pc300 350 6NLC

SEBM014307
MACHINE MODEL SERIAL NUMBER
PC300-6 33001 and up

PC300LC-6 33001 and up
PC350-6 12001 and up
PC350LC-6 12001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• PC300, 350-6 mount the SAA6D108-2 engine.

For details of the engine, see the 108-2 Series Engine Shop Manual.
© 2002 1
All Rights Reserved
00-1
Printed in Japan 05-02(01) 7
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD ......................................... 40-1
90 OTHERS........................................................................... 90-1
00-2 PC300, 350-6

2
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

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

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
‡ 00- 1 7 01- 1 10-14 10-45 10-75

00- 2 2 01- 2 4 10-16 4 10-46 10-76
‡ 00- 2-1 7 01- 3 4 10-17 10-48 10-77
‡ 00- 2-2 7 01- 4 10-18 10-49 10-78
‡ 00- 2-3 7 01- 5 10-19 10-50 10-80
‡ 00- 2-4 7 01- 6 10-20 10-51 10-81
‡ 00- 2-5 7 01- 7 10-21 10-52 10-82
00- 3 01- 8 10-22 10-53 10-84
00- 4 01- 9 10-24 10-55 10-85
00- 5 01-10 10-25 10-56 10-86
00- 6 01-11 10-26 10-57 10-88
00- 7 01-12 4 10-27 10-58 10-89
00- 8 01-13 10-28 10-59 10-90
00- 9 10-29 10-60 10-92
00-10 10-30 10-61 10-93
00-11 10- 1 4 10-31 10-62 10-94
00-12 10- 2 10-32 10-63 10-96
00-13 10- 3 10-33 10-64 10-97
00-14 10- 4 10-34 10-65 10-98
00-15 10- 5 10-35 10-66 10-100
00-16 10- 6 10-36 10-67 10-101
00-17 10- 7 4 10-38 10-68 10-102
00-18 10- 8 4 10-39 10-69 10-104
00-19 10- 9 4 10-40 10-70 10-105
00-20 10-10 4 10-41 10-71 10-106
00-21 10-11 4 10-42 10-72 10-108
00-22 10-12 10-43 10-73 10-109
10-13 4 10-44 10-74 10-110
PC300, 350-6 00-2-1

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10-112 10-155 10-197 5 20-14 5 20-131 1

10-113 10-156 10-198 20-15 5 20-132 1
10-114 10-157 10-199 20-16 5 20-133 1
10-116 10-158 10-200 20-17 5 20-134 1
10-117 10-159 10-201 20-18 1 20-135 6
10-118 10-160 10-202 20-19 1 20-136 1
10-120 10-162 10-203 20-20 1 20-137 1
10-121 10-163 4 10-204 20-102 1 20-138 1
10-122 10-164 10-205 5 20-103 4
10-123 10-165 10-206 20-104 1 20-201 5
10-124 10-166 10-207 20-105 1 20-202 1
10-125 10-168 10-208 5 20-106 1 20-203 1
10-126 4 10-169 10-209 5 20-107 1 20-204 1
10-127 4 10-170 10-210 5 20-108 1 20-205 1
10-128 4 10-171 10-212 ‡ 20-109 7 20-206 1
10-129 10-172 10-213 20-110 1 20-207 1
10-130 10-173 5 10-214 20-111 1 20-208 1
10-131 10-174 4 10-215 20-112 1 20-209 1
10-132 10-175 10-216 20-113 4 20-210 1
10-133 10-176 10-217 20-113-1 4 20-211 4
10-134 10-177 4 10-218 20-114 1 20-212 1
10-135 10-177-1 4 10-219 20-115 1 20-214 5
10-136 10-177-2 4 10-220 20-116 4 20-215 4
10-137 4 10-178 5 10-221 20-116-1 4 20-216 4
10-138 4 10-179 5 10-222 20-117 1 20-217 1
10-139 10-180 5 10-223 20-118 4 20-218 1
10-140 10-181 5 20-119 4 20-219 1
10-141 10-182 5 20-120 4 20-220 1
10-142 10-183 20- 1 1 20-120-1 4 20-221 1
10-143 10-185 20- 2 4 20-120-2 4 20-222 1
10-144 10-186 20- 4 4 20-121 1 20-223 1
10-145 10-187 20- 5 1 20-122 1 20-224 1
10-146 10-188 5 20- 6 1 20-123 1 20-225 1
10-147 10-189 20- 7 1 20-124 1 20-226 1
10-148 10-190 20- 8 1 20-125 1 20-227 1
10-149 10-191 20- 9 1 20-126 1 20-228 1
10-151 10-192 20-10 1 20-127 4 20-229 5
10-152 10-193 20-11 1 20-128 1 20-230 5
10-153 10-194 20-12 1 20-129 1 20-231 1
10-154 10-196 20-13 1 20-130 1 20-232 1
00-2-2 PC300, 350-6

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20-233 5 20-372 1 20-457 1 20-501 5 20-577 1

20-234 5 20-373 1 20-458 5 20-502 4 20-578 1
20-235 5 20-374 1 20-459 1 20-503 1 20-579 1
20-236 5 20-375 1 20-460 5 20-504 5 20-580 1
20-237 1 20-376 1 20-461 1 20-505 5 20-581 1
20-238 1 20-377 1 20-462 5 20-506 5 20-582 1
20-239 5 20-378 1 20-463 5 20-507 5 20-583 1
20-240 5 20-379 5 20-464 4 20-508 5 20-584 1
20-241 5 20-380 5 20-465 1 20-509 5 20-585 1
20-242 5 20-381 1 20-466 5 20-510 5
20-243 5 20-467 5 20-511 5 20-601 1
20-244 5 20-401 1 20-468 5 20-512 5 20-602 1
20-245 5 20-402 1 20-469 5 20-513 5 20-604 4
20-246 5 20-403 1 20-470 5 20-514 5 20-605 1
20-247 1 20-404 1 20-471 5 20-606 4
20-248 1 20-405 1 20-472 5 20-551 1 20-607 1
20-406 1 20-473 5 20-552 1 20-607-1 4
20-301 1 20-407 1 20-474 5 20-553 1 20-607-2 4
20-302 5 20-408 1 20-475 5 20-554 1 20-608 1
20-303 5 20-409 1 20-476 5 20-555 1 20-609 1
20-410 1 20-477 5 20-556 1 20-610 1
20-351 5 20-411 1 20-478 1 20-557 1 20-611 1
20-352 5 20-412 1 20-479 5 20-558 1 20-612 1
20-354 1 20-413 1 20-480 1 20-559 1 20-613 1
20-355 1 20-414 1 20-481 5 20-560 1 20-614 1
20-356 5 20-415 1 20-482 5 20-561 1 20-615 5
20-357 1 20-416 1 20-483 5 20-562 1 20-616 5
20-358 5 20-417 1 20-484 5 20-564 5 20-617 5
20-359 5 20-418 1 20-485 5 20-565 1 20-618 5
20-360 1 20-419 1 20-486 5 20-566 1 20-619 5
20-361 1 20-420 1 20-487 5 20-567 1 20-620 5
20-362 5 20-421 1 20-488 1 20-568 1 20-621 5
20-363 5 20-422 1 20-489 5 20-569 1 20-622 5
20-364 5 20-423 1 20-490 5 20-570 1 20-623 5
20-365 5 20-491 5 20-571 1 20-624 5
20-366 5 20-451 5 20-492 5 20-572 1 20-625 5
20-367 5 20-452 1 20-493 5 20-573 1 20-626 5
20-368 5 20-454 5 20-494 5 20-574 1 20-627 1
20-370 1 20-455 1 20-495 1 20-575 1 20-628 5
20-371 1 20-456 5 20-496 1 20-576 1 20-629 5
PC300, 350-6 00-2-3

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20-630 5 30-17 2 30-53-2 3 30-71 2 30-90 2

20-631 5 30-18 2 30-53-3 3 30-72 2 30-91 2
20-632 1 30-19 2 30-53-4 3 30-73 4 30-92 2
20-633 1 30-20 2 30-53-5 3 30-74 4 30-93 2
20-634 1 30-21 2 30-53-6 3 30-75 2 30-94 2
20-635 1 30-22 2 30-53-7 3 30-76 2 30-95 2
20-636 1 30-23 2 30-53-8 3 30-77 2 30-96 2
20-638 1 30-24 2 30-53-9 3 30-78 2 30-97 2
20-639 4 30-25 2 30-53-10 3 30-79 2 30-98 2
20-640 4 30-26 2 30-53-11 3 30-80 2 30-99 2
20-641 4 30-27 2 30-53-12 3 30-81 2 30-100 2
20-641-1 4 30-28 2 30-53-13 3 30-82 2 30-101 2
20-642 4 30-29 2 30-53-14 3 30-83 2 30-102 2
20-643 4 30-30 2 30-54 2 30-84 2 30-103 2
20-644 4 30-31 2 30-55 2 30-85 2 30-104 2
20-645 4 30-32 4 30-55-1 5 30-86 2 30-105 2
20-646 4 30-33 4 30-55-2 5 30-87 4 30-106 2
30-34 4 30-55-3 5 30-87-1 4 30-107 2
30-35 4 30-55-4 5 30-88 4 30-108 2
30- 1 5 30-36 4 30-55-5 5 30-88-1 3 30-109 2
30- 2 3 30-37 4 30-55-6 5 30-88-2 3 30-110 2
30- 3 2 30-38 4 30-55-7 5 30-88-3 3 30-111 4
30- 4 2 30-39 2 30-55-8 5 30-88-4 3 30-112 2
30- 5 2 30-40 4 30-55-9 5 30-88-5 3 30-113 4
30- 6 2 30-41 4 30-55-10 5 30-88-6 3 30-114 2
30- 7 3 30-41-1 4 30-56 2 30-88-7 3 30-115 2
30- 8 3 30-41-2 4 30-57 2 30-88-8 3 30-116 2
30- 9 3 30-42 4 30-58 2 30-88-9 3 30-117 2
30- 9-1 3 30-43 2 30-59 2 30-88-10 3 30-118 2
30- 9-2 5 30-44 2 30-60 2 30-88-11 3 30-119 2
30-10 2 30-45 2 30-61 2 30-88-12 3 30-120 2
30-11 2 30-46 2 30-62 2 30-88-13 3 30-121 2
30-11-1 5 30-47 2 30-63 2 30-88-14 3 30-122 2
30-11-2 5 30-48 2 30-64 2 30-88-15 3 30-123 2
30-11-3 5 30-49 2 30-65 2 30-88-16 3 30-124 2
30-12 2 30-50 2 30-66 4 30-88-17 3 30-125 2
30-13 2 30-51 2 30-67 4 30-88-18 3 30-126 2
30-14 2 30-52 2 30-68 4 30-88-19 3 30-127 2
30-15 2 30-53 2 30-69 2 30-88-20 3 30-128 2
30-16 2 30-53-1 3 30-70 2 30-89 2 30-129 2
00-2-4 PC300, 350-6

7

30-130 2 40-12 90- 3

30-131 2 40-13 90- 5
30-132 2 40-14 90- 7
30-133 2 40-15 90- 9
30-134 2 40-16 90-11 4
30-135 2 40-17 5 90-13 4
30-136 2 40-18 90-15 4
30-137 2 40-19 5
30-138 2 40-20
30-139 2 40-22
30-140 2 40-23
30-141 2 40-24
30-142 2 40-25
30-143 2 40-26
30-144 2 40-27
30-145 2 40-28
30-146 2 40-29
30-147 2 40-30
30-148 2 40-31
30-149 2 40-32
30-150 2 40-33
30-151 2 40-34
30-152 2 40-35
30-153 2 40-36
30-154 2 40-37
30-155 2 40-38 4
30-156 2 40-39 4
30-157 2 40-40 4
30-158 2 40-41
40-42
40-43
40- 1 4 40-44
40- 2 40-45
40- 4 40-46
40- 5 40-47
40- 6 4 40-48
40- 7 4 40-49
40- 8
40- 9
40-10 90- 1 4
PC300, 350-6 00-2-5

7
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol ¤ is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
• Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
• Always wear safety glasses when grind- 8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
10. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator's compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, • When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first 20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit. tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (–) terminal first. that 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
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit- tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
F O R EW OR D GENERAL
F O R EWOR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make 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 chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (123....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume: } Each issued as one
volume to cover all
models
REVISIONS
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
2. Following examples show how to read the Special safety precautions are
page number. ¤ Safety necessary when performing
the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
Item number (10. Structure

fl Caution serving standards are neces-
sary when performing the
and Function) work.
Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Example 2 (Engine volume):

4 Weight lecting hoisting wire, or when
working posture is important,
etc.
12 - 5
Tightening Places that require special at-
Unit number (1. Engine) 3 tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting) Places to be coated with ad-
Consecutive page number for 2 Coat
hesives and lubricants, etc.
each item.
Places where oil, water or fuel
5 Oil, water must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-) and number after the
Places where oil or water
page number. File as in the example. 6 Drain must be drained, and quan-
Example: tity to be drained.
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
 Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol 4
• If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
¤ Slinging with one rope may cause
turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
1) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-
(Standard "Z" or "S" twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg} when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN {1000 kg} vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2 to 19.6 kN {2000 kg} of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 {1000 kg} when two ropes make a 120°
20 43.1 4.4 hanging angle. On the other hand, two
ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN {4000 kg} if they sling
30 98.1 10.0
a 19.6 kN {2000 kg} load at a lifting angle
40 176.5 18.0 of 150°.
50 274.6 28.0 °
60 392.2 40.0
fl The allowable load value is estimated to

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

of the hook.
00-7
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Type 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
2) Hold in the condition in Step 1), and push 2) Hold in the condition in Step 1), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
00-8
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
• Hold the mouthpiece of the tightening por- • Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
Connection
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
fl The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
fl For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT–1A 790–129–9030 150 g Tube cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790–129–9140 50 g
1735 container • Used mainly for adhesion of metals, rub-
bers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• Used as adhesive or sealant for gaskets

LG-1 790–129–9010 200 g Tube
and packing of power train case, etc.
• Features: Resistance to heat

• Used as sealant for flange surfaces and
Gasket bolts at high temperature locations, used
sealant LG–3 790–129–9070 1 kg Can to prevent seizure.
• Used as sealant for heat resistance gasket
for high temperature locations such as en-
gine precombustion chamber, exhaust
pipe, etc.
00-10
F O R EW OR D COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Features: Resistance to water, oil

• Used as sealant for flange surface, thread.
LG-4 200 g Tube • Also possible to use as sealant for flanges
790–129–9020
with large clearance.
• Used as sealant for mating surfaces of fi-
nal drive case, transmission case.
• Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790–129–9080 1 kg
container • Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
• Features: Silicon based, resistance to heat,

Gasket cold
sealant LG-6 09940–00011 250 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive case,
etc.
• Features: Silicon based, quick hardening

type
LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing, in-
take manifold, oil an, thermostat housing,
etc.
Three bond • Used as heat-resisting sealant for repairing

790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking).
num
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
• Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease
SYG2-350CA steam.
G2-CA SYG2-400CA-A Various Various
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
F O R EW OR D STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2
16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5
27 41 1320 ± 140 135 ± 15
30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35
Thread diameter Width

of bolt across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

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

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

fl Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Nominal No.
mm mm Nm kgm
02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

fl Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Nominal No.
mm mm Nm kgm
08 8 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
6 8 ± 2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
1 / 16 3 ± 1 0.31 ± 0.10
1/8 8 ± 2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
00-14
F O R EW OR D ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rating
number Number of Dia. of strands Cross section (mm) (A) Applicable circuit
strands (mm) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Prior- Charging Ground Starting Lighting Instrument Signal Other
ity Classi-
fication
Pri- Code W B B R Y G L
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — Black & White Red & White Yellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Red
Auxi- Code WL — BR RY YG GY LY
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green Green & Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —
00-15
F O R EW OR D CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

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

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
..........................................
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
A ...........................................................................................
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1¶ = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1¶ = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

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

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
F O R EW OR D UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kw/rpm {HP/rpm}
g/kwh {g/HPh}
00-22
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GENERAL SPECIFICATIONS
SPECIFICATIONS
PC300,300LC-6
Machine model
Serial number
Bucket capacity m3
T PC300-6
33001 and up
1.4
PC3OOLC-6
33001 and up
1.4
Operating weight kg 30,800 31,900
Max. digging depth mm 7,380 7,380
Max. verticai waii depth mm 6,480 6,480
Max. digging reach mm 11,100 11,100
Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,210 10,210
Max. dumping height mm 7,110 7,110
Max. digging force (using power max. function) kN{kg) 21 1.9 {21,600} 21 1.9 (21,600)
s..,:--
VVlllY
-^^^
apead i-pm . ~ n
I v.v
r n n
Iw.w
Swing max. slope angle deg. 21 .o 21.o

Travel speed km/h Lo: 3.2 Mi: 4.5 Hi: 5.5 Lo: 3.2 Mi: 4.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure 62.72 {0.64} 50.96 (0.52)
[standard triple grouser shoe width] :Pa{kg/cm2) 1600 mml [700 mml
Overall length (for transport) mm 10,935 10,935
Overall width mm 3,190 3,290
Overall width of track mm 3,190 3,290
Overall height (for transport) mm 3,255 3,255
Overall height to top of cab mm 3,130 3,130
Ground clearance of counterweight mm 1,186 1,186
Min. ground clearance mm 498 498
Tail swing radius mm
...... 3,300 3,?0I!
Min. swing radius of work equipment mm 4,310 4,310
Height of work equipment at min. swing radius mm 8,440 8,440
Length of track on ground mm 3,700 4,030
Track gauge mm 2,590 2,590
Height of machine cab mm 2,580 2,580
01-4 PC300, 350-6

Machine model PC300-6 PC3OOLC-6

Serial number 33001 and up 33001 and up
Model SAA6D108-2
TY Pe 4-cycle, water-cooled, in-line, vertical, direct injection,

with turbocharger and aftercooler (air cooled)
No. of cylinders - bore x stroke mm 6 - 108 X 130
Piston displacement e {ccl 7.1 45 {7,145?
Flywheel horsepower kW/rprn{HP/rpm:
a
0
s Max. torque Nm/rpm{kgrn/rprn: 897.2/1,500 {91.5/1,5001
a
Max. speed at no load 2,300
0
5
R
Min. speed at no load 900
Min. fuel consumption 205 (151)
Starting motor 24V,7.5 kW
Alternator 24V, 33A
Battery 12V, 170 Ah x 2
Radiator core tvDe cwx-4
Carrier roller 2 on each side
Track roller 7 on each side 8 on each side
Track shoe
Type x No. HPV160+160, variable displacement

piston type x 2
Delivery Q/min. 262 x 2
Set pressure MPaIkg/cm2) 34.8 I3551
t 6-spool + l-spool type + l-service valve x 1
Type x No.
Control method Hydraulic
Travel motor HMVIGOADT-2, Piston type
(with brake vaive, shaft brake): x 2
Swing motor KMFIGOABE-3, Piston type (with safety valve,
shaft brake, reverse prevention valve): x 1
Boom Arm Bucket
Double-acting Double-acting, Double acting
piston piston piston
Inside diameter of cylinder mm 140 160 140
Diameter of piston rod mm 100 110 100
Stroke mm 1,480 1,685 1,285
Max. distance between pins mm 3,610 4,080 3,275
Min. distance between pins mm 2,130 2,395 1,990 L
Hydraulic tank Box-shaped, sealed
Hydraulic filter Tank return side
Hydraulic cooler Air cooled
PC300, 350-6 01-5

Machine model PC350-6 PC35OLC-6

Bucket capacity m3 1.4 1.4
Operating weight kg 32,300 33,400
Max. digging depth mm 7,380 7,380
Max. vertical wall depth mm 6,400 6,400
Max. digging reach mm 1 1,080 1 1,080
Max. reach at ground level rnrn 10,890 10,890
Max. digging height rnrn 10,070 10,070
Max. dumping height mm 7,030 7,030
Max. digging force (using power max. function) kN{kg) 212.9 (21,7001 212.9 (21,700)
Swing speed rpm 70.0 10.0
Swing Max. slope angle deg. 21.o 21.o
Travel speed km/h Lo: 3.2 Mi: 4.5 Hi: 5.5 Lo: 3.2 Mi: 4.5 Hi: 5.5
Gradeability deg. 35 35
Ground pressure 65.66 (0.67) 62.72 (0.64)
[standard triple grouser shoe width] kPa{kglcm2} [600 mml 1600 mrnl
Overall length (for transport) rnrn 1 1,030 1 1,030
Overall width mrn 3,190 3,190
Overall width of track mm 3,190 3,190
Overall height (for transport) mm 3,255 3,255
Overall height to top of cab mm 3,130 3,130
Ground clearance of countemeight mm 1,186 1,186
Min. ground clearance rnrn 498 498
Tail swing radius rnrn 3,300 3,300
Min. swing radius of work equipment mm 4,350 4,350
Height of work equipment at min. swing radius mm 8,510 8,510
Length of track on ground mm 3,700 4,030
Track gauge mm 2,590 2,590
Height of machine cab mrn 2,580 2,580
01-6 PC300, 350-6

Machine model PC350-6 PC350LC-6

Model SAA6D108-2
TY Pe 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders - bore x stroke mm 6 - 108 X 130
Piston dimlacement Q {cc) 7.145 {7,145}
Flywheel horsepower kW/rpm{HP/rpm 172.8/2,050 {231.7/2,050)
a
.-CUJ Max. torque Nmlrpm{kgm/rpm 897.2/1,500 {91.5/1,500)
w
C Max. speed a t no load rPm 2,300
Min. speed at no load rPm 900
Min. fuel consumption g/kW.h(g/HP.h) 205 (151)
Starting motor 24V, 7.5 kW
Alternator 24V, 33A
Battery 12V, 170 Ah x 2
Radiator core type CWX-4
Carrier roller 2 on each side
Track roller 7 on each
side
8 on each side
Track shoe
Type x No. HPV160+160, variable displacement

piston type x 2
Delivery Q/min. 262 x 2
Set pressure MPa{kg/cm2} 34.8 (355)
Type x No. 6-spool + l-spool type + l-service valve x 1
Control method Hydraulic
Travel motor HMVl60ADT-2, Piston type
(with brake valve, shaft brake): x 2
Swing motor KMF16OABE-3, Piston type (with safety valve,
shaft brake, reverse prevention valve): x 1
J Boom Arm
Double-acting Double-acting,
piston piston
Bucket
Double acting
piston
Inside diameter of cylinder mm 140 160 140
Diameter of piston rod mm 100 110 100
Stroke mm 1,480 1,825 1,285
Max. distance between pins mm 3,610 4,360 3,275
L Min. distance between Dins
Hydraulic tank
mm 2,130 2,535 1,990
Box-shaped, sealed
I
Hydraulic filter Tank return side
Hydraulic cooler Air cooled
PC300, 350-6 01-7

GENERAL WEIGHT
WEIGHT TABLE
This weight table is a guide for use when transporting or handling component.
PC300, 3OOLC-6 Unit: kg

Engine assembly 1,100 1,100
Engine 785 785
Damper 14.7 14.7
Hydraulicpump 200 200
Radiator, oil cooler assembly 165 165
Hydraulic tank, filter assembly (excl. hydraulic oil) 226 226
Fuel tank (excl. fuel) 218 218
Revolving frame 2,621 2,621
Operator's cab 287 283
Operator's seat 29 29
Counterweight 5,420 5,420
Swing machinery 380 380
Control valve (standard) 236 236
Swing motor 82 82
Travel motor ?73x 2 173 x 2
Center swivel joint 37 37
Track frame assembly 7,970 8,560
0 Track frame 4,695 5,182
Swingcircle 487 487
Idler 166 166
Idlercushion 257 x 2 257 x 2
Carrier roller 31 x 4 31 x 4
Track roller 52 x 14 52 x 16
Final drive (incl. travel motor) 629 x 2 629 x 2
01-8 PC300,350-6
GENERAL WEIGHT TABLE
Unit: kg

Track shoe assembly
Standard triple grouser shoe (600 m m l 3,600 3,840
Standard tripie grouser shoe (700m m i 3,940 4,220
Wide
triple
grouser shoe (800 mm) 4,300 4,560
Wide triple
grouser shoe ( mm) - -
Swamp shoe ( mml - -
Flat shoe ( mm) - -
Road liner(rubberpadtype) ( mm) - -
Boom assembly 2,478 2,478
Arm assembly 1,615 1,615
Bucket assembly 1,014 1,014
Boom cylinder assembly 296 x 2 296 x 2
Arm cylinder assembly 42 5 42 5
Bucket cylinder assembly 263 263
Link assembly (large) 320 320
Link assembly (small) - -
Boom pin '6t 15 x 2 t 56 + 17 + 42 r6 t 15 x 2 t 56 t 17 t 02
Arm pin 13 + 17 13 + 17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
PC300, 350-6 01-9

PC358,35OLC-6 Unit: kg

Engine assembly 1,100 1,100
Engine 785 785
0 Damper 14.7 14.7
0 Hydraulic pump 200 208
Radiator, oil cooler assembly 165 165
Hydraulic tank, filter assembly (excl. hydraulic oil) 226 226
Fuel tank (excl. fuel) 218 218
Revolving frame 2,741 2,741

Operator’s cab 287 287
Operator’s seat 29 29
Counterweight 6,320 6,320
Swing machinery 380 380
Control valve (standard) 236 236
Swing motor 82 82
Travel motor 173 x 2 173 x 2

Center s!$$JI.,.e!
Jcifit 33 37
Track frame assembly 8,045 8,670
Track frame 4,770 5,295
Swing circle 487 4.87
Idler 166 166
Idler cushion 257 x 2 257 x 2
Carrier roller 31 x 4 31 x 4
Track roller 52 x 14 52 x 16
* Final drive iinci. travei motor) 629 x 2 629 x 2
01-10 PC300, 350-6

Unit: kg

Serial number 12001 and up 12001 and u p
Track shoe assembly
Standard triple grouser shoe (600 mm) 3,600 3,840
Standard triple grouser shoe (700 mm) 3,940 4,220
Wide triple grouser shoe - -
Wide triple grouser shoe - -
Swamp shoe - -
Flat shoe - -
Road liner (rubber pad type) - -
Boom assembly 2,580 2,580
Arm assembly 1,747 1,747
Bucket assembly 1,274 1,274
Boom cylinder assembly 296 x 2 296 x 2
Arm cylinder assembly 447 447
Bucket cylinder assembly 263 263
Link assembly (large) 320 320
Link assembly (sma!l) - -
Boom pin 6+15x2+56+17+42 6+15x2+56+17+42
Arm pin 13 + 17 13 + 17
Bucket pin 30 x 2 30 x 2
Link pin 27 x 2 27 x 2
PC300, 350-6 01-11

GENERAL AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE I CAPACITY (el
RESERVOIR (IND OF
-22 -4 14 32
FLUID -30 -20 -10 0
50
10
68 86
:2cI 30
IT: ISpecifiedr
4 Refill
28
Engine oil pan
29
When bypass
filter is installed )
Swing machinery ease 13
Final drive case (each side) 9.5
Damper ease Engine

oil
Idler (1 each) 3.22 - 0.24
-
I rack roller (1 each) 1 0.25 - 0.28 3.25 - 0.28
l n r r n r n
v.43 - v.3v 3.45 - 8.58
Hydraulic system 205
Diesel
Fuel tank
fuel
Cooling system Coolant Add antifreeze
01- 1 2 PC300, 350-6

0
UEL, GENERAL AND LUBRICANTS
MOTE:
(1) When fuel sulphur content isless than 0.5%,
change oil in the oil pan every periodic main-
tenance hours described in this manual.
Change oil according to the following table
if fuel sulphur content is above 0.5%.
Change interval of oil in

sulphur
Fuel
content1 oil pan
0.5 t o 1.0% 1/2 of regular interval
Above 1.O% 1/4 of regular interval
When starting the engine in an atmospheric

temperature of lower than O"C, be sure to
use engine oil of SAEIOW, SAEIOW-30 and
SAE15W-40, even thoughanatmospheric
temperature goes upto 10°C more or less in
the day time.
Use API classification CD as engine oil andif
API classification CC, reduce the engine oil
change interval to half.
There isnoproblem if singlegradeoil is
mixed with multigrade oil(SAEIOW-30, 15W-
40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
We recommend Komatsu genuine oil which
hasbeenspecificallyformulatedand ap-
proved for use in engine and hydraulic work
equipment applications.
For the H046-HM, use the oil recommended
by Komatsu.
ASTM: American Society of Testing and Material

SAE: Societyof Automotive Engineers
API: American
PetroleumInstitute
Specified capacity: Total amount of oii inciud-

ing oil for components and
oil in piping.
Refillcapacity: Amount of oil needed to refill
system during normal inspection
and maintenance.
PC300, 350-6 01-13

10 STRUCTURE ANDFUNCTION
Parts related t o engine .............................. 10-2

Radiator. oil cooler..................................... 10-4
Power train ................................................. 10-5
Final drive ................................................... 10-6
Swing circle ................................................ 10-7
Swing machinery ....................................... 10-9
Track frame, recoil spring ......................... 10- 10
Track shoe ................................................... 10- 11
Hydraulic piping drawing .......................... 10- 12
Hydraulic circuit diagram .......................... 10- 14
Hydraulic tank, hydraulic filter .................. 10- 15
Hydraulic pump .......................................... 10- 17
Control valve .............................................. 10- 38
Self-reducing pressure valve .................... 10- 48
Suction safety valve................................... 10- 53
CLSS ............................................................ 10- 55
Swing motor ............................................... 10-120
Center swivel joint ..................................... 10-126
Travel motor ............................................... 10-128
Valve control ............................................... 10-137
Work equipment swing PPC vaive ........ 70-138
Travel PPC valve ........................................ 10-142
Service PPC valve ...................................... 10-146
PPC safety lock valve ................................. 10-149
PPC accumulator ........................................ 10-149
PPC shuttle valve, travel junction valve ... 10-151
LS-EPC valve ............................................... 10-158
Solenoid valve ............................................ 10-162
Boom holding valve ................................... 10-164
Work equipment......................................... 10-168
Air conditioner............................................ 10-169
Actual electric wiring diagram .................. 10-170
Electric circuit diagram.............................. 10-174
Engine control ............................................ 10-178
Electronic control system.......................... 10-185
Machine monitor system ........................... 10-212
Front window auto pull-up system .......... 10-222
PC300. 350-6 10-1

0
L1
2
W
0
+
N
STRUCTURE
FUNCTION
AND RELATED
PARTS TO ENGINE
A-A B-B
u..-
c-c
1. Driveplate 6. Air cleaner Outline

2. Torsionspring 7. Intake connector 0 The damper assembly is a wet
3. Stopper pin 8. Muffler t Y Pe
4. Frictionplate 9. Rear engine mount Oil capacity: 0.75
5. Damper assembly 10. Front engine mount
PC300, 350-6 10-3

*c
I
<C
m
I
m
I I .F I
0 0
t
N
AND STRUCTURE FUNCTION POWER TRAIN
POWER TRAIN
IO 9 8
I
12 SWPO4705
1. Idler 7. Hydraulic pump (HPV160+160)

2. Center swivel joint 8. Travel speed solenoid valve
3. Controlvalve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor (HMV160ADT-2) 11. Swing motor (KMF16OABE-3)
6. Engine(SAA6D108-2) 12. Swing circle
PC300, 350-6 1 0-5

CTION
STRUCTURE AND FINAL DRIVE
FINAL DRIVE
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 42)
4. No. 1 sun gear (No. of teeth: 11)
6. No. 1 planetary carrier
8. Cover
- 1 9. Wing gear (No. of teeth: 97)
10. Hub
11. Sprocket
12. Floating seal
13. Travel motor
Specifications
Reduction ratio: -
=- 58.943
10-6 PC300, 350-6

0
cn
? 2 2
a c o c o
D
I --
D
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
4. Coupling
6. Ring gear (No. of teeth: 95)
r
A
8.
9.
Cover
Swing motor
7
A
10.
11.
12.
Oil level gauge
No. 1 sun gear (No. of teeth: 28)
No. 1 planetary carrier
15. Drain plug
Specifications
28+95
2 1+95
Reductionratio: ~ x ~
28 21
= 24.265
10-8 PC300, 350-6

STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. S w i n g p i n i o n (No. of teeth: 13)

2. Cover
3. Case
4. Coupling
5. No. 2 p l a n e t a r y g e a r (No. of teeth: 36)
6. Ring gear (No. of teeth: 95)
7. Nc. ,! p!a!?etary gear !h!n. nf teeth: R3!
8. Cover
9. Swing motor
IO. O i l l e v e l g a u g e
11. No. 1 s u n g e a r (No. of teeth: 28)
13. No. 2 s u n g e a r (No. of teeth: 21)
15. D r a i n p l u g
Specifications
28+95
+95
21
Reductionratio: ~ x-
28 21
= 24.265
SWPO4707
PC300, 350-6 10-9

0
STRUCTURE AND FUNCTION SPRING
RECOIL
FRAME,
TRACK
TRACK FRAME, RECOIL SPRING

* The diagram shows the PC300-6
A-A
SWPO6558
% I . Pc3UU-6 Serlal No.: 33466 and up

PC350-6 Serial No.: 12284 and up
1. Idler The dimensions and number of track rollers

2. Track frame may differ according t o the model, but the
3. Carrier roller basic structure is the same.
4. Finaldrive No. of trackrollers.
5. Track roller
6. Track shoe Model I No. of rollers (each
side)
7. Center guard
8. Recoil spring PC300, 350-6 I 7
9. Frontguard PC3OOLC-6,PC35OLC-6 8
10-10 PC300, 350-6

0
STRUCTURE AND FUNCTION TRACK SHOE
TRACK SHOE
Standard shoe
PC300-6 PC35OLC-6 PC3OOLC

Shoe width (mm)
600 600 600 700
(triple shoe)
pitch
Link
No. of shoes
(mm) 216
I 216
I 216
I 216
45 48 48 45
(each side)
Selection of track shoe

Select the most suitable track shoe from the following table
\ 1 PC300-6 I PC350-6 I PC300LC-6 I PC35OLC-6
Standard 600 mm triple A 600 m m triple A 700 mm triple B 600 m m triple A

Option 700 mm triple B 700 m m triple B 600 m m triple A 700 m m triple A
Option 800 mm triple B 800 m m triple B
T
Categorb' I Use Precautions when using
+
Rocky ground, Travel in Lo speed when traveling on rough ground with
A
normal river soil obstacles such as large boulders and fallen trees.
Cannot be used on rough ground where there are large
obstacles such as boulders and fallen trees.
5 0 Travel in Hi speed only on flat ground; when it is impossible
to avoid traveling over obstacles, I ~ w ethe
r travel speed
to approx. half of Lo speed.
Use only for ground where "A" and "B" sink and are impossible
to use.
Cannot be used on rough ground where there are large
C Extremely soft ground
obstacles such as boulders and fallen trees
(swampy ground)
Travel in Hi speed only on flat ground; when it is impossible
t o avoid traveling over obstacles, lower the travel speed
t o approx. half of Lo speed.
D Paved surface The shoes are flat, so they have low gradeability
The shoes are made of rubber, so be careful when traveling
E Paved surface
on rough ground
* Categories "B" and "C" are wide shoes, so t Whenselectingthe shoewidth, select the
therearerestrictions ontheir use. There- narrowestshoepossiblewithinthe range
fore, before using, check the restrictions and that will give no problem with flotation and
consider carefully the conditions of use be- ground pressure.
fore recommending a suitable shoe width. If If a wider shoe thannecessary is used, there
necessary, givethecustomerguidance in will be a large load on the shoe, andthis
their use. may lead t o bending of theshoe, cracking of
the links, breakage of the pins, loosening of
the shoe bolts, or other problems.
PC300, 350-6 10-11

0
STRUCTURE AND FUNCTION PIPING
HYDRAULIC DRAWING
HYDRAULIC PIPING DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder 2
4. Center swivel joint
5. Swing motor
6. Oil cooler
7. Control valve
8. PPC shu?t!e va!ve
9. Hydraulic filter
IO. Hydraulic pump
11. L.H. travel motor
12. Hydraulic tank
13. PPC safety lock valve
14. L.H.PPC valve
15. R.H.PPC valve
16. Travel PPC valve
17. Boom holding valve
18. Accumulator
19. Active mode solenoid valve (Swing)
20. Solenoid valve assembly
20A. Swing brake solenoid valve
20B. Travel speed solenoid valve
20C. Merge/flow divider solenoid valve
20D. Boom Hi 2-stage safety solenoid valve
20E. Active mode solenoid valve (Boom)
SWPO4708 +
10-12 PC300,350-6
STRUCTURE AND FUNCTION DRAWING
PIPING
HYDRAULIC
% I , %2. PC300-6 Serial No.: 33466 and up

-t X1
I
17
20
20 E
Z SWPO6559
PC300, 350-6 10-13

0
9
5:
m
I
4-
m
Y
a)
b
0
hl
Y
c
m
*,
1 I
c
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
PdlF I PAF PAR 2
\
PPPR
P PLFLS1Sl l R Ps i o
4 PP2F PS 3 SWPO4710
1. Frontmainpump PS : Pumpsuction
2. Rear mainpump PAF : Front
delivery
3. Rear TVC, LS valve PAR : Rear delivery
4. Front TVC, LS valve PPSF : Front pump delivery pressure
PP2R : Rear pump delivery pressure
PLSIR : Rear LS pressure
PLSlFl : Front LS pressure
PdlF : Pumpdrain
Psig : LS control pressure EPC pressure
Outline
This pump consists of two variable displace-
ment swash plate type piston pumps and W C ,
LS valves.
PC300, 350-6 10-17

N
. . .. . . , .
N
.. .. .. .. ..
0
E
0
0
w PD
v)
%
0
0
2
m
W
S' A !? A-A -
.s
SWPO4823
Function
The enginerotationandtorquetransmitted Rocker cam (4) has flat surface A, and shoe
t o the pump shaft is converted into hydrau- (5) is always pressed againstthis surface
lic energy, and pressurized oil is discharged while sliding in a circular movement.
according to the load. Rocker cam (4! brings high pressure c?i!at
It is possible t o change the delivery amount cylindrical surface B with cradle (Z), which is
by changing the swash plate angle. secured to the case, and formsa static pres-
sure bearing when it slides.
Structure Piston (6) carries outrelativemovement in
Cylinder block (7)issupportedto shaft (1) the axial direction insideeach cylinder cham-
by spline S, and shaft (1) is supported by ber of cylinder block (7).
the front and rear bearings. Thecylinder block seals the pressure oil to
The tip of piston (6) is a concave ball, and valve plate ( 8 ) and carries out relative rota-
shoe (5) is caulked to it to form oneunit. tion. This surface is designed so that the oil
Piston (6) and shoe (5)form a spherical bear- pressure balance is maintained at a suitable
ing. level. The oil inside each cylinder chamber
of cylinderblock (7) is sucked in and dis-
charged through valve plate ( 8 ) .
10-20 PC300, 350-6

Operation
1. Operation of pump
Cylinder block (7) rotates together with shaft
1 7
( I ) , and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle a be-
tween center line X of rocker cam (4) and
theaxialdirection of cylinderblock (7)
changes. (Angle CL is called the swash plate
ang!e.)
1) Center line X of rockercam (4) maintains

swash plate angle a in relation to the axial B
SLPOO163
direction of cylinder block (71, and flat sur-
face A moves as a cam in relation to shoe
(5).In this way, piston ( 6 ) slides on the in-
side of cylinderblock (71, so a difference
4 5 A .6 F,
between volume E and F is created inside
cylinder block (7). The suction and discharge
is equal to this difference F - E.
In other words, when cylinder block (7)ro-
tates and the volumeof chamber E becomes
smaller,the oil isdischargedduringthat
stroke. On the other hand, thevolume of
chamber F becomes larger, and as the vol-
ume .becomes bigger, the oil is sucked in.
2) if center line X of rocker cam (4) is in line 7 E
SLP00164
with the axial direction of cylinder block (7)
(swash plate angle = 01, the difference be-
tween volumes E' and F' inside cylinder block
(7) becomes 0, so the pump does not carry F'
out any suction or discharge of oil.
SLP00165
PC300, 350-6 1 0-21

2. Control of discharge amount
SAP00166
If swash plate angle P becomes larger, the With servopiston (121, the area receiving
difference in volumes E and F becomes larger the pressure is different on the left
and right,
and discharge volume Q increases. so main pumpdischarge pressure(self pres-
Swashplateangle a is changed by servo sure) PP is always connected to the cham-
piston (12). ber receiving the pressure on the small di-
Servo piston (12) movesinareciprocal ameterpistonside(theself-pressure is
movement (-1 according to the command brought in). Output pressure Pen of the LS
from the control valve. valve is brought to the chamber receiving
This straight line movement is transmitted thepressure a t the largediameterpiston
through rod (13) to rocker cam(4), and rocker end. The relationship in thesize of self-pres-
cam (41, which is supported by the cylindri- sure PP and the pressure at the small diarn-
cal surface to cradle (21, moves in a rocking eter piston end, and the ratio between the
movementon the cylindricalsurfacein area receiving the pressure at the small di-
( $ direction). ameter piston end and the large diameter
piston end controls the movement of servo
piston (12).
10-22 PC300, 350-6

cy
Q
a
.. ..
ei d
P 9
0
A-A
1 2 3 4 5 6 7
B-B
9 IO I1 12 13 14
c-c
\1 5 S W P O ~ O Ot
LS valve TVC valve

1. Locknut 5. Sleeve 8. Solenoid 12. Spring
2. Plug 6. Piston 9. Piston 13. Piston
3. Spring 7. Plug 10. Sleeve 14. Lever
4. Spool 11. Spring 15. Valve body
PC300, 350-6 10-25

Function
1. LS valve
The LS va!ve detects the load and centrals
. the discharge amount.

Thisvalvecontrols mainpump discharge
amount Q according t o differential pressure
APLS (=PP2-PLS) (thedifferencebetween
main pump pressure PP2 and control valve
outlet port pressure PLS) (called the LS dif-
ferential pressure).
Main pump pressure PP2 coming from the
control valve inlet port, pressurePLS (called 1. 0 2. 5 MPa
the LS pressure) coming from the control (10. 0) (25.01 ik d c m ' ]
LS d i f f e r e n h a t P r e s s u r e APLS
valve output, and pressure Psig (called the SWPOSI 63
LS selector pressure) from the proportional
solenoid valve enterthis valve. The relation-
ship between discharge amount Q and dif-
ferential pressure APLS, (the difference be-
tween main pump pressure PP2 and LS pres-
sure PLS)(=PPZ-PLS) changes as shown in
t h e diagram cn the right accerding to LS
. selector pressure Psig.
When Psig changes between 0 - 2.9 MPa (0
- 30 kg/cm2),the springload changes ac-
cording to this, and the point for switching
the pump discharge amount changes at the
rated central value between 0.98 - 2.45 MPa
(10.0 - 25.0 kg/cm2).
2. TVC valve
When pump dischargepressure Pal (self-
pressure) and Pa2 (other pump pressure) are
high, the TVC valve controls the pump so 18A
that no more oil than the constant flow (in 4A
accordance withthedischargepressure)
7A
flows even if the stroke of the control valve
becomes larger. In this way it carries out
equal horsepower control so that the horse-
power absorbed by the pump does not ex-
ceed the engine horsepower.
P u m p d l s c h a r s eP r e s s u r ea v e r a g e (PF+PR)/2
In other words, if the load during the opera-
SWPOS I 6 4
tion becomes larger and the pumpdischarge
pressure rises, it reducesthedischarge
amountfrom the pump; and if the pump
dischargepressuredrops, it increases the
discharge amount from the pump. The rela-
tionship between the average of the front gine, and if the speed drops because of an
and rear pumpdischarge pressures (PF + increase in the load, it reducesthe pump
PR)/2 andpumpdischargeamount Q is discharge amount to allow the speed to re-
shown on the right, with the current given cover. !n other words, whenthe b a d in-
to the TVC valve solenoid shown as a pa- creases and the engine speed drops below
rameter. the set value, the command to theTVC valve
However, in the heavy-duty operation mode, solenoidfromthecontroller increases ac-
there are cases where it is given the func- cording t~ the drop in the engine speed to
tion of sensing the actual speed of the en- reduce the pump swash plate angle.
10-26 PC300,350-6
Operation
1. LS valve
1) When control valve is at NEUTRAL position
Y
( D i r e c t i o n o f m i n i m u md i s c h a r g e ]
The LS valve is a three-way selector valve, SWPO5076

7 1 3
with pressure PLS (LS pressure)from the out-
to spring
let port of the control valve brought
chamber i, and main pump discharge pres-
sure PP2 brought tochamber j of plug (6).
The size of the forceof this LS pressure PLS +
force F of spring(3)and the main pump pres-
sure (self pressure) BP2 determines the posi-
tion of spool (4). However, the size of the
output pressure Psig (the LS selection pres-
sure) of theEPC valve for the LS valve enter- A-A SAPO0173
ing port e also changes the position of spool nected with the drain circuit through con- the
(4). (The set pressure of the springchanges.) trol valve spool.) At this point, spool (4) is
Before the engine is started, servo piston (1) pushed to the left, and port d and port e are
Is pushed to the right by spring (7) installed connected. Pump pressurePP enters the large
t o rod (2). (See the diagram on the right) diameter end of the piston from porth, and
When the engine is started and the control the same pump pressure PP also enters the
lever is at the NEUTRAL position, LS pres- small diameter end the of piston, so the swash
sure PLS is 0 MPa (0kg/cm*). (It is intercon- plate is moved to the minimum angle by the
difference in area of piston(11.
PC300, 350-6 10-27

STRUCTURE PUMP
( D i r e c t i o n o f maximum d i s c h a r g e )
SWPO5077
When the differencebetween mainpump For this reason, the pressureatthelarge

pressure PP2 and LS pressure PLS, in other piston diameter end of servo piston (1) be-
words, LS differentialpressure APLS, becomes drain pressure PT, and pump pres-
comes smaller (for example, when the area sure PP enters the small diameter end, so
of openingofthecontrolvalvebecomes servo piston(1) is pushed to the right. There-
larger and pump pressure PP drops), spool fore, rod (2)moves to the right and moves
(4) is pushed to the right by the combined the swash plate in the direction to make the
force of LS pressure PLS and the force of discharge amount larger.
spring (3). If theoutput pressure Psig of the LS-EPC
When spool (4) moves, port b and port c are valve enters port e, this pressure creates a
joined and connected to the W C valve. When force to move piston (5)to the left. If piston
this happens, the TVC valve is connected to (5)is pushed to the left, it acts to make the
the drain port, so circuit c - h becomes drain set pressure of spring (3) weaker,and the
pressure PT. (The operationof theTVC valve differencebetween PLS and PP2 changes
is explained later.) when ports b and c ofspool (41 arecon-
nected.
10-28 PC300, 350-6

AND STRUCTURE
3) Operation in minimum direction for pump discharge amount
( D i r e c t i o n o f minimum discharae)
SWPO5078
0 The following explains the situation if servo end.

piston (1) moves to the left (the discharge Main pump pressure PP also enters the small
amount becomes smaller). When LS differ- piston diameter end, but because of the dif-
ential pressure APLS becomes larger (forex- ference in area between the large piston di-
ample, when the area of opening of the con- ameter end and small piston diameter end
trol valve becomes smaller and pump pres- of servo piston( I ) , servo piston(1) is pushed
sure PP rises), main pump discharge pres- to the left.
sure PP2 pushes spool (4) to the left. As a result, rod (2)moves in the direction to
When spool (4) moves, main pump pressure make the swash plate angle smaller.
PP flows from port d to port c, and from If LS selection pressure Psig enters port e, it
port h, it enters the large piston diameter acts t o make the set pressure of spring (3)
weaker.
PC300, 350-6 10-29

SWPO5079
Let ustakethe areareceiving the pressure Atthispoint,therelationshipbetweenthe

at the large piston diameter end as AI, the area receiving the pressure at both ends of
area receiving the pressure at the small di- piston (1) is A0 : A I = 2 : 5, so the pressure
ameter end as AO, and the pressure flowing applied to both ends of the piston when it is
into the large piston diameter end as Pen. If balanced becomes PP : Pen = 5 : 2.
main pump discharge pressure PP2 of the The position where spool (4) is balanced and
LS valve and the combined force of force F stopped is the standard center, and the force
of spring (3)and LS pressure PLS are bal- of spring (3) is adjusted so that it is deter-
anced, and the relationship is A0 x PP = A I mined when PP2 - PLS = 2.45MPa (25 kg/
x Pen, servo piston 11) will stop in that posi- cm2). However, if Psig (the output pressure
tion, and the swash plate will be kept at an of 0 - 2.94 MPa (0 - 30 kg/cm2) of the EPC
intermediate position. (It will stop a t a posi- valve of the LS valve) is applied to port e,
tion where the opening of the throttle be- the balance stop position will change in pro-
tween port b and port c and between port d portion to pressure Psig between PP2 - PLS
and port c of spool (4) is approximately the = 2.45 - 0.98 MPa (25 - 10 kg/cm2}.
same. At this point, the pressure of portc is
approx. 2/5 pump pressure PP.1
10-30 PC300, 350-6

STRUCTURE AND FUNCTION PUMP HYDRAULIC
2. TVC valve
1) When governor, pump controller are normal
SBP00178
* Otherpumppressure
This is the pressure the
of
p u m p a t theopposite
Resistor
SWPO5080 end.
For the front pump, it is
the rear pump pressure
For the rearpump, it is
the front pump pressure
a. When the load on the actuator is small and

pump pressures Pal and Pa2 are low
@ Action of solenoid (1)
Commandcurrent x fromthegovernor, anced, and the pressure (pressure of portc)
pump controller flows to solenoid (1). This output from the TVC valve changes accord-
command currentchanges the internal force ing to this position.
pushing solenoid push pin (11). The size of command current x is determined
On the opposite side tothe force pushing by the nature of the operation (lever opera-
this solenoid push pin ( 1l i is the spring set tion), the selection of the workingmode, and
pressure ofsprings (3)and (4) and pump the set value and actual value for the engine
pressure Pal and other pump pressure Pa2 speed.
(see *). Piston (2)stops a t a position where
the combined force pushing piston(2) is bal-
PC300, 350-6 10-31

@ Action of spring
The spring load of springs (3) and (4) in the the stop position for piston (9) (= pump dis-
TVC valve is determined by the position of charge amount) isdecided a t the point where
the swash plate. the forceof springs (3) and (4) and the push-
When servo piston(9) moves, cam (7),which ing force from the sotenoid and the pushing
is connected to rod (81, also moves. When force created by pressures Pal and Pa2 act-
this happens, lever ( 6 ) is rotated by the an- ing on piston (2) are in balance.
9!P c?? cam !?!, and pisten ( 5 ) meves tc the
right or left.
If piston (5)moves to the right, spring (3) is
compressed; and if it moves further to the
right, spring (4) contacts seat (lo), so both
spring (3)and spring (4) function. In other
words, the spring load is changed by piston
(5)extending or contracting springs (3) and
(4).
If command current x input to solenoid (1)
changes further, the pushing force of sole-
noid push pin (11) changes, and the spring
load of springs (3)and (4) also changes ac-
cording to the value of the solenoid com-
mand current.
Port c of the TVC valve is connected to port
e of the LS valve (see 1. LS valve).
Self pressure Pal enters portb and the small
piston diameter end of servo piston (91, and
theothermain pump pressure Pa2 enters
port a.
When pumppressures P a l and Pa2 are
small, piston (2) is on the right. At this point,
port c and port d areconnected, and thg
pressureentering the LS valvebecomes
drain pressure PT.
If port h and port e of the LS valve are con-
nected (see 1. LS valve), the pressure enter-
ing the large piston diameter end from port
f becomes drain pressure PT, and servo pis-
ton (9) moves to the right. In this way, the
pump discharge amount moves in the direc-
tion of increase.
As servo piston (9) moves further, piston (5)
is moved to the left by roc! !a!, c ~ m !7!, and
lever (6). Springs (3) and (4) expand and the
springforcebecomesweaker.Whenthe
springforcebecomes weaker, piston (2)
moves to the left, so the connection between
port c and port d is cut, and the pump dis-
charge pressure port b is connected to port
c. As a result, the pressure at port c rises,
and the pressure a t the large piston diam-
eter end also rises, so the movement of pis-
ton (9) to the right is stopped. In other words,
10-32 PC300, 350-6

SBP00178
(Direction of m i n i m u m d i s c h a r g e )
Resistor
SWPO5081
b. When load on actuator is small and pump

discharge pressure is high
When the load is large and pump discharge If main pump pressures Pal and Pa2 increase
pressures Pal and Pa2 are high, the force further and piston (21 moves ?!.!@her to the
pushing piston (2)to the left becomes larger left, main pump pressure Pal flows to port c
and piston (2) moves to the position shown and acts to make the discharge amount the
in the diagram above. When this happens, minimum. When piston (9)moves to the left,
as showninthediagram above, withthe piston (5) is moved to the right by cam (7)
pressurized oil flowing from port c to the LS andlever (6).For this reason, springs (3)
valve, part of the pressurized oil from port b and (4) are compressed and push back pis-
flows out to port d and becomes approxi- ton (2). Because of this force, piston (2) cuts
. mately 2/5 main pump pressure Pal.

When port h and port e of the LS valve are
off the connection from portb to port c, and
port c and port d are connected. As a result,
connected (see 1. LS valve),thepressure the pressure at port c (= f) drops, and piston
from port f enters the large piston diameter (9) stops moving to the left. The position in
end of servo piston (91, and servo piston (9) which piston (9) stops when this happens is
stops. further to the left than the position when
main pump pressures Pal and Pa2 are low.
PC300, 350-6 10-33

STRUCTURE PUMP
Therelationof average mainpump pres-

sure Pal + Fa2 andtheposition of servo
piston (9) forms a bent iine because of the
double-spring effect of springs (41 and (6).
Therelationshipbetweenaveragepump
pressure Pal + Pa2 andpumpdischarge
amount 0 is shownin the figure on the right.
Pump Pressure PaltPaZ

SWP05082
If command voltage X sent tosolenoid (1)

increases further, the relationship between 0
average pump pressure Pal + Pa2, and dis- I
c
charge amountQ is proportional to the push- 0
E
m
ing force of the PC-EPC valve solenoid and
moves in parallel. In other words, the push-
ing force of solenoid (IT is added to the force
pushing to the left because of the pumppres-
sure applied to the piston (21,the relation-
ship between theaverage pump purresure P
and 0 movesfrom A to B in accordance
Pump P r e s s u r e P
with the increase in X. SWPO5083
10-34 PC300, 350-6

STRUCTURE
HYDRAULIC
AND FUNCTION PUMP
2) When governor, pump controller is abnormal and TVC prolix switch is ON
-
SBPOO178
a. When load on main pump is light

e If there is a failure in the governor, pump At this point, port c is connected to the drain
controller,turn TVC prolixswitch ON to pressure of port d, and the large piston di-
switch to the resistor side. In this case, the ameter end of servo piston(9) also becomes
power source is taken directly from the bat- the drain pressure PT through the LS valve.
tery. But if the current is used as it is, it is When this happens, the pressure atthe small
too large, so use the resistor to control the piston diameter endis large, so servo piston
current flowing to solenoid (1). (9) moves in the direction to make the dis-
When this is done, the current becomes con- charge amount larger.
stant, so the forcepushingsolenoidpush
pin (11) is also constant.
If mainpump pressures Pal and Pa2 are
low, the combined force of the pump pres-
sure and the force of solenoid ( 7 ) is weaker
thanthespring set force, so piston (2) is
balanced at a position to the right.
PC300, 350-6 10-35

UNCTION
STRUCTURE AND HYDRAULIC PUMP
[ D i r e c t i o n o f m - i n i m u md i s c h a r g e )
T V C Prolix SBPOO178
Engine
throttle
controller
&, Battery
Resistor
SWPO5085
b. When load on main pump is heavy

In the same way as in thepreviousitem,
when the TVC prolix switch is ON, the corn-
mand currentx sent to solenoid(1) becomes
constant. For this reason, the force of sole-
noid push pin(11) pushing piston (2) is con-
. stant.
If mainpump pressures Pal and Pa2 in-
crease, piston (2)moves further to the [eft
than when the main pump load islight, and Pump discharse amount D
. is balanced at a position towards the left. SWPO5086
In this case, the pressure from port b flows sure P and discharge amount Q is deter-
to port c, so servo piston (9) moves to the mined as shown in the diagram for the value
left (to make the discharge amount smaller) of the current sent to the solenoid through
by the same mechanism as explained in Item the resistor.
2.1)-b, and stops at a position further to the The curve when the TVC prolix switch is ON
left than when the load on the pump is light. is curve B, which is to the left of
curve A for
In other words, even when the TVC prolix when the governor, pump controller is nor-
switch is ON, the curve for the pump pres- mal.
10-36 PC300, 350-6

STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
Name, port name
1. Cover 1 Outline
2. Cover 2 This esntrsi valve consists of a 7-spool valve
3. Service valve (the 6-spool valve + Hi valve) and 3 sets of
4. Service valve service valves. The merge/flow dividervalve
5. Service valve is installed to this.
6. Boom, arm Hivalve Allthe valves are connected by a bolt to
7. Mer.;e/f!w divide: va!ve f9rm one unit, and the p2553g9s are Inter-
8. 6-spool valve nally connected, so the structure iscompact
and is very easy to service.
0 This control valve is designed t o assist only
the boom and arm valves with their large
flow using the Hi valve, so it has a simple
structure.
AI :To bucket cylinder bottom B-l : To armcylinder bottom

A2 :To RH. travel motor B-2 : To attachment
A3 : To boom cylinder bottom B-3 : To attachment
A4 : To swing rnotor B-4 To attachment
A5 :To L.H. travel motor P-1A : From arm PPC valve
A6 :To arm cylinder head P-1B : From arm PPC valve
Bl :To bucket cylinder head P-2 : Fromboom PPC valve
B2 :To R.H. travel motor P-3 : From service PPC valve
83 :To boom cylinder head P-4 : From service PPC valve
84 :To swing motor P-5 : From service PPC valve
65 :To L.H. travel motor P-6 : From service PPC valve
B6 :To arm cylinder bottom P-7 : From service PPC valve
P I : From bucket PPC valve P-8 : From service PPC valve
P2 : From bucket PPC valve T :To tank
P3 : From R.H. travel PPC valve BP : From LS dividersolenoidvalve
PA : Frnm R.H. trave! PPC w ! v e CP : Frgm 2-stage safe+; va!ve se!ectcr sele-
P5 : From boom PPC valve noid valve
P6 : From boom PPC valve PS : Frommerge/flowdividersolenoid valve
P7 : From swing PPC valve SA : Pressuresensor mount port
P8 : From swing PPC valve SB : Pressuresensor mountport
P9 : From L.H. travel PPC valve TS : T o tank
P10: From L.H. travel PPC valve BP4 : From active mode selector solenoid valve
P I 1: From arm PPC valve BP5 : From swing stroke control selector valve
P12: From arm PPC valve BP6 : From swing stroke control selector valve
T I :To travel junction valve PPI : From front main pump
T2 : To travel junction valve PP2 : From rear main pump
T3 : To trave! junctl~nvalve PLSI : To front pump contro!
T4 : To travel junction valve PLS2 : To rear pump control
A-I : To boom cylinder bottom PPSl : To front pump control
A-2 : To attachment PPS2 : To rear pump control
A-3 : To attachment PTRl : To travel junction valve
A-4 : To attachment PTR2 : To travel junction valve
10-38 PC300, 350-6

AND STRUCTURE FUNCTION CONTROL VALVE
10-spool valve (STD + service valve x 3)
PS P T R 2
PPS2
T2 Tl SWPO47 13
PC300, 350-6 10-39

Main structure of 10-spool valve (1/3)
I 2 3 6 7 8 9 10 I1
13 B-B i2
15
K-K L- L SWPO4714
1. Spool (arm Lo) IO. Spool (service)

2. Spool (L.H. travel) 11. Spool return spring
3. Spool (swing) 12. Spool (arm Hi)
4. Spool (boom Lo) 13. Piston (arm Lo stroke control)
5. Spool (R.H. travel) 14. Unload valve (arm Lo)
6. Spool (bucket) 15. Main relief valve (arm Lo)
7. Spool (boom Hi) 16. Unload valve (bucket)
8. Spool (service) 17. Main relief valve {bucket)
9. Spool (service)
10-40 PC300, 350-6

H
0
0
0
(h
0
6 w
c /
u u L
I
c
0
L
IB
IB
NA-NA
1A 2 1A
1A 2 IA
IA. Pressure compensation valve

1 B. Variable type pressure compensation valve
2. Safety-suction valve
3. Safety-suction valve (for large flow)
4. Safety-suctionvalve (2-stage)
5. Check valve for regeneration circuit (arm)
6. Check valve for regeneration circuit (boom)
7. Suctionvalve
PC300, 350-6 10-43

STRUCTURE

* For details of the names of the ports and the main structure, see IO-SPOOL VALVE
PS PTR2
PPS2
G BP6
P11 P7 P3 P-1B P-5 PPSl
1 2
7 6 5 4
TS P P 2T $ PP 1 73 PylA
\ \ \ I / /
T i i t SWPO47 1 8
10-44 PC300, 350-6

STRUCTURE AND FUNCTION VALVE CONTROL

* For details of the names of the ports and the main structure, see IO-SPOOL VALVE
PPS2
i”
2
1
B 1’ K D E EEJAA H\N -NA- L

G BP6
P i 1 P7 P3 P-1 B
7 E 5
TS T4 PP2 PPI T3 P-1A
T2 Tl SWPO47 I 9
PC300, 350-6 10-45

7-spool valve (STD)

Ir For details of the names of the ports and the main structure, see 10-SPOOL VALVE
.PS P T R P
P 1’2 P1‘0 Pa P6 P4 P2 P-2

C
PPSP P P s1
T P 1.1 P9 P,7
P,6 43 P1 P
; f
\ \ \ \ \ I /
ypsl
I 2‘
PTRl / SA S3 \ CP 1 \
8 7 6 5
TS T4 PF2 PPI T;3 P71A
I / /
SWPO4720
10-46 PC300, 350-6

STRUCTURE AND FUNCTION SELF-REDUCING
VALVE
PRESSURE
SELF-REDUCING PRESSURE VALVE
n n
PR
B 6
PC
SWPO472 1
PI : From front pump

T : To hydraulic tank
PC : To front pump LS valve
PR : Supply t o electromagnetic valve,
PPC valve, solenoid valve
10-48 PC300, 350-6

VALVE
PRESSURE
1 2 3
\ I I
12 I1 SWPO4722
1. Controlvalveblock 7. Filter
2. Valve (sequencevalve) 8. Spring (reducing valve main)
3. Spring 9. Spring (reducing valve)
4. Screw IO. Filter
5. Poppet 11. Spring (safety valve)
6. Spring(reducingvalve pilot) 12. Ball
PC300, 350-6 10-49

PRESSURE VALVE
Function
Thisvalvereducesthedischargepressure
the main pump and supplies
of
it as the control
r---- 1
pressure for the solenoid valve and PPC valve.
Operation
1. When engine is stopped
Poppet (5) ispushedagainstthe seat by
spring (61, and the passage from port PR +
T is closed.
Valve (9) is pushed to the left by spring (81, PR
and the passage from port P I + PR is open.
\valve
I, i2i is pushed to the ieft by spring i3j,
so the passage betweenport P1 + P2 is
closed. (See Fig. 1)
t
T
HYDRAULIC CIRCUIT DIAGRAM SWPO5087
10-50 PC300, 350-6

STRUCTURE
FUNCTION
AND SELF-REDUCING
VALVE
PRESSURE
At neutral and
Whenload pressure P2 is low (when moving
down under own weight (boom LOWER or arm
P2
IN))
Note: When load pressure P2 is lower than out-
put pressure PR of the seif-reducingpres-
sure valve.
Valve (2) receivesforce in the directionto
close the passage from port P I --+ P2 from
spring (3)and pressure PR (when the engine
is stopped, the pressureis 0 MPa (0 kg/cm2?).
However, when hydraulic oil flows in from
port P I , thepressureis balanced so that
pressure P1 = force of spring( 8 ) + (area prd x
pressure PR), and the opening from port P I
4 P2 is adjusted so that pressure P I is kept
a t a certain value above pressure PR.
When pressure PR goes above the set pres-
sure, poppet (5)opens, and the hydraulic oil
flows in the following circuit: portPR --+ hole
a insidespool (9) openingofpoppet (5)
--+ tank port T.
As a result, a pressure difference is created
on both sides of hole a inside spool (91, so
spool (9) moves in the direction to close the
opening from port P I -+ PR. Pressure P I is
reduced to a certain pressure (set pressure) (F i a. 2) SWPO5089
by the amount of opening at this point, and
is supplied as pressure PR. (See Fig. 2)
When load pressure P2 is high

If load pressure P2 increases and the pump dis-
charge amount also increases because of dig-
gingoperations,pressure P I alsoincreases
(pressure P I > force of spring ( 8 ) + (area prd x
pressure PR),so valve (2) moves to the right to
the end of the stroke.
As a result, the amount of opening from portP I
+ P2 increases and the resistance in the pas-
sage is reduced, so the loss of enginehorse-
power is reduced.
e If pressure PR goes above the setpressure,

poppet (5) opens and the hydraulic oil flows
in the following circuit: port PR + hole a
inside spool ( 8 ) -+ opening of poppet (5) +
tank port T.
As a result, a pressure difference is created
on both sides of hole a is inside spool (91, so
spool (9) moves in the direction to closethe
opening from port P I -+ PR. Pressure P1 is
reduced to a certain pressure (set pressure)
by the amount of opening a t this point, and
is supplied as pressure PR. (See Fig. 3)
IF i a. 3) SWPO5090
PC300, 350-6 10-51

VE
NCTION
REDUCING
ESSURE
AND
STRUCTURE
4. When there is abnormal high pressure

When pressure PR of the self-reducing pressure
valve becomes abnormally high, ball (12) pushes
against the force of spring (111, separates from
the seat, and allows hydraulic oil to flow from
output port PR + T, so pressure PR goes down.
This action protects the equipment at the desti-
nation for the hydraulic pressure supply (PPC
valve, electromagnetic valve, etc.) from abnor-
mally high pressure. (See Fig. 4)
10-52 PC300, 350-6

NCTION AND STRUCTURE VALVE SAFETY
SUCTION SAFETY VALVE

FOR SERVICE VALVE
1 2 3 4 10 1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suctlcn valve spring
8. Sleeve
9. Adjustment screw
I O . locknut
SBPOO198
Part NO. I pressure Set I Use

709-70-74800 I 20.6 MPa {210 kg/cm2} at 19OUmin I Forbreaker(Okada)
709-70-75100 20.1 MPa C205 kg/cm2) at 5Umin For breaker (Mitsubishi Krupp)
709-70-75300 16.7 MPa (170 kg/crn2) at 19Ollmin For breaker (Matsuda)
709-70-74600 24.5 MPa (250 kg/cm*}at 5l/min 1 Forcrusher (Okada)
PC300, 350-6 10-53

ON STRUCTURE AND CLSS
CLSS
Outline of CLSS
Y
To actuators
r -
I
I I
I
I
I
I
I
I
I
I
I
I
I
1
I
I
I
I I I
I
I
I
1
I
I
I
I
I I
ston piston
SBP00199
Outline Structure
CLSS stands for Closed center Load Sensing The CLSS consists of a m a i np u m p (2
System, and has the following features. pumps), control valve, and actuators for the
work equipment.
Features pump the ofconsists
pump
The main itself,
e Fine control
not influenced by load
the TVC valve
and LS valve.
Control enabling digging even with fine con-
trol.
Ease of compound operation ensured by flow
dividerfunctionusing area of openingof
spool during compound operations.
Energy savingusingvariablepumpcontrol
PC300, 350-6 1 0-55

STRUCTURE AND FUNCTION CLSS
Basic principle
1) Control of pump swash plate angle Actuator
0 The pump swash plateangle(pump dis- I
charge amount) is controlled so that LS dif-
ferentialpressure APLS (the difference be-
tween pump pressure PP and control valve
outlet port LS pressure PLS) (load pressure
of actuator) is constant.
(LSpressure APLS = Pump discharge pres-
sure PP - LS pressure PLS)
I
I ~ L P a s s a g Se
I1
I 1
1;
I i
I 1
I i
Serbo I I
I 1
Piston I 1
I 1
I I
i i
i i 1 1
I 1 I 1
I 1 I 1
1 1
I 1
/ I
LS v a l v e I 1
Pressure
SWPO5161
If LS differentialpressure APLS becomes

lower than the set pressure of the LS valve
(when the actuatorload pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher than
the set pressure of the LS valve (when the
actuatorloadpressure is low), thepump
swashplatemoves towards the minimum
position.
-
LS differential pressure APLS
SAP00384
10-56 PC300, 350-6

2) Pressure compensation
A pressure compensation valve is installed to the outlet port side of the control valve to balance
the load.
When two actuators are operated together,this valve acts to make pressuredifference AP between
theupstream (inlet port) anddownstream(outletport) of the spool of each valve thesame
regardless of the size of the load (pressure).
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of
openings S1 and S2 of each valve.
I 1
SBPOO201
PC300, 350-6 1 0-57

Operation for each function of CLSS

Hydraulic circuit diagram for system
iPPSl
To t r a v e l j u n c t i o n v
SWP05092
10-58 PC300, 350-6

1A. Main relief valve (bucket group)

Set pressure: 34.8 2 0.5 MPa (355 * 5 kg/cm2)
IB. Main relief valve (arm group)
Set pressure: 34.8 * 0.5 MPa I355 2 5 kg/cm2)
2A. Unload valve (bucket group)
Clutch pressure: 2.9 * 0.2 MPa (30 .c 2 kg/cm21
2B. Unload valve (arm group)
Clutchpressure: 2.9 0.2 MPa I30 .c 2 kg/cm2)
3. Pressure compensation va!ve
4A. Safety-suction valve
Set pressure: 17.2 2 0.5 MPa (175 5 kg/cm21
Set pressure: 35.8 * 0.5 MPa (365 * 5 kg/cm21
5. Safety-suction valve (for large flow)
Set pressure: 35.8 f 0.5 MPa I365 * 5 kg/cm2)
6. Safety-suction valve (2-stage)
Set pressure:
l-stage: 28.4 f 0.5 MPa I290 r 5 kg/cm2)
2-stage: 14.7 f 0.5 MPa (150 -c 5 kg/cm21
7. Bucket spool
8. LS shuttle valve
9. R.H. travel spool
10. Suction valve
11. Boom Lo spool
12. Check valve (for boom regeneration circuit)
13. Swing spool
14. L.H. travel spool
15. Arm Lo spool
16. Check valve (for arm regeneration circuit)
17. Boom Hi spool
18. Arm Hi spool
19. LS select valve
20. Merge/flow divider valve
PC300, 350-6 10-59

0
'p
0
1. When unload valve is actuated
11A,11Ei A- d 9A,9B
SBPO0205
Function
Whenallthecontrol valves are a t neutral, force of springs ( I I A , I I B ) ,vafves (IOA, 10B)
the oil discharged when the pump is at the movetothe left, ports B and C are con-
minimumswashplateangleisdrained. nected and the pump pressure flows totank
When this happens, the pump pressure be- passages (9A, 9B). In addition, the pressu-
comes a pressure that matches the set load rized oil in LS circuits (8A, 8B) passes from
of springs (1IA, 118) inside the valve (PI orifice A through port C, and is drained to
pressure). The LS pressure is drained from tank passages (9A, 9B). Therefore, when the
LS bypass valve (12), so LS pressure = tank valve is actuated, LS pressure = tank pres-
pressure = 0 MPa (0kg/cm2). sure.
Whenoperated(foroperations in thedis- When theunloadoperationiscarried out,
charge range for the minimum swash plate thedifferentialpressure(pump discharge
angle), the discharge pressure of the oil dis- pressure - LS circuit pressure) is greater than
charged with thepump a t theminimum the pump LS control pressure, so a signal is
swash plate angle is LS pressure + P1 pres- sent to move the pump swash plate to the
sure. In other words, the LS control differen- minimum angle.
tial pressure (APLS) of the oil discharged at
the minimum swash plate angle is the P I
pressure.
Operation
Thepressure in pump passages(7A, 7B) is
received by the endface of valves (IOA, 10B).
The control valve is a t neutral, so the pres-
sure in ES circuits (8A, 85) is 0 MPa (0kg/
n
cm2).
Thepressurizedoilinpump passages (7A,
7B) is stopped by valves (IOA, IOB). There is
rl
no way for the pressurized oil discharged by
the pump to escape, so the pressure rises.
When this pressure becomes larger than the 11A,11B A C SBPOO206
PC300, 350-6 10-61

2. Operation of relief valve

(1) Cut-off control actuated
Function
0 When cut-off control is being carried out on
the pump by the l V C valve, the pumpswash
plate angle is at the minimum.
The reliefvalveacts to relieve the oil flow
when the pump is at the minimum swash
p!ate angle In wder tc? rnsintain the overa!!
balance.
Operation
When thecylinder reaches theend of its
stroke, main relief valves (2A, 2B) open and
Balance point SAW0207
J
pump discharge amount Q is relieved to tank
passages @A, 9B).
When pumpdeliverypressure PP comes
close totherelief pressure, thegovernor,
pump controller sends a signal to the sole-
noid of the TVC valve and carries out the
cut-offfunction t o makepumpdischarge
amount Q the minimum.
The spool is at the endof its stroke, so there
is no flow of oil upstream or downstream
from the spool. As a result, pump delivery
pressure PP and LS pressure PLS are almost
the same pressure, and LS differential pres-
sure APLS becomes 0.
LS differential pressure APLS is lower than
the LS set pressure of the LS valve, so the
LS valve acts to try to move the pump swash
plate angle to the maximum. However, be-
cause of the structure, the action of theTVC
valve is given priority over the action of the
LS valve, so the pump is held at the mini-
mum swash plate angle by the cut-off func-
tion of the TVC valve.
(2) Cut-offcanceled (powermax.mode,fine I

control mode, travel) Q
Pump flow
Function, operation
In the power max. mode, fine control mode,
or travel mode, the torque cut-off signal is
Relief valveflow
not given, so the torque moveson the pump
output curve.
When this happens, thepumpdischarge
amount is relieved from the relief valve, so
the overall balance is maintained.
10-42 PC300, 350-6

STRUCTURE FUNCTION CLSS
3. Introduction of LS pressure
A Thediagramshows the condition for arm
IN.
Upstream pressureof pressure

compensation valve
(for spool meter-in downstream)
1. Mainpump Function
2. Mainspool Theupstream pressure (= spoolmeter-in
3. Pressure compensationvalve downstream pressure) of pressure compen-
4. Valve sation valve (3) is introducedand goes to
5. B.!! E ! ! W shuttle valve (7) as the LS pressure. When
6 LS circuit this happens, it is connected to port B of the
7. LS shuttlevalve actuator through valve (41, and LS pressure
+ actuato: Isad pressure. Introduction hole a
inside the spool has a small diameter, so it
also acts as a throttle.
Operation
When spoo! !2! is operated, the pump pres-
sure passes through introduction holea, en-
ters port C, and is taken t o the LS circuit.
When the pump pressure rises and reaches
the load pressure of port B, ball valve (5)
opens.
PC300, 350-6 10-63

STRUCTURE AND FUNCTION
4. LS bypass valve
SLFu0211
1. Main pump Function

2. Main spool Theresidualpressure in LS circuit ( 6 ) isre-
3. Pressurecompensationvalve leased from orifices a and b.
4. LS shuttle valve This reduces the speed of the rise in the LS
5. LS bypass valve pressure, and prevents any sudden change
6. LS circuit in the oil pressure. Furthermore, a pressure
ioss is generated by thecircuit resistance
between throttle c of main spool (2) and LS
shuttle valve (4) according to thebypass flow
from LS bypass valve (5). As a result, the
effective LS differential pressure drops, and
the dynamic stability of the actuator is in-
creased.
1 0-64 PC300, 350-6

s9-0 1 9-OSE '00&3d
LBEOOdVS
3
L 3
From LS shuttle valve for otherwork equipment
Upstream pressureof pressure compensation valve

