulic pump assembly.

l For details, see REMOVAL OF
HYDRAULIC PUMP ASSEMBLY.
2. Remove cover (1). (See Fl)
3. Remove plate (2). (See Fl) m
4. Remove drive gear (3). (See Fl)
f Using a puller, remove the drive gear.
5. Remove housing assembly (4). (See F2, F3)
m
* Using eyebolts, remove the housing
assembly and the shim.
6. Remove oil seal (5). (See F3) m
l Remove the oil seal from the housing.
PUMP INPUT SHAFT OIL SEAL

removal.
m
e Mounting bolt:
m Mounting bolt:
Values Table
m
u Mounting bolt:
Values Table
m
* Using tool 0, press fit oil seal (5) in
housing (4). (See F4)
30-114
205FO5595
F2
- 205FO5486
L
F3
5
2OUFOl21 I-K
30-115
REMOVAL OF CONTROL INSTALLATION OF CONTROL
VALVE ASSEMBLY VALVE ASSEMBLY
Lower the work equipment to the ground l Carry out installation in the reverse order to
and release the remaining pressure inside removal.
the circuit. For details, see TESTING AND l Bleeding air
ADJUSTING, Releasing remaining Ir Fill with oil to the specified level, then
pressure in hydraulic circuit for machines bleed the air. For details, see TESTING
with PPC valve. AND ADJUSTING, Bleeding air from all
* After removing the piping, mark with tags parts.
to prevent mistakes when installing. * After bleeding the air, check the hydraulic
._ ~.
1. Remove frame (1). (See Fl) tank level.
l Remove the block between the hydraulic
filters. (PC4OOLC)
2. Disconnect wiring connectors (2). (See Fl)
* Disconnect the connectors of the front
and rear pump pressure sensors and
work equipment and swing pressure
switches.
3. Disconnect tubes (3). (See Fl)
* Disconnect 2 tubes.
4. Remove bracket (4). (See Fl)
6. Disconnect R.H. control valve hoses
1. Disconnect hoses (6). (See Fl)
* Disconnect 6 hoses
2. Disconnect PPC hoses (7). (See Fl)
* Disconnect 3 hoses at the front, 3 hoses
at the rear, and 2 hoses at the bottom.
7. Disconnect L.H. control valve hoses.
f Disconnect 7 hoses
2. Disconnect PPC hoses (9). (See Fl)
* Disconnect 3 hoses at the front, 5 at the
rear, 3 hoses at the top, and 2 hoses at
the bottom.
8. Remove control valve assembly (10).
(See F2)
* When removing the control valve
assembly, check that all the piping and
wiring has been removed, then remove
the assembly, taking care that there is no
interference.
* Sling the control valve assembly, remove
the mounting bolts, then remove together
with the bracket.
See Weight Table
30-116
Fl
F2
F20705333
30-117
DISASSEMBLY OF CONTROL 6. Bucket valve
1. Remove case (28), then remove spring (29)
VALVE ASSEMBLY and retainer (30), and pull out spool (31).
2. Remove case (32), then remove spring (33)
* The set pressure of the safety valve cannot and retainer (34).
be adjusted when the safety valve is installed l This applies to the arm Lo, service (R.H.
on the machine, so do not disassemble it. control valve), and arm Hi (L.H. control
l The following explanation uses the left valve) spools.
control valve as the example. l Arm Lo (R.H. control valve)
1. Main relief valve, jet sensor valve There is a retainer assembled
Remove main relief valve (1) and jet sensor between case (32) and spring
relief valve (2). (See Fl) (33).
2. Safety-suction valve l Arm Hi (L.H. control valve)
Remove safety-suction valve (3), (4), and (5). Shim (35) is assembled.
(See Fl) 7. Straight travel valve
3. Check valve 1. Remove plate (36), then remove spring (37).
Remove plug (6), then remove spring (7) and 2. Remove plug (38), then pull out spool (39).
check valve (8). (See Fl)
4. L.H. travel valve
1 Remove case (9), remove retainer (lo), shim
(ll), spring (12), retainer (13), spring (14),
and retainer (15), then remove spool (16).
2. Remove case (17), then remove retainer (18),
shim (19), spring (20), retainer (21), spring
(22), and retainer (23).
l This applies to the swing, R.H. travel,
boom Hi (R.H. control valve), and boom
Lo (L.H. control valve) spools.
l Swing spool (R.H. control valve)
i) Shim (11) and retainer (13) are not
assembled.
ii) Shim (19) and retainer (21) are not
assembled.
l Boom Hi (R.H. control valve)
i) 2 shims (11) are assembled.
ii) There is a plate installed instead of
parts (17) - (23) in step 2.
l Boom Lo spool (L.H. control valve)
i) Shim (11) is not assembled.
ii) Parts (18) - (21) in step 2 are not
assembled.
5. Arm throttle valve
1. Remove plug (24) and spring (25).
2. Remove plate (26), and pull out spool (27).
l For the swing priority valve (R.H. control
valve), parts (24), (25), and (26) in steps
1 and 2 are installed in the opposite way.
30-118
1
205FO5909
205FO59 I C,
30-119
ASSEMBLY OF CONTROL l Boom Hi (R.H. control valve)
i) Assemble 2 shims (11). (See Fl)
VALVE ASSEMBLY ii) Install a plate instead of parts (17)
- (23) in step 2. (See Fl)
1. Straight-travel valve l Boom Lo spool (L.H. control valve)
1. Assemble spool (39), then fit O-ring and i) Shim (11) is not assembled.
install plug (38). (See Fl) (See Fl)
2. Fit spring (37) and install plate (36). (See Fl) ii) Parts (18) - (21) in step 2 are not
2. Bucket valve assembled. (See Fl)
1. Assemble spool (31), fit retainer (34) and 5. Check valve
spring (33), then fit O-ring and install case Install check valve (8) and spring (7), then fit
(32). (See Fl) O-ring and install plug (6). (See Fl)
2. Fit retainer (30) and spring (29), then fit O- u Plug:
ring and install case (28). (See Fl) See Tightening Torques and
l This applies to the arm Lo, service (R.H. Standard Values Table
control valve), and arm Hi (L.H. control
6. Safety-suction valve
valve) spools.
Install safety-suction valve (5), (4), and (3).
l Arm Lo (R.H. control valve)
(See Fi)
Assemble retainer between case u Safety-suction valve:
(32) and spring (33). (See Fl)
l Arm Hi (L.H. control valve)
Assemble shim (35). (See Fl) 7. Jet sensor relief valve, main relief valve
3. Arm throttle valve
Install jet sensor relief valve (2) and main
1. Assemble spool (27), then fit O-ring and relief valve (1). (See Fl)
install plate (26). (See Fl)
u Jet sensor relief valve:
2. Fit spring (25), then fit O-ring and install plug
(24). (See Fl) Standard Values Table
l For the swing priority valve (R.H. control m Main relief valve:
valve), parts (24), (25), and (26) in steps
1 and 2 are installed in the opposite way.
(See Fl)
4. L.H. travel valve
1 Assemble spool (16), install retainer (23),
spring (22), retainer (21), spring (20), shim
(19), and retainer (18), then fit O-ring and
install case (17). (See Fl)
2. Fit retainer (15), spring (14), retainer (13),
spring (12), shim (1 l), and retainer (lo), then
fit O-ring and install case (9). (See Fl)
l This applies to the swing, R.H. travel,
boom Hi (R.H. control valve), and boom
Lo (L.H. control valve) spools.
l Swing spool (R.H. control valve)
i) Shim (11) and retainer (13) are
not assembled. (See Fl)
ii) Shim (19) and retainer (21) are
not assembled. (See Fl)
30-120
Fl
205FO5909
205FO59 IO
30-121
REMOVAL OF MAIN RELIEF DISASSEMBLY OF MAIN
VALVE ASSEMBLY RELIEF VALVE ASSEMBLY
*
A4Y Lower the work equipment to the ground
1. Loosen
(See F3)
nut (2), and remove plug (1).
levers several times to release the * Before loosening the nut, measure
remaining pressure in the hydraulic protrusion dimension a of the plug from
piping. Then loosen the oil filler cap the end face of the nut. (See F2)
slowly to release the pressure inside the 2. Remove retainer (3) (See F3)
hydraulic tank.
3. Loosen nut (5), and remove holder (4).
(See F3)
1. Disconnect hoses (1). (See Fl) * Before loosening the nut, measure
2. Remove R.H. control valve main relief valve protrusion dimension b of the holder from
(2). (See Fl) m the end face of the nut. (See F2)
3. Remove L.H. control valve main relief valve 4. Remove spring (6) and poppet (7). (See F3)
(3). (See Fl) m 5. Remove sleeve (8), then remove seat (9),
backup ring (lo), spring (1 l), and valve (12).
(See F3)
INSTALLATION OF MAIN 6. Remove plug (14) from sleeve (13). (See F3)
7. Remove backup ring (15) from sleeve (13).
RELIEF VALVE ASSEMBLY (See F3)

removal.
ASSEMBLY OF MAIN RELIEF
D Main relief valve: VALVE ASSEMBLY
Standard Values Table 1. Assemble backup ring (15) and O-ring in
l After installing the main relief valve on the sleeve (13). (See F3)
machine, adjust the set pressure. 2. Install plug (14) to sleeve (13). (See F3)
For details, see TESTING AND 3. Assemble backup ring (10) and O-ring to seat
ADJUSTING, Adjusting main relief valve. (9), then install valve (8) to sleeve (13).
(See F3)
4. Assemble poppet (7) and spring (6). (See F3)
5. Assemble nut (5) and O-ring to holder (4),
and install to sleeve (13). (See F3)
* Adjust so that protrusion dimension b of
the holder from the end face of the nut is
the same as when it was disassembled,
then secure with the nut. (See F2)
6. Assemble retainer (3). (See F3)
7. Assemble nut (2) and O-ring to plug (l), and
install to sleeve (13). (See F3)
* Adjust so that protrusion dimension a of
the plug from the end face of the nut is
the same as when it was disassembled,
then secure with the nut. (See F2)
30-122
Fl ._
205FO559:
-- -
w
2-g
3-9
lO-2
11--D
12-d
Q
13'-
8
14---&j
0
15-Q
0
205FO5598
30-I 23
REMOVAL OF TVC VALVE REMOVAL OF SERVO VALVE
ASSEMBLY ASSEMBLY
1. Disconnect wiring connector (1). (See Fl) 1. Remove CO*NC assembly.