(for spool meter-in downstream)
Spool meter-in upstream pressu

SLPOO213
2) When receiving compensation (during corn- Operation

poundoperations, whenload pressure is Spring chamber E is interconnected with port
lower than other work equipment) D. Piston (4) and valve (2)are actuated by
The pressurecompensationvalve is closed the LS circuit pressure from the other work
by the LS pressure of port D, and the spool equipment at port F in the direction of clos-
meter-in downstream pressure of port B being (to the right). In other words, the valve
comes ?he same as the maximum pressure upstream pressure of port B (= spool meter-
of the other work equipment.The spool me- in downstreampressure) is controlled by the
ter-in upstreampressure of port A is the LS pressure.
pump pressure, so spool meter-in differen-
tialpressure (upstreampressure(pressure
of port A) - downstream pressure (pressure
of port 6)) becomes the same for all spools
that are being operated. In this way, the
pump flow is divided in proportion to the
area of the meter-in opening.
10-66 PC300,350-6
Shuttle valve
1
1 1 +
From LS circuit TO actuator AI
Throttle,
A2
C I, S ~ meter-in
I
downstream pressure
SLPoO278
c Area ratio of pressure compensation valve > c Pressure compensationvalve for service
The condition of the flow division changes ac- valve >
cording to the ratio of the areas of portion A I The service valve uses a variable type pres-
and portion A2 of the pressure compensation surecompensationvalve, so it canadjust
va Ive . the division of the oil flow suitably to
match
Area ratio = A2iA1 the attachment installed.
When area ratio = 1: Spool meter-in down-
stream presst~re= Max; load p r e s s ~ r ea~n d
oil flow is divided in proportion to area of
. opening of spool.
- .. ratio is more than 1: Spooi meter-in
.wnen
downstream pressure > Max. load pressure,
and a smaller oil flow is divided than the
proportion between the areas of opening of
the spool.
When m i 0 is fess than 1: S p s d meter-ia
downstream pressure < Max. load pressure,
and a larger oil flow is divided than the pro-
portion between theareas of opening of the
spool.
PC300, 350-6 10-67

6. Shuttle valve inside pressure compensation valve
SLP00214
1. Mainpump Function
2. Valve When holding pressure at port A > LS pressure
3. Shuttle valve inside pressure compensation in spring chamber B.
va Ive valve
Shuttle (3)by
isright
pushed
the to
4.thePiston of
pressurebe-circuit A, and
portthe
tween ports A and C is shut off. In this con-
dition, the noiuingpressure at port A is taken
to spring chamber B, and pushes piston (4)
to the left to prevent piston(4) and valve (2)
from separating.
10-68 PC300, 350-6

W
4. Variable type pressure compensation valve

(for service valve)
F r o ms e r v i c e a C y l i n d e r b Load P r e s s u r e f r o m d e h
valve SDOO~ port other work e a u i m e n t SWPO5093
1. Valve Function
2. Spring It is possible to adjust the division of the oil
3. Sleeve flow to the service valve when the service
4. Poppet valve (for attachment) is operated together
5. Spring with the main control valve (boom RAISE,
6. Screw etc.).
7. Locknut (Variable in proportion to surface area)
8. Plastic cap The pump pressure leaving the service valve
spool acts on the left endof valve ( I ) , and at
the same time passes through throttle a and
enters chamber g.
The maximum LS pressure passes through
throttle d and enters chambere. At thesame
time,thecylinderportpressure passes
through passage c and throttle f, and goes
to chamber h.
In addition, the force of spring (2) acts on
valve ( I ) , and the force of spring (5) acts on
poppet (4). The force of spring (5) can be
adjusted with screw ( 6 )
10-70 PC300, 350-6

OpeR4tiQn
Simultaneous operation with work equipment
under heavy load (boom RAISE, etc.)
1. The pump pressure and LS pressure are de-
termined by the pressure of the other work
equipment, but the cylinder port pressure
becomes the actuating pressure of the at-
tachment.
When the difference between the pump pres-
sure and the cylinder pressure is less than
the force of spring (51, then balance of the Fsreormv i c e
C Y Ii n d e r
port 5
v a l v e spool
force acting on valve (1) is as follows. SWPO5094
-
P X A I = P X A2 + LS (A2 A I ) + F
AI: Cross-sectional area of diameter D l
A 2 Cross-sectional area of diameter 02
F: Force ofspring
2. If the difference betyeen pump pressure P

and the cylinder pressure becomes greater
thantheforceofspring (51, poppet (4) is
pushed to the right and the passage opens,
so the pump passage isconnected to the
cylinder port through throttle a, chamber 9,
and passages b and c, and the oil flows to
the cylinder port. When this happens, a dif-
ferentialpressure is formedbetweenthe \
C Y I inder
upstream and downstream sides of throttle From s e r v i c e Part
a, and the pressure in chamber g goes down, va Iv e spoo i
SWPO5095
so the force pushing valve {I) to the left is
reduced. In other words, the area ratio be-
comessmaller, so valve (1) moves ts the
right and increases the flow from the pump
to the cylinder.
PC300, 350-6 10-71

8. Boom regeneration circuit

2. Main spool 1) Cylinder head pressure cylinder bottom
3A. Pressure compensation valve pressure (free fall, etc.)
38.Pressure compensation valve A returnflowcircuit is providedfromthe
4A. Suction valve (with safety) cylinder bottom to the cylinder head so that
48. Suction valve when the boom is lowered, the return flow
5. Check valve can be used to increase the flow of oil from
6. i3 shuttie vaive the pump to the cylinder bottom.
7, Drain circuit
8. Regeneration circuit Operation
When the cylinder head pressure e cylinder
bottom pressure, part of the pressurized oil
from the cylinder bottom passes through the
notch in spool (21, goes through port B, and
enters drain circuit (7). The rest of the oil
goes from portC,enters regeneration circuit
($1, openscheckvalve (51, andpasses
through ports C and D to flow back to the
cylinder head.
10-72 PC300, 350-6

STRUCTURE CLSS
s LPOO22 1
2) Cylinderheadpressure > Cylinder bottom

pressure (digging operations, etc.)
Check valve (5) in regenerationcircuit (8)
acts to shut off the flow from the cylinder
head to the cylinder bottom.
PC300, 350-6 10-73

9. Arm regeneration circuit
SWPO5097

2. Main spool Cylinder head pressure > cylinder bottom pres-
3A. Pressure compensation valve sure
38. Pressure compensation vafve A returnflowcircuit is providedfromthe
4A. Safety valve cylinder head to the cylinderbottom so that
48. Safety valve when the arm is moved IN, the flow ofoil to
5. Check valve the cylinder becomesthe pump discharge
6. LS shuttie vaive amount + the return flow. This covers for
7. Drain circuit any negative pressure at the cylinder bot-
8 . Regeneration circuit tom, and, as a resuit, increases the cylinder
speed.
Operation
When the cylinder headpressure > cylinder
bottom pressure, the pressurized oilfrom
the cylinder head passes through the notch
in spool (21, enters port C and opens check
valve (81, then passes through ports D and E
to flow back to the cylinder bottom.
10-74 PC300, 350-6

10.
P2 P1
SWPO5098
1. Main spool Operation
2. Spring I ) When merging pump flow (when pilot pres-
3. LS spool sure PS is OFF)
4. Spring Pilotpressure PS is OFF, so main spool (1)
5. LS circuit(bucket) is pushed fully to the left by spring (2); and
6. LS circuit(arm) ports E and F are interconnected.
7. LS circuit(arm) Therefore, pressurized oil flows P1 and P2
8 . is circuit(buc&j discharged from the two pumps are merged
at ports E and F, and are sent to the control
Function valve that demands the oil.
This acts to merge or divide(send each to In the same way, LS spool (3) is also pushed
itsowncontrol valve group) oil flows P1 fully to theleft by spring (41, so the portsare
a n d p2 cf pressurized cj! dlsch2:ge-j frsm
"I I" ccmecte:! as fc!lc:vs.
the two pumps. Connected ports: A t)Q, B t)C
At the same time, it also carries out merging Therefore, the hS pressure supplied from the
and dividing of the LS circuit pressure. spools of each control valve to LS circuits
(51, (61, (7),and ( 8 ) is all sent to the pressure
compensation valve and other valves.
PC300, 350-6 10-75

ps
(ON)
*
To btlcket control valve
TO arm control valve
P2 PI
SLPoo224
2) When dividing pump flow (when pilot pres-

sure PS is ON}
When pilot pressure PS is ON, mainspool
(1) is moved to the right by the PS pressure,
and ports E and F are disconnected.
Therefore, thepressurizedoildischarged
from each pump is sent to its own control
vaive group.
Pressure PI: To bucket, R.H. travel, boom
group
Pressure P2: To swing, L.H. travel, arm group
In the same way, LS spool (3) is also moved
PS pressure, and the ports
to the right by the
are connected as follows.
Connected ports: B H D, others are not con-
nected.
Therefore, LS circuits (51, (61, (7), and ( 8 ) are
all connected totheir own controlvalve
group.
10-76 PC300, 350-6

11. LS select valve

* The diagram shows the situation when the
?.
2.
Valve
Spring
swingandlefttravel are operatedatthe
3. Piston
same time. (BP pressure ON)
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttlevalve
9. LS circuit
9 SLPOO225
Function
Thisvalve is used to increase the ease of
operatingtheworkequipmentltprevents
high pressure from being generated when
the swing is operated, It also prevents the
high LS pressure from the swing circuit from 4, 3 2 B I A
flowing into any other LS circuit when the
swing is operatedtogether with thework
equipment. BP
(OFF)
Operation
When pilot pressure BP is OFF
Pilotpressure BP is OFF, so piston (3) is
pushed to the left by spring (2). if the swing
is thenoperated,swing LS pressure P I To LS shuttle valve
SLPO0226
passes through swing spool (5)and enters
port A. It pushesvalve (1) to the left and
connects ports A and B.
TI---- e-- -.-..
I I I W C ~ V I awing
~ , LS pressu~eP i fiows io is
4. 3 2 I31 A
shuttle valve (8).
When pilot pressure BP is ON
When pilot pressure BP is ON, piston (3) is
moved to the rightagainst spring (2) by the
RP pressure. !t pushes va!ve !?) t= the right
and closes the circuit between ports A and
B. As a result, swing LS pressure Pa stops
flowing to LS shuttle valve (81, and even if
swing LS pressure P I rises to a high pres-
sure, it does not influence any other LS cir- TXSshuttle valve
SLPOO227
cuit.
PC300, 350-6 10-77

12.2-stage safety valve (installed to boom cylinder head)
1. Spring
\ f f 2. Piston
3. Spring
SAP00228
Function
Theset pressure of the safety valve canbe set
to two stages and the low pressure setting can
be made smaller. Because of this, when digging
with boom, even if high pressure is brought to
bear.on the boom cylinder, it is possible to let
the boom escape without operating the controf
lever. This makes it possible to carry out opera-
tions with high efficiency and with little vibra-
tion of the chassis.
Operation
Theset pressure of the safetyvalve is deter-
mined by the load pressure of spring (1).
When pilot pressure P is OFF highpressure
setting
Pilot pressure P is OFF, so piston (2) is pushed
to the left by spring (3). (Installed load of spring
(1) < installed load of spring (3)).
When this happens, the installed load of spring
(1) becomes the maximum, and the set pres-
sure is set to high pressure.
In passage
addition, B isdrain
connected
the to SAP00229
circuit through passage C and chamber D.
When pilot pressure P is ON: low pressure set-
ting
\ IL^^
S V I I ~ Ipilot
I pressure r" is ON,the p l b i pressure
goes to portion A through passage B, and pis-
ton (2) acts or: the diameter of portion A receiv-
ing the pressure (d2- dl). Piston (2) is moved
t o the right against spring (3) by this pilot pres-
sure.
It moves the full stroke until it contacts holder C P
(4). As a result, spring (1) extends, the installed
load becomes the minimum, and the set pres-
sure is set to low pressure.
In addition, an amount of oil equivalent to the
SAPO0230
pistonstroke passes through passage C and
chamber D, and is drained.
10-78 PC300, 350-6

1' I
a,
5
rc
0
6
c
m
I
I -
i
0
0 P L
do
1. Hydraulic tank 20. Plug

2A. Main pump (front) 21. LS shuttle valve (bucket)
2B. Main pump (rear) 22. LS shuttle valve (R.H. travel)
3A. TVC valve (front) 23. LS shuttle valve (boom)
3B. TVC valve (rear) 24. LS shuttle valve (L.H. travel)
4A. LS valve (front) 25. 1s shuttle valve (arm)
4B. LS valve (rear) 26. Check valve (for boom regeneration circuit)
5A. Merge/flow divider valve (main) 27.Check valve (for arm regeneration circuit)
58. Merge/flow divider valve (for LS) 28A.Main relief valve (bucket group)
6. Bucket spool 28B.Main relief valve (arm group)
7. R.H. travel spoof 29A.Unioad valve (bucket group)
8. Boom Lo spool 29B. Unload valve (arm group)
9. Swing spool 30. LS select valve
10.L.H. travel spool 31. LS check valve
11. Arm Lo spool 32. LS bypassvalve
12. Boom Hi spool 33. Suctionvalve
13. Arm Hi spool 34. Servicespool
14. Pressure compensation valve 35. Variable type pressure compensation valve
(with shuttle valve) 36.LS shuttle valve (service)
15.Pressure compensation valve (with shuttle
vaive, integrated type) bucket CURL)
16. Pressure compensation valve (without shut-
tle valve) (travel)
18. Safety-suction valve (bucket CURL)
19. 2-stage safety-suction valve (boom LOWER)
Note: Groups of control valves by main pump

circuit
Bucket group: Bucket,R.H. travel, boom Lo,
bcom Hi, aim Hi
Arm group: Swing, L.H. travel, arm Lo
Operation (When all work equipment is at neutral)

When the levers are a t neutral, the pump is
at the minimum swash plateangle, and the
oil flow is drained from unload valves(29A,
29B).
The LS pressure is connected to hydraulic
tank(1) by LS bypassvalve (32). The LS
differential pressure APLS (unload pressure
-tank pressurej at this point is AFLS > pump
LS control pressure, so the pumpswash plate
angle is the minimum.
PC300, 350-6
I
I
I
Operation(When pump flow merged, bucket

CURL operated independently)
,. When the bucket CURL is operated, unload
valves (29A, 29B) are closed.
The swashplate of the main pump is con-
trolled (LScontrol) to match the area of the
meter-in opening of bucket spool (61, so the
pump swash plate is balanced at a position
which matches the oil flow demanded by
the spool meter-in.
(APLS= pump LS control pressure)
10-86 PC300, 350-6

L
t
V
c2
0
0
Operation (Whenpump flow merged, boom

RAISE operated independently)
0 When the boom RAISE is operated, unload
valves <29A, 298) are closed.
The swash plate of the main pump is con-
trolled (LScontrol) to match the totalarea of
the meter-in opening of boom Lo spool ( 8 )
and boom Hi spool (12).
(APLS = pump LS control pressure)
When thespoolmeter-inopeningcomes
near the maximum, both pumps are at the
maximum swash plate angle.
(Whenthe pump discharge is the maximum,
the maximum area of opening of the spool
is also large, so the LS differential pressure
is smaller than the LS control pressure and
the swash plate angle is always a t the maxi-
mum.)
(APLS e pump LS control pressure)
10-90 PC300, 350-6

if
'9
I
f
L
cv
ch
0
c
E
0
0
w
4
d
0 J
Operation (When pump flow merged, arm O N

operated independently)
When the arm IN is operated, unload valves
(29A, 29B) are closed.
The swashplate of themainpumpiscon-
trolled (LS control) to match the totalarea of
the meter-in opening of arm Lo spool (11)
and arm Hi spool (13).
Whenthespoolmeter-inopeningcomes
near the maximum, both pumps are at the
(When the pumpdischarge is the maximum,
the maximum area of opening of the spool
is also large, so the LS differential pressure
is smaller than the LS control pressure and
the swash plate angle is always at the maxi-
mum.)
(APLS e pump LS control pressure)
10-94 PC300, 350-6

I
I
I
I
3
c,
t
P
0
9-
0
c
Operation (When pump flow merged, arm OUT

operated independently)
Whenthearm OUT is operated,unload
valves (29A, 298) are closed.
trolled (LS control) to match the area of the
meter-in opening of arm Lo spool ( I l ) , so
the pump swash plate is balanced a t a posi-
tion which matches the oil flow demanded
by the spool meter-in.
When this happens, the oil from the cylinder
bottomis divided,sent tothe Lo and Hi
spools, and then returned, so it is possible
to keep the pressure loss in the circuitsmall.
10-98 PC300, 350-6

0
N S
P
-l
P
P
Operation (When pump divided, travel operated

independently)
Pilot pressure PA of merge/flow divider valve
(5A) ON
1)
When the STRAIGHT TRAVEL is operated, a
flow of oil is supplied from the main pump
to match thestroke of the left and right travel
spools (10) and (7).
Flow of oil from main pump (2A):
To L.H. spool (IO) (arm group)
Flow of oil from main pump (2B):
To R.H. spool (7) (bucket group)
The straighttraveliscompensatedbythe
travel junction valve.
2)
Fromthe conditionin 1) above, if the lever
on the side being steered is returned (the oil
flow becomes small) or the lever on the other
side is operatedintheoppositedirection
(the direction of travel is reversed), the oil
flow from the pumpis being divided, so the
left and righttravelcircuits are controlled
independently and the machine is steered.
10-102 PC300,350-6
I
i
t
d
l
5
0
0
0
J
Operation (When pump flow merged, arm IN +

boom RAISE operated simultaneously)
When the arm and boom are operated si-

multaneously, the swash plate angle for both
pumps becomes the maximum.
When this happens, the load pressure at the
boom RAISE side is higher than at the a m
side, so the LS pressure passes through ports
E and F of boom t o spool (81, enters boom
LS shuttle valve (23)and is sent to the LS
circuit. This LS pressure is transmitted to
port G of pressure compensation valve(141,
and acts to increase the set pressure of the
pressure compensation valve. Because of
this, the pressure between port H of arm Lo
spool ( I I ] and port I of pressure compensa-
tion valve (14) rises, and the spool meter-in
LS differentialpressure(pumppressure -
LS pressure = APLS) becomes the same as
that at the boom end.
Because of the above operation, the oil flow

is divided in proportion to the total area of
opening of boom Lo spool (8) and boom Hi
spool (121, and the total area of opening of
arm Lo spool (11) and arm Hi spool (13).
Meter-in LS differential pressure APLS dur-
ing boom RAISE + arm IN is APLS e pump
LS centre! pressure, so the mair! pump
swash plate angle is set to maximum.
10-106 PC300, 350-6

3 'Q
0-
0
m
3 2
-
0
*
c m
a,
f"
I
00
0
0
, . ..
a
w
0
0
II 1
0
d
0
\o
Operation (When pump flow merged, swing +

boom RAISE operated simultaneously)
When the boom RAISE is being operated in
the heavy-duty digging mode the swing is
operated simultaneously, the pilot pressure
of LS divider valve (30)is turned ON.
When this happens, the LS divider valve is
shut off, and the high pressure generated
when the swing is operated does notflow t o
the LS circuit, so the LS circuit pressure be-
comes the boom pressure.
trolled (LS control) by the difference in pres-
sure between the boom and LS pressure.
In addition, the pump pressure is determined
by the boom pressure, so even if the swing
drive pressure is high, the pump can deliver
an ample flow of oil regardless of the pump
output curve.
10-110 PC300, 350-6

When pump flow divided (pump pressure: 19.6 MPa (200 kg/cm2) or above), travel + boom RAISE
operated simultaneously
SWPO4749
Connection of ports when pump flow is divided

Connected ports: B - D
Disconnected ports: A, C
10-112 PC300, 350-6

E
0
-0
Operation(When pump flow divided(pump

pressure: 19.6 MPa (200 kg/cm2)or above), travel
+ boom RASE operated sSmssitanesus5y)
When the travel and boom RAISE areoper-
ated simultaneously (such as when raising
the boom before traveling up a steep slope),
if the pump pressure rises to 19.6 MPa I200
kg!cm*!i the merg!?!f!c?w divider valve pilot is
turned ON and the pump flow is divided.
In addition,the boom Hispool doesnot
move because of the travel PPC pressure.
The flow of oil to the boom a t this point is
restricted, so the travel pressure ismain-
tained and it is possible to carry out com-
pound operations easily.
10-114 PC300, 350-6

r
E
0
p
/ II
r
L
L'
0
Qperation(When pump flow divided(pump

pressure: 19.6 MPa (200 kg/cm3 or above), travel
+ arm IN operated simultaneously)
Whenthetravelandarm IN areoperated
simultaneously (suchas when using the dig-
ging action of the arm to help the machine
travel up a steep slope), if the pump pres-
surerises to 19.6 MPa (200 kg/cm21, the
rnerge/flow divider valve pilot is turned ON
and the pump flow is divided.
* In addition, the stroke of the arm Lo spool is
restricted by the travel PPC pressure. The
flow of oil to the arm a t this point is re-
stricted, so the travel pressure is maintained
and it is possible to carryoutcompound
operations easily.
10-118 PC300, 350-6

m
LD
r.
r+
0
n
B
v1
0
STRUCTURE AND FUNCTION SWING MOTOR
D-D
I
c-c
14 15
A-A 6-6
SWPO4754
1. Spring 9. Pistonassembly
2. Outputshaft IO. Cylinder block
3. Oil
seal 11. Spring
4. Case 12. Center shaft
5. Plate 13. Valve plate
6. Disc 14. Suction valve spring
7. Brake piston 15. Suction-safety valve
8. Housing 16. Reverse prevention valve
PC300, 350-6 10-121

STRUCTURE AND FUNCTION MOTOR SWlNG
SUCTION-SAFETY VALVE
Function
When the swing is stopped, the outlet port
circuit of the motor is closed by the control
valve, but the motor continues to be turned
by the inertia of the swing. As a result, the
pressure at the outlet port of the motor be-
comes abnormally high and there is danger
that the motor will be damaged.
The safety valve is installed to prevent this
problem. It acts to release the abnormally
high pressure oil from the outlet port of the
motor to port S, andalsofunctions as a
swing brake.
The suction valve supplies an amount of oil
equivalent to the amount of oil released by
the safety valve. It sends this oil from port S
to the inlet port of the motor to prevent any
cavitation.
Control valve . .
Operation SAP00245
'i. When starting swing
. If the swing controllever is operated to swing
tothe right, the pressurized oilfromthe
pump passes through the control valve and
it supplied to port MA.
b
When this happens, the pressure a t port M A
rises and the starting force is generated'in
the motor, so the motor starts to turn.
The oil from the outlet port of the motor
flows from port MB through the control valve
and returns io the tank.
2. When stopping swing
b
When the swing control lever is returned to
the neutral position, no morepressurized oil
is supplied from the pump to portMA.
At the same time, the oil from the outlet
port of the motor returns from the control
. valve to the tank, and the circuit is closed.

The pressure at port M6 rises, and rotating
resistance to the motor is generated, so the
brake starts to take effect.
if +L.. .
-
.
e
LllG p
-
.
.
a ci3suIG a: PO;: ME! rises to the Set
I.--
pressure of safety valve (1 1, safety valve (1 1

opensand releases the pressurized oil at
. port M B to port S.
No pressurized oil is supplied at port MA,
but the swing continues, so negative force
is generated. SAP00246
Whenthisnegativepressure drops to the
set pressureofsuctionvalve (21, suction
valve (2) opens and oil is supplied from port
S t o prevent cavitation.
10-122 PC300, 350-6

AND STRUCTURE SWING MOTOR
Operation of swing brake

1) Swing brakesolenoidvalve de-energized
If the swing brake solenoid valve isde-ener-
gized, the flow of pressurized oil from the
main pump is shut off, and port B is con-
nected t o the tank circuit.
M a i n uumu
As a result, brake piston ( 7 ) is pushed down
by brake spring (11, pushes disc (6)and plate
(5)together, and the brake is app!Ied. 0/I
M SWPO5 1 0 0
2) Swing brake solenoid valve energized

When the swing brake solenoid valve is en-
ergized, the valve is switched, and pressu-
rized oil from the main pump enters port B
and flows tobrake chamber a.
The pressurized oil entering chambera over- Swing b r a k e
M a i n uumu
comesbrake spring 11) andpushesbrake solenoid v a l v e
piston (7)up. As a result, disc ( 6 ) and plate
( 5 ) are separated and the brake is released.
SWPOS 1 0 1
PC300, 350-6 10-123

STRUCTURE AND FUNCTION SWING MOTOR
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Swind control valve

1
SAP03475
Explanation of effect
:with reversal Prevention valve
I prevention valve
P r e s s u r e MA
P r e s s u r e MB
I I I I I I I
1st reversal
MGtGi speed
Start Brake
w ‘\/ ’ ‘L/
Reversal
4
SAP03476
10-124 PC300, 350-6

STRUCTU
SWINGRE AND FUNCTION MOTOR
Outline
Thisvalvereducestheswingbackgener-
ated in the swing body by the inertia of the
swing body, the backlash and rigidity of the
machiner y system, and the compress ion of
the hydraulic oil when the swing is stopped.
This is effective in preventing spillage of the
load and reducing thecycle time whenstop-
pingtheswing(thepositionin gabiiiiyis
good and it is possible to move swift!y to
the next job).
Notch SAPO3477
Operation
1) When brake pressure is being generated at
port MB
Pressure M B passes throughthenotchand
goes to chamber d, spool (5) pushes spring
( 6 ) according t o the difference in area D l >
D2, moves to the !eft, and M B is connected
t o e.
When this happens,pressure MA is below
the set pressure of spring (31, so spool (2)
doesnotmove. For this reason, the pres-
sure oil is closed by spool (21, and the brak-
ing force is ensured.
Notch SAPO3694
2) After motor stops

The motor is reversed by the closing pres-
sure generated at port MB. (1st reversal)
When thishappens, reversal pressure is gen-
eratedat port MA. Pressure M A goes t o
c h ~ m h e r8 , so spoo! (2! pushes spring (3)
and moves to the right, and MA is connected
t o B. At the same time, b is connected t o f
through the drill hole in spool (51, so the
reversal pressure at port MA is bypassed t o
port T to prevent the 2nd reversai.
3 ME
SAP02642
PC300, 350-6 10-125

STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT

PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No.: 12001 - 12283
1
AI
2
i i
c1
Dl El
A-A
TI T2 D2
I \ \
B2 A2 c2
Z
SBP00249
1. Cover AI : From control valve port B2 D l : From control valve port A5

2. Body A2 : To R.H. travel motor port PB D2 : To L.H. travel motor port PB
3. Slipper seal B1 : From control valve port B5 E l : From travel speed EPC valve
4. O-ring B2 : To L.H. travel motor port PA E2 : To L.H. and R.H. travel motors
5. Shaft C1 : From control valve port A2 port P
C2 : To R.H. travel motor port PA T I : To tank
T2 : From L.H. and R.H. travel motors
port T
10-126 PC300, 350-6

0
FUNCTION
STRUCTURE AND JOINT SWIVEL CENTER
PC300-6 Serial NO.:33466 a d UP

i
A1
+
CI
El
A-A
I: A-
c2
I
A2 D2
T l
L B2 SJPO6560
I . Cover A9 : From control valve port B2 D l : From controi valve port A5

2. Body A2 : To R.H. travel motor port PB D2 : To L.H. travel motor port PB
3. Slipper seal B1 : From control valve port B5 E l : From travel speed EPC valve
4. O-ring B2 : To L.H. travel motor port PA E2 : To L.H. and R.H. travelmotors
5. Shaft C1 : From control valve port A2 port P
C2 : To R.H. travelmotorport PA T I : Totank
T2 : From L.H. and R.H. travel motors
port T
PC300, 350-6 10-927

0
+
r-
N Lo
h
d
0
a
5
L1
N
..
E
3
O
s
n a ..
m a
a n
W
Y
2
m
03
cv
-0
0
K
w
0
-0
w
ch
0
6
m D
I I
m D
co
U
0
P
-4
VI
m
STRUCTURE AND FUNCTION TRAVEL MOTOR
Operation of motor
1) At low speed (motor swash plate angle at
maximum)
The solenoid valve is de-energized, so the At the same time, the pressurized oil at regu-
pilot pressure oil from the mainpump does lator piston (13) passes through orifice c in
not flow to portP. regulator valve (21) and is drainedto the
For this reason, reguiator valve(21)is pushed motor case.
fully to the right by spring (22). As a result, rocker cam (3) moves in the
Because of this, it pushes slow return valve maximum swash plate angle direction, the
(81, and the main pressure oil from the con- motor capacity becomes maximum, and the
trol valve going to end cover (7) is shut off system is set to low speed.
by regulator valve (21).
Fulcrum a of rocker cam (3) is eccentric t o
point of application b of the combined force
of the propulsion force of the piston of cyl-
inder (51, so the combined force of the pis-
ton propulsion force acts as a moment to
angle rocker cam (3) in the direction of the
10-130 PC300, 350-6

21 At high speed ( m ~ t swash

~a plate angle et
minimum)
When thesolenoid valve is energized, the

pi!ot pressure si! from the main pump flows
t o port P,and pushes regulator valve(21) to
the left.
Because of tnis, the main pressure oii from
the control valve passes through passage d
in regulator valve (211, enters regulator pis-
ton (13), and pushes regulator piston (13) t o
the right.
0 As a result, rockercam (3) movesinthe
minimum swash plate angle direction, the
motor capacity becomes minimurn, and the
system is set to high travel speed.
PC300, 350-6 10-131

Operation of parking brake
-
1) Whenstarting totravel
When the travel lever is operated, the pres-
surized oil from the pump actuates counter-
balance valve spool(171, opens the circuit to
the parking brake, and flows into chamber a
of brake piston (IO). It overcomes the force
of spring (91, and pushes piston (IO)to the
right.
When this happens, the force pushing plate
(11) and disc (12) together is lost, so piate
(11) and disc (12) separate and the brake is
released.
12 11
SWPO5104
2) When stopping travel

* When thetravel lever is placed in neutral,
counterbalance va!ve spm! !?7! rewrns
the neutral position and the circuit to the
parking brake is closed.
The pressurized oil in chamber a of brake
piston ( I O ) is drained to the case from the
orifice in the brake piston, and brake piston
(10) is pushed fully to the left by spring(9).
As a result, plate (11) anddisc (121 are
pushed together, and the brake is applied.
A time delay is provided by having the pres-
surized oil pass through a throttle in slow
r e t ~ r nva!ve !A! when the brake pistnn rg-
turns, and this ensures that the brake is ap-
plied after the machine stops. SUP05 105
10-132 PC300, 350-6

STRUCTURE AND FUNCTION MOTOR TRAVEL
Operation of brake valve

Thebrakevalveconsists ofa checkvalve, PA PB
counterbalance valve, and safety valve in a
circuit as shown in the diagram on the right.
(Fig. 1) I , L
The functionandoperationof each compo-

nent is as given beiow.
1) Counterbalancevalve,checkvalve
Function
When travelingdownhill,theweight of the Safety
machine makes it try to travel faster than

the speed of the motor.
As a result, if the machine travels with the (Fig. 1)
SAPO0262
engine at low speed, the motor will rotate
without load and the machine will run away,
which is extremely dangerous.
To prevent this, these valvesact to make the
machine travel accordingto the engine speed
(pump discharg,e amount).
I9
Operation when pressurized oil is supplied
surized oil from the control valveis supplied
to port PA. It pushes open check valve (18a)
and flows from motor inlet port M A to mo-
tor outlet port MB.
However, the motor outlet port is closed by
checkvalve (18b) and spool(191, so the pres- W
sure at the supply side rises. (Fig. 2). (Fig. 2)
Thepressurized oil at the supply side flows SAP00263
from orifice E l in spool (19) and orificeE2 in
the piston to chamber S I . When the pres-
sure in chamber S I goes above the spool I Control valve I
switching pressure, spool (19) is pushed to
the right. As a result, port M B and port PB
areconnected, the o u t k t port side of the
motor is opened, andthemotor starts to 9
rotate. (Fig. 3).
(Fig. 3)
SAW0264
PC300, 350-6 10-133

UNCTION
STRUCTURE AND TRAVEL MOTOR
Operation of brake when traveling downhill

0 Ifthemachinetriestorunawaywhen
traveling downhill, the motorwill turn under valve
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber 1
SI through orifices E l and E2,will also drop.
When the pressure in chamber SI drops be-
low the spool switchingpressure, spool (19)
is returned to the left by spring (201, and
outlet port MB is throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the ro-
tation of the motor, and this prevents the SI’
machine from running away.
In other words, the spool moves to a posi-
tion where the pressure at outlet port MB (Fig.4) SBPOO265
balances the pressure at the inlet port and
the forcegeneratedby the weightofthe
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged f m m :he pump.
(Fig. 4)
2) Safetyvalve (2-directionoperation,2-stage
set safety valve)
Function
Whentravel is stopped(orwhentraveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve. However, the motor is ro- I
tated by inertia, so the pressure at the outlet (Fig. 5)

port of the motor will become abnormally SBP00266
high and will damage the motor or piping.
The safety valve acts to release this abnor-
mal pressure and send it to the inlet port
side of the motor to prevent damage to the
equipment.
h Operation in directions D2
1) When pressure in chamber MB has become
high (when rotating clockwise)
When the travei is stopped (or when traveling
downhill),chamber MB in theoutletport
circuit is closed by the check valve of the
counterbalancevalve, butthepressure at
the outlet port rises because of inertia. (Fig.
5)
If the pressure goes above the set pressure,
byproduced
the force in area MB
between D l and D2 h 4 ( D l 2 - DZ2) x pres-
sure] overcomes the force of the spring and
the
poppet
moves
the
to left,flows
sooilthe Poppet
t o chamber MA in the circuit
oppo-
the
on (Fig. 6 )
site side. (Fig. 6 ) . SBPOO267
10-134 PC300, 350-6

FUNCTION
STRUCTURE AND TRAVEL MOTOR
2) When pressure in chamber MA has become

high (when rotating counterclockwise)
When the travel is stopped (or when traveling
downhill),chamber M A in theoutletport
circuit is closed by the check valve of the
counterbalance valve, but thepressureat
the outlet port rises because of inertia. (Fig.
7)
I f the pressure goes above the set pressure,

the force produced by the difference in area
between D l and D3 [7c/4(D3* - D l 2 ) x pres-
sure] overcomes the force of the spring and
moves the poppet to the left, so the oil flows
to chamber MB in the circuit on the oppo-
site side. (Fig. 8 )
Poppet
(Fig.8 )
SBP00269
Operation of mechanism for varying set pres-

sure Piston Spr i no
1) When starting travel (high-pressure setting)
surized oil from the pumpactuates counter-
balance valve spool (191, and opens the pi-
lot circuit tothe safety valve. The oil passes
fromchamber G to passage H andflows
intochamber J, pushes the piston to the
right, and compresses the spring to make
the set load larger. Because of this, the set
pressure of the safety valve is switched to
1112 high p r e ~ ~eitiiig,
LC. ~ ~ e 2nd B large draw-
bar pull is made available.
Travel control
va I v e
(Fi o. 9) SWPO5106
PC300, 350-6 10-135

21 When stopping travel (low-pressure setting)

When the travel lever is placed at neutral, PS il sj it no rn
the pressurein chamber PA drops andcoun- \
terbalance valve spool (19) returns t o the
neutral position. While the counterbalance
valve spool is returning t o the neutral posi-
tion, the pressurized oil in chamber J passes
through passage H, and escapes to chamber
PA from chamber G. The piston moves to
the left, and the set load becomes smaller. J H
Because of this, the set pressureof the safetv
valve is switchedto the.low-pressure setting
and relieves the shock when reducingspeed,
[Set pressure of safety valve]
Whenstarting, : High-pressure
whentraveling)setting
37.8 MPa (385 kg/cm*)

setting
I
When stopping:
Low-pressure
27.5 MPa (280 kg/crn2)
M
* T r a v e l control
va Ive
( F i e . 10) SWPO5 107
10-136 PC300, 350-6

5
0
0
w
tn
0
0.
!ii
6
@@@@@@@@@L
..................
@@@@@@
............
2:z
P
. . .?.
4
WORK
STRUCTURE AND FUNCTION EQUIPMENT SWING PPC VALVE
WORK EQUIPMENT SWING PPC VALVE
A C
C A
J-4
H
SWPO5734
% I . PC3on-6 Spria! Nc?.:31466 and e:,

PC350-6 Serial No.: 12284 and UP
P : From main pump PI : L.H: Arm OUT/R.H: Boom LOWER

T : To tank P2 : L.H: Arm IN/R.H: Boom RAISE
P3 : L.H: Right swing/R.H: Bucket CURL
P4 : L.H: Left swing/R.H: Bucket DUMP
10-138 PC300, 350-6

0
STRUCTURE AND FUNCTION WORK EQUIPMENT SWING
VALVE
PPC
5 7
4
a
3
9
2 10
1' A-A c-c
,------.
D-D
B-B
E-E
1. Spool 7. Joint
2. Meteringspring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
PC300,350-6 10-139
STRUCTURE AND FUNCTION WORK EQUIPMENT SWING PPC VALVE
OPERATION
1) At neutral
Ports A and B of the control valve and ports
P I and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool ( I ) . (Fig. 1)
2) During fine control (neutral -+fine control)

When piston !4j starts t~ be pushed by disc
(51,retainer (9) is pushed; spool (1) is also
&
,,s, Control v a l v e
pushed by metering spring (21, and moves ( F i g . 1)

down. SRPO3493
When this happens, finecontrolhole f is
shut off from drain chamber D, and at al-
most the sametime, it is connected to pump
pressure chamber PP, so pilot pressure oil
fromthemainpump passes throughfine
control hole f and goes from port P I to port
A.
Whenthepressureatport P I becomes
higher, spool (1) is pushedbackandfine
control hole f is shut off from pump pres-
sure chamber PP. At almost the same time,
it isconnected to drainchamber D to re-
lease the pressurea t port PI. When this hap-
pens, spool (1) moves up or down so that
the force of metering spring (2) is balanced
with the pressure at port P I . The relation-
ship in the position of spool (1) and body
(IO)(fine control holef is a t a point midway
betweendrainhole D and pump pressure
chamber PPI does not change until retainer
(9) contacts spool (I).
Therefore, metering spring(2) is compressed
proportionally to the amount of movement
of the control lever, so the pressure at port
PI also rises in proportion to the travel of
the control lever. In this way, thecontrol
valve spool moves to a position where the
pressure in chamber A (the same as the pres- (F i g. 2) SBPO3494
sure a t port P I ) and the force of the control
valvespool return springarebalanced.
(Fig.2)
10-140 PC300, 350-6

STRUCTURE AND FUNCTION WORK EQUIPMENT SWING PPC VALVE
3) During fine control

{when control lever is returned)
When disc (5)starts to be returned, spool(1)
is pushed upby the force of centering spring
(3)and the pressure at port P I .
Whenthis happens, finecontrolhole f is
connected to drain chamberD and the pres-
sure oil at port P1 is released.
If the pressure ai port FS drops roofar, spool
(1) is pushed down by metering spring (21,
and fine control holef is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port P1 recovers to a pressure
that corresponds to the lever position.
When the spoolof the control valve returns,
oil in drainchamber D flows in from fine
control holef' in the valve on the side that is
not working. The oil passes through port P2
and enters chamber B to fill the chamber
with oil. (Fig. 3)
(F i 8 . 3)
SEPO3495
4) A t full stroke
When disc (5) pushes down piston (41, ar;b
retainer (9)pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
hole f and flows to chamberA from port P1,
and pushes the control valve spool.
The oilreturningfromchamber B passes
from port P2 through fine control holef' and
flows to drain chamber D. (fig. 4)
(Fig. 41
SBP03496
PC300,350-6 7 0-141
R
U I-
N
(u
N
Tt
c
.. .. .. .. .. .. 0
-wr9*
LI-QLQQ
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
2
\
\
/8
B-8 A-A
’\
i f
B
D-D
c-c
SAP01250
1. Plate 5. Meteringspring
2. Body 6. Centeringspring
3. Piston 7. Valve
4. Collar 8. Bolt
PC300, 350-6 10-143

STRUCTURE AND FUNCTION TRAVEL PPC VALVE
OPERATION
1) A t neutral
P I and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
2) Finecontrol (neutral -+fine control)

When piston (4) starts to be pushed by disc
(51, retainer (9)is pushed. Spool ( I ) is also
pushed by metering spring (2) and moves
down.
When this happens, finecontrolhole f is
shut off from drain chamber D. At almost
the same time, it is connected to pumppres-
sure chamber PP, and the pilot pressure of
the main pump is sent from port A through
fine control hole f to port P1.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al-
most the same time, it is connected to drain
chamber D, so the pressure a t port P I es-
capes.
As a result, spool (1) moves up and down
until the force of metering spool (21 is bal-
anced with the pressure of port P I .
The relationship of the position of spool(1)
and body (IO) (fine control hole f is in the
middle between drain hole D and pumppres-
sure chamber PPI does not change until re-
tainer (9) contacts spool ( I ) .
Therefore, metering spring (2) iscompressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve (F i 6 . 2)
moves to a position where the pressure of SBP03498
chamber A (same as pressureatport PI)
and the force ofthereturnspringofthe
control valve spool are balanced. (Fig.2)
10-144 PC300, 350-6

STRUCTURE AND FUNCTION VALVE PPC TRAVEL
n
3) Fine control ( c ~ n t r dlever returned)
When disc (5) starts to be returned, spool(1
is pushed up by the force of centering spring
(3)and the pressure at port P I .
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressu-
rized oil a t port P I is released.
If the pressure at port P I drops too much,
s g m ! !,!I is pushed LIP by metering sprlnn J
(Z),so fine control hole f is shut off from

drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure a t port P I supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control holef'
of the valve on the side that is not moving.
It passes through port P2 and goes to cham-
ber B to charge the oil. (Fig. 3) (Fig. 3)
SBP03499
4) At full stroke
Disc (5) pushes down piston (41, and retainer
(9) pushes down spool (1). Fine control hole
f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, thepilotpressureoilfromthe
main pump passes through fine control hole
f and flows to chamber A from port P I t o
push the control valve spool. The return oil
from chamber B passes from portP2 through
fine control hole f' and flows to draincham-
ber D. (Fig. 4)
(F i g. 4)
SBPO3695
PC300,350-6 10-145
AND STRUCTURE PPC VALVE
SERVICE PPC VALVE
1. Pin
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
’\ A:
B:
P:
To service valve P-1
To service valve P-2
From main pump
T: To tank
A B
SWPO4767
10-146 PC300, 350-6

ALVE PPC
STRUCTURE
SERVICE
AND FUNCTION
OPERATION
At neutral
The pressurized oil from the main pump en-
ters from port P and is blocked by spool (9).
a and b of the PPC valve are connected to
drain port T through fine control hole X of
spool (9).
SBPO3500
When operated
When c a m (2)is moved, metering spring ( 8 )
is pushed by ball (31,piston (41, and sleeve
(61, and spool (9)is pushed down by this.
As a result, finecontrolhole X is shut off
from the drain circuit. At almost the same
time, fine control portionY is connected with
port a, and the pressurized oil from port P
flows from port a to port A of the control
va Ive.
SEPO3501
PC300, 350-6 10-147

STRUCTURE AND FUNCTION PPC SERVICE VALVE
When the pressure at port a becomes higher,

spool (9) is pushed back by the force acting
on the end of the spool. When fine control
portion Y closes, fine control hole X is con-
nected to the drain circuit
at almost the same
time.
As a result, spool (9) moves up and down to
balance the force at port a and the force at
metering spring ( 8 ) .
Therefore, metering spring (8) is compressed
in proportion to the amount the control ie-
ver is moved.Thespringforcebecomes
larger, so thepressureatport a also in-
creases in proportion to the amount the con-
trol lever is operated.
In this way, the control valve spool moves
to a position where the pressure of port A
(the same as the pressure at port a) is bal-
anced with the force of the return spring of
the control valve spool. SBPO3502
10-148 PC300, 350-6

PPC SAFETY LOCK VALVE
STRUCTURE AND FUNCTION PPC ACCUMULATOR
PPC SAFETY LOCK VALVE

1. Lever
2. Body
3. Seat
4. Ball
5. End cap
2 3 4 5
SBPOO289
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas volume: 500 cc
SBPOO290
PC300, 350-6 10-149

E
0
0
“9
0
STRUCTURE AND FUNCTION SHUTTLE
PPC VALVE,
TRAVEL JUNCTION VALVE
PPC SHUTTLE VALVE
P2P
1 61 P3 1
P12 P22
A1
P42 A8
P32 A2
P62 A3
P52 A7
P82 P72
A4
P82 PA2
A5
PC2 P92
P7.1 / P91 PC1 \ P81

PB PA1 1
PR
\ PAA
SWPO4768
Function
The PPC shuttlevalve sends the PPC valve
outputpressure to the controlvalve and
travel junctionvalve.It is provided with a
mount port for the pressure switch for de-
tecting the pilot pressure.
10-152 PC300, 350-6

STRUCTURE AND FUNCTION PPC SHUTTLE VALVE,
A I : Mount port for swing pressure switch

A2 : Mountportforbucket CURL pressure
switch
A3 : Mount port for arm IN pressure switch
A 4 : Mount port for arm OUT pressure switch
A5 : Mountportforboom RAISE pressure
switch
A6 : Mount port for travel pressure switch
A7 : Mount port for boom LOWER pressure
switch
A8 : MountportforbucketDUMPpressure
switch
P11 : To control valve (swing)
P I 2 : From swing PPC valve
P21 : To control valve (swing)
P22 : From swing PPC valve
P31 : To control valve (bucket)
P32 : From bucket PPC valve
P41 : To control valve (bucket)
P42 : From bucket PPC vaive
P51 : To control valve (boom)
P52 : From boom PPC valve
P61 : To control valve (arm)
P62 : From arm PPC valve
P71 : To control valve (arm)
P72 : From arm PPC valve
P81 : To control valve (boom)
P82 : From boom PPC valve
P91 : To control valve (R.H. travel)
P92 : From R.H. travel PPC valve
PA1 : To control valve (R.H. travel)
PA2: From R.H. travel PPC valve
PBI : To control valve (L.H. travel)
PB2 : From L.H. travel PPC valve
PC1 : To control valve (L.H. travel)
PC2 : From L.H. travel PPC valve
PF : To travel junction valve
PR : To travel junction valve
PLS : From LS select valve
PC300, 350-6 10-153

STRUCTURE
AND FUNCTION PPC SHUTTLE VALVE,
F-F A-A
w
G-G B-B
N-N
J-J
(2P LACES) c-c
K-K
(2PLACES) D-D
i-i E-E
AA-AA
SDPO0293
1. Body
2. Plug
3. Ball
10-154 PC300, 350-6

STRUCTURE AND
FUNCTION PPC SHUTTLE
VALVE,
PF PR
T2 T4
T1 T3
A-A Sap044 i 2
1. Body T I : From L.H. travel control valve

2. Plug T2 : From R.H. travel control valve
3. Spring T3 : From L.H.travel control valve
4. Spool T4 : From R.H. travel control valve
5. Spring PF : From PPC shuttle valve
6. Plug PR : From PPC shuttle valve
PC300, 350-6 10-755

I
4-
f- U I
1 1 H I
f-
L
I I
, I
I
I
. .
0
STRUCTURE AND FUNCTION PPC SHUlTLE VALVE,
TRAVEL
JUNCTION
VALVE
Operation From control valve From control valve

A:PPC output pressure (R.H. travel REVERSE (L.H. REVERSE) (L.H. FORWARD)
or L.H. travel FORWARD) 1 From PPC shuttle 1
B: PPC output pressure (RH. travel FORWARD
or L.H. travel REVERSE)
When traveling in a straight line in forward or

reverse
' When trave!lng fC!r\..arc! (er in :sverse),theis
is no difference in the pilot pressure from
the PPC shuttle valve (the output pressure
of each PPC valve), so the spool is balanced
in the middle.
Inthiscondition,the R.H. FORWARD and
L.H. FORWARD, and R.H. REVERSE and L.H.
REVERSE areinterconnectedthroughthe
spool.
+-v---r
From
(R.H. REVERSE)
control
(R.H. FORWARD)
valve
SBPO0296
When steering in forward or reverse From control valve From control valve
When the steering is operated in forward (or (L.H. REVERSE) (L.H. FORWARD)
reverse), if the difference in the pilot pres-
surefromthe PPC shuttlevalvebecomes
greater than the switching pressure (spring
force), the spool moves to the right or left
and the left and right forward and left and
right reverse passagesare separated. Be-
cause of this, a difference in pressure is cre-
ated inthe left and right circuits, and the
steering can be operated.
FromcontrolvalveFromcontrolvalve
(R.H. REVERSE) (R.H. FORWARD)
SBP00297
PC300, 350-6 10-157

0
P-
h
* . .. ..
ut-0,
a
I
a
STRUCTURE AND FUNCTION LS-EPC VALVE
Function MPa
The EPC valveconsists of the proportional (kg/crn*)I
solenoidportionand the hydraulicvalve

portion.
When it receivessignal current i from the
controller, it generates the EPC output pres-
sure in proportion to the size of the signal,
and outputs it to the LS valve.
0 200 400 600 800 1000

Current i (mAI
SAPO0303
Operation
1. When signal current is 0 (coil de-energized)
There is no signal current flowing from the LS v a l v e
controller to coil (51, coil (5)is de-energized.

For this reason, spool (2) is pushed tothe
right by spring (3).
As a result, port P closesandthepressu-
rized oil from the main pump does not flow
to the LS vaive.
. A t the same time, the pressurized oil from
the LS valve passes from port C through
port T and is drained to the tank.
PC300, 350-6 10-159

STRUCTURE AND FUNCTION LS-EPC VALVE
2. When signal current is very small (coil ener-

. gized, fine control)
When a very small signal current flows to
n
LS v a l v e
coil (51, coil (5) is energized,a propulsion

force is generated, and this pushes plunger
(6) to the left.
Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port P t o port C.
When the pressure at port C rises and the
load of spring (3)+ the force acting on sur-
face a of spool (2)becomes greater than the
propulsion force of plunger (61,spool (2) is
pushed to the right. The circuit between port
P and port C is shut off, and at the same
. time, port C and port T are connected.
As a result, spool (2)moves up and downso
that the propulsion force of plunger (6)is
balanced with the load of spring (3)+ pres-
. sure of port C.
Therefore, the circuit pressure between the
EPC valve and the LS valve is cor;:;olleb in
SWPOS 1 10
proportion to the size of the signal current.
3. When signal current is maximum (coil ener-
.
.
gized, operated fully)
When thesignalcurrentflowsto
coil (5) is energized.
coil (5),
LS v a l v e
Tt
When this happens, the signal current is at
its maximum, so thepropulsionforceof
plunger (6) is also at its maximum.
For this reason, spool ( I ) is pushed fully to
the left by push pin (4).
As a result, the flow of pressurized oil from
port P flows at its maximum to port C, and
the circuit pressure between the EPC valve
and LS valve becomes the maximum.
At the same time, port T closes and stops
the oil from flowing to thetank.
SWPOS 1 1 1
10-160 PC300, 350-6

STRUCTURE FUNCTION SOLENOID VALVE
SOLENOID VALVE
FOR ACTIVE MODE, PUMP MERGE-DIVIDER, BOOM Hi 2-STAGESAFETYVALVE,TRAVELSPEED,
SWING BRAKE SOLENOID VALVE
A4 A3 A2 A5
/ I I I
1 2 3 I 5 P1
ACC
SwP04714
I. Activemodesolenoidvatve T : T o tank
2. Boom Hi 2-stage safety valve solenoid valve AI : To main valve (active mode)
3. Pumprnerge-dividersolenoidvalve A2 : To L.H. and R.H. travel motor
4. Travel speed solenoidvalve A3 : To main valve (pump merge-divider valve)
5. Swing brake solenoidvalve A4 : To main valve (boom control valve)
A5 : To swing motor
PI : Frommain pump
ACC: To accumulator
PPC : To PPC valve
10-162 PC300, 350-6

STRUCTURE AND FUNCTION SOLENOID VALVE
1 1. Connector
\ /I /5 2.
3.
Movable core
Coil
4. Cage
PC300-6 Serial No.: 33001 -
[
PC350-6 Serial No.: 12001 - 12283
5. Spool
6. Block
7. Spring
T I
7 \6
SWPO4775
2
I Actua-tor I
Operation
When solenoid is deactivated
* When the signal current does not flow from
the PPC lock switchorswinglock switch,
solenoid (3) is deactivated.
For this reason, spool (5)is pushed fully to
the right by spring ( 6 ) .
As a result, the circuit between ports P and
A closesandthepressurized oil from the
main pump does not flow tothe actuator. SWPOSI 12
At the same time, the pressurized oil from

the actuator flows from port A to portT, and I Actuator I
is then drained to the tank.
When solenoid is excited

When the signal current flows from the PPC
lock switch or swing lock switch t o solenoid
(31, solenoid (3) is excited.
For this reason, spool (5)is pushed t o the
left in the direction of the arrow.
As a result, the pressurized oil from the main
pump flows from port P through the inside
of spool (5)to port A, and then flows to the
actuator. At the same time, port T is closed,
and this stopsthe oil from flowing to the
tank.
S W P O S I 13
PC300,350-6 10-163
0
m
r-
h
. . . . .. .
,
!- >&i
a
> w
sr
0
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
Operation
I) At boom RAISE
When the boom israised, the main pressure
from the control valvepushes poppet (5) up.
Because of this, the main pressure from the
control valve passes through the valve and
flows to the bottom end of the boom cylin-
der.
SWPOBl14
2) Boom fever at HOLD

Whentheboom is raisedandthecontrol
lever is returned to HOLD, the circuit for the
holding pressure at the bottom end of the
boomcylinderisclosedbypoppet (5).At
the same time, the oil flowing into poppet
(5)through orifice a of poppet (5) is closed
by pilot spool (3).
As a result, the boom is held in position.
SWPO5115
PC300, 350-6 10-165

STRUCTURE AND FUNCTION BOOM HOLDING VALVE
3; At boom LOWER
When the boom is lowered, the pilot pres-
sure flows to port Pi from the PPC valve
pushes pilot spool (3)and the pressurized
oil in chamber b inside the poppetis drained.
When the pressure at port Cy rises because
of the pressurized oil from the bottom end
of the boom cylinder, the pressure of the
pressurized oil in chamber b is lowered by
orifice a.
If the pressure in chamber b drops below
the pressure at port V, poppet ( 5 ) opens, the
pressurized oil flows from portCy to port V,
and then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylin-
der, safety valve ( 1 ) is actuated and drain oil
from port Cy to port T.
SWPO51 I 6
10-166 PC300, 350-6

STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
SBP00311
1. Arm
2. Bucket cylinder
3. Armcylinder
4. Boom
5. Boomcylinder
6. Bucket
10-168 PC300, 350-6

STRUCTURE AND FUNCTION AIR CONDITtONER
AIR CONDITIONER
AIR CONDITIONER PIPING
8 SRPO2755
1. Hotwaterpickuppiping A : Fresh air

2. Airconditionercompressor B : Recirculatedair
3. Refrigerantpiping C: Hot aidcold air
4. Condenser
5. Receivertank
6. Hotwaterreturnpiping
7. Airconditionerunit
8. Duct
PC300, 350-6 10-169

STRUCTURE ANDELECTRIC
FUNCTION
ACTUAL WIRING DIAGRAM
ACTUAL ELECTRIC WIRING DIAGRAM

(1121
+
4
SIP04782 t
10-170 PC300, 350-6

E
0
0 +
0
0
co
X
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
1. Working lamp 37. Alternator

2. Front pump pressure sensor 38. Additional right head lamp
3. Rear pump pressure sensor 39. Right front lock
4. Radiator water level sensor 40. Room lamp
5. Engine speed sensor 41. Auto pull-up motor
6. Front pump TVC solenoid 42. Window limit switch (rear)
7. Rear pump TVC solenoid 43. Left front lock
8. Window washer tank 44. Window limit switch (front)
9. Hydraulic oil level sensor 45. Additional left head lamp
10. LS-EPC valve 46. Left knob switch
11. Horn (high tone) 47. Wiper motor
12. Horn (low tone) 48. Horn switch
13. Battery relay 49. Fuse box
14. Battery 50. Alarm buzzer
15. Right head lamp 51. Starting switch
16. Fuel level sensor 52. Fuel control dial
17. Active (swing) solenoid valve 53. Cigarette lighter
18. Swing brake solenoid valve 54. Swing lock switch
19. Travel speed solenoid valve 55. Wiper, washer switch
20. Pump merge/divider solenoid valve 56. Lamp switch
21. Boom Hi 2-stage safety solenoid valve 57. Buzzer cancel switch
22. Active (boom) solenoid valve 58. Car heater fan switch
23. Swing pressure switch 59. Machine push-up switch
24. Bucket DUMP pressure switch 60. Front window auto pull-up switch
25. Bucket CURL pressure switch 61. Speaker
26. Arm IN pressure switch 62. Kerosene mode connector
27. Boom LOWER pressure switch 63. Air conditioner control panel
28. Arm OUT pressure switch 64. Engine throttle, pump controller
29. Travel pressure switch 65. Radio
30. Boom RAISE pressure switch 66. TVC prolix resistor
31. Engine water temperature sensor 67. Wiper motor controller
32. Electrical intake air heater 68. Lamp relay
33. Engine oil pressure sensor 69. Lamp relay
34. Starting motor 70. Monitor panel
35. Air conditioner compressor 71. Swing prolix switch
36. Engine oil level sensor 72. Pump prolix switch
PC300, 350-6 10-173

10-173
5
-1
AUTO ‘OPT!
m
CN-M41
m .-
CN-MBB
I
-
~ CONTHOLLER ,
AIR
CON[! T I O N E R - UN I I
E
0
p
!I
STRUCTURE AND FUNCTION CIRCUIT
ELECTRIC DIAGRAM

WITHOUT POWER WINDOW
* For details of this page, see Section 90.
(1/3)
PC300, 350-6 10-177

0
L z A’ I M I I n
... ..
Y- lih31 110
O
.
.
..
..
P C -.
4 0 0.- 6- O .I ' E L
: F.O LRO A D-I N.-.SG H-
,-
!
I
! I
I ~
M A I N BODY
! TO M23 !
! !
I I
i I
I ! ....
I !
I
HflRN
i I ! ( H I G H TONEl,- .-
1348HzI
, 1116dBl
I I
I I HORN
I [LOW TONE) -
[
I I l290Hrl
A
I I 1 l116dEl
1. 1
i: CIOSE. 1
! VALVE
!
!
! I
! !
! i
! 1
! !
! !
I ! !I 1
! !
.... I ! FUSE
20A BATTERY i
!
! !
I I
L -
T BO A T T E R Y RELAY-..]
_ 0-6. PC450-6)
H O R N ( P C 4 0- -
I
j I I
,
1
0 I
..*".'.
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Battery relay Function

2. Battery • The engine can be started and stopped sim-
3. Starting switch ply by using the starting switch (3).
4. Fuel control dial • A dial-type engine control is used to control
5. Governor motor the engine speed. The engine throttle, pump
6. Starting motor controller (7) receives the control signal from
7. Engine throttle, pump controller the fuel control dial (4), sends a drive signal
8. Fuel injection pump to the governor motor (5), and controls the
angle of the governor lever in the fuel injec-
tion pump.
10-178
10-178 PC300, 350-6
5
1. Operation of system
Starting engine (Power source) Starting
Engine switch
• When the starting switch is turned to the Fuel control Starting motor (Starting
signal)
dial High Low S
START position, the starting signal flows to Hi
the starting motor, and the starting motor Governor
motor
BR C
Lo M
turns to start the engine.
P
When this happens, the engine throttle, pump
(Potentiometer
(Drive signal)
controller checks the signal from the fuel
control dial and sets the engine speed to the
signal)
speed set by the fuel control dial.
Engine throttle,
(Throttle signal) pump controller
(Starting switch ON signal)
SBP00321
Engine speed control

• The fuel control dial sends a signal to the Starting
engine throttle, pump controller according Fuel control Engine Starting motor
switch
to the position of the dial. dial High Low S
Hi
The engine throttle, pump controller calcu- Governor
motor
lates the angle of the governor motor accord- Lo M
BR C
ing to this signal, and sends a signal to drive P
(Potentiometer
the governor motor so that it is at that angle.
(Drive signal)
When this happens, the operating angle of signal)
the governor motor is detected by the
potentiometer, and feedback is sent to the
Engine throttle,
governor and pump controller, so that it (Throttle signal) pump controller
can observe the operation of the governor (Starting switch ON signal)
SBP00322
motor.
Stopping engine
Starting
• When engine throttle, pump controller de- Engine switch
Fuel control Starting motor
tects that the starting switch is turned to the dial High Low S
Stop
STOP position, it drives the governor motor Governor
so that the governor lever is set to the NO M
motor BR C
INJECTION position. P
(Potentiometer
• When this happens, to maintain the electric

(Drive signal)
power in the system until the engine stops

signal)
completely, the engine throttle, pump con-

troller itself drives the battery relay.
Engine throttle,
(Throttle signal) pump controller
(Starting switch ON signal)
SBP00323
PC300, 350-6 10-179

10-179
5
2. Components of system
Fuel control dial
HIGH
A 1. Knob
2. Dial
3. Spring
45° 4. Ball
Front of 5. Potentiometer
machine
6. Connector
45°
A
LOW
1
R
CW
1 1
2 W 2
B 3
3
6
A–A Composition of circuit
3 SBP00324
Function
• The fuel control dial is installed at the bot-
(%) Hi
tom of the monitor panel. A potentiometer 100
is installed under the knob, and when the
Accelerator angle
knob is turned, it rotates the potentiometer

shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is Lo
sent to the engine throttle, pump controller.
The shaded area in the graph on the right is 0 0.25 1 4 4.75 5
the abnormality detection area and the en- Characteristics of Voltage (V)
throttle voltage
gine speed is set at low idling. SAP00325
10-180
10-180 PC300, 350-6
5
Governor motor
1. Potentiometer
2. Cover
3. Shaft
4 5 6 4. Dust seal
A
5. Bearing
6. Motor
7. Gear
3 8. Connector
A
7
A–A
A Black
1
2 1 A Green
2
B Red
3
4 3 B Yellow
4
AP
1 AP sig
2 1
2
AP
3
3
Composition of circuit
8
SBP00326
Function Operation
• The motor is rotated and the governor lever Motor stationary
of the fuel injection pump is controlled by • Both A phase and B phase of the motor are
the drive signal from the engine throttle, pump continuous, and a holding torque is gener-
controller. ated in the motor.
A stepping motor is used for the motor which Motor rotating
provides the power. • A pulse current is applied to the A phase
• In addition, a potentiometer for giving feed- and B phase from the engine throttle, pump
back is installed to allow observation of the controller to give synchronous rotation with
operation of the motor. the pulse.
• The rotation of the motor is transmitted to
the potentiometer through a gear.
PC300, 350-6 10-181

10-181
5
Engine throttle, pump controller
10-182
10-182 PC300, 350-6
5
Input and output signals

CN-CO1 CN-CQ3 CN-16
Pin/
No.
Name of signal IInput/
output
Pin
No.
I1 IName of signal Input/
output
Pin
No.
Name of signal Input/
output
1 1 Batteryrelay driveoutput 1 1
/Output/ 1 Enginewatertemperaturesensor] Input I 1 1 \Engine speedsensorGND 1 Input 1
Pump mergeidivider I 2 1 Fuel
level
sensor I tnout I 2 Engine speed sensor Input
solenoid/NC
~~ ~.. . ~ loutput(
I
3 Pump F pressure input Input 3 GND Input
Swing holding brake
output
~~~
solenoid 4 Throttle potentiometer input 1 Input 4 GND input

14 pc I I ! ! , 5 ,Swing pressure switch , !nput ,
5 NC Pressure sensor power 6 Service valve pressure switch Input
output
source 1+24V)
6 GND Engine oil pressure sensor H
I7 !Power source
(+24V) 1
input
Input I Potentiometer power
1 7 1 source (+5W
I output 1 7
8 Radiator water level sensor
Input
Input
8 Active mode solenoid (boom) Output 8 Starting switch (ACC) Input 9 Hydraulic oil level sensor Input
9 Travel selector solenoid Output 9 Knob switch Input 1 10 I Engine speed sensor GND I Input I
10 Active mode solenoid (swing) Output Hydraulic oil temperature 11BucketCURLpressureswitch Input
sensor (monitor Danel)
NC 11 12 BucketDUMPpressureswitch Input
12 GND
13 Power source (+24V)
Input
lnwt ,
1 1 Hydraulic oil temperature
sensor (thermistor type)
charge (alternator
1 I1
I13 /Travel pressure switch 1 Input I
1~1 1 1
Input
termlnal R )
CN-C02 13 Pump R pressure input Input
I 15 I Engine oil pressure sensor L 1 Input 1
16 Engine oil level sensor Input
(+24v;ame of signal Input/ 14 Feedback potentiometer input Input
output 17 Air cleaner clogging sensor Input
Solenoid power source
Input
I 16 1 PressuresensorGND 1 Input 1
1 17 1 Potentiometer
GND I Input I
Input
hfiovernor motor phase B (4 Output 1 I 20 I controller abnormality
Hydraulic filter sensor 1 Input 1
I7 ] LS-EPC solenoid (+) 1 Output1 CN-C17
lpin
No.
1 I
1 Name
I PPC pressure
of signai Input/
output
I Input I
2BoomRAISEpressureswitch Input
3 Arm IN pressure switch Input
1 5 1 Model selection 1 I input i

6 Model selection
3 Input
7 Model
selection 5 j Input I
1 9 I Overload
sensor I input I
I 10 1 Boom LOWER pressureswitch1Input 1
11 Arm OUT pressure
switch
Input
Input,
12 S-NET(+)
output
13 Model selection 2 input
14 Model selection 4 input
I 15 I Kerosene mode selection ] Input 1
~~
1 16 I Swing lock switch I input !

PC300, 350-6 10-183
STRUCTURE AND FUNCTION CONTROL
ELECTRONIC SYSTEM
ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTION
1
_____- Pump & Engine Mutual control function
2
_____ P s ~ ap d V ~ I W c o ~ i r o lfunciioil
3
~
Power maximizing function
3
_____ Swift slow-down function
4
___ Auto deceleration function
Electronic control system

5
~
Engine automatic warming-up, overheat
prevention system
6
_____ Swing control function
7
Travel control function
8
. Active mode system
- Self-diagnostic function
* For details of the self-diagnostic function, see TROUBLESHOOTING.
PC300, 350-6 10-185

4.
1' 4 -n
I
I
I
I
I 1
I I
I I
I I I
I I I
I 1 I
I I I
I 1
1 1 I
1 1
I 1 I
I 1 I
I II Ir-1
I
I I 1
I I I
I I /
I I 1
I I 1
I I 1
I I 1
I I 1
I I 1
I I I
I I 1
I I 1
I I 1 I
I 1 1 I
I
I
I
I
t 1 I
I
I
I
I
I
I
I
I
I
I
I
I
I
t
ii
1
I
I
I
t
I'
I
I
i @-
0
AND
STRUCTURE FUNCTION SYSTEM
CONTROL
ELECTRONIC
I
I I r,
M o n i t o r Panel
Mode I Kerosene
s e l e c ti o n mode
c o n n e c t co or n n e c t o r
Alarm
buzzer
Net-
work
S w i n el o c ks w t t c h
En9
can
,
1
7
1B
+ //
19
1 / I
SWPO512 I
PC300, 350-6 10-187

STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Pump & Engine Mutual control system
Function
• There are five modes available for selection • The engine throttle, pump controller detects
with the working mode switch on the moni- the actual engine speed and the speed set
tor panel. These modes are the heavy-duty by the engine governor through the fuel con-
operation mode (H/O), general operation trol dial in accordance with the pump ab-
mode (G/O), finishing operation mode (F/O), sorption torque set for each mode, and car-
lifting operation mode (L/O), and the breaker ries out control so that the pump absorbs all
mode (B/O). It is possible to select the most of the torque at each output point of the
suitable engine torque and pump absorp- engine.
tion torque to match the nature of the work.
• Engine torque curve • Engine horsepower curve • Pump output curve

L/O
Pump discharge pressure P
F/O H/O, power max. H/O Power max.

B/O
G/O G/O
Engine horsepower HP
Engine torque T
G/O
H/O, B/O
power
max.
B/O F/O
F/O L/O
L/O
Engine speed N Engine speed N Pump discharge amount Q

SAP00330 SAP00331 SAP00332
10-188
10-188 PC300, 350-6
5
1) Controt method in each mode

Heavy-duty operation mode
I I fll
Engine speed N Pump dischargeamount

SAP00334
Matchingpoint in heavy-duty
operation When the load
on
the pump risesandthe
mode:
Rated
output
point pressure rises,engine
the speed
goes
down.
Whenthis happens, thepump discharge
PC300,
350-6 amount is reduced, and the
engine speed
is
Heavy-duty 172.8 kW (232
HP)/1,950 rpm controlled so that it becomesneartherated
output point.
If the reverse happensand thepressure goes
down, the system is controlled so that the
pump discharge amount is increased until
the engine speed becomes near the rated
output point.
By repeating this control, the engine can al-
ways be used at near the rated outputpoint.
General, breaker, finishing operation mode
SAP00338
Matching
point When the load on the pump rises and the
pressure rises, the engine speed goes down.
Mode GI0 BIO FiO When this happens, mutual control of the
Partial output point 90% 85% 80% engine and pump is used to control thesys-
tem so that the pump absorption torquefol-
lows the equal horsepower curve of the en-
PC300, 350-6
gine, and the engine speed is lowered while
G/O 154 kW (207 HPV1.850 rDm keeping the torque constant.
In this way, the engine is used in a range
B/O 1 147 kW HP)/1,850
1197 rpm which provides good fuel efficiency
FIO 136 kW (182 HP)/1,700 rpm
PC300, 350-6 10-189

AND
CONTROL
ELECTRONIC
Lifting operation mode
a
m
a
I
Pump discharge amount 0

SAP00340 SAP00341
* Matchingpoint in lifting operation mode: When the lifting operation modeis selected,
60% partial output point the engine speed isautomaticallylowered
to the partial position.
PC300,350-6 In this condition, control is carried outin the
LiO 102.9 kW (138 HP)/1,500 rpm same way as for the general operation, fin-
ishing,andbreakeroperationmodesto
match the load on the pump.
In this way, the fuel consumption is reduced
and the fine control ability is improved.
Power max. mode, travel
I
al
I
Pump discharge amountQ

SAP00344
e Matching point in power

max.mode: e When
the
pump
load increases, the
engine
Rated output
point
speed
drops.
When this happens, the pump discharge is
PC300, 350-6 reduced t o prevent
engine
the speed from
Power max. 172.8 kW (232 HP)/1,950 rpm going downand to ensure that theengine is
used at near the rated output point.
The cut-off at relief is canceled and the oil
flow at relief is increased.
10-190 PC300,350-6
ELECTRONIC SYSTEM
2) Control function when TVC prolix switch is

ON
Pump discharge amount Q SAP00349
Even if any abnormality should occur in the In this case, it is designed to allow a con-
controller or sensor, the TVC prolix switch stant current to flow from the battery to the
can be turned ON to provide an absorption TVC valve, so oil pressure sensing is carried
torque more or less equivalent to the gen- out only by the TVC valve.
eral operation mode, thereby allowing the
machine to maintain its functions.
PC300, 350-6 10-191

I
f-- -+
I I
I t I J I
r--
+-
7
0
STRUCTURE
SYSTEM
AND
CONTROL
ELECTRONIC
FUNCTION
1) LS controlfunction
e The switching point (LS set differential pres-
sure) for the pump discharge amount in-
side the LS valve is changed by changing
the output pressure from theLS-EPC valve
to the LS valve according to the operating
condition of the actuator.
Because of this, the timing for starting the
discharge S K G U ~from
~ the p ~ m pC ~ Rbe
optimized, to give excellent ease of com-
pound operation and fine control. LS set differential pressure
SAPO0351
2) Cut-offfunction MPa
0 If the load becomes large during the opera-
tion and the pump discharge pressure rises
dkg’cmz’l Cut-off
/
t o a point close to the relief pressure, the

pump pressure sensor detects this, and the
controller sends a signal to the N C valve to
reduce the discharge amount in order to re-
duce the relief loss.
Pump discharge amountQ

SAP00352
3) Cut-offcancelfunction Cut-off is
MPa
Thecut-off cancel function stops the actua- cance Ied
tion of the cut-off function in order to en- Cut-off is
sure the flow of oil from the pumpnear the
relief pressure, thereby preventing any drop
in speed.
The relief pressure when the cut-off function
is actuated is 33.8
MPa (345 kg/cm21, but ._
I
I)
=
when the cut-offis canceled, the relief pres- El
E
sure rises to approx. 34.8 MPa (355 kg/cm2). 3
a
Because of this,thehydraulic pressure is
Pump d i s c h a r e e amount 0
increased by one stage. SWPO6 1 2 4
Switches and cut-off functions

Working mode switch Swing lock switch Knob switch
Heavy digging Digging ON OFF ON OFF
Cut-off function Actuated Actuated Canceled Actuated Canceled Actua
% Whentheswing lockswitch is set to ON,

hydraulic oil is quickly warmed, also when
the swing lock switch is set to ON, the func-
tion is canceled.Underthese conditions,
when work equipment is relieved, hydraulic
oil temperature goes up more quickly, and
warming time is shortened.
PC300,350-6 10-193
ELECTRONIC SYSTEM
49 Fine control mode function

e When the finishing mode is selected as the
working mode, the pump LS valve is con-
trolled, and the pump discharge amount is
reduced to improve the ease of fine control
and the precision when finishing.
Relationshipbetween working mode and pump discharge amount

(for independent operation)
Lifting mode (UO) 75 75 55 45 40 -

Breaker (B/O) 100 30 100 75 60 55 45
* Ineach working mode, the full flow of the

pump at the set engine speed is taken as
100%.
10-194 PC300, 350-6

3. Power max. function, swift slow-down function
Control v a l v e
SWPO5125
Function
This function provides an increase in the dig-
ging power for a certain time or switches
the working mode to the fine operation to
reduce the speed. It is operatedusing the
L.H. knob switch to momentarily match the
operating conditions.
* The power max. functionand swift slow-
down function are operated with the same
switch. Only one of these functions can be
selected at any time; they cannot both be
operated together.
10-196 PC300, 350-6

1) Power max. function

• If the L.H. knob switch is kept pressed when
the working mode is set to H/O or G/O, the
cut-off function is canceled, and the canceled
portion is added to the oil flow to increase
the speed of the power max. function.
• Even if the L.H. knob switch is kept pressed,
the increased speed of the power max. func-
tion is canceled after 8.5 seconds.
• If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows.
Working Engine, pump Cut-off Actuating

mode control function time
Heavy-duty Matching at Automatically

operations rated output Canceled canceled
point after 8.5 sec
2) Swift slow-down function

• During normal operations, if it is desired to
carry out lifting operations or finishing op-
erations for a moment, the working mode
can be switched to L/O by operating the L.H.
knob switch.
• If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows.
Working mode Actuating time
Lifting operation While switch is kept pressed
PC300, 350-6 10-197

10-197
5
F
I
1 7
I
I
ri
eL
<> L. I
m
c
.- I
CD
c
Lu
f
3 0
u . "
ELECTRONIC SYSTEM
Operation
Control
levers at neutral control
lever
When is operated
Iftheengineisrunning a t abovethe decel- Ifanycontrollever is operatedwhenthe
erationactuation speed (approx. 1400 rprn), engine speed is a t No. 2 deceleration,
the
and all the control
levers are returned
to
engine speed will immediately rise to the
neutral, theengine speed dropsimmediately speed set by thefuelcontrol dial.
to approx. 100 rprn below the set speed to
the No. 1 deceleration position.
If another 4 seconds passes, t h e engine
speed is reduced to the No. 2 deceleration
position (approx. 1400 rprn), and is kept at
that speed until a lever is operated.
4 Less than 2 -Less than 1

I - -
I I
Time (secl
Levers at neutral Lever operated
SAP00356
PC300, 350-6 10-199

CTION
ONIC AND
STRUCTURE CONTROL SYSTEM
5. Automatic warming-up and engine overheat prevention function
(Water temperature signal)

I- Ensine
Main PumP
sensor
L SSvv eaea rlrl vv eoeo
F u e l c o n t r o dl i a l
4
i
Ensine t h r o t t l e
controller
SWPO5127
Function
If thewatertemperature is low, this auto-
matically raises the engine speed to warm
up the engine after it is started. (Automatic
warming-up iunctionj.
In addition, if the water temperature rises
too high during operations, it reduces the
load of the pump to prevent overheating.
(Engine overheat prevention function)
10-200 PC300,350-6
AND
STRUCTURE FUNCTION CONTROL
ELECTRONIC SYSTEM
11 Engine automatic wasming-up function

After the engine is started, if the engine cool-
ant temperature is low, the engine speed is
automatically raised to warm up theengine.
I
Conditions for actuation (both are necessary) I

I
h
1
I Actuation
I
Coolant temperature: Less than 30°C Engine speed: 1,250 rpm or below
I
Engine speed: Less than 1,250 rpm
-
Engine speed: As desired
10 minutes or more
I I 1
Fuel control dial: Held a t more
Manual than 70% of full throttle for more
than 3 seconds
2) Engineoverheat prevention function

Thisfunction protects the engine by lower-
ing the pump load and engine speed to pre-
vent overheating when the engine coolant
temperature has risen too far.
This system is actuated when the water tern-
perature is 105°C and above.
Water temperature: 105°C and above

Engine speed: Low idling
Water temperature gauge:Red range)
I Aiarm buzzer:Sounds
Fuel controldial:Returntemporarily
to low idling position
When the above conditions are met, the
system returns to the condition before
the overheat preventionfunction was ac-
tuated (manual reset)
PC300, 350-6 10-201

I
'0
L
r
0
rr)
m
L "
1
0
1
LL
LL
0
-m
c
1
T
0
--
L
c
L
m
0
AND
STRUCTURE FUNCTION CONTROL
ELECTRONIC SYSTEM
.
1) Swing lock. swing holding brake function
Theswinglock(manual)canbelockedat
Swing lockswitch
holding brake
and swing lock, swing
any desired position, and the swing holding

brake (automatic) is interconnected with the
swing, so it prevents any hydraulic drift af-
LockLock
switch I
I
lamp I
I
Function I
I
Operation
ter the swing is stopped. When swing lever is placed
OFF 1 I 1
OFF
Swing atneutral, swing brakeis
holding applied after approx. 5 sec;
brake when swing lever is operated,
I brake is cmcelecl snci swing
can be operated freely
Swing lock is actuated and
swing is held in position.
ON ON Swing Even when swing lever is
lock operated, swing lock is not
canceled and swing does
not move.
34 Operation of swing lock prolix switch

If any abnormality should occur in the con-
troller, and the swing holding brake is not
actuated normally and the swing cannot be
operated, the swing lock prolix switch can
beoperated to cancel the swing lock and
allow the swing to be operated.
* Even when the swing lock prolix switch is
switch
Swing Swing lock Swing lock Swing lock Swing hold-

turned ON, the swing lock switch stays ON
brake applied canceled applied ing brake
and the swing brake is not canceled. aoolied
* When the swingbrake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
2) Hydraulic oil quick warm-up function when

swing lock switch is ON
When the swing lock switch is turned ON,
the pump cut-offis canceled. If thework
equipment is relieved in this condition, the
hydraulicoiltemperature will risemore
quickly and the warming-up time can be re-
duced.
PC300, 350-6 1 0-203

STRUCTURE AND FUNCTION SYSTEM
CONTROL
ELECTRONIC
7. Travel control system
T r a v el el v e r
Engine throttle
SWPOS I29
Function
Whentraveling,the pump control is carried
out, andthetravel speed canbeselected
manually or automatically to give a travel
performance that suits the natureof the work
or the jobsite.
10-204 PC300, 350-6

1) Pump control function when traveling

• If the travel is operated in any working mode
other than the heavy-duty operation mode,
this increases the pump absorption torque
while keeping the working mode and engine
speed as they are.
fl For details, see PUMP & ENGINE MUTUAL
CONTROL.
2) Travel speed selection function

i) Manual selection using travel speed switch
If the travel speed switch is set to Lo, Mi, or
Hi, the engine throttle, pump controller con-
trols the pump flow and motor volume at
PC300, 350-6 10-205

8. ACTIVE MODE FUNCTION
FUNCTION
• When the active mode switch on the moni-
tor panel is ON (lighted up), the work equip-
ment speed is increased. The bucket lift is
also increased during swing + boom RAISE
operations, so it is effective in loading dump
trucks.
• The active mode is actuated only when the
fuel control dial is at the Max. position. If
the fuel control dial is not at the Max. posi-
tion, the load sensing function is actuated
but the pump discharge increase function is
not actuated.
10-206 PC300, 350-6

1) Increase in engine speed

The pump discharge amount is increased by
the increase in the engine speed. This means
that the cycle time can be reduced, giving
increased production.
Heavy-duty digging
Active
operations
172.8kW/1,950rpm 172.8kW/2,050rpm
PC300
{231.7HP/1,950rpm} {231.7HP/2,050rpm}
172.8kW/1,950rpm 172.8kW/2,050rpm
PC350
{231.7HP/1,950rpm} {231.7HP/2,050rpm}
2) 2-stage boom lowering speed

When the active mode switch is ON, the
stroke of the boom LOWER spool is switched
(9.0 mm → 11.5 mm) to increase the lower-
ing speed.
Change in spool stroke:
A: 9.0 mm (active mode OFF)
B: 11.5 mm (active mode ON)
3) 2-stage stroke for swing spool

When the active mode switch is ON and the
boom is operated to RAISE, the stroke of the
swing spool is switched (9.5 mm → 7.0 mm).
This increases the bucket lift during swing +
boom RAISE operations, so it is effective in
loading dump trucks.
Change in spool stroke:
C: 9.5 mm (active mode OFF)
D: 7.0 mm (active mode ON)
PC300, 350-6 10-207

9. Components of system
1) Engine speed sensor
1 2 3 4
0.75fG
1
0.75fB
2
SBP00365
1. Wire Function
2. Magnet • The engine speed sensor is installed to the
3. Terminal ring gear portion of the engine flywheel. It
4. Housing counts electrically the number of gear teeth
5. Connector that pass in front of the sensor, and sends
the results to the engine throttle, pump con-
troller.
• This detection is carried out by a magnet,
and an electric current is generated every
time the gear tooth passes in front of the
magnet.
2) PPC hydraulic switch
1. Plug
2. Switch
1 2 3
3. Connector
Specifications
Composition of points:
Normal open points
Actuation (ON) pressure:
0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 ± 0.05 MPa
{3.0 ± 0.5 kg/cm2}
Function
1 • There are 8 switches in-
2 stalled to the PPC shuttle
Composition of valve. The operating con-
circuit
SBP00366
dition of each actuator is
detected from the PPC
pressure, and this is sent
to the engine throttle, pump
controller.
10-208
10-208 PC300, 350-6
5
3) Pump pressure sensor
1. Sensor
1 2 2. Connector
2 1
AEX0.5f B
1
AEX0.5f R 2
Amplifier
AEX0.5f W 3
SBP00367
Insulation layer
Function
• This sensor is installed to the inlet port cir-
cuit of the control valve. It converts the pump Gauge layer
discharge pressure to a voltage and sends
this to the engine throttle, pump controller.
Operation
• When the pressurized oil entering from the
Diaphragm
pressure introduction portion pressurizes the (strainless steel)
diaphragm of the pressure detection portion, SAP00368
the diaphragm deflects and changes shape.
• A gauge layer is installed to the face oppo- 5
site the diaphragm, and the resistance of
the gauge layer converts the deflection of
4
the diaphragm into an output voltage and
Sensor output voltage (V)
sends it to the amp (voltage amplifier).

• The voltage is further amplified by the am- 3
plifier and is sent to the engine throttle, pump
controller. 2
• Relationship between P pressure (MPa {kg/
cm2}) and output voltage (V).
V = 0.008 x P + 1.0 1
0 9 .8 19 .6 29 .4 39 .2 49 .0
(100) (200) (300) (400) (500)
Pressure P (MPa (kg/cm2))
SAP00369
PC300, 350-6 10-209

10-209
5
4) TVC prolix resistor
1. Resistor Function
2. Connector • This resistor acts to allow a suitable current
to flow to the TVC solenoid when the TVC
Specification prolix switch is ON.
Resistance: 8.5 Ω • No current flows when the TVC prolix switch
is OFF.
5) Fuel control dial, governor motor, engine 8) LS-EPC valve

throttle, pump controller fl See LS-EPC VALVE
See ENGINE CONTROL
9) Solenoid valve
6) Monitor panel • Active solenoid valve (boom)
fl See MONITORING SYSTEM • Boom Hi 2-stage safety valve solenoid valve
• Merge/flow divider valve solenoid valve
7) TVC valve • Travel speed solenoid valve
fl See HYDRAULIC PUMP • Swing brake solenoid valve
fl See SOLENOID VALVE
10-210
10-210 PC300, 350-6
5
I I
I
x
L
W
c
c
m
m
L
STRUCTURE
FUNCTIONAND MACHINE MONITOR SYSTEM
CN-PO2
\
CN-PO 1
5
SAPO3677
OUTLINE Input and output signals

The monitor panel consists of the time dis- CN-PO1 CN-PO2
1
w '1 ~
play, monitordisplay,andmode selector Pin
No. of signal Pin No.
Name_____ Name of signal
1 GNn
switches.
-- 2 Washer drive
It has a built-in CPU (Central Processing Unit), __._~ 3 Motor drive (Reverse)
and processes, displays, and outputs the data 4 I Network
- _. signal -~-
I 4 Wiper switch (ON) I
[
~~
0
from the sensors and controllers.
The monitordisplayandmonitordisplay
5
6 1
Swlng
lock
Buzzer cancel -I 7
5
6
Wiper-switch (Washer)---
Limit switch
NC
panels use a liquid crystal display (LCD) and
KEY ON
1 slgnal 9 GND
LED lamp. -~
The mode switches are flat sheet switches. ~ ~ _ _ _- 10
11
Washer drive
Motor drive (Normal)1-
I 12 1 -
NetworkGND
(Window) I
switch 12 WiDer
switch
Limit (INTI -1
~-
.. NC
18 I Preheating
PC300, 350-6 10-213

ANDSTRUCTURE
MONITOR
MACHINE
FUNCTION SYSTEM
15
14
I3
12 II IO 9 '7 SAP02731
1. Clock
2. Service meter
3. Fuel level gauge
4. Fuel level caution lamp
5. Engine oil level caution lamp
6. Hydraulic oil level caution lamp
7. Preheating pilot lamp
8. Swing holding brake pilot lamp
9. Oil maintenance pilot lamp
IO. Battery charge caution lamp
11. Air cleaner clogging caution lamp
12. Engine oil pressure caution lamp
13. Coolant level caution lamp
14. Coolant temperature caution lamp
15. Coolant temperature gauge
10-214 PC300, 350-6

STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
T -r
Symbol Display item Display range When engine is stopped When engine is running
43SAP00519
Coolant level Below low level Flashes when abnormal
Flashes and buzzer
sounds when abnormal
Below 1500 rpm:

below 0.05 MPa
Lights up when normal
Engine oil {0.5 kg/cmzl Flashes and buzzer sounds
(goes out when engine
pressure Above 1500 rpm: when abnormal
SAP00520 starts)
above 0.15 MPa
I7.5 kg/cm21
Air cleaner
When clogged Flashes when abnormal OFF
clogging
SAP00521
Lights up when normal

When charging is
Charge level (goes out when engine Flashes when abnormal
defective
starts)
Engine oil level Below low level Flashes when abnormal OFF
SAP00523
a SAP00524
Hydraulic oil level Below low level Flashes when abnormal OFF
Parking When swing is Lights up w h e n s w i n g lock switch is ON, flashes

(Swing lock) locked when swing lock prolix switch is ON
Oil maintenance See next page "OIL MAINTENANCE FUNCTION.".
Lights up for 30 secondswhenstartingswitch is at

Preheating During preheating HEAT, then flashes for 10 seconds to indicate that
SAPO0526
preheating is completed
Coolant Flasheswhenabove 102"C, flashesand

temperature buzzer sounds when above 105°C
SAP00527
Fuel level Flashes when below low level

SAP00528 SWPO4803
PC300, 350-6 10-215

OIL MAINTENANCE FUNCTION
‘l. Function, operation

The oil maintenance function uses LED lamps
on the monitor panel to inform the operator
a t a fixedinterval after theengineoilis
changed that the oil change interval has been
reached.
At the sametime, it also functionst o display
the service contact telephone number on the
liquid crystai dispiay.
1) Confirmation of elapsed time
Normally, no display is given until the
elapsed time reaches the point B on the A:Reset
rightdiagram after reset. However, if 8 : l O h b e f o r e s e t time
C:Set t i m e
the buzzer cancel switch is pressed and
the key is turnedt o the ON position (with
the buzzer cancel switch hold for2.5 sec-
onds), the elapsed time is displayed on
the service meter display. Possible t o c o n f i r m Oil change i n t e r v a l
e l a p s e d time when d i s D l a Y when k e y i s
2! Qi! changedisplay iter i s ON 1 t u r n e d ON
When the elapsed time has reached or SWPO4701 I
passed the pointB on the right diagram,
theservicemeterdisplaygivesthe
elapsed time and the LED flashes when
the key is turned ON.
2. Setting change interval

1) The change interval can be set by using
the interval setting mode. The time that
can be set are [I25 hl, [250 hl, 1500 hl,
[no setting], and [demo model. The de-
fault setting is [no setting].
2) Toenterthechangeintervalsetting
mode, keep the time switch and active
modeswitch(swingpriorityswitch)
pressed simultaneously for 2.5 seconds.
3) If the buzzer cancel switch is pressed in
thechangeintervalsetting mode, the
timedisplay will change from [...I 4
11251 + [2501 -+ [5001 -+ d l ([ ...I indi-
cates[no
setting]
and d l indicates
[demo model).
4) To save the change interval time, set the
monitor panel displayt o the desiredtime
(mode), then keep the time switch and
activemodeswitch(swingpriority
switch) pressedsimultaneously for 2.5
seconds.
1Q-216 PC300,350-6
3. Display timing, content

I ) Oil changedisplay A i l lamps, I i e h t UP I O ,see 2 0 ,sec
After all the lamps light up, the elapsed I
I
I
I
I
I
1 - Time
time is displayed for 10 seconds. For the TeI No. I
- J
I
input
next 10 seconds, the telephone number II E l a p steidm e
I
T e l No. 1
is displayed. 1 display ; displayed ~
I I I
However, if no telephonenumberhas No T e I . I
d
I
No. input I II I
been input, the elapsed time is displayed I Elapsed t1me;disPlau II
for 20 seconds after all the lamps light I

I
I
I
I
I
I
E l a p s e d t \me
UP- i
2) Elapsed timeconfirmation
confirmation
I E l a p-
sed time
I display ,
I
After all the lamps light up, the elapsed
SWPO4702
time is displayed for 10 seconds.
4. Elapsed time reset

1) During the oil change interval display and
the elapsed time display, for 10 seconds
afteralllamps light up(duringthe
elapsed time display), if the buzzer can-
cel switch is pressed and held for 3 sec-
onds, the elapsed time is reset. When
theelapsedtime is reset, the elapsed
time shows [Oh] for 1 second.
2) W h e nt h e set timeischanged,the
elapsed time is reset t o Oh.
5. Demo mode
1) The set time in the demo mode is 250h
and theelapsed time is set to 240h. When
the key is turnedON, the oil change dis-
play is given.However, the elapsed time
does not increase.
It is also possible to carry out the reset
operation during this display.
In the demomode, after the key is turned
ON three times,theintervalsetting is
automatically set to [nosetting1 from the
4th time. In addition, the elapsed time is
reset t o Oh and the elapsed time count
starts.
PC300, 350-6 10-217

MODE SELECTION SWITCHES
1. Workingmodeswitch
It ' 3 II
H/O G/O F/O L/O 2. Auto-decelerationswitch
0 0 0 0 /I 3. Active
mode
switch
4. Travelspeedswitch
5, 5. Knobbuttonswitch
Mi
0 /I
3 '
Switch actuation table

The bold letters indicate the default position of the switch when the starting switch is turned ON.
Item I Action
WORKING MODE p H/O t), G/O H F/O CJ UO e, B/O7
AUTO DECEL O N e, OFF (Note 1)
KNOB BUTTON POWER UP H SPEED DOWN
TRAVEL SPEED Hi ++ M i t), Lo
ACTIVE MODE ON tj OFF (Note 2)
Note 1: If the working mode is operated F/O G/O or YO -+ B/O, theauto-decelerationswitch is

automatically turned ON if it is OFF. (If it is already ON, it stays ON.)
Conversely, if it is operated G/O 3 W O or B/O -+ L/O, the auto-deceleration switch is auto-
matically turned OFF if it is ON.
Note 2: Even if it is ON, when the working mode switch is pressed, it is automatically turned OFF.
18-218 PC300, 350-6

2. Semers
Thesignals from the sensors are input di-
rectly to the monitor panel.
Thecontacttype sensors are alwayscon-
nected at one end to the chassis GND.
Name of sensor1 Type of sensor I When I abnormal

When
Engine oil level 1 Contact type i c c l ~ ~1 d ) OFF

(open)
Engine oil
oressure
I Contact type
I (En) I (closed)
L
0
E,
0
0
4 co
AND
MONITOR
MACHINE
1. Float
2. Connector
FULL 3. Cover
4. Variable resistor
EMPTY
3 4
SBP00380
Air cleaner clogging sensor
U Composition of circuit
SBPOO381
PC300, 350-6 10-221

STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM
FRONT WINDOW AUTO PULL-UP SYSTEM
15
8
13
\
12
11
7
SBP00382
4
I.
I----* ...
:-..I -.-.o---a-..a-l..cl,,~ ~ ~ u c y
rlulll W I I I U U V V
1 1 ...... ....
14. ??Gal (rUVGI
2. Bracket assembly (tension roller) 15. Bracket (for motor mount)

3. Right block (roller support) 76. Cable assembly
4. Right geared cable 17. Motor assembly (for lifting)
5. Right return cable 18. Motor output shaft
6. Controller 19. Geared cable assembly
7. Control switch 20. Spoiler cover
8. Right lock assembly 21. Limit switch (rear lock)
9. Right tightening motor 22. Rear lock
IO. Limit switch (front) 23. Left block (dovetail)
11. Right bracket assembly (slide link) 24. Left block (return cable guide)
12. Harness 25. Left block (return cable holder)
13. Right rail 26. Left cover (return cable holder)
10-222 PC300, 350-6

STRUCTURE AND FUNCTION FRONT WINDOW AUTO PULL-UP SYSTEM
Function
An electric motor is used for the front glass
(top)ofthe operator’s cab. Thismakes it
possible to open, close, or tighten simply by
operating the switch.
Operation
1. Opening front window
Press the UP control switch.
Whenleftandrightfront locks (8)are
actuated inthe OPEN direction,front
window (1) is moved to the LOWER po-
sitionbyslidelink (1 l). Whenthe re-
lease operation is completed, the move-
ment of front lock (8)stops.
After the movement of frontlock (8)has
been completed, operate lift motor (17)
to theOPEN direction. Geared cable(191,
which is meshed with motor outputshaft
(181,will move and pull up front window
(1 1.
Front window (1) is set at the OPEN po-
sition, and lift motor (17)stops operat-
ing a t the point where rear lock (12)is
engaged.
2. Closing front window

1) Press the DOWN controlswitch,and
push the release lever of rear lock
(22)a t
the same time.
2) Lift motor (17)moves in the CLOSE di-
rectionandmovesfrontwindow (1)
down.
3) When front window (1) has moved down
fully, lift motor (17)stops.
4) When the movement of lift motor (17)
has been completed, front locks (8)are
moved in the tightening direction by left
and righttighteningmotors (9).When
the tightening is completed, the motor
stops.
PC300, 350-6 10-223

TI
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS .............................................................. 20-4

STANDARD VALUE TABLE FOR CHASSISRELATEDPARTS .......................................................... 20-5
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ....................................................................... 28- 13
Tools for testing, adjusting, and troubleshooting ....................................................................... 20-102
Measuring engine speed ............................................................................................................... 20-103
Measuring exhaust color ............................................................................................................... 20-104
Adjusting valve clearance .............................................................................................................. 20-105
Measuring compression pressure ................................................................................................. 20-106
Measuring blow-by pressure ......................................................................................................... 20-106
Testing and adjusting fuel injection timing ................................................................................. 20-107
Measuring engine oil pressure ..................................................................................................... 20-108
Testing and adjusting a!ternator beit tension ............................................................................. 20-109
Testing and adjusting water pump belt tension ......................................................................... 20-109
Testing and adjusting belt tension for air conditioner compressor .......................................... 20-110
Adjusting engine speed ................................................................................................................. 20-110
Me=lsi;rir?g air supp!\/ (bsost pressure?......................................................................................... 20-411
Testing and adjusting governor motor lever stroke ................................................................... 20-112
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ............. 20-113
Testing and adjusting TVC vaive output pressure (servo piston input pressure) .................. 20-4116
Testing and adjusting LS valve output pressure
(servo piston input pressure) and LS differential pressure ................................................. 20-118
Testing control circuit oil pressure
(oil pressure when self-pressure is reduced) ........................................................................ 20-121
Testing sn!enoid \!2!\.E nutput pressL!rp ..................................................................................... _3n-122
_
Measuring PPC valve output pressure and testing PPC shuttle valve ...................................... 20-125
Adjusting werk equipment, swing PPC \JE?!\Je .............................................................................. 20-127
. .
Testing travel ................................................................................................................. 20-128
Testing locations causing hydraulic drift of work equipment ................................................... 20-129
Measuring oil leakage .................................................................................................................... 20-131
Rp!pasinn, remaining pressure in hydraulic r.ir~uit;;;;;;;;;;;;;;;;;;::;;;;;;;;;;;;;;;;;;;;:~:~=~~~~~~:~:~~:~~~~~~~~~~~~~ 20-13.3
Testing clearance of swing circie bearing ................................................................................... 20-134
-
I esting wear of sprocket ............................................................................................................... 26-735
Testing and adjusting track shoe tension .................................................................................... 20-136
Bleeding air ..................................................................................................................................... 20-137
TROUBLESHOOTING .............................................................................................................................. 20-201
PC300. 350-6 20- 1

0
* Notethefollowingwhenmakingjudgementsusingthestandardvaluetablesfortesting,adjusting,or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
a Be careful not to get caught in the fan, fan belt or other rotating parts.
20-2 PC300, 350-6

0
TESTING AND ADJUSTING STANDARD VALUE TABLE
FOR ENGINE RELATED
PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Applicabie model PC300, 350-6
Engine SAA6D1 08E-2
Item vleasurement
conditions1
Unit I Standard value
for new machine Service limit value
High idling
(Active
mode,
iever operated siightiy)
l l 2,250 2 70 2;ofio f 50
Engine speed Low idling rPm 900 +lo; 900 +';;

Rated speed
(Active mode) 2,050
Rated speed Air supply pressure kPa 120 - 147 120 - 147
(boost pressure) ImmHg1 (900 - 1 ,1001 I900 - 1,100}
Exhaust gas color

sudden
At acceleration, Bosch , Max. 5.5 7.5
At high idling
I index I Max. 1.5 2.5
Valve clearance Intake valve I I 0.34

(normal temperaure)
1
valve Exhaust 0.66
Oil temperature:
Compression pressure 40 - 60°Cl MPa
(SAE oil) Min. 2.7 I281 2.3 (231
Ikg/cm21
I 1
I
(Engine
speed) (rpm) (250 - 300) (250 - 300)
(Water temperature:
Blowby pressure Operating range) kPa
(SAE oil) {mmHzO) Max. 1.47 I1501 2.94 {300}
At rated output
(Water temperature:
Operating range)
At high idling
(SAE30) 392 - 637 I4.0 - 6.5} 235.2 (2.41
Oil pressure At high idling
At low idling
I I
(SAE 1OW) (kg/cm2)
(SAE30)
kPa
- -
78.4 {0.8}
At low idling
SAE.i@".". I I Min. 78.4 10.81 4910.5)
1
Oil temperature
Whole speed range
(inside oil pan) I
I
"C 1
I
8 0 - 110 120
Fuel injection timing Before topdeadcenter 1 (degree) 1 1 7 k 0.75 17 k 0.75
6 - 10
Belt tension 3 6 - 10
air conditione;
compressor
I 15 - 18 15 - 18
20-4 PC300, 350-6

0
TESTING AND
ADJUSTING STANDARD VALUE
TABLE FOR CHASSIS
RELATED
PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

.j, The S t a n d a r d v a l u e for n e w m a c h i n e a n dService limit v a l u e in t h e t a b l e b e l o w a r e a i l v a i u e s w h e n
m e a s u r e d in t h e h e a v y - d u t y mode.
Applicable model
T PC300, 350-6
item I M e a s u rceomnedni t i o n s
Standard value
Unit for new machme
i e r v i c e limit value
. Engine water temperature: When swing lock When swing lock

Within operating range switch is OFF: switch is OFF:
. Hydraulic oil temperature: 2,100 F 100 2,100 i 100
At 2-pump relief 45 - 55°C
. Engine at full throttle When swing lock When swing lock
. In H/O m o d e switch is ON: switch is ON:
. A r m IN relief 1,950 F 100 1,950 k 100
rPm
At 2-pump relief . Engine at full throttle
+ . In H/O mode 1,950 t 100 1,950 -I 100
power max. . Arm IN relief + power max. ON
~~
Engine speed when Auto-deceleration switch ON

auto-deceleration is . Fuel control dial at MAX. 1,400 k 100 1,400 t 100
actuated . Control levers at neutral. - -
Boom Lo control valve
-
e a b b
Boom Hi control valve
Arm Lo control valve
Arm Hi control valve

mm 9.5 ? 9.5 f
0.5
9.5
0.5
*
Bucket control valve 0.5
Swing control valve 'oom LC Boom LC
Left travel control valve
SWEA on1
1.5 i 0.
I LOWER on\
11.5 i O!
Right travel control valve BLPOolOl

- - -
control
lever
. Center of lever knob 85 k 10
Max. 95
. Read max. value to end of travel Min. 75
. Engine stopped
. Exclude play at neutral. Max. 95
Arm control lever 85 t 10 Min. 75
8 5 t 10 Max. 95
Bucket control lever Min. 75
Swing
control
lever 1 mm 85 i 10
Max. 95
Min. 75
115 i 12 Max. 127

Travel control lever
Min. 103
I
Work equipment, swing Max. 10 Max. 15
Play of control lever
Travel Max. 20 Max. 30
PC300, 350-6 20-5

@
TESTING AND ADJUSTING STANDARD
VALUE TABLE FOR CHASSIS RELATED
PARTS
Applicable model PC300, 350-6
Item Measurement conditions Standard value

for new mach,ne Service limit value
Boom control lever - Engine at full throttle

Oil temperature: 45 - 55°C
15.68f 3.92
(1.6 f 0.4)
1 Max. 24.5 (2.51
Arm control lever

. Fit push-pull scale to center of
control lever knob or tip of
pedal to measure
- Measure max. value to end of
15.68 f 3.92
11.6k 0.4)
I Max. 24.5 (2.51
Bucket control lever travel 12.74 f 2.94

I1.3 f 0.3)
1 Max. 21.56 I2.2)
Swing control lever 12.74i 2.94 Max. 21.56 (2.21
Lever 24.5 f 5.88

(2.5f 0.6)
1 Max. 31.92 I4.01
Travel control lever
Pedal 74.48 f 18.62
(7.6f 1.9)
1 Max. 107.8 1111
. Engine at full throttle

Unload pressure . Oil temperature: 45 - 55°C 3.92 i 0.98 3.92 k 0.98
All levers at neutral I40 f 10) 140 k 10)
. Pump outlet port pressure
RAISE
1
'L
Boom PC At high-pressure setting 31.36 f 1.47 Max. 33.32 I3401
(320 5 15) Min. 29.4 13001
~~
9 At
low-pressure setting 18.13 f 0.98
{I85 f IO}
Max. 19.6 (2001
Min. 16.66 I1701
Arm +
33.81 0.98 (34.79
i 0.98) Max35.n ax3.26 Max.385 Max.370
C 10))
(345t 10 (355 Min32.34 $nB32)[M1a330[M~n.310]}
Bucket . Oil temperature: 45 - 55°C 33.81 t 0.98 (34.79i 0.98) MaY35.77 Mar36.26 Max.365 Max.370
' Engine at full throttle (345f I O !355 t ?Ol! Min.3?.?4[M1n3.32)( Min. 31(!,!IC!$]}
I In heavy-duty mode
Pump outlet port pressure Max. 32.34 I3301
Swing 8
' Relieve only circuit being 30*87fy:; {315T:,0 1 Min. 28.42 (290}
measured
f The values in t 1 are the values
Left travel
when using the power max. 34.79:i {355z?,0 1 Max. 37.24(380)
Min. 33.32 {340}
Right travel
Self-reducing valve
Oil temperature
I
45 - 55°C
Engine at full All levers 3.92 i 0.98 3.92 k 0.98
throttle at neutral I40 5 10) I40 f IO}
In heavy-duty
LS differential pressure mode
It LS differential Travel Hi under
pressure = no load, travel 2.45f 0.1
Pump outlet 2.45 f 0.1
port pressure lever at half- (25k 1) {25 f 1)
- LS pressure way position
20-6 PC300, 350-6

0
TESTING
AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
A p p l i c a b l e model 7 PC300, 350-6
Item Measurement conditions Un Standard v a l u e Service limit value

for new machln
-
Work equipment posture Max. react PC300 I PC350 PC300 PC350
Overrun when BKWOlO2

stopping swing

a Hydraulic oil temperature: 45 - 55°C
I
Max. 110 Max. 12 Max. 140 Max. 150
. In H/O mode
. Stop after swinging one turn
and measure distance that
swing circle moves
WorkequipmentMax.reach
I posture
3.6 F 0.4 Max. 4.5
Time taken to start swinl EKP00326
a Engine at full throttle

. Hydraulic oil temperature: 45 - 55'C 5.1 k 0.5 Max. 6.1
. In H/O mode
. Time taken to swing 90"and
180" from starting position
Sec
Work equipment posture Max. reach
rime taken to swing 30 rt 1.5 Max. 35

. Engine a t fu!l throttle BKWO102
. Hydraulic oil temperature: 45 - 55°C
. In H/O mode
' Swing one turn, then measure
time taken to swing next 5 turns
iydraulic drift of swing BKP00103 mm 0 0

Engine stopped
Hydraulic oil temperature: 45 - 55°C
Set machine on 15' slope, and set
upper structure at 9O'to the side,
Make match marks on swing circle
outer race and track frame.
Measure distance that match
marks move apart afier 5 minutes.
Engine at full throttle

eakage from swing Hydraulic oil temperature: 45 - 55°C 'min Max. 5.5 Max. 1 1
1 oto r Swing lock switch ON
Relieve swing circuit.
PC300, 350-6 20-7

0
TESTING AND ADJUSTING STANDARD
VALUE TABLE FOR CHASSIS
RELATED
PARTS
I
Measurement conditions Standard value Service limit value

Unit for new machin
Travc
STD LC STD 1 LC
56.5 k 11 60.5 k 11 45.5 - 70.0 49 - 74.5
Travel speed (1) BKP00104
- Engine at full throttle 40.5 k 5.5 43 i 6

- Hydraulic oil temperature:
45 - 55'c
. In H/O mode
- Raise track on one side at a
time, rotate one turn, then
measure time taken for
----I--
32.0 ? 3.5 34.1 & 3.
next 5 turns with no load.
.-
See I
23.3 ? 4.4 18.9 - 31.0
Travel speed (2)

16.7 f 2.2 14.4 - 21.0
. Hydraulic oil temperature:
. Run up for at least 10 m, and 13.1 ? 1.0 12.1 - 15.1

measure time taken to travel
next 20 rn on flat ground.
- Engine at full throttle

. Hydraulic oil temperature: 45 - 55'C
. In H/O mode
- Travel speed : Hi
rravel deviation * Run UP for at !eaet I D K, 2nd ??lax. 20!? ??lax. 300
measure deviation when traveling
next 20 rn on flat ground.
* Use a hard horizontal surface.
20m
BKWO107
t Measure dimension x.
20-8 PC300, 350-6

0
TESTING AND
ADJUSTING STANDARD
VALUE TABLE FOR CHASSIS
RELATED
PARTS
Item
~
Applicable model
Measurement conditions Uni

1 Standard value
PC300, 350-6
- for new machtnt service limit value
Hydraulic drift of trave mm 0 0

- Engine stopped
- Hydraulic oil temperature: 45 - 55'C
. Stop machine on 12' slope
with sprocket facing straight
up the slope.
. Measure the distance the
machine moves in 5 minutes.
I
Leakage of travel motor Lock' pin !/rnIT Max. 15 Max. 30
BKPOOlO9

. Hydraulic oil temperature: 45 - 55'C
- circuit.
Lock shoes and relieve travel
-
lotal work equiprneni
(hydraulic drift at tip
of bucket teeth)
Posture for measurement PC300 PC350
lax. 450 Max. 55a

lrb t-
PC350
PC300
1
lax. 675 Max. 825
BKPWllO
Boom cylinder
(amount of retraction illax. 25 Max. 30 Max.38 Max. 45
of cylinder) Place in above posture and
t
measure extension or
retraction of each cylinder and
downward movement at tip of
1
Arm cylinder bucket teeth.
[amount of extension lax. 135 Max. 165 Max. 203 Max. 248
of cylinder) fforizon'tal, flat ground
Levers at neutral
Engine stopped
Hydraulic oil temperature: 45 - 55'C
Bucket cylinder Start measuring immediately
after setting.
I Max. 38
i
larnount of retraction Measure hydraulic drift every 5 flax. 20 Max. 25 Max. 30
I f cylinder) minutes, and judgefrom
results for 15 minutes.
PC300, 350-6 20-9

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSJS
RELATED
PARTS
Applicable model 1 PC300, 350-6
Item Measurement conditions blni Standard value

for new machlnt Service limit value
-
I
Boom I
3.9 f 0.4 Max. 4.7

Bucket teeth in
contact with grounc
3 EKPOOl 1 1
Cylinder fully . Engine at full throttle

extended . Hydraulic oil temperature: 3.0 ? 0.3 Max. 3.5
45 - 55°C
. In H/O mode
PC300 I PC350 PC300 PC350
Arm
3.9 i 0.4 4.1 i. 0.1 Max. 4.6 Max. 4.9
Cylinder fully I
retracted
BKP00112
$ . Engine at full throttle
-ully extended . Hydraulic oil temperature: Max. 3.6 Max. 4.1
45 - 55°C
. !C H/Q mode I
3ucket
3.2 f 0.3 Max. 3.8
Zylinder fully
,etracted
$ RKPOOll3
:ully extended . Engine at full throttle
Hydraulic oil temperature: See 2.3 f 0.3 Max. 2.9
45 - 55°C
. In H/O mode
3oom BKP00114 Max. 3.0 Max. 3.6
' Lower boom and measure time

taken from point where bucket
contacts ground to point where
chassis rises from ground
Engine at low idling
Hydraulic oil temoerature: 45 - 5 5 T
wm Max. 3.0 Max. 3.6

BKP00115
Stop arm suddenly and measure

time taken for arm to stop
Engine a t low idling
20-10
0
TESTING AND ADJUSTING PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED
T
I
7
item Measureme nt conditions Uni Standard value Service limit value

for new machln
-
T
!i
Bucket See Max. 3.0 Max. 5.0
BKP00116
. Stop bucket suddenly and

measure time taken for
bucket to stop at bottom
and then start again
. Engine at low idling
' Hydraulic oil temperature: 45 - 55'C
Engine a t full throttle

-
cct
nnax. 4.5
I M.X. 20
Relieve circuit to be measured min

:enter swivel joint Max. 10 Max. 50

t Use a hard horizontal surface
t Measure dimension x.
rravel deviation when

c- 20m
Nork equipment + mm Max. 400 Max. 440

:ravel are operated
I
w BKP00107
Oil temperature: 45 - 55°C

I
-
L
!I
i/
1
I
Piston pump See next page 'min See next page
PC300, 350-6 20-1 1

0
STANDARD
VALUE TABLE FOR CHASSIS RELATED
PARTS
re
'Y PC300,350:Discharge amount of main piston pump (in H/O mode)
-
I I I I
9. a 19. 6 29. 4 34. 3

( 1001 (2001 [ 3001 (350)
. Pump speed: At 2050 rpm, TVC current 180 mA

Test pump Discharge Standard value Judgement
A~~~~~~ for discharge standard lower
Check point pressure of pressure
~~~~~~~~
Other pump (MPe {kg/!/cm2?) amount limit
iMPa iicgicmiij (MPa Ikg/cm2}) Cr (elmin) U (elmin)
P1 f P2
As desired PI P2 See graph See graph
2
Ir As far aspossible, bring pumpdischargepressuresP1and P2 ascloseas possible to theaverage

pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
Jr When measuring with the pump mounted on the machine, if itis impossible to set the engine speed to
the specified speed with the fuel control dial, takethe pump discharge amount andthe engine speed at
the point of measurement, and use them as a base for calculating the pump discharge amount a t the
specified speed.
i
20-1 2 PC300, 350-6

TESTING
AND ADJUSTING STANDARD
VALUE TABLE FOR ELECTRICAL
PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Name of Zonnectol nspectior Measurement

rllethod Judgment table conditions
component No.
If the condition is within the range shown 1 ) Turn starting
in the table below, it is normal switch OFF.
2) Disconnect
Fuel control dial E06 Between (1) - (2) I 0.25 - 7 k!2 1 connector.
(male)
~~
If the condition is within the range shown 1) Turn starting

2) Disconnect
Potentiometer E04 Between (1) - (2) 1 0.25 - 7 kR connector.
(male) 0.25 - 7 kR
Between (2) - (3)
Between (1) - (3) 4-6kQ
If the condition is as shown in the table 1 ) Turn starting

Se!c:t, It is ncrme! switch OFF.
2)Disconnect
E05 connector.
Motor (male)
Between (3) - (4) 2.5 - 7.5 Q
I Between (1) - (3) No continuity I

Between (1) - chassis No continuity
Between (3) - chassis No continuity
if the condition is within the range shown 1) Turn starting

2)Disconnect
1 Eetween(rnale1('1) - (21 1 500 - 1,000 Q I connector.
1 Betweenhale) (2) -chassis1 Min. 1 MR 1
~~ ~~
Engine speed E07 Measure with AC range 1) Start engine.

sensor 2) Insert
Between (1) - (2) 0.5 - 3.0 V T - adapter.
*.I
v)
1) Screw in rotation sensor until it contacts
3 ring gear, then turn back 1 ? 1/6 turns.
3 2) It must work normally when adjusted
d as above.
ravel SO1 If the condition is as shown in the table 1) Start engine
bels:..., It is m r m a ! (orwith engine
oom RAISE SO2 When boom, arm, and bucket levers are stopped and
operated accumulator
rm OUT SO3 charged)
Between All leversat neutralMin. 1 MQ 2) Disconnect
oom LOWER SO4 (male) connectors
PPC oil pressure ( 1 ) - (2) Levers
operated
Max. 1 R SO1 - S08.
SWifC!! rm !?! sa5
ucket CURL SO6
ucket DUMP SO7
Between (male)
(1),(2) - chassis I Min. 1 MR
i
i Ning SO8
PC300, 350-6 20-1 3

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sys- Name of Connector Inspection Measurement

Judgment table
tem component No. method conditions
If the condition is as shown in the table 1) Start engine.
below, it is normal 2) Turn fuel
control dial to
Measure
voltage
C07 (male) Between (2) – (1) 18 – 28 V MAX position.
Pump pressure (rear) 3) Insert
sensor C08 (male) T – adapter.
(front) Between All levers at neutral 0.5 – 1.5 V
(3) – (1)
At arm IN relief 3.1 – 4.5 V
If the condition is as shown in the table 1) Turn starting

resistance
below, it is normal switch OFF.

Measure
X05 2) Disconnect
Swing lock switch (male) Between (1) – (2) When switch is OFF Min. 1 MΩ connector X05.
Between (3) – (4)
When switch is ON Max. 1 Ω
If the condition is within the range shown 1) Turn TVC

in the table below, it is normal prolix switch
resistance
Measure
C04 OFF.
TVC solenoid valve (male) Between (1) – (2) 10 – 22 Ω 2) Turn starting
switch OFF.
C13 Between(1), (2) – chassis Min. 1 MΩ 3) Disconnect
(male) connectors
C04, C13.

resistance

Measure
Control system
Swing holding brake V04 2) Disconnect

solenoid valve (male) Between (1) – (2) 20 – 60 Ω connector V04.
Between(1), (2) – chassis Min. 1 MΩ

resistance

Measure
Travel speed V06 2) Disconnect


resistance

Measure
LS select V02 2) Disconnect


resistance

Measure
Pump merge/divider V03 2) Disconnect


resistance
Machine push-up in the table below, it is normal switch OFF.

Measure
solenoid valve V05 2) Disconnect

(engine throttle, pump (male) Between (1) – (2) 20 – 60 Ω connector V05.
controller does not carry
out control) Between(1), (2) – chassis Min. 1 MΩ
20-14 PC300, 350-6

1
5

Judgment table
resistance
Measure
2) Disconnect
LS-EPC solenoid C10 connector C10.
(male) Between (1) – (2) 7 – 14 Ω

in the table below, it is normal switch ON.
2) Insert
Measure
voltage
Between C01 T – adapter.

Power source C01 (7),(13) – (6),(12) 20 – 30 V
voltage C02
Between C02
(11),(21) - (6),(12) 20 – 30 V

below, it is normal switch ON.
2) Insert
Between (7) – (17) T – adapter.
4.75 – 5.25 V
Measure
voltage
(power source)
Fuel control dial C03
Between (4) – (17)
(low idling) 4.0 – 4.75 V
Between (4) – (17)

(high idling) 0.25 – 1.0 V
Control system

2) Insert
Between (14) – (17) T – adapter.
2.9 – 3.3 V
Measure
(low idling)
voltage
Governor C03
potentiometer Between (14) – (17)
(high idling) 0.5 – 0.9 V
Between (7) – (17) 4.75 – 5.25 V

(power source)

resistance
Measure
2) Disconnect
Coolant P07 Normal temperature (25˚C) Approx. 37 – 50 kΩ connector P07.
temperature (male) 3) Insert
sensor 100˚C Approx. 3.5 – 4.0 kΩ T – adapter.
into connector
at sensor end.

Measure

voltage
2) Insert
Governor motor C02 Between (2) – (3) 1.8 – 4.6 V T – adapter.
Between (4) – (5) 1.8 – 4.6 V

Measure
voltage
2) Insert
Battery relay C01 Between (1) – (6) 20 – 30 V T – adapter.
fl This is only for 2.5 sec after the starting

switch is operated ON → OFF; at other
times it must be 0 V.
PC300, 350-6 20-15

1
5

Judgment table
below, it is normal 2) Turn swing lock
switch OFF.
When either swing 3) Turn swing lock
or work equipment prolix switch
control lever is 20 – 30 V OFF.
operated (solenoid 4) Insert
Measure ON, swing holding T – adapter.
Swing holding voltage brake canceled) fl The lever can
brake solenoid C01 Between be operated
Approx. 5 sec after (3) – slightly
swing lever and (6),(12) (without
work equipment moving
control levers are 0–3V the equipment).
placed at neutral
(solenoid OFF,
swing holding
brake applied)

below, it is normal 2) Insert
T – adapter.
With travel speed 3) Turn fuel
switch at Hi or Mi control dial to
(solenoid ON, 20 – 30 V MAX position.
Measure
voltage
travel motor swash 4) Operate the

Travel speed plate angle MIN) Between lever slightly
solenoid C01 not enough to
(9) –
When travel speed (6),(12) move the
Control system
switch is at Lo machine.
(solenoid OFF, 0–3V To check that the
travel motor swash solenoid is OFF,
plate angle MAX) measure with the
fuel control dial at
LOW (1200 rpm or
below)
2) Insert
When active mode T – adapter.
switch is OFF
(solenoid ON,
Measure
boom lower spool 20 – 30 V

voltage
Active (boom) stroke 9 mm)

C01 Between
solenoid
(8) –
When active mode (6),(12)
switch is ON
(solenoid OFF,
boom lower spool 0–3V
stroke 11.5 mm)

below, it is normal. switch ON.
2) Insert
When travel is T – adapter.
operated independ- fl The lever can
Measure
voltage
Pump merge/ ently (solenoid ON, 20 – 30 V be operated

divider valve C01 divided) Between slightly
solenoid (2) – (without
When levers and (6),(12) moving
pedals are at the equipment).
neutral (solenoid 0–3V
OFF, merged)
20-16 PC300, 350-6

1
5

Judgment table
Measure
current
TVC · H/O mode 2) Turn fuel
solenoid valve C02 control dial to
(default value) Between front (8) – (18) MAX position
360 ± 100 mA 3) Turn prolix
Between rear (9) – (19) switch OFF.
4) All levers at
neutral

Measure
current
LS-EPC · H/O mode 2) Turn fuel

solenoid valve C02 control dial to
(default value) Between (7) – (17) 900 ± 80 mA MAX position
3) All levers at
neutral.

Measure
voltage
2) Insertl
L.H. knob switch C03 When switch is ON 20 – 28 V T – adapter.
Between
(9) – GND 0–1V
When switch is OFF

Measure
voltage

S-NET C17 2) Insertl
Between (4),(12) – GND 4–8V T – adapter.
Control system

Measure
voltage
2) Insertl
Kerosene mode C17 Standard mode 20 – 28 V T – adapter.
Between
Kerosene mode (15) – GND 0–2V

below, it is normal 2) Set monitoring
High idling (rpm) code to 10 or 16
(command
Approx. 2300 (during operation)
Active Approx. 2050 (idling) value).
3) Operate
Approx. 2200 (during operation)
H/O Approx. 2050 (idling) working mode
Engine
speed
No. 2 throttle Monitoring Approx. 2050 (during operation)

switch and L.H.
signal code 16 G/O Approx. 1900 (idling) knob switch.
F/O Approx. 1900
L/O Approx. 1700
Power max. (H/O) (G/O) Approx. 2250
Swift slow-down (H/O) (G/O) Approx. 1700

2) Disconnect
Between selection 1 C17(5) – CO2(11) No continuity
Continuity
connector.
Between selection 2 C17(13) – CO2(11) Continuity 3) Connect
Model selection C17 – C02 T – adapter to
Between selection 3 C17(6) – CO2(11) Continuity wiring harness
end.
PC300, 350-6 20-17

1
5
Monitor
"d
Measure Measure tleasure Measure Continuity

resistance resistance Adjust voltage resistance
W N t
.. .. .. . ..
Monitor
E
0
0
Measure Measure Measure Measure

resistance resistance resistance resistance
3 5
? ?
a I-.
3 3
3 D
TESTING AND ADJUSTING STANDARD VALUE TABLE
ELECTRICAL
FOR PARTS
Name of componen
No. I 1
onnector Inspection
method Judgment table Measurement
conditions
11
When engine is running (1/2throttle or above I) Start engine.
Alternator
:hassis
F a g r
if is defective.
Ir If the battery is old, or after starting in
cold areas, the voltage may not rise
some time.
~ g ~ ~ ~ s s y o r
for
~
Display revel resistance kQ 1) Insert a

Position oi (Monitor panel input dummy
gauge display resistance) resistance with
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Min. - Max. resistance of
- 0.646 the sensor.
2) Check the
display with
19) 0.575 - 0.342
3.156 - 3.708
the starting
switch ON.
Measure
resistance 3.422 - 3.900
between
coolant 3.600 - 4.349
temperature
gauge C03 4.015 - 5.122
(female) (1
- C03 1 4 1 4.728 - 6.816
(female) (16)
1 3 6.294 - 10.774
9.946 - 36.535
side r i
1
Left
2 1
33.725 -
Gauges
Display level resistance kil 1) insert a
Position of dummy
gauge display (Monitor panel input
resistance) resistance with
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Min. - Max. resistance of
I - 13.82 I the sensor.
2) Check the
display with
1 11.71 - 21.25 I the starting
switch ON.
Measure
resistance
II 18.90 - 28.45
25.82 - 31.85 I
between
fuel level
gauge C03
(female) (2) 37.00 - 44.60
- chassis
1 41.77 - 55.14 I
Ir Level 1 flashes.
20-20 PC300, 350-6

TESTING AND ADJUSTING TOOLS FOR TESTING,
ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks

Kit Part No.:799-203-9000
1 799-203-8001
Multi-tachometer Digital display L: 60 - 2,000 rpm
H: 60 - 19,999 rpm
Engine speed A
6142-82-51 12 22 x 1.5
Gear box
6210-81-4111 7/8 - 18NS
Coolant and oil temoeratures B 799-101-1502
Digital
temperature
gauge -50 - 1,200"C
Pressure gauge
799-101-5002
Hydraulic
tester 2.5,5.9,39.2,58.8MPa
1
.-
125, 60, 400, 600 kg/cm2}
790-261-1203Digitalhydraulictester p r ~ ~kg/cm21
r ~ ~ ~ ~ ~
*799-101-5160 Nipple PT1/8
799-101-5220
2 Nipple *
10 ~1.25
07002-11023 0 ring
*790-267-1311 Both male and female
qd Y 1.5 (female PT 1/8)
I - n . .
3 e790-261-1321
Adapter Both male and female
Oil pressure 18 x 1.5 (female PT1/81
0790-261-1331 Both male and female
22x1.5 (female PT1/81
1 4 I 799-401-2701 I Differentialpressuregauge 1
I I I
790-261-1360
Adapter Both male and female
14 x 1.5 (female PT 1/81
. . .
790-261-1370 Nut For 14 x 1.5 blind

5
07003-31419
Gasket For blind
07040-1
1409
Plug For 14 x 1.5 blind
799-401-2320
6 Hydraulic
gauge 1.0 MPa (10 kg/cm2}
0 - 6.9 MPa (0 -70
kg/cm2}
795-502-1590
1 Compression
gauge
Compression pressure D
Part
Kit
No.:
795-502-1205
795-472-1370
2 Adapter
~~~
Blowby pressure E 799-201-1504 Blow-bv

checker 0 - 4.9 kPa (0- 500 mmHzO1
I 1
Air supply pressure -1 0 1.3 - 200 kPa
(boost pressure) F 799-201-2202
Pressure
gauge (-760 - 1500 mmHg)
Valve clearance I
Discoloration 0 - 70% (with

1 799-201-9000 Handy Smoke Checker standard color)
Exhaust color H '
(Discoloration % x 7/10 =
2 'Ornrn
availabffe rcially
Smoke meter I
Bosch index)
I
79A-264-0020 0 - 294N (30 kg)

Operating effort J Push-pull scale
79A-264-0091 0 - 490N 150 kg]
Stroke, hydraulic drift K $ ~ ~ ~ ~Scale
~ c i a l l ~
Work equipment speed L Corqnbcjrcially
e aval
Sto p awatch
Measuring voltage and M 79A-264-0211 Tester
resistance values
1 799-601-7100
T-adapter
box
Troubleshooting of wiring v 799-601-7070 For SWP14
harnesses and sensors 2 . Adapter
799-601-7360 For relay 5P
\ I I 1 I
Measuring wear of sprocket 796-627-1130 P
Wear gauge
28-102 PC300, 350-6

0
TESTING
ENGINE
AND
MEASURING
ADJUSTING SPEED
MEASURING ENGINE SPEED

A W h e n removingorinstalling the measuring
equipment,becarefulnot to touch any high
temperature parts.
* Measure the engine speed under the following
conditions.
Coolanttemperature: Withinoperatingrange
Hydraulicoiltemperature : 45 - 55°C
1. Remove the fan guard.
2. Remove cover ( I ) .
3. Install the gear box A2.
4. Install the sensor of multi-tachometer A I to the r

speed pulloutport,thenconnect it to multi-
tachometer A I .
5. Start the engine, and measurethe engine speed

when it is set to the conditions for measuring.
1) Measuring low idling and high idling speeds
Measure the engine speed with the fuel con-
trol dial set to low idling and high idling.
* Measure intheheavy-dutymode witn
the auto-deceleration OFF.
* Whenmeasuringthehighidling speed, l I /\\ BWP02993
place in the active modeand operate

the lever slightly.
2) Measure the speed at near the rated speed.
i j Sei the working mode to the H i 0 mode,
active mode.
i i j Set the power max.iswiit siow-down
switch to the power Max. position.
iii) Run theengine at full throttle, set the
knob switch to the ON position, operate
the arm lever, andmeasurethespeed
when the arm IN circuit is relieved.
* Even ifthe L.H. knobswitch is kept
pressed, the power max. function is
autnmatica!!y turned off after apprnu.
8 seconds, so measure during the
first 8 seconds.
* Measuring speed whentravel is op-
erated: Knob switch ON
3) Measuring speed at 2-pump relief:
i) Set the working mode the H/O mode.
ii) Run theengine at full throttle, operate
rL--
Llle dl I l l
I
level,
^..Î--A
OllU
----..I-
IlledDUle
SL-
LIIe
--...:...-
'SIIYIII'S
speed when the armIN circuit is relieved.
PC300, 350-6 20- 103

0
AND TESTING ADJUSTING
MEASURING EXHAUST COLOR

Whenmeasuring inthefieldwhenthere
equipment, becareful nottotouch

temperature part.
1. Measuring with handysmokechecker H I

1) Fit filter paper in tool H I .
2) Inserttheexhaust
t o secure it t o the exhaust pipe.

is no
air or power supply, use handy smoker checker
HI; whenrecordingofficial
meter H2.
data,use smoke
Raise the coolant temperature to the operating

range before measuring.
A W h e n removingorinstallingthemeasuring
any high
gas intake port into the

exhaust pipe, accelerate the engine suddenly,
and at the same time operate the handle of
tool H I t o catch the exhaust gas on the filter
paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter HZ

Insert-the probe of tool H2 into the outlet
port of exhaust pipe(l), then tighten the clip
Connect the probe hose, accelerator switch

plug, and air hose to tool H2.
20-I 04
0
* The pressure of the air supply should be
less than 1.47 MPa I15 kg/cm2}.
Connect the power cord to the
source socket.
*
AC power
When connecting the port,check first that

the power switch of tool H2 is OFF.
Loosen the cap nutofthesuctionpump,
then iit the iiiter paper.
* Fit the filter paper securely so that the
exhaust gas does not leak.
Turn the power switch of tool H2 ON.
Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool H2 and catch the exhaust gas color on
the filter paper.
Lay the filter paper used t o catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) inside the filter pa-
per holder, and read the indicated value.
I
I
MEASURING EXHAUST COLOR
.
I
BLP00297
BKP00215
PC300, 350-6
TESTING AND ADJUSTING VALVE
ADJUSTING CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction to

align TOP 1.6 line (1) on the crankshaft pulley
with pointer (2). When rotating, check the move-
ment of the intake valve of No. 6 cylinder.
3. When No. 1 cylinder is at compression top dead

center, adjust the valves marked 0 in the valve
arrangement chart. Next, rotate the crankshaft
one turn (360") in the normal direction and ad-
I ' BLP00298
just the valve clearanceof the remaining valves

marked 0. VALVE ARRANGEMENT DIAGRAM
4. To adjust thevalveclearance,loosen locknut

(61, then insert feeler gauge G between rocker
lever (3) andvalvestem (41, andturnadjust-
ment screw !5)until the c!earance is a s!iding fit.
Then tighten locknut ( 6 ) to hold the adjustment
screw in position.
Locknut : 44.1 k 4.9 Nm (4.5 k 0.5 kgm}
* The firing order is as follows: 1 - 5 - 3 - 6 - 2 -

4.
* AfteradjustingNo. 1 cylinder a t compression
TYPO1432
top dead center, it is also possible to turn the

crankshaft 120" each time and adjust the valve
clearance of the intake and exhaust valves of
each cylinder according to the firing order.
* Fordetails of thevalveclearance, see the
STANDARD VALUE TABLE for enginerelated
parts.
* Aftertighteningthelocknut, check thevalve
clearance again.
-__
1
----
'
4
fi--11
BLP00300
PC300, 350-6 20- 1 05

0
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING COMPRESSION
PRESSURE
A W h e n measuring the compression pressure, be
carefulnottotouchthe exhaust manifoldor
muffler, or to get yourclothes caught in the fan,
fan belt or other rotating parts.
1. Adjust the valve clearance.
For details, see ADJUSTING VALVE CLEARANCE.
2. Warm up the engine to make the oil tempera-
ture 40 - 60°C.
3. Removenozzie hoider assembiy ( l j from the
cylinder to be measured.
4. Install adapter D2 in the mount of the nozzle
holder, then connect pressure gauge D l .
5. Connect tachometer A I and gear box A2.
For details, see MEASURING ENGINE SPEED.
6. Disconnect the fuel controlrod, place the gover-
nor lever of the injection pump in the NO IN-
JECTION position, then crank the engine with
the starting motor and measure the compres-
sion pressure.
* Measure the compression pressure a t the point
wherethepressuregaugeindicatorremains
steady.
* Whenmeasuringthecompression pressure,
measure the engine speed to confirm that it is
within the specified range.
* After measuring the compression pressure, in-
stall nozzle holder assembly (1).
MEASURING BLOW-BY
PRESSURE
* Measure the blow-by pressure under the follow-
ing conditions.
Coolanttemperature: Within operating range
0 Hydraulicoiltemperature: 50 - 80°C
1. Install the nozzle of blow-by checker E to blow-
by hose (1).
2. Connect the nozzle and gauge with the hose.
3. Run theengine a t near the rated outputand
read the gauge measurement.
* Nearratedoutput
Relieve thearmINcircuit in the H/O mode
and power max. mode.
* Measure the blow-by at the point where the
gauge indicator remains steady.
20-106 PC300, 350-6

0
TESTING
TESTING AND ADJUSTING ADJUSTING
AND FUEL INJECTION TIMING

FUEL INJECTION TIMING
Testing
* If thefuelinjectionpumphasbeenremoved,
check as follows.
1. Check that line a on the injection pump is aligned
with line b on the mounting case.
w BLP00305
Adjusting
* If the lines are not aligned, adjust as follows.
1. Loosen nut (1) at the oblong portion and pump
mounting nut(21,then move fuel injection pump
(3)to align the lines.
2; Tighten nuts ( I ) and (2)=

Nut : 66.15 & 7.35 Nm I6.75 k 0.75 kgm)
* If thegearflangeand gear train for thefuel

injectionpump drive has beendisassembled,
adjust the fuel injection timing. For details, see
the 108-2 Series Shop Manual.
PC300, 350-6 20- 1 07

0
MEASURING
ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
* Measure the engine oil pressure under the fol-
lowing conditions.
Coolant temperature: Within operating range
1. Remove engine oil low-pressure sensor (PT1/8)

(1) andhigh-pressuresensor (PT1/8) (2),then
install nipple C2 and oil pressure gauge C6 (1.0
MPa (10 kg/cm2}).
2. Start the engine, and measure the oil pressure

with the engine a t low idling and a t high idling.
* For low-pressure sensor ( I ) , measurethe en-

gine oil pressure caution end with the engine at
lowidling,andforhigh-pressure sensor (a),
measuretheengine oil pressurecautionend
and the controller troubledata display end with
the engine at high idling.
20-188 PC300, 350-6

0
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING WATER PUMP BELT TENSION

ALTERNATOR BELT TENSION a
Fan pulley
fl If the deflection of the belt when it is pressed at Alternator pulley
a point a midway between the alternator pulley
and the fan pulley is not within the standard
value, or after carrying out maintenance or re-
placing the belt, adjust the belt tension as fol-
lows.
• Deflection of V-belt : 6 mm
1. Remove the upper fan guard of the alternator.
2. Tighten adjustment nut (3) until clearance of re-
Crankshaft pulley
tainer (2) is eliminated. BLP00310
fl Do not tighten the adjustment nut further after
the clearance is eliminated.
3. Tighten mounting bolt (1).
3 Mounting bolt:
53.9 – 122.5 Nm {5.5 – 12.5 kgm}
4. Tighten mounting bolt (5).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
5. Tighten locknut (4).
6. After adjusting the belt tension, check again to
confirm that the belt tension is within the stand-
ard value.

a
WATER PUMP BELT TENSION
fl If the deflection of the belt when it is pressed at Fan pulley
a point a midway between the water pump pul- Water pump
ley and the fan pulley is not within the standard pulley
value, or after carrying out maintenance or re- Tension
placing the belt, adjust the belt tension as fol- pulley
lows.
• Deflection of V-belt : 6 mm
1. Loosen mounting bolts (2) and locknut (3) of
Crankshaft pulley
tension pulley (1). BLP00312
2. Turn belt tension adjustment bolt (4) and move
tension pulley (1) to adjust the tension of the
belt. When the tension is adjusted, tighten
mounting bolts (2).
3 Mounting bolt :
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
3. Loosen adjustment bolt (4) 1/2 turns, then tighten
2
locknut (3).
fl To prevent the adjustment bolt from falling
out, loosen the tension applied to the bolt.
4 3
3 Locknut:
30.87 ± 3.43 Nm {3.15 ± 0.35 kgm}
4. After adjusting the belt tension, check again to
1
confirm that the belt tension is within the stand- BLP00313
ard value.
PC300, 350-6 20-109

20-109
1
7
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

BELT TENSION FOR AIR
a
CONDITIONER COMPRESSOR Crankshaft pulley
Air conditioner
compressor pulley
1. Remove the upper fan guard of the air condi-
tioner compressor.
fl If the deflection of the belt when it is pressed at
a point a midway between the drive pulley and
the compressor pulley is not within the stand-
ard value, or when carrying out maintenance
after replacing the belt, adjust the belt tension
as follows.
BKP00314
• Deflection of V-belt : 15 – 18 mm
2. Loosen mount bolt (1) and (2).
3. Move the position of compressor (3) to adjust
the tension of the belt.
4. When the position of the compressor is fixed,
tighten mount bolts (1) and (2) to secure in posi-
tion.
5. After adjusting the belt tension, repeat the above
procedure to check that the belt tension is within
the standard value.
ADJUSTING ENGINE SPEED

SENSOR
1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (1), turn back 1 ±
1/6 turns.
3. Tighten locknut (3). 1
3 Locknut : 58.8 ± 9.8 Nm {6 ± 1 kgm}
fl Be particularly careful when handling the sen-
BLP00316
sor wiring to ensure that no excessive force is
brought to bear on the wiring.
fl Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to the
sensor tip. 3 1
Clearance
2
BLP00317
20-110 PC300, 350-6

1
TESTING AND ADJUSTING MEASURING AIR
SUPPLY
PRESSURE
(BOOST
PRESSURE)
MEASURING AIR SUPPLY

PRESSURE
(BOOST PRESSURE)
A W h e n removingorinstallingthemeasuring
equipment or when carrying out the measure-
ments, becareful not to touch any high tem-
perature parts or rotating parts.
1. Remove air supply pressure measurement plug

(1) (PT1/8), then install the nipple C2.
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge F (-101.3 - 200
kPa (-760 - 1,500 mmHg).
Note: Run the engine at a mid-range speed or

above, anduse the self-seal portion of
the gauge to bleed the oil from inside /F
the hose.
. Insert the gauge about half way, and
repeatedly open the self-seal portion
to bleed the oil.
* The gauge does not work if there is
any oil inside thehose, so always be
sure to bleed all the oil.
3. Run theengine a t neartherated speed and

measure the pressure indicated by the gauge.
-*Near rated output

Run the engine a t near the rated output. For
details, see the measurement of the engine
speed when the arm IN circuit is reiieved in
the H/O mode and power max. mode.
* The air supply pressure (boost pressure) should

be measured with the engine running a t rated
output. However, when measuring in the field, a
similar value can be obtained with the above
conditions.
PC300, 350-6 20-111

0
TESTING AND
ADJUSTING
TESTING
AND
ADJUSTING
GOVERNOR
MOTOR LEVER
STROKE

GOVERNOR MOTOR LEVER
STROKE
3
Testing
* Use the governor motor adjustment mode.
1. Preparatorywork
1) Keep the monitor panel time switch + travel
speed (R.H.)switch + working mode (R.H.)
switch pressed for 2.5 seconds.
2) Set thefuelcontroldial to MAX, and the
auto-deceleration switch to OFF.
can mode *
workingAny used.
2. In this condition, check the governor lever and
II BLP00320
spring rod.
3. After checking,repeat the procedure in Step 1
to completethegovernormotoradjustment
mode.
Adjusting
1. Turn the starting switch OFF, then remove the
nut and disconnect joint (1) from governor lever
(2).
2. Repeat the procedure in Step 1 above t o set to
the governor motor adjustment mode.
3. Set governor lever (2) to a positionwhere it
contacts full speed stopper (3) of the fuel injec-
tion pump, then turn joints (1) and (4) t o adjust
the length of spring assembly (5) and adjust to
the position of the hole of governor lever(2).
4. From the above position, shorten joints (1) and
(4) a total of 2 turns iapprox. 2.5 mmj, ana se-
cure in position with the locknut.
Caution
* When the spring assembly is removed and the
starting switch is at the OFF position, if the gov-
ernor motor lever is moved suddenly, the gov-
ernor motor will generate electricity, and this
may cause a failure in the governor controller.
* Whenmovingthegovernormotor lever, dis-
connect connector E05 first.
20-1 12 PC300, 350-6

0
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT,
SWING,
TRAVEL
CIRCUIT

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No.: 12001 - 12283
Measuring
* Oil temperature when measuring: 45 - 55°C
A ~ o w e the
r work equipment to the gro~inda ~ d
stop the engine. Loosen the oil filler cap slowly
t o release the pressure inside the hydraulic tank.
Then put the safety lock lever in the LOCK posi-
tion.
1. Remove the upper cover of the main pump.
2. Remove pressure pick-up plug (1) or (2) (thread
dia.=lOmm, Pitch=l.25mm) from the circuit to
be measured, then install the nipple C2 and oil
pressure gauge C1 (58.8 MPa (600 kg/cm*}).
3. Measuringunloadpressure
1) Run the engine at full throttle and measure
in the H/O mode.
2) Measure the hydraulic pressure when all le-
vers are at neutral.
4: Measuring main relief pressure
in the H/O mode.
2) Measurethehydraulic pressure when each
actuator is relieved.
* If the power max. switch is turned ON,
the pressure will rise, so measure with
both the switch OFF and ON.
(When the switch is turned ON, it is au-
tomaticallyturned OFF afterapprox.8
seconds, so measure during the first 8
seconds.)
* Note that the set pressure of the safety
valve for the swing motor and head end
of the boom is lower than the LS relief
pressure, so the value measured will be
the relief pressure of the safety valve.
Sr To check the operation of the safety vaive
a t the boom LOWERend, measure the
hydrau!icpressurewhenthemachine Table 1 Combination of pumps and actuators
push-up switch is OFF (low pressure) and controlled when fiow from front
and
ON (high pressure). rear pumps is divided
* When measuring the hydraulic pressure Plug Pump Controlled actuator
intheboom LOWER circuit,block the Boom cylinder (Lo, Hi)
hose (fit blind plug) at the boom cylin- I Arm cylinder (Hi)
der head end.
Sr Iftheswing lockswitchisturned ON, R.H. travel motor
the pressure will rise, so always keep
the lock switch OFF when measuring. Arm cylinder (Lo)
Sr To relievethetravel circuit, put block
under the trackshoe grouser, or putblock
between the sprocket and frame t o lock
the track.
PC300,350-6 20-113
0
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL
CIRCUIT
PC300-6 Serial No.: 33466 and up I n

Measuring
A L o w e r the work equipment to the ground and
stop the engine. Loosen the oil fillercap slowly
t o release the pressure inside the hydraulic tank.
tion. 2
1. Remove the upper cover of the main pump.
2. Remove pressure pick-up plug (1) or (2) (thread
dia.=lOmm, Pitch=l.25mm) from the circuit to BWPO3980
be measured, then install the nipple C2 and oil
pressure gauge C1 (58.8 MPa {SO0 kg/cm2}).
3. Measuring unloadpressure I n
in the H/O mode.
2) Measure the hydraulic pressure when all le- C2
vers are at neutrai.
4. Measuringmain relied pressure
1) Run the engine at iuii throtiie ana measure
in the H/O mode.
2) Measure the hydraulic pressure when each
actuator is relieved.
* If the power max. switch is turned ON,
the pressure will rise, so measure with Bw P 0 3 9 8 I
both the switch OFF and ON.
(When the switch is turned ON, it is au-
1191
tomaticallyturned OFF afterapprox. 8
seconds, so measure during the first 8
seconds.)
* Note that the set pressure of the safety
valve for the swing motor andhead end
of the boom is lower than the LS relief
pressure, so the value measured will be
the relief pressure of the safety valve.
* To check the operation of the safety valve
at the boom LOWERend, measure the
hydraulicpressurewhenthemachine BLP00120
push-up switch isOFF (low pressure) and
ON (high pressure).
* When measuring the hydraulic pressure
Table 1 Combination of pumps and actuators
in theboom LOWER circuit,block the
hose (fit blind plug) at the boom cylin- controlled when flow from front and
der head end. rear pumps is divided
* If the swing lock switch is turned ON, Plug I Pump 1
~
Controlled actuator
~~~~~
the pressure will rise, so always keep Boom cylinder ( L o , H i )

the lock switch OFF when measuring. Arm cylinder (H i)
* To relieve thetravel circuit, put block 1 Front pump Bucket cylinder
under the track shoe grouser, or putblock R.H. travel motor
between the sprocket and frame to lock Service
the track.
2 Rear pum
Arm cylinder ( L o )
Swing motor
L.H. travel motor
28-11 3-1 PC300, 350-6

0
EQUIPMENT,
SWING.
TRAVEL
CIRCUIT
Adjusting
* The unload valve cannot be adjusted.
1. Main reliefvalve
(1): For frontpump
(2): For rear pump
Loosen locknut (3), then turn adjustment screw
(4) to adjust.
k Turn the adjustment screw to adjust as fol-
lows.
9 To INCREASEpressure, turn CLOCKWISE.
To DECREASE pressure, turn COUNTER-
CLOCKWISE.
* Amount of adjustment for one turn of ad-
justment screw:
Approx. 12.6 MPa (128 kg/cm2}
Locknut : 29.4 - 39.2 Nm {3 - 4 kgm} I 3. 4
2. Boomcylinder head safety valve

Adjust the safety valve a i the high-pressure
end first, ?her! adjust the lowpressure end.
ti):
Boom eyiinder head (LOWER) end
Disconnect pilot hose (2).
Adjusting high-pressure setting
Loosenlocknut (31, then turn holder (4) to
adjust.
Locknut : I BLPOO122
93 - 123 Nm I9.5 - 72.5 kgm)
Adjusting low-pressure setting
Loosen locknut (51, then turn holder (6) to
adjust.
Locknut : 78 - 93 Nm I8 - 9.5 kgml
Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCKWISE.
9 To DECREASE pressure, turn COUNTER-
CLOCKWISE.
Amount of adjustment for one turn of holder:
Approx. 21.8 MPa (222 kg/cm2}
[Reference] The oil pressure acting on port Cp

is as follows.
Machinepush-up switch ON (high
pressure): 0 MPa (0 kg/cm2)
Machine push-up switch OFF (low
pressure): 2.74 MPa (28 kg/cm2} 3 4 5 6
\
I BLW0124
28-114 PC300, 350-6

0
TESTING AND ADJUSTING EQUIPMENT. SWING. TRAVEL
CIRCUIT
3. Swing motor safzty valve

( 11: For starting left swing (stoppingright swing)
(2): For starting right swing (stopping left swing)
1) Removethe mounting bolts, thenremove
cover (3) and spring (4).
2) Loosenlocknut (51, thenturnadjustment
screw (6) t o adjust.
* Carry out the adjustment with the valve
assembly ifistalled to the motor.
* Turn the adjustment screw to adjust as
follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUN-
TERCLOCKWISE. I 6 5
* Amount of adjustmentfor one turn of
adjustment screw: Approx.3.9 MPa I39.5
kg/cm21
Locknut :
118 - 147 Nm {I2 - 15 kgm)
3) Aftercompletingtheadjustment,install
spring (4) andcover (3), thentightenthe
mounting bolts to the specified torque.
Cover mounting bolt :
98 - 123 Nm I10.0 - 12.5 kgm}
'00126
PC300, 350-6 20-1 15

0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO
PISTON INPUT PRESSURE)

TVC VALVE OUTPUT
PRESSURE (SERVO PISTON
INPUT PRESSURE)
PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No.: 12001 12283 -
Measuring
to release the pressure inside the hydraulictank.
Then put the safety iock [ever in the LOCK posi-
tion.
1. Remove pressuremeasurementplugs (2),

(I),
(31, and (4) (Thread dia.=lO mm, Pitch=l.25 mm),
theninstallnipple C2 andoil pressuregauge
c1.
* Plugsandmeasuredpressure
2 Front pump Front servo piston

discharge pressure input pressure
Rear pump Rear servo piston
discharge pressure input pressure
* Install a 39.2MPa (400 kg/cm21gauge to the /I tg BWPO2976

servovalve end, and a 58.8MPa I600 kg/
cm2} gauge to the pump outlet port end.
2. Turn the swing lock switch ON.
3. Set the working mode to H/O mode.
4. Run the engine at full throttle, turn the L.H. knob

switch ON, and measure the oil pressure when
the arm IN circuit is relieved.
* For thefront pump, measure the oil pres-
sure at plugs (1) and (3) at the same time;
for the rear pump, measure the oil pressure
at plugs (2) and (4) at the same time.
A Turn the swing lock switch ON and measure
the oil pressure when the circuit is relieved
(oil p r e s s u r e w h e n p r e s s u r e is rising!.
* Check that the servo piston input pressure is
2/5 of the pump discharge pressure.
[Reference]
If there is any abnormality in the LS valve or servo
piston, theservo piston input pressure will beal-
most the same or 0 of the pump discharge pres-
sure.
20-1 16 PC300, 350-6

0
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)

PC358-5 SerIa! No.: ?2284 axd up
Measuring
to release the pressure inside the hydraulictank.
tion. 1
1. Removepressuremeasurement plugs ( I ) , (21,