2. Remove TVC valve assembly (2). (See Fl) For details, see REMOVAL OF CO*NC VALVE
ASSEMBLY.
2. Remove servo valve assembly (1). (See F3)
INSTALLATION OF TVC VALVE

ASSEMBLY INSTALLATION OF SERVO
VALVE ASSEMBLY
removal. l Carry out installation in the reverse order to
removal.
REMOVAL OF CO.NC VALVE

ASSEMBLY
1. Remove hoses (1). (See F2)

* Remove the hoses (4 hoses for front
pump, 5 hoses for rear pump).
2. Remove CO *NC valve assembly (2). (See F2)
j, Remove the CO*NC valve of the front
pump as an assembly with the TVC valve.
INSTALLATION OF CO.NC
VALVE ASSEMBLY

removal.
30-124
:1 F3
F20505336
F2
i \\Y@!i
30-125
REMOVAL OF WORK 3. Remove piston assembly (5). (See F4)
EQUIPMENT PPC VALVE
Remove the following parts from piston (6).
ASSEMBLY (See F4)
1 Remove collar (7), then remove dust seal (8).
A4
% Y Lower the work equipment to the ground
(See F4)
2. Remove collar (9), then remove seal (10).
levers several times to release the (See F4)
remaining pressure in the hydraulic 3. Remove piston (li), and spring (12).
piping. Then loosen the oil filler cap (See F4)
slowly to release the pressure inside the 5. Remove valve assembly (13), then remove
hydraulic tank. spring (14). (See F4)
1. Plate (1). (See Fl) 6. Disassembly of valve assembly
2. Seat assembly (2). (See Fl) Push retainer (16) to remove collar (15), then
3. Wiring connector (3). (See F2) remove retainer (16), spring (17), and shim
4. Lever assembly (4). (See F2) (18) from valve (19). (See F4)
5. Cover (5). (See F2) m
6. Bracket (6). (See F3)
f Remove the mounting bolts, and move ASSEMBLY OF WORK
the bracket towards the window.
7. Hoses (7). (See F3)
EQUIPMENT PPC VALVE
* Disconnect 6 hoses ASSEMBLY
8. PPC valve assembly (8). (See F3)
f Remove the mounting bolts, then remove 1. Assembly of valve assembly
the valve assembly together with the Assemble shim (18), spring (17), and retainer
hose. (16) to valve (19), and push down retainer
(16) to install collar (15). (See F4)
2. Assemble spring (14) and install valve
INSTALLATION OF WORK
3. Assembly of piston assembly
EQUIPMENT PPC VALVE Assemble the following parts to piston (6).
ASSEMBLY 1. Assemble spring (12) and piston (11).
(See F4)
l Carry out installation in the reverse order to e Piston: grease (G2-LI)
removal. 2. Fit seal (10) to collar (9) and assemble.
(See F4)
m
* Fit the slide stopper securely into the 3. Fit dust seal (8) to collar (7) and assemble.
inside lever. (See F4)
4. Install piston assembly (5). (See F4)
5. Fit plate (4) and install joint (3). (See F4)
u Joint:
DISASSEMBLY OF WORK Standard Values Table
EQUIPMENT PPC VALVE 6. Fit disk (2) and install nut (1). (See F4)
ASSEMBLY 0 Adjust the clearance between disc (2)
and piston (6).
1. Remove nut (l), then remove disc (2). For details, see TESTING AND
(See F4) ADJUSTING, Adjusting PPC valve for
work equipment.
2. Remove joint (3), then remove plate (4).
(See F4) a Nut:
30-126
\
@
-2
63 !3
2---i_ O
/1
F20505369
F3
I I
F20505371 205FO5493
30-127
REMOVAL OF TRAVEL PPC DISASSEMBLY OF TRAVEL PPC
VALVE ASSEMBLY VALVE ASSEMBLY
*
A
4
1. Remove plate (l),
then remove piston
levers several times to release the 2. Disassembly of piston assembly.

remaining pressure in the hydraulic Remove collar (4) from piston (3), then
piping. Then loosen the oil filler cap remove seal (5). (See F2)
slowly to release the pressure inside the 3. Remove valve assembly (6), then remove
hydraulic tank. spring (7). (See F2)
1. Disconnect yokes (1). (See Fl) 4. Disassembly of valve assembly
2. Disconnect hose (2). (See Fl) Push retainer (9) to remove collar (8), then
* Disconnect 6 hoses. remove retainer (9), spring (lo), and shim
3. Remove travel PPC valve assembly (3). (11) from valve (12). (See F2)
(See Fl)
ASSEMBLY OF TRAVEL PPC

INSTALLATION OF TRAVEL PPC
VALVE ASSEMBLY
VALVE ASSEMBLY
1. Assembly of valve assembly
l Carry out installation in the reverse order to Assemble shim (1 l), spring (lo), and retainer
removal. (9) in valve (12), then push down retainer (9)
to install collar (8). (See F2)
2. Assemble spring (7), and install valve
3. Assembly of piston assembly
Assemble seal (5) to collar (4), and install to
piston (3). (See F2)
4. Assemble piston assembly (2), and install
plate (1). (See F2)
30-128
Fl
-_k
5--
4-a
I 205FO5599 @
0
205FO5495
30-I 29
REMOVAL OF BOOM HOLDING DISASSEMBLY OF BOOM
VALVE ASSEMBLY HOLDING VALVE ASSEMBLY
YY Lower the work equipment to the ground * The set pressure of the safety valve cannot
A and release the remaining pressure in the be adjusted when the safety valve is installed
4 circuit. For details, see TESTING AND on the machine, so do not disassemble it.
ADJUSTING, Releasing pressure in 1. Remove safety valve assembly (1). (See F2)
hydraulic circuit for machines with PPC 2. Remove plug (2), then remove spacer (3),
valve. spring (4), seat (5), and spool (6). (See F2)
1. Disconnect hoses (1). (See Fl) 3. Remove body (7), then remove spring (8) and
2. Disconnect tubes (2). (See Fl) check valve (9). (See F2)
3. Remove boom holding valve assembly (3).
(See Fl)
ASSEMBLY OF BOOM
INSTALLATION OF BOOM HOLDING VALVE ASSEMBLY
HOLDING VALVE ASSEMBLY
1. Assemble check valve (9) and spring (a),
l Carry out installation in the reverse order to then fit O-ring and install body (7). (See F2)
removal. u Mounting bolt:
l Refilling with oil See Tightening Torques and
* Refill to the specified level, and run the Standard Values Table
engine to circulate the oil through the 2. Fit seat (5) to spool (6) and insert in body
system. Then check the oil level again. (7), then install spring (4), spacer (3), plug
(2) and O-ring. (See F2)
u Plug:
3. Fit O-ring and install safety valve (1).
(See F2)
m Safety valve:
30-I 30
Fl
205FO5900
1
205FO5497 1
30-131
REMOVAL OF PPC SHUTTLE INSTALLATION OF PPC
VALVE ASSEMBLY SHUTTLE VALVE ASSEMBLY
A4 Y
l Carry out installation
removal.
in the reverse order to
levers several times to release the

remaining pressure in the hydraulic
piping. Then loosen the oil filler cap
slowly to release the pressure inside the
hydraulic tank.
1. Arm PPC shuttle valve assembly
* Disconnect 2 hoses at the front, and 3
hoses at the rear.
2. Remove arm PPC shuttle valve assembly (2).
(See Fl)
2. Swing PPC shuttle valve assembly
-k Disconnect 2 hoses at the front, and 3
hoses at the rear.
2. Remove pressure switch (4). (See Fl)
3. Remove swing PPC shuttle valve assembly
(5). (See Fl)
3. Boom, bucket PPC shuttle valve assembly
* Disconnect 4 hoses at the front, and 5
hoses at the rear.
2. Remove boom, bucket PPC shuttle valve
assembly (7). (See Fl)
4. Travel PPC shuttle valve assembly
f Disconnect 4 hoses at the front, and 4
hoses at the rear.
2. Remove pressure switch (9). (See Fl)
3. Remove travel PPC shuttle valve assembly
(10). (See Fl)
30-132
Fl
1
2 3 6 8 205FO5901
I
30-133
REMOVAL OF BOOM INSTALLATION OF BOOM
CYLINDER ASSEMBLY CYLINDER ASSEMBLY
A
Extend the arm and bucket fully, lower l Carry out installation in the reverse order to
the work equipment to the ground, and removal.
operate the control levers 2 or the times.
1. Disconnect hose (1). (See F2) Tighten with the locknut so that the
2. Remove lock bolt (2). (See F2) m clearance between the boom boss and
3. Remove pin (3). (See F2) w] m RI nut is 0.5 - 1.5 mm. (See F5)
* Sling the boom cylinder assembly, and
remove the pin.
When aligning the position of the pin
A
Start the engine, and retract the rod hole, run the engine at low idling. Never
of the boom cylinder, tie the rod with insert your fingers in the pin hole.
wire to prevent it from coming out,
then lower it onto the block.
*A Y Release the remaining pressure in the

circuit. For details, see TESTING AND
* Adjust with shims so that the clearance
between cylinder rod (7) and plate (8) is less
than lmm. (See F5)
4 ADJUSTING, Releasing pressure in
hydraulic circuit for machines with
PPC valve.
* Adjust with shims so that the clearance
4. Disconnect hose (4). (See F3) between cylinder bottom (9) and bracket (10)
5. Remove pin (5). (See F4) m wj is less than 1 mm. (See F6)
* Sling the boom cylinder assembly, then
use forcing screws @ to remove the pin.
6. Remove cylinder assembly (6). (See F4) XI& Inside surface of bushing: LM-P
See Weight Table * For grease, use MPG.
l Bleeding air
f Bleed the air from the cylinder.
ADJUSTING, Bleeding air from hydraulic
cylinder.
f After bleeding the air from hydraulic
cylinder, check the level of the oil in the
hydraulic tank.
30-I 34
Fl F5
I 7
mm
\ 9
I 205FO5499 1 F20705344
F2 F6
_ Max. 1 mm
\ 10
F20505332 F20705345
F3
F20505333
F4
I
-1
0.5 - 1.5 mm
30-I 35
REMOVAL OF ARM CYLINDER INSTALLATION OF ARM
ASSEMBLY CYLINDER ASSEMBLY
A
Set block @ between the arm and the l Carry out installation in the reverse order to
boom, then extend the arm fully, lower removal.
the work equipment to the ground, and
operate the control levers 2 or 3 times.
* Sling the arm cylinder assembly. When aligning the position of the pin
1. Remove pin (1): (See Fl) mm] hole, run the engine at low idling. Never
insert your fingers in the pin hole.
A
Start the engine, and retract the rod
of the arm cylinder, then tie the rod
with wire to prevent it from coming Adjust with shims so that the clearance
out. between cylinder bottom (6) and bracket
(7) is less than 1 mm. (See F2)
YY Release the remaining pressure in the
A circuit. For details, see TESTING AND
4 ADJUSTING, Releasing pressure in
Inside surface of bushing: LM-P
For grease, use MPG.
PPC valve.
l Bleeding air
* Bleed the air from the cylinder.
4. Remove pin (4). (See Fl) mm\
5. Remove arm cylinder assembly (5). (See Fl)
el kg See Weight Table