(3),and (4) (Threaddia.=lO mm, Pitch=1.25 mm), BWPO3980
theninstallnipple C2 andoil pressuregauge
c1.
* Plugsandmeasuredpressure
piston
servo
Front
pump
Front
discharge pressure
discharge
pressure
input
pressure
* Install a 39.2 MPa(400 kg/cm*)gauge to the

servovalve end, and a 58.8 MPa (600 kg/
cm2) gauge to the pump outlet portend.
2. Turn the swing lock switch ON. II Id BWPO2976
3. Set the working mode to H/O mode.
4. Run the engine at full throttle, turn the L.H. knob

switch ON, and measure the oil pressure when
the arm IN circuit is relieved.
Ir For thefront pump, measuretheoilpres-
sure at plugs (1) and (3) a t the same time;
for the rear pump, measure the oil pressure
at plugs (2) and (4) at the same time.
* Turn the swing lock switch ON and measure
the oil pressure when the circuit is relieved
(oil pressure when pressure is rising).
* Check that the servo piston input pressure is
2/5 of the pump discharge pressure.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure will be al-
most the same or 0 of the pump discharge pres-
sure.
PC300, 350-6 20-1 16-1

0
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
Adjusting
* If theload becomes larger, theengine speed
will drop. Or if the engine speed remains nor-
mal, theworkequipment speed will drop. In
such cases, if the pump discharge pressure and \
LS differential pressure are normal, adjust the

TVC valve as follows. \eccentric position 2'
1
?. Loosen locknut (11, ai;d ti;K sc:e:*uJ (2) t D adjust. @ -
* The direction to turn differs according t o the
\ L
1
I I
position of theeccentric position punch mark
on thescrew, so check the mark before turn- BLW0130
Ing.
* Turn the screw as follows.
If workequipment isslow, turn in IN- Punch mark showing
CREASE direction eccentric position
If engine speeddrops, turn in DECREASE
direction.
Punch mark Increase Decrease
Within 90° in Within 90" in
Range (8 clockwise counterclockwise
direction direction
Within 90' in Within 90" in
Range @ counterclockwise clockwise
direction direction
I
I I
BLPO0132
2. After completing the adjustment, tighten locknut

(11.
Locknut : 24.5 - 34.3 Nm (2.5- 3.5 kgml
80 - I I I
Note: The screw is an eccentric cam, so if it is turned 70 -
Change 60 -
from the 0 position in thegraph, the stroke of in oil
the servo piston (changein oil flow) will move flow 40 -
as shown in the graph. (-!/min)
If it is turned one full turn, will
it return to the
original position, but the screw will become
0 90~ 180~ 270' 360~
looser, so there will be play in the screw. Angle of turning of eccentric pin
Therefore, turn the screw a maximum of 90" BKP00131
to tne iefi or right fromthe position set when
the machine was shipped.
PC300, 350-6 28-1 17

0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LSDIFFERENTIALPRESSURE
TESTING AND ADJUSTING LS

VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE) AND LS
DIFFERENTIAL PRESSURE
1. Measuring LS valve output pressure (servo pis-
ton input pressure)
PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No;: 12001 - 12283
1) Removepressure measurementplugs (I),
(21, ( 3 ) , and ( 4 ) (Thread dia.= 10 mm,
Pitch=1.25 mm), andinstallnipple C2 and
oil pressure gauge C1.
* Plugs andmeasuredpressure
Front servo piston
discharge
pressure
input
pressure
Rear servo piston
* Install a 39.2 MPa {400 kg/cm2) gauge to

the servo valveend, and a 58.8 MPa (600
kg/cm21 gauge to the pump outlet port
end. /I t v BWPO2976
2) Set theworkingmodeto H/O mode, and

turn the travel speed switch to Hi.
3) Use the work equipment t o raise the track
assembly on one side.
* Whenmeasuringthefront pump, push
up the right track; when measuring the
rear pump, push up the left track.
4) Run theengineatfullthrottle, set t o the
conditions shown in Table 1, and measure
the pump discharge pressure and servo in-
let pressure.
* For the front pump, measure the oil pres-
sure atplugs (1) and (3) atthe same
time; for the rear pump, measure the oil
pressure at plugs (2) and (4) at the same
time.
i
Working
Travel
mode 1 1 lever
pressure
Pump
Servo inlet
port pressure Remarks
(MPalkg/cmzl 'MPa{kg/crn2})
HI0
mode I Neutral
1 3.92 k 1.0
{40 f IO}
3.92 f 1.0
{40 f IO}
About
pressure
H'o
mode I I
Half (travel A ~
under 12.74 {1301
circuit
no load)
~
Approx.
~ ~ 215 ~
About .
20-118 PC300,350-6
0
PC300-6 Serial No.: 33466 and up 17

PC350-6 Serial NO.:12284 and UP
1) Removepressuremeasurement plugs ( I ) ,
(21, (31, and ( 4 ) (Threaddia.= 10 mm,
Pitch=1.25 rnm),andinstallnipple C2 and
oil pressure gauge C1.
*
Plugsandmeasuredpressure
Front pump Front servo piston 2

input pressure discharge pressure
Rear pump Rear servo piston
discharge pressure input pressure BWP03980
*Install a 39.2 MPa {400 kg/cm21 gaugeto

the servo valve end, anda 58.8 MPa (600
kg/cm2) gauge to the pump outlet port
end.
2) Set theworkingmodeto H/O mode,and
3) Use the work equipment to raise the track
*Whenmeasuringthefrontpump,push
up the right track; when measuring the
rear pump, push up the left track.
4 ) Run theengine at fullthrottle, set tothe
conditions shown in Table 1, and measure 1 I/ t i BWPO2976
the pump discharge pressure and servo in-
let pressure.
Sr For the front pump, measure the oil pres-
sure at plugs (1) and (3) at thesame
time; for the rear pump, measure the oil
pressure a t plugs (2) and (4) at the same
time.
Table 1
Working
mode
1 Travel 1 Pump
Servo
inlet
1 1
pressure portpressure Remarks
lever (MPa(kg/cm21)tMPa{kg/cm21)
PC300, 350-6 20-119

0
PC300-6 Serial No.: 33001 - 33465, PC350-6 Serial No.: 12001 - 12283
I
2. Measuring LS differential pressure
1) Measuring with a differential pressure gauge
i) Removepressuremeasurementplugs
(I), (21, (31, and (4) (Thread dia.=lOmm,
Pitch=1.25mm), and install nippleC2 and
differential pressure gauge C4.
*Plugsandmeasuredpressure
Front pump Front LS
pressure discharge pressure
Rear pump Rear LS
pressure discharge pressure
* Connect the pump dischargepres-
sure to thehigh-pressure side of the PC300-6 Serial No.: 33466 and up, PC3504 Serial No.: 12284 and up
differentialgaugeandthe LS pres-
sure to the low-pressure side. -=-=a=-====%
ii) Set the working mode to H/O mode, and
iiii Use the work equipmentto raise the track
#r Whenmeasuringthefrom purxp,
push up the right track; when meas-
uringthe rear pump, push up the 2'
left track.
iv) Run the engine at full throttle, set to the
conditions shown in Table 2 and meas- BWPO3980
ure the LS differential pressure.
Table 2
Working Travel lever LS differential Remarks
mode Dressure
H/o
mode
1 Neutral I 3.92
{40 f 1.0 I (Note)
Half (travel 2.45 o.l

{25 f 1)
no load)
Note: Whenallcontrol leversare atneu-

tral, the LS differentialpressureis
the same as the unload pressure.
lirr '3 BWPO2977
20- 7 2Q PC300, 350-6

0
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIALPRESSURE
PC300-6 Serlal No.: 33001 - 33465.PC350~6Serial No.: 12001 - 12283

2) Measuring with oii pressuregauge
Ir Themaximumdifferentialpressure is
2.94 k 1.0 MPa (30 ? 10 kg/cm2}, so meas-
ure with the same gauge.
i) Remove pressuremeasurement plugs
(I), (21, (31, and ( 4 ) (threaddia.=lOmm,
pitch=1.25mm), and install the nippleC2.
ii) Set the working mode t o H/O mode, and
turn the travei speed switch to Hi.
iii) Use the work equipmentto raise the track
Ir Whenmeasuringthefrontpump,
push up the right track; when meas-
L
uringthe rear pump,push up the 300-6Serlal No.: 33466 and up, PC350-6 S e r n No.: 12284 and up
left track. n
iv) Install oil pressuregauge C1 (58.8 MPa
(600 kg/cm2}) to the measurement plug
for the pump discharge pressure.
Ir Use a gauge with a scale in units of
1.0 MPa { I O kg/cm2).
(If no 58.8MPa (600 kg/cm2) pres-
sure gauge is available, a 39.2 MPa
(400 kg/cm2} pressure gauge can be 2
used.)
v) Set t o theconditionsinTable 2 and
measure the pump discharge pressure.
* Stand directly in front of the indica-
L
tor and be sure to read it correctly.

vi) Remove oil pressure gauge C1 and nip-
ple C2, then install it t o the LS pressure
measurement plug.
vii) Set t o theconditionsinTable2and
measure the LS pressure.
* Stand directly in front of the indica-
tor and be sure t o read it correctly.
(Pumpdischargepressure) - (LS
pressure) = LS Differential pressure
II t i f BWPO2977
PC300, 350-6 2Q-120- 1

0
3. Adjusting LS valve
When the differential pressure is measured un-
der the conditions above, and the results show
that the differential pressure is not within the
standard value, adjust as follows.
1) Loosen locknut ( I ) and turn screw (2) t o ad-
just the differential pressure.
* Turn the screw to adjust the differential
pressure as follows.
To INCREASE pressure, turn CLOCK-
WISE
To DECREASE pressure, turn COUN-
TER-CLOCKWISE
* Amountofadjustmentforoneturn of
adjustmentscrew:Approx. 1.29 MPa
113.2 kg/cm2)
Note: Always measure the differential pres-
sure while adjusting.
2) After adjusting, tighten locknut.
Locknut: 58.8 - 78.5 Rlrn (5- 8 kgm)
20-120-2 PC300, 350-6

0
TESTING CONTROL CIRCUIT OIL PRESSURE
TESTING
AND ADJUSTING (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED)
TESTING CONTROL CIRCUIT

OIL PRESSURE (OIL PRESSURE
WHEN SELF-PRESSURE IS RE-
DUCED)
Measuring
Ir Oil temperature when measuring: 45 - 55°C
stop the engine. Loosen the oil filler cap s!ow!y
to release the pressure insidethe hydraulic tank.
tion.
1. Remove oil pressure measurement plug (2) (PTI/

8) from LS-EPC solenoid valve block ( I ) .
2. Install nipple C2, then connect oil pressure gauge

C1 (5.8 MPa {60kg/cm21).
3.
PC300, 350-6 20-121

0
TESTING AND ADJUSTING TESTING
SOLENOID
VALVE
OUTPUT
PRESSURE
TESTING SOLENOID VALVE

OUTPUT PRESSURE
1. Measuring output pressure of LS-EPC solenoid
valve
1) Disconnect output hose (1) of the LS-EPC
solenoid valve.
2) Installadapter C3 and nipple C2 in the oil
pressure gauge kit, and install oil pressure
gauge C1 (5.8 MPa (60 kg/cm*))
3) Measure the output piessiiie tinder the COG-
ditions in Table 1.
Table 1
Operation and Engine speec Output [Reference]
working mode (rpm) pressure Current (A)
MPa{kg/cm21)
= All control
levers at Min. 1500
neutral
0 H/O mode or
G/Q mode
Operate any Min. 1900 0 0
control lever IO} IO1
with travel at
neutral
* The enginespeed and LS-EPC currentcan be
measuredusingthemonitoringcodeonthe
monitor panel.
Enginespeed : [IO]or [401
LS-EPC current : [I51
20-1 22 PC300, 350-6

0
TESTING
ADJUSTING
ANDTESTING SOLENOID VALVE OUTPUT PRESSURE
2. Measuring output pressure of ON/OFF solenoid

valve
1) Disconnectoutlet hoses ( l ) , (21, (31,(41, (5)
and ( 6 ) of the solenoid valve to be meas-
ured.
2) Install adapter C3 and nipple C2, and install
oil pressure gauge C1 (5.8 MPa (60 kg/cm2)).
3) Measure the output pressure under the con-
ditions in Table 2.
I\ BWP02986
c3
PC300, 350-6 20- 123

0
TESTING AND ADJUSTING TESTING SOLENOID VALVE OUTPUT PRESSURE
Table 2
Condition of Oil pressure
Solenoid
Measurement
conditions
Operating
conditions
solenoid {kg/cm2})
(MPa
Boom under spool Min. 2.74 {281
Active mode switch OFF stroke 9 mm ON
Active
Boom under spool OFF 0 IO)
Active mode switch ON stroke 11.5 rnrn
When machine
push-up switch is at
Safetyvalve at high- OFF
Machine high-pressure setting setting pressure 0 {OI
push-upWhenmachinepush-upswitch is atSafetyvalve at b w - ON Min. 2.74 {283
setting
pressure
setting
low-pressure
Pump
Travel
operated
independently
pumps
divided
rear Flow from front and ON Min. 2.74 (281
merge/
divider Flow from front and
valve All levers at neutral OFF
I 1 rear pumps merged 1 I
Whenoperatetravellever with travelMotor swash Plate ON Min. 2.74 (283
speed
switch
Hiat or Mi angle at MIN
~~~~~l
. .
speed 1Travelspeedswitchat Lo
Motor swash plate
angle a t MAX OFF 0 IO)
Swing spool stroke

Active mode switch OFF 9.5 mrn OFF 0 (01
Active
(swing) I Active
mode
switch ON ISwing spool stroke
boom raise lever FULL (durina operation) 7.0 rnm 1 ON 1 Min. 2.74 {28)
With monitoring code (23),check at the same time that the solenoid is switched ON/OFF electri-
cally.
(The machine push-up solenoid is not displayed.)
The measurement conditions in the table are typical conditions for measuring the output
pressure.
The solenoid valve may be actuated (ONIOFF) underconditionsother than themeasurement
conditions given above.
Operate the lever slightly not enough to move the machine.
20-1 24 PC300, 350-6

0
MEASURING PPC VALVE OUTPUT PRESSURE AND
TESTING
ADJUSTING
AND TESTING PPC SHU'ITLE
VALVE
MEASURING PPC VALVE

OUTPUT PRESSURE AND
TESTING PPC SHUlTLE VALVE
1. Measuring PPC valve output pressure
1) Disconnect hose(1) of the circuit tobe meas-
u red.
2 ) Install adapter C3 and nipple C2.
3) Installoilpressuregauge C1 (5.8 MPa (60
kg/cm211.
4) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
and measure the oil pressure.
2. Checking PPC shuttle valve

* Iftheoutput pressure at the controtvalve
end is low, check for leakage of oii from the
PPC shuttle valve as follows.
1) Disconnect hose (1) between the PPC valve
andtheshuttle valve of the circuit to be
measured.Disconnect thehosefromthe
shuttle valve together with the nipple.
2) Install adapter C5 and nipple C2 to the tip of
the hose, then install oil pressure gauge C1
(5.8 MPa I60 kg/cm2)).
* lnstali a blind plug to the shuttle valve.
3) Run the engine at full throttle, operate the
control lever, and measure the output pres-
I
sure.
* If the output pressure becomes normal,
there is leakage from the PPC shuttle
valve; if there is nochange, the PPC valve
is defective.
PC300, 350-6 20- 1 25

0
MEASURING PPC VALVE OUTPUT PRESSURE AND
TESTING AND ADJUSTING TESTING PPC SHUlTLE VALVE
3. Checkingdefectiveoperationof PPC shuttle

va Ive
1) Remove the applicable oil pressure switch,
P r e s s u r es w i t c h
then install nippleC2 and oil pressure gauge a r r a n g e m e ndt i a g r a m
C1 (5.8 MPa (60 kg/cm2)).
*
Disconnect the outlet hose of the LS se-
Swing
608)
lect shuttle valve before installing the oil B u c k eCt U R L
pressure gauge. 606)
B u c k e t DUMP
2) Run the engine at full throttle, operate the 607)
applicable lever, andmeasure theoutput
pressure.
Sr Ifoutput pressure is generated forall A r m IN
theapplicable operations, theshuttle (SO51 Boom LOWER
604)
valve is normal.
.k If no output pressure is generated all the
applicable operations, the shuttle valve
is defective. ArmOUT
(S03)
0: Swing left, right shuttle valve
0: LS select shuttle valve (boom RAISE, arm OUT, /
all travel)
0: Boom RAISE, arm OUT shuttle valve B o o mR A I S E
0: L.H. travel FORWARD, R.H. travel REVERSE shut- 602)
tle valve
0:
*
All travel shuttle valves (L.H.,R.H.FORWARD,
REVERSE)
@: L.H. travel REVERSE, R.H. travel FORWARD shut-
tle valve
1 TWPO I402
R. H. w o r k euuioment
PPC s h u t t l e .
t r a v e jl u n c t i o nv a l v e
PPC v a l v e
(From t o o )
TWPO I403
20- 126 PC300, 350-6

0
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT,

SWING PPC VALVE
* If there is excessive play in the work equipment
or swing lever, adjust as follows.
to release the pressure inside the hydraulic tank.
Then set the safety lock lever t o the LOCK posi-
tion.
1. Remove the PPC valve assembly.

For details, seeDISASSEMBLY AND ASSEM-
BLY, Removal of work equipment PPC valve as-
sembly.
2. Remove boot ( I ) .
3. Loosen locknut (21, then screw in disc (3) until it

contacts the 4 heads of piston (4).
*When doing this, do not move the piston.
(I
4. Secure disc (3) in position, then tighten locknut
(2) t o the specified torque.
~ t - 127 Nm {1Q - 13 kg@
L ~ c k n 198
BWPO3619
5. Install boot ( I ) .
* Withtheaboveadjustment,the clearancebe-
tween disc (3) and piston (4) becomes 0.
PC300, 350-6 20- I 27

0
TESTING AND ADJUSTING TESTING
DEVIATION
TRAVEL
TESTING TRAVEL DEVIATION

Sr When traveling on level ground. ~ Travel posture
'I. Set the machine in the travel posture.
Sr For the travel posture, extend the bucket and
arm cylinder rods fully, and hold the boom
angle at 45".
2. Travel for 10 m, then measure thedeviation

when traveling for the next 20 m.
*Set to H/O mode and measure with the en-
gine ai full throttle.
-Ir Installthehydraulicpressuregaugeand
BKP00156
measure the pump discharge pressure a t the
same time.
tMake a mark
t
Make a mark at the
1Om midway point
z
Make a mark
10m midway point

Lay out a string
point20m \
distance a atthispointMark
BLP00157
20- I 28 PC300, 350-6

0
TESTINGANDADJUSTINGTESTINGLOCATIONSCAUSINGHYDRAULICDRIFT OF WORK EQUIPMENT
TESTING LOCATIONS
CAUSING HYDRAULIC DRIFT
OF WORK EQUIPMENT
* If there is any hydraulic drift in the work equip-
ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checkingfor defective cylinder packing
1) Checking boom and bucket cylinders
i) Set in the same posture as when meas-
uringhydraulic drift, andstoptheen-
gine. BKWO158
ii) Operate the boom control lever to RAISE
or the bucket control lever to CURL.
If thelowering speed increases, the
packing is defective.
If there is no change, the boom lock
valve(boom) or thecontrolvalve
(bucket) is defective.
2) Checking armcylinder
I) Operate the arm cylinder to move the
arm in fully, then stop the engine.
ii) Operate the control lever to arm IN.
If thelowering speed increases, the
packing is defective.
e If there is n o change, thecontrol
* valve is defective.
If thepressure in theaccumulator
hasdropped, run theenginefor
I BKPO0159
approx. 10 seconds to charge the ac-

cumulator again before operating.
[Reference] If the cause of the hydraulic drift is
in the packing, and theabove opera-
tioniscarriedout,thedownward
movement becomes faster for thefoi-
lowing reasons.
If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil a t the bottom end leaks to
the head end. However, the volume at the
head end is smaller than the volume a t the
bottom end by the volume of the rod, so the
internal pressure at the head end increases
because of the oii fiowing in from the bot-
tom end.
When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
When the pressure is balanced, the down-
ward movement becomes slower. If the le-
ver is then operated according to the proce-
duregiven above, thecircuitatthe head
end is opened to the drain circuit (the bot-
tom end is closed by the check valve), so
the oil at the head end flows to the drain
circuitandthedownwardmovementbe-
comes faster.
PC300, 350-6 20-1 29

0
TESTINGANDADJUSTINGTESTINGLOCATIONSCAUSINGHYDRAULICDRIFT OF WORK EQUIPMENT
2. Checking boom lockvalve

A S e t theworkequipment a t the maximum
reach, and the top of the boom horizontal,
I
then stop the engine.
Lock the work equipment controllevers and
release the pressureinside thehydraulic
tank.
Disconnect pilot hose (1) of the boom lock
valve and drain hose (21, and install a blind
plug in the hose.
Ir Pilot hose side blind plug: 07376-50315
* Blind plug for drain hose:07376-50522
9r Leave the boom lock waive end open.
Starttheengine,chargetheaccumulator, BKP00572
then stop the engine.
Operatetheboomcontrollevertothe
LOWER position.
* If any oil leaks from the port that is left
open, the boom lock valve is defective.
* Whendisconnect hoses, take care to
spout of oil and movementofwork
equipment, and loosen them gradually.
3. Checking PPC valve

If the hydraulic drift differs when thesafety lock
lever is in the LOCK or FREE position, (engine
running), the PPC valve is defective.
20-130 PC300, 350-6

0
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

* Oil temperature when measuring: 45 - 55°C I Posture for measuring boom cylinder
1. Work equipment cylinder

* If the hydraulic drift of the work equipment
is outside the standard value, measure the
leakage inside the cylinder as follows, and
judge if the cause of the hydraulic drift is in
the cylinder or in the control valve.
* Ifthe leakage iswithinthestandard
value, the problem is in the control valve.
0 If the leakage is greater than the stand-
ard value, the problem is in the cylinder.
1) Fullyextend the rod of the cylinder to be
-2T5 BLPOO161
measured, then stop the engine.

2) Disconnect piping (1) at the head end, then
Posture for measuring arm, bucket cylinder
block the piping at the chassis end with a
Adg:!zeful not to disconnect the piping

at the bottom end.
3) Start theengineandapplythereliefpres-
sure to the bottom end of the cylinder with
the engine at full throttle.
.k Boomcylinder : RAISE
Armcylinder : IN
Bucket cylinder : CURL
4) Continue this condition for 30 seconds, then
BLPOO162
measure theoil leakage for the nextone
minute.
Boom cylinder/ II 1 I
Arm cylinder
I
I BLP00164
PC300, 350-6 20-131

0
TESTING AND
EASURING
ADJUSTING LEAKAGE OIL
I Bucket cylinder
I BLW0165
n Disconnect
2. Swing motor
1) Disconnectdrain hose (1) fromtheswing
motor, then install a blind plug at the tank
end.
2) Turn the swing lock switch ON.
3) Start the engine and operate the swing re-
lief with the engine at full throttle.
measurethe oil leakage forthenextone
minute.
* Aftermeasuring,swing 180" and meas-
ure again.
20-132 PC300, 350-6

0
TESTING AND
ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
3. Travel motor
1) Disconnectdrain hose (1) fromthetravel
motor, then fit a blind plug at thehose end.
2) Fit block @ I the track shoe grouser, or
under
fit block @ between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at full throttle.
bb,Whenmeasuringtheoil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always use signals andcheck
when carrying out this operation.
measuretheoil leakage forthenextone
minute.
* When measuring, move the motorslightly
(to changethepositionbetweenthe
valve plate and cylinder, and piston and
cylinder!, and zeasure several times.
BLP00170 BLPOO171
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
* 16 the piping between the hydrau!Ic cy!Inder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oit filler cap.
1. Loosen the oil filler cap slowlyto release the
pressure inside the tank.
2. Operate the control levers.

* When the levers areoperated 2 - 3 times,
thepressurestoredin the accumulator is
removed.
3. Start the 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.
PC300, 350-6 20-1 33

0
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE
BEARING
TESTING CLEARANCE OF
SWING CIRCLE BEARING
Method of testing clearance of swing circle bearing Revolvingframe]
when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle
(or inner circle) of the swing circle, and put the
tip of the probe in contact with the inner circle
(or outer circle)*
Set the dial gauge at the front or rear.
I BLW0172
2. Extend the work equipment to the maximum

reach, and set the tip of the bucket to the same
height as the bottom of the revolving frame.
When this is done, the upper structure will tilt
forward, so the front will go down and the rear
will rise.
3. Set the dial gauge to the zero point.

1
’//////////////////
BKPO0173
4. Set the arm more or less at right angles to the

ground surface, then lower the boom until the
front of the machine comes off the grmnd.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
down.
5. Read the value on the dial gauge a t this point.

The value on the dial gauge is the clearance of
the swing circle bearing.
A W h e n carrying out the measurement, do not
put your hand or feet under the undercar-
riage.
I BKP00174
6. Return to the condition in Step 2, and check that

the dial gauge has returned to the zero point. If
it has not returned to thezero point, repeat Steps
3 to 5.
20- 1 34 PC300, 350-6

0
TESTING AND ADJUSTING TESTING WEAR OF SPROCKET
TESTING WEAR OF SPROCKET
1. Remove the track shoe assembly.

fl For details, see TESTING AND ADJUSTING,
REMOVAL OF TRACK SHOE ASSEMBLY.
2. Align wear gauge P with the sprocket.

fl Align the benchmark line, then align the
sprocket wave pattern and wear gauge wave
pattern.
3. Judge the wear of the sprocket.

fl If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
fl If the sprocket wave pattern has reached the
wear limit line, replace the sprocket with a
new part.
PC300, 350-6 20-135

1
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
TESTING
1. Travel the machine forward by the length of
track on ground, keeping the engine at low idling,
and stop the machine slowly.
2. Place straight bar [1] on the track shoe between

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

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

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

Add grease through grease fitting (2).
fl If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
20-136
20-136 PC300, 350-6
1
6
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations andprocedure for bleeding air
. -
Air bleeding item Air

procedure
bleeding
1 2 3 4 5 6
Bleeding air Bleeding air from Bleeding air fromBleeding air from start
Nature of w o r k from pump start engine cylinder swing motor trave/ motor Operations
Replace return
filter element I I
I
I
I
I
I
Replace,
pumprepair 0 -
I . 0 ~ I 0 I I+ 0
Remove suction piping 1
I
control
* Replace, repair valve I I> 0
Replace cylinder
Remove cvlinder DiDina
9
Reoplace swing motor
I . . -
Remove swina motor Dipinn I
I
10-0-0
I
1
I
I I
I
I I
I
I
Replace travel motor, swivel I I I
>
Remove travel motor, swivel piping I I I 0 L I O
Note: Bleed the air from the swing and travel motors only whenoilthe
inside the motor case has been drained.
1. Bleeding air from pump

Loosen air bleed plug (11, and check that oil
oozes out from the plug.
When @I! QOZS out, tighter? plug(’!).
Air bleed plug:
-
7.8 9.8 Nm l0.8 3.0 kgm! -
If no oil oozes out from the air bleed plug:
Leave plug (1) loosened and remove drain
hose (2) and elbow (3).
Pour in oil through the elbow mount hole
until oil oozes out from plug (1).
Fit elbow (3)and install drain hose (2).
Tighten air bleed plug (1).
Air bleed plug:
-
7.8 9.8 Nm 10.8 1.0 kgm) -
Precautions when starting the engine
After csmpieiing the above procediire m d
starting the engine, run the engine at low
idling for 10 minutes.
If the coolant temperature is low and auto-
matic warming-up is carried out, cancel it by
using the fue! contrs! dial after starting the
engine.
PC300, 350-6 20-137

0
TING TESTING AND AIR BLEEDING
2. 5leeding air from hydrauliccylinders 1 Boom cylinder

1) Start the engine and runa t idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 - 5 times in succession.
* Operate thepistonrodto approx. 100
m m before the end of its stroke. Do not
relievethecircuitunderanycircum-
stances.
3) Run theengineat full throttleandrepeat
Step 2). After that, run the engine at !ow
idling, and operate the piston rod to the end I BLP00179
of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air from
the arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful notto operate the cyl-
inder to the end of its stroke when the pis-
ton rod has been connected to the LOWER
end of the boom cy!inder.
3. Bleedingair from swing motor

1) Insidemotor case
Run the engine at low idling for 5 minutes.
* Thisoperation will bleedtheairinside
the motor case automatically.
2) Insidebrake case
* Normally, the air inside thebrake case is
bled automatically, but if it feels that the
brake i s draggingwhenoperatingthe
swing, bleed the air as follows.
Loosen the sleeve nut of brake hose (11, start
the engine, andoperatetheswingprolix
switch ON-OFF repeatedly. When oil oozes
out, tighten the sleeve nut.
4. Bleedingair from travel motor

1) Run the engine at low idling, loosen air bleed
plug (11, and check that oil oozes out from
the plug.
2) Whenoil oozes out, tighten air bleed plug
(1) again.
Air bleed plug:
- -
7.84 9.8 Nm (0.8 1.0 kgm)
20-138 PC300, 350-6

0
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20-202

Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ...................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Connector types and mounting locations .......................................................................................... 20-214
Connector arrangement diagram ........................................................................................................ 20-216
Connection table for connector pin numbers .................................................................................... 20-219
Explanation of control mechanism of electrical system ................................................................... 20-229
Display method and special functions of monitor panel .................................................................. 20-230
Method of using judgement table ....................................................................................................... 20-239
Method of using troubleshooting charts ............................................................................................ 20-241
Details of troubleshooting and troubleshooting procedure ............................................................. 20-243
Service code table ................................................................................................................................. 20-248
Troubleshooting of communication abnormality system (N mode) ............................................... 20-301
Troubleshooting of engine throttle, pump controller (governor control system) (E mode) ........ 20-351
Troubleshooting of engine system (S mode) .................................................................................... 20-401
Troubleshooting of engine throttle, pump controller (pump control system) (C mode) ............. 20-451
Troubleshooting of engine throttle, pump controller (input signal system) (F mode)................. 20-501
Troubleshooting of hydraulic, mechanical system (H mode) .......................................................... 20-551
Troubleshooting of machine monitor system (M mode).................................................................. 20-601
PC300, 350-6 20-201

5
1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

A Stop the machinein a level place, and check thatthe safety pin, blocks, and parking brake are securely fitted.
A 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.
A If the radiator cap is removed when the engine is hot, hot water may spurt outand cause burns, wait so for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A When removingthe plug or cap from a locationwhich isunder pressurefrom oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carryingout troubleshooting, and importantpoint isof course to understand the structure and function.
However, a short cut to effective troubleshootingis to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1; When carrying out troubleshooting, do not hurry 4.1 Check the stroke of the control valve spoo!.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item thatis considered
failure occurs: to be necessary.
0 Parts that havenoconnection with thefail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirmtheextent of thefailureyourself,
sembled. and judge whetherto handle it as a real fail-
It will becomeimpossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or It Whenoperating the machine to reenact
oil or grease, and at thesame time, will also lose thetroubleshootingsymptoms,do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it isnecessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in Usetheresults of theinvestigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to askuser or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Wasthere anythingstrangeabout the ma- It Thebasicprocedure fortroubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from thesimplepoints.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigateotherrelatedparts or in-
4) Under what conditions did the failure occur? formation.
5 ) Hadanyrepairsbeen carried out before the 6. Measures to remove root cause of failure
failure? Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Hasthesame kind of failureoccurredbe- will occur again.
fore? To prevent this, always investigate why the
3. Checkbefore troubleshooting problem occurred.Then,removethe root
1) Check the oil level cause.
2 ) Check foranyexternalleakage of oil from
the piping or hydraulic equipment.
3) Checkthe travel of the control levers.
20-202 PC300, 350-6

0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Jobsite
TEW00181
Step 1
]Examination, confirmation of symptoms I
1) When a request for repairs is received, first
*
-
ask the following points.
Nameofcustomer
Type,serialnumber ofmachine
------- Ring! R i n e !
* Detailsofjobsite,etc.
2) Ask questions to gain an outline of the prob-
lem. -
* Condition of failure
* Work being carried out at the time of the TEWOO 182
failure
Operating environment
Past history, detailsof maintenance, etc.
.I
Step 2 TEPO I 3 4 8
IDetermining probable location of causej
1) Lookatthetroubleshootingsection of the
shopmanual to flnd locations o i POSSlble
causes.
TEPO 1 3 5 0
Step 3
IPreoaration of troubleshootina toolsl
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
-
tools.
T-adapter
iiydrauiic pressure gauge kit, etc.
2i Look in ihe paris book and prepare the aec-
essary replacement parts.
r TEPOl349
1) Before starting troubleshooting,locateand

repair simpie faiiures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual,selectatroubfeshootingflowchart
that matches the symptoms, and carry out
\
\ Driveandoperatethemachinetoconfirm
Shor, m a n u a l condition
the and judgereally
if there
is a
failure.
--"A,"-*
ItYUI53I
Step 4
1-
operator questions to confirm details of] n 00 n
Was there anything strange about the ma-
chine before the iaiiure occurredi
TEWOO I89
-
* Didthefailureoccursuddenly7
Had any repairs been carried out before the
It i failure7 TEWOO 19(
PC300, 350-6 20-203

0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs mustbe carriedout. This sectiondeals particularly withcorrect repair proceduresfor mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling
electric equipment" and "Handling hydraulic equipment" (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUfPMENT
3) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component t o another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes orcases, wiring harnesses are more
likely to be affected by the directeffects of rain,
water, heat, orvibration.Furthermore,during
inspection and repair operations, they are fre-
quentlyremovedandinstalled again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremelycare-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

@ Defectivecontactofconnectors(defective
contact between male and fema!e!
Problems with defective contact are likely to
improper inseriion
I
occurbecause themaleconnector is not
properly inserted into the femaleconnector,
or because one or both of the connectors is
deformedorthepositionisnotcorrectly
aligned,orbecause thereiscorrosionor
oxidization of the contact surfaces.
TEPOt352
@ Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at thecrimpedterminal or
solderedportion, but if there is excessive
force broughtto bear on the wiring, the plat-
ing a t the joint will peel and cause improper
connection or breakage.
TEP01353
28-204 PC300, 350-6

0
0 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are liftedwith a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
@ High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
~ e c i o r ,depwding on the dirzctioi; of the
water jet.
As already said, the connector is designed
to prevent water from entering, but a t the
same time, if water does enter, it is difficult
for it to be drained.Therefore, if water should
b
get into theconnector, the pins will be short- T E W O O I95
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
@ Oil or dirt stuck to connector

If oil or grease arestuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blowit dry
with compressed air and sprayit with a con- I TEWOO 196
tact resrorer.
* When wiping the mating portion of the
connector, be careful not t o use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
PC300, 350-6 20-205

0
2) Removing, installing, and drying connectors and

wiring harnesses
0 Disconnecting connectors
0 Hold the connectors when disconnecting. Press lightly
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by ascrew, 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 puli the con- TEPOf354
nectors apart.
Jr Never pull with one hand.
@ When removing from clips

When removing a connector froma clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
~r to the !e??or right, the housing may
break.
TBW00484
TBPO I355
C$ 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.
k If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contactto occur, so always cover
the connector.
TEWOOl98
20-206 PC300,350-6
0
TROUBLESHOOTING
e Connecting connect~rs
@ Check the connector visually.
Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
Check that there is no deformation, de- CIiks i n t o position
fective contact, corrosion, or damage to
the connector pins.
Check thlt thew is ne damage nr break-
age to the outside of the connector.
If there is any oil, water, or dirt stuck t o
the connector, wipe it off with a dry cloth. TEP01356
If any water has got inside the connec-
tor, warm the insideof 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.
@ FIX the ccnnecttc: securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lockstopper, push in
theconnectoruntil the stopper clicks into
position.
I I TEW00200
@ Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fittedwith boots, correct any
protrusionoftheboot.Inaddition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct ps-
sition.
* If the connector cannot be corrected eas-
ily,removetheclampandadjustthe
position.
@ If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. TBW00487
PC300,350-6 20-207
0
TROUBLESHOOTING
0 Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with com- I TEW00196
pressed air, there is the risk that oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
@ Dry the inside of the connector witha dryer.

If water gets inside the connector,
use a dryer
to dry theconnector.
* Hot air from the dryer can be used, but
regulate the time that the hot air used
is
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
TEW00202
@ Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any shortcircuitsbetweenpins
caused by water.
Ir Aftercompletelydryingthe connector,
blow it with contact restorer and reas- 7,
semble.
T-adapter
TEP01357
20-208 PC300, 350-6

TROUBLESHOOTING POINTSREMEMBER
TO WHEN CARRYING OUT MAINTENANCE
3) Handling control box

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.
Do not open the cover of the control box
unless necessary.
Do not place objects on top of the control

box.
Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contactswith your
hand.
During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
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).
Precautions when carrying out arc welding
When carrying outarc welding on the body,
disconnect all wiring harness connectors con-
nected to the controlbox. Fit an arc welding
ground close to the welding point.
11 TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectorsare properly inserted.
+- Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity,or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
* If there is any change, there is probably defective contact in that circuit.
PC300, 350-6 20-209

0
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most commoncause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
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.
I
Disassembly and maintenance work in thefield

If disassembly or maintenance work is carried
out on hydraulic equipmentin 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. Disaa-
semblyand main-tenanceof hydraulicequip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmedwith special test equipment.
Sealing openings
I TEW00207
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 en-
tering. 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 leak-
ing oil so never do this.
Do not simply drain oil out on t o the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
i TEW00208
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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
I TEW00209
20-210 PC300, 350-6

0
5) Changehydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change theoilwhen it isstill
warm. When changing the oil, as much as pos-
sibleof the old hydraulic oil must bedrained
out. (Draii-1 the oil from the hydragliC task; also
drain the oil from the filter and from the drain
plug in thecircuit.) If any oldoilis left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
I
6 ) Flushingoperations
After disassembling and assembling the equip-
ment,orchangingthe oil, use flushing oil to
removethecontaminants,sludge,andoldoil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaningoperations
After repairing the hydraulic equipment (pump,
control valve, etc.) or whenruaning the ma-
chine, carry out oilcleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3y) particles that the filter
builtintothehydraulicequipmentcannot re-
move, so it is an extremely effective device.
TEWOOP 1 1
PC300, 350-6 20-21 1

0
CHECKS
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Action

lalue
I
1. Check fuel level, type of fuel - Add fuel
2. Check for impurities in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydrauiic strainer - Clean, drain
5. Check swing machinery oil level - Add oil
6. Check engine oil level (oil pan oil level), type of oil - Add oil
7. Check coolant level - Add water
8. Check dust indicator for clogging - Clean or replace
9. Check hydraulic filter - Replace
1. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wiring __ Tighten or replace
3. Check for looseness, corrosion of starting motor terminal, wiring - 1 Tighten
replace
or
-
I
1. Check torabnormal noise, smell Repair
2. Check foroil leakage - Repair
3. Carryoutairbleeding - Bleed air
1. Check batteryvoltage(enginestopped) 20 - 30V Replace

2. Check batteryelectrolytelevel - Add or replace
3. Check fordiscolored,burnt,exposedwiring - Replace
4. Check for missing wiring clamps, hanging wiring - Repair
5. Check for water leaking on wiring (be particularly careful attention - Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check forblown,corrodedfuses - Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) fter running Replace
for several
minutes:
17.5 - 29.5V
8. Check operating sound of battery (when switch is turned ONIOFF) - Replace
20-21 2 PC300, 350-6

0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

fl The Address column in the table above shows the address in the connector arrangement drawing
(2-dimensional drawing).
Con- No. Add- Con- No. Add-

nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
AC1 — 20 Air conditioner (external air system) O-1 E11 X 2 Electrical intake air heater relay J-4
AC2 — 4 Air conditioner (control system) O-1 F01 X 2 Travel alarm (option) A-3
C01 MIC 13 Engine throttle, pump controller D-1 H12 S 16 Intermediate connector F-2
C02 MIC 21 Engine throttle, pump controller C-2 H13 S 16 Intermediate connector C-8
C03 040 20 Engine throttle, pump controller E-1 H14 M 6 Intermediate connector C-8
C04 X 2 Rear pump TVC solenoid valve I-5 H15 L 2 Intermediate connector F-2
C05 S 10 Pump prolix circuit switch N-1 M02 X 2 Starting motor L-2
C06 M 2 TVC prolix resistor O-1 M06 M 3 Heater fan switch (option) —
C07 X 3 Rear pump pressure sensor D-9 M07 M 2 Light switch N-4
C08 X 3 Front pump pressure sensor D-9 M08 M 1 Right front light A-4
C09 S 8 Model selection connector P-2 M09 M 1 Working lamp (boom) B-8
C10 X 2 LS-EPC solenoid valve I-5 M10 M 1 Intermediate connector C-2
C13 X 2 Front pump TVC solenoid valve I-5 M11 L 2 Fusible link —
C16 MIC 17 Engine throttle, pump controller E-1 M12 KES1 3 Heater (option) E-1
D-8
C17 040 16 Engine throttle, pump controller D-1 M13 KES0 2 Speaker P-4
D01 KES1 2 Window washer circuit — M14 L 2 Fusible link —
D02 KES1 2 Active (swing) solenoid curcuit — M16 — 1 Horn (high tone) B-3
D03 KES1 2 Active (boom) solenoid curcuit — M17 — 1 Horn (low tone) A-3
D04 KES1 2 Pump merge/divider solenoid circuit — M18 M 4 Wiper, washer switch N-4
D05 KES1 2 Swing holding brake solenoid circuit — M20 — — Cigar lighter M-4
D06 KES1 2 Machine push-up solenoid circuit — M21 PA 9 Radio O-2
F-1
D07 KES1 2 Travel speed selector solenoid circuit — M22 M 2 Intermediate connector P-7
F-2
D08 KES1 2 Heater circuit — M23 M 2 L.H. knob switch O-6
D11 KES1 2 Alarm buzzer circuit — M23 M 2 Horn switch O-5
D13 KES1 2 Battery relay drive circuit — M26 — 6 Air conditioner F-3
D14 KES1 2 Diode — M28 KES0 2 Window washer motor I-4
D17 KES1 2 Diode — M33 250 3 Power window switch —
D26 KES1 2 Swing holding brake solenoid — M34 X 1 Electromagnetic clutch for air conditioner compressor J-1
E04 X 3 Governor potentiometer F-8 M35 — 2 Condenser for air conditioner B-2
E05 X 4 Governor motor F-9 M38 M 2 Machine push-up switch N-5
E06 M 3 Fuel control dial M-4 M40 M 1 Right front light (option) K-8
E07 X 2 Engine speed sensor J-5 M41 M 1 Left front light (option) K-7
K-1
E08 SWP 14 Intermediate connector I-6 M42 M 1 Rear working lamp I-6
20-214 PC300, 350-6

5
1
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
Con- No. Add- Con- No. Add-

nector Type of Mounting location nector Type of Mounting location
ress res
No. I Dins I
I ' I
No. Dins
M44 I SWP I 6 I Intermediateconnector for automatic lubrication (optioni B-3 SW1 - 20 Air conditioner control panel P-2
I M45 IM I 3 I Network
bus I L-1 I vo2 x LS select solenoid valve
A-5
2
H-8
8-7
M46 M 3 For troubleshooting K-3 V03 2 Pump mergeidivider solenoid valve
X
C-8
M47 16 040
Troubleshooting [with power window) M-4 2 Swing
X holding brake solenoid valve
V04
H-8
V05 X 2 Machine push-up solenoid valve c-8
M65 M
A-4 2 Fusible link for automatic lubrication ioption) 8-8
V06 X 2 Travel speed selector solenoid valve
M66 - 1 Warning lamp for automatic lubrication - I V07 / X I 2 1 Active(swing)solenoid I J-6 I
M67 - 1 Warning lamp for automatic lubrication - I WO1 1 KESl 1 4 I Right front lock (option,with power window) I L-9 I
M68 6 Automatic lubrication system (option) -
SWP WO2 KESl 4 Left front lock (option, with power window) P-8
M71 - 1 Intermediate connector (room lamp) K-7 W03 1 Intermediate connector N-9
$;:c:otr
I M80 I- I 2 I Externalairsensor(option) 1 A-6 1 W04 M 6 Wiper motor K-2

K-6
1 PO1 I040 20 I Monitor I L-3 ! ! W05 I KESl 1 2 I Power window motor (with power window)1 - I
L-3
PO2 040 16 Monitor L-3 W06 070 14 Intermediate connector (withpower window) N-5
PO3 M 2 Buzzer cancel switch N-4 W07 KESl 2 Front limit switch (with power window) -
PO4 M 2 buzzer L-3 Alarm

W08 18 Wiper
070 motor controller N-I
IT05 x 1 Engine oil level sensor K- 1 WO9 14 Wiper

070 motor controller [withpower window] 0 - 1
PO6 X 1 h e ! level ssnsor A-5 W10 M 4 Intermediate Connector (with power window) N-1
I PO7 IX I 2 Enginecooianttemperature SeiiSOil 1-3 I w 1 2 1- I 3 Power wiiib0.y;.switch I -
c-2
PO8 X 2 Radiator water level sensor D-9 MIC 21 connector
X01 Intermediate 0-5
PO9 x Hydraulic oil level sensor 1 1-4 X05 M 4 Swing lock switch M-4
P11 - 1 Air cleaner clogging sensor - X07 MIC 17 Intermediate connector P-3
I PI2 I- 1 1 I Aircleanercloggingsensor 1 - I
I I
I I I
i
1
41 SO8 2 X
so9 x
2
2
Bucket DUMP pressure switch
Swing
pressure
switch
Service
pressure
switch (option)
G-2
1 [i
PC300, 350-6 20-21 5
0
TROUBLESHOOTING CONNECTOR
DIAGRAMARRANGEMENT
CONNECTOR ARRANGEMENT DIAGRAM
20-216 PC300, 350-6

0
CONNECTOR
TROUBLESHOOTING ARRANGEMENT DIAGRAM
-t
El I
I Y
M34
BWP03003
PC300, 350-6 20-2 17

0
-4 -4
*
0 cv
I
m
0
-
3
X
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No.
of
T X type connector
pins Male (female housing) Female (male housing)
i
1
2'
'2
TEW00221 TEW00222
1 3 3 1
\
2 2
TEW00223 TEW00224
I 3
3 1
2 4
TEW00225 TEW00226
PC300,350-6 20-219
0
m
cn P LJ
$
ii
0
h
!2 UI
I VI
)[ c
--)I
u) m
m
C
N 0
b N
u.o z
3 -ho
v,
a
Q
0
Ir)
(3
0
'
0
(3
2
P w N z
-"?
N
w
W m W
< <
r I- 5
0 0
-
- -- z
m
N
e 4 w
0
k
ri
I N
m m
< m I-
r <- D
0 r- 0
- 0
&
- P
8
e a N
w
10
.i
0
0
3
m
v)
illl
co
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL

SYSTEM
1. Explanation of machine control functions
The control mechanism for the electrical system consists of the monitor panel and engine throttle,
pump controller. The monitor panel and the engine throttle, pump controller input the signals that
are necessary, and together with the signals selected by the monitor panel, the engine throttle,
pump controller outputs or inputs the necessary signals and control the pump absorption torque
and engine output.
PC300, 350-6 20-229

5
1
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR

PANEL
1. Display on machine monitor
When the starting switch is turned on, all the monitor and gauge lamps light up for approx. 3
seconds, and the buzzer sounds for approx. 1 second. During this time, the monitor itself carries
out self diagnosis, and after it has finished, it returns to the normal display.
2. Recording of service codes and user code display function

1) All the abnormality data for the engine throttle, pump controller is sent to the monitor panel.
When the monitor panel receives this data, it records the abnormality data, and at the same
time, depending on the nature of the abnormality, it displays the user code on the time display
panel to advise the operator of the action to take.
However, in cases of abnormalities which are not urgent and do not require the user code to
be displayed, only the content of the abnormality is recorded, and no display is given.
2) Types of user code and system

E02 (TVC system)
E03 (Swing holding brake system)
E05 (Governor motor system)
fl For details of the service codes included in the user code, see the action taken by the
controller when an abnormality occurs, the symptoms on the machine or the judgement
table.
3) Displaying user code

If it becomes necessary to display the user code, the time displayed panel is automatically
switched to advise the operator to take the necessary action.
• Actual display (Example: Disconnection in the cancel solenoid system for the swing hold-
ing brake)
OFF OFF
OFF OFF User code OFF OFF OFF

BKP00077
20-230 PC300, 350-6

5
1
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL
FUNCTIONS OF MONITOR PANEL
4) Display of trouble data

The monitor panel records bothservice codes which are includedin the user code, and service
codes which are not included. This data can b e displayed on the time display as follows.
It For details of the service codes that are not included in the user code, see ACTION TAKEN BY
CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGE-
MENT TABLE
7
Time d Se r' v i c e m e t e r
I
T i m e swi
,
W o r k i n e mode
switch
J
Monitor Panel f r o n t M o n i t o r Panel r e a r TWPO1406
i) Method of displaying trouble data

Operation Display
1. To set t o the trouble data display 1. On the time display and service meter display, the serv-
mode, ice code and number of hours(service meter hours)
Keep the TIME switch + L.H. travel that have elapsed since the occurrence of the abnor-
speed switch pressed for 2.5 sec- mality are displayed.
onds. 0 Example of display : When E212 hasoccurred 12
Note: It is possible t o call it up at hours before (service meter)
the following times. 1) Display of service code 2) Display of elapsed time
11 In the normal mode
OFF
2) In the user code display mode OFF
3) In the machine data monitoring i I
mode
4) In the time adjustment mode
wY-v--v
OFF
OFF Service code OFF
OFF Elapsed ON
time data
2. To go to the next service code dis- EKPOO079
play, press the time switch + R.H.
woking mode switch.
3. To go back to the previous service 3) ff any abnormality exists at this time, the E mark is
code display, press the time switch dispiayed.
+ L.H. woking mode switch. OFF
OFF
Service code
time data
or the controller is carrying out
If there is an abnormality,
self diagnosis. the output
is shutoff, and E is displayed.
BKPOOOBO
PC300,350-6 20-231
0
TROUBLESHOOTING DISPLAY METHOD AND
SPECIAL FUNCTIONS OF MONITOR PANEL
Operation I Display
I
data dl$-
4, TQ finish with the trouble 4) If there is no abnormality code in memory
play mode, keep the TIME switch
+ L.H. travel speed switch pressed OFF OFF
for 2.5 seconds.
5. To erase thememory, keep the i I
time switchpressed, turn the start-
ing switch from OFF to ON, and
keep the time switch pressed for
5 seconds.
w-
w -
v
OFF O is dispiayed OFF - is dispiayed OFF
BKPOO081
3. Machine data monitoringfunction

The input signals from the sensors and the output signals to drive the solenoid are displayed on
the time display and service meter display.
i
T i m ed i s p l a y - Serv ic e meter
T i m e swi
Working m o d e
switch
Knob b u t t a ?
function
switch
Monitor panel front

1 M o n i t o r Panel rear TWPOt407
1) Method of displaying monitoring code

Operation I Display
~~~
To set to the machine data moni- 1. On the time displayand service meter display, the moni-
toring mode, do as follows. toring code and data are displayed.
Keep the time switch + knob but- Example of display
ton function switchpressed for 2.5 1) When engine speed is monitored (monitoring code
seconds. 10)
Note: This is possible at the fol- OFF OFF
lowing times.
1) Duringthenormalmode
i i
2) During the user code display
mode
3) Duringthetimeadjustment Y--wv-wv
OFF OFF Monitoring OFF Monitoring OFF
mode data code code
4) During the trouble data display (example of 1950 rpm)
mode BKP00083
20-232 PC300, 350-6

0
Operation Display
2. To go to the next monitoring code 2) When displaying bit pattern

display, press the time switch + • For monitoring codes 08, 20 – 24, 36, 37, 47 –
R.H. working mode switch. 49, 4A, display the bit pattern.
3. To go back to the previous moni- • Example of monitoring code 20
toring code display, press the time
OFF OFF
switch + L.H. working mode Displays
switch. y r w
4. To finish with the machine data
monitoring code mode, keep the
t e q
time switch + knob button func-
tion switch pressed for 2.5 sec- OFF OFF Displays OFF Displays bit OFF OFF
monitoring pattern
onds. code BKP00084
• The code No. is displayed in the monitoring

code portion, and the display lights up to dis-
play bit patterns (1) – (6).
2) Table of machine data monitoring codes

fl For details of the B in the Unit column, see the bit pattern chart in the next section.
No. Item Unit Name of component
01 Monitor model code — Monitor panel
02 Engine throttle, pump controller model code — Engine throttle, pump controller
03 Engine throttle, pump controller model code — Engine throttle, pump controller
08 S-NET component condition display B Engine throttle, pump controller
10 Engine speed 10rpm Engine throttle, pump controller
11 Pump discharge pressure (F) input MPa{kg/cm2} Engine throttle, pump controller
12 Pump discharge pressure (R) input MPa{kg/cm2} Engine throttle, pump controller
13 TVC current (F) output 10mA Engine throttle, pump controller
14 TVC current (R) output 10mA Engine throttle, pump controller

15 LS-EPC current output 10mA Engine throttle, pump controller
16 No. 2 throttle command 10mA Engine throttle, pump controller
20 Engine throttle, pump controller PPC oil pressure switch input signal (1) B Engine throttle, pump controller
23 Engine throttle, pump controller solenoid actuation B Engine throttle, pump controller
24 Input condition 1 of sensor for engine throttle, pump controller monitor warning B Engine throttle, pump controller
25 Input condition 2 of sensor for engine throttle, pump controller monitor warning B Engine throttle, pump controller
30 Fuel control dial input value 10mV Engine throttle, pump controller
31 Potentiometer voltage 10mV Engine throttle, pump controller
PC300, 350-6 20-233

5
1
fl For details of the B in the Unit column, see the bit pattern chart in the next section.
No. Item Unit Name of component
32 VBB voltage (battery voltage) 100mV Engine throttle, pump controller
33 Governor motor A phase current 10mV Engine throttle, pump controller
34 Governor motor B phase current 10mV Engine throttle, pump controller
35 Battery relay output voltage 100mV Engine throttle, pump controller
36 Engine throttle, pump controller input condition B Engine throttle, pump controller
37 Engine throttle, pump controller output condition B Engine throttle, pump controller
40 Engine speed 10rpm Engine throttle, pump controller
41 Coolant temperature sensor voltage 10mV Engine throttle, pump controller
42 Fuel sensor input voltage 10mV Engine throttle, pump controller
43 Battery charge input voltage 100mV Engine throttle, pump controller
47 Monitor panel output condition 1 B Monitor panel
48 Monitor panel input condition 1 B Monitor panel

49 Monitor panel input condition 2 B Monitor panel
4A Monitor panel input condition 3 B Monitor panel
4C Monitor panel input condition 4 B Monitor panel
20-234 PC300, 350-6

5
1
3) Bit pattern chart

As shown in the diagram below, the time display has bit numbers which light up to show that
the signal is being transmitted. (For details, see METHOD OF DISPLAYING MONITORING
CODE.)
OFF OFF
y r w
t e q
OFF OFF Code portion OFF OFF OFF
BKP00085
Code Content Bit Details (condition when lighted up)
(1) Engine throttle, pump controller connected (ID=2)

(2) Engine throttle, pump controller connected (ID=3)
(3)
08 Connection of S-NET components
(4)
(5)
(6)
(1) Swing switch ON

(2) Travel switch ON
Input condition of engine throttle, (3) Boom LOWER switch ON
20
pump controller PPC switches (4) Boom RAISE switch ON
(5) Arm IN switch ON
(6) Arm OUT switch ON
(1) Bucket CURL switch ON

(2) Bucket DUMP switch ON
Input condition of engine throttle,
(3) Swing lock switch ON
21 pump controller PPC switches and
(4) Service switch ON
other switches
(5) Model selection 5
(6) Swing prolix switch ON
(1) Model selection 1 GND connected

Input condition of engine throttle,
22 pump controller model selection
and other switches
(5) Kerosene mode input GND connected
(6) Knob switch ON
(1)
(2) Solenoid ON: Active mode (boom), OFF: Standard mode
Drive condition of engine throttle,
(3) Swing holding brake ON
23 pump controller ON/OFF solenoid
(4) Pump merge/divider solenoid ON
valves
(5) Actve mode (swing) solenoid ON
(6) Travel speed selector solenoid ON
PC300, 350-6 20-235

5
1
Code Content Bit Details (condition when lighted up)
(1) Above engine oil pressure sensor Lo set pressure

(2) Above engine oil pressure sensor Hi set pressure
Input condition 1 of sensor for
(3) Radiator water level sensor abnormal
24 engine throttle, pump controller
(4) Engine oil level sensor abnormal
monitor warning
(5) Hydraulic oil level sensor abnormal
(6) Air cleaner clogging sensor abnormal
(1)
(2)
Input condition 2 of sensor for
(3)
25 engine throttle, pump controller
(4)
monitor warning
(5) Auto greasing control abnormal
(6)
(1)
(2)
Input condition of engine throttle, (3)
36
pump controller (4)
(5) Starting switch ON
(6)
(1) Battery relay: Actuated

(2)
Output condition of engine (3)
37
throttle, pump controller (4)
(5)
(6)
(1)
(2) Alarm buzzer: when operated machine
(3) Wiper motor drive (R): when operated machine
47 Monitor panel output condition 1
(4) Wiper motor drive (L): when operated machine
(5) Window washer drive: when operated machine
(6)
(1) Wiper (ON) OFF

(2) Wiper (INT) OFF
(3) Wiper (washer) OFF
48 Monitor panel input condition 1
(4) Window limit switch OPEN
(5) Limit switch (P) OPEN
(6) Limit switch (W) OPEN
(1) KEY ON SW OFF

(2) Terminal BR Voltage Hi
(3) LIGHT SW OFF
49 Monitor panel input condition 2 (4) Preheating switch OFF
(5) START C Sometimes turns ON
(6) Monitor panel LED lighting output OFF
20-236 PC300, 350-6

5
1
TROUBLESHOOTING
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Code Content Details (condition when lighted up)
switch Time OFF

PPC oil pressureselector switch OFF
Monitor panel input condition 3
Overload
selector
switch OFF
4A
STD/DLX selection STD
Swing
switchlock OFF
cancel
Buzzer switch OFF
Wiper motor normal rotation relay output: when specified voltage is abnormal
Wiper motor reverse rotation relay output: when specified voltage is abnormal
4c Monitor panel input condition 4
Window washer motor drive output
4. Governor motoradjustmentmode
TI-:
is ..---I
I 111s
...L - - I -1.. the iiniiage bet-weenthe governor motor and the injection pump. (For
uxu W I I ~ I aujus~illg
_+I_^
details of the procedure, see TESTING AND ADJUSTING.)
Operation I Display
1. To set to the governor motor ad- 1. OFF

OFF
justmentmode,pressthetime
switch + R.H. travel speed switch I
+ R.H. working mode switch.
\ - - r J v - - v
OFF Displays "9-SET" OFF OFF OFF
BKP00086
2. To return to the time display mode 2. Buzzer sounds once a second
use the same procedureas in Step
1.
5. Timeadjustmentmode
To adjust the time, do as follows.
Operation Dispiay
1. To set tothetimeadjustment 1. The time mark portion flashes
mode, keep the time switch de- OFF OFF
pressed for 2.5 seconds.
1 i
2. Use the L.H. working mode switch
to advance the hour.
+--17--I-v
BHBHBBBBh
Flashes Hour Minute ON Normal display ON
3. Usethe R.H. w o r k i n gm o d e (24-hour clock)
BKP00087
switch to advance the minute.
* The exampleshowsthesituationwhensetting to
4. To return to thetimedisplay 12:34.
mode use the same procedure as
in Step 1.
PC300, 350-6 20-237

a
TROUBLESHOOTING
DISPLAY
METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
6. Working mode default setting mode

The default (initiai position) for the working mode can be changed as follows (the default can be
changed for the working moue oniy).
Time C#!
Workins mode
sw i i c h
(H s w i t c h )
W o r k i n s mode
swltch
(M s w i t c h )
-
Monitor panel front M o n i t oDr a n e r1e z r TWPO 1408
1) Set to the working mode default setting mode.

i) Keep theTIMEswitch and WORKINGMODESWITCH (M SWITCH) pressed a t the same
time for a t least 2.5 seconds.
ii) Check that one of the working mode LEDs is flashing.
2) Method of setting working mode default
i! Use the WQRK!NG MODE SW!TCH !!-!SW!?GH! or WORKING MODE S\N!TCH (M SW!TCH?
to change the working mode and set the working mode to the default to bechanged.
ii) Keep the TIME switch and WORKINGMODESWITCH ( M SWITCH) pressedat the same
time for at least 2.5 seconds.
iii) When the setting is completed, the buzzer "beeps" (when the system returns to the normal
mode, the working mode LED lights up).
* Note that if the starting switch is turned OFF when the normal mode LED is flashing
(default setting mode), the content of the working mode default is not changed.
4) Method of checking after setting working mode default
i) Check that the LED remains lighted up.
ii) Turn the starting switch OFF,then turn it ON again.
...
!!!) Check that the wnrking mnde def2u!t h2S changed k?the new setting.
k When the starting switch is turned ON, the auto- deceleration setting changes accord-
ing to the working mode.
20-238 PC300, 350-6

0
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormal-
ity 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–● ●, S–● ●, N–● ●, C–● ●, F–● ●, H–● ●, M–
● ●) matches the symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code
which troubleshooting table to go to.
fl The abnormality display (warning) given by the monitor panel leads directly to troubleshooting of
the machine monitor (M–● ●). (See troubleshooting of the machine monitor system)
1. When using judgement table for engine throttle, pump controller (governor control system) and
engine related parts
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (E–● ●).
(A ● mark is put at the places where the failure mode and service code match.)
• If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the troubleshooting code on the right of the judgement
table (E–● ● or S–● ●).
<Example> Failure mode “Engine does not start”.
Procedure: Check if the service code is being displayed on the monitor panel.
Engine throttle, pump

Abnormality in engine throttle, pump controller power source
controller, engine related Machine

Checking monitoring, monitor
parts (E3: system)
check items check item
Self-diagnostic display
Abnormality (disconnection) in motor drive system
Troubleshooting code if no service code display is given

Abnormality (short circuit) in battery relay output
Abnormality (short circuit) in motor drive system
Abnormality in feedback potentiometer system
Abnormality in fuel control dial input value
Is red range displayed?

Fuel control dial command value
Governor motor A phase current

Governor motor B phase current
Abnormality (step-out) in motor
Governor motor potentiometer

No. 2 throttle command value
Coolant temperature voltage
Does starting motor turn?

Battery relay drive signal
102˚C or above
105˚C or above
system
User code E05 Monitoring code

Failure mode
Service code 308 317 318 306 315 316 35 16 30 31 33 34 41 108
1 Engine does not start easily S-1
2 Engine does not start ● S-2
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor ● ● ● ● ● ª ª ª ª ● S-3
4 Engine stops during operation S-4
When idling speed is irregular E-9 a), S-5
5 Engine rotation is irregular
When there is hunting ● ● ● ● ● ª E-9 a), S-5
6 Lack of output (engine high idling speed is too low) ● ● ª ª ● E-10, S-6
7 Auto-deceleration does not work E-3 · E-4
8 Engine does not stop ● ● ● ● ● ● ª ª E-11
9 Warming-up operation is defective ● ● E-3 · E-4
10 Exhaust gas is black S-7
11 Oil consumption is excessive, or exhaust gas is blue S-8
12 Oil becomes dirty prematurely S-9
13 Fuel consumption is excessive, or exhaust gas is blue S-10
14 Oil is mixed in coolant S-11
15 Engine oil pressure caution lamp lights up S-12
16 Oil level rises S-13
17 Coolant temperature rises too high (overheating) ● ● S-14
18 Abnormal noise is generated S-15
19 There is excessive vibration S-16
20 Engine speed does not change even when working mode is switched ª E-3 · E-4
Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-6 E-7 — — — — — — — — — —
Troubleshooting code when there is abnormality in monitoring or machine monitor check — — — — — — — E-12 — — — — — M-14 M-13 M-13 E-8
● : This shows applicable item for service code ● : This shows item to check with monitoring or machine
ª : This shows item that needs only checking with monitoring monitor
[Judgement]
1) If a service code is being displayed on the monitor panel...... go to troubleshooting [E3:●●] for the
engine throttle, pump controller (governor control system).
2) If no service code is displayed on the monitor panel, and the engine does not start:
Starting motor rotates .................. Go to troubleshooting S-2 of
mechanical system
• Check that starting
motor rotates
Starting motor does not rotate .... Go to troubleshooting E-8 of
electrical system
PC300, 350-6 20-239

5
1
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
2. When using judgement table for engine throttle, pump controller (governor control system) and
hydraulic related parts
• If a service code is displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (C–● ●).
(A ● mark is put at the places where the failure mode and service code match.)
• If a problem has appeared but no service code is displayed on the monitor panel, go to the
point where the failure mode matches the input signal, and check the display for the input
signal (the display at the place with a ● mark).
• If it is displayed normally, go to the troubleshooting code on the right of the judgement
table (H–● ●).
• If the input signal is not displayed on the monitor panel, go to the troubleshooting code at
the bottom of the judgement table (F–● ●).
<Example> Failure mode “Upper structure does not swing”.

Procedure: Check if the service code is being displayed on the monitor panel.
[Judgement]
1) If a service code is being displayed on the monitor panel...... go to troubleshooting [E2:●●] for the
engine throttle, pump controller (pump control system).
2) If no service code is displayed on the monitor panel, and the upper structure does not swing: .
There is a signal .... Go to troubleshooting H-25 of
Check engine throttle, pump
mechanical system
• controller input signal
(Check in monitoring mode)
There is no signal . Go to troubleshooting F–● ● of engine
throttle, pump controller input signal
system
(F mode for applicable system)
20-240 PC300, 350-6

5
1
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
6) Installation position, pin number

A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
<Example>
(1) M-9 When starting switch is turned ON (engine stopped), check item for previous
troubleshooting flashes
(4) fl Before carrying out troubleshooting, check that all the related connectors are prop-
erly inserted.
fl Always connect any disconnected connectors before going on the next step.
fl Check that the coolant is at the specified level before carrying out troubleshooting
(2) a) (coolant level) flashes

SAP00519 Divided into sections a) and b)
b) (engine oil level) flashes
SAP00523
(3)
Cause Remedy
YES Defective coolant level

sensor system (see M-26) —
1
Does display go 4 YES Defective engine throttle,
out when short pump controller Replace
connector is
connected to P08 YES Is bit (3) of
(female)? monitoring code
3
24 lighted up?
• Disconnect P08. Is continuity
Defective monitor panel Replace
• Turn starting YES between C16 • Turn starting NO
(female ) (8) and
switch ON. chassis as shown switch ON.
2 Defective contact, or
in table? • Set to monitoring
disconnection in wiring
Is there continuity • Turn starting code 24. Repair or
harness between C16
between P08 switch OFF. NO replace
(female) (8) – P08
NO (female) (2) and • Disconnect C16, P08. (female) (1)
chassis?
• Connect disconnect short
• Turn starting connector to P08 (female). Defective contact, or
switch OFF. disconnection in wiring Repair or
• Disconnect P08. NO harness between P08 replace
(female) (2) – chassis
ground
Table
Short connector Continuity
Connected Yes
Disconnected No
20-242 PC300, 350-6

5
1
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING

PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accord-
ance with the judgement table for that type of failure (engine throttle, pump controller (governor
control system) and engine throttle, pump controller (pump control system). For details of the trouble-
shooting and troubleshooting procedure, refer to this flow chart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the
machine, and check the following items before starting.
(1) Condition of controller connection (check with monitoring codes 02 – 03)
(2) Blown fuses
(3) Battery voltage (monitoring mode 32)
(4) Electricity generation (charge input) voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the
following pages.
E02 (TVC system)

YES
E03 (Swing holding brake system)
E05 (Governor motor system) } Go to Item 2
E2 group: Troubleshooting for

engine throttle, pump controller (pump
}
Carry out troubleshooting in applicable mode
1 YES control system ) (C mode)
(Note: For E218, carry out troubleshooting of the
Is user code E3 group: Troubleshooting for communication abnormality system (N mode).)
displayed on engine throttle, pump controller Carry out
monitor panel? (governor control system ) (E mode) 6 YES troubleshooting
for engine
Engine Is engine electrical (S mode)
system for which
system there is no failure Carry out
5 code display troubleshooting for
2 Is problem in engine electrical system
normal?
(E mode).
Is service code YES engine system • Go to flow chart for NO (Use flow chart for items
of hydraulic section where there is
displayed on where there is no
(mechanical) no abnormality display
NO monitor panel? system?
display)(E11 – E15)
on judgment table.
4
• After adjusting Hydraulic Carry out
• Operate and Are engine
oil pressure, (mechanical) troubleshooting for
check service YES throttle, pump
controller input judge from system hydraulic (mechanical)
code. engine speed. system (H mode)
and output
signals normal? • Is all work equipment slow and
• Check using does engine speed drop under
3
monitoring code. heavy load?
Are monitor • Governor
Carry out troubleshooting for
codes 02, 03, controller: 30, 31, NO
input signal system (F mode).
NO 08 normal?
33, 34
• Pump controller:
10 – 24
• Check
• Valve controller:
connection 50 – 69
condition of
S-NET in Carry out troubleshooting
monitoring NO for communication
codes abnormality system
02, 03, 08. (N comde).
fl For details, see engine throttle, pump controller (governor control system) (pump control system)
in the JUDGEMENT TABLE.
PC300, 350-6 20-243

5
1
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken
that the output signal from the monitor panel has been transmitted. However, even if there is no
abnormality display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following
default mode, so be careful when carrying out troubleshooting.
Default Mode when communications cannot be carried out for the monitor and engine throttle,
pump controller
Set mode Pump control Governor control
1 Working mode G/O mode H/O mode
2 Throttle signal FULL FULL
3 Auto-deceleration ON (deceleration mode ON (deceleration mode)
4 Coolant temperature signal OFF —
5 Active mode OFF —
6 Power max. mode ON (power max. possible) —
7 Travel speed Lo —
8 Automatic warming up — ON (automatic warming-up mode)
1. Procedure for checking monitor panel output signal

fl For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
1. Connection condition of components
1) Set to the monitoring mode and display monitoring code 08.
2) The time display (bits) will light up to display the components that are connected.
fl Engine throttle, pump controller (pump control system) (1) and engine throttle, pump
controller (governor control system) (2) will light up.
2. Checking working mode signal {check No. 2 throttle signal (monitoring code 16) at the same
time}
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
High idling speed (rpm)
Working mode [The figures in ( ) are the rated speed]
Approx. 2220<during operation>
H/O Approx. 2050 <idling> (1950)
Approx. 2050 <during operation>
G/O Approx. 1900 <idling> (1850)
F/O Approx. 1900 (1700)
L/O Approx. 1700 (1500)

Approx. 2300 <during operation>
Active Approx. 2050 <idling> (2050)
20-244 PC300, 350-6

5
1
3. Checking travel speed selection signal

2) Change the speed selector switch to Hi or Mi and run the engine at 1500 rpm or above.
Check that bit (6) lights up when traveling at Hi or Mi (front or rear pump oil pressure: 21.56
– 32.34 MPa {220 – 330 kg/cm2}
4. Checking swing priority mode signal
fl If the travel oil pressure switch signal is not input to the controller, the flow from the front
and rear pumps will remain divided.
2) Check that bit (4) lights up when the travel is operated (even when operated slightly).
fl Check the operating condition of the pump merge/divider solenoid valve
2. Checking input signal of engine throttle, pump controller

fl Check the input signals for each controller as follows.
• Pump control system
1. Checking input signal
1) Check hydraulic switch
i) Set to the monitoring mode, and display monitoring codes 20 and 21.
ii) Operate each work equipment lever, and check how the bit pattern lights up.
fl For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
2) Check speed sensor (check engine speed)
i) Set to the monitoring mode, and display monitoring code 10.
ii) Use the fuel control dial to change the speed, and measure the speed when this is
done.
3) Check pump discharge pressure sensor
fl Code 11 is for the front pump and code 12 is for the rear pump.
ii) Refer to Table 2 and measure the hydraulic pressure at the front or rear pump.
Table 2 Pump merge/flow logic and pumps actuated by control levers
Independent operation Travel operated independ-

(basic flow merged) ently or compound opera-
tion together with travelª
Front pump Rear pump Front pump Rear pump
L.H. travel fi fi
Swing fi fi fi
Arm fi fi fi
Boom fi fi fi
Bucket fi fi fi
R.H. travel fi fi
ª Conditions for compound operation with travel.
(1) When measuring the oil pressure for any circuit other than travel, operate the
travel lever slightly or connect a short connector (X-2P) to the travel oil pressure
switch connector (CN-S01).
(2) The circuits merge when the pressure of the front pump or rear pump is more
than 19.6 MPa {200 kg/cm2}.
PC300, 350-6 20-245

5
1
4) Check kerosene mode input signal

ii) Connect the CN-M36 connector and check that bit (5) lights up.
5) Check knob switch input signal .
ii) Turn the knob switch ON and check that bit (6) lights up.
2. Check output signals

1) Check LS-EPC solenoid output current
ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode,
and measure the current.
fl All levers at neutral: 900 ± 80 mA
Engine at high idling, any lever operated (other than travel): 0 A
2) No. 2 throttle signal
ii) Use the procedure in Item 2 for checking the monitor panel output signal, and measure
the engine speed.
3) Checking ON ↔ OFF solenoid condition
ii) Refer to Table 3 and check that the applicable bit lights up.
Table 3 Types of solenoid and conditions for actuation
Name of solenoid Actuation condition Bit that lights up
Active (boom) Active mode switch OFF (2)
Swing holding brake Swing or work equipment lever operated (3)
Pump merge/divider Travel operated independently (4)
Travel speed selector Travel speed selector switch Hi or Mi (6)

Active mode switch ON + swing + boom
Active (swing) raise lever operated simultaneously (5)
fl Operate the lever slightly not enough to move the machine.
4) Check TVC solenoid output current

• Code 13 is for the front pump and code 14 is for the rear pump.
ii) With the starting switch kept at the ON position (G/O mode), measure the current when
the fuel control dial is turned to the MAX position.
• Current with starting switch ON (G/O mode) and fuel control dial at MAX
: 520 ± 80 (mA)
20-246 PC300, 350-6

5
1
TROUBLESHOOTING
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
Governorcontrolsystem
1. Check inputsignal
4 ) Check fuel control dial input voltage
ii) Measure the voltage when the fuel control dial is turned from low idlingt o high idling.
* Voltage: 0.25 - 4.75 V
2) Check governor potentiometer voltage
ii) Measure the potentiometer voltage when the fuel controldial is turned from low idling
to high idling.
* Voltage: 0 5 - 3.3 V
2. Check outputsignal
1) Check governor motor drive current
* Code 33 is the A phase (engine speed acceleration direction) and code 34 is the B
phase (engine speed deceleration direction)
ii) Measure the governor motor drive current when the fuel control dial is turned in the
acceleration direction and deceleration direction.
* Current: 700 +_ 70 (mA)
2) Measure battery relay drive eutpu: vdtage

ii) Measure the battery relay drive output voltage when the starting switch is turned from
ON to OFF.
or
iii) Set to the monitoring mode, and display monitoring code 37.
iv) Check that bit (1) lights up when the starting switch is turned from ON to OFF.
PC300,350-6 20-247
0
TROUBLESHOOTING SERVICE CODE TABLE
SERVICE CODE TABLE

Service User Service User
Abnormal system code code Abnormal system code
w i t h 24V wiring harness for buzzer drive
E222 Short circuit in LS-EPC solenoid system
E223 Disconnection in LS-EPC solenoid system
E231 Short circuit in active mode (swing) solenoid system
E232 Short circuit in F pump TVC solenoid system E02

E233 Disconnection in F pump TVC solenoid system E02
E235 Disconnectioninactive mode (swing) solenoid system
E236 Shortcircuit in R pump TVC solenoid system E02
E237 Disconnection in R pump TVC solenoid system E02
E306 Abnormality in feedback potentiometer system

E308 Abnormality in fuel control dial input value E05
20-248 PC300, 350-6

0
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
(N MODE)
N-1 [E2181 Communicationabnormality ........................................................................................ 20-302
PC300, 350-6 20-301

0
TROUBLESHOOTING N-1
N-1 [E218] Communication abnormality

fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
fl If the starting switch was turned off after the abnormality occurred, turn the starting switch on and
check that the service code displays E. (If it is not displayed, the problem has been removed.)
fl Before carrying out troubleshooting, check that all the re-
Cause Remedy
lated connectors are properly inserted.
fl Always connect any disconnected connectors before going
on to the next step.
YES
Has been reset
4 YES
1 Is resistance
YES between P01 (4)
Is monitoring (11) and chassis or
3 P01 (4) (11) and
code 02, 03
When C17 is P01 (12) normal? Disconnection is between
display normal? Repair
YES disconnected, do • Disconnect NO P01(4) (11) and P01 (12)
bits (1) and (2) light connector C17, or chassis
• Disconnect C17. P01, and install
up in monitoring
• Turn starting T-adapter to P01.
switch ON. 2 • Disconnect • Min. 1 MΩ Defective engine throttle,
pump controller Replace
• See Table 1. Do bitts (1) and connector C17. NO
(2) light up in • Turn starting
NO monitoring code switch ON.
08? YES Defective engine throttle,
• See Table 2. 5
• Turn starting Is voltage
switch ON. between C17 (4)
NO (12) and chassis 6 YES
normal? Defective monitor panel Replace
Is resistance
• Turn starting between P01(4),
switch ON. NO (11) and C17 (4),
• Min. 7.5 V (12) normal? Disconnection in wiring Replace
• Disconnect C17 • Disconnect P01, NO harness between P01(4),
and measure C17. (11) and C17 (4), (12)
voltage at • Max. 1Ω
harness end.
Table 1
Monitoring code Display • When each controller is connected to the
01 Monitor panel model code 300 network, “—” is displayed. If the correct
alphanumerics are not displayed (another
02 Engine throttle, pump controller model code 300
model is displayed), each controller shows
03 Engine throttle, pump controller model code 300 model selection abnormal.
Table 2
Display
Monitoring code
08 Network connection condition
• Light up when connected • Note: Checks can be carried out with code
(1) Engine throttle, pump controller 08 only when there is a disconnection.
(2) Engine throttle, pump controller The display does not change when there
is a short circuit.
Therefore, checks when there is a short
circuit should be carried out basically us-
ing Table 1.
20-302 PC300, 350-6

1
5
TROUBLESHOOTING N-1
N-1 Related electric circuit diagram
Engine throttle, pump controller Monitor panel

C16(MIC17) P01(04020)
GND e r S–NET(+)
GND r !2 S–NET(–)
!1 S–NET(+)
S–NET(+) r H14
(M6)
S–NET(+) !2 w
C17(04016)
BKP00092
PC300, 350-6 20-303

1
5
TROUBLESHOOTING OF ENGINE THROTTLE,
PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Points to remember when carrying out troubleshooting of engine throttle,

pump controller system .................................................................................................................. 20-352
Action taken by controller when abnormality occurs and problems on machine ......................... 20-354
Judgement table for engine throttle, pump controller (governor control system)
and engine related parts ................................................................................................................. 20-358
Electrical circuit diagram for E mode system ..................................................................................... 20-360
E- 1 Abnormality in engine throttle, pump controller power source (controller LED is OFF) .. 20-362
E- 2 [E308] Abnormality in fuel control dial input value is displayed .................................. 20-363
E- 3 [E317] Abnormality (disconnection) in motor drive system is displayed .................... 20-364
E- 4 [E318] Abnormality (short circuit) in motor drive system is displayed ....................... 20-365
E- 5 [E306] Abnormality in feedback potentiometer system is displayed ........................... 20-366
E- 6 [E315] Abnormality (short circuit) in battery relay output system is displayed ......... 20-367
E- 7 [E316] Abnormality (step-out) in motor is displayed ...................................................... 20-368
E- 8 Engine does not start ......................................................................................................... 20-370
E- 9 Engine speed is irregular ................................................................................................... 20-372
a) Idling speed is irregular ............................................................................................... 20-372
b) There is hunting ........................................................................................................... 20-374
E-10 Lack of output (engine high idling speed is too low) ..................................................... 20-376
E-11 Engine does not stop ......................................................................................................... 20-378
E-12 Defective operation of battery relay system (engine does not stop) ........................... 20-380
PC300, 350-6 20-351

1
5
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-

SHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER
SYSTEM
1. Points to remember when there is abnormality which is not displayed by user code
The engine is controlled by the engine throttle, pump controller.
The problems that may occur with this system include the following.
1. Idling speed is too high (too low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (too low)
4. Engine speed for automatic warming-up operation is too high (too low)
5. There is hunting
6. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the time display portion of the
monitor panel, use the troubleshooting table to determine the appropriate troubleshooting flow
chart from E-1 to E-12.However, if there is any abnormality in the machine and no abnormality
display is given, it is necessary to determine whether the problem is in the mechanical system or
in the electrical system. If the linkage between the governor motor and the injection pump is not
properly adjusted, problems 1 to 6 listed above may occur. Therefore, if there is no abnormality
display, but one of problems 1 to 6 above has occurred, carry out troubleshooting as follows.
YES 2
YES Defective adjustment of governor motor
If linkage between
governor motor likage See TESTING AND ADJUSTING.
1
and injection pump
If linkage between is disconnected,
governor motor and does operation of
injection pump is governor motor Go to troubleshooting E-9 – E-12 of
disconnected and become normal? NO electrical system
pump lever is
operated by hand or • With starting switch at ON, operate fuel
is fixed with wire, control dial and working mode switch.
does condition Go to troubleshooting S-1 – S-16 of
returen to normal? NO engine system
• If engine does not stop, push
governor lever to STOP position
and check if engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting
flow chart for the mechanical system or electrical system.
For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
2. Points to remember if abnormality returns to normal by itself

In the following two cases, there is a high probability that the same problem will occur again, so
it is desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed
and the connector is returned to its original position when carrying out troubleshooting of the
failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
3. User code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down
the content of the display, then erase the display. After trying to re-enact the problem, carry out
troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-352 PC300, 350-6

1
5
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING
OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS O N MACHINE
User Service
Abnormal system Nature of abnormality
code code
1. Short circuit in wiring
- harness between C03 (7) - (14), (7)
- (171, (14) - (17)
2. Short circuit in wiringharness between E04 (1) - (21,11) -
(31, (2) - (3)
- harness between E06 (1) - (2), (1) -
3. Short circuit in wiring
!3!, !2! - (31
Abnormality in fuel (17)
-
4. Short circuit in wirina harness between C03 (7) - (41, (4) -
E308 control dial input value 5. Disconnection in wiring harnessbetween C03 (7) - X04
(6) - E06 (1
6. Disconnection in wiring - harnessbetween C03 (4) - X07
(5) - E06 (2)
7. Disconnection in wiring harness between C03 (17) - X07
(4) - E06 (3)
8. Defective fuel control dial
9. Defective contact of C03, X07, E06 connectors
1. Disconnection inside governor motor

E05 2. Disconnection in wiring harness between C02 (2)- E05 (1)
Abnormality 3. Disconnection in wiringharness between C02 (4) - E05 (3)
E317 (disconnection) in motor 4. Disconnection in wiring harness between C02 (3) - E05 (2)
drive system 5. Disconnection in wiringharness between C02 (5)- E05 (4)
6. Defective contact of E05 connector
1. Short circuit inside governor motor

2. Wiring harness between CO2 (2) - E05 (1) andbetween
Abnormality CO2 (4) - E05 (3) short circuiting with wiring harness be-
E318 (short circuit) in motor tween C02 (3)- E05 (2)
drive system 3. Wiring harnessbetween C02 (4)- E05(3) andbetween
CO? (2)- EO5 ( I f sh=:t ci:cc;itIng with :.:king harness be-
tween C02 (5) - E05 (4)
4. Wiring harness in Items 2 and 3 shortcircuitingwith
ground
20-354 PC300, 350-6

0
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears o n machinf
(voltage, current, resistance) abnormality is detected when there is abnormality
Resistance
value
(male)
(female)
I I 0.25 - 7kR
1I (7) - (4)
(4) - (17)
(7) - (17)
I
(1) - (2)
(2)- (3) I 0.25 - 7kR
2 - 3kR
Maintainsenginespeed at
1. Does not become partial speed
when set a t MAX position
2. Does not reach high idling when
position of fuelcontroldial set at partial speed
immediately before abnor- 3. There are cases of hunting
Between mality occurred 4. Lacks output(max.speed of en-
1 each
Min.pin MR gine is too low)
I and chassis I
1
II
value
(female)
(male) I c02 Resistance
1. When there is a disconnection in

both the A phase and B phase at
the same time, the problem is the
sameas for a short circuit in the
governor motor system
2. When there is a disconnection in
Takes no particular action only one of A phase or B phase
1) Engine does not stop
2) Stops movingatposition im-
mediately before failure, so en-
I I I ginespeedcannotbecontrol-
Motor drive current: Hold: 0.7 A led
3) There are cases of hunting
Start: 0.84 A
E05 c02 Resistance

value
(female)
(male)
(1) - (2) (2) - (3) 0.25 - 7kR 1. If during operation
1) Set to low idling
(3) - (4) (4) - (5) 0.25 - 7kR 2) Engine does not stop
(1) - (3) (2)- (4) Min. 1 MR 3) There are cases of hunting
(1) - (4) (2)- (5) Min.
1
MR 2. When stopped
Between
Between Sets motor drive currentto 0 1) Engine starts, but stays at low
pins (I). (2), pins (21, (3).
idling
2) Engine does not stop after start-
(3), (4) and (41, and (5) Min.1MR ing
I chassis I andchassis I 3) There are cases of hunting
Motor drive current: Hold: 0.7 A
Start: 0.84 A
PC300, 350-6 20-355

0
User Service
code code
1. Short circuit in wiring harness between C03 (7) – (14), (7)

– (17), (14) – (17)
2. Short circuit in wiring harness between E04 (1) – (2), (1) –
(3), (2) – (3)
3. Short circuit in wiring harness between E06 (1) – (2), (1) –
(3), (2) – (3)
Abnormality in feedback 4. Short circuit in wiring harness between C03 (7) – (4), (4) –
— E306 (17)
potentiometer system
5. Disconnection in wiring harness between C03 (7) – E04 (1)
6. Disconnection in wiring harness between C03 (14) – E04
(2)
7. Disconnection in wiring harness between C03 (17) – E04
(3)
8. Defective governor motor potentiometer
9. Defective contact of C03, E04 connectors
Abnormality (short cir- If excess current flows between C03 (1) and battery relay
— E315 cuit) in battery relay out- fl This occurs only when turning starting switch to OFF and
put system stopping engine
1. Defective adjustment of rod or scuffing of loose spring
Abnormality (step-out)
— E316 2. Abnormality in governor motor
in motor
3. Abnormality in engine throttle, pump controller
20-356 PC300, 350-6

1
5
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Precision of engine speed control
may be reduced.
For example:
C03 E04 Resistance 1) Engine does not rise to high
(female) (male) value idling speed (a little too low)
2) Engine does not go down to
(7) – (14) (1) – (2) 0.25 – 7kΩ low idling speed (a little too
Calculates position of motor
(7) – (17) (2) – (3) 0.25 – 7kΩ and carries out control from high)
(14) – (17) —— 2 – 3kΩ value of voltage immediately 3) Defective engine speed for auto-
deceleration or automatic
—— (1) – (3) 4 – 6kΩ before abnormality occurred warming-up
Between 4) Engine may not stop
each pin —— Min. 1 MΩ fl The governor motor moves
and chassis in the direction to stop the
engine, but the motor may
not move completely to the
position to stop the engine.
5) There are cases of hunting
Between C03 (1) and chassis: 20 – 30 V

fl Holds with the motor in the stop
position for 2 – 2.5 sec, returns to Sets battery relay drive cur-
rent to 0 Engine does not stop
the low idling position, then turns
the battery relay OFF.
1. Displays when returning

1. Linkage adjustment correct from high idling to low
idling
fl Starts again (repeats Engine speed cannot be controlled
2. Must move lightly when connector step-out)
is removed 2. In some cases it may not (particularly at high idling), so there
display when returning is hunting
3. Normal from partial speed to low
idling
PC300, 350-6 20-357

1
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS

(GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
Abnormality in engine throttle, pump controller power source

controller, engine related
parts (E3: system)
Abnormality (disconnection) in motor drive system
Abnormality (short circuit) in battery relay output

Abnormality (short circuit) in motor drive system
Abnormality in feedback potentiometer system
Abnormality in fuel control dial input value
Abnormality (step-out) in motor

system
User code E05
Failure mode
Service code 308 317 318 306 315 316
1 Engine does not start easily
2 Engine does not start
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor ● ● ● ● ●
4 Engine stops during operation
When idling speed is irregular
5 Engine rotation is irregular
When there is hunting ● ● ● ● ●
6 Lack of output (engine high idling speed is too low) ● ●
7 Auto-deceleration does not work
8 Engine does not stop ● ● ● ● ●
9 Warming-up operation is defective
10 Exhaust gas is black
11 Oil consumption is excessive, or exhaust gas is blue
12 Oil becomes dirty prematurely
13 Fuel consumption is excessive, or exhaust gas is blue
14 Oil is mixed in coolant
15 Engine oil pressure caution lamp lights up
16 Oil level rises
17 Coolant temperature rises too high (overheating)
18 Abnormal noise is generated
19 There is excessive vibration
20 Engine speed does not change even when working mode is switched
Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-6 E-7
Troubleshooting code when there is abnormality in monitoring or machine monitor check — — — — — — —
● : This shows applicable item for service code

ª : This shows item that needs only checking with monitoring
20-358 PC300, 350-6

1
5
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
Machine
Checking monitoring, monitor
check items check item
Troubleshooting code if no service code display is given

Is red range displayed?
Fuel control dial command value
Governor motor A phase current

Governor motor B phase current
Governor motor potentiometer
No. 2 throttle command value
Coolant temperature voltage
Does starting motor turn?

Battery relay drive signal
102˚C or above
105˚C or above
Monitoring code
35 16 30 31 33 34 41 108
S-1
● S-2
ª ª ª ª ● S-3
S-4
E-9 a), S-5
ª E-9 a), S-5
ª ª ● E-10, S-6
E-3 · E-4
● ª ª E-11
● ● E-3 · E-4
S-7
S-8
S-9
S-10
S-11
S-12
S-13
● ● S-14
S-15
S-16
ª E-3 · E-4
— — — — — — — — — —
E-12 — — — — — M-14 M-13 M-13 E-8
● : This shows item to check with monitoring or machine
monitor
PC300, 350-6 20-359

1
5
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
20-360 PC300, 350-6

1
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Electric governor actuator

E04(X3) Potentiometer
0.85WB 1 +
0.5G 2 sig
0.5B 3 –
E05(X3) Governor motor

0.75B B
1 A
0.75G 2 G
A
0.75R 3 R B
0.75W 4 Y
B
D13(KES1)
1 0.85RG 2
2 0.85BR 1
3
4
5
6
7
8
9
10
11
12
13
1.25B
M14
1 2 (L2)
1 2
Battery relay H15(L2) Fuse box
85B 10A
B M 5R 1 1
3R 5R 5R 2W
2
10A
2BR 5B 3R 2R 2R 14 2B
1
BR E 2W 2W
4
2R 5 2R
1 2
1 2
M11 H14(M6)
(L2)
1.25B
Battery
85B 85B 85B
BKP00095
PC300, 350-6 20-361

1
TROUBLESHOOTING E-1
E-1 Abnormality in engine throttle, pump controller power source

(controller LED is OFF)
fl Check that fuse 1 is not blown.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy
YES Defective engine throttle,

Replace
1 pump controller
Is voltage
between C01 (7) Defective contact, or
(13) and C02 (11) 2 YES disconnection in wiring Repair or
(21) normal? Is voltage harness between fuse 1 replace
between fuse 1 and C01 (female) (7) (13)
• Turn starting
switch ON. NO and chassis Defective contact, or
• 20 – 30 V normal? disconnection in wiring Repair or
harness between fuse replace
• Turn starting NO
1–H15 (2)–M14 (2)
switch ON. (1)–battery relay M
• 20 – 30 V
E-1 Related electric circuit diagram

C01(MIC13)
H14(M6) Fuse H15(L2)
Power source
(+24V) u
1
Power source
(+24V)
!3 r w
PGND !1 Fusible link

PGND @1 R E
qw M14(L2)
C02(MIC21)
Battery
B M
BKP00096
20-362 PC300, 350-6

1
5
TROUBLESHOOTING E-2
E-2 [E308] Abnormality in fuel control dial input value is displayed
Cause Remedy
2 YES Defective engine throttle,

Is resistance
between each pin
YES of C03 (female) (4)
1 (7) (17), or
between each pin
Is resistance and chassis as
between E06 shown in Table 1? Defective wiring harness
(male) (1)-(2), (2)- in system with defective Replace
(3) as show in • Turn starting NO
resistance
Table1? switch OFF.
• Turn starting • Disconnect C03.
Defective fuel control dial Replace
switch OFF. NO
• Disconnect E06.
fl If E306 also occurs at the same time, check the wiring harness below.
• Wiring harness between C03 (female) (7) – E04 (female) (1) short circuiting with ground, or
contact with other wiring harness
Table 1
C03 E04 Resistance
(female) (male) value
(7) – (4) (1) – (2) 0.25 – 7kΩ
(4) – (17) (2) – (3) 0.25 – 7kΩ
(7) – (17) —— 2 – 3kΩ
—— (1) – (3) 4 – 6kΩ
Between each
pin and —— Min. 1 MΩ
chassis
Engine throttle, pump controller X07(MIC17) E06(M3)

C03(04020)
y q
Fuel control
Throttle r t w dial
command
r e
E04(X3)
Throttle power u q Governor

source (+)
Feedback !4 w potentiometer
Throttle power !7 e
source (–)
BKP00097
PC300, 350-6 20-363

1
5
TROUBLESHOOTING E-3
E-3 [E317] Abnormality (disconnection) in motor drive system is

displayed
fl During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
1) the engine will run at low idling
2) the engine will not stop
2) a disconnection in either A phase or B phase, the engine speed will remain the same as before
the abnormality occurred
fl If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
¤ Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
INJECTION position).
Cause Remedy

Is resistance pump controller Replace
between each pin of
YES C02 (female), or
1 between each pin
and chassis as Defective wiring harness
Is resistance shown in Table 1?
between each pin of in system with defective Replace
E05 (male), or • Turn starting NO resistance
between each pin
and chassis as switch OFF.
shown in Table 1? • Disconnect C02.
• Turn starting Defective governor Replace
switch OFF. NO motor
• Disconnect E05.
Table 1
E05 C02 Resistance
(male) (female) value
(1) – (2) (2) – (3) 2.5 – 7.5kΩ
(3) – (4) (4) – (5) 2.5 – 7.5kΩ

C02(MIC21) E05(X4)
Governor motor
A(+) w q
A(–) e w
B(+) r e
B(–) t r
BKP00098
20-364 PC300, 350-6

1
5
TROUBLESHOOTING E-4
E-4 [E318] Abnormality (short circuit) in motor drive system is

displayed
fl If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling
2) the engine will not stop
fl If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Cause Remedy

between each pin of
YES C02 (female), or
1 between each pin
and chassis as Defective wiring harness
Is resistance shwon in Table 1?
between each pin of in system with defective Replace
E05 (male), or • Turn starting NO resistance
between each pin
and chassis as switch OFF.
• Disconnect E05.
Table 1
E05 C02 Resistance
(male) (female) value
(1) – (2) (2) – (3) 2.5 – 7.5kΩ
(3) – (4) (4) – (5) 2.5 – 7.5kΩ
(1) – (3) (2) – (4) Min. 1 MΩ
(1) – (4) (2) – (5) Min. 1 MΩ
Between chassis Between chassis
and pins and pins Min. 1 MΩ
(1)(2)(3)(4) (2)(3)(4)(5)

C02(MIC21) E05(X4)
Governor motor
A(+) w q
A(–) e w
B(+) r e
B(–) t r
BKP00098
PC300, 350-6 20-365

1
5
TROUBLESHOOTING E-5
E-5 [E306] Abnormality in feedback potentiometer system is displayed
Cause Remedy

Is resistance Replace
pump controller
between each pin of
YES C03 (female) (4) (7)
1 (14), or between
each pin and chassi Defective wiring harness
Is resistance as shown in Table1?
between E06 in system with defective Replace
(male) (1)-(2), (2)- • Turn starting NO resistance
(3) as shown in switch OFF.
Table 1? • Disconnect C03.
• Disconnect E04.
fl If E308 also occurs at the same time, check the wiring harness below.
• Wiring harness between C03 (female) (7) – X07 (6) – E06 (female) (1) short circuiting with
ground, or contact with other wiring harness
Table 1
C03 E04 Resistance
(female) (male) value
(7) – (4) (1) – (2) 0.25 – 7kΩ
(14) – (17) (2) – (3) 0.25 – 7kΩ
(7) – (17) —— 2 – 3kΩ
—— (1) – (3) 4 – 6kΩ
Between each
pin and —— Min. 1 MΩ
chassis
Engine throttle, pump controller X07(MIC17) E06(M3)

C03(04020)
y q
Fuel control
Throttle r t w dial
command
r e
E04(X3)
Throttle power u q Governor

source (+)
Feedback !4 w potentiometer
Throttle power !7 e
source (–)
BKP00097
20-366 PC300, 350-6

1
5
TROUBLESHOOTING E-6
E-6 [E315] Abnormality (short circuit) in battery relay output system is

displayed
fl This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy

Replace
1 pump controller
Is resistance
between C01
(female) (1) and 2 YES
chassis normal? Is resistance between Defective battery relay Replace
C01 (female) (1) and
• Between C01 battery relay terminal 1) Contact between
BR, and between
(female) (1) and NO wiring harness and other wiring harness
chassis: Approx. chassis normal? and wiring harness
100Ω between C01 (female) Replace
• Between C01 NO
• Turn starting (female) (1) and (1)-H02 (9)-battery
switch OFF. battery relay BR: relay BR.
• Disconnect C01. Max 1 Ω 2) When light is
• Beetween wiring connected
harness and
chassis: Min. 1 MΩ.
• Turn starting switch
OFF.
• Disconnect C01 and
battery relay BR.
PC300, 350-6 20-367

1
5
TROUBLESHOOTING E-7
E-7 [E316] Abnormality (step-out) in motor is displayed
fl If any other service code [E306] – [E318] has occurred at the same time, start troubleshooting from
the code except code[E316].
fl Check that the fuse is normal.
fl Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor
lever” before carrying out the troubleshooting.
Cause Remedy
YES Go to applicable failure

—
mode
YES Defective engine throttle, Replace

1
3 pump controller
Are E306, E317, Operate fuel control
dial 0 MAX and
and E318 YES turn starting switch
displayed? OFF. 4 YES 1) Defective linkage Adjust or
Is operation 2) Defective injection
normal? Is there any replace
• Turn starting scuffing when pump
switch ON. • Turn starting spring rod is
2 switch ON. NO moved to injection
• Turn auto pump end? Defective governor Replace
Is adjustment of deceleration OFF. • Disconnect E05 NO motor
NO linkage normal? • Disconnect
linkage at
• Turn starting governor motor
switch ON. end.
• Turn auto- Adjust (For
deceleration OFF. Defective governor details, see
• Set to governor NO linkage TESTING AND
motor ADJUSTING)
adjustment
mode.
• See TESTING
AND
ADJUSTING.
20-368 PC300, 350-6

1
5
TROUBLESHOOTING E-8
E-8 Engine does not start
* When starting motor does not rotate.

* Check that fuse No= 14 is not blown before starting troubleshooting.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
4 YES
Is voltage between
terminal B and
chassis normal?
starting
Turn NO
H
switch ON.
YI
starting motor Approx. 24V
pinion engaging?
5 YES
Is voltage between
starting switch
terminal C and
-
chassis normal?
.Turn
starting NO
switch t o START.
* Approx. 24V
SYES
I$ there continuity
heard from battery
YES between chassis -
8 ground and battery
switch ON+OFF wiring harness

relay terminalE?
-
YES between starting
switch BR and
- NO
- 7 battery relay
,normal?
BR
- .B~~~~~
, Is there continuity starting
YE ! between
L
switch BR andbattery NO
switch terminal B relay BR: Max.
specific gravityof and BR? 1 Mi2
* Between wiring harness and chassis: Min.
battery noromal?
starting switch
I
- Turn starting
switch ON.
Disconnect both starting switch and battery relay ends.
Min. 241’ terminal B NO

Remove
Specific gravity: normal?
terminal B.
Min. 1.26 Connect ( 4 end
of tester to
battery terminal
(4.
20 - 29V
I
NO
TWP0141 1
20-370 PC300, 350-6

0
TROUBLESHOOTING E-8
Cause Remedy
Defective starting motor ReDlace
Defective contactof wiring

harness between battery
(+)-battery relay B-battery
relay M-starting motor Replace
terminal B (including
battery relay)
Defective contact,or
harness betweenstarting Replace
switch terminalC-X07
-M2 (1)-starting
(10)-E08 (1)
motor terminalS
Defective starting switch
(between terminals B and Replace
C)
Defective battery relay Replace
Defective contactof wiring

relay terminal E and Replace
revolving frame grond
connection terminal
Defective contact, or
harness betweenstarting Replace
switch terminal BR-D13-
battery relayterminal BR
Defective starting switch

Replace
(between B and BR)
Defective contact,or
terminal (+)-Mll-H05 Replace
(6)-X07 (1)-starting switch
terminal B (including
fusible link)
Lack of battery capacity Charge or

replace
PC300, 350-6 20-371

0
code
TROUBLESHOOTING
E-9 Engine speed is irregular
*
a) Idling speed is irregular
model as
shown in Table
- displayed?
YE§ IsE218
Turn starting
switch ON.
No
.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ A!ways cnnnecr my disconnected cmnectcrs b e f ~ r e@n.;
-
When linkage is
disconnected and
motor lever is
3
placed at position
engine low idling?
Turn starting
switch ON.
Q R the ~ e x step.
-
5 See
t
TESTING
AND
ADJUSTING.
1s voltage 1At
NO
E-9
Starting motor signal 7 YE§
Turn starting
switch ON.
- and
betweenco3 (4) -
(17) normal
MIN: 2.9 - 3.3V
NO
NO
Set to monitoring and stable?
code 03 or 02.
* At MIN
I
I 4.0 - 4.75V
NO
I
NO
Table 1
I Controller
model code I
BKWOZlO
* The diagram shows monitoring

code 03.
20-372 PC300, 350-6

0
TROUBLESHOOTING E-9
Cause Remedy
See N mode
Dafeciive adjustment of Adjust

linkage
. Defective injection pumF See S mode
Defective governor Replace

motor
Defective contact of
wiring harness between Repair or
starting switch ACC-X07 replace
(17kCO3(femal) (8).or
defective starting switch
See E-5
See E-2
See C-74

S t a r t i n s switch X07hiIC17) H14 (M6) Fuse
3 -3 &
Engine throttle c o n t r o l l e r
Start in9
ON s i g n a
Fuel d i a Fue
dia
E04 (X31
Power S U P D I Y f o r
fuel d i a l (t)
F e e d b a cski g n a l
a
@
-
A
Governor
Potent io-
Power s u p p l y f o r meter
f u e l d i a l (-) (ip
TWP01412
PC300, 350-6 20-373

0
TROUBLESHOOTING E-9
b) There is hunting
4 YES
J--- = g g1
' f.Jurr1pIS
IllUlLIl d1lU
adjusted, does
displayed? condition become
normal7
NO
Turn starting
switch ON.
I I
disconnected and
motor lever is
3 1
1 ,
Is voltage between
.
Starting motor signal 7
YES
YES C03 (8)and
1
I I
I I I1
Is controller Turn starting
model codeas switch ON.
1 shown in Table Turnfuel control
I l? I dial from MIN to
*Turn starting MAX and stop
switch ON. also at midway
Set to monitoring position. NO * At MAX
code 03 or 02. : 0.5 - 0.9V
: 4.0 - 4.75V
NO
At M A X
: 0.25 - 1.OV
1
NO
Table 1
I Controller
model
code I
BKP00210
* The diagram shows monitoring

code 03.
20-374 PC300, 350-6

a
TROUBLESHOOTING E-9
Cause Remedy
See N mode
Defective adjustment of Adjust

linkage
Defective injection pump See S mode

notor
3efective contact of
wiring harness between
starting switch ACC - Repair or
replace
KO7 (17) - C03 (female)
8). or defective starting
;witch
;ee E-5 -
jee E-2
iee C- 14

S t a r t i n s switch X07 (MIC17) H14 (M6) Fuse
3 -3 &
Engine t h r o t t l e c o n t r o l l e r
ON s i g n a l
Fuel d i a l Fue I
dial
E04 (X31
Power S U P P ~ Y f o r
f u edl i a l (+I Governor
Feedback s i g n a l P o t e n t io-
Power S V P P I Y f o r meter
f u e l d i a l (-)
I I I u TWPOl412
PC300, 350-6 20-375

0
TROUBLESHOOTING E-10
E-10 Lack of output (engine high idling speed is too low)
** Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
YES
Yl - -_. _
displayed?
=Turn starting
switch ON. i 3
Potentiometer
YES
t;I-
pump lever
IIS voltage
and (17) normal
Fuel control dial 5
Start engine.
1 Set fuel control
is controller 1
dial to MAX.
H/O mode.
shown i n Table
1s adjustment of
4.0 - 4.75V
- .i
’
linkage between
tMAX NO
Turn starting r governor motor : 0.25 - 1.OV
switch ON. and pump
* Set to monitoring normal? 8 YES
-7-
code 03 or 02. When linkage
- between governor
motor and pumpis
adjusted, does
NO condition become
normal?
. See TESTING
AND
NO
ADJUSTING.
NO
Table 1
I Controller
model
code t
BKP00210
It The diagram shows monitoring

code 03.
20-376 PC300, 350-6

0
Cause T Remedy
See N mode
Defective injection pump ;ee S mode
Starting motor
;?%r-l, 7 YES
Defective governor
motor
;eplace
- and
between C03 (8) -
chassis Defective contact of
normal and wiring harness between
epair or
stable?
During
- NO starting switch ACC -
X07 (17) - C03 (female)
?place
operation: 20 - (E), or defective starting -
30V switch
See E-5 -
’
See E-2
Defective adjustment of
governor motor linkage djust
See S mode
i
See C- 14

S t a r t i n g switch X07(MIC171 H14 F
Engine ihroiiie c o n t r o l i e r
C03 (0
S t a r t i n g switch
ON s i g n a l
Fuel d i a l Fue I
dial
E04 (X31
Power S U P P ~ Yfor
fuel dial (t) Governor
F e e d b a c ks i g n a l P o t e n t io-
Power S U P P ~ Yf o r meter
fuel d i a l (-1 1
TWP01412
PC300, 350-6 20-377

0
TROUBLESHOOTING E-I 1
E 4 1 Engine does not stop
A Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
* Read the precautionsgiven in TESTING AND ADJUSTING, “Adjusting travel of governor motor
lever” before carrying out the troubleshooting.
YI
1
Is controller 1
- Turn starting
switch ON.
Set to
monitoring code
03 or 02. NO
Table 1
I Controller
model
code I
BKP00210
Ir The diagram shows monitoring

code 03.
Table 2
Voltage from I When

ON (Approx. 24V)
I
starting switch (C03( 8 ) )
OFF To battery relay (BR)
. - - - - - -See
- - Note 1 Voltage output
from controller when starting switch is OFF
When ON
(Approx. 24V)
Condition of actuation To battery relay (BR)
of controller circuit
co1 (1) OFF ~ Min. 4.0 sec.
Drive time Max. 7sec. (when it impossible
is to set to
NO IINJECTION becauseof failure in motor)
BKP00206
Note 1:When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a
voltage of 20 - 30V.
20-378 PC300, 350-6

0
Cause Remedy
Defective injection pump See S mode
Defective adjustment of Adjust

linkage

motor
See E-5 —
Defective engine throttle,

Contact with 24V wiring

harness of wiring
harness between starting Replace
switch ACC – X07 (17) –
C03 (female) (8), or
defective starting switch
See C-14 —
PC300, 350-6 20-379

1
5
E-12 Defective operation of battery relay system (engine does not
stop)
20-380 PC300, 350-6

1
E-12 Relatedelectriccircuitdiagram
X07 (MIC17) H 14 (M6) Fuse Ml 1 (L2)
S t a r t in9
3 3
swi tch 3 -3
fj F u s i b l el i n k
I
E n g i n e th r a t t l e c o n t r o l l e r I II Battery reiay
E.
C03 (04020)
Start ins
sw i t c h
ON s i g n a l
Battery
r e l a yd r i v e
CO1 (MIC13) TWPO1414
PC300, 350-6 20-381

0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts............................................................................................. 20-402

s-1 Starting performance is poor (starting always takes time) .................................................. 20-406
s- 2 Engine does not start ............................................................................................................... 20-407
( I ) Engine does not turn.......................................................................................................... 20-407
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............. 20-408
(3)Exhaust smoke comes out, but engine does not start (fuel is being injected) ........... 20-409
s- 3 Engine does not pick up smoothly ......................................................................................... 20-410
s- 4 Engine stops during operations .............................................................................................. 20-411
s- 5 Engine does not rotate smoothly (hunting) ........................................................................... 20-412
S- 6 Engine lacks output (no power) ............................................................................................... 20-413
s- 7 Exhaust gas is black ................................................................................................................. 20-414
S- 8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20-415
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-416
s-10 Fuel consumption is excessive ................................................................................................
20-417
s-I1 Oil is in cooling water, or water spurts back. or water level goes down .......................... 20-418
s-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................. 20-419
S-I3 Oil level rises (water, fuel in oil) .............................................................................................20-420
S-14 Water temperature becomes too high (overheating) ............................................................ 20-421
s-15 Abnormal noise is made .......................................................................................................... 20-422
Si6 vibration is excessive ...............................................................................................................
^ ^
ZU-~ZS
.-.-
PC300. 350-6 20-401

0
TROUBLESHOOTING METHOD OF USING "TROUBLESHOOTING
CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, ana iroubleshoot-
ing. Thequestions andcheck items areused to
pinpoint high probabilitycauses that can be located
from the failuresymptoms or simple inspecitonwith-
out using troubleshooting tools.
Next, trQubleshGotingt m l s c: direct inspzctinn
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @I in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user's level.
[Check items]
The sewiceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond io this.
/ Czuses i
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshootingl
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-402 PC300, 350-6

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING
CHARTS
The basicmethod of using thetroubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0,and of these, causes that have a high prob-
ability are marked with 0.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or Q in the chart for items
where the prob!ern appeared. The \.w?Ica! c ~ ! u m n
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation ofcause. the
'%I. For [Confirmrecentrepair history] in the
[Questions1 Section, ask the user, and mark
the Cause column with A to use as reference
3 for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down thecauses.
%2. Use the A in the Cause column as reference
for [Degree ofuse (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calcuiating the
points for locating the cause, but it can be
included ifnecessary to determine the order
for troubleshooting.
I1 Confirm recentrepair history

12 Degree of use Operatred
for long period ann
PC300, 350-6 20-403

0
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHARTS
Exampie of troubieshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causai relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If w e look from these three symptoms tofind the causes, we find that there isa relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
s-7
20-404 PC300, 350-6

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Iu_tLLI
Five causes
symptoms in the [Questions1 and [Check items]

section and the five Cause items in the vertical
1
I
column.
Three symptoms
t tI '
I
I
SteD 2
Add up the total of 0 and Omarks where the
horizontal linesfor the three symptoms and the
vertical columns for thecauses intersect.
(1)Cloggedcleaner
air element: OOQ
(2) Air leakage between turbocharger
and head: 00
(3)Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn
piston ring, cylinder: 0
Step 3
~- ~~~~
The calculation in Step 2 show thatthe closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked0 . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
PC300, 350-6 20-405

0
TROUBLESHOOTING s-I
S-1 Starting performance is poor (starting always takes time)

* Check that the monitor panel does not displayany
abnormality in the governor control system.
Generai causes why exhaust smoke comes outbut
engine takes timet o start
e Defectiveelectricalsystem
* Insufficientsupply of fuel
insufficientintake of air
e !mp:oper selection of fuel
(At ambient temperatureof 10°C or below, use
ASTM 0975 No. 1)
* Batterychargingrate
~
\~
I*ll.t"I.
b Charwe
i ~m f
~
100% ~ ~,
90% 80% 75% 70%
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-70°C I1.25
1.24
1.26
1.28
1.30
The specific gravity should exceed the value
for the charging rate of 70% in the above table.
In cold areas thespecific gravitymust ex-
ceed the value for the charging rate of 75%
ir: the abccc3 tab!€.
Legend
20-406 PC300, 350-6

0
TROUBLESHOOTING s-2
S-2 Engine does not start

(1) Engine does not turn Causes f
General causes why engine does not turn
internalparts of engine seized
* If internal parts of the engine are seized,
carryouttroubleshooting for "Engine
stops during operations".
Defective electrical system
Legend
0: Possible causes(judging fromQuestions and check items)
0: Most probable causes(judgingfrom Questions and Check items)
: Possible causes dueto length of use (usedfor a long period1
e:Itemsto confirm the cause.
I 1 Confirm recent
historyrepair I
VI Degree of use of machine Operated for long period
0
'= Condition of horn when Horn sounds
a,
5 starting switch is turnedON Horn does not soundor volume is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages again
moves out, but Makes rattling noise anddoes not turn
VI
6
.-
Y
When starting switchis turned to START, pinion does not moveout
5 When starting switch is turnedt o ON, there is no clicking sound

2
t Battery termlnal is loose
When battery is checked, battery electrolyte is found to be low
i
Specific gravity of electrolyte,voltage ofbattery is low I

For the following conditions 1) - 5),turn the starting switch
OFF, connect the cord, and carry out troubleshooting ON
at
1) When terminal B and terminalC of starting switch are
connected, engine starts
2) When terminal B and terminalC of starting motor are
3) When terminal B and terminalC of safety relay are
4) When terminal of safety switch and terminalB of
starting motor are connected, engine starts
5)There is no24V between battery relay terminalM and
terminal E
When ring gear is inspected directly, tooth surface is
found to be chipped
PC300, 350-6 20-407

0
TROUBLESHOOTING s-2
(2) Engine turns but no exhaust smoke comes

out (fuel is not being injected)
J,Check that the monitor panel does not dis-

play any abnormality in the governor control
system.
General causes why engine turns but no ex-
haust smoke comes out
Supply of fuelimpossible
* Supp!yof fuel is extremely small
Improper selection of fuel (particularly in win-
ter)
-k Standards for use of fuel

Causes /
Ambient temprature
Type Of -22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 10 20 30 40°C
Diesel fuel
Legend
from Questions and Check items)

h of use (used for a long period)
1) Injection pump couplingdoes not turn
0 ) .
C
Inspect injectionpump directly e
‘g When control rack is pushed,it is foundto be heavy, or does not return
0 -
f
0
Inspect feedpump directly a
2 When fuel filter, strainer are inspected directly, they are found
to be clogged a a
,!? When feed pump straineris inspected directly,it is found to be clogged e
When fuel cap is inspected directly, it is foundto be clogged e
o o o
o o o 0 0 0
m m m c c y ~ _ m
Remedy 3 g k dP
2 I 2 8 a G 6 v
20-408 PC300, 350-6

0
TROUBLESHOOTING 5-2
(3) Exhaust smoke comes out but engine does

not start
(Fuel is being injected)
* Generalcauses why exhaustsmokecomes

out but engine does not start
Lackof rotating force due todefectiveelec-
trical system
Insufficientsupply of fuel
Insufficient intake of air
Improper selection of fue! and oi!
Legend
0: Possible causes (judgingfrom Ouestiosns and check items1
0 : Most probable causes (judging from Questions andCheck items)
A : Possible causes due to length of use (used for a long period)
:Items to confirm the cause.
PC300, 350-6 20-409

0
TROUBLESHOOTING s-3
5-3 Engine does not pick up smoothly (follow-up is poor)
rt Check that the monitor paneldoesnotdisplay any

abnormality in the governor control system.
General causes why engine does not pick up smoothly
Insufficientintake of air
* Insufficientsupply of fuel
lmpropercondition of fuel injection
e lmproper fuel used
Legend
0: Possible causes(judging fromQuestions and check items)
0: Mast probable causes(judgingfrom Questions andCheck items)
a:Possible causes due tolength of use (usedfor a long period)
Color of exhaust gas

Blue under light load Q
Black 8 0 0 0
Clanging sound is heard from around cylinder head 0
VI
Mud isstuck t o f u etank
l cap 0
.-E
+d
There is leakage from fuel piping 0
Y
2 High idling speed underno load is normal,

0
but speed suddenly drops when loadis applied
00 0
There is huntingfrom engine (rotation is irregular) 000 0
When exhaustmanifold is touched immediately after
starting engine, temperature of some cylinders islow
80
Blow-by gas is excessive 0
~~ ~ .-
-
When air cleaner elementis inspected directly,it is found tobe clogged
When fuel filter, strainer are inspected directly. theyare found to be clogged
When feed pump strainer is inspected directly,it is found to be clogged
m
.5
4-
of certain cylinders is stopped
Speed does not change when operation
9VI When control rack is pushed, it is found tobe heavy, or does not return
2
1 '
it is found tobe low
When compression pressure is measured,
+2 When turbocharger isrotated by hand, it is found t o be heavy

When valve clearance is checked directly, it is found to be outside standard value
When fuel cap is inspecteddirectly, it is found to be clogged
When feed pump isoperated, operation is too light or too heavy
Remedy
20-410 PC300, 350-6

0
TROUBLESHOOTING s-4
S-4 Engine stops during operations

* Check that the monitor panel fuel level dis-
play shows that there is still fuel remaining.
General causes why engine stops during opera-
tions
Seized parts inside engie Causes
Insufficientsupplyoffuel
overheating
* If there is overheating and the engine stops,
carry out troubleshooting for overheating.
Failure in mainpistonpump
* If the engine stops because of a failure in the
main piston pump, carry out troubleshooting
for the hydraulic system (H MODE).
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes(judgingfrom Questions and Checkitems)
: Possible causesdue to length ofuse (used for a long period)
Condition when
engine stopped
Metal particles arefound when oil is drained
When oil pan is removed and inspection

is made directly,
it is foundto be abnormal
When head cover is removed and inspection

is made directly
m
.C
c it is found t o be abnormal
0
0 When gear train is inspected, it does not turn
f
2 2
When fuel filter, strainer are inspected directly,
2 they are found to be clogged
-i
When feed pump strainer is inspected directly,it is foundto be clogged
Remedy
PC300, 350-6 20-411

0
3 '
Check items \ Questions

'tI
1 Q
0
8
3
Q 2
0
(0
v)
-.
a 3
U 4
m2 3
Q B
8
n
3
c
8
3
CQY
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

* Check that the monitorpaneldoesnotdisplay
any abnormality in the governor control system.
Measure the engine speed and judge if the cause is
in the engine or in the chassis.
General causes why engine lacks output
Insufficientintakeofair
Insufficientsupplyoffuel
Improperconditionoffuelinjection
!mproper fue! used
(if non-specified fuel is used, output drops)
Lack of output due to overheating
* If there is overheatingandinsufficientoutput,
carry out troubleshooting for overheating.
Confirm recent repair history

Degree of use of machine 1 Operated for long
period IC 1 lnlnI/\/ I 1 1 3 1 1 I 1
Power was lo
PC300, 350-6 20-413

0
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black

(incomplete combustion!
Generai causes why exhaust smoke is biack

* insufficientintakeofair
= Improper condition of fuelinjection
Excessiveinjection of fuel
Legend
0: Possible causes (judging fromQuestions and checkitems)
0: Most probablecauses (judging fromQuestions and Check items)
: Possible causes due to length of use [usedfor a long period)
0 : Items t o confirm the cause.
Power waslost
When turbocharger i s rotated by hand, it is found to be heavl

When aircleaner is inspected directly, it is found tobe clogged
m When compression pressure is measured, it is found tobe low
.-
c
is stopped
Speed does not change when operation of certain cylinders
8
When check is made using delivery method,injectiontiming is found to be incorrect
-
R
Injection pump test shows that injection amount
is incorrect
2
When valve clearanceis checked directly it is foundto be outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found tobe heavy, or does not return
I
Remedy
__
20-414 PC300, 350-6

0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (orexhaust smoke is blue)

* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
s ive
Abnormalcombustion of oil
Externalleakageof oil
Wear of lubrication system
Legend
0: Possible causes(judging from Questions and checkitems)
0: Most probablecauses (judgingfrom Questions and Check items)
: Possible causesdue to length of use (used for a long period)
0 : Items to confirmthe cause.
When compression pressure is measured, it is found to be low 0

When breather elementis inspected, it is found to be clogged with dirty oil
VI There is external leakage of oil from engine
E
.-
x
~ Pressure-tightness test ofoil cooler shows thereis leakage
Excessive play of turbocharger shah
c .
inspect rear seal directly
When intake manifold is removed,
dust is foundinside
When intake manifold is removed, insideis found to be dirty with oil
e
I
PC300, 350-6 20-415

0
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
Intake of exhaust gas due to internal wear
Cloggingoflubricationpassage
e Improperfuel
Improperoil used
Operationunderexcessive load
gth of use (used for a long period)
Degree of use of machine I Operated for long period I n I 1 In1 1 1

Engine oil must be added more frequently 0
Non-specified oil is being used 0
Blue under light load 0
Black Q
d
Amount of blow-by gas V
4
m
v, I
w
4
u)
I-
,
..
When safety valve is directlyinspected, spring is foundto

be catching or broken
20-416 PC300, 350-6

0
TROUBLESHOOTING S-1 0
S-10 Fuel consumption is excessive

General causes why fuel consumption is exces-
sive
Leakage of fuel
Improper condition of fuelinjection
9 Excessive injection of fuel
from Questions andCheck items)

h of use (usedfor a long period)
I injection
pump
measurement
shows
that
injection
amount is excessive I I 1 1 I I I
Speed does not change when operation of certain
cylinders isstopped
(I)
,S
4-
When control rack is pushed, it is found to be heavy, or does not return
0
When check is made using delivew method, injection timing
f
22
is found to be incorrect
S' Remove head cover and inspect directly
I-
Remove feedpump andinspect directly
low idling speedis found to be high
When engine speed is measured,
I
Remedy
PC300, 350-6 20-417

0
TROUBLESHOOTING s-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
* Internal ieakage in lubricationsystem
iniernai ieakage in cooiingsystem
Legend
0:Possible causes(judgingfrom Questions andcheck items)
0:Most probablecauses (judgingfrom Questions and Check items)
: Possible causes dueto length of use (used fora long period)
20-418 PC300, 350-6

0
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

Ik Check that the monitor panel engine oil level lamp is
not lighted up.
* When the oil pressure sensor is normal (see M mode).
General causes why oil pressure lamp lights up
Leakage, clogging, wear of lubricating system
Defectiveoilpressurecontrol
Improperoil used (improperviscosity)
Deterioration of oilduetooverheating
* Standards for engine oil selection
Ambient temperature
Type of fulid
-22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 10 20 30 40°C
8
m Deoree of use ofmachine I Operatedforlong period A
I -
.A
0
'g Replacement of filters has not beencarried out according
a, 0
5 t o Operation Manual
(--
Non-specified oil is being used
up Lightsidling
at low 0 1_3
Condition
oil when . . .
Oil is cloudy white or smells of diesel oil
I
~~
When oil filter is inspected directly, it is found tobe clogged
I
~
.-C
6 Remove oil panandinspectdirectly
o
r
Oii pump rotation is heavy, there is play
-a
(o
2 There is catching of relief valve or regulator valve, spring or

0
2
I- valveguide is broken
When oil pressureis measured, it is found to be within
I standard value
I Remedy
PC300, 350-6 20-419

0
TROUBLESHOOTING 5-73
S-13 Oil level rises (water, fuel in oil)

* I f there is oil in the cooling water, carry out
troubleshooting for "Oil is in cooting water".
Generai causes why oii ievei rises
Water in oil
a Fuel in oil (diluted, and smells of diesel fuel)
Entry of oil from other component
Legend
Pressure-tightness testof oil cooler shows there is leakage

Pressure-tightness testof cylinder head shows there is leakage
When cornoression Dressure is measured. i is W
20-420 PC300,350-6
0
TROUBLESHOOTING S-I 4
5-14 Water temperature becomes too high (overheating)

* Check that the monitor panel coolant level caution
lamp is not lighted up.
* When the monitor panel water temperature gauge
is normal, go to troubleshooting of machine moni-
tor system (M mode).
General causes why water temperature becomes too
high
Lack of cooling air (deformation, damage of fan)
Drep in heat dlssipaticn efficiency
Defective coolingcirculationsystem
* Carry out troubleshooting for chassis.
Legend
PC300, 350-6 20-421

0
VI
.I
0
VI
.I
0
C
v)
0
m
+a
VI
a
m
.c
2
c
0
-
L
0
8
-1
S-16 Vibration is excessive

* If there is abnormal noise together with the
vibration, carry out troubleshooting for "Ab-
normal noise is made".
General causes why vibration is excessive
Defectiveparts (abnormal wear, breakage)
Improper alignment
Abnormal combustion
I Causes I
Legend
0: Possible causes(judging fromQuestionsand check items)
0: Moa probable causes (judgingfrom Questions andCheck items)
: Possible causes dueto length of use (usedfor a long period)
1
1
Remove oil pan andinspect directly
rn Remove side cover and inspect directly
c
,-
+-
Inspect directly for loose engine mounting bolts, broken cushion
r
g Inspect inside of output shaft (damper) directly
EJ Remove front cover and inspect directly
e
Remove head cover and inspect directly
Injection pump testshows that injection amountis incorrect
I
PC300, 350-6 20-423

0
PUMP CONTROLLER
(PUMP CONTROL SYSTEM)
(C MODE)
Points to remember when troubleshooting pump controller system .............................................. 20-452

Action taken by controller when abnormality occurs and problems on machine ......................... 20-454
Judgement table for engine throttle, pump controller (pump control system) and
hydraulic related parts ...................................................................................................................... 20-462
Electrical circuit diagram for C mode .................................................................................................. 20-464
C- 1 Abnormality in controller power source system (controller LED is OFF) ........................ 20-466
C- 2 [E232] Short circuit in front pump TVC solenoid system is displayed ............................ 20-467
C- 3 [E233] Disconnection in front pump TVC solenoid system is displayed ......................... 20-469
C- 4 [E236] Short circuit in rear pump TVC solenoid system is displayed .............................. 20-471
C- 5 [E237] Disconnection in rear pump TVC solenoid system is displayed ........................... 20-473
C- 6 [E207] Short circuit in action mode (boom) solenoid system is displayed ..................... 20-475
C- 7 [E208] Disconnection in action mode (boom) solenoid system is displayed .................. 20-476
C- 8 [E203] Short circuit in swing brake solenoid system is displayed ....................................20-477
C- 9 [E213] Disconnection in swing brake solenoid system is displayed .................................20-479
C-10 [E204] Short circuit in pump merge/divider solenoid system is displayed ..................... 20-481
C-11 [E214] Disconnection in pump merge/divider solenoid system is displayed .................. 20-482
C-12 [E206] Short circuit in travel speed solenoid system is displayed ....................................20-483
C-13 [E216] Disconnection in travel speed solenoid system is displayed .................................20-484
C-14 [E231] Short circuit in active mode (swing) solenoid system is displayed .................... 20-485
C-15 [E235] Disconnection circuit in active mode (swing) solenoid system is displayed ..... 20-486
C-16 [E217] Model selection input error is displayed .................................................................. 20-487
C-17 [E222] Short circuit in LS-EPC solenoid system is displayed ............................................. 20-489
C-18 [E223] Disconnection in LS-EPC solenoid system is displayed ......................................... 20-490
C-19 [E224] Abnormality in front pump pressure sensor system is displayed ........................ 20-491
C-20 [E225] Abnormality in rear pump pressure sensor system is displayed ......................... 20-492
C-21 [E226] Abnormality in pressure sensor power source system is displayed .................... 20-493
C-22 [E227] Abnormality in engine speed sensor system is displayed ..................................... 20-494
C-23 Abnormality in machine push-up solenoid system (no service code displayed) ........... 20-495
PC300, 350-6 20-451

1
5
POINTS TO REMEMBER WHEN TROUBLESHOOTING
TROUBLESHOOTING PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP

CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself
In the following two cases, there is a high probability that the same problem will occur again, so
it is desirable to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed
and the connector is returned to its original position when carrying out troubleshooting of the
failure, and the service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the user code from memory.
2. User code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down
the content of the display, then erase the display. After trying to re-enact the problem, carry out
troubleshooting according to the failure code that is displayed.
(There are cases where mistaken operation or abnormalities that occur when the connector is
disconnected are recorded by the memory retention function. Erasing the data in this way saves
any wasted work.)
20-452 PC300, 350-6

1

OCCURS AND PROBLEMS ON MACHINE
User Service
code code
1. Short circuit with ground, short circuit inside front pump TVC sole-
noid
2. Short circuit with power source, short circuit with ground in wiring
Short circuit in front harness between controller C02 (8) and TVC solenoid C13 (1) ((+)
E232 pump TVC solenoid side)
system 3. Short circuit with power source in wiring harness between control-
ler C02 (18) and TVC solenoid C13 (2) ((-) side)
4. Defective engine throttle, pump controller
1. Disconnection, defective contact inside front pump TVC solenoid

2. Disconnection, defective contact in wiring harness between con-
troller C02 (8) and TVC solenoid C13 (1) ((+) side)
3. Disconnection, defective contact, short circuit with ground in wir-
ing harness between controller C02 (18) and TVC solenoid C13 (2)
Disconnection in ((-) side)
E233 front pump TVC so- 4. Defective engine throttle, pump controller
lenoid system
E02
1. Short circuit with ground, short circuit inside rear pump TVC sole-
noid
Short circuit in rear harness between controller C02 (9) and TVC solenoid C04 (1) ((+)
E236 pump TVC solenoid side)
system 3. Short circuit with power source in wiring harness between control-
ler C02 (19) and TVC solenoid C04 (2) ((-) side)
1. Disconnection, defective contact inside rear pump TVC solenoid

2. Disconnection, defective contactin wiring harness between control-
ler C02 (9) and TVC solenoid C04 (1) ((+) side)
ing harness between controller C02 (19) and TVC solenoid C04 (2)
((-) side)
Disconnection in rear 4. Defective engine throttle, pump controller
E237 pump TVC solenoid
system
1. Short circuit with ground, short circuit inside swing holding brake
solenoid
Short circuit in swing 2. Short circuit with ground in wiring harness between controller C01
E203 holding brake sole- (3) and solenoid V04 (2) ((+) side)
noid system 3. Defective engine throttle, pump controller
E03 1. Disconnection, defective contact inside swing holding brake sole-

noid
2. Disconnection, defective contact, short circuit with power source in
Disconnection in wiring harness between controller C01 (3) and solenoid V04 (2) ((+)
E213 swing holding brake side)
solenoid system 3. Disconnection, defective contact in wiring harness between sole-
noid V04 (1) and chassis ground ((-) side)
20-454 PC300, 350-6

1
5
Condition when normal Action by controller when abnor- Problem that appears on machine
(voltage, current, resistance) mality is detected when there is abnormality
1. Makes output to TVC solenoid 0. 1. No current flows to the front
2. Displays user code E02 on monitor pump TVC solenoid.
panel. Therefore, when the load is
· Resistance of solenoid: fl If the abnormality is restored by the large, there is a big drop in the
10 – 22 Ω vibration of the machine, it resets the engine speed which may result
power source to restore to the proper in the engine stalling.
condition. (However, the service code 2. The swing acceleration is poor
display does not go out.)
1. The current stops flowing to the TVC 1. In the case of 1, it is the same
solenoid, so no particular action is as E232.
taken. 2. In the case of 2, the current (min.
· Resistance of solenoid: 2. If there is a short circuit with the 1A) continues to flow to the
10 – 22 Ω ground at the (-) end, the current (min. front pump TVC solenoid, so the
· Current: 1000 mA 1A) continues to flow to the TVC so- output of the front pump TVC
(H/O mode, auto-decel- lenoid. valve increases and the overall
eration ON, levers at 3. It displays user code E02 on the moni- speed becomes slower.
neutral, fuel control dial tor panel.
at MAX.) fl If the abnormality is restored by the
vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
1. Makes output to TVC solenoid 0.

2. Displays user code E02 on monitor
panel.
· Resistance of solenoid: fl If the abnormality is restored by the Same as E232 (but for the rear
10 – 22 Ω vibration of the machine, it resets the pump)
1. The current stops flowing to the TVC

solenoid, so no particular action is
taken.
· Resistance of solenoid: 2. If there is a short circuit with the
10 – 22 Ω ground at the (-) end, the current (min.
Current: 1000 mA 1A) continues to flow to the TVC so-
(H/O mode, auto-decel- lenoid. Same as E233 (but for the rear
eration ON, levers at 3. It displays user code E02 on the moni- pump)
neutral, fuel control dial tor panel.
at MAX.) fl If the abnormality is restored by the
1. Makes output to TVC solenoid 0.

panel. When the swing is operated, the
· Resistance of solenoid: fl If the abnormality is restored by the motor brake is not released, so the
20 – 60 Ω vibration of the machine, it resets the upper structure does not swing.
1. The current stops flowing to the sole-
noid, so no particular action is taken.
· Resistance of solenoid: panel.
20 – 60 Ω fl If the abnormality is restored by the Same as display for E203
PC300, 350-6 20-455

1
User Service
code code
1. Short circuit with ground, short circuit inside pump merge/divider
Short circuit in pump solenoid
—— E204 merge/divider sole- 2. Short circuit with ground in wiring harness between controller C01
noid system (2) and solenoid V03 (2) ((+) side)
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in travel 2. Short circuit with ground in wiring harness between controller C01
—— E206 speed solenoid sys- (9) and solenoid V06 (2) ((+) side)
tem 3. Defective engine throttle, pump controller
1. Short circuit with ground, short circuit inside active mode (boom)
Short circuit in active solenoid
—— E207 mode (boom) sole- 2. Short circuit with ground in wiring harness between controller C01
1. Disconnection, defective contact inside active mode (boom) solenoid

Disconnection in ac- wiring harness between controller C01 (9) and solenoid V02 (2) ((+)
—— E208 tive mode (boom) side)
solenoid system 3. Disconnection, defective contact in wiring harness between sole-
1. Disconnection, defective contact inside pump merge/divider sole-

noid
Disconnection in 2. Disconnection, defective contact, short circuit with power source in
—— E214 pump merge/divider wiring harness between controller C01 (2) and solenoid V03 (2) ((+)
solenoid system side)
3. Disconnection, defective contact in wiring harness between sole-
1. Disconnection, defective contact inside travel speed solenoid

Disconnection in wiring harness between controller C01 (9) and solenoid V06 (2) ((+)
—— E216 travel speed solenoid side)
system 3. Disconnection, defective contact in wiring harness between sole-
1. Disconnection, defective contact, short circuit with ground in model

Model selection input selection wiring harness C17(5) (6) (7) (13) (14)
—— E217 2. Defective engine throttle, pump controller
error
20-456 PC300, 350-6

1
5
1. Makes output to solenoid 0. The pump merge/divider valve con-
fl If the abnormality is restored by the tinues to merge the oil flow.
· Resistance of solenoid: vibration of the machine, it resets the 1. In the L/O and F/O modes, the
20 – 60 Ω power source to restore to the proper work equipment and swing
condition. (However, the service code speeds become faster.
display does not go out.) 2. The steering is difficult to turn.
1. Makes output to solenoid 0. Even if the travel speed is switched,

fl If the abnormality is restored by the the travel speed does not change
· Resistance of solenoid: vibration of the machine, it resets the (remains at Lo)
20 – 60 Ω power source to restore to the proper
1. Makes output to solenoid 0.

fl If the abnormality is restored by the When mode is STD (active mode
· Resistance of solenoid: vibration of the machine, it resets the OFF), the boom lower speeds be-
20 – 60 Ω power source to restore to the proper come faster.

fl If the abnormality is restored by the
· Resistance of solenoid: vibration of the machine, it resets the Same content as display for E207


· Between C17 (6), (13) and Detects abnormality in input 1. Engine stalls, or
chassis: Max. 1 Ω 1) Retains data when starting switch is 2. Work equipment, swing, travel
Between C17 (5),(7),(14) ON speeds are all slow, and there
and chassis: Min. 1 MΩ 2) Functions as PC100 when non-set con- is no power
ditions are input
PC300, 350-6 20-457

1
User Service
code code
1. Disconnection, short circuit, short circuit with ground in network
wiring harness
2. Abnormality in engine throttle, pump controller
3. Abnormality in monitor
Network response
—— E218 overtime error
1. Short circuit with ground, short circuit inside LS-EPC solenoid

Short circuit in LS- harness between controller C02 (7) and solenoid C10 (1) ((+) side)
—— E222 EPC solenoid system 3. Short circuit with power source in wiring harness between control-
ler C02 (17) and solenoid C10 (2) ((-) side)
1. Disconnection, defective contact inside LS-EPC solenoid

2. Disconnection, defective contact in wiring harness between con-
troller C02 (7) and solenoid C10 (1) ((+) side)
ing harness between controller C02 (17) and solenoid C10 (2) ((-)
Disconnection in LS- side)
—— E223
EPC solenoid system 4. Defective engine throttle, pump controller
1. Disconnection, defective contact, short circuit, short circuit with

ground inside front pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness
Abnormality in front between controller C03 (6) and pressure sensor C08 (2) ((+) side)
—— E224 pump pressure sen- and between C03 (16) and C08 (1) ((-) side)
sor system 3. Disconnection, defective contact, short circuit with power source,
short circuit with ground in wiring harness between controller C03
(3) and pressure sensor C08 (3) (SIG side)
1. Disconnection, defective contact, short circuit, short circuit with

ground inside rear pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness
Abnormality in rear between controller C03 (6) and pressure sensor C07 (2) ((+) side)
—— E225 pump pressure sen- and between C03 (16) and C07 (1) ((-) side)
sor system 3. Disconnection, defective contact, short circuit with power source,
short circuit with ground in wiring harness between controller C03
(13) and pressure sensor C07 (3) (SIG side)
1. Short circuit, short circuit with ground inside front pump pressure
sensor or rear pump pressure sensor
2. Short circuit, short circuit with ground in wiring harness between
Abnormality in pres- controller C03 (6) and front pressure sensor C08 (2) or rear pres-
—— E226 sure sensor power sure sensor C07 (2) ((+) side)
source system 3. Defective engine throttle, pump controller
1. Disconnection, defective contact, short circuit inside engine speed

sensor
Abnormality in speed 2. Disconnection, defective contact, short circuit with ground in wir-
—— E227
sensor system ing harness between controller C16 (1) and speed sensor E07 (2) ((-)
side) and between C16 (2) and E07 (1) (SIG side)
20-458 PC300, 350-6

1
5
1. When communications are impossi- 1. q Even when travel is oper-
ble with the monitor, control is car- ated, the power max. func-
ried out with the following settings. tion does not work
q Working mode: G/O w The swift speed-down func-
w Priority mode: OFF tion does not wor
e Travel speed: Lo e The auto-deceleration cannot
r Auto-deceleration: ON be canceled
t Power max. : ON (others are as r The travel speed does not in-
usual) crease
t The priority mode has no effect
y The automatic mode has no
effect
1. Makes output to LS-EPC solenoid 0. 1. The Lo travel speed is too fast.

fl If the abnormality is restored by the 2. In L/O and F/O modes, the work
· Resistance of solenoid: vibration of the machine, it resets the equipment speed is too fast.
7 – 14 Ω power source to restore to the proper 3. When the engine is running at
condition. (However, the service code low idling, the swing speed is
display does not go out.) too fast.
1. The current stops flowing to the LS- 1. In the case of 1, it is the same
EPC solenoid, so no particular action as E222
is taken. 2. In the case of 2, electric current
2. If there is a short circuit with the (min. 1A) continues to flow to
ground at the (-) end, the current (min. the LS-EPC solenoid, so the
· Current: Approx. 705 mA 1A) continues to flow to the LS-EPC work equipment, travel, and
(Levers at neutral, low solenoid. swing speeds are slow
idling) fl If the abnormality is restored by the
· Between C03 (3) and (16): 1. Takes front pump pressure as 0 MPa 1. The travel speed does not auto-
0.5 – 4.5 V {0 kg/cm2} when actuating. matically shift (it does not
· Between C03 (6) and (16): fl If the abnormality is restored by the change from Hi to Lo).
18 – 28 V vibration of the machine, it resets the fl If the button is operated
· Between C03 (female) (3) power source to restore to the proper manually, the panel display
and (16), (3) and chassis condition. (However, the service code is switched.
· Resistance: Min. 1 MΩ display does not go out.)
(Disconnect connectors
C03 and C08.)
· Between C03 (13) and (16): 1. Takes rear pump pressure as 0 MPa 1. The travel speed does not auto-
0.5 – 4.5 V {0 kg/cm2} when actuating. matically shift (it does not
· Between C03 (6) and (16): fl If the abnormality is restored by the change from Hi to Lo).
18 – 28 V vibration of the machine, it resets the fl If the button is operated
· Between C03 (female) (13) power source to restore to the proper manually, the panel display
and (16), (13) and chassis condition. (However, the service code is switched.
· Resistance: Min. 1 MΩ display does not go out.)
(Disconnect connectors
C03 and C07.)
1. Takes front pump and rear pump pres- 1. The travel speed does not auto-
sure as 0 MPa {0 kg/cm2} when actu- matically shift (it does not
ating. change from Hi to Lo).
· Voltage between C03 (6) 2. When abnormality is detected, it fl If the button is operated
and (16): 18 – 28 V switches the output OFF, and when manually, the panel display
all levers are returned to neutral, it is switched.
outputs again.
fl This automatic resetting is repeated
up to 3 times.
· Resistance: 500 – 1000 Ω 1. It functions in the equivalent of the G/ It operates about the same as G/O
· Voltage (AC range) : O mode (the speed rises) mode (prolix) (the power is slightly
0.5 – 3.0 V (engine lower)
started)
PC300, 350-6 20-459

1
User Service
code code
1. Short circuit with ground, short circuit inside active mode (swing)
Short circuit in active solenoid
—— E231 mode (swing) sole- 2. Short circuit with ground in wiring harness between controller C01
1. Disconnection, defective contact inside active mode (swing) sole-

noid
Disconnection in ac- 2. Disconnection, defective contact, short circuit with power source in
—— E235 tive mode (swing) wiring harness between controller C01 (10) and solenoid V07 (2)
solenoid system ((+) side)
3. Disconnection, defective contact in wiring harness between sole-
noid V07 (1) and chassis ground ((–) side)
20-460 PC300, 350-6

1
5
1. Makes output to solenoid 0. In active mode and heavy-duty
fl If the abnormality is restored by the mode, the rise in the bucket edge
· Resistance of solenoid: vibration of the machine, it resets the is the same in swing + boom RAISE.
20 – 60 Ω power source to restore to the proper There is no priority.