*
cylinder.
After bleeding the air from hydraulic
hydraulic tank.
30-136
Fl
I F20505334
F2
30-I 37
REMOVALOF BUCKETCYLINDER INSTALLATION OF BUCKET
ASSEMBLY CYLINDER ASSEMBLY
A
operate the control levers 2 or three m
times. f Tighten with the locknut so that the
clearance between the link boss and nut
A
Set block @ between the link and arm is 0.5 - 1.5 mm. (See F2)
and sling the bucket cylinder assembly. m
A
1. Remove lock bolt (1). (See Fl) m hole, run the engine at low idling. Never
2. Remove pin (2). (See Fl) m mj m insert your fingers in the pin hole.
A
of the bucket cylinder, then tie the -k Adjust the shims so that the clearance
rod with wire to prevent it from between link (6) and link (7) is less than
coming out. 1 mm. (See F3)
A
%
4
Y Release the remaining pressure in the
circuit. For details, see TESTING AND -k Adjust with shims so that the clearance
ADJUSTING, Releasing pressure in between cylinder bottom (8) and bracket
hydraulic circuit for machines with (9) is less than 1 mm. (See F4)
PPC valve.
4. Remove pin (4). (See Fl) mm1 &&, Inside surface of bushing: LM-P
5. Remove bucket cylinder assembly (5). * For grease, use MPG.
(See Fl)
See Weight Table l Bleeding air

* Bleed the air from the cylinder.
cylinder.
* After bleeding the air from hydraulic
hydraulic tank.
30-138
Fl
2050533! 5
F2
----k-I
0.5 - 1.5 mm
2OSF6065
F3
F4
_ Max. 1 mm
9 F20705348
30-I 39
DISASSEMBLY OF HYDRAULIC 4. Disassembly of collar assembly
l Disassembly of the collar assembly is for
CYLINDER ASSEM BLY the boom and arm cylinders only.
1. Remove O-ring and backup ring (15).
1. Cylinder assembly (See F5)
1. Remove mounting bolts, and disconnect head 2. Remove collar (17) and ring (18) from collar
assembly (1). (See Fl) (16). (See F5)
2. Pull out piston rod assembly (2). (See Fl)
* Put and oil pan or container under the
cylinder to catch the oil. 5. Disassembly of cylinder head assembly
2. Piston rod assembly (See F6)
1. Remove mounting bolts, then remove spacer 2. Remove snap ring (20), then remove dust
(3). (See F2) seal (21). (See F6)
2. Remove piston assembly (4). (See F2) 3. Remove rod packing (22). (See F6)
3. Remove plunger (5). (See F2) 4. Remove buffer ring (23). (See F6)
l Plunger (5) is for the boom and arm 5. Remove bushing (24). (See F6)
cylinders only.
4. Remove collar assembly (6). (See F2)
l Collar assembly (6) is for the boom and
arm cylinders only.
5. Remove head assembly (7). (See F2)
6. Remove screw (8), then take out balls (9)
(Qty 11 for PC3OOLC, 12 for PC400LC), then
remove plunger (10). (See F3)
l Plunger (10) is for the arm cylinder only.
(See F3)

1. Remove ring (12). (See F4)
2. Remove wear ring (13). (See F4)
3. Remove piston ring (14). (See F4)
30-140
Fl F5
202FO546 I 205FOE.904
5 4
5 24
19
23
21
22
205FO5902 202FO5486
F3
i 2OSFO5903
202FO5485
30-141
ASSEMBLY OF HYDRAULIC 4. Piston rod assembly
1. Assemble O-ring and backup ring (11).
CYLINDER ASSEMBLY (See F5)
2. Set plunger (10) to piston rod, and assemble
* Be careful not to damage packings, dust 12 balls (9) (11 balls on 6400LC) and tighten
seals or O-rings when installing. screw (8). (See F5)
f Do not try to force the backup ring into u Screw:
position. Warm it in warm water (50 - 60C) See Tightening Torques and Standard
before fitting it. Values Table
1. Assembly of head assembly * After tightening the screw to the specified
1. Press fit bushing (24). (See Fl) torque, stake it with center punch.
2. Assemble buffer ring (23). (See Fl) * Check that there is a small amount of
3. Assemble rod packing (22). (See Fl) play at the tip of the plunger.
4. Assemble dust seal (21), and secure with l Plunger (10) is for the arm cylinder only.
snap ring (20). (See Fl) 3. Assemble head assembly (7). (See F6)
5. Assemble O-ring and backup ring (19). 4. Assemble collar assembly (6). (See F6)
(See Fl) l Collar assembly (6) for boom and arm
2. Assembly of collar assembly cylinders only.
1. Assemble ring (18) and collar (17) to collar 5. Assemble plunger (5). (See F6)
(16). (See F2) l Plunger (5) is for the boom and arm
2. Assemble O-ring and backup ring (15). cylinders only.
(See F2) 6. Assemble piston (4). (See F6)
7. Fit spacer (3) and tighten with mounting
3. Assembly of piston assembly bolts. (See F6)
1. Using tool E,, expand piston ring (14). 5. Cylinder assembly
(See F3) 1. Assemble piston rod assembly (2). (See F7)
* Set the piston ring on tool E, and turn & Seal: Grease (G2-LI)
the handle 8 - 10 times to expand the -k Set the end gap of the ring in a horizontal
ring. (sideways) position, align it with the
2. Set tool E, in position, and compress piston center of the axis of the cylinder, then
ring (14). (See F4) insert. (See F7)
3. Assemble wear ring (13). (See F4) * After inserting, check that the rings are
4. Assemble ring (12). (See F4) not broken of missing, then insert fully.
* Be careful not to open the end gap of the 2. Tighten head assembly (1) with mounting
ring too far. bolts. (See F9)
& Ring groove: Grease (G2-LI) u Mounting bolt:
30-142
Fl F5
24
19
23
21
22
202FO5486 9 205FO5906
F2 F6
7 6 5
205FO.5905 205FO5907
F3
.
E:2
14.
End gaps of rings
202FO541 38 I 205FO5908
/
F4
I 202FO5485 202FO548 I
REMOVAL OF WORK INSTALLATION OF WORK
EQUIPMENT ASSEMBLY EQUIPMENT ASSEMBLY
A
operate the control levers 2 or 3 times. m
1. Disconnect hose (l), (See Fl) * When tightening the locknut, tighten so
2. Remove lock bolt (2). (See Fl) m that the clearance between the boss of
3. Remove pin (3). (See Fl) 1m ml Ml the boom and the nut is 0.5 - 1.5 mm.
* Sling the boom cylinder assembly and (See F5)
remove the pin m
A
A
Start the engine and retract the boom hole, run the engine at low idling.
cylinder rod fully, then tie the rod with Never insert your fingers in the pin
wire to prevent it from coming out, hole.
and lower it onto the block.
* Disconnect the boom cylinder on the
opposite side in the same way. Adjust with shims so that the clearance
A
% Y Release the remaining pressure in the
4 circuit. For details, see TESTING AND

between cylinder rod (8) and plate (9) is
less than 1 mm. (See F6)
ADJUSTING, Releasing pressure in
the hydraulic circuit for machines with
PPC valve. Adjust with shims so that the clearance
4. Disconnect hose (4). (See F2) between boom (10) and bracket (11) is
5. Disconnect wiring (5). (See F2) less than 1 mm. (See F7)
6. Remove pin (6). (See F3) m ml
* Sling work equipment assembly (7), then
using tool F, remove the pin (See F3) Inside surface of bushing: LM-P
7. Remove work equipment assembly (7). For grease, use MPG.
(See F4)
See Weight Table l Bleeding air
f Bleed the air from the cylinder. For
details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
-k After bleeding the air from the cylinder,
30-144
Fl
1
0.5 - 1.5 mm
\ 205FO5499 2OSF6065
F6
8 9
205FO5500 F20705349
F7
Max. 1 mm
I
11 10
205FO5501 F20705350
30-145
REMOVAL OF BUCKET REMOVAL OF ARM ASSEMBLY
ASSEMBLY
1. Bucket assembly
A
l Remove bucket assembly
Set the back of the bucket facing down,
lower the work equipment to the ground, For details, see REMOVAL OF BUCKET
and operate the control levers 2 or 3 ASSEMBLY.
times. 2. Work equipment set
1. Remove lock bolt (1). (See Fl) m j, Secure the bucket cylinder assembly to
2. Remove plate (2). (See Fl) m the arm, pull in the arm, and lower it onto
block 0. (See F4) mj mj
3. Remove pin (3). (See Fl) m
-k Sling the arm cylinder assembly, and remove
4. Remove lock plate (4) (See Fl) m
the pin.
A
5. Remove pin (5) (See Fl) m
6. Remove bucket assembly (6). (See Fl) of the arm cylinder, then tie the rod
* Raise the work equipment and disconnect with wire to prevent it from coming
the arm from the bucket. out.
See Weight Table *
A
4
ADJUSTING, Releasing pressure in
INSTALLATION OF BUCKET PPC valve.
ASSEMBLY 4. Remove pin (3) (See F4) m mj
5. Remove arm assembly (4). (See F4)
* Raise the boom and disconnect the boom
removal.
from the arm.
Tighten
clearance
with the locknut so that the
between the bucket boss and
el kg
See Weight Table
nut is 0.5 - 1.5 mm. (See F2)
Adjust the shim thickness so that the

INSTALLATION OF ARM
clearance between bucket boss (7) and ASSEMBLY
spacer (8) is 2 mm. (See F3)
When aligning the position of the pin removal.
hole, run the engine at low idling. Never
insert your fingers in the pin hole. When aligning the position of the pin
hole, run the engine at low idling. Never
insert your fingers in the pin hole.
Adjust with shims so that the clearance
between boom (5) and arm (6) is less
than 1 mm. (See F5)