· Resistance of solenoid: vibration of the machine, it resets the Same as E231
PC300, 350-6 20-461

1
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROL-

LER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
Engine throttle, pump controller (E2:XX system)
Abnormality in controller power source

Disconnection in active mode (boom) solenoid system
Short circuit in active mode (swing) solenoid system

Disconnection in active mode (swing) solenoid system
Short circuit in active mode (boom) solenoid system
Disconnection in front pump TVC solenoid system
Disconnection in travel speed selector solenoid system

Disconnection in swing holding brake solenoid system
Disconnection in pump merge/divider solenoid system

Disconnection in rear pump TVC solenoid system
Short circuit in front pump TVC solenoid system
Short circuit in travel speed selector solenoid system

Short circuit in swing holding brake solenoid system
Disconnection in LS-EPC solenoid system

Short circuit in pump merge/divider solenoid system
Short circuit in rear pump TVC solenoid system
Short circuit in LS-EPC solenoid system

Model selection input error
Failure mode
User code LED E02 — E03 —
Service code OFF 232 233 236 237 207 208 203 213 204 214 206 216 217 222 223 231 235
Speeds of all work equipment, swing, travel are slow or lack power ▲ ▲ ▲ ▲ ● ●
All work equipment,
There is excessive drop in engine speed, or engine stalls ● ● ● ● ●

travel, swing
No work equipment, travel, swing move

Abnormal noise generated (around pump)
Auto-deceleration does not work ●
Fine control ability is poor or response is poor ● ●
Boom is slow or lacks power ● ● ●
Arm is slow or lacks power ●
Bucket is slow or lacks power
Work equipment
Boom does not move

Arm does not move
Bucket does not move
Excessive hydraulic drift
Excessive time lag (engine at low idling) ●
Other equipment moves when single circuit is relieved
In L/O, F/O modes, work equipment speed is faster than specified speed ● ● ● ●
Machine push-up function does not work
Compound
operations
In compound operations, work equipment with larger load is slow

In swing + boom (RAISE), boom is slow ● ●
In swing + arm, arm is slow
In swing + travel, travel speed drops excessively
Deviation is excessive during normal travel
Travel system
Travel deviation
Deviation is excessive when starting
Travel speed is slow ●
Steering does not turn or lacks power ● ●
Travel speed does not switch or is faster than specified speed ● ● ● ● ●
Does not move (one side only)
Both left and right ● ●
Does not swing
One direction only
Swing acceleration is poor Both left and right ● ● ● ●
or swing speed is slow One direction only
Both left and right
Swing system
Excessive overrun
when stopping swing One direction only
Excessive shock when stopping swing (one direction only)
Excessive abnormal noise when stopping swing
Excessive hydraulic When holding brake is released
drift of swing When holding brake is applied
Swing speed is faster than specified swing speed ● ● ● ●
Troubleshooting code when service code is displayed C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12 C-13 C-14 C-15 C-16 C-22 C-23
Troubleshooting code when there is abnormality in monitoring check – – – – – – – – – – – – – – – – – –
▲ :This shows applicable item for service code (simultaneous abnormality at front or rear)
‡ :This shows applicable item for service code
ª :This shows item that needs only checking with monitoring
fi :This shows item to check with monitoring or machine monitor
20-462 PC300, 350-6

1
5
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
fl If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Troubleshooting code if no service

controller (E2:XX system) Check items in monitoring mode
Pressure switch Actuation of solenoid
Front pump TVC current output

Front pump discharge pressure input
Abnormality in pressure sensor power source system
Rear pump discharge pressure input
Rear pump TVC current output

Abnormality in engine speed sensor system
Abnormality in front pump pressure sensor system
Abnormality in rear pump pressure sensor system
Swing holding brake (3)

Active mode (boom) (2)
Pump merge/divider (4)
LS-EPC current output

Swing lock switch (3)
Active mode (swing)
Engine speed input

Kerosene mode (5)
Boom LOWER (3)
code is displayed
Bucket DUMP (2)
Bucket CURL (1)
Boom RAISE (4)
Travel speed (6)

Knob switch (6)
Arm OUT (6)
Model code
Arm IN (5)
Swing (1)
Travel (2)
Bit pattern Monitoring code

224 225 226 227 20 21 22 23 02 10 11 12 13 14 15
● fi ª ª ª ª ª ª H-1
● ª ª ª H-2
H-3
H-4
● fi fi fi fi fi fi fi fi H-5
H-6
fi fi ª ª ª ª H-7
fi fi ª ª ª H-8
fi fi ª ª H-9
H-10
H-11
fi fi fi ª H-12
H-13
ª ª H-14
H-15
C-21
H-16
ª ª ª H-17
H-18
H-19
H-20
fi ª H-21
fi ª H-22
● ● ● ● fi ª ª ª ª ª H-23
H-24
fi fi ª ª
H-25
ª
H-26
H-27
H-28
H-29
H-30
ª ª ª ª ª ª ª ª
ª ª H-31
C-17 C-18 C-19 C-20 – – – – – – – – – – – – – – – – – – – – – – –
– – – – F-1 F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 – – – – – – – – – – – –
PC300, 350-6 20-463

1
5
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
20-464 PC300, 350-6

1
4
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
PC300, 350-6 20-465

1
TROUBLESHOOTING C-1
C-1 Abnormality in controller power source system (controller LED is

OFF)
tor to its original position, if an E service code is not displayed, the problem has been removed.
fl Check that fuse 1 is not blown.
fl When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
C-1 Related electric circuit diagram
20-466 PC300, 350-6

1
TROUBLESHOOTING C-2
C-2 [E232] Short circuit in front pump TVC solenoid system is

displayed
fl If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (If it is not displayed, the problem has been removed.)
fl Always turn the TVC prolix switch OFF.
Cause Remedy

YES between C02
2 (female) (8) and (18),
(8) and chassis as
Is resistance shown in Table 1? Go to A
YES between C13 NO
(male) (1) and (2), • Turn starting
1 (1) and chassis as switch OFF.
Interchange shown in Table • Disconnect C02.
connector with 1?
rear pump TVC NO
• Turn starting Defective front pump TVC
solenoid. Is switch OFF. solenoid (internal short Replace
[E232] displayed? • Disconnect C13. circuit or short circuit with
• Interchange C04 ground)
with C13. NO
Short circuit with ground or
• Turn starting short circuit with power
switch ON. source in wiring harness
between C02 (female) (8) –
Repair or
5 YES H12 (5) – C05 (female) (1) ,
or short circuit with power replace
Is resistance source in wiring harness
YES between C05 (male) between C02 (female) (18) –
(1) and (3), (2) and H12 (7) –C05 (female) (2)
4 (4), (1) (2) (3) (4) and
chassis as shown in Defective TVC prolix
Table 2 ? switch (internal short
between C05 NO circuit with ground or
From A (female) (3) and • Turn starting switch OFF. short circuit with power
(4), (3) and • Disconnect C05. source)
chassis as shown • Turn TVC prolix switch
in Table 1? OFF. Short circuit with ground Repair or
or short circuit with replace
• Turn starting NO power source in wiring
switch OFF. harness between C05
• Disconnect C05. (female) (3) – H12 (3) –
C13 (female) (1), or short
circuit with power source
in wiring harness
between C05 (female) (4)
–H12 (4) –C13 (female) (2)
Table 1
Troubleshooting No. 2 Troubleshooting No. 3 Troubleshooting No. 4 Resistance value
Between C13 (male) (1) – (2) Between C02 (female) (8) – (18) Between C05 (female) (3) – (4) 10 – 22 Ω
Between C13 (male) (1) – chassis Between C02 (female) (8) – chassis Between C05 (female) (3) – chassis Min. 1 MΩ
Table 2
Troubleshooting No. 5 Resistance value
Between C05 (male) (1) – (3), (2) – (4) Max. 1 Ω
Between C05 (male) (1)(2)(3)(4) – chassis Min. 1 MΩ
PC300, 350-6 20-467

1
5
TROUBLESHOOTING C-2
TVC prolix switch

OFF ON
1
Engine throttle, pump controller 2
C02(MIC21) H12(S16) C05(S10)
3
4
FTVC(+) i e q 5
FTVC(–) !8 r w 6
7
t e 8
C13(X2) u r 9
10
Front 11
TVC q 12
valve w Normal Prolix
BKP00187
20-468 PC300, 350-6

1
5
TROUBLESHOOTING C-3
C-3 [E233] Disconnection in front pump TVC solenoid system is

displayed
fl If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A)
continues to flow to the solenoid.
Cause Remedy

Is resistance
YES between C02
(female) (8) and
2 (18), (18) and
Is resistance chassis as shown
between C13 (male) Go to A
YES in Table 1? NO
(1) and (2), (2) and
• Turn starting
1 chassis as shown in
Table 1? switch OFF.
Interchange • Disconnect C02.
connector with rear • Turn starting
pump TVC soleoid. switch OFF. NO
Is [E233] displayed? • Disconnect C13. Defective front pump
TVC solenoid (internal
• Interchange C04 disconnection or Replace
defective contact)
with C13. NO
• Turn starting Defective contact or
switch ON. disconnection in wiring
harness between C02 (female)
(8) – H12 (5) – C05 (female) (1),
YES or defective contact, short Repair or
5 circuit with grond, or replace
Is resistance disconnection in wiring
YES between C05 (male) harness between C02 (female)
(1) and (3), (2) and (18) – H12 (7) – C05 (female)
(4), (1) (2) (3) (4) and (2)
4 chassis as shown in Defective TVC prolix switch
Is resistance Table 2? (internal disconnection, Replace
between C05 • Turn starting NO defective contact, or short
From A (female ) (3) and circuit wth ground)
switch OFF.
(4), (4) and • Disconnect C05. Defective contact or
chassis as shown disconnectio in wiring
in Table 1? • Turn TVC prolix switch
OFF. harness between C05
(female) (3) – H12 (3) – C13 Repair or
• Turn starting
(female) (1), or replace
switch OFF. NO
• Disconnect C05. disconnection in wiring
harness between C05
(female) (4) – H12 (4) –C13
(female) (2)
Table 1
Table 2
PC300, 350-6 20-469

1
5
TROUBLESHOOTING C-3
TVC prolix switch

OFF ON
1
C02(MIC21) H12(S16) C05(S10)
3
4
FTVC(+) i e q 5
FTVC(–) !8 r w 6
7
t e 8
C13(X2) u r 9
10
Front 11
TVC q 12
BKP00187
20-470 PC300, 350-6

1
5
TROUBLESHOOTING C-4
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed
Cause Remedy

pump controller
YES between C02
(female) (9) and (19),
2 (9) and chassis as
Is resistance shown in Table 1?
between C04 (male) Go to A
YES • Turn starting NO
(1) and (2), (1) and
1 chassis as shown in switch OFF.
Interchange Table 1? • Disconnect C02.
connector with • Turn starting
front pump TVC switch OFF. NO
solenoid. Is • Disconnect C04.
[E236] displayed? Defective rear pump TVC
soleoid (internal short
• Interchange C13 circuit or short circuit
with C04. Replace
NO with ground)
• Turn starting
switch ON. Short circuit with ground or
short circuit with power
source in wiring harness
YES between C02 (female) (9) – Repair or
5 H12 (6) – C05 (female) (6), or replace
Is resistance short circuit with power
YES between C05 (male) source in wiring harness
(6) and (8), (7) and between C02 (female) (19) –
(9), (6) (7) (8) (9) H12 (8) – C05 (female) (7)
4 and chassis as Defective TVC prolix switch
Is resistance shown in Table 2? Replace
(internal short circuit with
between C05 NO
From A • Turn starting ground or short circuit with
(8) and chassis as switch OFF. power source)
• Turn TVC prolix switch Short circuit with ground or
• Turn starting short circuit with power source
OFF. Repair or
switch OFF. in wiring harness between C05
NO replace
• Disconnect C05. (female) (8) – H12 (1) – C04
(female) (1), or short circuit with
power source in wiring harness
between C05 (female) (9) – H12
(2) – C04 (female) (2)
Table 1
Table 2
PC300, 350-6 20-471

1
5
TROUBLESHOOTING C-4
TVC prolix switch

OFF ON
1
C02(MIC21) H12(S16) C05(S10) 3
4
RTVC(+) o q y 5
6
RTVC(–) !9 w u 7
y i 8
9
C04(X2) i o 10
11
Rear
TVC q 12
BKP00188
20-472 PC300, 350-6

1
5
TROUBLESHOOTING C-5
C-5 [E237] Disconnection in rear pump TVC solenoid system is

displayed
fl If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A)
continues to flow to the solenoid.
Cause Remedy

Is resistance
YES between C02
2 (female) (9) and (19),
Is resistance (19) and chassis as
YES between C04 (male) shown in Table 1? Go to A
NO
(1) and (2), (2) and • Turn starting
1 chassis as shown in switch OFF.
Interchange Table 1? • Disconnect C02.
connector with • Turn starting
front pump TVC switch OFF. NO
solenoid. Is [E237] • Disconnect C04.
displayed?
Defective rear pump TVC
• Interchange C13 solenoid (internal
with C04. disconnection or defective Replace
• Turn starting
NO
switch ON. Defective contact or
harness between C02 (female)
(9) H12 (6) – C05 (female) (6), or
YES defective contact, short circuit Repair or
5 replace
with ground, or disconnection
Is resistance in wiring harness between C02
YES between C05 (male) (female) (19) – H12 (8) – C05
(6) and (8), (7) and (female) (7)
(9), (6) (7) (8) (9)
4 and chassis as Defective TVC prolix switch
Is resistance shown in Table 2? (internal disconnection, Replace
between C05 NO defective contact, or short
From A (female) (8) and (9), • Turn starting switch OFF. circuit with ground)
(9) and chassis as • Disconnect C05.
shwon in Table 1? Defective contact or
• Turn TVC prolix switch disconnection in wiring harness
• Turn starting OFF. between C05 (female) (8) – H12
switch OFF. (1) – C04 (female) (1), or Repair or
• Disconnect C05. NO defective contact, short circuit replace
with ground, or disconnection
in wiring harness between C05
(female) (9) – H12 (2) –C04
(female) (2)
Table 1
Table 2
PC300, 350-6 20-473

1
5
TROUBLESHOOTING C-5
TVC prolix switch

OFF ON
1
C02(MIC21) H12(S16) C05(S10) 3
4
RTVC(+) o q y 5
6
RTVC(–) !9 w u 7
y i 8
9
C04(X2) i o 10
11
Rear
TVC q 12
BKP00188
20-474 PC300, 350-6

1
5
TROUBLESHOOTING C-6
C-6 [E207] Short circuit in active mode (boom) solenoid system is

displayed
Cause Remedy
3 YES Defective engine throttle, Replace

Is resistance pump controller
YES between C01
2 (female) (8) and
Is resistance chassis normal? Short circuit with chassis Repair or
YES between V02 (male) ground in wiring harness replace
• Turn starting NO between C01 (female) (8)
(1) and (2), (2) and
1 chassis as shown in switch OFF. and V02 (female) (2)
Interchange
• Turn starting • 20 – 60 Ω
connector with
other solenoid. Is switch OFF. NO
[E207] displayed? • Disconnect V02.
• Interchange V02 Defective LS select solenoid

with other Replace
NO (internal short circuit or
connector.
• Start engine. short circuit with ground)
• Active mode switch
OFF.
Table 1
Between V02 (male) (1) – (2) 20 – 60 Ω
Between V02 (male) (2) – chassis Min. 1 MΩ
PC300, 350-6 20-475

1
5
TROUBLESHOOTING C-7
C-7 [E208] Disconnection in active mode (boom) solenoid system is

displayed
Cause Remedy
4 YES
Go to A
When V02 (female) (2) is
YES grounded to chassis, is Short circuit with power
resistance between C01 ground, defective contact,
3 (female) (8) and chassis
normal?
or disconnection in wiring Repair or
Is resistance harness between C01
YES between V02 • Turn starting NO (female) (8) and V02 replace
(female) (1) and switch OFF. (female) (2)
2
chassis normal? • Disconnect V02.
Is resistance Defective contact or
• Turn starting • Max. 1 Ω
YES between V02 disconnection in wiring Repair or
(male) (1) and (2) switch OFF. NO harness between V02 replace
1 normal? • Disconnect C01. (female) (1) and chassis.
• Max. 1 Ω
Interchange • Turn starting
connector with switch OFF.
other solenoid. Is • Disconnect V02. NO
[E208] displayed? • 20 – 60 Ω
• Interchange V02
Defective LS select solenoid
with other Replace
NO (internal disconnection)
connector.
• Turn starting switch
ON.
Is voltage between
C01 (female) (8) and
From A V02 (female) (2), V02
(female) (2) and Short circuit with power
chassis normal? source in wiring harness Repair or
between C01 (female) (8) replace
• Disconnect C01, NO and V02 (female) (2)
V02.
• Turn starting
switch ON.
• Max. 1V
20-476 PC300, 350-6

1
5
TROUBLESHOOTING C-8
C-8 [E203] Short circuit in swing brake solenoid system is displayed

fl Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause Remedy

YES between C01
2 (female) (3) and
Is resistance chassis normal?
YES between V04 Go to A
• Turn starting switch NO
(male) (1) and (2),
OFF.
1 (2) and chassi
• Disconnect C01.
Interchange nornal?
• Turn swing lock
connector with • Turn starting switch OFF.
other solenoid. Is switch OFF. • 20 –60 Ω
NO
Defective swing holding
• Interchange V04 brake solenoid (internal
with other short circuit or short circuit Replace
connector.
NO
with ground)
• Start engine.
• Operate swing Short circuit with chassi
lever. 5 YES ground in wiring harness Repair or
Is resistance between C01 (female) (3) – replace
D26 (1)(2) – H13 (1) –X01 (7)
YES between X05 – X05 (male) (3)
4 (male) (4) and
chassis normal? Short circuit with chassis
Is resistance ground in wiring harness Repair or
between X05 • Turn starting NO between X05 (male) (4) replace
From A (female) (3) (4) and –X01 (7) – H13 (7) –V04
switch OFF.
chassis normlal? (female) (2)
• Disconnect X05.
• Turn starting • 20 – 60 Ω Defective swing lock sitch
(internal short circuit with Replace
switch OFF. NO
• Disconnect X05. ground)
• Turn swing lock
switch OFF.
• Min. 1 MΩ
Table 1
Between V04 (male) (1) – (2) 20 – 60 Ω
PC300, 350-6 20-477

1
5
TROUBLESHOOTING C-8
20-478 PC300, 350-6

1
TROUBLESHOOTING C-9
C-9 [E213] Disconnection in swing brake solenoid system is displayed

fl Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Note: If the swing prolix switch is operated, this error [213] is detected, but it does not indicate a
failure.
Note: When the swing prolix switch is operated, if error [213] occurs, carry out troubleshooting (F-9)
for the swing lock signal input system.
Cause Remedy
3 YES Go to A
Is voltage between
YES D26 (1) and chassis
2 as shown in Table
Is resistance 1? Defective engine throttle,
Replace
YES between V04 • Disconnect D26. pump controller
NO
(male) (1) and (2) • Turn starting
1 normal? switch ON.
Interchange
• Turn starting
connector with
switch OFF. NO
other solenoid. Is
• Disconnect V04.
[E213] displayed?
• 20 – 60 Ω Defective swing holding
• Interchange V04 brake solenoid (internal
with other disconnection or short Replace
connector. NO circuit with power
• Turn starting source)
switch ON.
Defective contact or
disconnection in wiring Repair or
YES
harness between D26 replace
5 (female) (2) – H13 – X01
Is resistance (7) – X05 (male) (3)
YES between X05
(male) (4) and Short circuit with power
4 chassis normal? source, defective contact,
Is resistance or disconnection in
• Turn starting Repair or
between X05 wiring harness between
From A switch OFF. NO replace
(female) (3) and (4) X05 (male) (4) – X01 (6) –
• Disconnect X05.
normal? H13 (7) – V04 (female) (2)
• 20 – 60 Ω
• Turn starting Defective swing lock
switch OFF. switch (internal Replace
• Disconnect X05. NO disconnection or short
• MAX. 1 Ω circuit with power
source)
Table 1
Troubleshooting No. 3 Voltage Measurement condition
Between D26 0 – 10 V 4 – 5 seconds after all levers are returned to neutral

(1) – chassis Swing lever or work equipment lever operated (operated in small movements)
20 – 30 V
PC300, 350-6 20-479

1
5
TROUBLESHOOTING C-9
20-480 PC300, 350-6

1
TROUBLESHOOTING C-11
C-11 [E214] Disconnection in pump merge/divider solenoid system is

displayed
Cause Remedy
4 YES
Go to A
YES grounded to chassis, is
resistance between C01 Defective contact or
3 (female) (2) and chassis disconnection in wiring Repair or
Is resistance normal? harness between C01 replace
YES between V03 • Turn starting NO (female) (2) and V02
2 • Disconnect V03.
chassis normal? Defective contact or
Is resistance
• Turn starting • Max. 1 Ω disconnection in wiring Repair or
YES between V03 harness between V03 replace
(male) (1) and (2) switch OFF. NO
• Disconnect C01. (female) (1) and chassis
1 normal?
• Max. 1 Ω
[E214] displayed? • 20 – 60 Ω
• Interchange V03 Defective pump
with other merge/divider solenoid Replace
connector. NO (internal disconnection)
• Turn starting
switch ON.
pump controller
Is voltage between
C01 (female) (2),
From A
V03 (female) (2) – Short circuit with power
• Disconnect C01 NO between C01 (female) (2) replace
and V03. and V03 (female) (2)
• Turn starting
switch ON.
• Max. 1 V
20-482 PC300, 350-6

1
5
C-12 [E206] Short circuit in travel speed solenoid system is displayed

Cause Remedy

Replace
YES between C01
2 (female) (9) and
Short circuit with chassis Repair or
Is resistance chassis normal?
ground in wiring harness replace
YES between V06 (male) • Turn starting NO between C01 (femle) (8) and
(1) and (2), (2) and
1 chassis as shown in switch OFF. V02 (female) (2)
Interchange
connector with
other solenoid. Is switch OFF.
NO
• Interchange V06
Defective travel speed
with other Replace
connector. NO solenoid (internal short
• Start engine. circuit or short circuit
• Travel speed switch with ground)
at Mi or Hi
• Operate the lever
slightly not enough to move the
machine.
Table 1
Between V06 (male) (1) – (2) 20 – 60 Ω
PC300, 350-6 20-483

1
5
C-13 [E216] Disconnection in travel speed selector solenoid system is

displayed
Cause Remedy
4 YES
Go to A
Is resistance normal? harness between C01
YES between V06 replace
• Turn starting NO (female) (9) and V06
2 chassis normal? • Disconnect V06.
Is resistance
YES between V06
switch OFF. NO harness between V06 replace
(male) (1) and (2) (female) (1) and chassis
1 • Disconnect C01
normal?
and V06.
Interchange
• Turn starting • Max. 1 Ω
connector with
switch OFF.
other solenoid. Is
• Disconnect V06.
NO
[E216] displayed?
• 20 – 60 Ω
• Interchange V06 Defective pump
with other merge/divider solenoid Replace
connector. NO (internal disconnection)
• Turn starting
switch ON.
pump controller
Is voltage between
C01 (female) (9) –
From A
V06 (female) (2) Short circuit with power
normal? source in wiring harness Repair or
• Turn starting NO between C01 (female) (9) replace
switch OFF. and V06 (female) (2)
• Disconnect C01
and V06.
• Max. 1 V
20-484 PC300, 350-6

1
5
C-14 [E231] Short circuit in active mode (swing) solenoid system is

displayed
Cause Remedy

YES between C01
2 (female) (10) and
Is resistance chassis normal? Short circuit with chassis Repair or
YES between V07 (male) ground in wiring harness replace
• Turn starting NO between C01 (female) (10)
(1) and (2), (2) and
1 chassis as shown in switch OFF. and V07 (female) (2)
Interchange
connector with
other solenoid. Is switch OFF. NO
• Interchange V07 Defective LS select solenoid

with other Replace
NO (internal short circuit or
connector.
• Start engine. short circuit with ground)
• Swing lock switch
OFF.
• Active mode switch
ON.
• Operate swing +
boom raise lever
slightly at the same
time.
Table 1
Between V07 (male) (1) – (2) 20 – 60 Ω
PC300, 350-6 20-485

1
5
C-15 [E235] Disconnection in active mode (swing) solenoid system is

displayed
Cause Remedy
4 YES
To A
Is resistance normal? harness between C01 replace
YES between V07 • Turn starting NO (female) (10) and V07
2 chassis normal? • Disconnect V07.
Is resistance
YES between V07 harness between V07 replace
(male) (1) and (2) switch OFF. NO
• Disconnect C01. (female) (1) and chassis
1 normal?
• Max. 1 Ω
[E235] displayed? • 20 – 60 Ω
• Interchange V07 Defective active mode
with other (swing) solenoid (internal Replace
connector. NO disconnection)
• Turn starting
switch ON.
Is voltage between pump controller
C01 (female) (10),
From A
V07 (female) (2) – Short circuit with power
• Disconnect C01 NO between C01 (female) replace
and V07. (10) and V07 (female) (2)
• Turn starting
switch ON.
• Max. 1 V
20-486 PC300, 350-6

1
5
C-16 [E217] Model selection input error is displayed

Cause Remedy

Replace
1 pump controller
Is monitoring
mode display as
shown in Table 2 YES
1? Is voltage between
C17 (5) (6) (7) (13)
• Turn starting
switch ON. NO (14) and chassis as Defective model selection
shown in Table 2? Repair or
• Set to monitoring connector, or disconnection,
codes [02, 03] • Turn starting NO short circuit with ground, or replace
and [21, 22]. switch ON. short circuti in witing
harness where voltage is
defective
Table 1 Monitoring code display

Model code display Model selection signal input display
Monitoring codes 02, 03 Monitoring code 21 Monitoring code 22
BKP00193 BKP00194 BKP00195
fl The diagram shows monitoring code 02.

fl Check the bit pattern display marked with ←.
Table 2 Voltage of wiring harness

C17 Between (5) - chassis Between (6) - chassis Between (7) - chassis Between (13) - chassis Between (14) - chassis
Voltage 20 - 30 V Max. 1 V Max. 1 V Max. 1 V 20 - 30 V
PC300, 350-6 20-487

1
5
20-488 PC300, 350-6

1
C-17 [E222] Short circuit in LS-EPC solenoid system is displayed

Cause Remedy

Is resistance
YES between C02 Short circuit with ground or short
1 (7) and chassis as circuit with power source in wiring
Is resistance shown in Table 1? harness between C02 (female) (7) Repair or
between C10 (male) – C10 (female) (1), or short circuit replace
(1) and (2), (1) and • Turn starting NO with power source in wiring
chassis as shown in switch OFF. harness between C02 (female) (17)
Table 1? • Disconnect C02. – C10 (female) (2)
• Turn starting Replace
Defective LS-EPC solenoid
switch OFF. NO
(internal short circuit with
• Disconnect C10.
ground or short circuit
with power source)
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Resistance value
Between C10 (male) (1) – (2) Between C02 (female) (7) – (17) 7 – 14 Ω
Between C10 (male) (1) – chassis Between C02 (female) (7) – chassis Min. 1 MΩ

C02(MIC21) C10(X2)
LS • EPC (+) u q LS-EPC

solenoid
LS • EPC (–) !7 w valve
BKP00251
PC300, 350-6 20-489

1
5
C-18 [E223] Disconnection in LS-EPC solenoid system is displayed

Cause Remedy

Is resistance
YES between C02 Defect contact or short circuit
(female) (7) and (17), with chassis ground in wiring
1 (17) and chassis as harness between C02 (female)
Is resistance shown in Table 1? (7) and C10 (female) (1), or Repair or
between C10 (male) NO defective contact, short circuit replace
(1) and (2), (2) and • Turn starting with ground, or disconnection
chassis as shwon in switch OFF. in wiring harness between C02
Table 1? • Disconnect C02. (female) (17) – C10 (female) (2)
• Turn starting Defective LS-EPS Replace
switch OFF. NO solenoid (internal
• Disconnect C10. disconnection, defective
contact, or short circuit
with ground)
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Resistance value
Between C10 (male) (1) – (2) Between C02 (female) (7) – (17) 7 – 14 Ω
Between C10 (male) (2) – chassis Between C02 (female) (17) – chassis Min. 1 MΩ

C02(MIC21) C10(X2)
LS • EPC (+) u q LS-EPC

solenoid
LS • EPC (–) !7 w valve
BKP00251
20-490 PC300, 350-6

1
5
TROUBLESHOOTING C19
C-19 [E224] Abnormality in front pump pressure sensor system is

displayed
Cause Remedy

Replace
Is voltage pump controller
YES between C03 (3)
and (16) normal? Short circuit with powe
source, defective contact, or Repair or
2 disconnection in wiring
• Engine at high NO replace
harness between C03
Is voltage ilding (female) (3) – C08 (female)
YES between C08 (2) • Operate repeatedly arm IN (3)
and (1) normal? relief lever NEUTRAL.
Short circuit with ground,
• 0.5 – 4.5 V defective contact, or
4 YES disconnection in wiring Repair or
1 • Turn starting
Is voltage harness between C03 replace
Interchange switch ON.
between C08 (2) (female) (16) and C08
connector with rear • 18 – 28 V
NO and chassis (female) (1)
pump pressure
sensor. Is [E224] normal? Short circuit with ground, Repair or
displayed? defective contact, or replace
• Disconnect C08. NO disconnection in wiring
• Interchange C07 • Turn starting harness between C03 (female)
with C08. switch ON. (6) and C08 (female) (2)
• Engine at high • 18 – 28 V
idling Defective front pump Replace
NO pressure sensor (internal
disconnection, defective
contact, short circuit, or
short circuit with ground)

C03(04020) C08(X02)
Front pump pressure

sensor SIG e q
Pressure sensor Front pump
power source
y w pressure sensor
Pressure sensor GND !6 e
BKP00252
PC300, 350-6 20-491

1
5
C-20 [E225] Abnormality in rear pump pressure sensor system is

displayed
Cause Remedy

Replace
Is voltage pump controller
YES between C03 (3) Short circuit with power
and (16) normal? source, defective contact, or
2 harness between C03
• Engine at high NO replace
(female) (13) – C07 (female)
Is voltage
idling (3)
YES bwtween C07 (2) • Operate repeatedly arm IN
and (1) normal? Short circuit with ground,
relief lever NEUTRAL. defective contact, or
• 0.5 – 4.5 V disconnection in wiring
4 YES harness bewtween C03 Repair or
1 • Turn starting
Is voltage (female) (16) and C07 (female) replace
Interchange switch ON.
between C07 (2) (1)
connector with • 18 – 28 V
front pump NO and chassis Short circuit with ground,
pressure sensor. Is normal?
defective contact, or Repair or
[E225] displayed?
• Disconnect C07. NO disconnection in wiring replace
• Interchange C08 • Turn starting harness between C03 (female)
with C07. (6) and C07 (female) (2)
switch ON.
• Engine at high • 18 – 28 V Defective rear pump
idling pressure sensor (internal Replace
NO disconnection, defective
contact, short circuit, or
short circuit with ground)

C03(04020) C07(X03)
Pressure sensor
power source y q
Rear pump pressure Rear pump
sensor SIG !3 w pressure sensor
Pressure sensor GND !6 e
BKP00253
20-492 PC300, 350-6

1
5
C-21 [E226] Abnormality in pressure sensor power source system is

displayed
Cause Remedy
YES Defective front pump

Replace
2 pressure sensor (internal
Is voltage short circuit or short
YES between C03 (6) circuit with ground)
and (16) normal? 3 YES Defective rear pump
pressure sensor (internal Replace
Is voltage
1 between C03 (6) short circuit or short
Is resistance • Turn starting
and (16) normal? circuit with ground)
between C03 switch ON. NO
(female) (6) and • Disconnect C08. Defective engine throttle,
(16), (6) (16) and pump controller Replace
• 18 – 28 V • Disconnect C07. NO
chassis normal?
• Turn starting
• Turn starting switch ON.
switch OFF. • 18 – 28 V Short circuit or short Repair or
• Disconnect C03, circuit with ground in replace
C07, and C08. NO
wiring harness of system
• Min. 1 MΩ where resistance value is
defective

C08(X3)
Engine throttle, pump controller q

C03(04020) Front pump
w pressure sensor
Front pump pressure
sensor SIG e e
Pressure sensor
power source y
Rear pump pressure C07(X3)
sensor SIG !3
Pressure sensor GND !6 q
Rear pump
w pressure sensor
e
BKP00254
PC300, 350-6 20-493

1
5
C-22 [E227] Abnormality in engine speed sensor system is displayed

Cause Remedy

Is resistance
YES between C16 Short circuit with ground,
(female) (1) and defective contact, or
1 (2) normal? disconnection in wiring Repair or
Is resistance harness between C16
NO replace
between E07 • Turn starting (female) (1) – E08 (10) – E07
(male) (1) and (2) switch OFF. (female) (2), or between C16
normal? • Disconnect C16. (female) (2) – E08 (9) – E07
• 500 – 1000 Ω (female) (1)
• Turn starting
Defective engine speed
switch OFF. sensor (internal Replace
• Disconnect E07. NO
disconnection, defective
• 500 – 1000 Ω contact, or short circuit with
ground)

C16(MIC17) E08(SWP14) E07(X2)
Speed sensor
GND q o q Engine
speed
Speed sensor
SIG
w !0 w sensor
BKP00255
20-494 PC300, 350-6

1
5
C-23 Abnormality in machine push-up solenoid system (no service

code displayed)
* Even if any abnormality occurs in the machine push-up solenoid system, the service code is not
displayed on the monitor panel.
a) If soienoid is not actuated(turned ON) when machinepush-up switch is set to low-pressure

setting
* Check that fuse No. 2 is not blown.
* Carry out troubleshooting with the machine push-up switch at the low-pressure setting posi-
tion.
I Cause Remedy
disconnection inwiring Repair 01
harness betweenV05 replace
Is resistance (female)( 7 ) and chassis
ground
(male) (1) and(2)
normal? Defective machine push-up
solenoid (internal Replace
disconnectionor defective
contact)
Short circuitwith ground,
defective contact, or Repair or
disconnection inwiring
harness betweenM38 replace
(male)(1) - X01 ( 1 6 ) -H13 (3
- V05 (female)(2)
Defective machine push-up Replace
switch (internal
disconneciion, defective
contact, or short circuitwith
ground)
Defectivefuse 2 or short
circuit with ground, Repair or
defective contact, or replace
disconnectionin wiring
harness between fuse2 -
X01 (12) -M38 (male)(2)
@-23 Related electric circuit diagram
DO6 (KES1 2)
Machine push
UP switch
13 (SI6) Machine push
t -
iir
TWPO I423
PC300, 350-6 20-495

0
b) If solenoidis not canceled (turned OFF) when machine push-up switch is set to high-pressure
setting
* Carry out troubleshooting with the machine push-up switch at the high-pressure setting posi-
tion.
YES
P+--
I Defective machine push-up
solenoid (internalshort
circuit withpower source)
Remedy
Replace
Is voltage
between V05 (2) -
--- Defective machine push-up
and chassis
YES 2 switch (internalshort circuit Replace
normaf? Is voltage with power source)
Turn starting
switch ON.
between M38 (1)
NG and chassis
-
normal? Short circuitwith power
Max. 1 V source in wiringharness Repair or
starting
Turn NO between M38 (male) (1) - replace
switch ON. X01 (16)-H13(3)-V05
- Max. 1 V (female) (2)
m
DO6 (KESI 2)
UP switch I
H13 (S16) Machine push
- -- UP solenoid
1 I
TWP01423
20-496 PC300, 350-4

0
PUMP CONTROLLER (INPUT SIGNAL SYSTEM)
(F MODE)
Electrical circuit diagram for F mode ................................................................................................... 20-502

F- 1 Bit pattern 20-(1) Swing oil pressure switch does not light up ........................................... 20-504
F- 2 Bit pattern 20-(2) Travel oil pressure switch does not light up ........................................... 20-505
F- 3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up ............................. 20-506
F- 4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up ............................... 20-507
F- 5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up ......................................... 20-508
F- 6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up...................................... 20-509
F- 7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up ............................... 20-510
F- 8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up ............................. 20-511
F- 9 Bit pattern 21-(3) Swing lock switch does not light up ......................................................... 20-512
F-10 Bit pattern 22-(5) Kerosene mode connection does not light up ......................................... 20-513
F-11 Bit pattern 22-(6) L.H. knob switch does not light up ........................................................... 20-514
PC300, 350-6 20-501

1
5
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
20-502 PC300, 350-6

1
4
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
PC300, 350-6 20-503

1
TROUBLESHOOTING F-1
F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
¤ Turn the swing lock switch ON before operating the swing lever.
fl If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.
(See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Cause Remedy

pump controller
3
Is voltage YES disconnection in wiring Repair or
Is resistance between harness between S08
between C16 (5) C16 (female) (5) and replace
(female) (1) and chassis
and chassis YES S08 (female) (2) ground
normal? normal, and is circuit
insulated from Defective contact, short
• Start engine. 2 circuit with ground, or Repair or
chassis?
• Swing lever at Is resistance between NO disconnection in wiring replace
neutral S08 (male) (1) and (2) • Turn starting switch harness between C16
: 20 – 30 V normal, and is circuit OFF. (female) (5) and S08
NO insulated from • Disconnect C16 and S08. (female) (2)
• Swing lever
opereated
chassis? • Between C16 and S08: Max. 1 Ω
• Disconnect S08. • Between wiring harness and Defective swing oil
: Max. 1V
• Start engine. chassis: Min. 1 MΩ pressure switch
(If the condition does Replace
• Swing lever at NO
neutral not return to normal
: Min. 1 MΩ even when the switch
• Swing lever operated: Max. 1 Ω is replaced, go to H-5.
• See Note 1.
Note 1: It is also possible to fit a short connector

and judge the condition. In this case,
check the voltage between C16 (5) and
the chassis.
• If it is 20 – 30 V: Go to YES
• If it is less than 1 V: Go to NO
F-1 Related electric circuit diagram
Engine throttle, pump controller S08(X2)

C16(MIC17)
Swing oil q Swing oil
pressure switch
pressure t w
switch
BKP00257
20-504 PC300, 350-6

1
5
TROUBLESHOOTING F-2
F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up
removed.
¤ Before operating the travel lever, check that the surrounding area is safe.
fl If there is no display when the travel lever is operated on one side, the PPC shuttle valve is
defective. (See H-5)
Cause Remedy

Replace
pump controller
1
Is voltage YES disconnection in wiring harness Repair or
Is resistance between
between C16 (13) C16 (female) (13) and between S01 (female) (1) and replace
and chassis YES S01 (female) (2) chassis ground
insulated from Defective contact, short circuit
• Start engine. 2 with ground, or disconnection in Repair or
chassis?
• Travel lever at Is resistance between NO wiring harness between C16 replace
neutral S01 (male) (1) and (2) • Turn starting switch (female) (13) and S01 (female) (2)
normal, and is circuit OFF.
: 20 – 30V NO insulated from
• Travel lever • Disconnect C16 and S01.
chassis? Defective travel oil
operated • Between C16 and S01: Max. 1 Ω
• Disconnect S01 • Between wiring harness and chassis: Min. 1 MΩ pressure switch
: Max. 1 V
• Start engine. (If the condition does
not returen to normal Replace
• Travel lever at NO
neutral even when the switch
: Min. 1MΩ is replaced, go to H-5.)
• Travel lever operated
: Max: 1 Ω
• See Note 1.
Note 1: It is also posibble to fit a short connector and

judge the condition. In this case, check the
voltage between C16 (13) and the chassis.
• If it is 20 – 30 V: Go to YES
• If it is less than 1 V: Go to NO

S01(X2)
C16(MIC17)
Travel oil
q Travel oil
pressure switch
pressure !3 w
switch
BKP00258
PC300, 350-6 20-505

1
5
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up
removed.
¤ When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
20-506 PC300, 350-6

1
TROUBLESHOOTING F-4
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up
removed.
Cause Remedy

Replace
pump controller
Is voltage YES Repair or
Is resistance between harness between S02
• Start engine. 2 Repair or
chassis? with ground, or disconnection
• Boom lever at Is resistance between NO in wiring harness between C17 replace
neutral: 20 - 30V S02 (male) (1) and (2) • Turn starting switch
(female) (2) – H13 (9) – S02
• Boom lever normal, and is circuit OFF.
NO • Disconnect C17 and S02. (female) (2)
operated to RAISE insulated from chassis?
: Max. 1 V • Between C17 and S02 : Max. 1 Ω Defective boom RAISE oil
• Disconnect S02. • Between wiring harness and chassis pressure switch
• Start engine. : Min. 1 MΩ (If the condition does Replace
• Boom lever at NO not return to normal
neutral: Min. 1 MΩ even when the switch
• Boom lever operated to RAISE is replaced, go to H-5.)
: Max. 1 Ω.
• See Note 1.
Note 1: It is also possible to fit a short connector

and judge the condition. In this case, check
the voltage between C17 (2) and the
chassis.
• If it is 20 – 30V: Go to YES
• If it is less than 1V: Go to NO
Engine throttle, pump controller S02(X2)

C17(04016)
H13(S16)
Boom q Boom RAISE oil
RAISE oil pressure switch
pressure w o w
switch
BKP00260
PC300, 350-6 20-507

1
5
TROUBLESHOOTING F-5
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up
removed.
Cause Remedy

Replace
pump controller
3
• Start engine. 2 with ground, or disconnection Repair or
chassis?
• Arm lever at Is resistance between NO in wiring harness between C17 replace
neutral: 20 – 30V S05 (male) (1) and (2) • Turn starting (female) (3) – H13 (10) – S05
normal, and is circuit switch OFF.
• Arm lever NO insulated from (female) (2)
operated to IN • Disconnect C17 and S05.
: Max. 1 V Defective arm IN oil
• Arm lever at NO not return to normal
: Min. 1 MΩ is replaced, go to H-5.)
• Arm lever operated to IN: Max. 1 Ω
• See Note 1.
Note 1: It is also possible to fit a short connector and


S05(X2)
C17(04016)
H13(S16)
Arm IN oil
q Arm IN oil
pressure switch
pressure e !0 w
switch
BKP00261
20-508 PC300, 350-6

1
5
TROUBLESHOOTING F-6
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up
removed.
Cause Remedy

Is voltage YES harness between S03 Repair or
between C17 (11) C17 (female) (11) and (female) (1) and chassis replace
normal? normal, and is circuit Defective contact, short
2 insulated from circuit with ground, or
• Start engine. chassis? Repair or
• Arm lever at Is resistance between disconnection in wiring replace
NO harness between C17
neutral: 20 – 30V S03 (male) (1) and (2) • Turn starting
normal, and is circuit switch OFF. (female) (11) – H13 (12) –
• Arm lever NO insulated from S03 (female) (2)
operated to • Disconnect C17 and S03.
OUT: Max. 1 V Defective arm OUT oil
• Arm lever at NO not return to normal
: Min. 1 MΩ is replaced, go to H-5.)
• Arm lever operated to OUT: Max. 1 Ω
• See Note 1.
Note 1: It is also possible to fit a short connector and


S03(X2)
C17(04016)
H13(S16)
Arm OUT
q Arm OUT oil
pressure switch
oil pressure !1 !2 w
switch
BKP00262
PC300, 350-6 20-509

1
5
TROUBLESHOOTING F-7
F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up
removed.
Cause Remedy

Replace
pump controller
Defective contact, or
1
Is voltage YES harness between S06 Repair or
between C16 (11) C16 (female) (11) and (female) (1) and chassis replace
• Start engine. 2 Repair or
chassis? circuit with ground, or
• Bucket lever at Is resistance between NO replace
S06 (male) (1) and (2) disconnection in wiring
neutral: 20 – 30V • Turn starting
normal, and is circuit harness between C16
• Bucket lever switch OFF.
NO insulated from • Disconnect C16 and S06. (female) (11) and S06
operated to chassis? (female) (2)
CURL: Max. 1 V • Between C16 and S06: Max. 1 Ω
• Disconnect S06. • Between wiring harness and chassis
Defective bucket CURL
• Start engine. : Min. 1 MΩ
oil pressure switch Replace
• Bucket lever at NO (If the condition does
neutral: Min. 1 not return to normal
MΩ even when the switch
• Bucket lever operated to CURL: Max. 1 Ω is replaced, go to H-5.)
• See Note 1.
Note 1: It is also possible to fit a short connector and judge the

condition. In this case, check the voltage between C16
(11) and the chassis.

S06(X2)
C16(MIC17)
Bucket q Bucket CURL oil
CURL oil pressure switch
pressure !1 w
switch
BKP00263
20-510 PC300, 350-6

1
5
TROUBLESHOOTING F-8
F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up
removed.
Cause Remedy

Replace
pump controller
1
3 Defective contact or
• Start engine. 2 circuit with ground, or Repair or
chassis?
• Bucket lever at Is resistance between NO disconnection in wiring replace
neutral: 20 – 30V S07 (male) (1) and (2) • Turn starting switch harness between C16
normal, and is circuit OFF. (female) (12) and S07
• Bucket lever NO insulated from
operated to • Disconnect C16 and S07. (female) (2)
DUMP: Max. 1 V
• Disconnect S07. • Between wiring harness and chassis: Defective bucket DUMP
• Start engine. Min. 1 MΩ oil pressure switch
Replace
• Bucket lever at NO (If the condition does
neutral not return to normal
: Min. 1 MΩ even when the switch
• Bucket lever operated to DUMP: Max. 1 Ω is replaced, go to H-5.)
• See Note 1.
Note 1: It is also possible to fit a short connector and judge the

condition. In this case, check the voltage between C16
(12) and the chassis.

S07(X2)
C16(MIC17)
Bucket q Bucket DUMP oil
DUMP oil pressure switch
pressure !2 w
switch
BKP00264
PC300, 350-6 20-511

1
5
TROUBLESHOOTING F-9
F-9 Bit pattern 21-(3) Swing lock switch does not light up
removed.
fl If the panel display is normal. (If the swing lock lamp does not light up, go to M-21.)
Cause Remedy

pump controller
1 Defective contact, short circuit

3 with ground, or disconnection
Is voltage YES Repair or
Is resistance between in wiring harness between X05
(female) (2) – X01 (5) – H14 (6) –
and chassis YES X05 (female) (1) chassis ground
2 insulated from Defective contact, short
• Turn starting chassis? circuit with ground, or Repair or
switch ON. Is resistance between replace
X05 (female) (1) and NO disconnection in wiring
• Swing lock • Turn starting
(2) normal, and is harness between C17
switch NO circuit insulated from switch OFF.
• Disconnect C17 and X05. (female) (16) – X01 (4) –
ON: Max. 1V chassis? X05 (male) (1)
OFF: 20 – 30V • Between C17 and X05 : Max. 1 Ω
• Turn starting • Between wiring harness and chassis
switch OFF. : Min. 1 MΩ
Defective swing lock Replace
• Disconnect X05. NO switch
• Swing lock
switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
Engine throttle, pump controller Swing lock switch

C17(04016) OFF ON
X01(MIC21) X05(M4) 1
Swing lock 2
switch !6 r q 3
t w 4
5
Monitor panel 6
P01(04020)
Normal
Lock
H14(M6)
Swing lock t y
BKP00265
20-512 PC300, 350-6

1
5
TROUBLESHOOTING F-10
F-10 Bit pattern 22-(5) Kerosene mode connection does not light up
removed.
Cause Remedy

1 pump controller
Is voltage
between C17 (15) Defective contact, or
and chassis 2 YES disconnection in wiring Repair or
normal? Is resistance between harness between M36 replace
C17 (female) (15) and (male) (1) and chassis
• Turn starting
ground
switch ON. NO M36 (female) (1)
normal? Defective contact or
• M36 connector Repair or
Connected • Turn starting NO replace
harness between C17
: Max. 1V switch OFF. (female) (15) and M36
Open: 20 – 30V • Disconnect C17 (female) (1)
and M36.
• Max. 1 Ω

C17(04016) Kerosene mode connector
M36(M1)
Kerosene
mode !5 q q
• Kerosene mode
(connected)
• Diesel oil mode (open)
BKP00266
PC300, 350-6 20-513

1
5
TROUBLESHOOTING F-11
F-11 Bit pattern 22-(6) L.H. knob switch does not light up
removed.
fl When fuse No. 5 is not blown.
Cause Remedy

Replace
pump controller
Is voltage 3 YES disconnection in wiring Repair wiring
between C03 (9) harness between knob harness
Is resistance switch outlet – M23 (2) –
and chassis YES between
normal? terminals of knob M22 (2) – C03 (female) (9)
• Turn starting 2 switch normal?
Defective L.H. knob Replace
switch ON. Is voltage between • Turn starting NO switch
• Knob switch knob switch inlet switch OFF.
ON: 20 – 30V NO terminal and chassis • Disconnect switch terminal.
OFF: Max. 1 V normal? • Knob switch Defective contact, or
ON: Max. 1 Ω disconnection in wiring
• Turn starting OFF: Min. 1 MΩ harness between fuse Repair wiring
switch ON. No. 5 – H12 (16) – M22 (1)
NO harness
• 20 – 30V – H23 (1) – knob switch
inlet
H12(S16) Fuse
5
!6
Engine throttle,
pump controller L.H. knob switch
M22(M2) M23(M2)
C03(040)
q q
Knob switch o w w
BKP00267
20-514 PC300, 350-6

1
5
TROUBLESHOOTING OF HYDRAULIC.
MECHANICAL SYSTEM
(H MODE)
Pump merge/divider logic. solenoid actuation table .......................................................................... 20-553

Table of failure modes and causes ...................................................................................................... 20-554
All work equipment, travel. swing
H-.i Speeds of aii work equipment. swing, travel are slow or lack power ........................... 20-558
H-2 There is excessive drop in engine speed, or engine stalls .............................................. 20-560
H-3 No work equipment. travel, swing move ........................................................................... 20-561
H-4 Abnormal noise generated (around pump) ....................................................................... 20-561
H-5 Auto-deceleration does not work (when PPC shuttle valve is cause) ............................ 20-562
H-6 Fine control ability is poor or response is poor ................................................................ 20-562
Work equipment
H-7 Boom is slow or lacks power .............................................................................................. 20-564
H-8 A r m is slow or lacks power ................................................................................................. 20-566
H-9 Bucket is slow or lacks power ............................................................................................. 20-568
H-IO Work equipment (boom, arm, bucket) does not move
(but travel and swing are normal) ...................................................................................... 20-569
H-11 Excessive hydraulic drift (boom, arm, bucket) .................................................................. 20-569
H-12 Excessive time lag (engine at low idling) .......................................................................... 20-570
H-13 Other equipment moves when single circuitis relieved .................................................. 20-570
H-I4 In L/O, F/O modes, work equipment speed is faster than specified speed ................... 20-571
H-I5 Defective actuation of machine push-up function............................................................. 20-571
Compound operations
H-16 In compound operations. work equipment with larger load is slow ............................. 20-571
H-17 In swing + boom RAISE. boom RAISE is slow.................................................................. 20-572
H-18 In swing + arm. arm is slow ................................................................................................ 20-572
H-19 In swing + travel. travel speed drops excessively ............................................................ 20-572
Travel system
H-20 Travel deviation ..................................................................................................................... 20-573
a) When there is deviation in normal travel .................................................................. 20-573
b) Excessive trave! deviation when starting .................................................................. 20-573
H-21 Travel speed is slow ............................................................................................................. 20-574
H-22 Steering does not turn easily orlacks power .................................................................... 20-576
H-23 Travel speed does not switch or is faster than specified speed ..................................... 20-578
H-24 Travel does not move (one side only)................................................................................ 20-578
Swing system
H-25 Does not swing ..................................................................................................................... 20-579
a) Does not swing to either left or right ........................................................................ 20-579
b) Does not swing in one direction ................................................................................ 20-579
H-26 Swing acceleration is poor or swing speed is slow
(both left and right. one direction only) ............................................................................. 20-580
a)Swing accelerations is poor ........................................................................................ 20-580
PC300. 350-6 20-551

0
H-27 Excessive overrug when stopping swing ........................................................................... 20-582
a) Onedirectiononly ........................................................................................................ 20-582
bf Both directions .............................................................................................................. 20-582
H-28 Excessive shock when stopping swing (one direction only) ............................................ 20-583
H-29 Excessive abnormal noise when stopping swing ............................................................. 20-583
H-30 Excessive hydraulic drift of swing ......................................................................................20-584
a) When swkg holdingbrake is released ....................................................................... 0-584
b) Whenswing holding brake is applied ....................................................................... 20-584
!-!-3? Swing speed is faster than specified speed ...................................................................... 20-585
20-552 PC300. 350-6

0
TROUBLESHOOTING PUMP MERGE/DIVIOER LOGIC, LS SELECT LOGIC,SOLENOIDACTUATION TABLE
PUMP MERGE/DIVIDER LOGIC
s
~ ~~ ~ ~ ~ ~~~ ~~
Divide (pump merge/divider solenoid ON) Merge (pump merge/divider solenoid OFF)
1. Travel operated independently. All operations except those on left.
2. Travel + work equipment (anyone of boom,
arm,bucket, swing, or service) + front or
rear pump oil pressure 19.6 MPa (200 kg/
cm2) or above when raised or 14.7 MPa {150
kg/cm2) or above when lowered. (See dia-
gram)
I
14.7 19.6
(1 50) (200)
Pressure MPa(kg/cm*) BKPOD22,
3. Breaker mode + service (breaker) valve pres-

sure switch ON.
SOLENOID ACTUATION TABLE

r
Name of solenoid ON (energized) OFF
Swing holding brake Brake released Brake applied
Travel speed Travel motor swash plate angle at MIN Travel motor swash plate angle at MAX
Active mode (boom) STD mode Active mode
Pump merge/divider valve Divided flow Merged flow
Low pressure Machine push-up High pressure
Active mode (swing) Active mode STD mode
PC300,350-6 20-553
0
ladwea
x
u)
m
s'
m
i2
E
m
u)
.-0
I
Ea,
P
c
a,
m
c
I;
n
7J
.-
C
-c
E
7J
b)
m
e
m
'5m
c
0
E
m
a,
t c 4
T
T1 r 1-
'T T b Main relief valve
E3 $
b
valve
Unload us
/Pressure compensation valve
ILS shuttle valve
LS circuit throttle
Suction valve
~ ~~~~
Swing PPC slow return valve
Engine system
I- - -
0
n
m
I
i 1
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES (2/2)
Parts causing failure

Solenoid valve
T-1Swing
motor
-$
Failure mode
Speeds of all work equipment, swing, travel are slow or lack power
There is excessive drop in enginespeed, or engine stalls
No work equipment, travel, swing move
Abnormal noise generated (around pump)
Auto-deceleration does not work
Fine controlabiliisooror res onse isoor
Deviation is excessive during normal travel

Travel deviation
Deviation is excessive when startino
Travel speed is 0
does power
Steering
turn lacks not or 0
Travel speed
switch
not
does or is specified
faster
than speed 0 0
Does not move (one side only)
Does not swing

Both left and right I
One direction only
Swing acceleration is poor Both left and right
or swing speed isslow One direction only
Excessive overrun
Both
and
left
right
when
stoppingswing OneI
direction
only
Excessive shock when stopping swing (one direction only)
Excessive abnormal noise when stopping swing
Excessive hydraulic Whenbrake ON
drift
swing
of When
brake OFF
speed is faster
Swingspecified
than swing speed (3
* In the failure modes, modes for compound operations are used when independent operations are normal
A: When there is an abnormality for both front andrear
20-556 PC300, 350-6

0
T valve Safety I
Counterbalance valve
Check valve
Trevel speed selector servo piston
Leakage, breakage inside body

Swing machinery
Final drive
Hydraulic cylinder
Boom lock valve

Back pressure valve
Travel junction valve
RAISE
LOWER
IN
OUT
CURL
X
DUMP
Swing
-$- 2
Travel
Front pump
Pressure sensor
Rear pump
TROUBLESHOOTING H-I
H-I Speeds of all work equipment, swing, travel are slow or lack
power
It Carry out troubleshooting in the H/0 mode.
* Check thatnoabnormalnoise is being generated fromthemainpumpbeforecarrying out
troubleshooting. (If there is any abnormal noise, carry out troubleshooting for H-4.)
4 See TESTING
AND
Is input pressure of
ADJUSTING.
-
YES servo piston
approx. 2/5 of main
circuit pressure?
Engine at high 7 YES
Is output
YES pressure of
- idling
Power max.
Does condition
become normal when -
Ls- -
r EPC valve . mode
L.H. knob switch NO
replaced?
is
I
Arm IN relief of
* Distribution NO
servo (LS valve) and
Engine
pump
piston
at high (servo
piston)
Arm IN relief NO
* Arm IN relief
NO
Sr Measuring servo piston inlet port pressure in Item No. 4

Measure the input pressure to the large diameter end of the servo piston when the arm is
relieved in the power max. mode. (Approx. 12.74 MPa (130 kg/cm2))
Basically, the pressure at the large diameter endis approx. 2/5 of the small diameter end. (For
details, see TESTING AND ADJUSTING.)]
20-558 PC300, 350-6

0
TROUBLESHOOTING H-1
I Cause Remedy
Defective adjustment of
TVC valve Adjust
Defective servo assembly Repair or

(defective TVC valve) replace
- Defective piston pump

Repair or
replace
Defective servo assembly Repair or

(defective LS valve) replace
Defective piston pump Repair or

(servo piston) replace
Defective operation of
LS-EPC solenoid valve Replace
main relief assembly
(valve which becomes Adjust
normal when adjusted)
. Defective operation of
unload valve (valve Replace
which becomes normal
when replaced)
main relief valve Replace
Defective self-reducing Repair or

va Ive replace
PC300,350-6 20-559
0
TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

k Carry out troubieshooting in the H/O mode.
* Check that the main relief pressure is normal.
I Remedy
YES
I
Clogged throttle inside
servo or clogged
inside servo
filter
Defective TVC valve or

! Clean
Adjust or
replace servo
IlOli I I I defective operation of LS valve
valve
assembly
Replace
Defective servopiston (piston pump
assembly)
See troubleshooting for

-
engine (Smode)
Note 1:Replace the servo valve assembly on the defective side with a new part, and if the engine
speed is lower than the reference value below, carry out troubleshooting for S mode (engine).
If it is higher,it can be judged that the
TVC valve (servo valveassembly) is defective, so replace
it.
* Engine speed (reference) at arm IN relief when engine and pump are normal
Engine speed at arm IN relief Conditions

9 Engine at high idling
2100 k 100rpm Power max. mode
L.H. knob switch ON
20-560 PC300, 350-6

0
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel, swing move
I I
I Cause Remedy
2 YES
....".....". . v"...r I, I
8,When -sip ntomn I
II
I
Defectiveself-reducina
valve, defective control
clrcni?, nr defective main
Replace
.- -
-
Is safety lock
YES pressure pickup
1 plug is removed,
-
does oil come out?
w
piston pump
Defective damper Replace

valve working - * Crank with
starting motor.
NO
properly?
P Defective operation of
safety lock valveor Adjust
NO safety linkage
H-4 Abnormal noise generated (around pump)
YES
Goto 4
Do bubbles
YES disappear when
_I
2
stopped?
~--
engine is
NO
Improper hydraulic oil
Change
hydraulic oil
YE^ Are there

- bubbles inside -
hydraulic zsnk7 YES
Remove
4
-
NO
Is suction strainer
clogged
by
external object?
-- 5 YE:
Repair or
clogged with Defect inside pump
replace
External
normal?
level
Is hydraulic tank
oil
Cloth,
etc.
object: -
metal particles or
NO are metal H Inspect again
Operate for ashort time
oarticles stuck to I I
and watch forany (depending on
drain plug?
- change in symptoms
I
changes i n
symptoms)
I Lack of hydraulic oil Add hydraulic

NO oil
PC300, 350-6 20-561

0
H-5 Auto-deceleration does not work (when PPC shuttle valve is

cause)
* The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied
to the pressure switch.
Does condition
become normal
when pressure
1 YES
switch is replaced?
-
aDefective pressure
switch
PPC shuttle valvein
Remedy
Replace
Repair or
NO applicable system (swing replace
or travel)
H-6 Fine control ability is poor or response is poor
6 Cause Remedy
2 YES Clogged throttle inLS

circuit Clean
i Is throttle in LS
circuit clogged?
-
Defective servovalve
Is output assembly (LSvalve), or Replace
pressure of LS- NO defective servo piston
EPC normal?
Output pressure: I Defective LS-EPC valve

Repair or
replace
2.94 f 0.2 MPa NO
I30 2 2 kg/cm21
20-562 PC300, 350-6

TROUBLESHOOTING H-7
H-7 Boom is slow or lacks power

fl When travel and swing speeds are normal.
fl Carry out troubleshooting in the H/O mode.
YES
6
Does LS shuttle
YES
valve move
5 smoothly?
Is relief pressure
of front and rear • Check LS shuttle
pumps normal for R.H. travel NO
when boom RAISE
and bucket
circuit is relieved?
• 32.34 – 35.77 MPa
YES {330 – 365 kg/cm2}
• Engine at high NO
idling
4 8 YES
High
Is pressure Is operating pressure
compensation valve normal when boom
YES for boom normal, or LOWER is being
does pressure
compensation piston operated?
3 move smoothly? Low
• 4.9 ± 2.94 MPa NO
• It is also possible
Does control {50 ± 30 kg/cm2}
YES valve spool for to interchange
• Engine at high
with other
boom move idling
compensation
smoothly?
2 valve. NO
• See Note 2.
YES Is output
pressure of PPC
valve normal?
1 NO
Is pressure • Min. 2.74 MPa
switch for boom {28 kg/cm2}
RAISE, LOWER • Engine at high
normal? idling NO
• See Judgement • Operate boom.
Table. (Bit
pattern 20 (3)(4))
• See Note 1. NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, system is
normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-564 PC300, 350-6

1
5
TROUBLESHOOTING H-7
pressure normal
when boomRAISE
is being operated?
15.68 f.1.0 MPa
I160f 10 ks/crnq
-
YES
Engine at hlgh idling

* At max. reach, no
load
NO
High
Low
Cause
boom lock valve
Defective boom cylinder

piston packing
Defective operation of LE
shuttle valve (LSshuttle
for R.H. travel or bucket)
Defective boom lock

I
I
Remedy
Repair or
replace
Repair or
replace
Repair or
replace
valve or suction valvefor Replace

boom in control valve
Jefective operation of Repair or

boom lock valve replace
3efective operation of Repair or

3oom regeneration valve replace
Iefective operationof boom
xessure compensation valveor
~ressure compensation piston Repair or
for boom RAISE end, check replace
loom Hi also)
lefective operation of
Repair or
:ontrot valve spool (for
realace
loom RAISE end, check
loom Hi spool also)
Iefective PPC valve Replace
Iefective boom RAISE or

)oom LOWER pressure 3eplace
:witch
PC300, 350-6 20-565

0
TROUBLESHOOTING H-8
H-8 Arm is slow or lacks power

*
A
When travel and swing speeds are normal.
Carry out troubleshooting in the H10 mode.
-H
YES Does LS shuttle
valve move
5 smoothly?
Is relief pressureof
- normal when arm
YES front and rearpumps Check Ls
for L.H. travel, NO
4 circuit is relieved? boom, R.H.
Is pressure travel and
32.34- 35.77 MPa
-
YES compensationvalve for
arm normal. or does - (330- 365 kg/cm21 NO
bucket
pressurecompensation Engine at high

piston move smoothly? idling
Does control It is also possible
YES valve spool for
arm move
- t o interchange
other
with NO
smoothly) l cocpensaiion
rl H
valve.
YES Is output
* See Note 2.
pressure of PPC
valve normal? NO
1
Table. ( k t I
pattern 20 (5). NO
(6))
aSeeTable 1.
Note 1: If theauto-decelerationiscanceledwhenarmINorarm OUT is operated, the system is

normal.
20-566 PC300, 350-6

0
TROUBLESHOOTING H-8
1
~ ~
Cause Remedy
7 YES Defective operation of Repair or

arm regeneration valve replace
Is leakage from
- arm cylinder -
normal?
Defective arm cylindef Repair or
* Max. 20 cc/min NO piston packing replace
Engine athigh
idling Defective operation of LS
shuttle valve (LS shuttle Repair or
for L.H. travel, boom, replace
R.H.travel or bucket)
Defective safety-suction
valve for arm Replace
arm pressure
compensation valve or 1Repair or
pressure compensation Ireplace
piston (for arm Lo and
arm Hi)
Defective operation of I3epair or
I.eplace
control valve spool (for
arm Lo and arm Hi)
Defective PPC valve I3eplace
Defective arm IN or arm

f3eplace
OUT pressure switch
PC300, 350-6 20-567

0
TROUBLESHOOTING H-9
H-9 Bucket is slow or lacks power

* When travel and swing speeds are normal.
Cause Remedy
Repair or
control valve spool for
replace
bucket
Defective PPC valve Replace
Defective bi;eke: CURL

Table. (sit bucket DUMP pressure Replace
pattern 21 switch
- (2))
See Note 1
5 YE:
Repair or
-I- safety-suction valve for
bucket replace
Defective bucket cylinder Repair or

piston packing replace
does pressure Engine at high
comDensation Diston idling Defective operation of
lmove smoothly? II pressure compensation Repair or
It is also possibte NO valve for bucket or replace
to interchange pressure compensation
with other piston
compensation
valve.
See Note 2 .
Note 1: Iftheauto-decelerationis canceled when bucket CURL or bucket DUMP is operated, the
system is normal.
20-568 PC300, 350-6

0
TROUBLESHOOTING H-10,
H-10 Work equipment (boom, arm, bucket) does not move (but travel
and swing are normal)
* When boom, arm,andbucket areeach operatedinde-
pendently.
Defective control valve

1 YES Repair or
spool
replace
Is output
pressure ofPPC
-
.Is!ve norma!?
Min. 2.74 MPa NO
(28kg/cm*J
Engine at high
idling
H-11 Excessive hydraulic drift (boom, arm, bucket)

1) Excessive hydraulic drift of boom
Cause Remedy
YES Defective hydraulic

1 1
Replace
cylinder piston packing
downward movement
I
when
become faster
lever is operated? II
Decorne n
2 YES
I Defective operation of
safety-suction valve Replace
See TESTING
AND tion valve is
ADJUSTING. led? Repair or
It is also possible NO boom lock valve replace
to measure
leakage of
cyiinder.
* Max. 20 cc/min
* At relief
Engine athigh
idling
2) Excessive hydraulic drift of arm or bucket Cause Remedy
Defective hydraulic
cylinder piston packing Replace
Does speed of
downward movement YES Defective operation of
become faster when safety-suction valve Replace
1 lever is operated? I Does condition
-
See TESTING become normal 3

AND
ADJUSTING.
N i when safety-
suction valve is
Is slipper seal of YES Defective control valve
spool Replace
pressure
It is also possible
to measure
leakage of
interchanged?
-
compensation valve
damaged?
No Or does pressure
- Damaged slipper seal of
pressure compensation Repair 01
cylinder. compensation piston valve, or defective
* Max. 20 cdmin move smsothly? NO mp!ace
operation of pressure
- A t relief It is also possible
to interchange with compensation piston
Engine at high other compensationvalve.
idling See Note 1.
Note 1: After inspection, do not forget to return the interchanged alves to the original position.
PC300, 350-6 20-569

0
H-12 Excessive time lag (engine at low idling)

Cause Remedy
valve, or defective Replace
regeneration valve
Replace
valve
pressure compensation Repair or
valve or pressure replace
compensation piston
Defective operation of Repair or

LS-EPC solenoid valve replace
Note 1 : Output pressure of LS-EPC solenoid

2.94 rf: 0.2 MPa (30 k 2 kg/cm21is output from the LS-EPC solenoid when the all leverare at
neutral.
H-13 Other equipment moves when single circuit is relieved
Cause Remedy
I Defective operation of
pressure compensation
valve slipper seal
(The slipper seal in the
pressure compensation
valve of the circuit that
moved is defective.)
Replace
20-570 PC300, 350-6

0
TROUBLESHOOTING H-14, H-15, H-16
H-I4 In L/O, F/O modes, work equipment speed is faster than

specified speed
r Cause Remedy
1 YES Repair or
Defective LS valve
Is output replace
pressure of LS-
EPC solenoid
valve normal? Defective operation of Repair or
see
Note 1. i\0
j is-EPC soienoia vaive repiace
Note 1: Output pressure of LS control EPC solenoid (travel OFF)

2.94 k 0.2 MPa {30 f 2 kg/cm2) is output from theLS-EPC solenoid when the all lever are at
neutral.
H-I5 Defective actuation of machine push-up function

-k When electrical system is normal. Cause Remedy
1 YES
Defective safety valve Replace
Is output pressure
of machine push-
up solenoid valve -
as shown in Table
l?
solenoid valve replace
* Engine at high NO
- idling
For details of the measurement
procedure, see TESTING AND
ADJUSTING.
Table I
Machine push-up switch Oil pressure (MPa {kg/cm2))
0Low pressure setting 2.942:;: (301; 1
I @pressure
High setting 1 0 (0) I
H-1’16 in compound operations, work equipment with iarger ioad Is slow
~ ~~
Cause Remedy
Defective operation of pressure Replace (replace pressure compensation
compensation valve valve on side where load is lower)
1 1 Combination of compoundoperation 1 Sidewhereload is larger I

I z 1
1 Boom RAISE +a
Boom RAISE -+ arm BUT
m IN Boom RAISE
Arm OUT
I
I
I 3I Boom RAISE + bucket CURL I Boom RAISE I
4 Arm OUT + bucket CURL Arm OUT
5 Boom LOWER + arm OUT Arm OUT
PC300, 350-6 20-571

0
TROUBLESHOOTING H-17, H-18, H-19
H-17 In swing + boom RAISE, boom RAISE is slow

Je If swing and boom RAfSE work normaliy when operated independently.
(11 In active mode
NO Defective operation of Repair or

active (swing) solenoid replace
1 valve
Is output
pressure of active
(swing) solenoid 2 YES Defective operation of LS Repair or
valve normal? select valve replace
- Does PPC shuttle
Min. 2.74 MPa - valve forLS
Select circuit
- Defective operation of
{28 kg/cm2)
YES
Boom lever move smoothly? PPC shuttle valve forLS
Repair or
operated fully NO select circuit (PPC shuttle
replace
t o RAISE for boom RAISE, LS
select)
(2) In other mode
1 YES Defective operation of LS Repair or

I [DoesPPCshuttle II select valve replace
valve forLS
operation Defective select circuit of
PPC shuttle valve forLS
Repair or
select circuit (PPC shuttle
replace
for boom RAISE, LS
select)
H-I8 In swing + arm, arm is slow

* See H-17.
(If the operation is normal when the swing and arm are operated independently.
If the Cause column shows that there is defective operation of the LS shuttle valve, the cause
is in the shuttie valve for the arm OUT, IN and LS select.)
H-19 In swing + travel, travel speed drops excessively

.st See H-17.
(If the operation is normal when the swing and travel are operated independently.
If the Cause column shows that thereis defective operation of the PPC shuttle valve, the cause
is in the shuttle valve for the LS select.)
20-572 PC300, 350-6

0
TROUBLESHOOTING H-20
H-20 Travel deviation

* Carry out troubleshooting in the H/O mode.
* When swing and work equipment speeds are normal.
a) When there is deviation in normal travel
Does control
3 YES
F assembly
Cause
Defective travel motor

Remedy
Repair or
replace
YES_ valve spool for
2 travel move
- Defective operation of Repair or
move - valve
Does junction
- NO
control valve spool replace
smoothly?
travel junction valve replace
and right PPC valves
normal, or is output
4. YES
__ Repair or
Defective PPC shuttle replace
Output pressure:
Min. 2.74 MPa
- (28kg/cm?
Difference in
~ ~. .
outout Dressure
NO end) ofPPC valve
normal!
between Same conditions NO
FORWARD and as for Item 1
REVERSE * See Note 1
: Within 0.39 MPa
{4 kg/cm2 1
Engine at high
idling
Travel relief
Note 1: Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip.
If the adapter for blocking the circuit is not available, interchange the travelPPC hoses with
the PPC hoses for the bucket (CURL, DUMP), boom (LOWER), or arm (IN) at both the inlet
and outlet ports of the shuttle block, and check operation.
b) Excessive travel deviation when starting
I Cause 1 Remedy I
Defective operation of travel
Correct or reptace
counterbalance valve
Clogging of throttle inside servo
Correct or rep,ace
of front or rear pump
PC300, 350-6 20-573

0
H-21 Travel speed is slow

-k Check that the spool of the travel PPC valve is moving the full stroke before carrying out troilbie-
shooting.
* When swing and work equipment speeds are normal.
3- YES
Is output
YES pressure of LS-
2
-
EPC solenoid
valve normal?
Slow in both
FORWARD and - switch
Is pressure
normal?
- See Note 2. NO
REVERSE
NO
YES
7 r
compensation valve
YEA normal, or does
bath FORWARD Dressure
and REVERSE, or is
I it s!ow in one
8 Does contro!
compensation piston
movesrnoothiv? I1
direction only?
- See Note 1.
travel move
It is also possible
to interchange
with other
NO
-n
compensation valve.
Does junction
valve move II - See Note 3.
smoothly? NO
yEil
Check as
4 individual part.
TIS difference
in 1 NO
Slow in one output pressure
direction only between left and
(FORWARD or right PPC valves
normal. or is output
REVERSE)
Difference in (shuttle block inlet
REVERSE Same conditions

: Within 0.39 MPa as for item 4
- (4 kg/cm21
Output pressure:
Min. 2.74 MPa
* See Note 4.
I28 kg/cm2}
* Engine at high
idling
* Travel relief
Note 1: Measure the travel speed under no load or measure the time taken to travel 20 m. (See
MAINTENANCE STANDARD FOR CHASSIS RELATED PARTS.)
When measuring the speed of the travel motor under no load + Remove connector of LS
control EPC solenoid, and measure travel speed in Lo and Hi.
Note 2: Output
pressure of LS-EPC solenoid Unit: MPa {kg/cm2)
Travel speed Lo Mi Hi
LS-EPC 0.2 k 0.2 1.8 f 0.2 0.2 t 0.2
output pressure (2.0 k 2.0) (18.4 f 2.0) {2.0 i 2.0}
Remarks Engine at high idling

Operate travel lever slightly (auto-deceleration cancel position)
20-574 PC300, 350-6

0
Cause Remedy
Defective operation of LS Repair or

shuttle valve (for bucket) replace

LS-EPCsolenoid valve replace
Defective travel pressure

' switch Repiace
travel
,+
become
4 when
valve forcontrol
YES
1
A
normal
I
travel suction valve for
control valve
Defective travel motot

Repair or
replace
Repair or
assembly replace
See Note 1. NO
Defective pressure
compensation valve, or
defective operation of Repair or
pressure compensation replace
piston
Repair or
travel spool for control replace
valve

junction valve replace
Repair or
Defective PPC shuttle replace
?-dote3: After inspeetion, do not forget to return the interchanged vaives to the originai position.
Note 4: Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip.
0 If the adapter for blocking the circuit is notavailable, interchange the travel PPC hoses with
the PPC hoses for the bucket (CURL, DUMP), boom (LOWER), or arm (IN) at both the inlet
and outlet ports of the shuttle block, and check operation.
PC300, 350-6 20-575

0
H-22 Steering does not turn easily or lacks power

-A Carry o ~ troubleshooting
t in the H/O mode.
Both front and pump mergeldivider

rear high solenoid valve
How is relief
Both left and pressure of front NO
right and rear pump
when relieved on Pressure high
only onside
being relieved
(oil pressure is
normal)
is it difficult to turn in Both front and
I
one direction only? rear high
I I
t
One direction of front and rear
oniy 1 pump when reiievea
Does not turn to -
I
left or right
When steering,
pressure switch
drive side is low
normal?
(opposite side is
normal)
See Judgement
Table. (Bit
pattern 20 (2))
Does not turn to -
left only
If auto-
deceleration is
canceled when
travel is
operated, system
is normal.
NO
20-576
0
z
0
L
H-23 Travel speed does not switch or is faster than specified speed
3 YES travel speed selector
servo piston in travel Replace
Is output pressure
motor
YES of travel speed
2 r
selector solenoid
- 1
Is output Defective operation of Repair or
YES pressure of travel speed selector replace
Ls-
-~ -, EPC solenoid
valve normal?
Min. 2,74 MPa
(28 kg/cm21
* Travel speed selector switch: Mi, Hi
solenoid valve
* See Table 1. Turn travel switchON. Defective operation of Repair or

-
IS travel pressure
switch normal? NO LS-EPC solenoid valve replace
w
See Judgement Defective travel pressure
Table. (Bit switch Replace
pattern 20 (2))
NO
If auto-
deceleration is canceled
when travel isoperated,
system is normal.
Table 1. Output pressure of LS-EPC solenoid Unit: MPa {kg/cm2}