0 Bleeding air
* Bleed the air from the cylinder. For
Bleeding air.
* After bleeding the air from the cylinder,
30-146
F
F20505336 F20505338
1
F5
Max. 1 mm
.
0.5 - 1.5 mm
2OSF6065 I 6 5 F20705351
i-
7 8 Shim
Clearance 2 wmm
II
I F20505337
30-147
REMOVAL OF ARM, BUCKET INSTALLATION OF ARM,
ASSEMBLY BUCKET ASSEMBLY
A
operate the control levers 2 or 3 times.
1. Remove pin (1) (See Fl) mjm When aligning the position of the pin
f Set block @ between the arm and the hole, run the engine at low idling. Never
boom, then sling the arm cylinder insert your fingers in the pin hole.
assembly, and remove the pin. (See Fl)
A
of the arm cylinder, then tie the rod Adjust with shims so that the clearance
with wire to prevent it from coming between boom (5) and arm (6) is less
out. than 1 mm. (See F3)
3L Y Release the remaining pressure in the
4 circuit. For details, see TESTING AND

ADJUSTING,
hydraulic
Releasing
circuit
pressure
for machines with
in
PPC valve. For grease, use MPG.
l Bleeding air
3. Remove pin (3). (See F2) m mj
* Sling the arm and bucket assembly, then
remove the pin.
Bleeding air.
4. Remove arm and bucket assembly (4).
See Weight Table check the level of the hydraulic tank.
30-148
I F20505339 1
F2
F20505340
F3
Max. 1 mm ~
\
I 5 F20705351
30-149
REMOVAL OF BOOM ASSEMBLY INSTALLATION OF BOOM
ASSEMBLY
1. Arm and bucket assembly
l Remove arm and bucket assembly. l Carry out installation in the reverse order to
2. Disconnect hose (1). (See Fl) removal.
3. Remove lock bolt (2). (See Fl) m
4. Remove pin (3). (See Fl) mj m m Tighten with the locknut so that the
* Sling the boom cylinder assembly, and clearance between the boom boss and
remove the pin. nut is 0.5 - 1.5 mm. (See F5)
A
of the boom cylinder, then tie the rod When aligning the position of the pin
with wire to prevent it from coming hole, run the engine at low idling. Never
out, then lower it onto the block. insert your fingers in the pin hole.
* Disconnect the boom cylinder assembly
on the opposite side in the same way.
Y
A
4
between the cylinder rod (8) and plate (9)
ADJUSTING, Releasing pressure in is less than 1 mm. (See F6)
PPC valve.
6. Disconnect wiring (5). (See F2)
between boom (10) and bracket (11) is
7. Remove pin (6). (See F3) mm[ less than 1 mm. (See F7)
* Sling the boom assembly, then use tool F
to remove the pin. (See F3)
6. Remove assembly (7). (See F4)
See Weight Table For grease, use MPG.
& kg
l Bleeding air
Bleeding air.
30-150
Fl F5
I
--4---I
0.5 - 1.5 mm
\ 205FO5499 2OSF6065
F2 F6
205FO5500 F20705349
F3 F7
Max. 1 mm
11 10
205FO5501 1 F20705350
F4
I I
F20505341
30-151
REMOVAL OF OPERATORS REMOVAL OF
CAB ASSEMBLY COUNTERWEIGHT
1. Remove seat assembly (1). (See Fl) 1. Remove counterweight (1). (See F4) m
* Sling the counterweight, then remove the
See Weight Table
6 kg mounting bolts.
2. Disconnect wiper motor wiring (2). (See Fl) * Width across the flats of bolt:
3. Disconnect antenna wiring (3). (See F2) 45mm (PCBOOLC)
4. Disconnect room lamp wiring (4). (See F2) 65mm (PC4OOLC)
5. Disconnect ground connection (5). (See F2)
6. Remove instrument panel assembly (6) elkg See Weight Table
(See F2)
* Remove the cover, then loosen the
mounting bolts, and move the instrument
panel assembly towards the inside.
INSTALLATION OF
7. Remove cab assembly (7). (See F3)
COUNTERWEIGHT
kg See Weight Table
r5zl
removal.
m
INSTALLATION OF
u Mounting bolt:
OPERATORS CAB ASSEMBLY See Tightening Torques and Standard
Values Table
removal.
30-152
Fl
L
Y
2
F20505372
_J
c
\
/ / /.....--yy-+\
\ \
F20505342
1
F2
205FO5504
30-I 53
REMOVAL OF ENGINE REMOVAL OF MONITOR
THROTTLE CONTROLLER PANEL ASSEMBLY
1. Pump controller assembly. 1. Screws (1). (See F5)

For details, see REMOVAL OF PUMP * Remove 4 screws, and move the monitor
CONTROLLER ASSEMBLY. panel assembly upward.
2. Wiring connector (1). (See Fl) 2. Wiring connector (2). (See F5)
* Disconnect the connector from the wiring 3. Monitor panel assembly (3). (See F5)
clamp.
3. Bracket (2). (See Fl)
4. Wiring connector (3). (See Fl)
INSTALLATION OF
5. Bracket (4). (See Fl)
* Remove the mounting bolts, and move
MONITOR PANEL
the bracket toward the inside. ASSEMBLY
6. Engine throttle controller assembly (5).
(See F2) l Carry out installation in the reverse order to
removal.
INSTALLATION OF ENGINE
THROTTLE CONTROLLER

removal.
REMOVAL OF PUMP
CONTROLLER ASSEMBLY
1. Box assembly (1). (See F3)

* Disconnect the antenna wiring of the
radio, the wiring connectors, and the
ground connection, then remove together
with the radio.
2. Wiring connector (2). (See F4)
3. Pump controller assembly (3). (See F4)
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY

removal.
30-154
r- ./ I
-5
I F20505373 F20505377
F2
F20505374
F4
30-155
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
PC3OOLC
* When carrying out flushing to remove dirt in the hydraulic circuit, use the following procedure. Select
one of the patterns below to match the level of contamination in the hydraulic circuit.
Flushing
No. Contamination level
pattern
, Hydraulic equipment is broken; there are A
metal particles in the circuit
Parts in the circuit have been
2 disassembled and assembled (there are
no metal particles in the circuit) B
3 Periodic flushing
4 After assembly at job site following
C
disassembly and transportation
1. Parts to prepare
* The figures in the table below show the number of parts required.
3 Extension hose for PPC

circuit 07102-20340 5 5 -
7 Extension nipple for PPC 21T_04_1 158O 3 S _

circuit
l In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
* For details, see Installation of filter element.
30-I 56
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of the
filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
1 Short-circuiting the piping
Using the piping short-circuiting flange, short-circuit the following piping.
Method for short-circuiting piping
Position Attachment Con~~~~ons Part No. CYty The whole hydraulic circuit, including the
hoses and tubes, is flushed, so short-circuit
(E) and (P) the supply and return pipes in the circuit.
1 Boom 07377-01018 2
I I
(G) and U-0 I I
I
2 I Arm 1 (C) and (D) 107377-01018 1 1
3 Bucket (A) and (B) 07377-01018 1
4 Swing (I) and (J) 07377-01018 1
5
I Travel (K) and (L) 07377-01018
I (2 places) I I
2
Flange
F20505378
F20705337
30-157
2. Installation of filter element
Plate22
RelieZlI
Small strainer-9
0
.-:..
Flashing element *.*
(Install)
4 Strainer (Clean)
O-ring -----+
/
F20705338
* When removing the element from the

return filter, use the stopper to prevent
the dirt inside the filter case from entering
the tank.
l Inside diameter of hole: 53mm
* When parts have been removed for short-
circuiting, clean the individual parts and
blow with air, then mask with tape to
prevent dirt from entering, and store in a
safe place until assembling again.
* When replacing the pilot filter, always use
the special tool. For details, see TESTING
AND ADJUSTING. LJ
F2070533
30-158
3. Cleaning cylinder
f Disassemble all cylinders and clean them
i) Remove cylinder head, then pull out
piston rod
F20505382
ii) Fix cylinder at an angle, then use a

pump to clean with flushing fluid.
Pump
* If no pump is available, use a Cylinder
crane, collect the flushing fluid at
\
the bottom end, shake well, then
drain the flushing fluid, and blow
with air.
F20505383
iii)Apply flushing fluid to the cylinder

head and piston and brush well with
a nylon brush, then blow with air.
f Dirt is likely to collect particularly
in the insert portions, so clean
these parts well.
iv) Check inside of cylinder for damage.
l Any verticle scratches in cylinder Rod Piston Piston ring Wear ring Guard ring Space1
l Any breakage or seizure of wear
\ \ I I//
rings, piston rings, or guard ring
Scratches on piston
; If there is any scuffing of the
piston or cylinder, replace the
assembly.
* If only the wear ring, piston ring,
or guard ring are damaged,
replace the damaged part with a
..
new part, and use again. F2070534C
30-I 59
4. Flushing PPC circuit
Disconnect PPC hose from

It is not necessary to remove main valve, then fit
noses for port P and port T. blind plug in main valve
Port P
Use nipple to connect hose -