Travel speed Lo Mi Hi
LS-EPC 0.2 k 0.2 1.8 k 0.2 0.2 f 0.2
output pressure (2.0 f 2.0) (18.4 f 2.0) {2.0 f 2.01
Remarks Engine at high idling
Operate travel lever slightly (auto-deceleration cancel position)
H-24 Travel does not move (one side only)

~~~ ~~ ~ ~~ - ~
Cause Remedy
YES Repair or
Defective final drive
I replace
1 1
Is any foreign 3 YES Defective operation of
material found i n
oil drained from
- Does condition suction valve of control
valve
Replace
final drive?
YES become normal when -
- left and right suction
2are
valves of control valve
inlerchansed?
Is drain amount counterbalance valve or Replace
NO
- of travel motor - NO travel motor safety valve
normal?
P
Max. : 30 2! /min
Defective travel motor Replace
Engine a t high NO
idling
* At travel relief
20-578 PC300, 350-6

0
H-25 Does notswing

a! Does not swing to either left or right
Is any foreign
3 YES
F
machinery
Cause
Defective swing
Remedy
Repair or
replace
YES materialfound in
*I- oil drained from -
swing machinery? Defective swing holding Repair or
YES of swing holding NO brake or swing motor replace
I-
brake solenoid
Repair or
ISswing pressure
switch normal?
-Min. 2.74 MPa
(28kg/cm2} NO
holding brake solenoid
valve replace
Operate swing
lever (or operate work
a See Judgement equipment lever). Defective swing pressure
Table. (Bit switch Replace
pattern 20 (1))
NO
If auto-
deceleration is
canceled when
swing is
operated, system
i s normal.
b) Does not swing in one direction
Cause Remedy
Defective swing motor

2 YES safety valve or suction Replace
I Does control valve
YES valve spool
YEdvalve spool for
for
hlv7 Defective operation of

contrG! V2!YB s p m ! fc: Repair or
NO swing replace
output plc:55ult:
output pressure
normal?
* Min. 2.74 MPa I ~

I28 kg/cm2) NO
* Operate swing
iever (oroperate
work equipment
lever).
I
PC300,350-6 20-579
0
H-26 Swing acceleration is poor or swing speed is slow

A Carry out troubleshooting in the H/O mode.
* If condition is normal when work equipment is operated independently.
a) Swing acceleration is poor
2 YES
Does LS shuttle
Both left
- and right -smoothly?
valve move -
I
Is swing
acceleration poor
in both directions
or in one
direction nnly?
other Compensationvalve.
end) of PPC valve
pressure -
One
direction Is PPC valve Same
conditions
- only -output as for Itern 6
NO
(left
right)
normal?
or See Note 1.
Min. 2.74 MPa

I28 kg/cm2}
Engineat high NO
idling
Operate swing
Note 1: * Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip.
is available, interchange the swingPPC hoses with
If the adapter for blocking the circuit not
the PPC hoses for the bucket (CURL, DUMP?,a t both the inlet and outlet ports of the shuttle
block, and check operation.
28-580
0
Cause Remedy
Defective swing motor

Replace
assembly
Defective operation of LS Repair or

shuttle valve (allLS
replace
shuttles)

swing motorsafety- replace
suction valve
pressure compensation Repair or
replace
valve or compensation
piston
:ontrol valve spool for Repair or
swing replace
3efective operation of Repair or

'PC shuttle valve replace
Iefective ?PC vaive Replace
PC300, 350-6 20-581

0
0
z
H
0
0
6n
2
C
I.
I
CI
L 0
3
0
m
c
'i5
v)
yl
0
Q)
Y
E
P
0
z
. .
H-31 Swing speed is faster than specified swing speed
Cause Remedy
1 YES Defective operation of LS Replace servo

valve assembly
Is output
pressure of LS-
EPC solenoid
valve normal? Defective LS-EPC Repair or
* See Table 1. NO solenoid replace
Table 1. Output pressure of LS-EPC solenoid valve
Engine a t high idling

Travel OFF
PC300, 350-6 20-585

0
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
Action taken by monitor panel when abnormality occurs

and problems on machine................................................................................................................ 20-604
Electrical circuit diagram for M mode system.................................................................................... 20-606
M-I [E1011 Abnormality in error data is displayed
[E1021 Error in clock data is displayed ................................................................................. 20-608
M-2 [E1031 Short circuit in buzzer output or contact of 24V wiring harness
with buzzer drive harness is displayed ................................................................................. 20-609
M-3 [E1041 Air cleaner clogging detected is displayed .............................................................. 20-610
M-4 [E1061 Drop in engine oil pressure Hi detected is displayed .............................................20-610
M-5 [E1081 Engine water temperature 105°C detected is displayed .......................................... 20-611
M-6 When starting switch is turned ON, none of lamps on monitor panel
light up for 3 seconds ............................................................................................................ 20-612
a) None of lamp on monitor panel light up ....................................................................... 20-612
b) Some of lamps on monitor panel do not light up ........................................................ 20-612
M-7 When starting switch is turned ON. monitor panel lamps all stay lighted up
and do not go out................................................................................................................... 20-614
M-8 When starting switch is turned ON. items lighted up on monitor panel are
different from actual machine (model) ................................................................................. 20-614
M-9 When starting switch is turned ON {engine stopped). basic check items flash .............. 20-615
iani aj
..
ievert rlashes ......................................................................................................
I t
20-615
b) (engine oil level) flashes .................................................................................................. 20-616
c) (hydraulic oil level) flashes .............................................................................................. 20-617
M-10 Preheating is not being used but (preheating monitor) lights up ..................................... 20-618
M-11 When starting switch is turned ON and engine is started. basic check items flash ......20-619
a) Alternator system ............................................................................................................. 20-619
b) Engine oil pressure system ............................................................................................. 20-620
M-12 When starting switch is turned ON (engine stopped). caution items.
emergency stop items flash................................................................................................... 20-621
a) Alternator system ............................................................................................................. 20-621
b) Engine oil pressure sensor system ................................................................................. 20-622
M-13 When starting switch is turned ON and engine is started, caution items.
emergency stop items flash................................................................................................... 20-623
a) (engine oil pressure) flashes ........................................................................................... 20-623
b) (coolant level) flashes ...................................................................................................... 20-623
c) (battery charge) flashes ................................................................................................... 20-623
d) (coolant temperature) flashes .......................................................................................... 20-624
e) (fuel level) flashes ............................................................................................................. 20-624
f) (air cleaner clogging) flashes .......................................................................................... 20-625
PC300. 350-6 20-601

@
M-14 When starting switch is turned ON (engine stopped). buzzer does not sound for 1 second
Caution item flashes but buzzer does not sound ................................................................ 20-626
M-I5 No abnormality is displayed on monitor but buzzer sounds ............................................. 20-626
M-16 Night lighting on monitor panel does not light up (liquid crystal display is normal) ... 20-627
M-17 Coolant temperature gauge does not rise ........................................................................... 20-628
M-18 Coolant temperature gauge does not give any display ...................................................... 20-628
M-19 Fuel level gauge always displays FULL ................................................................................ 20-629
M-20 Fuel level gauge does not give display ................................................................................ 20-629
M-21 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up .... 20-630
M-22 Swing prolix switch is turned ON (prolix), but (swing lock monitor) does not flash .... 20-630
M-23 Service meter does not advance while engine is running ................................................. 20-631
M-24 When starting switch is a t OFF and time switch is pressed.
time and service meter are not displayed ............................................................................ 20-631
M-25 Defective fuel level sensor system ........................................................................................ 20-632
M-26 Defective coolant temperature sensor system ..................................................................... 20-633
M-27 Defective engine oil level sensor system ............................................................................. 20-634
M-28 Defective coolant level sensor system ................................................................................. 20-635
M-29 Defective hydraulic oil level sensor system ......................................................................... 20-636
M-30 Wiper does not work or switch is not being used but wiper is actuated
(include €112. E1131................................................................................................................ 20-638
a) Wiper does not work ........................................................................................................ 20-638
b) Wiper switch is not being operated but wiper is actuated .......................................... 20-642
M-31 Washer motor does not work. or switch is not being used but washer motor
is actuated (include E114) ...................................................................................................... 20-643
a) Washer motor does not work ......................................................................................... 20-643
b) Switch is not being operated but washer is actuated .................................................. 20-644
M-32 Electric grease gun does not work ........................................................................................ 20-645
20-602
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
ACTION TAt :EN BY MONITOR PANEL WHEN ABNORMALITY

86CUWS AI\ ID PROBLEMS ON MACHINE
Servict
code
1. Abnormality in internal memory

El01 Abnormality in error 2. Excess voltage (more than 36V) has occurred
data 3. Low voltage (less than 12V) has occurred
4. Connectorhasseparated
1. Abnormality in internal clock function

E102 Abnormality in clock 2. Excess voltage (more than 36V) has occurred
data 3. Low voitage (less than 12V) has occurred
4. Connectorhasseparated
1. Short circuit inside buzzer

E103 Short circuit inbuzzer 2. Power line in contact with wiring harness between monitor(PO1 (
output system pin) and buzzer
3. Abnormality in monitor panel
Air cleaner clogging

E104 1. Air cleaner clogging sensor has detected clogging
detected is displayed
Drop in engine oil Hi

E106 pressuredetectedis 1. Engine oil pressure Hi sensor has detected drop in oil pressure
displayed
Engine water 1. Coolanttemperaturegauge has detectedwatertemperature

E108 temperature 105°C 105°C
detected is displayed
1. Short circuit with ground, short circuit inside wiper motor

Short circuit in wiper 2. Short circuit with ground, short circuit inside relay box
motordrivenormal 3. Short circuit, short circuit with ground between monitor PO2 (11)
E112 relay box W08 (2) ((17)), or between W08 (6) ((7)) - wiper monit
rotation system
W04 (3)
( ): For machines without power window specification
1. Short circuit with ground, short circuit inside wiper motor

Short circuit in wiper 2. Short circuit with ground, short circuit inside relay box
E113 motordrive reverse 3. Short circuit, short circuit with ground between monitor PO2 (3)
reiay box VVO8 i3j iiisjj, or between WU8 iri ( ( 6 ) )- wiper monitl
rotation system
W04 (3)
( 1: For machines without power window specification.
1. Short circuit inside washer motor

Short circuit in win- 2. Short circuit inside relay box
E114 d o ww a s h e rd r i v e 3. Shortcircuitwithpowersourcebetweenmonitor PO2 (2)(10)
system (relay box W08 (171, or between W08 ((16)) - M28 (1)
( ): For machines with power window specification.
20-604
@
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
~~
Condition w h e n n o r m a l A c t i o n by c o n t r o l l e r w h e n Problem that appears on machine

(voltage, current, resistance) a b n o r m a l i t y is detected when there is abnormality
1. Service code cannot be cleared

2. Timebecomes 0O:OO.
. Whenstartingswitch is
turned ON, keep time
switch pressed for 5
seconds to actuate clear 1. Service code cannot be cleared
function 2. Time becomes 0O:OO.
3. Clock does not advance.
. Voltagebetween PO1 ( 7 )
- chassis
Buzzer ON: Max. 1V
Buzzer OFF: 20 - 30V
* When there is a discon-
nection, E103 is not
1. Buzzer does not sound
displayed and the buzzer

does not sound
. Resistancebetween P I 1 1. If abnormality detection contin-

(male) - PI2 (male): ues, air cleaner clogging caution
Min. 1 Cl (engine started) lamp flashes and buzzer sounds
. Resistance
between
1. If abnormality detection contin-
sensor terminal - chassis
1 Mi2 (engine at rnid- ues, engine oil pressure caution
range speed or above) lamp flashes and buzzer sounds
1. If abnormality detection contin-

. Resistancebetween PO7 ues, coolanttemperaturecau-
(1) - (2): tionlampflashesand buzzer
Min. 3.156 kR (engine sounds
started) 2. If abnormality detection contin-
ues, engine speed is reduced to
I
-
low idling
Voltagebetween W04 (3) 1. Sets output to relay box to 0 1. Operation of wiper stops
and (5) : Max. 3 V
5
20 - 30 V
* Repeats in regular cycle
- \r-a~---
VUlldLJa
L-r i A l A A
U ~ l V V C C l IV V V ' t
and (5) : Max. 3 V
/I\
\ I1
Same as E112 Same as E112

20 - 30 V
Ir Repeats in regular cycle
I Resistance of motor : 1. Sets output to washer motor to 0 1. Operation of windowwasher

stops
I
PC300, 350-6 20-605

@
TROUBLESHOOTING
ELECTRICAL
CIRCUIT DIAGRAM FOR M MODE SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM

WITH POWER WINDOW
I
WINDOWWASHER
M28 ( K E S O )
ll
I
tt
L !
l
11
II
II
l
'i
16
21
1R
ALARM
(M4
NETWORK BUS
1
M 35) I 3
30
BUZZER P O 4 ( M 2 )
Dl 1 (KESI)
Em== AIR CLEANER
RADIATOR
CLOGGING WATER LEVEL
FUEL
LEVEL
LEVEL
OIL
SENSOR
SENSORSENSOR SENSOR TWP01424
28-686
0
TROUBLESHOOTING
ELECTRICAL
CIRCUIT DIAGRAM FOR M SYSTEM
MODE
1
IIII , RW08
Box
E L A Y( 0 7 0 1 8 )
1
R
7
REAR
II I / FNGINE THROTTLE
I ' I /IIt CONTROLLER .
//I/
1lIll I
X1) * ,
ENGINE O I L
L E V E L SENSOR
ENGINE WATER L E V E L SENSOR
AEXI). 8 5
Si 1
ENGINE O I L PRESSURESWITCH
TWPO I 4 2 5
PC300, 350-6 20-607

/n
il/
TROUBLESHOOTING
ELECTRICAL
CIRCUIT DIAGRAM FOR M MODE SYSTEM

STARTINGSWITCH
HEAD LAMP
(R. HI
WORK I NG LAMP
(BOOM) H12 (S16)
I
I
WINDOWWASHER
i
I I I I I
NETWORK BUS
AL
BU
CLOGGING WATER LEVEL FUELLEVEL O I LL E V E L

SENSOR SENSOR SENSOR SENSOR TJP01971
20-607-? PC300, 350-6

0
u-
F
j: tt m
W
=s
D
rn
I
m
W
rn
h-m s
I
D 1
-i
m
W
t
I
m I l l / /
ccc
z
c) U
=
D
-i
m
73
I
L
TROUBLESHOOTING M-1
M-I [E1011 Abnormality in error data is displayed

[E1021 Error in clock data is displayed
* This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting
connector PO2 (for the monitor panel electrical system), fuse No. 13, connector M14, connector
M11, battery relay terminal B, or the battery terminal.
(When the monitor panel power source circuit is shut off with the starting switch turned OFF.)
Ir If the service code display appears again after the system has been reset, carry out troubleshoot-
ing as follows.
Cause Remedy
2 YES
Is voltage
YES between PO2
1 ,- (8)(14)and
- Disconnection, defective
contact, short circuit with
- ground in wiring harness
chassis normal?
D~~~ code between battery- battery Repair or
display appear starting
Turn NO relay B - M I 1 (1)(2)- HI4 replace
again after system switch OFF. ( i ) - f u s e No. 13-PO2
has been reset?
After resetting
II 20.30 v
iiernaie) (8)(14)
Normal -
system, carry out NO
normal
operations fora
short time and
watch the
condition. (See
Note 1.)
Note 1: Resetting operation:

Turn t h e starting switch OFF. Then keep the time switch at the back of the monitor panel
depressed, switch the starting switch ON again, and keep the time switch depressed for 5
seconds t o return the system t o normal.
(With this operation, all the service codes in the internal memory are erased.)
M-1 Related electric circuit diagram
Monitor panel P02(04016)

w
I GND iI I h ~
I
Fuse
I
14(M6)
I--?--? m
Mll(L2)
Power source
GND
Power source
1
I
20-608 PC300, 350-6

0
TROUBLESHOOTING M-2
M-2 [E1031Short circuit in buzzer output or contact of 24V wiring

harness with buzzer drive harness is displayed
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and
check if an E service code is displayed. (if it is not displayed, the system has been reset.)
* Always connect any disconnected cqnnectors before going on the next step.
2 YES
Is voltage
YE2 between PO4 (2)
1
- Short circuit with power
source in wiring harness
and chassis
between PO1 (femaleI(7) Repair or
Is resistance between norma'? and PO4 (fernale)(2) or replace
PO4 (male) (1) - (2).
(2) -chassis as shown
- Turn
starting NO short circuit in wiring
switch ON. harness between PO4 (1)
in the table? Buzzer ON:Max. 1 V and (2)
Turn starting Buzzer OFF: 20 - 30 V
Defective buzzer Replace
switch OFF. NO
Disconnect P04.
Table
PO4 (male) I Resistance
value 1
I Between (1) and (2) 1 200 - 300 Q 1
1 Between (2) andchassis I Min. 1 Mi2 i
Buzzer
I I I 1
D l I(KES)
Fuse
-
-
BKPOO273
PC300, 350-6 20-609

0
TROUBLESHOOTING M-3, M-4
M-3 [ E l041 Air cleaner clogging detected is displayed
Cause Remedy
See M-13 f )
clogging caution
monitor
lamp on 2 YES
flashing? Defective monitor panel
Is "E" service
NO code displayed?
-
Failure in engine system
Turn starting NO (See Note 1)
switch ON.
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has
detected symptoms of clogging in the past, so carry out troubleshooting of the engine to
remove the problem.
M-4 [El061 Drop in engine oil Hi pressure detected is displayed
Cause Remedy
YES -
See M-13 a)
1 1
pressure caution
monitor
lamp on 2 YES
!!ashing? Defective monitor panel Replace
Is "E" service
code displayed?
I
Failure in engine system -
Turn
starting NO (See Note 1)
switch ON.
Note 1: The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has
detected symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of
the engine to remove the problem.
20-61 0 PC300, 350-6

0
TROUBLESHOOTlNG M-5
M-5 [E1081 Engine water temperature 105°C detected is displayed
Cause Remedy
YES -
1 See M-13 d)
Does coolant
temperature gauge on
monitor panel display -
red rangeand is 2 YES
caution lamp flashing?
- Is "E" service
I -
NO code displayed?
Failure in engine system
Turn
starting NO (See Note 1)
switch ON.
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has
detectedsymptoms of thecoolanttemperaturereaching 165°C inthe past, so carry out
troubleshooting of the engine to remove the problem.
PC300, 350-6 20-611

0
TROUBLESHOOTING M-6
M-6 When starting switch is turned ON, none of lamps on monitor

panel light up for 3 seconds
*
.)i
Check that fuses No. 10 and 13 are not blown.
t check :he: a!! the ~ ! a t C~CdR R E Z ~ ~ are
f 3 e f o ~cairjing s ~t;~ut;ht;o~:izg, ~ S p r ~ p e . !I~seCed.
~
a) None of lamps on monitor panel light up
I Cause Remedy
Disconnection, defective
contact, short circuit with
chassis and 3 YE§ ground in wiring harness Repair or
between PO1 (female) (9) replace
between fuse No. - and fuse No. 10
Is voltage
switchON, NO 10 and chassis contact, shortcircuit with
-20-30V normal? Repair or
between PO2
(8)(14)- (1)(9)
- Turn starting NO
ground in wiring harness
between fuseNo. 10 - H05 (2)
replace
normal? ON. - M14 12)(1)- battery relayM

- Turn starting
switch ON.
*20-3QV
4 YES
contact, short circuit with Repair or
replace
Is voltage ground in wiringharness
*20-30V
- between fuseNo. -
NO 13 and chassis
between PO2 (female)
W 1 4 ) and fuse No. 13
normal? Disconnection, defective Repair or
Turn
starting NO contact, short circuitwith replace
switch ON. ground in wiringharness
between fuse No. 13 - H14
*20-30V
(2) - M11 (2)(1)- battery
relay B
b) Some of lamps on monitor panel do not light up

Remedy
Replace
20-612 PC300, 350-6

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77
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0
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TROUBLESHOOTING M-7. M-8
M-7 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
F Cause Remedy
F I
M-8 When starting switch is turned ON, items lighted up on monitor

panel are different from actual machine (model)
Sr Immediately after replacing the monitor panel, turn the starting switch OFF, then turn it ON again
and check.
Cause Remedy
1
IIs display of 1
monitoring code
Go t o troubleshooting fog
-
Turn starting
C mode (See C-14)
switch ON.
Set to monitoring
code 01.
Table
j o i
20-614 PC300,350-6
0
TROUBLESHOOTING M-9
M-9 When starting switch is turned ON (engine stopped), basic check

items flash
a) (coolant level) flashes

SAP00519
fl Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective coolant level

1
Does display go 4 YES Defective engine throttle,
out when short pump controller Replace
connector is
connected to P08 YES Is bit (3) of
(female)? monitoring code
3
24 lighted up?
• Disconnect P08. Is continuity
• Turn starting YES between C16 • Turn starting NO
(female ) (8) and
switch ON. chassis as shown switch ON.
in table? • Set to monitoring
Is there continuity • Turn starting code 24. Repair or
harness between C16
between P08 switch OFF. NO replace
(female) (8) – P08
NO (female) (2) and • Disconnect C16, P08. (female) (1)
chassis?
• Connect disconnect short
• Turn starting connector to P08 (female). Defective contact, or
switch OFF. disconnection in wiring Repair or
• Disconnect P08. NO harness between P08 replace
(female) (2) – chassis
ground
Table
Short connector Continuity
Connected Yes
Disconnected No
M-9 a) Related electric circuit diagram

Monitor panel C16(MIC17)
P08(X2)
Coolant
Network level i q Coolant
level sensor
w
BKP00277
PC300, 350-6 20-615

1
5
TROUBLESHOOTING M-9
b) (engine oil level) flashes

SAP00523
fl Check that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective engine oil level

—
sensor system (see M-27)
1
Does display go out 3 YES Defective engine throttle,
when P05 (female) (1) Replace
pump controller
is connected to Is bit (4) of
chassis ground? YES monitoring code
2 24 lighted up?
• Disconnect P05. Is continuity between
• Turn starting Defective monitor panel Replace
C16 (female) (16) and • Turn starting NO
switch ON.
NO chassis as shown in switch ON.
table? • Set to monitoring code 24. Defective contact, or
• Turn starting
harness between C16 replace
switch OFF. NO
(female) (16) – E08 (5) –
• Disconnect C16,
P05 (female) (1)
P05.
• Connect disconnect short connector to
P05 (female) (1).
Table
Chassis ground Continuity
Connected Yes
Disconnected No
M-9 b) Related electric circuit diagram
Engine throttle, pump controller Engine oil level sensor

E08(SWP14) P05(X1)
Network Engine oil

level
!6 t q
BKP00278
20-616 PC300, 350-6

1
5
TROUBLESHOOTING M-9
c) (hydraulic oil level) flashes

SAP00524
fl Check that the hydraulic oil is at the specified level before carrying out troubleshooting
Cause Remedy
Defective hydraulic oil

YES level sensor system (see
—
M-29)
1
Does display go out 3 YES Defective engine throttle,
when P09 (female) (1) Replace
pump controller
is connected to Is bit (5) of
YES monitoring code
chassis ground?
2 24 lighted up?
• Disconnect P09. Is continuity between
• Turn starting Defective monitor panel Replace
C16 (female) (9) and • Turn starting NO
switch ON.
NO chassis as shown in switch ON.
table? • Set to monitoring code 24. Defective contact, or
• Turn starting harness between C16
switch OFF. NO replace
(female) (9) and P09
• Disconnect C16, (female) (1)
P09.
• Connect disconnect short connector to
P09 (female) (1).
Table
Chassis ground Continuity
Connected Yes
Disconnected No
M-9 c) Related electric circuit diagram
Engine throttle, pump controller Hydraulic oil level sensor

P09(X1)
Network Hydraulic oil

level
o q
BKP00279
PC300, 350-6 20-617

1
5
TROUBLESHOOTING M-10
M-10 Preheating is not being used but (preheating monitor)

lights up SAP00526
Cause Remedy
2 YES Defective monitor panel Replace

Is voltage
YES between P01 (18) Short circuit with power
1 and chassis source in wiring harness
normal? between starting switch
Is voltage between Repair or
R1 – X07 (3) – H13 (6) –
starting switch • Turn starting NO replace
P01 (female)(18) or E11
terminal R1 and switch ON. (female)(1) – E08 (3) –
chassis normal? • Max. 1 V H13 (female)(6)
• Disconnect
Defective starting switch Replace
terminal R1. NO
• Turn starting
switch ON.
• Max. 1 V
20-618 PC300, 350-6

1
5
M-11 When starting switch is turned ON and engine is started, basic

check items flash
fl Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy

Does monitoring
YES code 43 show a
2 value of greater
Is voltage than 100?
YES between C03 (12) • Start engine and NO
and chassis run at mid-range
1 normal? Defective contact, or
or above.
Is voltage between disconnection in wiring
• Start engine and • Set to monitoring code 43. Repair or
alternator terminal harness between
R and chassis run at mid-range NO alternator terminal R – replace
normal? or above. E08 (2) – C03 (female)
• 20 – 30 V (12)
• Start engine and
run at mid-range Defective alternator Replace
or above. NO
• 20 – 30 V

Monitor panel C03(04020) Alternator
E08(SWP14)
B
Network Battery
charge
!2 w R
E
BKP00282
PC300, 350-6 20-619

1
5
b) Engine oil pressure system

fl When engine oil pressure is normal.
1) Low-pressure sensor
Cause Remedy
YES Defective oil pressure

sensor (for low pressure) Replace
1
When engine is
running at high idling Contact of chassis
and wiring harness ground with wiring Repair or
of oil pressure sensor YES
is removed, does 2 harness beteen C16 repalce
display go out? (female) (15) – E08 (8) –
Is there continuity sensor
• Engine at low
between C16
idling 3 YES Defective engine throttle,
NO (female) (15) and Replace
chassis? pump controller
Is bit (1) of
• Turn starting monitoring code
switch OFF. NO 24 lighted up?
• Disconnect
sensor wiring • Engine at low NO
harness C16. idling
• Set to monitoring
code 24.
2) High-pressure sensor Cause Remedy
YES Defective oil pressure

1 sensor (for high Replace
When engine is pressure)
running at high idling
and wiring harness of Contact of chassis
oil pressure sensor is 2 YES
removed, does ground with wiring Repair or
display go out? Is there continuity harness between C16 replace
• Engine at high between C16 (female) (7) – E08 (7) –
idling NO (female) (7) and sensor
chassis? 3 YES Defective engine throttle,
Replace
• Turn starting pump controller
switch OFF. Is bit (2) of
• Disconnect monitoring code
NO
sensor wiring 24 lighted up?
harness C16 NO
• Engine at high
idling
code 24.

Monitor panel C16(04017) E08(SWP14)
Engine oil Engine oil pressure
Network
pressure Hi u u sensor (high pressure)
Engine oil
pressure Lo
!5 i
Engine oil pressure

sensor (low pressure)
BKP00283
20-620 PC300, 350-6

1
5
M-12 When starting switch is turned ON (engine stopped), caution

items, emergency items flash
(battery, engine oil pressure lamps do not light up)
fl Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy

Replace
Does monitoring pump controller
YES code 43 show a
2 value of greater
Is voltage than 100?
YES between C03 Defective monitor panel Replace
• Start engine and NO
1 (female) (12) and run at mid-range
chassis normal? speed or above. Short circuit with power
Is voltage between • Set to monitoring code 43.
• Disconnect C03. source in wiring harness Repair or
alternator terminal
• Turn starting NO between C03 replace
R and chassis
switch ON. (female)(12) – E08 (2) –
normal?
• Max. 1V alternator R
• Disconnect
terminal R. Defective alternator Replace
NO
• Turn starting
switch ON.
• Max. 1 V

Monitor panel C03(04020) Alternator
E08(SWP14)
B
Network Battery
charge
!2 w R
E
BKP00282
PC300, 350-6 20-621

1
5
b) Engine oil pressure sensor system

fl When engine oil pressure is normal.
1) Low-pressure sensor Cause Remedy

Replace
pump controller
YES Is bit (1) or
monitoring code
2
24 lighted up?
Is there continuity Defective monitor panel Replace
YES between C16 (female) • Engine at low NO
(15 )and sensor wiring idling
harness? • Set to monitoring code disconnection in wiring
Is there continuity 24. Repair or
• Turn starting harness between C16
between sensor replace
switch OFF. NO (female) (15) – E08 (8) –
terminal and
• Disconnect C16 sensor
chassis?
and sensor
• Turn starting wiring harness. Defective oil pressure
switch OFF. Replace
NO sensor (low pressure)
• Remove sensor
wiring hanrness.
2) High-pressure sensor
Cause Remedy

Replace
pump controller
YES Is bit (2) of
2 monitoring code
24 lighted up?
Is there continutiy
YES between C16 (femle) • Engine at high NO
(7) and sensor wiring ilding
1 harness? Defective contact, or
• Set to monitoring code 24.
Is there continuity disconnection in wiring
• Turn starting harness between C16 Repair or
between sensor
switch OFF. NO (female) (7) – E08 (7) – replace
terminal and
chassis? • Disconnect C16 sensor
and sensor
• Turn starting wiring harness.
switch OFF. Defective oil pressure Replace
• Remove sensor NO sensor (high pressure)
wiring harness.

Monitor panel C16(04017) E08(SWP14)
Engine oil Engine oil pressure
Network
pressure Hi u u sensor (high pressure)
Engine oil
pressure Lo
!5 i
Engine oil pressure

sensor (low pressure)
BKP00283
20-622 PC300, 350-6

1
5
M-13 When starting switch is turned ON and engine is started,

caution items, emergency items flash
(when there is no abnormality in engine or items to check
before troubleshooting)
a) (engine oil pressure) flashes

SAP00520
fl Check that the engine oil pressure is normal before
carrying out troubleshooting. Cause Remedy
See M-11 b) —
b) (coolant level) flashes

SAP00519
fl Check that the coolant level is normal before carrying

out troubleshooting. Cause Remedy
See M-9 a) —
c) (battery charge) flashes

SAP00522 Cause Remedy
See M-11 a) —
PC300, 350-6 20-623

1
5
d) (coolant temperature) flashes

SAP00527
fl Check that the coolant temperature is normal before car-

Cause Remedy
rying out troubleshooting.
YES Defective coolant
2 temperature sensor —
When P07 is system (see M-26)
YES disconnected,
does only level 1 3 YES Defective engine throttle,
(left end) of gauge pump controller Replace
1 display light up? Is resistance
between C03
(female) (1) – (16), Short circuit of wiring
Is coolant • Start engine. NO (1) (16) – chassis harness between C03
temperature in normal? (female) (1) – E08 (6) – Repair or
red range? NO P07 (female) (1) and replace
• Turn starting wiring harness between
switch OFF. C03 (female) (16) – E08
• Start engine and
• Disconnect C03 and P07. (11) –P07 (female) (2)
run at mid-range
• Max. 1 MΩ
or above. Defective monitor panel Replace
NO
M-13 d) Related electric circuit diagram
Engine throttle, pump controller Coolant

Monitor panel C03(04020) E08(SWP14) P07(X2) temperature sensor
Coolant
Network temperature q y q
GND !6 !1 w
BKP00284
e) (fuel level) flashes

SAP00528 Cause Remedy
fl Check that there is fuel before carrying out trouble-

shooting.
Defective fuel level
YES sensor system (see —
2 M-25)
When P06 (female) (1) is
YES connected to chassis
ground, do all lamps to
level 14 (right end) of 3 YES Defective engine throttle,
Replace
gauge display light up? pump controller
1 Is voltage
• Start engine. between C03 (2)
• Wait for approx. NO and (16) normal? Defective contact or
Is fuel gauge in
2 minutes. disconnection in wiring Repair or
red range?
(The fuel level harness between C03 replace
• Connect P06 (female) NO
may vary, so the (female) (2) and P06
(1) to chassis ground.
• Start engine. display is given a (female) (1)
• Turn starting switch ON.
time delay.) • Max. 0.3 V
NO
M-13 e) Related electric circuit diagram

Monitor panel C03(04020)
P06(X1)
Fuel level sensor
Network Fuel level w q
BKP00285
20-624 PC300, 350-6

1
5
f) (air cleaner clogging) flashes

SAP00521
fl Check that the air cleaner is not clogged before carrying out troubleshooting.
Cause Remedy
YES Defective air cleaner

clogging sensor Replace
1 4 YES Defective engine throttle,

Replace
Does display go out pump controller
Is bit (6) of
when P11 (female) YES monitoring code
is connected to P12 3 24 lighted up?
(male)? Is continuity between
• Start engine. YES C16 (female) (17) and • Start engine. NO
chassis as shown in • Set to monitoring
2 table? Defective contact or
code 24.
Is there continuity disconnection in wiring
• Turn starting Repair or
between P12 harness between C16
switch OFF. NO replace
NO (male) and (female) (17) and P11
• Disconnect C16, P11, and P12. (female)
chassis?
• Connect disconnect P11 (female) to
• Turn starting P12 (male). Repair or
switch OFF. replace
• Disconnect P12. NO harness between P12
(male) and chassis
ground
M-13 f) Related electric circuit diagram

P11
Air cleaner
Network clogging !7 Air cleaner
P12 clogging sensor
BKP00286
PC300, 350-6 20-625

1
5
M-14 When starting switch is turned ON (engine stopped), buzzer

does not sound for 1 second
Caution item flashes but buzzer does not sound
fl Of the caution items, the buzzer will not sound even if
there is an abnormality in the battery charge or fuel level.
lated connectors are properly inserted. Cause Remedy
fl Always connect any disconnected connectors before go-
ing on to the next step.
YES
2
When P01 (female) Defective contact or
YES (7) and chassis are disconnection in wiring
connected, does 3 YES harness between P01 Repair or
buzzer sound? Is voltage (female) (7) and P04 replace
1 between P04 (female) (2)
• Disconnect P01.
Is resistance • Turn starting NO (female) (1) and Disconnection, defective
between P04 switch ON. chassis normal? contact, short circuit with Repair or
(male) (1) and (2) NO ground in wiring harness replace
• Disconnect P04.
normal? between P04 (female) (1)
• Turn starting
• Turn starting and fuse No. 13
switch ON.
switch OFF. • 20 – 30 V
• Disconnect P04. Defective buzzer Replace
• 200 – 300 Ω NO
M-15 No abnormality is displayed on monitor but buzzer sounds

fl When the buzzer sounds continuously.
If the buzzer sounds intermittently, carry out troubleshoot-
ing M-14.)
ing on to the next step. Contact of chassis
ground with wiring
1 YES harness between P01 Repair or
(female) (7) and P04 replace
When P01 is
disconnected, (female) (2), or defective
does buzzer buzzer
sound?
• Disconnect P01. NO
• Turn starting
switch ON.
M-14, 15 Related electric circuit diagram
20-626 PC300, 350-6

1
5
M-16 Night lighting on monitor panel does not light up (liquid crystal
display is normal)
fl When the front lamp and working lamp light up normally.
Cause Remedy
Blown bulb or defective Replace bulb,

YES contact of bulb or clean
(defective
1 contact)
Is bulb blown, or
is there defective YES
contact? 2
• Remove bulb. Does bit (3) of

• Check visually monitoring code
NO 49 go out? 3 YES
for blown bulb.
Is voltage
• Turn starting between P01 (8) Defective contact, or
switch ON. NO and (12) normal? disconnection in wiring
• Set to monitoring harness between P01 Repair or
code 49. • Turn starting NO (female) (8) – X01 (1) – replace
switch ON. M07 (female) (1)
• Turn light switch
ON.
• 20 – 30 V
Monitor panel
P01(04020) Light switch
X01(MIC21) M07(M2)
OFF ON
Light i q q 1
e w 2
Fuse
4
BKP00287
PC300, 350-6 20-627

1
M-17 Coolant temperature gauge does not rise

fl If the coolant temperature actually does not rise, check
the engine system.
Defective coolant
YES temperature sensor
system (see M-26)
—
1
When short
connector is 3 YES
connected to P07
(female), do level Does monitoring
lamps on gauge go YES code 41 show a
up in turn and then value of less than
all lamps go out? 2 50? Defective engine throttle,
Replace
• Disconnect P07. Is there continuity • Connect short connector NO pump controller
• Turn starting between C03 (female) to P07 (female).
switch ON. (1) and (16) when short • Turn starting switch ON. Defective contact, or
NO connector is connected • Set to monitoring code 41. disconnection in wiring
to P07 (female)? 4 YES harness between C03 Repair or
• Turn starting Is there continuity (female) (16) – E08 (11) – replace
switch OFF. between C03 P07 (female) (2)
• Disconnect C03 NO (female) (1) and Defective contact or
and P07. P07 (female) (1)? Repair or
replace
• Turn starting switch NO harness between C03
OFF. (female) (1) – E08 (6) –
• Disconnect C03 and P07 (female) (1)
P07.
M-18 Coolant temperature gauge does not give any display

(none of gauge lamps light up during operation)
Cause Remedy
ing on to the next step. Defective coolant
YES temperature sensor
system (see M-26) —
1
When P07 is Contact of chassis
disconnected, does ground with wiring
coolant temperature YES Repair or
gauge display harness between C03
2 replace
appear? (female) (1) – E08 (6) –
Is there continuity P07 (female) (1)
• Disconnect P07. between C03
• Turn starting 3 YES
NO (female) (1) and Defective engine throttle, Replace
switch ON. chassis? pump controller
Does monitoring
• Turn starting code 41 show a
switch OFF. NO value of less than
• Disconnect C03, 50?
P07. NO
• Turn starting
switch ON.
code 41.

Engine throttle, pump controller Coolant
Monitor panel C03(04020) E08(SWP14) P07(X2) temperature sensor
Coolant
Network temperature q y q
GND !6 !1 w
BKP00284
20-628 PC300, 350-6

1
5
M-19 Fuel level gauge always displays FULL

fl Check that there is actually remaining fuel before carrying
out troubleshooting.
YES Defective fuel level
1
When P06 is
disconnected, do Contact of chassis
level lamps on ground with wiring
gauge go down in YES Repair or
turn and then all 2 harness between C03 replace
lamps go out? (female) (2) and P06
Is there continuity
• Turn starting (female) (1)
between C03
switch ON.
(female) (2) and 3 YES
• Wait for approx. NO Defective monitor panel Replace
chassis? Does monitoring
2 minutes. (The
fuel level may • Turn starting code 42 show a
vary, so the switch OFF. NO value of greater
display is given a • Disconnect C03, than 40? Defective engine throttle, Replace
time delay.) P06. • Turn starting NO pump controller
switch ON.
code 42.
M-20 Fuel level gauge does not give display

fl Check that there is actually remaining fuel before carrying
out troubleshooting.
YES Defective fuel level
sensor system (see —
M-25)
1
Does display appear 3 YES Defective engine throttle,
Replace
when P06 (female)(1) Does monitoring pump controller
and chassis ground YES code 42 show a
are connected? 2 value of less than
Is there continuity 408?
• Disconnect P06. between C03 (female) Defective monitor panel Replace
• Turn starting (2) and chassis when • Turn starting switch NO
switch ON. NO P06 (female)(1) and
chassis ground are ON. Defective contact, or
connected? • Set to monitoring code disconnection in wiring
• Turn starting 42. harness between C03 Repair or
switch OFF. NO (female) (2) and P06 replace
• Disconnect C03, (female) (1)
P06.

Monitor panel C03(04020)
P06(X1)
Fuel level sensor
Network Fuel level w q
BKP00285
PC300, 350-6 20-629

1
5
M-21 Swing lock switch is turned ON (LOCK) but (swing lock

monitor) does not light up SAT00098
fl Carry out this troubleshooting only if the swing lock is actually being actuated.
1 YES
Is voltage
between P05 and
chassis as shown Defective contact or
in table? disconnection in wiring Repair or
harness between P01 replace
(female) (5) – X01 (4) –
switch ON. X05 (male)

Swing lock switch
Monitor panel
OFF ON
P01(04020) 1
X01(MIC21) X05(M4)
2
Swing 3
lock t r q 4
t w 5
Table 6
Normal
Lock
Swing lock switch ON Max. 1 V H14(M6)
Swing lock switch OFF 20 – 30 V
y
BKP00288
M-22 Swing prolix switch is turned ON (prolix), but (swing lock

monitor) does not flash
SAT00098
fl Carry out this troubleshooting only if the swing prolix is
actually being actuated.
Cause Remedy
ing on to the next step. 2 YES
Is bit (6) of
YES
monitoring code
1 21 lighted up?
Is voltage Defective engine throttle,
between C17 (8) • Turn starting NO
and chassis as switch ON.
shown in table? • Set to monitoring code Defective contact or
• Turn starting 21. disconnection in wiring Repair or
switch ON. NO harness between C17 replace
(female) (8) and prolix
switch (4)
Table
M-22 Related electric circuit diagram Swing prolix switch
Swing prolix switch ON Max. 1 V
Engine throttle, pump controller OFF ON
Swing prolix switch OFF 20 – 30 V Monitor panel C17(04016) 1
2
Swing 3
Network prolix i 4
5
switch
6
Normal
Prolix
H14(M6)
y
BKP00289
20-630 PC300, 350-6

1
5
TROUBLESHOOTING M-23, M24
M-23 Service meter does not advance while engine is running
Cause Remedy
YES
See M-13 d) —
1
Does battery
charge caution
lamp flash? 2 YES
Does monitoring
• Start engine and code 43 show a
run at mid- NO value of greater
range or above. than 100? Defective engine throttle,
Replace
• Start engine and NO pump controller
run at mid-range
or above.
• Set to monitoring code 43.
M-24 When starting switch is at OFF and time switch is pressed, time
and service meter are not displayed
Cause Remedy
1 YES
When starting
switch is ON, is
panel display
normal?
See M-6 —
switch ON.
PC300, 350-6 20-631

1
5
M-25 Defective fuel level sensor system

* Remove the fuel ieirel sensor when carrying s u i the troubleshooting.
-
3 YES
Is there anylarge
YES crack, chip, or -
-t
I
Cause
Interference with sensor

inside tank
Remedy
Replace (See
Note 2)
r damage to float? Clean

Defective contactof connector or
- smoothly?
YES Does arm move NO connector replace
When float is
1 - Defective sensor (See
Note 2) Replace
moved up and NO
down, is resistance
between connector
-
(1) and flangeas Disconnection in wiring
shown in table? 4 YES
I I ,
harness (See Note 3) Replace sensor
4
(defective clamp)
Check wiring
(external force applied)
harness visually.
No Is it broken? I I !
Defective sensor Replace
Table
I TOD (FULL) stomerrtosition I Approx. 12 or below 1
I Bottom (EMPTY) stopperposition I Approx. 85 - 110 f
2 I
t TOP (FULL)
i Bottom (EMPTY)
BLPOOZW
Note 1: Difference between fuel level and gauge display

For gauge display position 14 (FULL), the amount of fuel is 78-100%; and for display position
1 (EMPTY)it is below 14.5%. If the chassis is at an angle, the displayed amount of fuelwill be
different from the actual amount.Therefore, when checking, stop the machine at a horizontal
place and waitfor at least 2 minutes before checking the gauge. (The display is given a time
delay so that the gauge can deal with sudden changes in the fuel level.)
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank,
so be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropri-
ate action.
28-632 FC300, 350-6

0
M-26 Defective coolant temperature sensor system
I Cause I Remedy
Clean
Defective contactof
connector or
connector (See Note 1)
replace SenSOr
Disconnection in wiring
harness (See Note 2) Replace
(defective clamp) sensor
(external force appfied)
Table
1
lNormal temperature (25°C) Approx. 37 - 50 kR I
I 100°C 1 Approx. 3.5 - 4.0 WT I
Note 1: If the problem occursagain, the connector (female)at the chassis end is probablydefective, so
check the connector and wiring harness at the chassis end.
If there is excessive vibration, takethe appropriate
Note 2: Check for vibration at the connector mount.
action.
PC300, 350-6 20-633

0
Cause Remedy
YES Defective movement of

Clean
2 1 float due to dirt
r -1 I
Is any foreign
stuck to moving Resonance of mount Replace sensor

(See Note 2) (See Note 4)
and down, is resistance

between connector (11
crack, chip, or
damage to float? n
NO
Defective contact of
connector (See Note2)
Clean
connector or
replace
and flange as shown in
4 YES harness (See Note 3) Replace sensor
Check wiring (defective clamp)
-
harness visually.
540 Is it broken?
I Defective sensor Replace

NO
Table
1 Float UP I Max. 1 R I
1 Float DOWN 1 Min. 1 Mi2 1
U
BLW0292
Note 1: Variations in oil level

The oil level may change according to the angle of the machine, the engine speed, or the
temperature ofthe oil, so if there is any display, check the oil level againwith the machine at
a horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
again,check for any vibration of the mount, and if there is excessive vibration, take the
appropriate action.
2Q-634 PC300, 350-6

0
M-28 Defective coolant level sensor system

* Remove the coolant level sensor when carrying out troubleshooting.
Cause Remedy

float dueto dirt Clean
YE material (dirt) Replace

stuck to moving Resonance of mount
(See Note 2) sensor (See
Is there any large Note 4)
crack, chip, or
Defective contact of Clean
up and down, is 1
connector or
resistancebetween NO connector (See Note2)
connector 11) and (2) as
replace
shnwn inTnhle 17
Disconnection in wiring Replace
harness (SeeNote 3) sensor
(defective clamp)
Table
I Float UP I Max. 1 l2 I
I Float DOWN I Min. 1 MSZ I
BLP00293
Note 1: Variations in coolant level

The coolant level may change according to the angle of the machine, or the swaying of the
machine, so if there is any display, check the coolant level again with the machine at a
horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check tne connector ana wiring narness at tne chassis end.
Note 3: Check for vibration at theconnector mount. If there is excessive vibration, take the appropri-
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing.If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the
appropriate action.
PC300, 350-6 20-635

0
M-29 Defective hydraulic oil level sensor system

A Remove the hydrau!ic GI! !ewl senscr when carr-,4ng os: t:oihleshooting.
F------ Cause Remedy

Clean
float due to dirt
YES Replace
Resonance of mount
F (See Note 2)
sensor (See
Note 4)
Defective contactof Clean

up and down, is connector or
resistance between connector (See Note 2)
connector (1) and replace
flsnosns shnwn in
4 YES
~
Replace
' harness (See Note 3)
sensor
(defective clamp)
Check wiring
harnessvisually.
No Is it broken?
- ~
Replace
NO
Table
UP
I
DOWN
BLP00292
Note 1: Variations in hydraulic oil level

The hydraulic oil level may change according to the angle of themachine, or the swaying of
the machine, so if there is any display, check the hydraulic oil level again with the machine at
a horizontal place.
Note 2: If the problem occurs again, the connector (female) a t the chassis end is probably defective,
so check the connector and wiring harnessa t the chassis end.
ate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the
appropriate action.
20-636
0
M-30 Wiper does not work, or switch is not being used but wiper is
actuated (include E l 12, E l 13)
** Before carrying out troubleshooting, check that all the retated connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
a) Wiper does not work
* Check that fuse 7 is normal.

* Carry out this troubleshooting if service code [E1121 or [E1131 is displayed.
YES
r l
pins of PO2 (female).
Disconnect M18.
switch ON. - 1 :: :‘E§
Set to monitoring
I5 resistancebetween
code 1481.
-
YES w10 h l e ) (3)- w2
lfernalel (131. WlO(rnale) -
10 W-POZ Ifernale) (1)
Is resistance 7
-
-
between W10
NO (female) (3)and
(4) normal?
Turn starting
switch OFF.
-
NO
Turn
starting
switch OFF.
NO
Disconnect W04, P O 2
=Max. 1 R
Disconnect
WIO.
28-538 PC300, 350-6

0
Cause Remedy
Defective wiper motor Replace
Defective relay box Replace
harness with defective replace
resistance
Short circuit with power
source in wiring harness Repair or
between PO2 (female) (3)- replace
W08 (female) (18) [(3)1,or
between PO2 (female) (11) -
W08 (female) (17)[(2)1
Defective contact or Repair or
disconnection in above replace
wiring harness
Defective contact or Repair or

disconnection in wiring replace
harness with defective
resistance
Defective wiper,washer Replace

switch

n..z--*:. .^ ^^...^^
--
*
VCIG-lrllYG l."lllalrl "I
harness between PO2
(female) (13) and W10 Repair or
(male) (3).or between PO2 replace
(female) (1) - HI4 (2) -
chassis, or between W10
(male) (4)- H15 (1) -
chassis
Defective rear limit Inspect or
switch, or front window replace
IS open
PC300, 350-6 20-639

@
Table 1
Timing chart when wiper switch is at ON
,ctuat ton ON
f wiper Item Symbol Set tirnc
wltch OFF
Length of pause until
Tla 0.13sec
I I next actuation
contact
@e OFF Safety circuit during op-
eration of wiper [safety Tsa 1Osec
S I
contact ON function ( I ) ]
8-0 OFF
Length of pause when
Normal stowing wiper blade 1.5sec
c
z rotation ON
.E @Q
Revcrrc OFF Safetycircuitduring
fotai ion
stowing of wiper [safety Tsp 10sec
08 ON
function (291
TKP00827
Timing chart when wiper switch is at INT
+
item
Length of pause until

Tla 4sec
I I next actuation
contact
@8 OFF Safety circuit during op-
eration of wiper [safety
ON function (1)l
contact
@@ OFF
Length of pause when
stowing wiper blade
Safetycircuitduring
stowing of wiper [safetylOsecTsp
I function (2)l
OFF: Max. 3 V
TKPOO828
ON: 20 - 30 V
Table 2 Table 3
1I Between W04 (female) (1) and W08 (female) (6) 1(7)1

Resistance
value
I Between W04 (female) (3) and W08 (female) (7) 1(6)1

I Between W04 (female) (4) and PO2 (female) (5) ~ ~~
Max. 1 Q
Between W04 (female) (5) and PO2 (female) (1)
Between W04 (female) (6) and PO2 (female) 16)
I Between W04 (female) (1),(3),(4),(5),(6) and GND Min. 1 MQ
Between WOE (female) (17) [(2)1 and PO2 (female) (111
Max. 1 Q
Between W08 (female) (18) [(3)1 andPO2 (female) (3)
[ 1: For machines with power window specification
20-640
0
W
0
w
Ji;
t
tr I I
T
L
t
N
L
rn
'I
---
r 1
I
I
r
I
t -1
.. ..
& 0 , o
3 2 2
b) Wiper switch is not being operated but wiper is actuated
Cause Remedy
4 YE
-
YES
W04 (male),W08
(female) shown in
-
- pins of PO2 (female),
as
resistance
Is Table 2? Defective contact or Repair or
Yt -
s between pins of * Turn starting disconnection in wiring replace
1
I
M18(fernale) (11, harness with defective
L (Z),(4) as shown in switch OFF. resistance
Do bits(1) or (2) Table I ? * Disconnect P02, W08
wo8, N' Defective wiper, washer
Yl * Turn starting switch
Replace
code [481go out? NO
- switch OFF.
Disconnect M18.
* Turn starting
switch ON.
1
Set to
monitoring code
Does bit ( 4 ) of
monitoring code
I [481 lightup?
i1
* Turn starting
switch ON. Defective monitor panel Replace
Set to monitoring
code I481. Short circuit with ground
Do bits (3) or (4)
of monitoring in wiringharness
Y'ES between PO2 (female) (3) Repair or
and W08 (female) (3J, or replace
Do bits(2) or (3) between PO2 (female)
Turn starting of monitoring (11) and W08 (female) (2)
switch ON. code I4C1 light 7 YE!
N
* Set to Defective relay box Replace
monitoring code
* Turn starting WO8 (female)(1)and
1471. (6), or between (1)
- Set to
monitoring code
source in wiring harness Sepair or
Detween W08 (female) (6) ?eplace
Disconnect WO8, N(
[4CI. starting
* Turn and W04 (male) (I), or
switch ON. setween W08 (female) (7)
Max. 1 V md W04 (male) (3)
Table 2 Table 3
Resistance
value
Max. 1 R l Between (1) - (2) Between (1) - (4)

Between W04 (female) (5) and PO2 (female) (1) OFF mode (1) - (4) Between (1) - (12) Between
Min. 1 MQ
Between (2) - (4) Between ( 4 ) - (12)
Between (1) - (2) Between (1) - (4) Max. 1 R
BetweenW08 (female) (17)[(2)1 and PO2 (female) (11) ON mode Between (1) - (4) Between (1) - (12)
Max. 1 R .
Between W08 (female) (18) 1(3)1and PO2 (female) (3) Min. 1 MR
Between (2) - ( 4 ) Between (4) - (12)
[ I: For machines with power window specification
28-642 PC300, 350-6

0
M-31 Washer motor does not work, or switch is not being used but
washer motor is actuated (include E1141
* Alwaysconnectanydisconnectedconnectorsbefore going
on to the next step. Cause Remedy
a) Washer motor does not work
*Check that fuse 5 is normal.
a ) - I When E114 is displayed
2 YES
YES
-
Is resistance of
washer motor
-
1 normal? Defective washer motor
'Is voltage between Replace
(internal short circuit)
PO2 (female) ( 2 ) . * Turn
starting NO
(10). M28 (female) -
(1) and chassis -
switch OFF.
Disconnect W28.
* Check as
normal?
nindividual part. Short circuit in wiring
*Turn starting *5-20R
switch OFF. harness between PO2 Replace
Disconnect P02, No (female) ( 3 , (9) and M28
(female) (1)
-
M28.
Connect T-adapter to PO2 (female) or M28
(female).
Turn starting switch to ON or OFF. Cause Remedy
* Max. 1 V
a)-2 When E l 1 4is not displayed

YES Defective monitor panel Replace
3 1
11svoltage -1 I
(female) (5) and
(9) normal?
between M I 8
Insert T-adapter
in PO2.
I Defective wiper
switch
washer
Replace
Turn starting
* Turn starting switch OFF.
switch ON. * Disconnec? M18.
I I
Is voltage *Wiper washer Check as
Yt between PO2 switch at [WASH individuai pai?.
(female) (2), ( I O )
and (9) normal?
* Turn starting
I I] or [WASH Ill:
Max. 1 V
*Wiper washer
*Wiper washer
switch at [WASH
I] or [WASH Ill:
switch at [OFF]: Max. 1 R
switch OFF.
__-_- * Insert T-adapter
20 - 30 V Wiper washer
switch at [OFF]:
in P02. Short circuit with ground
Turn starting Min. 1 M R
6 YES or disconnection in
between relay I switch ON. Repair 01
wiring harness between
replace
box W08 (16) and
(17) normal?
* Turn starting
II Wiper washer
switch at [WASH
I] or[WASH Ill: 1
Is voltage
between M I 8
iiemaiej i i 6 i ana
U PO2 (female) (2), (10) and
M28 (1)
Max. 1 V Short circuit with ground Repair or

switch OFF. I *Wiper washer
*Disconnect M28. NO or disconnection in replace
Disconnect W08. switch a? [OFF!:
* Connect T-adaDter.
......
. ...^
" Y l l " ' y ha:ness between
Max. 1 R 20 - 30 V fuse 5 and M28 (16)
L----
Turn2tarting switch ON.
- 2 0 - 3 0 7
, ----
__ Defective relay box
Replace
IO (internal disconnection)
I
----- --
r - - -! 5YE: source or defective Rspai: e:
I!__.
j : For machines with power window specification contact in wiringharness replace
between pins of between PO2 (5) - X01
From P. M18 (male) (1) (10) - M I 8 (3)
and chassis
Disconnection in wiring Repair or
.Turn
starting N( harness between M I 8 replace
switch OFF. (male) - X01 (21)-
* Disconnect M18.
chassis ground
Max. 1 R
PC300, 350-6 26-643

0
b) Switch is not being operated but washer is actuated Remedy
Ir For this failure mode, E114 is not displayed.
1 YES Defective monitor panel Replace

Is resistance
between PO2
(female)(3).M18 -
(male)(3).W08 (13) Short circuit with ground
and chassis normal? in wiring harness Repair or
between PO2 (female) (5) replace
Turn starting NO
- M I 8 (male) - W08
-switch OFF.
Disconnect P02, M18, W08.
Min. 1 MR Cause Remedv
(female) (13)
M-31 Relatedelectriccircuitdiagram
with power window
MONITORPANEL H14 ( M 6 ) I
I
I
1 I
I
PO2 ( 0 4 0 1 6 ) WIPER MOTOR
1
WASHER DRIVE
, 41 I
bm
WIPERSWITCH (ON)
WIPER SWITCH
(WASHER) 5
L I M I T SWITCH W
I)
NC
POWER SUPPLY [+24V)
CND
WASHER DRIVE O
I
kT
MOTOR DRIVE (NORMAL) 1 1
WIPERSWITCH (INTI 1
LIMIT SWITCH (WINDOW) 13
POWER SUPPLY it24V)
LIMIT SWITCH (PI
NC 16
I /
RELAY BOX
WOO ( 0 7 0 18)
X01 (MIC2
I
MI8 (M
TJP01973
20-544 PC300, 350-6

0
P
m
D
W
0
x
k
I I 1
fr I / I
I '
+
I
0
-
:
-c
I
e
N
Lo
M-32 Electric grease gun does not work

jr Befme carrying s u t t r ~ u b l ~ h ~ check g , all the related connectors are properly inserted.
~ t i ~that
* Check that there is grease before starting troubleshooting.
* Check that fuse No. 1 for the electric grease gun is normal.
-
YE j electric grease gun
2 YES
-
-t gun
Cause
Defective electric grease

Remedy
Repair or
replace
connector CN (female) Defective contact or Repair or

(2) and chassis normal?
disconnection in wiring replace
electric grease gun
connector CN (1)
-
Turnstarting
switch OFF.
NO harness between CN
and chassis normal? Disconnect CN.
- Turn starting
switch ON. VO
Repair or
redace
*20-28V harness between CN
(female) ( I ) and fuse No.
Special
fuse (20A) Cable
electric
grease
Battery
for g u n A Electric
grease gun
1
-
(Inside battery cas
m
R
BKP00220
20-646 PC300, 350-6

0
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................. 30- 3 FUEL TANK ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT Removal and Installation .................... 30-40
OPERATION .......................................... 30- 5 CENTER SWIVEL JOINT ASSEMBLY
SPECIAL TOOL LIST ................................... 30- 7 Removal and Installation .................... 30-41
SKETCHES OF SPECIAL TOOLS ............... 30-10 Disassembly and Assembly ................ 30-42
STARTING MOTOR ASSEMBLY FINAL DRIVE ASSEMBLY
Removal and Installation .................... 30-12 Removal and Installation .................... 30-43
ALTERNATOR ASSEMBLY Disassembly ......................................... 30-44
Removal and Installation .................... 30-13 Assembly .............................................. 30-48
ENGINE OIL COOLER ASSEMBLY TRAVEL MOTOR ASSEMBLY
Removal and Installation .................... 30-14 Disassembly ...................................... 30-53-1
FUEL INJECTION PUMP ASSEMBLY Assembly ........................................... 30-53-6
Removal ................................................. 30-15 SPROCKET
Installation ............................................ 30-16 Removal and Installation .................... 30-54
WATER PUMP ASSEMBLY SWING MOTOR ASSEMBLY
NOZZLE HOLDER ASSEMBLY Disassembly ...................................... 30-55-1
Removal and Installation .................... 30-18 Assembly ........................................... 30-55-4
TURBOCHARGER ASSEMBLY SWING MACHINERY ASSEMBLY
THERMOSTAT ASSEMBLY Disassembly ......................................... 30-57
Removal and Installation .................... 30-20 Assembly .............................................. 30-61
ENGINE FRONT SEAL REVOLVING FRAME ASSEMBLY
Removal ................................................. 30-21 Removal ................................................ 30-66
Installation ............................................ 30-22 Installation ............................................ 30-67
ENGINE REAR SEAL SWING CIRCLE ASSEMBLY
GOVERNOR MOTOR ASSEMBLY IDLER, RECOIL SPRING ASSEMBLY
CYLINDER HEAD ASSEMBLY IDLER ASSEMBLY
Removal ................................................. 30-26 Disassembly ......................................... 30-70
Installation ............................................ 30-28 Assembly .............................................. 30-71
AFTERCOOLER ASSEMBLY RECOIL SPRING ASSEMBLY
Removal and Installation .................... 30-31 Disassembly ......................................... 30-73
HYDRAULIC COOLER ASSEMBLY Assembly .............................................. 30-74
Removal ................................................. 30-32 TRACK ROLLER ASSEMBLY
RADIATOR, HYDRAULIC COOLER Removal and Installation .................... 30-75
ASSEMBLY Disassembly ......................................... 30-76
Removal ................................................. 30-33 Assembly .............................................. 30-77
Installation ............................................ 30-34 CARRIER ROLLER ASSEMBLY
ENGINE, MAIN PUMP ASSEMBLY Removal and Installation .................... 30-79
Removal ................................................. 30-35 Disassembly ......................................... 30-80
Installation ............................................ 30-38 Assembly .............................................. 30-82
DAMPER ASSEMBLY
Removal and Installation .................... 30-39
PC300, 350-6 30-1

2
5
TRACK SHOE ASSEMBLY BOOM CYLINDER ASSEMBLY
Removal and Installation .................... 30-84 Removal .............................................. 30-124
HYDRAULIC TANK ASSEMBLY Installation .......................................... 30-125
Removal .............................................. 30- 85 ARM CYLINDER ASSEMBLY
Installation .......................................... 30- 86 Removal .............................................. 30-126
MAIN PUMP ASSEMBLY Installation .......................................... 30-127
Removal .............................................. 30-87 BUCKET CYLINDER ASSEMBLY
Installation .......................................... 30- 88 Removal .............................................. 30-128
Disassembly ...................................... 30-88-1 Installation .......................................... 30-129
Assembly ........................................... 30-88-7 HYDRAULIC CYLINDER ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL Disassembly ....................................... 30-130
Removal and Installation .................. 30- 89 Assembly ............................................ 30-133
CONTROL VALVE ASSEMBLY WORK EQUIPMENT ASSEMBLY
Removal .............................................. 30- 90 Removal .............................................. 30-137
Installation .......................................... 30- 92 Installation .......................................... 30-138
Disassembly ....................................... 30-93 BUCKET ASSEMBLY
Assembly ............................................ 30- 99 Removal .............................................. 30-139
PUMP MERGE/DIVIDER VALVE Installation .......................................... 30-140
ASSEMBLY ARM ASSEMBLY
Disassembly and Assembly .............. 30-106 Rernovai .............................................. 38-141
PRESSURE COMPENSATION VALVE Installation .......................................... 30-142
ASSEMBLY BUCKET, ARM ASSEMBLY
Disassembly and Assembly .............. 30-107 Removal .............................................. 30-143
SERVO VALVE ASSEMBLY FOR Installation .......................................... 30-144
FRONT PUMP BOOM ASSEMBLY
Removal and Installation .................. 30-108 Removal .............................................. 30-145
SERVO VALVE ASSEMBLY FOR Installation .......................................... 30-1 46
REAR PUMP OPERATOR’S CAB ASSEMBLY
LS-EPC SOLENOID VALVE ASSEMBLY Installation .......................................... 30-148
Removal and Installation .................. 30-110 COUNTERWEIGHT ASSEMBLY
SOLENOID VALVE ASSEMBLY Removal and Installation .................. 30-1 49
Removal and Installation .................. 30-111 AIR CONDITIONER COMPRESSOR
WORK EQUIPMENT PPC VALVE ASSEMBLY
ASSEMBLY Removal and Installation .................. 30-150
Removal and Installation .................. 30-112 AIR CONDITIONER CONDENSER ASSEMBLY
Disassembly ....................................... 30-113 Removal and Installation .................. 30-151
Assembly ............................................ 30-1 14 RECEIVER TANK ASSEMBLY
TRAVELPPCVALVE ASSEMBLY Removal and Installation .................. 30-152
Removal and Installation .................. 30-115 AIR CONDITIONER UNIT ASSEMBLY
Disassembly ....................................... 30-116 Removal .............................................. 30-153
Assembly ............................................ 30-177 instaiiatisn .......................................... 38-154
PPC SHUTTLE VALVE ASSEMBLY GOVERNOR, PUMP CONTROLLER
Removal .............................................. 30-118 ASSEMBLY
Installation ....:..................................... 30-119 Removal and Installation .................. 30-155
Disassembly ....................................... 30-120 MONITOR PANEL ASSEMBLY
Assembly ............................................ 30-121 Removal and Installation .................. 30-156
BOOM LOCK VALVE ASSEMBLY CONTROL STAND CASE
Disassembly and Assembly .............. 30-123 Installation .......................................... 30-158
30-2 PC300. 350-6

0
DISASSEMBLY
AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. Whenremoving or installing unit assemblies
@ I removing or installing aunit assembly, the order of work andtechniques used are given
When
for the removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked
same mark i s placed after the relevant step in the removal procedure indicate
to
and the
which step in
a,
the installation procedure it applies to.
(Example)
REMOVAL OF 0000ASSEMBLY ............ Title of operation
A ...................................................................... Precautions related to safety when carrying out
the operation
1. X XX X (1) ..................................................... Step in operation
* ................................................................... Technique or important point to remember
when removing XXXX (1).
2. A A A A (2): .
.
.
..
.
..
.
.
..
.
..
.
..
.
..
.
.. Indicates that 'a technique is listed for use
during installation
3. 0000 assembly (3)
b
............................................................ Quantity of oil or waterdrained
INSTALLATION OF 0000ASSEMBLY ....Title of operation

Carry out installation in the reverse order t o removal.
.............................................................. Technique used during installation
*
................................................................... Technique or important point to remember when
installing A A A A (2).
Adding water, oil ................................. Step in operation
*
............................................................ Point t o remember when adding water or oil
&......................................................... Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTIONS WHEN CARRYING BUT OPERATION, so be sure t o follow
these precautions when carrying out the operation.
3. Listing of specialtools
@ For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
PC300, 350-6 30-3

0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

* In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
Thread diameter Width across flats

SAW0482
rnrn mrn Nrn
6 10 1.35 2 0.15 13.2 f 1.4
8 13 3.2 f 0.3 31.4 f 2.9
10 17 6.7 f 0.7 65.7 2 6.8
12 19 11.5 k 1.0 112 f 9.8
14 22 18.0 r 2.0 177 2 19
16 24 =
28.5 3 279 f 29
18 27 39 2 4 383 r 39
20 30 56 f 6 549 k 58
22 32 76 -c 8 745 r 78
24 36 94.5 f 10 927 98*
27 41 135 +. 15 1320 ~t:140
30 46 175 & 20 1720 2 190
33 50 225 2 25 2210 f 240
36 55 280 f 30 2750 2 290
39 I 60 335 r 35 3280 +. 340
Seal surface
SAD00483
5. Table of tightening torques for flared nuts
* is special instruction, tighten to the torque givenin the
In the case of flared nuts for which there no
tabie below.
Thread diameter Width across flats Tightening torque
mm mrn kgrn Nrn
14 19 2.5 2 0.5 *
24.5 4.9
18 24 5 r 2 49 k 19.6
22 27 8.+2 78.5 & 19.6
24 32 14 f 3 137.3 2 29.4
36 30 *
18 3 176.5 f 29.4
33 41 20 f 5 196.1 2 49
36 46 2 5 245.2 +. 49 25
42 55 f 5 294.2 .c 49 30
6. Table of tightening torques for split flange bolts

.A In the case of split flange bolts for which thereis no special instruction, tightento the torque given
in the table below.
Thread diameter Width across flats Tightening torque
mm rnrn kgm Nrn
10 14 6.7 f 0.7 65.7 f 6.8
12 17 11.5 A 1 112 r 9.8
16 22 r3 279 2 29 28.5
30-4 PC300, 350-6

0
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes,cover them or fit blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Bo not puii the wires.
Fit wires and hoses with tags to show theirinstallationpositiontopreventany 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 uniformly in
turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
Sr Precautions when handling piping during disassembly
Fit the following blind plugs into the pipingafter disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items below as a set
number Plug (nut end)
02 07376-50210 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 07376-51 034 07221-21034 (Nut), 07222-01018 (Plug)
07376-51 234 12 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07378-10400 07379-00400 07377 -30400
05 07378-10500 07379-00500 0737 1-30500
3} If the part is not under hydraulic pressure, the following corks can be used.
Taper 118
77
. ..
I 07049-02228
07049-02430
1 22
(18.51
28
1 24 I 20 1 30
L
-I
24
27 I 07049-02734 1 27
122.51
34 DEWW401
PC300, 350-6 30-5

0
..
2. Precautions when carrying out installation work
Tighten all bolts and nuts (sleeve nuts) t o t h e specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
e
Bend the cotter pins and lock plates securely.
b
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 gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
e
When press fitting parts, coat the surface with anti-friction compound (LM-PI.
.
0
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.
When using eyebolts, check that there is n o deformation or deterioration, screw them in fully, and
align the direction of the hook.
0
When tightening split flanges, tighten uniformiy in turn to prevent excessive tightening on one
side.
* When operating the hydraulic cylindersfor the first time after reassembiing cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the airas follows:
1. Start the engine and run at low idling.
2. Operate theworkequipmentcontrolleverto operate thehydrauliccylinder 4 - 5 times,
stopping the cylinder 100 mm from the end of its stroke.
-
3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* Whenusingthemachineforthefirsttimeafterrepair or long storage, followthe same
procedure.
.
3. Precautions when completing the operation
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine t o circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil tothe specified
. level. Run the engine to circulate the oil through thesystem. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
.* For details, see TESTING AND ADJUSTING, Bleeding air.

Add the specified amount of grease (molybdenum disulphide grease)to the work equipment parts.
30-6 PC300, 350-6

0
DISASSEMBLY
SPECIAL
AND ASSEMBLY TOOL LIST
SPECIAL TOOL LIST

* Tools with part number790T-000-0000cannot besupplied (they are i t e m s t o be locallymanufac-
tured).
* Necessity: I: Cannot be substituted, should always be installed (used).
0: Extremely useful if available, can be substituted with commercially available part.
* Newhemodel: N: Tools with new part numbers, newly developed for this model.
* R: Tools with upgradedpart
numbers,remodeled from
items
already available for
other models.
* Blank: Tools
already
available for other models, used without any modification.
* Tools marked 0in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
Part No. Part Name Neces- Q t y remodel
New/ Sketch Nature of work,
Component Symbol sity remarks
Removal, Tightening of
Engine assembly A 790-331-1110 Wrench 1 installa-
cylinder head bolt
tion
Dis-
Swing machinery F 7961-626-1110 Push tool 1 N 0 assembly, Press fitting of
assembly assembly bearmg
796-627-1210 Wrench I N Removal, installa-

~ 1 round nut
I tion of
I
1 I796T-627-1230 Push tool I I 1 1 N 1 0 I
2 1790-101-2510
I
I Block
I
I
I
I l l
I I
I
I
I
i
3 792-104-3940 Bolt 2
4 01580-11613 Nut 2
Pushing of
Final drive J Dis-
Washer
assembly bearing inner
assembly 5 790-101-2570 2 assembly race
6 01643-31645 Washer 1
7 790-105-2100 jack I I
8 790-101-1102 Pump 1
I
Tightening of
3 1790-331-1110 1 Wrench 1 / 1 1 I i cover bolt
Installation of
4 791-580-1510 Installer 1 floatma., seal
lnstaliation of
1 796-570-1020 Installer 1 Dis- floating seal
Idler assembly
I 2 791-601-1000 Oil pump 1
assembly
assembly Charging with oil
Installation of
3 796-670-1010 Installer 1 Dis- floatmg seal
Track roller
___-I LI..
asst.llluly
II 4 791-601-1000 Oil pump 1
- assembly
assembiy Charging with oii
790-302-1 500 Wrench kit 1 Removal,
5 ~.
instaliation of nut
09003-05560 Wrench 1
Carrier roller Dis- lnsta!lation of
assembly 6 796-670-1020 Installer 1 assembly floatma seal
assembly
------+
7 796T-630-1130 Push tool I N 0
8 1791-607-1000 lGii pump I 1 4 1 I
Dis- Removal,
Recoil spring M assembly, installation of
assembly assembly recoil spring
PC300, 350-6 30-7

0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/ Sketch Nature of work,

PartComponent Symbol No. remodel remarks
790-201-1500 Push tool kit 1
Recoil spring 0 790-201-1650 Plate 1 Dis- Installation of

assembly assembly,
790-101-5021 Grip 1 assembly piston dust seal
* 01010-50816
1 9 Bolt
791-646-3000 Remover,1installer
Removal, Removal,press
Track shoe R 790-101-1300 Cylinder 1 instaiia- fitting of master
assembly tion pin
1790-101-1 102 Pump 1
796-660-1 200 Oil stopper assembly 1 N
796-460-1210 Oil stopper 1 Shutting off
1
796-660-1210 Rod I N
instal-
* 20Y-60-27330 * Rod assembly
1 lation
2
790-207-2700
Push tool kit , Press fitting of
790-201-2740 4 Spacer I
shaft oil seal
t I
790-501-5000 Unit repair stand

stand
repairUnit 1 (for 100 v) D l Disassembly, assembly
790-501-5200 (for 220,240 V1 of pump assembly
790-901-2110
3 2Bracket D l
Plate
3 793-617-1
110 D l For front pump
Plate
4 796-660-1
430 m 1 pumprear For
799-201-3610
Bolt 1 D l
796-465-1
Washer
110
2 D l
Disassembly, assembly
01643-33080
Washer
3 D l of cylinder block
Washer
01643-32060 4 D 2 assembly
501582-02016 Nut D l
796-720-2250
1 Screwdriver m 1 Removal, installtion of
2796-720-2220 Socket D l cover
791-463-1100
1 Holder D l
!?smo.ra!, insta!!tIon of
i 2791-463-1150 Plate D l servo piston rod
Bolt
791-463-1
160 3 D l
~ ~~~~ ~