_
Using extension hose,

return PPC circuit hose
directly to hydraulic filter
1 Replace element and clean
small strainer
Hydraulic tank
\
F20505386
i) Disconnect PPC circuit hose from ii) Run the engine at high idling, operate
main valve, and return directly to the control lever in each direction and
hydraulic tank filter case hold it for 2 minutes in each position.
* The ARM IN PPC circuit hoses are iii) Repeat the procedure in Step 4....ii)
connected to both the 4-spool at least 5 times.
and 5-spool main valves, so iv) Carry out the procedure in Steps
disconnect from both main valves, 4 . . . . i), 4 . . . . ii), and 4 . . . . iii) for each
and return to the hydraulic tank. circuit.
* Carry out the operation for one
PPC valve.
30-160
3. Flushing pattern [A] iii) Run the engine at high idling and
1. Disassembly, cleaning, and reassembly carry out the following operation.
i) Failed parts l Operating pattern
f If the part is badly damaged, Boom RAISE - Boom LOWER -
replace it. Arm IN - Arm OUT - Bucket
ii) Hydraulic tank CURL 4 Bucket DUMP - Right
iii) Suction strainer swing - Left swing - Left travel -
Right travel
iv) Oil cooler
l Operating time
Ir If excessive amounts of dirt and
dust are stuck in the core, Hold the lever in each position for
replace. two minutes.
v) Cylinder l Number of times of operation
* For details, see Cleaning Repeat the above pattern at least
cylinder. 5 times.
vi) Other hydraulic equipment 4. Restoring cylinder circuit. swina motor circuit
2. Preparatory work for flushing i) Restore the cylinder &it and swing
motor circuit to the standard circuit.
i) Install the flushing element, clean the
small strainer, then install it again. * Keep the travel motor circuit
Replace the pilot filter with a new short-circuited.
part. ii) Add hydraulic oil to the specified
* For details, see Installing filter level.
element. iii) Bleed the air from the main pump,
ii) Short-circuit the cylinder circuit, cylinders, and swing motor.
swing motor circuit, and travel motor 5. Flushing center swivel joint
circuit. i) Run the engine at high idling and
* For details, see Short-circuiting carry out the following operation.
the piping. 0 Operating pattern-
iii) Add hydraulic oil to the specified Left and right FORWARD + 90
level. swing
iv) Bleed the air from the main pump. Left and right REVERSE + 90
3. Flushing cylinder circuit, swing motor circuit, swing
travel motor circuit * Swing 90 to either the left or
i) Run the engine at low idling for 30 right, but swing in the same
minutes. direction each time.
-k The control levers must not be l Operating time
moved during this time. Hold the lever in each position for
ii) Run the engine at midrange speed for 2 minutes
30 minutes. 0 Number of times of operation
* The control levers must not be Repeat the abovepattern 4 times,
moved during this time. and rotate the swing one turn.
* If the oil temperature is low, * The purpose of swinging 90
increase the length of the each is to remove dirt inside the
operation in Steps 3....i), and center swivel from the oil grooves
3....ii) to raise the temperature. on the rotor side and shaft side
The oil temperature should be around the whole circumference.
50 - 80C.
30-161
6. Restoring the travel circuit 4. Flushing pattern [B]
i) Restore the travel circuit to the 1. Preparatory work for flushing
standard circuit. Install the flushing element, clean the small
ii) Replace the flushing element with a strainer and install it again.
new part. * For details, see Installing filter element.
j, For details, see Installing filter 2. Flushing PPC circuit
element. Flush the PPC circuit.
iii) Bleed the air from the travel motor. * For details, see Flushing PPC circuit.
7. Flushing PPC circuit. 3. Restoring PPC circuit
i) Flush the PPC circuit Restore the PPC circuit to the standard
*For details, see Flushing PPC circuit.
circuit. 4. Flushing during actual operation
8. Restoring PPC circuit With the flushing element installed, carry out
i) Restore the PPC circuit to the normal operations for 10 - 20 hours.
standard circuit. * If the oil temperature is low, carry out the
9. Flushing during actual operation warming-up operation.
i) With the flushing element installed, 5. Replacing element
carry out normal operations for 10 - Replace the return filter with a standard
20 hours element, clean the small strainer and install it
* If the oil temperature is low, carry again. Replace the pilot filter with a new part.
out the warming-up operation. _k For details, see Installing filter element.
10. Replacing element
i) Replace the return filter with a
standard element, clean the small
strainer and install it again. Replace
the pilot filter with a new part.
* For details, see Installing filter
element.
ii) Add hydraulic oil to the specified
level.
iii) Bleed the air from the main pump.
30-162
5. Flushing pattern [C] 4. Flushing during actual operation
* If the cylinder piping is connected and i) With the flushing element installed,
the cylinder is operated before the carry out normal operations for 10 -
system is flushed, there is danger that the 20 hours.
dirt that entered during assembly * If the oil temperature is low, carry out the
operations will be circulated inside the warming-up operation.
cylinder. Therefore, do not wait until 5. Replacing element
completion of assembly to flush the Replace the return filter with a standard
system; carry out flushing before element, clean the small strainer and install it
connecting the piping to the cylinder. again. Replace the pilot filter with a new part.
1. Preparatory work for flushing * For details, see Installing filter element.
i) Short-circuit the cylinder circuit. i) Add hydraulic oil to the specified
-k For details, see Short-circuiting level.
the piping. ii) Bleed the air from the main pump.
ii) Install the flushing element, clean the
small strainer and install it again.
element.
2. Flushing
i) Run the engine at low idling for 30
minutes.
* The control levers must not be
moved during this time.
ii) Run the engine at midrange speed for
30 minutes.
iii) Run the engine at high idling and
carry out the following operation.
l Operating pattern
Boom RAISE - Boom LOWER -
Arm IN - Arm OUT - Bucket
CURL - Bucket DUMP
l Operating time
Hold the lever in each position for
two minutes.
0 Number of times of operation
Repeat the above pattern at least
5 times.
3. Restoring cylinder circuit
0 Restore the cylinder circuit to the
standard circuit.
level.
iii) Bleed the air from the main pump and
cylinders.
30-163
PROCEDURE FOR FLUSHING HYDRAULIC CIRCUIT
PC4OOLC
* When carrying out flushing to remove dirt in the hydraulic circuit, use the following procedure. Select
one of the patterns below to match the level of contamination in the hydraulic circuit.
No.
~~ I Contamination level
I Flushing
pattern
, Hydraulic equipment is broken; there are
A
*
2 disassembled and assembled (there are
no metal particles in the circuit) B
I
3 /Periodic flushina
4 After assembly at job site following
C
Idisassembly and transportation I
1. Parts to prepare
* The figures in the table below show the number of parts required.
l In addition to these, a stopper is also needed as a blind plug for the hydraulic tank filter case.
* For details, see Installation of filter element.
30-I 64
2. Order of operations
The following explanation describes the procedure for short-circuiting the piping, installation of the
filter element, cleaning of the cylinder, and flushing of the PPC circuit that is carried out in the
operation for each flushing pattern.
1. Short-circuiting the piping
Using the piping short-circuiting flange, short-circuit the following piping.
Method for short-circuiting piping

Position Attachment con~~$ons Part No. Qty The whole hydraulic circuit, including the
hoses and tubes, is flushed, so short-circuit
(E) and (P) the supply and return pipes in the circuit.
1 Boom 07377-01018 2
(C) and (H)
2 Arm (C) and (D) 07377-01018 1
3 Bucket (A) and (B) 07377-01018 1
4 Swina (I)
. , and (J)
. . 07377-01018 1
5 Travel (K) and (L) 07377-01018 2

(2 places)
Flange
F20505378
C D
F20705341
30-I 65
2. Installation of filter element
Plate&
Spring
Relief valve
Small strainer-3
0
.:::.
1
Flashing element
(Install)
4 Strainer (Clean)
O-ring-----d?
/
* When removing the element from the

return filter, use the stopper to prevent
the dirt inside the filter case from entering
the tank.
l Inside diameter of hole: 53mm
* When parts have been removed for short-
circuiting, clean the individual parts and
blow with air, then mask with tape to
prevent dirt from entering, and store in a
safe place until assembling again.
* When replacing the pilot filter, always use
the special tool. For details, see TESTING
AND ADJUSTING.
30-166
3. Cleaning cylinder
* Disassemble all cylinders and clean them.
0 Remove cylinder head, then pull out Cylinder Rod Head
piston rod. I \ I
F20505382
ii) Fix cylinder at an angle, then use a

pump to clean with flushing fluid.
* If no pump is available, use a
crane, collect the flushing fluid at
the bottom end, shake well, then
drain the flushing fluid, and blow
with air.
F20505383
iii)Apply flushing fluid to the cylinder

head and piston and brush well with
a nylon brush, then blow with air.
j, Dirt is likely to collect particularly
in the insert portions, so clean
these parts well.
iv) Check inside of cylinder for damage.
Rod Piston Piston ring Wear ring Guard ring Spacer
l Any verticle scratches in cylinder
l Any breakage or seizure of wear
rings, piston rings, or guard ring
l Scratches on piston
* If there is any scuffing of the
piston or cylinder, replace the
assembly.
f If only the wear ring, piston ring,
or guard ring are damaged,
replace the damaged part with a
new part, and use again. F20705340
30-167
4. Flushing PPC circuit
Disconnecti PPC hose from

It is not necessary to remove main valve, then fit
noses for sort P and Prt T. ^I..^ :- ..,.:.. .,.
From charg
pump -
Main valve
. . to connect hose -
nioDle /
Using extension hose,

nnnn Replace element and clean
small strainer
return PPC circuit hose
directly to hydraulic filter case
F20505386
0 Disconnect PPC circuit hose from ii) Run the engine at high idling, operate
main valve, and return directly to the control lever in each direction and
hydraulic tank filter case hold it for 2 minutes in each position.
* The ARM IN PPC circuit hoses are iii) Repeat the procedure in Step 4....ii)
connected to both the 4-spool at least 5 times.
and 5spool main valves, so iv) Carry out the procedure in Steps
disconnect from both main valves, 4 . . . . i), 4 . . . . ii), and 4....iii) for each
and return to the hydraulic tank. circuit.
* Carry out the operation for one
PPC valve.
30-168
3. Flushing pattern [A] iii) Run the engine at high idling and
1. Disassembly, cleaning, and reassembly carry out the following operation.
l Operating pattern
i) Failed parts
jlr If the part is badly damaged, Boom RAISE - Boom LOWER -
replace it. Arm IN - Arm OUT - Bucket
ii) Hydraulic tank CURL - Bucket DUMP - Right
swing - Left swing 4 Left travel -
iii) Suction strainer
Right travel
iv) Oil cooler
* For loader specification machines,
* If excessive amounts of dirt and
continue the above operating
dust are stuck in the core,
pattern as follows: Bottom dump
replace.
OPEN - Bottom dump CLOSE.
v) Cylinder 0 Operating time
-k For details, see Cleaning
cylinder.
two minutes.
vi) Other hydraulic equipment 0 Number of times of operation
2. Preparatory work for flushing
i) Install the flushing element, clean the 5 times.
small strainer, then install it again.
4. Restoring cylinder circuit, swing motor circuit
Replace the pilot filter with a new
part. 0 Restore the cylinder unit and swing
motor circuit to the standard circuit.
* Keep the travel motor circuit
element.
short-circuited.
ii) Short-circuit the cylinder circuit,
swing motor circuit, and travel motor
level.
circuit.
iii) Bleed the air from the main pump,
* For details, see Short-circuiting
cylinders, and swing motor.
the piping.
5. Flushing center swivel joint
iii)Add hydraulic oil to the specified
level. i) Run the engine at high idling and
iv) Bleed the air from the main pump.
0 Operating pattern
3. Flushing cylinder circuit, swing motor circuit,
Left and right FORWARD + 90
travel motor circuit
swing
Left and right REVERSE + 90
minutes.
swing
moved during this time. * Swing 90 to either the left or
right, but swing in the same
direction each time.
30 minutes
l Operating time
moved during this time. Hold the lever in each position for
2 minutes
* If the oil temperature is low,
increase the length of the
l Number of times of operation
operation in Steps 3....i), and Repeat the above pattern 4 times,
3....ii) to raise the temperature. and rotate the swing one turn.
The oil temperature should be * The purpose of swinging 90
50 - 80C. each is to remove dirt inside the
center swivel from the oil grooves
on the rotor side and shaft side
around the whole circumference.
30-I 69
6. Restoring the travel circuit 4. Flushing pattern [B]
i) Restore the travel circuit to the 1. Preparatory work for flushing
standard circuit. Install the flushing element, clean the small
ii) Replace the flushing element with a strainer and install it again.
new part. f For details, see Installing filter element.
* For details, see Installing filter 2. Flushing PPC circuit
element. Flush the PPC circuit.
iii) Bleed the air from the travel motor. * For details, see Flushing PPC circuit.
7. Flushing PPC circuit. 3. Restoring PPC circuit
i) Flush the PPC circuit Restore the PPC circuit to the standard
-k For details, see Flushing PPC circuit.
circuit. 4. Flushing during actual operation
8. Restoring PPC circuit With the flushing element installed, carry out
i) Restore the PPC circuit to the normal operations for 10 - 20 hours.
standard circuit. * If the oil temperature is low, carry out the
9. Flushing during actual operation warming-up operation.
i) With the flushing element installed, 5. Replacing element
carry out normal operations for 10 - Replace the return filter with a standard
20 hours. element, clean the small strainer and install it
f If the oil temperature is low, carry again. Replace the pilot filter with a new part.
out the warming-up operation. * For details, see Installing filter element.
10. Replacing element
i) Replace the return filter with a
standard element, clean the small
strainer and install it again. Replace
the pilot filter with a new part.
element.
level.
iii) Bleed the air from the main pump.
30-170
5. Flushing pattern [C] 4. Flushing during actual operation
j, If the cylinder piping is connected and i) With the flushing element installed,
the cylinder is operated before the carry out normal operations for 10 -
system is flushed, there is danger that the 20 hours.
dirt that entered during assembly f If the oil temperature is low, carry out the
operations will be circulated inside the warming-up operation.
cylinder. Therefore, do not wait until 5. Replacing element
completion of assembly to flush the Replace the return filter with a standard
system; carry out flushing before element, clean the small strainer and install it
connecting the piping to the cylinder. again. Replace the pilot filter with a new part.
1. Preparatory work for flushing * For details, see Installing filter element.
i) Short-circuit the cylinder circuit. i) Add hydraulic oil to the specified
* For details, see Short-circuiting level.
the piping. ii) Bleed the air from the main pump.
ii) Install the flushing element, clean the
small strainer and install it again.
element.
2. Flushing
minutes.
30 minutes.
f The control levers must not be
iii) Run the engine at high idling and
. Operating pattern
Boom RAISE - Boom LOWER -
Arm IN - Arm OUT - Bucket
CURL - Bucket DUMP
Operating time
two minutes.
Number of times of operation
5 times.
3. Restoring cylinder circuit
0 Restore the cylinder circuit to the
standard circuit.
level.
iii) Bleed the air from the main pump and
cylinders.
30-171
30-I 72
40 MAINTENANCE STANDARD
FINAL DRIVE, PC300LC .......... ........................................... 40-4
FINAL DRIVE, PC4OOLC .......... ........................................... 40-6
SWING MACHINERY, PCBOOLC .... ........................................... 40-8
SWING MACHINERY, PC4OOLC .... ........................................... 40-l 0
SWING CIRCLE, PCBOOLC ........ ........................................... 40-l 2
SWING CIRCLE, PC4OOLC ........ ........................................... 40-l 3
TRACK FRAME AND RECOIL SPRING, PC3OOLC ................................. ..40-14
TRACK FRAME AND RECOIL SPRING, PC4OOLC ................................. ..40-15
IDLER, PCBOOLC ............... ........................................... 40-l 6
IDLER, PC4OOLC ............... ........................................... 40-l 8
TRACK ROLLER, PC3OOLC ........ ........................................... 40-20
TRACK ROLLER, PC4OOLC ........ ........................................... 40-21
CARRIER ROLLER .............. ........................................... 40-22
TRACK SHOE, PCBOOLC ......... ........................................... 40-24
TRACK SHOE, PC4OOLC ......... ........................................... 40-26
CHARGING PUMP AND RELIEF VALVE .......................................... 40-28
CONTROLVALVE ....................................................... ..40-2 9
TRAVELSHUTTLEVALVE ................................................. ..40-3 6
SWING MOTOR . .......................................................... 40-37
TRAVEL MOTOR, PCBOOLC ................................................ ..40-3 8
TRAVEL MOTOR, PC4OOLC ................................................ ..40-3 9
40-I
PPC VALVE, FOR WORK EQUIPMENT AND SWING ................................. 40-40
PPCVALVE,FORTRAVEL ................................................. ..40-4 1
PPCSHUTTLEVALVE .................................................... ..40-4 2
BOOM HOLDING VALVE .................................................... 40-43
HYDRAULIC CYLINDER, PC3OOLC ............................................ .40-44
HYDRAULIC CYLINDER, PC4OOLC ............................................ .40-45
WORK EQUIPMENT, PC3OOLC ................................................ 40-46
WORK EQUIPMENT, PC400LC ................................................ 40-48
40-2
40-3
FINAL DRIVE
PCSOOLC
. 7
\,,f.
; .
m-
.
..
3.
.1
, 6
~7+lkgm------
IJ
20JF05056K
40-4
Unit: mm
Check item I Remedy
Standard clearance Clearance limit
0.19 - 0.54 1 .oo
2 gear and No.

Backlash 1 ring No.
between gear
1 planet 0.21 - 0.62 I 1.10 I
3 Backlash between No. 1 planet 0.06 - 0.22 1.20

carrier and idle gear
Replace
4 Backlash between No. 2 sun 0.19 - 0.54 1 .oo
gear and No. 2 planet gear
Backlash between No. 2 planet

5 0.21 - 0.62 1.10
gear and ring gear

6 0.39 - 0.67
carrier and No. 1 sun gear I
7 1 End play of sprocket shaft I 0.10 - 0.15 I
Amount of wear on sprocket
8 Repair limit: 6
tooth Rebuild
or
Standard size Repair
9 Width of sprocket tooth replace
87 84
40-5
FINAL DRIVE
PC4OOLC
. .,
40-6
Unit: mm
No. Check item Criteria Remedy

Backlash between No. 1 sun
1
gear and No. 1 planet gear 0.20 - 0.57 1 .oo

2
gear and No. 1 ring gear

3 0.06 - 0.21
carrier and idle gear
Replace
Backlash between No. 2 sun
4 0.19 - 0.53
I gear and No. 2 planet gear
5 0.20 - 0.57 1.10
gear and ring gear
0.41 - 0.73
0.10 - 0.15 I
Amount of wear on sprocket
8 Repair limit: 6
tooth Rebuild
or
Standard size Repair
Width of sprocket tooth replace
9
90 87
40-7
SWING MACHINERY
PC3OOLC
10
2OJFO505 7
40-8
Unit: mm
No.
~~ I Check item Criteria Remedy
Backlash between swing Standard clearance Clearance limit

1
motor shaft and drive gear 0.07 - 0.18
0.18 - 0.49 1.00
0.07 - 0.18
Backlash between sun gear Replace

4 0.21 - 0.59 1.10
and planet gear
Backlash between planet

5 0.22 - 0.63 1.10
gear and ring gear

6 0.07 - 0.22
carrier and swina oinion
0 - 1.21
0.38 - 0.82 I Adiust
Standard Size Repair limit Apply hardchrome

plating, recondi-
0140 O/-6.169 139.7 tion or reolace
Standard clearance I Clearance limit
Adjust shim
Axial clearance of driven
11
aear
40-9
SWING MACHINERY
PC4OOLC
10
2
_.
208FO5629
40-I 0
Unit: mm
Check item Criteria I Remedy
Backlash between swing Standard clearance Clearance limit

1
motor shaft and drive gear 0.07 - 0.18
Backlash between drive

2 0.18 - 0.50 1 .oo
gear and driven gear
between driven
0.09 - 0.21
gear and sun gear
Backlash between sun gear Replace

4 0.21 - 0.59 1.10
and planet gear I
5 0.24 - 0.71 1.10
gear and ring gear I
6 carrier and swing pinion 0.10 - 0.23
Backlash between swing

7 pinion and swing circle 0 - 1.22 1.90
81End play of swing pinion 1 0.39 - 0.87 I - Adjust
Wear of swing pinion sur- Standard Size Repair limit Apply hardchrome
9 face contacting with oil plating, recondi-
seal 0150 o/-0.100 149.7 tion or replace

Axial clearance of drive
10
gear 0.08-0.32 _
Adjust shim
Axial clearance of driven
11 0.08-0.32
gear I I
40-11
SWING CIRCLE
PC300LC
Section A- A
207FO5058
Unit: mm
Standard size Clearance limit

1 Axial clearance of bearing Replace
0.5 - 1.6 3.2
40-12
SWING CIRCLE
PC4OOLC
94.5 f 10.5 kgm
w 94.5 f 10.5 kgm Section A - A 208FO5030
Unit: mm
Standard size Clearance limit

1 Axial clearance of bearing Replace
0.5 - 1.6 3.2
40-13
PC3OOLC
207FO5059
Unit: mm
Standard Tolerance Repair limit

size
Vertical width of idler
1 guide +2
Track frame 123 -1 127 Rebuild
or
Idler support 120 20.5 118 replace
Track frame +3. 271

Horizontal width of 266
2 idler guide
Idler support 261 259
I
Standard size Repair limit
Installation Installation Installation Replace

3 Recoil spring Free length Free length
lenath load load
795 x 241 648 17,680 kg 14,140 kg
40-14
PC4OOLC
208FO5031
Unit: mm
Standard Tolerance Repair limit

size
Vertical width of idler
1 guide Track frame 148 +_: 152 Rebuild
or
Idler support 145 +0.5 143 replace
Track frame +3
Horizontal width of 302 -1 307
2
idler guide
Idler suooort 297 295
3
I
Recoil spring
I Free length
I
Installation
lenath
I
Installation
load II
Free length
II
Installation
load I
Replace
857 x 270 707 23,375 kg 19,500 kg
40-15
IDLER
PC3OOLC
5 --_
1
3
--- L
--_ ---. \ 8
_-f \ T
I
\
\
\
:I
I I
!
I
/
i 1
d ! L /
- - II
207FO5060
40-16
Unit: mm
Outside diameter of protru- Standard size Repair limit
Rebuild
Outside diameter of tread 590 578 Or
replace
3 Width of protrusion 101
4 Total width 190
5 Width of tread 44.5 50.5

I I I I
Standard Tolerance Standard Clearance
Replace
size clearance limit
Clearance between shaft and Shaft Hole bushing
6 bushing
80 -0.225 +0.130 -
0.215 1.5
-0.325 -0.010 0.205
7 Clearance
support
between shaft and
I
80
I
-0.225
-0.290
-0.085
-0.195
0.030 -
0.205 I I Replace
Interference between idler

8 and bushing

9 Side clearance of idler (each)
2
40-17
IDLER
PC4OOLC
I
- - --1;
1 -
f I
J - I L
208FO5032
40-18
Unit: mm
Clearance between shaft and
Interference between idler
40-19
TRACK ROLLER
PC3OOLC
7
-I- -67*7
I
kgm
L---L-l
3 4 207FO5061
Unit: mm
Interference between roller
Side clearance of roller
40-20
TRACK ROLLER
PC4OOLC
4J -,76 + 8.5 kgm
A---------3 /!I T
-
r- _ I I
_I
-1
l---l-l
3 4 207F05601A
Unit: mm
Interference between roller
Side clearance of roller
40-21
CARRI ER ROLLER
,.
I-
Unit: mm

6 Side clearance of roller
0.01 - 0.24
40-22
40-23
TRACK SHOE
PC3OOLC
9
207FO5063
40-24
Unit: mm
No.
___~ I- Check item I ~~ Criteria I Remedy
1 Link pitch
203.45 207.45 Turn or
-r----
2 Outside
ing
diameter of bush- 66.9
I 61.9
Lug
welding,
3 Height of grouser 31 19 rebuild
or
replace
Rebuild
4 Height of link 116 107 or
replace
Interface of bushing and

5 link
Replace
6 Interference of regular pin 44.6 (Shaft) t 0.235 t 0.062 0.350- 0.140

and link 44.35 (Hole) + 0.085 0 0.464
I Replace
Interference of regular 44.4 (Shaft) t 0.230 t 0.062 o.iaa- with
7 master pin and link
44.35 (Hole) t 0.200 0 0.280 0.080
larger
one
5.25 2 0.3
Initial tightening torque: 4025 kgm Replace

Additional tighteneing angle: 120-~10 I
40-25
TRACK SHOE
PC4OOLC
i r
1
-I
9 .- 208FO5033
40-26
Unit: mm
No. Check item Criteria Remedv
Standard size I Repair limit

1 Link pitch
216.25 I 220.25 Turn or
replace
Outside diameter of bush- 74.3 69.3
ing I
Lug
welding,
Height of grouser 36 21 rebuild
or re-
place
Rebuild
Height of link 129 119 or
replace
Standard Tolerance Standard Interfer-

size clearance ence limit
Interface of bushing and Shaft Hole
5 link
Replace
71 +0.494 + 0.074 0.380 - 0.100
+0.454 0 0.494
Interference of regular pin 47.0 (Shaft) + 0.235 + 0.062 0.303 -

6 0.190
and link 46.72 (Hole) + 0.085 0 0.515
Replace
Interference of regular 46.8 (Shaft) + 0.230 +0.062 0.218 - with
46.72 (Hole) + 0.200 0 0.310 0.130
master pin and link larger
one
Protrusion of bushing 5.25 2 0.3
Tightening torque of shoe Initial tightening torque: 4025 kgm

9 Replace
bolt Additional tighteneing angle: 120?10
40-27
CHARGING PUMP AND RELIEF VALVE
,.
m 6.75 f 0.75 kgm
6.5 f 0.5 kgm I-
Section A - A
207FO5064,
Unit: mm

1 Top clearance of gear
0.090 - 0.130 0.145
2 Side clearance of gear 0.055 - 0.075 I 0.105
Clearance between gear 0.045 - 0.076 0.13

3 Replace
shaft and bushing
Standard value Repair limit

Delivery Engine oil
CLASS-CD SAElOW Revolution Delivery Revolution Delivery
4 5025C speed (rpm) (elmin) speed (rpm) (elmin)
30 kg/cm2
3,200 90 3,200 62
Standard size Repair limit Replace

I spring if
any dam-
Free Installed Installed Free Installed ages or
5 Charging relief valve spring length length load length load deforma-
x O.D. tions are
found
30.3x- 26.1 10.4 kg 9.4 kg
13.0
40-28
CONTROL VALVE
. _
.
._:. ,-2i>;O:?k
.. :.1 c,- .
e.O.9 t 0.1 kgm

, .
w 10.0 f 1.0 kgm ~
207FO5065
40-29
f
5.5 f 0.5 kgm 5.5 f 0.5 kgm 3.0 + O&kgm
SectionA-A . ._
.I.. ._ 207FO5066
Unit: mm
No. Check item Criteria 1 Remedy

I I 1 I
I I Standard size 1 Repair limit 1
Main relief valve pilot Free length Installed

1 1 InrEyd 1 l~~~~h 1 Installed 1
poppet spring x O.D. length
30.7 x 9.6 26.8 33.1 kg 26.5 kg

Replace
Main relief valve main 25.0 4.6 kg 3.7 kg spring if
2 30.4 x 11.3
valve spring
any
Jet sensor relief valve damages
3 26.3 x 8.0 26.1 0.39 kg 0.31 kg or defor-
pilot poppet spring
, mations
Jet sensor relief valve are
4 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
main valve spring I I found
Spool return spring

5 78.3 x 22.1 54.5 14.3 kg - 11.4 kg
(Straight-travel valve) I I
Spool return spring
6 (arm throttle valve) 53.8 x 26.5 52.5 10.6 kg - 8.5 kg
40-30
I _ _ . . . _ .
."-.I.9 * 1.0 lyrn

3
Qzl 5.5 f 0.5

r- .,
kgm
14.5 ?r:2.0 kgm
Section C 1 C Section IJ - D
. . 207FO50$1
. . .
Unit: mm
Free
Main relief valve pilot Installed Installed Free
1 length x Installed
poppet spring length load length
O.D.
30.7 x 9.6 26.8 33.1 kg - 26.5 kg

Replace
2 Main relief valve main 30.4 x 25.0 4.6 kg - 3.7 kg spring if
valve spring 11.3
any dam-
ages or
3 Jet
pilot sensor
poppet relief valve
spring 26.3 x 8.0 26.1 0.39 kg - 0.31 kg deforma-
tions are
Jet sensor relief valve found
4 main valve spring 23.8 x 7.8 18.1 2.41 kg - 1.93 kg
53.8 x
$;; return PC3OOLC 27.5 52.5 12.2 kg - 9.8 kg
5 (Swing
priority 53.8 x
valve) PC4OOLC 26.5 52.5 10.6 kg - 8.5 kg
40-31
w 9.0 * 0.5 kgm w 14.5 f 2.0 kgm
-.20> f 2.0 kgm

-
-1
20.0 k 2.0 kgm
Section F - F
1 w 20.0 k 2.0 kgm
Section E - E
m 15.5 f 2.5 kgm w 15.5 f 2.5 kgm -19.0 f 1.0 kgm 3
\ I
\ \
.5 kgm
3- .5
/ w \
6 \
4 m 19.0 + 1.0 kgm 5
Section G - G
Sedtion H - H
207FO5068
40-32
Unit: mm
Check valve spring
Replace
spring if any
damages or
deforma-
tions are
found
6 Spool return spring 21 x 16.9 21 0 kg 20
7 Check valve spring 55.9 x 30.2 29 0.8 kg - 0.64 kg
40-33
4 w 19:0*1.0 kgm
-\5.0 f 0.5 kgm

19.0 * 1.0 kgm I I 5.0 * 0.5 kgm 19.0 * 1.0 kgm
Section J - J Section K - K
m 7.0 * 1.0 kgm 2 3 m 15.5 * 2.5 kgm
_.__.__- ,. .-/ ..,_ _-,.I..

.; ,.,., _
._ .._
. . .,
.-. :
. -
Section L - L
_. 207FO5069
40-34
Unit: mm
Free length Installed Installed Free Installed

1 Spool return spring Replace
x O.D. length load length load
spring if any
54.8 x 34 53.5 12.7 kg - 10.2 kg damages or
deforma-
2 Spool return spring 30.7 x 32.5 26.5 26 kg - 20.8 kg tions are
found
3 Spool return spring 54 x 34.2 52 26 kg - 20.8 kg
4 1 Check valve spring 1 55.9 x 30.2 1 29 1 0.8 kg 1 - 1 0.64 kg 1
40-35
TRAVEL SHUTTLE VALVE
1 m 2.25 f 0.25 kgm
w 2.25 f 0.25 kgm w 2.25 f 0.25 kgm

I
: ;. : LT. .I _. ,. _ _=_._ _ 207EO5070,

.,. _..
-,
Unit: mm

. spring if any
Free length Installed Installed Free Installed damages or
1 Spool return spring
x O.D. length load length load deforma-
tions are
53.7 x 13.4 34.0 4.6 kg - 3.7 kg found
40-36
SWING MOTOR
w 56.7 f 6.0 kgm

!
Section 6 - 6
207FO5071
Unit: mm

spring if any
Free length Installed Installed Free Installed damages or
1 Check valve spring
x O.D. length load length load deforma-
tions are
66.5 x 25.6 45 0.71 kg - 0.57 kg found
40-37
TRAVEL MOTOR
PCBOOLC
-_. .-._ _.. ,_ I ., _- I
km
r
_. :
.,- -
.__ ..--. A _
., :. .
.2.4 f 0.4 kgm
-. _.
w w
w 37.0 rt 4.0 kgm 2 428,&4.7.kgm. 66.5 f 7.5 kgm
\
.6 kgm
Section B - B
I
Section A .- ..A-. 207FQ5072
Unit: mm

1 Spool return spring length load Replace
x O.D. length load
spring if
42.5 x 40 41 37.8 kg - 26.5 kg anv
2 Check valve spring 52.7 x 22.4
Regulator piston mations

3 55 x 9 are
spring I I found
4 Pilot piston spring 82.7 x 19.4 60.5 63.7 kg - 51 .o
5 Check valve spring 9.4 x 4.6 7.75 0.05 kg - 0.04 kg
40-38
TRAVEL MOTOR
PC4OOLC
76 k 8.5 kgm
I--
.A
2.4 + 0.4 kgm
1 2 m 42.8 rt 4.7 kgm
5.4 f 0.6 kgm
m 66.5 f 7.5 kgm

.O kgm
0.9 k 0.1 kgm Section 0 - B
Section A - A
208FO5034
Unit: mm

1 Spool return spring length Replace
x O.D. length load load
spring if
42.5 x 40 41 37.9 kg - 26.5 kg
any
2 Check valve spring 52.7 x 22.4 37 0.5 kg - 0.4 kg damages
or defor-
Regulator piston mations
3 spring 55 x 9 50 10kg - 8.0 are
found
4 Pilot piston spring 82.7 x 19.4 60.5 63.7 kg - 51.0
5 Check valve spring 9.4 x 4.6 7.75 0.05 kg - 0.04 kg
40-39
PPC VALVE
FOR WORK EQUIPMENT AND SWING
-I ,w 11.5 f 1.5 kgm
1.8 k 0.4 kgm
F Min. 3 kgm
205FO5198
Unit: mm
4 Centering spring 45.2 x 16.8 36.5 3.8 kg - 3.0 kg

(For P,, P&
40-40
PPC VALVE
FOR TRAVEL
,- 3.5 kgm
w Min. 3 kgm
\
FO20705004
Unit: mm

Replace
Free length Installed Installed Free Installed spring if any
1 Metering spring
x O.D. length load length load damages or
deforma-
31.4 x 7.4 29.4 1.7 kg - 1.4 kg tions are
found
2 Centering spring 47.4 x 16.8 36.5 2.3 kg - 1.8 kg
40-41
PPC SHUTTLE VALVE
FOR BOOM . BUCKET AND TRAVEL
m 3.5 ? 0.5 kgm
. .
, .
.,
. -,
_-
w 3.5 * 0.5 kgni

207FO5073
FOR ARM AND SWING
w 3.0 f 1 :O kgm
w 3.5 ?Z 0.5 kgm

207FO5074
40-42
BOOM HOLDING VALVE
w.4.0 + 0.5 kgm I
.w 11.25 f 1.25kgm
_ SectionA - A
-19.0 f 1.0 kg! : _;
207FO5075
Unit: mm

spring if
Free length Installed Installed Free Installed any
1 Pilot valve spring
x O.D. length load length load damages
or defor-
26.0 x 11.5 24.5 0.64 kg - 0.51 kg mations
are
2 Check valve spring 49.7 x 24.6 45.0 2.2 kg - 1.76 kg found
40-43
HYDRAULIC CYLINDER
PC300LC
* The drawing shows boom cylinder !
,.; ._
w Soom:: 38.0 * 5,5 kgm w Boom: 11.5 ? 1.0 kgm

Arm:: 64.9 f 8.0,kgm Arm: 18.0 i 2.0 kgm
I, B.ucket,:. 38.0 f 5.5 kgm Bucket: 11.5 f 1.0 kgm
.- ,
207FO5076
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size clearance limit
Shaft Hole I I
-0.036 + 0.257
Clearance between piston Boom
+ -0.090 + 0.047
1 rod and bushing
Arm
Bucket
0.083 - 0.447
0.347
0.406 -
Boom 100 1.0
0.528 I I
Clearance between piston -0.036 +0.457 0.406 -
2 rod support and bushing 1 .o
-0.090 I +0.370 0.547 I I
--I--
Bucket -0.036 +0.457
0.090 +0.370
-0.036 +0.457
Boom
-0.090 +0.370
Clearance between cyl-
3 inder bottom support and Arm 100 -0.036 + 0.457 0.406 - 1 .o
bushing -0.090 + 0.370 0.547 I I
~ Bucket 90
-0.036 +0.457 0.406 - 1.0
~ -0.090 I +0.370 0.547
40-44
HYDRAULIC CYLINDER
PC4OOLC
Sr The drawing shows boom cylinder
m Boom: 54.0 k 8.0 kgm

Arm: 91.0 f 14.0 kgm
Bucket: 54.0 + 8.0 kgm m Boom, Arm, Bucket: 18.0 i 2.0 kgm
208FO5035
Unit: mm
No. Check item Criter Remedy
Standard
clearance
-0.036 + 0.257
Boom 110
Clearance between piston -0.090 + 0.047
1 rod and bushing f
I Arm
I
120
-0.036
I -0.090
+0.263
I +0.048
0.083 -
0.353 I
0.453
I
Bucket 110 -0.036 +0.261
-0.090 + 0.047
Boom 110 -0.036 + 0.457

-0.071 + 0.370
Clearance between piston -0.036 + 0.457

2
rod support and bushing Arm 110 -0.090 + 0.370
Clearance between cyl-

3 inder bottom support and
bushing
I Bucket 100 -0.036

I -0.090
+ 0.457
I + 0.370
0.406 -
0.547 I
1.0
I
40-45
WORK EQUIPMENT
PCBOOLC
._ - . .. ,_D _ , ._ _ _ _. . -.
.-,_.
I_
.. .
. :; .:,: \/. A.
.-
i
207FO5077
_ ,. . I
,__ . . _._
Section D - D
Section E - E .-. -
Section B - B
Section F - F
Section K - K
Section C - C
Section G - G 207F05078A
40-46
Unit: mm
Clearance between bushing and connect-
2 Clearance between bushing and connect- 110 -0.036 + 0.354 0.311 - 1.0
ing pin of boom and arm -0.090 + 0.275 0.444
3 Clearance between bushing and connect- 90 -0.036 + 0.338 0.308 - 1.0 Replace
ing pin of arm and link -0.090 +0.272 0.428
4 Clearance between bushing and connect- 90 -0.036 +0.337 0.307 - 1.0

ing pin of arm and bucket -0.090 +0.271 0.427
Clearance between bushing and connect-

5
ing pin of link and bucket I

ing pin of link and link -0.090 + 0.275 0.436
7 Bucket clearance (a) 0.5 - 1.0 Shim

adjust
a Bucket clearance (bl 2.0
40-47
WORK EQUIPMENT
PC4OOLC
207FO5077
Section D - D
Section H - H
, . , . . _. .
Section A - A k3
. . _ ..-,._ .. ^. .- ,,_. . . .
Section E - E
Section B - B
Section F - F
Section C - C Section K - K
Section G - G
207F05078A
40-48
Unit: mm
Standard Tolerance Standard Clearance

size clearance limit
Clearance between bushing and connect- Shaft Hole
1
ing pin of revolving frame and boom. I
ing pin of boom and arm -0.090 +0.219 0.406
3 Clearance between bushing and connect- 100 -0.036 + 0.379 0.295 - 1.0 Replace
ing pin of arm and link -0.090 +0.259 0.469
ing pin of arm and bucket -0.090 +0.267 0.430
ing pin of link and bucket -0.090 + 0.259 0.419
6 Clearance between bushing and connect-

ing pin of link and link
7 Bucket clearance (a) 0.5 - 1.0 Shim

adjust
8 Bucket clearance (b) 2.0
40-49

Komatzu pc300-2

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CEBM207041

PC3OOLC-5 A30001 and up

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LIST OF REVISED PAGE

0 00-l 01-12 lo-20 lo-50 10-80

00-2 01-13 lo-21 lo-51 10-81

0 O&2-1 01-14 lo-22 lo-52 10-82

01-15 lo-23 10-53 10-83

10-110 lo-142 2@16 20-53 20-90

lo-111 0 10-143 20-17 20-54 20-91

lo-112 lo-144 20-18 20-S 20-92

0 lo-113 ltb145 20-19 20-56 20-93

0 10-113-l lo-146 2wu 20-57 20-94

lo-147 20-21 20-58 a95

lo-148 20-22 20-59 2cN6

lb149 20-23 20-60 20-97

20-127 20-164 20-200 20-236 3B16

20-128 a165 20-201 20-237 30-17

20-129 20-166 20-202 20-238 30-18

20-130 20-167 20-203 20-239 30-19

20-131 20-168 20-204 20-240 30-20

20-132 20-169 20-205 20-241 30-21

20-133 20-170 20-206 M242 30-22

20-W 20-171 20-207 20-243 w23

20-135 20-172 2wo8 20-244 30-24

20-136 20-173 20-209 20-245 30-25

20-137 20-174 20-210 20-246 30-26

20-138 20-175 20-211 20-247 30-27

20-139 20-176 20-212 a248 30-28

20-140 20-177 20-213 20-249 30-29

20-141 xF178 20-214 20-250 30-30

2B142 a179 20-215 20-251 30-31

a143 20-180 XI-216 20-252 30-32

20-144 20-181 20-217 20-263 30-33

20-145 20-W 20-218 20-254

2-O-146 20-183 M219 20-255

20-147 20-W 20-220 20-256

20-148 20-185 20-221

30-52 30-126 30-163 40-27

30-53 30-90 30-127 30-164 40-28

30-54 30-91 3@128 30-165 40-29

30-55 30-92 30-129 30-166 40-30

30-93 30-130 30-167 40-31

30-57 30-94 30-131 30-168

30-58 30-95 30-W 30-169

30-59 30-96 3Cb133 30-170

30-97 30-W 30-171

30-61 30-98 30-135 30-172

30-62 30-99 30-138

01 GENERAL ..................................... 01-I

10 STRUCTURE AND FUNCTION ....................... IO-I

20 TESTING AND ADJUSTMENT ....................... 20-I

30 DISASSEMBLY AND ASSEMBLY ..................... 30-I

40 MAINTENANCE STANDARD ........................ 40-I

99 OTHER METRIC CONVERSIONS ..................... 99-1

for the safe operation of your machine. The

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

4. When carrying out any operation with two or

5. Keep all tools in good condition and learn the

16. When removing components, be careful not

17. When removing piping, stop the fuel or oil

18. As a general rule, do not use gasoline to