790-201-2700
Push tool
kit W 1
7 . Press fitting of bearing
790-201-2740
Spacer D l
796-660-1400
Gauge
assembly 1
* 796-660-1
440 Plate I
D l
Positioning servo piston
8 796-660-1450 Plate D l
swash plate angle
01010-51030 Bolt D l
01010-51835 * Bolt D l
-
33-8 PC300, 350-6

0
T
Component Symbol No. Part Name Part
Push tool kit

N:r New/
Qty remodel Sketch
1
Nature of work,
remarks
790-101-5201
1 1-
a
il
790-101-5251 I * Plate m 1 Press fitting of needle
790-101-5221 Grip m 1 bearing
01010-51225 Bolt H I
Hydraulic pump I I I I I
assembly 796-730-2140 Wrench Measuring rotating

10 m 1 torque of shaft
01306-00616 Bolt m 2
11 799-301-1600 Oil leak tester 1 Leak test of servo valve
790-201-2700 Push tool kit W 1
12 Press fitting of oil seal
790-207-2740 Spacer m 1
790-501-5000 1 Unit repair standFor Japan

1
Motor Unit repair stand 790-501-5200
1 For Overseas
25
sssembly 2 10 1 Bracket 790-901-21
Dis-
assembly,
; 3 Plate 790-901-1361 1 assembly
I 1799-307-1600 I Oil leak 1 I I 1 Pulling

~~
%ton 26 tester f 1 out

Piston
1 799-465-1 110 1 Washer
2 790-201-3610 Bolt 1
- Dis-
2ylinder block 27 3 01582-02016 Nut 1 assembly,
assembly
4 0164332460 Washei I
5 i 01643-32060 1 Washer
i I I i I I I
Main bearing 28 796-465-1 120 tool 1 Push Press fitting of main
bearing
Zylinder block, 1 796-465-1131 tool 1 Push Installation of cylinder
iston assembly 29 I
block, piston
2 01010-51070 Bolt 1
Sub bearing 30 796-460-1120 Push tool 1
Press fitting of sub
bearing
I
3il seal '790-101-52212 1 Grip Press fitting of oil seal

01010-51225 3 Bolt 1
790-101-2501 Push tool kit 1
* 790-101-2510 Block 1
I
Center swivel joint

assembly
790-101-2540 Washer 1
790-101-2630 Leg 2
PC300, 350-6 30-9

0
DISASSEMBLY AND ASSEMBLY TOOL SPECIAL LIST
4
Nature of work,
Component Symbol remarks
Center swivel joint Dis- >isconnectionof

assembly T assembly,
;haft and rotor
assembly
Securing of
iylinder
nstallation of
)iston ring
Dis-
assembly,
assembly
3oom, bucket
Hydraulic cylinder
assembly
b
nstallation of
just seal I
3oom, bucket
Dis-
assembly,
assembly
7 1
Work equipment Removal, 3emoval of

assembly, boom V 791-775-1
150 Adapter 1 instal- 3oom
assembly lation 'oot pin
01643-33080 Washer 1
01803-13034 9 Nut 1
790-101-4000 Puller 1
790-101-1102 Pump 1
799-703-1200 Service tool kit 1
799-703-1 100 Vacuum

pump (1oov) 1
Components Removal, Zharging with
related to air X 799-703-1 110 Vacuum
(220v)
pump 1 instal-
lation 'reon gas (R134a)
conditioner 799-703-1 120 Vacuum
pump (240V) 1
799-703-1400 Gas leak detector 1
I
30-9-1
0
Component Symbol Part No. Part Name Neces- Q’ty New/ Sketch Nature of work,
sity remodel remarks
790-501-5200 Unit repair stand ‡ 1
Dis-
Y 1 790-901-2110 Bracket ‡ 1 assembly, Swing motor
assembly
790-401-1470 Plate ‡ 1
796-730-2120 Screwdriver ■ 1 Removal, Removal, instal-

Y 2 installation of retainer
796-720-2220 Socket ■ 1 lation fitting screw
796T-660-1510 Pump adapter ■ 1 fi
• 790-101-1430 • Coupler assembly ■ 1
• 796-660-1490 • Nipple ■ 1
• 799-101-5130 • Gauge ■ 1
• 799-101-5160 • Nipple ■ 1
Y 3 • 790-301-1190 • Nipple ■ 1 Release of brake
• 790-301-1660 • T-piece ■ 1
• 205-70-51390 • Nipple ■ 1
• 790-301-1210 • Joint ■ 1
• 07002-01423 O-ring ■ 1
790-101-1102 Pump ■ 1
Press fit of main
Y 4 790-201-2850 Spacer ■ 1 bearing inner race
Installation of sub
Swing motor Y 5 790-201-2860 Spacer ■ 1 bearing outer race
assembly Y 6 790-201-2840 Spacer ■ 1 Press fit of sub
bearing inner race
790-101-2510 Block ■ 1 Dis-
assembly,
791-600-1120 Bolt ■ 2 assembly
01643-31845 Washer ■ 6 Pushing out of

Y 7
01580-11613 Nut ■ 6 drive shaft
790-105-2100 Jack ■ 1
790-101-1102 Pump ■ 1
Judgment of revolving
Y 8 01435-01220 Bolt ■ 1 torque of drive shaft
790-201-1500 Push tool kit ■ 1
• 790-201-1590 • Plate ■ 1
Y 9 Press fit of oil
• 790-101-5021 • Grip ■ 1 seal
• 01010-50816 • Bolt ■ 1
796T-660-1520 Plate ■ 1 fi
01010-51020 Bolt ■ 2
Y 10 Fixing of housing
01010-51835 Bolt ■ 4
01580-11815 Nut ■ 4
Y 11 796T-660-1540 Push tool ■ 1 fi Press fit of

dowel pin
Y 12 799-301-1600 Oil leak tester ■ 1
Removal, Removal of brake
installation piston
PC300, 350-6 30-9-2

5
DISASSEMBLY AND SKETCHES
ASSEMBLY OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools
manufactured according t o these sketches.
F Push tool
CDPOO506
TREATMENT
MATERIAL
HEAT
STKM13A
PART NAME
PUSH TOOL
I 796T-626-1110 A 1
J2-1 Push tool
I
1- 140 1
CDP00507
PART NAME OW
PUSH TOOL 1
796T-627-1230
PC300, 350-4
DISASSEMBLY AND ASSEMBLY SKETCHES OF
TOOLS
SPECIAL
L7 Push tool
c1 c1
9o-co.2
4 COP00508
HEAT TREATMENT MATERIAL

--- STKM13A
PART NAME QTY
PUSH TOOL 1
796T-630-1138
PC300, 350-6 30-11

0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
Y3 Pump adapter
30-11-1 PC300, 350-6

5
Y10 Plate
PC300, 350-6 30-11-2

5
Y11 Push tool
30-11-3 PC300, 350-6

5
AND DISASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
A Disconnect the cable from the negative ( 4 ter-
minal of the battery.
1. Open engine hood.
2. Remove engine undercover.
3. Remove starting motor wiring harness cover.
4. Disconnect starting motor harnesses (1) and (21,

and connector (3) (CN-M2).
I CEW0301
5. Remove 3 mounting bolts, then remove starting

motor assembly (4).
\ 4 I
Ir The two mounting bolts at the top are also
used for tighteningthecovermounting
bracket in Step 3.
INSTALLATION OF STARTING
MOTOR ASSEMBLY
CEW0302
Carry outinstallation inthe reverse order to
removal.
30-12 PC300, 350-6

0
ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
a Disconnect the cable from the negative ( 4 ter-
2. Disconnect alternator wiring (11, (2), and (3).
3. Remove fan guard (4j.
4. Loosen lock bolt (5) and mount bolt (6). I \ I CEW0303
5. Loosen tension adjustment bolt(71, then remove

belt (8) from alternator pulley.
6. Remove lock bolt (5)and mount bolt (61, then

remove alternator assembly(9).
INSTALLATION OF
ALTERNATOR ASSEMBLY
Carryoutinstallationinthe reverse orderto
removal.
* Adjust the belt tension.

For detai!s, see TESTING AND Af?J?!ST!la!G,
Testing and adjusting. of alternator belt ten-
§io&
PC300, 350-6 30-13

0
DISASSEMBLY AND ASSEMBLY COOLER
ENGINE OIL
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Drain coolant.
2. Remove fuel injection pump assembly.

For details, see REMOVAL OF FUEL INJECTION
PUMP ASSEMBLY.
3. Disconnectengine oil pressuresensorwiring

harnesses (1) and (2) from sensor.
4. Remove oil filter (3) together with bracket. 3 i 2 CEF90310
5. Disconnect bottom part of tube (4).
6. Remove oil cooler assembly (5).
7. Remove oil cooler core (7)from cover ( 6 ) .
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
5-4
Carry out installation in the reverseorder to CEP00311
removal.
Mounting bolt of oil filter markedwith 7

=
%: 18.63 2 4.9 N m 11.9 0.5 kgm)
CEP00312
I 1
30-1 4 PC300., 350-6

--- -
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
2. Disconnect governor motor wiring connector (1)

(CN-E05).
3. Disconnect governor motor spring rod (2).

* Do not rotate the shaft of the governor mo-
tor suddenly.
Sr Always disconnect governor motor connec-
tor CN-EO5 before disconnecting the rod.
* Check the position of the lever hole.
4. Remove fuel filter (3)together with bracket and

hose.
* Disconnectthe hoseat the injection pump
end. a
5. Disconnect fuel supply hose (4) and return hose
(5).
st There is no stop valve installed to the sup-
ply hose, so stop the fuel.
1 5’
4 CEW0315
6. Remove boost compensation tube (6) and injec-

tion pump lubrication tube (7).
9 . Disconnect 6 delivery tubes ( 8 ) .
8. Removebracket (9).
I 9
‘ CEW0316
9. Remove mounting bolts, thenremovefuelin-

jection pump assembiy iiOi. i-zTJ
10 CEW0317
PC300, 350-6 30-15

0
MBLY AND
DISASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Carry outinstallation in the reverse order to
removal.
* Adjust the spring rod.

For details, see TESTING AND ADJUSTING,
Adjusting governor motor lever stroke.
* Connect thespringrodbeforeconnecting
the CQnneCtOP (CN-€05).
Joint bolt (width across flats: 22 mm):

17.2 z 2.5 Nrn (1.75 t 0.25 kgm}
Joint bolt (width across flats: 22 mm):

17.2 3 2.5 Nm (1.75 a 0.25 kgm}
Boost compensation tube nut

Intake manifold end: 24.5 t 9.8 N m
(2.5 1.0 kgm}
Injection pump end: 10.3 t 2.5 Nm
(1.05 2 0.25 kgmf
Lubrication tube joint bolt:
11.3 j: 1.5 Nm (1.15 2 0.15 kgm}
Delivery tube sleeve nut:

22.1 3 2.5 Nm (2.25 t 0.25 kgml
* Align the spline notch, then align the tine on

the fuel injection pump with the line on the
gear case, and install the coupling.
* Adjust the injection timing.
Adjusting fuel injection timing.
* Bleed the air from the fuel circuit.
CDPOOB 18
1 1
30-16 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Draincoolant.
2. Open enginehood.
3. Loosen adjustment bolt (2)and mount bolts (3)
of tension pulley (I), and remove belt (4) from
water pump pulley.
4. Disconnectbypasshose (51, aeration tube (6),
heater hose (71, and clamps (8) and 19).
* Check the angle of the clamps.
5. Disconnect water pump inlet hose (10).
6. Remove mountingbolts,thenremovewater 0319
pump assembly (11).
* There is one mounting bolt at the cylinder
block end.
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.

For details, seeTESTING ANDADJUST-
1
ING, Testing and adjusting of water pump
belt tension.
p
J
Ir Set one mounting bok at the fan puiiey end
installed to the water pump(it will not go in
later).
Refilling withwater
* Addwaterthroughthe water fillertothe
specified level.
Run the engine to circulate the water through
+h.
. Thn- nhnnL +hrr .a,-+
C J Y B I F I I I. 1 I IGI -1 IGbn LI I C V V c l L e r !eve! again.
nr.r+nm
LI I I
PC300, 350-6 30-1 7

0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
I. Openenginehood.
2. Disconnect delivery tube (1).
3. Disconnect spill hose (2).
4. Remove holder-(3).
i CEW0323
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
Carry out installation in the reverse order to
removal.

22.1 d 2.5 Nm 4.25 2 0.25 kgm}
Nozzle holder mounting bolt :

=
44.1 t 4.9 Nm i4.5 0.5 kgm)
30-1 8 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
2. Remove top adiabatic cover (1) together with
stay.
3. Remove intake hose (2).
4. Remove turbocharger outlet hose (3).
5. Remove bottom adiabatic cover (4).
6. Remove clamp (7) and bolts and nuts of con-
nectingciamp i6j of exhaustpipe (5j. 0
7. Remove turbocharger lubrication inlet tube (8).
8. Disconnect turbocharger lubrication returnhose I- 3’ CWPOG I03
(9).
9. Remove turbocharger assembly (10) while pull-
exhaust
pipe
out ing (5). a
INSTALLATION OF
TURBOCHARGER ASSEMBLY
* Carry outinstallation in the reverse order to
removal.
p
J
l
* Do not use the connection clamp again. Re-
place it with a new part.
Exhaust pipe connection:
Coat with thermosetting agent
(Mihon Holt Fire Gum or equivalent)
Tightening nut of connecting ciamp (6):
83.4 z 14.7 Nm (8.5f 1.5 kgml
Turbocharger mounting nut:

36.8 t 7.4 Nm I3.75 z 0.75 kgml
CEP00327
PC300,350-6 38-19
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY I
1. Drainenginecoolant.
2. Open enginehood.
-1
3. Disconnectaerationtube (1).

It The mounting bolts (inside bottom bolts) of
/
the thermostat covercannot be removed, so
disconnect the hose. CEPO0328
I
5. Remove thermostat cover (3).

* There are two clamps, so check the mount-
ing angle.
6. Remove thermostat (4).
INSTALLATION OF
THERMOSTAT ASSEMBLY
Carry outinstallation in the reverse orderto
removal.
Refilling with water

* Addwaterthroughthewaterfiller tothe
specified level.
the system. Then checkthe water levelagain.
30-20 PC300, 350-6

0
DISASSEMBLYENGINE
AND ASSEMBLY FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator andhydrauliccoolerassem-
bly.
For details, seeREMOVAL OF RADIATOR, HY-
DRAULIC COOLER ASSEMBLY.
2. Remove fan (1).
3. Remove fan guard (2).
I CEPW330
4. Loosen tension of alternator (31, tension pulley

(4), and air conditioner compressor (5), and re-
move belts (61, (71, and (8).
* For details, see REMOVAL OF ALTERNATOR,
WATER PUMP, AIRCONDITIONER COM-
PRESSOR.
5. Remove damper (9). a

Sr The compressor drive pulley will also come
off at the same time.
I
I
32
CEP00333
PC300, 350-6 30-21

0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
8. Remove front oil seal (12).
INSTALLATION OF ENGINE
FRONT SEAL
Carry outinstallation in thereverseorder to
removal.
a Fan mounting bolt: 66.2 t 2.5 Nm

(6.75 t 0.25 kgm)

Testing and adjusting alternator belt, water
pump belt, and air conditioner compressor
belt tension.
Damper mounting bolt:

66.2 t 2.5 Nm I6.75 t 0.25 kgm}
Front pulley mounting bolt:

*
451.1 29.4 Nm (46t 3 kgml
* Press fit the front seal until it is level with

the surface of the front cover.
a Lip of oil seal: Grease (G2-LI)
(approx. 2 cc.)
30-22 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY SEALENGINE REAR
REMOVAL OF ENGINE REAR

SEAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.
2. Remove damper assembly (1).
3. Remove flywheel assembly (2).
CWPOG 165
4. Remove rear seal (3).

f Be careful nottodamagethe crankshaft
when removing.
!NS?ALLA?!OIV OF ENG!NE
REAR SEAL
1. Installationofrear seal
1) Install rear seal with TOP mark facing up.
2) Press fit 20 mm from endface of crankshaft.
3) If there is wear of lip contact face of crank-
shaft (fingernails catch: more than 0.7 mm),
move rear seal approx. 3 mm to rear when
assembling.
6 Lip of oil seal : Grease tG2-LI)
CWP06187
PC300, 350-6 30-23

0
DISASSEMBLY AND ASSEMBLY SEALENGINE REAR
2. Installation of flywheel
1) Coat flywheelmounting bolts,thread por-
tion, seat face, and washer with engine oil.
Mounting bolt: Engine oil (EO#30)
2) Install mounting bolts in order shownin dia-
gram on right.
Mounting bolt :
1st step: 88.3 N m 19 kgm)
2nd step: 186.3 Nm I19 kgrn)
3) Measurement of face runout, radial runout
Face runout: Max. 0.20 mrn
Radial runout: Max. 0.15 mm
* If the measurement is not within the stand-
166
ard value, take the action given in the MAIN-

TENANCE STANDARD.
3. Installationofdamper
QZg Damper mounting bolt:
110 t 12.3 N m (11.25 f 1.25 kgm}
30-24 PC300,350-6
0
DISASSEMBLY
GOVERNOR
AND ASSEMBLY MOTOR
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY I

2. Disconnect wiring connectors (1) (CN-EO4) and

(2) (CN-€05).
3. Remove cover (3).
4. Disconnect spring rod (4).
5. Remove governor motor assembly(5).
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
Carryoutinstallation in thereverse order to
removal.
a
* Adjust the spring rod.
For details, see TESTINGAND ADJUSTING, Test-
ing and adjustingof governor motorlever stroke.
PC300, 350-6 30-25

0
AND DISASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
A Disconnect the cable from the negative
( 4 ter-

2. Drain coolant.
3. Remove intake connector (2).
4. Removeclamp (3), anddisconnectspillhose
(4).
5. Disconnect fuel filter (5) a t bracket end, then
move it towards counterweight.
6. Disconnect heater relay (6) a t bracket end.
* Oneconnector clampandonewiringhar-
ness clamp are tightened together.
7. Disconnect wiring harness clamp (71, then re-

turn bolt to its original position.
8. Disconnectbypasshose (8) and aeration tube
19).
9. Disconnect block (IO)from cylinder head.
10. Disconnect oil filter bracket (1 1) from intake

manifold.
11. Remove boost compensation tube (12).
12. Disconnect both ends of delivery tube (13).
13. Remove intake manifold (14).
* There is a wiringclampatthebolt
bottom of the No. 6 cylinder.
a t the
14. Lmsen tensic:: of aete;na:o; belt, theii iaiiove

plate mounting bolt (15).
15. Disconnectturbocharger outlet hose (16)and
remove inlet hose (17).
16. Remove top adiabaticcover (18) and bottom
adiabatic cover (19).
* Remove the top adiabatic cover togetherwith
the stay.
I - 16- CWPOG 105
30-26 PC300,350-6
0
HEAD DISASSEMBLY
CYLlNDER
AND ASSEMBLY
17. Disconnect turbocharger lubrication inlet tube

(21) and outlet tube (22).
* Loosen thenut at the bottom, thenmove
the inlet tube towards the control valve.
18. Remove mounting bolts and nuts of connecting
clamp (23)of exhaust pipe (201, then remove
clamp (24).
19. Disconnect level gauge clamp (25).
20. Lift off turbocharger and exhaust manifold as-

sembly (26). p g
21. Remove exhaust pipe (20).
22. Remove wiring harness (28)and lead ( 2 9 1 . m

23. Remove 6 glow
plugs (30). pJ
24, Disconnect spil! hose !3?!; remove ho!der W ! ,
remove 6 nozzle holders (33).
then /x101
25. Disconnect blow-by hose (341, and remove head
cover (35).
26. Remove rocker armassembly (36). /x121

.ir ioosen the iocknut, then ioosen the adjust-
rI
ment screw 2 - 3 turns.
PC300, 350-6 30-27

0
HEAD DISASSEMBLY
CYLINDER
AND ASSEMBLY
27. Remove push rods (37).
28. Remove cylinder head bolts (38).
29. Lift off cylinder headassembly (39). Jx13)

Cylinder head assembiy: 65 kg
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
removal.
Boost compensation tube nut.

Intake manifold end: 24.5 t 9.8 Nm
4 . 5 1.0 kgm)
*
Injection pump end: 10.3 2.5 Nm
(1.05 t 0.25 kgml

22.1 t 2.5 Nm (2.25 +1 0.25 kgml
Intake manifold mounting bolt:

24.5 t 9.8 Nm (2.5 s 1.0 kgml
Ir Adjust the belt tension.

Testing and adjusting alternator belt
tension.
30-28 PC300, 350-6

0
HEAD DISASSEMBLY
CYLINDER
AND ASSEMBLY
* Do not use the connection clamp again. Replace

it with a new part.
Connecting clamp (23)tightening nut:
83.4 14.7 Nm {8.5 1.5 kgm}
Exhaust manifold mounting bolt:

44.1 f 9.8 Nm (4.5 'e 1.0 kgm}
Exhaust pipe connection:

Coat with thermosetting agent
Wiring harness and lead mounting nut:

=
1.5 0.5 Nm I0.15 t 0.05 kgmj
T
pcJ
Glow plug:
17.2 t 2.5 Nm (1.75 0.25 kgm}
/x101
* Clean themountingportion.
Nozzle holder mounting bolt:
44.1 4.9 Nm (4.5 t 0.5 kgm}
Head cover mounting nut:

8.8 t 1.0 Nm (0.9 r 0.1 kgm}
txl2j
* When tighteningthe nuts and bolts, start
from the center and work towards the out-
side.
* Check that the ball of the adjustment screw
is fitted properly into the socket of the push
rod.
Adjust the valve clearance.
Adjusting valve clearance.
Mounting bolt, nut:
24.5 4.9 Nm (2.5 0.5 kgm)
PC300, 350-6 30-29

0
DISASSEMBLY
CYLINDER
AND ASSEMBLY HEAD
Jx13)
* If any rust ofmorethan 5 mm square is
found on the shaft or the thread of thebolt,
replace the head bolt with a new bolt. Intake side
* Be careful to check that there is no dirt or
dust on the mounting surface of the cylinder
Front
head or inside the cylinder.
* When installingthe gasket, check thatthe
grommets have not comeout.
* Coat the thread and seat of the bolt, and the
seat sf the cy!inder held holes cornp!etely I
Exhaust side
a
with molybdenum disulphide (LM-P).
Mounting bolt: Anti-friction compound
I CEP00353
(LM-PI.
* Tighten the cylinder head mounting bolts 2
- 3 turns by hand, then tighten in the order
given in the diagram. A
Cylinder head mounting bolt:
1stpass: Tighten to 98.1 r 9.8 Nm
I10 t 1 kgml
2nd pass: Tighten to 147.: P 4.9 Nrn
(15 1: 0.5 kgm)
3rd pass: 1. When using tool A.
Usinganangletightening
wrench, tighten bolt 9Oot3f8”. CEW0354
2. When not using tool A.
1) Using the angle of the bolt
h e a d as t h e base,make
startmarksonthecylinder Cylinder head
headand socket. start mark
2) Make an end mark at a point Socket
start
I
90°’38fr~m the start mark.
3) Tighten so that the start mark
on the socket is aligned with
the end mark on the cylin-
derhead at the 9Ooi3: posi-
tion.
CEW0355
.ir After tightening, make one punch mark on the

bolt head to indicate the numberof times it has
been tightened.
If any bolt already has five punch marks, do
not reuse it. Replace it with a new bolt.

* Refill to the specified level, and run the en-
gine to circulate the water through the sys-
tem. Then check the water level again.
I CEP00356
30-30 PS300,350-6
0
AFTERCOOLER
REMOVAL OF AFTERCOOLER
ASSEMBLY
1. Open aftercoolerfront cover
2. Loosen clamps of aftercooler inlet hose (1) and ,

outlet hose (2). I " \ \
3. Remove mounting bolts, pull out from hose, and

remove aftercooier assembiy i3j.
INSTALLATION OF
AFTERCOOLER ASSEMBLY
Carry outinstallationinthereverseorder to
removal.
PC300, 350-6
DISASSEMBLY
HYDRAULIC
AND ASSEMBLY COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
a Loosen the oil filler cap slowly to
pressure inside the hydraulic tank.
release the
1. Drain oil from hydraulic tank.

4
Hydraulic tank: Approx. 200 2!
2. Lift off engine hood (1).

* Loosen the hinge mounting boits before iift-
mg. CEP00359
&?I Engine hood assembly: 85 kg
3. Remove aftercooler top cover, and open front

cover.
4. Remove aftercooier assembiy.

F=r details, see REMOVAL OF AFTERCOOLER
ASSEMBLY.
5. Disconnect hose (2) and tube (3).

* Set a container under the cooler assembly
3
t o catch the oil.
CWPO7201
6. Slinghydrauliccoolerassembly (41, remove
mounting bolts, then lift off hydraulic cooler as-
sem bly.
Hydraulic cooler assembly: 90 kg
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
Carry outinstallation inthe reverseorder to
removal.
-
. D-C:BB:--
ncInInnnIy
...
:aL -:I lL..mAw.....B:a a-..L\
*
WBLII UBI r1nyunaumlr. rollnl
Add oil through the oil filler to the specified

level.
Run the engine t o circulate the oil through
the system. Then check the oil level again.
38-32 PC300, 350-6

0
DISASSEMBLYCOOLER
AND
HYDRAULIC
RADIATOR,
ASSEMBLY
REMOVAL OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
Loosen the oil filler cap slowly to release the
b
,A,Hydraulic tank: Approx. 200 k!
2. Drain coolant
3. Lift off engine hood (1).
* Loosen the hinge mounting bolts before lift-
CEP00359
ing.
& Engine hood assembly: 85 kg

4. Removeaftercooler top cover, and open front
cover.
5. Remove radiator undercover.
6. Remove aftercooler assembly.
For details, see REMOVAL OFAFTERCOOLER
ASSEMBLY.
7. Disconnect hydraulic coolerhose (2) and tube
(3).
* Setacontainerunderthecoolerassembly
t o catch the oil.
8. Remove shroud left cover (4).

* The shroudmountingboltscannot bere-
moved, so remove the cover.
rtor out!e!t hOSe !5!=

* Disconnect the clamps at two places a t the
same time.
10. Disconnect sub-tank hose (6)
11. Remove 2 mountingboltsofshroud (7)from

below.
PC300, 350-6 30-33

0
DISASSEMBLY COOLER
AND
HYDRAULIC
RADIATOR,
ASSEMBLY
12. Disconnect radiator inlet hose (8).
13. Remove top 2 mounting bolts of shroud (71, and

move it towards engine.
14. Sling radiator and hydraulic cooler assembly(91,

remove top and bottom mount bolts, then lift
off radiator and hydraulic cooler a s s e m b 1 y . m
* Check the direction of the holder plateat the
bottom of the top mount. r
A
1 kg 1 Radiator,nydrauiiccooierassembiy:
160 kg
INSTALLATION OF RADIATOR,
HYDRAULIC COOLER
ASSEMBLY
removal.
Mount bolt: 110.3 = 12.3 Nm

I1l.25 +: 1.25 kgrn}
Refilling withwater
* Addwaterthroughthewaterfillerto the
specified level.
the system. Thencheck the water level again.
Refilling with oil (hydraulic tank)

* Add oil through the oil filler to the specified
level.
Run the engine to circulate the oil through
30-34 PC300, 350-6

0
DISASSEMBLYENGINE,
AND ASSEMBLY MAIN PUMP
REMOVAL OF ENGINE, MAIN

PUMP ASSEMBLY
a Disconnect the cable from the negative (-1 ter-
A Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil
filler cap slowly to release the pressure inside
the hydraulic tank.
i . Remove nydrauiic tank strainer, and usiiiy iooi
S I , stop oil.
Whennotusingtool SI, removethedrain
plug,anddrainthe oil fromthehydraulic
tank and inside the system.
4
Hydraulic tank : Approx. 200 Q
2. Drain coolant.
3. Remove mainpumpundercoverandengine
undercover.
5. Remove rnain pump top cover (1); andparti-

tions (2) and (3).
6. Remove muffler drain tube ( 4 ) .

7 ;Disconnect chassis ground cable (5).
8 . Remove bracket (6)of pump branch hose.
*Do not disconnect the branch hose.
9. Disconnect suction tube (7).
20. Disconnect cooling hose ( 8 ) .
IS CWPO7204
7 1 . Disccnnect LS centre! hose @!.

12. Disconnect rear pump LS pressure detection hose
(10).
13. Disconnect rear pump delivery pressure detec-
tion hose (11).
14. Disconnect TVC wiring connectors (12) (C13,14).
15. Disconnect TVC wiring clamp (13).
16. Disconnect frontpump LS pressuredetection
hose (14).
17. Disconnect front pump delivery pressure detec-
tion hose (15).
-k After disconnecting the hoses, fit tags to dis-
tinguish them.
PC300, 350-6 30-35

0
DISASSEMBLYENGINE,
PC300-6 Serial No.:33001 - 33465, PC350-6 Serial No.: 12001 - 12283

18. Disconnect hose (16A) and spacer (16B) going
t o self- reducing valve.
* Spacer (16B):
PC350-6 Serial No.: 12284 and u p
t o control valve.
* Spacer (17B):
20. Disconnect drain hose (18).
PC300-6 Serial No.:33466 and UD, PC350-E Serial No.: 12284 and uo
A CWPO7205
21. Disconnect fuel return hose(19) and supply hose

(20).
* There is no stop valve installed t o the sup-
ply hose, so stop the fuel.
22. Disconnect car heater hose (21).
23. Disconnect spill hose clamp (22).
! 20 __ 23
U
22 _ _
CEPO0370
25. Remove aftercooler joint tube (24) together with

bracket.
26. Disconnect governor motor wiring connectors
(251,(261, and (E04, 05).
26 25 CWPOGI I I
30-30 PC300, 350-6

0
DISASSEMBLYENGINE,
27. Remove clamps (27) (2 places), then disconnect

spill hose (28).
28. Disconnect engine coolant outlet hose (29).
29. Remove fan guard (30), then remove fan (31).
a
30. Disconnect hose (32) going to aftercooler.

31. Remove hose (33) coming from air Cleaner.
32. Disconnect hose (34) going to dust indicator.
33. Remove air cleaner assembly (35) together with
bracket.
- - - I \ 35 __
32 C9 34 @ CWPO6113
34. Disconnect air conditionercompressorwiring

connector (36)(M34).
35. Discoflnect ai: conditioner hcse (37!.
.k Before disconnecting the hose, use tool X1
t o collect the refrigerant (R134a).
36. Disconnect wiring cable (38) from starting mo-
tor.
37. Disconnect wiring connector (39)(E08) and clamp
(40).
CWPO61 14 I
U-- CWPO61 15
I Q 0
CWPOGI I 6
PC300, 350-6 30-37

0
LY AND
DISASSEMBLY PUMP MAIN
39. Lift off engine and main pump assembiy (43).

* Check that all wiringandpiping hasbeen
disconnected, then lift off slowly.
Engine and main pump assembly:
1062 kg
INSTALLATION OF ENGINE,
MAIN PUMP ASSEMBLY
Carryoutinstallationin the reverseorder to
removal.
Joint bok:
15.2 2 2.5 Nm c1.75 I 8.45 kg1141
p g
Fan mounting bolt:
66.2 2 7.4 Nm (6.75 2 0.75 kgml
* Check that there is no damage or deteriora-

tion of the O-ring, then connect the hose.
a Engine mount bolt

(front): 384.9 z 41.7 Nm 139.25 2 4.25 kgml
(rear): 926.7 = 103.0 Nm (94.5 I 10.5 kgml

* Add water up to the water filler port.
the system. Thencheck the water level again
at the reserve tank.
Chgrging air conditioner with ggs

*
0
Usingtool X I , charge the air conditioner

circuit with refrigerant (R134a).
Refilling with oil

level.
Bleeding
air
* Bleed the air from the main pump.
Bleeding air.
38-38 PC300, 350-6

E
0
0
w
8
b
;3
w o
C
ij 2.
rr
3
m
-
cd
<
cn
m
X
cn
-3
DISASSEMBLY
FUEL AND ASSEMBLY TANK
REMOVAL OF FUEL TANK

ASSEMBLY
a Disconnect the cable from the negative (-1 ter-
1. Open drain valve of fuel tank and drain fuel.

b
Fuel tank: Approx. 456 k?
(when tank is full)
2. Remove air conditioner condenser top cover.

I
3. Remove handrail (11, front cover (21, and battery
case cover (3).
4. Disconnect fuel level sensor connector (4) (CN- 4

\
P06).
I
5. Disconnect fuel supply hose (5). return hose (61,
spill hose 673, and damp (81.
6. Remove mounting bolts, and lift off fue'I tank

assembly (9). r i
I4
& Fuel tank assembly: 210 kg
CEPOOll3
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
Fuel tank mounting bolt:

277.0 2 31.9 N m 128.25 = 3.25 kgm}
CEPOOl14 CEPOOll5
30-40 PC300, 350-6

0
ASSEMBLY AND
DISASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
-
PC300-6 Serial No.: 33001 33465
-
PC350-6 Serial No.: 12001 12283
Release the remaining pressure in the hydraulic
circuit.
For details, see TESTING AND ADJUSTING, Re-
leasing remaining pressure from hydraulic cir-
Ase:n:: the hydraulic tank oil filler cap slowlyt o

release the pressure inside the hydraulic tank.
* Markallthepipingwithtagstopreventmis-
takes in the mounting position when installing.
1. Disconnect travel motor hoses (1) and (2).
2. Disconnect speed selector hose (3).
3. Disconnectdrainhose (41, andremoveelbow
(5).
* Install a blind plug in the drain hose.
4. Disconnect drain hoses (7) and ( 8 ) .
5 . Disconnect travel hoses (9)and (IO),and speed
selector hose (11).
6. Pull out pin (121, and disconnect plate (13).
7. Sling center swivel joint assembly (14), remove
mounting bolts from below, then lift off.
& Center swivel joint assembly: 40 kg
INSTALLATION OF CENTER
SWPWEL JOINT ASSEMBLY
PC300-6 S ~ i a NO.:
i 3300'; - 33465
PC350-6 Serial No.: 12001 - 12283
Carryoutinstallation inthe reverseorder to
removal.
* Assemble the center swivel as shown in the

diagram below.

level.
Bleeding air
* Bleed the air from the travel motor.
Bleeding air.
a: Center swivel
b: Sprocket
PC300, 350-6 30-41
0
DISASSEMBLY
SWIVEL CENTER
AND ASSEMBLY JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
a Release the remaining pressure in the hydraulic
circuit.
cuit.
a Loosen the hydraulic tank oil filler cap slowly t o
A Mark ail the piping with tags to prevent mis-
takes in the mounting position when installing.
1. Disconnect travel motor hoses (1) and (2).
2. Disconnect speed selector hose (3).
3. Disconnect drain hose (41, andremoveelbow
(5).
4. Disconnect drain hoses (7) and (8). IO
j r !nstall a blind plug in the drain hose.
5. Disconnect travel hoses (9)and (IO),and speed
selector hose !I I!.
6. Pull out pin (121, and disconnect plate (13).
7. Sling center swivel joint assembly (141, remove
mounting bolts from below, then lift off.
13
Center swivel joint assembly: 40 kg
CWPO7207
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
Carry outinstallation in the reverseorder to
removal.
* Assemble the center swivel as shown in the

diagram below.

level.
Bleeding
air a
* Bleed the air from the travel motor.
Bleeding air.
1 b DJP00845
a: Center swivel
b: Sprocket
30-41- 1 PC300, 350-6
0
ENTER
ASSEMBLY AND
DISASSEMBLY
DISASSEMBLY OF CENTER
PC300-6 Serial No.: 33601 - 43465
PC350-6 Serial No.: 12001 - 12283
1. Removecover (1).
2. Removesnap ring (2).
3. Using puller T, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4. Remove O-ring (6)andslipperseal (7) from

swivel rotor.
-6Q
ASSEMBLY OF CENTER 0
I

PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No.: 12001 - 12283 5
, rO swivel
1. Assemble slipper sea! (7) and O-ring (6’ +
rotor.
I
2. Set swivelshaft (5) to block, thenusingpush

B CEPO0381
i
tool, tap swivel rotor (4) with a plastic hammer
to install.
6 Contact surface of rotor, shaft:
Grease (G2-el)
* When installing the rotor; be extreme!)/ care-
ful not to damage the slipper seal and the
O-ring. T
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

Mounting bolt: 31.4 +. 2.9 Nm
(3.2 +. 0.3 kgm}
PC300, 350-6 30-41-2

0
DISASSEMBLY
SWIVEL CENTER
AND ASSEMBLY JOINT
DISASSEMBLY OF CENTER
1. Removecover ( I ) .
5
2. Removesnap ring (2).
3. Using puller T, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4. Remove O-ring (61, de;§: seal (81, and slipper

seal (7) from swivel rotor.
ASSEMBLY OF CENTER
SWiVEL 40iMT ASSEMBLY
1. Assemble slipper seal (7) and O-ring ( 6 )to swivel
rotor.
1
-///--a
i CWPO7209
2. Set swivelshaft (5) t o block, thenusingpush
tool, tap swivel rotor (4) with a plastic hammer
t o install.
Contact surface of rotor, shaft:
Grease (G2-LI)
* When installing the rotor, be extremely care-
ful not to damage the slipper seal and the
O-ring.
3. Install ring (3) and secure with snap ring (2).
4. InstallO-ring (6)anddust seal (81, theninstall

cover ( I ) .
Mounting bolt: 108 L 14.5 Nm
@ CWPOG I79
I l l . 0 2 1.5 kgm}
30-42 PC300, 350-6

0
ASSEMBLY
DISASSEMBLY AND FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove the track shoe assembly.
Fordetails, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Using work equipment, pushup track frame and
set block between track frame and link.
A Loosen the oil filler cap slowly to release the
pressure inside the hydraulictank.
3. R ~ ~ T o;rprockei.
v~
For details, see REMOVAL OF SPROCKET.
4. Removecover ( I ) .
5. Disconnectdrainhose (2).
* Set a container to catch the oil, then discon-
nect the hose and install a blind plug.
2 d m
6. Disconnect speed selectorhose (3) andmotor
hoses (4) and (5).
7. Slingfinaldriveassembly ( 6 ) , andremove
mounting bolts, then remove.
& Final drive assembly: 550 kg
INSTALLATION OF FINAL
DRIVE ASSEMBLY
e Carry outinstallation in thereverse orderto
remsva!.
Final drive mounting bolt:

549.1 2 58.8 Nm (56 * 6 kgmi
* Add oil through the oil filler to thespecified
level.
the system; Then check the GI! !eve! again.
Bleeding air
* %eea the air from the travei motor (hydrau-
lic tank).
Bleeding air.
PC300, 350-6 30-43

0
D DISASSEMBLY HNAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil
oil from final drive
Remove drain plug and drain
case.
b
Final drive case: Approx. 11
2. Cover
1) Removemounting bolts, thenuseforcing
screws @ to disconnect cover (1) from ring
gear.
2) Use eyebolts @ t o remove cover (1).
CEW0472
3. Spacer 2
Remove spacer (2). /
4. No. 1 carrierassembiy
1) Remove No. 1 carrier assembly (3).
1474
I I
30-44 PC300,350-6
0
DISASSEMBLY
FINAL AND ASSEMBLY DRIVE
Disassemble No. 1 carrier assembly as fol-

lows.
i) Push in pin (41, and knock out shaft (5) 8 4 7 6
from carrier (6).
.k After removing shaft (51, remove pin
(4).
ii) Remove thrust washer (71, gear (8),bear-
ing (91, and thrust washer (10).
9 5 10
CEW0475
5. No. 1 sun gearshaft

Remove No. 1 sun gear shaft (11).
II
6. No. 2 sungear
't
Remove No. 2 sun gear (12).
CWPOG I20 CWPOG 1 2 I
7. Thrustwasher
Remove thrust washer (13).
8. Ringgear
usin.; eyebc!ts 0,
remcve ring .;ear ( ? 4 ) .
PC300,350-6 30-45
0
DISASSEMBLY
FINAL AND ASSEMBLY DRIVE
9. No. 2 carrier assembly.

2) Disassemble No. 2 carrier assembl)/ as fol-

lows.
20 17 19 18
i) Push in pin (16)and pullout shaft (17)
from carrier (18).
* After removing the shaft, remove pin
(16).
ii) Remove thrust washer (IS), gear (201,
bearing (211, and thrust washer (22).
21 16 22
CEP00481
10, Nut
1) Remove lock plate (23).
2j ijsing iooi Ji, remove nut (24j.

J1
\7
-24
30-46 PC300. 350-6

0
0
Y
cii
N
m
n
W Q
0
m
-
N
c
n
DISASSEMBLY AND ASSEMSLY DRIVE FINAL
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
I 27. 20
* Clean all parts, andcheck for dirt or damage.
Coat the slidingsurfaces of all parts with engine
oil before installing.
1. Hub assembly
1) Assemble hub assembly as follows.
i) Usingpush tool, press fit bearings (28)
and (29) to hub.
ii) Using tool 54, install floating seal (26).

* Remove all oil and grease from the
O-ring and O-ringcontact surface,
anddrythepartsbeforeinstalling
the floating seal.
* Afterinstallingthefloating seal,
check that the angle of the floating
seal is within 1 mm.
* After installing the floatingseal, coat
the sliding surfacethidywitt; engine
oil.
2) Usingtool 54, installfloating seal (30)to

travel motor (31).
* The procedure for installation is the same
as in Step l)-ii)
above.
J4
3) Using eyebolts 0,
set hub assembly (25) to
travelmotor,then using pushtool,tapto
press fit bearing portion.
CEPOO484
30-48 PC300, 350-6

0
Lo
.,
3 g -
h)
P
Y
9)
v)
N
P
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7) Installlockplate (23).
I 2 1
*Installthelockplate as shown in the

diagram on the right.
& Thread of mounting bolt:
Thread tightener (LT-21
* Do not coat the threaded portion
of the nut with thread tightener
(LT-2).
=
Mounting bolt: 66.2 7.4 Nm
i6.75 t 0.75 kgm)
Casting notch
Install toplace where there is no
casting notch. Bring lockplate and
spline of motor into tight contact. CEP00494
3. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as follows.
* Thereare the remains of thecaulking
20 19 18
when the pin is inserted a t the end face
of hole h at the side of the carrier, so
remove the caulked metal from the in-
side diameter of the hole before starting
to assemble.
i) Assemblebearing (21) to gear (201, fit
top and bottom thrust washers (19) and
(221,andset gear assembly incarrier 21 h 22
(18). CEP00495
iij Aiign with positiorl of pin h i e s of shaft 7

and carrier, then tap with a plastic ham- 17
mer to install shaft (17).
When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
iii) Insert pin (16).
* After inserting the pin, caulk the pin
portion of the carrier.
* Afterassemblingthecarrierassembly,
check that gear (20) rotates smoothly.
CEFU0496
30-50 PC300, 350-6

0
2) Install No. 2 carrier assembly (15).

-A: Align the position so that the three tips
of the gearshaftsofcarrier assembly
(15) enter the three hollows in the end
face of the motor case, then install.
4. Ring gear
Fit O-ring to hub end, then using eyebolts 0,
install ring gear (14).
* Install so that the side with two grooves ma-
chined in the outside circumference of the
ring gear is at the top (cover end).
* Remove all grease and oil from the mating
surface of the ring gear and hub.
* Do not put any gasket sealant on the mating
surface of the ring gear and hub under any
circumstances.
5. Thrust washer
Install thrust washer (13).

1) Asseinble No. 1 carrier assembiy as ioiiows.
I
It Therearetheremains ofthecaulking 1 8 h 7 fi
when the pin is inserted a t the end face
of hole h a t the side of the carrier, so
side diarnet9r of the he!e befcre starting
to assemble.
i) Assemble bearing (9) to gear (8), fit top
and bottom thrust washers ( 7 ) and (10) \
and set gear assembly to carrier (6). 10
I CEP00498
~-~
PC300, 350-6 30-51

0
ii) Align position of pin holes of shaft and

carrier, then tap with a plastic hammer
to install shaft (5).
1 4
* When installing the shaft, rotate the
planetary gear, and be careful not to
damagethethrust washer. I
iii) Insert pin (4).

.k After inserting the pin, caulk the pin
portion of the carrier.
* Afterassemblingthe carrier assembly,
l 8 5
check that gear E ! rotates smo0th!y.
I CEW0499
2) Install No. 1 carrier assembly (3).

I ,3

1) Assemble No. 1 carrier assembly as follows.
* Thereare the remains of the caulking 8 h 7 6
when the pin is inserted at the end face
of hole h at the side of the carrier, so
side diameter of the hole before starting
to assemble.
i) Assemble bearing (9) to gear (81, fit top
and bottom thrust washers (7) and (IO)
9
/ \10
and set gear assembly to carrier (6).
CEF'O0498
9. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11). I 11
30-52 PC300, 350-6

0
AND DISASSEMBLY ASSEMBLY FINAL DRIVE
IO. Spacer 2
Install spacer (2). /
/ p h
CEP00473
11. Cover
1) Using eyebolts @, install cover ( I ) .
Mounting surface of cover:
Gasket sealant (LG-6)
CEP00472
2) Using tool 53, tighten mounting bolts.

Mounting bolt: J3
Initial torque: 98.1 Nm (10 kgml
Additional tightening angle:
100 - 110"
Refillins with oil

* Tightendrainplugandaddengine oil
through oil filler.
Final drive case: Approx. 11

* Carry out a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
PC300, 350-6 30-53

0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY OF TRAVEL
MOTOR ASSEMBLY
4. Travel motorassembly
Set travel motor assembly (1) to tool S25.
I CLPOO688
2. Plug, piston
Loosenplug (2) slowlyandremove,then
move spring (3) and piston (4).
AThere is a force
re-
of approx. 294 N I30 kg)

I *\ 4
applied to the plug, so pushtheremoval b o

tool at a rightangle when loosening theplug.
I /;""
3
CLW0689
3. End coverassembiy, valve plate

1) Turn over tool S25 and remove safety valve
assembly (5).
2) Loosen plug ( 6 ) slowly.
3) Lift off end cover (7).

* The valve plate may be stuck to the end
cover, so be careful not to dropit.
CKP00690
4) Removevalve plate ( 8 ) .
* When using again, keep in a safe place 8
and be careful not to scratch or damage \
the cylinder block contact surface.
5 ) Remove outer race (91, then remove spacer

(10).
I CKP00691
30-53-
1 PC300, 350-6
0
DISASSEMBLY
TRAVELAND ASSEMBLY MOTOR
6 ) Disassembly of end cover assembly

i ) Loosen plug (6)slowly and remove, then
remove spring(1I),piston (121, and spool
(13).
A There is a force of approx. 441 N (45

kg) applied to the plug, so push the
removal tool at a right angle when
loosening the plug.
ii) Remove plug (141, then removespring

(15) and valve (16).
iii) Remove ring (17), then remove seat (181,

spring (191, and spool (20).
iv) Remove plug (211, then remove ball (22). 1

v)Removeplug (231, then removevalve
(241. 11 23
4. Spring
Remove parking brake spring (25).
CLPO0693
PC300, 350-6 30-53-2

0
5. Brakepiston
Blow in compressed air with tool 526, and re-
move brake piston (26).
Ir Air pressure: 0.2MPa(2 kg/cm2)
* Be carefulthatthe air pressure is not too
high. The brake piston will fly out.
6. Bearing
Using bearing race puller @ and gear puller 0,
remove bearing (27).
* Be careful not toapply any force to the bear-
ing holder.
& Whenusing the cylinder b!ock again, put
gasket paper on the valve plate contact sur-
face to protect the surface.
* Never allow the puller to scratch or damage
the cylinder block sliding surface.
k.----4 CLP00695
7. Cylinderblock,pistonassembly
Rotate tool S25 go", and remove cylinder block C 28
and piston assembly (28) from motor case (29).
* The cylinder block and piston assembly may
come off separately, so becarefulnotto
drop them.
I \
CKP00696
Disassembly of cylinder block, piston assem-

bly
1) Remove plate (30) and disc (31).
2) Pull out piston assembly (33) from cylin-

der block (321, and remove retainer guide
(34) and preload pin (35).
* When removing the piston assembly
from the cylinder block, the preload
pin may come out, so be careful not 35
to lose it.
-. CKP00697
30-53-3 PC300, 350-6

0
Disassembly of piston assembly

Pull out piston (37) from retainer shoe (36).
I ”‘\
36’
CKP0069E
Disassembly of cylinderblock
1) Set tool S27 to cylinder block (32). I 40 32
2) Hold bolt of tool S27 with wrench, tighten

nut to compress spring, then remove snap
ring (38).
3) Loosen nut of tool S27 slowly to relieve ten-

sion of spring (391, then remove tool S27.
4) Remove spacer (401, spring (39), and spacer

(40) from cylinder block (32). 39
CKP00699
8. Rocker cam,shaftassembly
1) Remove rocker cam (41) together with shaft
assembly (42) from motor case (29).
I
\42
41
CKP00700
2 j using push tooi @, remove bearing (44j from

shaft (43).
44
CKPOO701
PC300, 350-6 30-53-4

9. Disassembly of motor case

1) Remove ball (45).
2) Rotate tool S25 go", remove snap ring (46)

from motor case (29f, then remove spacer 46
(47).
3) Remove oii seal (489.

47
4) Remove outer race (49).
CKP00702
10. If above disassembly operation is not needed, I

and only oil seal is to be replaced, replace oil
seal as follows.
1) Remove snap ring (46) and spacer (47).
2) Using bar 8(hit end face with hammerIi hit

through to core of oil seal (481, then twist to
remove.
*
*
Hit at a point midway between the
side andoutsidecircumference
in-
of the
oil seal, and twist a t two places on op-
posite sides (A and B in d'iagram) to re-
move.
Be careful not to damage the shaft case.
i'" I
4a w DVPOO763
30-53-5 PC360, 350-6

0
DISASSEMBLY
TRAVELAND ASSEMBLY MOTOR
ASSEMBLY OF TRAVEL
MOTOR ASSEMBLY
Clean all parts, remove all burrs, and check for dirt
or damage. Coat the rotating and slidingsurfaces of
all parts with engine oil (E010-CD) before installing.
Always check the following partsbefore assembling.
* This check isunnecessaryifboththecylinder
block and valve plate are replacement parts (new
parts).
Check contact between cylinder block and valve

plate (Fordetails,seeprocedureforchecking
contact.) 49 CKPW704
1. Motor case
1) Using push tool 0,
press fit outer race (49).
2) Set motor case (29) to tool S25.
3)Installball (45).
I CLw0705
2. Rockercam, shaft assembly

1) Using tool S28, press fit bearing (44) to shaft
(43) to make shaft assembly (42).
1
* When press fitting the bearing, push the
end face of the bearing inner race with
44
tool S28 and press fit until it is in tight
contact with the end face of the shaft.
Sr Press-fittingload:
2,392 - 9,787 N {244 - 998 kg) 43
Press-fitting surface of bearing:
Lubricating oil (EO10-CD)
I CKP00706
2) Instalf rocker cam (41) to motorcase (29)

together with shaft assembly (42).
* When installing the rocker cam, check
the contact with the ball, and check
that the rocker cam moves smoothly
withoutinterferingwiththemotor
case or shaft.
* Coat the ball hole in the rocker cam
with grease (G2-LI). (To prevent the
ball from coming out when the cyi-
inder block and piston assembly is
assembled.)
PC300, 350-6 30-53-6

0
D DISASSEMBLY TRAVEL MOTOR
3. Cylinderblock, piston assembly

e Assembly of cylinderblock 40 32
1) Assemble spacer (401, spring (391, and spacer
(40) to cylinder block (32).
2) Set tool S27 to cylinder block (32).
3) Mold b d t Qf tool s27 With wrench, tighten

nut to compress spring (391, then install snap
ring (38).
* Check that the snap ring is fitted securely
in the groove. 39
CKPOO699
4) Remove tool S27.
Assembly of pistonassembly 37
5) Assemble piston (37) to retainer shoe (36).
Assembly of cylinderblock, piston assembly

36'
B CKW0698
6) Assemble3 preloadpins(35) tocylinder 32

\
block (32).
* Coat thepreloadpins with grease(G2-
LI) to prevent them from coming out.
7 ) Assembleretainerguide(34) tocylinder
block (321, then assemble piston assembly
(33) to make cylinder block and piston as-
35
sembly (28).
* Align the cylinderblockandthespline
of the retainer guide. -.
'43
- 33
CKP00708
Assembly of cylinderblock and piston assem-

bly
I 7 / / I
8) Secure shaft assembly in position with tool
S29.
9) Rotate tool S25 90" and set opening of mo-

tor case facing side.
I CLW0709
30-53-7 PC300, 350-6

0
0 , w
0
<
V
0
0
4
m
P
DISASSEMBLY
TRAVEL AND ASSEMBLY MOTOR
* Assemble so that the groove in the brake r
piston is aligned with the dowel pin in

the end cover. Dowel D i n
I DVP00765
5. Adjusting end play of shaft

1) Using tool S30 and puller 0, press fit bear-
r
ing (27) to shaft (43).
tool S30 and press fit until it is in tight
contact with the end face of the shaft.
* Press-fitting load:
2,667 - 10,963 N (272 - 1, I 18 kg)
Press-fitting surface of bearing:

CKP00714
2) Assemble spacer ( I O ) t o end cover (71, and

install outer race (9). 9 10
* Assemble the same spacer that was re- 8\ I I
moved.
3) Align with dowel pin and install valve plate

( 8 )t o end cover (7).
* Check that there is no interference with
the bearing and pin.
* Do not hit the valve plate or apply any
impact when assembling.
(There is danger that this will damage CKP00691
the sliding surface or cause distortion.)
4) Install end cover (7) to motor case (29).

* Do notinstalltheO-ring and springof
the parking brake.
Mounting bolt:
461 r 29 Nm {47 c 3 kgrn}
5) Fit dial gauge @ to motor case (291, move

shaft in axial direction, and measure end
play between shaft and bearing.
* End play: 0.05 - 0.25 m m 1
7
L
CKP00715
30-53-9 PC300, 350-6

0
6) If dimensionisnotwithinstandard value,
adjust again as follows. 9
\
d
i) Removeend cover.
ii) Remove valve plate and outer race.
iii) Set outer race (9) to bearing, then meas-

ure dimension a betweenend face of
cuter race and case, and ca!cu!ate spacer
b from the following formula.
b = 12.95 - a CKW0716 I
.k Be careful not to install the shaft at
an angle.
.j, Measure at several places and take
the average value as "a".
iv) Select spacer from table below.
T!Spacer part No.

1.70 - 1.79 708-8H-32220
1.80 - 1.89 708-8H-32230
1.90 - 1.99 708-8H-32240
Spacer to 2.00 - 2.09 708-8H-32250
select 2.10 - 2.19 708-8H-32260
2.20 - 2.29
2.30 - 2.39
i 708-8H-32270
708-8H-32280
v) Fit selected spacer, then assemble again

according t o assembly Steps 5-21 - 5-51,
and measure end play.
vi) After completion of adjustment, remove

end cover, then remove valve plate.
6. End cover assembly

1) Assembly of end cover assembly
* Precautionswheninstalling plug
Removealloil and grease fromthe
plug and female thread tend cover),
and dry completely.
Whencoating with adhesive, coat
with two drops tapprox. 0.04 g) at a
point 2 - 3 mm from the tip of the
thread of the plug.
6 Plug: Thread tightener
(Loctite 638/648)
Do not apply any pressure to the plug DUP00746
for 30 minutes after tightening.
PC300, 350-6 30-53-1 0

0
D DISASSEMBLY
Assemble valve (241,then fit O-ring and

install plug (23).
Plug (23):
23.5 3 3.9 Nm {2.4 0.4 kgml
II Assemble ball (221, then fit O-ring and

install plug (21).
Plug (21):
23.5 t 3.9 Nm 12.4 z G.4 lcgmi
0
0
iii) Assemble spool (20),spring (191, and seat 15-
0
(18)in order, then fit O-ring and install

ring (17). 16 ---%
iv) Assemblevalve (16)and spring (15)in

order,then fit backup ringandO-ring
1
and install plug (14).
Plug (14):
‘% 23
137.4 14.7 Nm i14 = 1.5 kgm) /
Assemble spool (131, piston (121, and

spring (11) in order, then fit O-ring and
tighten plug (6) temporarily.
15-$
&I
v 1
v
0
14
CLF’00692
30-53-11 PC300, 350-6

0
DISASSEMBLY
TRAVEL AND ASSEMBLY MOTOR
2) Align with dowel pin, and install valve plate

(8)to end cover ( 7 ) . 8 7
(There is danger that this will damage
3) Install parking brake spring (25).
4) Fit O-ring, align dowel pin with groove por- CKPW718

tion of brake piston, and install end cover
(7).
* Be extremely careful that the O-ring does
not come out or get caught.
Mating surface of motor case:
Gasket sealant (LG-7 or LG-5)
Mounting bolt:
461 2 29 Nm I47 2 3 kgm) &J
5) Tightenplug (6).
Plug (6):
419.2 z 46.6 Nm (42.75 r 4.75 kgml
6 ) Fit backup ring and O-ring, and install safety CKP00719
valve assembly (5).
Safety valve assembly:
318.7 z 24.5 Nm 132.5 z 2.5 kgml
7. Plug, piston
Assemble piston (4) and spring (3), then fit 0-
ring and install plug (2).
* Precautions when installing plug
1) Remove all oil and grease from the plug
and female thread (motor case), and dry
completely.
2) Whencoating with adhesive, coat with

two drops (approx. 0.04 g) at a point 2 -
3 mm from the tip of the thread of the
nlc an
rn-a.
Plug (2):
Thread tightener (Loctite 638/648)
b
9:”
Plug (2):
362.8 +. 39.2 Nm (37 +. 4 kgm)
3) Do not apply any pressure to plug for 30 3

minutes after tightening.
CLP00689
PC300,350-6 30-53-12
0
D DISASSEMBLY MOTOR
8. Installation of oil seal

1) Check that there are no burrs or flashes a t
the corners of the shaft. s3’
2) Using tool S31, press fit oil seal (48).
.Lr Press fit until the end face of the motor
case contacts tool S31.
-Lr Cieanthe oil seal lip.
Tip of oil seal lip (whole circum-
ference): Grease iG2-LE-5)
DUPO074E CKP00721
3) Assemble spacer (471, and install snap ring

(46). 46, e7
30-53-13 PC300, 350-6

0
ASSEMBLY
DISASSEMBLY AND TRAVEL MOTOR
CHECKING CONTACTBETWEENCYLINDER
BLOCK AND VALVE PLATE
This check is unnecessary if both the cylinder Centerine tool

Cylinder block / Valve P l a t e
block and valveplate are replacement parts (new
parts).
This check applies if one of the parts is a re-
placement part or a restored part.
If the contact is defective, use a surfaceplate
\
and correct by lapping.
Make a centering tool for the cylinder block and

valve plate.
* The tool can be made from plastic, bakelite DUP'007
or any other soft material.
Remove all oil and grease from the parts t o be
checked.
* Do not wipe with a cloth.
Set the tool in position, then paint the cylinder
block with inspection paint.
* Coat thinly with paint.
Push the valve platewith a force of 39 - 49 N (4
- 5 kg) against the cylinder block, turn thevalve
plate 90°, then turn it back to the original posi-
tion. Repeat this process 2 or 3 times.
Remove the valve plate, transfer the contact sur- Contact at s e a l p o r t i o n : Cantact a t land portion:
face t o a tape, and check the contact surface. R a n o ea t l e a s t 80% R a n o e at least 60%
.k The contact of theplane surface of the valve DUPOO749

plate and cylinder block must fulfill the con-
ditions below and must cover the whole cir-
cumference without any break.
i) The contact at the seal portion (range of
4B4.4 - $1 16.5 mrn from the inside) must
be at least 80%.
ii) The contact at the land portion (range of
$128 - @I42 mrn) must be at least 60%.
For details of theoperation, see the Parts Judge-

ment Guide.
PC300, 350-6 30-53-

14
0
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL OF SPROCKET
1. Removetrackshoeassembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Swing work equipment 90°, then push up chas-

sis with work equipment and set block (ijbe-
tween track frame and track shoe.
3. Remove mounting bolts, then lift off sprocket

(1). p g
& Sprocket : 70 kg
INSTALLATION OF SPROCKET
0 Carry outinstallation in the reverse orderto
removal.
aThread of sprocket mounting bolt:

Thread tightener (LT-2)
Sprocket mounting bolt:
=
637.4 2 49.1 Nrn (65 5 kgm)
30-54 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING MOTOR

ASSEMBLY
Release the remaining pressurein the hydraulic
circuit.
cuit.
pressure inside the hydraulictank.
* Fit blindplugs in thedisconnected hoses and
tubes.
1. Disconnect suction hose (11.
2. Disconnect swing hoses (2).
3. Disconnect drain hoses (3) and (4).
4. Disconnect swing holding brake hose (5).
5. Remove mounting bolts, and lift off swing rno-
tor assembly (6).
6 Swing motor assembly: 110 kg
INSTALLATION OF SWING
MOTOR ASSEMBLY
Carryoutinstallationinthe reverse orderto
removal.
Refiiiing with oii ikydrarislie ianki

levei.
Run the engine to circufate the oil through
Bleeding air
* Bleed the air from the swing motor.
Bleeding air.
PC300, 350-6 30-55

0
DISASSEMBLY OF SWING
MOTOR ASSEMBLY
KMF160ABE-3 WITH BRAKE
1. Motor assembly
Set swing motor assembly (1) to tool Y3.
2. Reverse prevention valve assembly

Remove reverse prevention valve assembly (34)
and O-rings (35) and (36).
3. Housing
1) Remove covers (2), springs (3), and safety-
suction valve assemblies (4).
2) Remove housing mounting bolts (5).
3) Using hanging bolts 1 (Thread dia. = 12 mm,
Pitch = 1.75 mm), lift off housing (6).
fl When removing the housing, springs (7)

may come off. Take care.
4) Remove 6 springs (7) from the valve case.
30-55-1 PC300, 350-6

5
4. Valve plate
Remove valve plate (8).
5. Cylinder block
Remove cylinder block (9).
6. Spring
Remove spring (10) and center ring (11).
7. Retainer
Using tool Y2, remove 7 mounting screws and
retainer (12).
8. Shaft and pistons

Remove center shaft (13) and 7 pistons (14).
9. Brake piston
1) Using tool Y12, supply air through port B to
remove brake piston (15).
fl Air pressure: 0.2 MPa {2 kg/cm2}
fl If the air pressure is high, the brake pis-
ton may jump out. Take care.
2) Remove O-rings (16) from the piston.
10. Plates and discs

1) Remove plates (17) and discs (18).
2) Remove plates (19).
fl Plates (17) and (19): 5 pieces
Discs (18): 3 pieces
PC300, 350-6 30-55-2

5
11. Cover
1) Remove the case assembly from tool Y1 and
turn it over.
2) Remove snap ring (20) and cover (21).
fl Apply a screwdriver, etc. to part a to
remove cover (21).
3) Remove oil seal (22) from cover (21).
12. Shaft assembly

1) Remove snap ring (23) and 2 spacers (24).
2) Set the case assembly to a press and re-

move shaft assembly (25) from case (26).
3) Remove bearing (27) from shaft (28).
13. Bearing, seat, and belleville spring

1) Remove bearing inner race (29) from the
case.
2) Remove bearing outer race (30).
3) Remove seat (31) and belleville spring (32).
4) Remove main bearing outer race (33).
30-55-3 PC300, 350-6

5
ASSEMBLY OF SWING MOTOR

ASSEMBLY
KMF160ABE-3 WITH BRAKE
Clean the all parts and remove burrs, etc.

Coat the rotating and sliding parts with engine oil
(EO10-CD) before installing. Remove the all lapping
powder from the lapped parts with chromium ox-
ide.
1. Outer race
Using push tool 2 (Outside diameter: 159 mm),
press fit outer race (33) to the case.
2. Shaft assembly
1) Using tool Y4, press fit bearing (27) to the
shaft.
fl Press fit the bearing until the inner race
end is fitted to the shaft.
Press fitting load:
7.72 – 39.2 kN {787 – 4,000 kg}
2) Set shaft assembly (25) to block 3 (130 mm
in diameter and 50 mm in height), then in-
stall case (26).
3. Belleville spring, seat, and bearing

1) Install belleville spring (32) and seat (31).
fl Install the belleville spring as shown in
View A.
2) Using tool Y5, install outer race (30).
PC300, 350-6 30-55-4

5
3) Using tool Y6, press fit bearing (29).

fl While press fitting the bearing, turn case
(26) to check that the bearing turns
smoothly.
fl Press fit the bearing until seat (31) is
fitted to case (26).
fl Load to press fit bearing:
3.92 – 20.0 kN {400 – 2,055 kg}
4. Spacer
1) Measure clearance a between the bottom
of snap ring (23) and top of the bearing in-
ner race. Then, select 2 spacers (24) having
thickness equivalent to clearance a from the
following table and install them.
Part No. of spacer (24) Thickness

1 706-77-42440 2.3 mm
2 706-77-42450 2.5 mm
3 706-77-42460 2.7 mm
fl Standard thickness of spacers: 5.1 mm

2) After installing spacers (24), install snap ring
(23).
fl Check that the snap ring is fitted to the
snap ring groove securely.
3) Pressing out drive shaft

i) Set tool Y7 to case (26) and press out
the drive shaft with the following load
until the end of bearing inner race (29) is
fitted to snap ring (23).
fl Load to press out drive shaft:
3.92 – 16.18 kN {400 – 1,650 kg}
ii) After the bearing inner race is fitted, ap-
ply the load of 21.58 kN {2,200 kg} fur-
ther and check that spacer (24) is fitted
and cannot be turned with the hand.
30-55-5 PC300, 350-6

5
4) Check the axial clearance between case (26)

and seat (31) according to the following pro-
cedure.
i) Using tool Y7, apply a load of 4.90 – 21.6
kN {500 – 2,200 kg} to the drive shaft end
and measure the moving distance of the
drive shaft and check that it is in the
standard range.
fl Moving distance of drive shaft:
0.1 – 0.4 mm
ii) If the moving distance of the drive shaft

is out of the standard range, replace the
spacers as explained below.
• When the clearance is less than 0.1
mm
Replace the spacers with 706-77-
42440 and install the snap ring.
• When the clearance is larger than 0.4
mm
Replace the spacers with 706-77-
42460 and install the snap ring.
• Measure the moving distance of the
drive shaft according to steps 4-3) –
4) and check that the clearance is in
the range of 0.1 – 0.4 mm.
iii) Set the motor case to tool Y1 and meas-

ure the revolving torque of the drive shaft
with tool Y8.
fl Revolving torque of drive shaft:
1.47 – 4.90 Nm {0.15 – 0.50 kgm}
fl When measuring the revolving
torque, supply sufficient oil to the
bearing and turn the drive shaft at
the speed of about 1 turn in 5 sec-
onds.
PC300, 350-6 30-55-6

5
fl If the revolving torque is not in the

range of 1.47 – 4.90 Nm {0.15 – 0.50
kgm}, replace bearings (27) and (33)
with new ones and adjust again.
5. Cover
1) Using tool Y9, press fit oil seal (22) to cover
(21).
2) Install cover (21) and snap ring (20).
fl When installing the cover, take care not
to damage the oil seal lip.
2 Oil seal lip: Grease (G2-LI-S)
6. Plates and discs

Install plates (19), discs (18), and plates (17) to
the case.
fl Plates (17) and (19): 5 pieces
Discs (18): 3 pieces
fl Before installing the discs, apply lubricating
oil to their surfaces.
fl Do not clean the discs with trichloroethylene
or denatured alcohol or blow air strongly
against them.
2 Disc surfaces:
7. Brake piston
1) Install O-rings (16) to the piston.
2) Install brake piston (15).
30-55-7 PC300, 350-6

5
8. Pistons and shaft

1) Set 7 pistons (14) and center shaft (13).
2) Using tool Y2, tighten 7 retainer mounting
screws.
fl Replace the retainer mounting screws
with new ones.
2 Screw: Liquid adhesive
(LT-2, LOCTITE #262, or equivalent)
3 Screw:
1st time: Max. 0.9 Nm {Max. 0.1 kgm}
2nd time:
3.92 – 5.88 Nm {0.4 – 0.6 kgm}
3rd time:
11.77 – 14.7 Nm {1.2 – 1.5 kgm}
(Target: 13.24 Nm {1.35 kgm})
fl Degrease and dry the threaded parts
(male and female) thoroughly.
fl Tightening order: 1 – 4 – 7 – 3 – 6 –
2 – 5 in either direction
fl After tightening the screw, check that liq-
uid adhesive is not projected.
fl After tightening the screws, check that
the large sphere of piston (14) and center
shaft (13) move smoothly.
3) Measure the axial play of piston (14) with

dial gauge 5.
fl Axial play of piston: Max. 0.40 mm
9. Spring
1) Set housing (6) to tools Y10 and Y1 and
adjust its angle so that the valve plate mount-
ing face will be level.
2) Install valve plate (8).
PC300, 350-6 30-55-8

5
3) Install cylinder block (9) to housing (6).

4) Install spring (10) and center ring (11) to the
cylinder block.
5) Install 6 springs (7) to the housing.
6) Press fit dowel pin (34).
fl Drive the dowel pin with tool Y11 so

that standard dimension a will be ob-
tained.
fl Standard dimension a: 9 ± 1.0 mm
fl Fit the tapered side to the hole of the
housing.
fl Take care not to damage the dowel pin
and brake piston.
10. Sling the motor case assembly and lower it

gradually, matching it to the housing and match-
ing the 7 center shaft pistons to the holes of the
cylinder block, and install it to housing (6).
2 Mating face of case:
Liquid adhesive [LG-7 (ThreeBond
1207C), LOCTITE #572, #575, or
Sealend #242]
fl When installing the motor case, position it
to the dowel pin securely.
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
11. Set swing motor assembly (1) to tool Y1.
12. Install safety-suction valves (4), springs (3), and

covers (2).
2 Mating face of cover:
Liquid adhesive [LG-7 (ThreeBond
1207C), LOCTITE #572, #575, or
Sealend #242]
3 Cover mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
30-55-9 PC300, 350-6

5
13. Reverse prevention valve assembly

Fit O-rings (35) and (36) and install the reverse
prevention valve assembly.
2 Mating face:
Gasket sealant (LOCTITE #222 or
Sealend #242)
3 Mounting bolt:
1st time: 15 – 20 Nm {1.5 – 2.0 kgm}
2nd time: 27 – 34 Nm {2.8 – 3.5 kgm}
fl Tighten the mounting bolts in diagonal or-
der.
fl Check that O-rings (35) and (36) are fitted
securely.
14. Check of revolving torque of drive shaft

1) Using tool Y3, apply hydraulic pressure of
2.94 ± 0.49 MPa {30 ± 5 kg/cm2} through port
B to release the brake.
2) Set tool Y8 and measure the revolving

torque.
fl Check that the drive shaft revolves with-
out uneven revolving torque.
Unevenness of revolving torque:
Max. 1.47 Nm {Max. 0.15 kgm}
Revolving torque:
5.9 – 15.2 Nm {0.60 – 1.55 kgm}
fl If the revolving torque is out of the above
range, repeat the adjustment from Step
4.
PC300, 350-6 30-55-10

5
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Remove swing motor assembly.
For details, see REMOVAL OF SWING MOTOR
ASSEMBLY.
2. Remove mounting bolts (1).
3. Sling swing machinery assembly (21, screw in

forcing screws @ t o separate swing machinery
fro= frame, then lift ~ff.
& Swing machinery assembly: 331 kg
MACHINERY ASSEMBLY
removal.
Swing machinery case mounting bolt:

927 2 103 Nm 194.5 f 10.5 kgml
PC300, 350-6
DISASSEMBLY OF SWING
MACHINERY ASSEMBLY
1. Draining oil
Loosen drainpluganddrainoilfromswing
machinery.
b
Swing machinery case: Approx. 12.5 t
2. Cover
Remove mounting boits, tnen iift oii cover (7 j.
3. No. 1 carrierassembly.
1) Remove thrust washer (2).
2) Remove No. 1 sun gear (3).

4
4. Disassemble No. 1 carrier assembly as follows.

1j Push in pin i5j, and knock out shaft ( 6 ) from
carrier (7).
*
After removing the shaft, remove pin (5).
2) Remove thrust washer (8), gear (9),bearing
(lo), and thrust washer (11).
PC300, 350-6 30-57

0
Y
L
[o
a,
0)
i"
.._
Z
pbl 0
8. Disassemble No. 2 carrier assembly as follows.

1) Push in pin (18), and knock outshaft (19)
19 22 17
from carrier (17).
*Afterremovingthe shaft, removepin
(18).
2) Remove thrust washer (201, gear (211, bear-
ing (22), and thrust washer (23).
i 1'8
CEP00213
9. Pinion shaft assembly.

1) Remove bolt (241, then remove holder (25).
2) Removegear (26).
3) Turnover case andpinion assembly, then

remove mounting bolts(28) of cover assem-
b!t" ?27?.
27
28
I CEWOZ 15
4) Turnover case andpinion assembly (29),

ana set on press stand, then using push tooi
0, remove pinion shaft assembly (30)with
press.
* Set a wooden block under thepress, and
be careful notto damage the pinion shaft
assembly when :emoving it.
J CEW0216 CEP00217
PC300, 350-6 30-59

0
18; Disassemble pinion shaft assembly as f ~ h w s . i

1) Using push tool @, remove cover assembly
(27) and bearing (31) from shaft (32). 33
2) Remove oil seal (33) from cover (27).
iJ
I
CEW0218
I
1
27
CEPOD219
11. Bearing
Using push tool, remove bearing (34) from case 35 34
(35).
CEP00220
30-60 PC300, 350-6

0
ASSEMBLY OF SWING
MACHINERY ASSEMBLY
n
* Clean all parts, and check for dirt or damage.

Coat the sliding surfacesof all parts with engine
oil before installing.
1. Bearing
Using push tool0,
press fit bearing (31) to case
(35).
2.Coverassembly I
11 Using push tool 0, press fit oil seal (33)t o

cover (27).
a Outside circumference of oil seal:
* Be careful not to let the gasket sealant
(LG-6) get on the oil seal lip when press 27
fitting.
1 33/ CWPO6140
2 ) Fit coverassembly (27)to case (35),and

tighten mounting bolts (28).
27
+c Be careful 2 ~ tct !et the gasket sealant
(LG-61 get on the oilseal lip when press
fitting.
& Cover mounting surface:
Mounting bolt: 66.2 t 7.4 Nm
=
I6.75 0.75 kgm)
6 Lip of oil seal: Grease (G2-Ll)
CWPOG I 4 1
3. Caseassembly
l j Sei case assembiy (35)to shaft (32j,then
using push tool 0, press fit bearing inner
race portion.
* When setting the case assembly to the
shaft, be extremely careful not to dam-
age the GI! sea!.
I I
CWPO6142
PC300, 350-6 30-61

0
2) Bearing
Using tool F, press fit bearing (34).
* Press thebearinginner race and outer
raceat the same time when press fit-
ting. Do not press only the inner race
when press fitting.
* After press fitting the bearing, check that
the case rotates smoothly.
3) Gear, holder
Assemble gear (261, then fit holder (25) and
tighten bolt (24).
Mounting bolt:
Mounting bolt: 388 z 46.6 Nm
138.75 2 4.75 kgn)
CEWOPll
4. Assemble No. 2 carrier assembly as follows

* There are the remains of the caulking when 22
the pin is inserted at the end face of hole h 20 I
at the side ofthe carrier, so removethe
caulkedmetal from the inside diameter of
the hole before starting t o assemble. 21
1) Assemblebearing (22) to gear (211, fit top
and bottom thrustwashers (23)and (20) and 23
set gear assembly to carrier (17).
I
F
ti
CEP00226
2: Align with position of pin holes of shaf aiid

carrier, then tap with a plastic hammer to 21 19
install shaft (19).
* When installing the shaft, rotate the plan-
etary gear, and be careful not to dam-
age the thrust washer.
3) Insert pin (18).
* After inserting the pin, caulk the pin por-
tion of the carrier.
* Afterassemblingthecarrierassembly,
check that gear (21) rotates smoothly. 18
CEP00227
30-62 PC300, 350-6

0
BLY AND
DISASSEMBLY . SWING MACHINERY
8. Assemble No. 1 carrier assembly as fol!sws.

* There are the remains of the caulking when
the pin is inserted at the end face of hole h
atthe side ofthe carrier, so removethe
caulked metal from the inside diameter of
the hole before starting toassemble.
1) Assemblebearing (10) t o gear (9), fit top
and bottom thrust washers ( 8 ) and (11) and
set gear assembly to carrier (7).
9 11
CEPOOZZB
Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to in-
stall shaft (6). 5
* When installing theshaft, rotate the plan-
\
etary gear, and be careful not to dam-

age the thrustwasher.
Insert pin (5).
Jr After inserting the pin, caulk the pin por-
tion of the carrier.
* Afterassemblingthecarrier assembly,
check that gear (9) rotates smoothly.
l 9 6
CEP00229

Install No. 1 carrier assembly (4). 4
10. No. 1 sun gear

1) Assemble No. 1 sungear (3)to carrier as-
sembly.
2) Install thrust washer (2).
30-64 PC300, 350-6

0
11. Cover
Install cover (1).
6 Cover mounting surface:
Mounting bolt: 1st pass: 98 Nm {IO kgm}
2nd pass: 80 - 90"
12. Refiliing with oil

Tighten drain plug and add engine oil through
oil filler.
& Swingmachinery case: Approx. 12.5 t
PC300, 350-6 30-65

0
DISASSEMBLY AND ASSEMBLY FRAME REVOLVING
REMOVAL OF REVOLVING
FRAME ASSEMBLY
1. Remove work equipment assembly.
For details, seeREMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
a When disconnecting the hydraulichoses, release
the remaining pressure in the hydraulic circuit.
For detaiis, see TESTiNG AND ADjuSTiNG, Re-
cuit.
2. Disconnect boom cylinder hoses ( I ) .
* Fit blind plugs in thehoses and make it pos- /I 1 \' CEP00391
sible to swing the upper structure.
1
3. Raise boom cylinder assembly (21, then pull out
foot pin (3) and lift off.
* Remove therightcylinderassembly in the
same way.
& Boom cylinder assembly: 300 kg
4. Remove counterweight assembly.

For details, see REMOVALOF COUNTERWEIGHT
ASSEMBLY.
!
5. Remove engine hood (41, cover (51, and frame
(6).
* For detailsofthemethodofremovingthe
engine hood, see REMOVAL OF HYDRAULIC
COOLER ASSEMBLY.
6. Leave 3 mounting bolts each at front and rear of

revolving frame,and removeothermounting
bolts.
* Swing the upper structure and set to a posi-
tion where it is easy to remove the mount-
ing bolts. 6 CEP00393
PC300-5Serial KO.: 3300: ~ 33455, rc350-5 Serial No.: :00: ~ :::33

7. Disconnect drain hoses (7) and ( 8 ) .
* Install blind plugs in the drain hoses.
8. Disconnect travel hoses (9) and ( I O ) , and speed

selector hose (11).
9. Pull out pin (121, and disconnect plate (13) from

swivel joint.
30-66 PC300, 350-6

0
DISASSEMBLY
REVOLVING
AND ASSEMBLY FRAME
PC300-6 Serial No.: 33466 and UI). PC350-6 Serial No.:12284 and uu
IO. Slingrevolvingframe assembly (14), then re-

move mounting bolts, and lift off revolving frame
assembly.
* Use 2 leverblocks.
* Loosen the mounting bolts remaining at the
front and rear and adjust the center of grav-
ity with the lever block while lifting off.
& Revolving frame assembly: 7000 kg
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
Carry outinstallationin the reverseorder to
removal.
6 Mating surface of swing circle:

Thread of revolvingframe mounting bolt:
QzclRevolving frame mounting bolt:
926.7 = 103 Nm 194.5 +. 10.5 kgm!
PC300, 350-6 30-67

0
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembiy.
Fordetails,seeREMOVAL OF REVOLVING
FRAME ASSEMBLY.
2. Sling swing circle assembly (1) at three points,

then remove momtifig bolts, ami lift off swing
circle assembly.
& Swing circle assembly: 500 kg

PC300-6 Serial No.: 33001 ~ 33465, PC350-6 Serial No.: 12001 - 12283
CIRCLE ASSEMBLY
* Carry outinstallation in the reverseorder to
removal.
& Thread of swing circle mounting bolt:

Thread tightener (LT-29
Swing circle mounting bolt:
926.7 2 103 Nm 194.5 2 10.5 kgml CWPO7210
j , Set the soft zone S mark on the inside ring
of the inner race facing the right side of the PC300-6 Serial No.: 33466 and up, PC350-6 Serial No.: 12284 and up
machine as shown in the diagram, then in-

stall to the track frame.
6 Swing circle: Grease (G2-LI) 33 2l
30-68 PC300,350-6
0
DISASSEMBLY AND ASSEMBLY RECOIL IDLER, SPRING
REMOVAL OF IDLER, RECOIL

SPRING ASSEMBLY
1. Removetrackshoeassembly.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY.
* Remove lubricator (1).
CEP00534 CEPOOO!
2. Sling idler and recoil spring assembly (21, and

pull out to the front to remove.
j , Fit wire to the idler and spring of the idler
and recoil spring assembly, and adjust the
balance when removing.
& Idler, recoil spring assembly: 430 kg
3. Disconnect recoil spring assembly (4) from idler

assembly (3).
I /
4
idler assembly: 170 kg
Recoil spring assembly: 260 kg
INSTALLATION OF IDLER, I
w CEP00053
REEOii SPRING ASSElit+iBi'r'

removal.
a* Wheninstallingtheidlerassemblyand re-
coii spring assembiy, assembie so that the
position of the greasing plug on the idler is
on the outside for the right side of the ma-
chine and on the inside for the left side of
the machine.
PC300, 350-6 30-69

0
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY OF IDLER
ASSEMBLY
5. Remove pin (29,then remove support (3).
2. Remove floating seal (4) from support (3) and

idler (5). 6
3. Pull out shaftandsupportassembly (6) from

idier (51.
* It is filledwith approx. 230 cc. of oil, so
drain the oil at this point or lay a cloth to
prevent the area from becoming dirty.
I3
CEP00540
4. Remove floating seal ( 7 ) on opposite side from

idler (5) and shaft and support assembly (6). 5 7
CEP00068
12 ,5
6. Remove bushing (12) from idler (5).
lo I
CEW0069 CEP00550
30-70 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY tDLER
ASSEMBLY OF IDLER
ASSEMBLY
11
1. Press fit bushing (12)to idler (5).
12
2. Fit O-ring and install support (IO)t o shaft (111,
then install pin ( 9 ) .
* After inserting the pin, caulk the pin portion
&I2
of the support.
lo /
CEP00071 9 CEP00550
3. Using tool Ll, install floating seal (7)to idler (5)

and shaft and support assembly (6).
* Coat the sliding surface of the floating seal
with oil, and be careful not to letany dirt or
dust get stuck to it. 6
* Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
I CEWOOSB
I L1
I CEW0075
4. Assemble shaft and support assembly (61to idler

(5).
II 5
CEP00074
PC300, 350-6 30-71

0
DLER DISASSEMBLY AND ASSEMBLY
5. Using tool L1, install floating seal (4) to idler (5)

and support (3). i
.It Coat the sliding surface of the floating seal
with oil, and be careful not tolet any dirt or
I ,4
dust get stuck to it.

.It Remove all grease and oil from the contact
surface of the O-ring and the floating seal.
CEP00080
I I
CEP00081
6. InstallO-ring, then assemble support (3)and

install pin (2).
* After inserting the pin, caulk the pin portion
of the support.
7. Add oil and tighten plug.
& Oil:Approx. 230 cc (E030-CD)
Plug: 152 'c 24.5 Nm I15.5 2 2.5 kgm)
CEP00540
30-72 PC300, 350-6

0
DISASSEMBLY
RECOIL AND ASSEMBLY SPRING
DISASSEMBLY OF RECOIL SPRING ASSEMBLY
IDJPOO847
XI. PC300-6Serial No.: 33466 and up

PC350-6Serial No.: 12284 and up
1. Remove pistonassembly (2)from recoil spring

assembly (I!. I 1 M? I
2. DkaSSe!llb!y Of WGOi! Spring assembly

1) Set tool M I to recoil spring assembly (1).
a The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
* Installedloadofspring:
173.3 kN (17,680 kg)
2) Apply hydraulic pressure slowly to compress
spring, then remove lock plate (31, and re- CEP00055
move nut (4).
Ir Compress thespringto a pointwhere
+hrr hn.-rrm
.-.I#+
UGbWlllCS IGGse.
*
L I I G I l U L
Free length of spring: 795 mm

3) Removeyoke (61, cylinder (7A), collar (781,
and dust seal (8)from spring (5).
* Collar (7B):
3. Disassembly of piston assembly

1) Remove lock plate ( I O ) from piston (91, then
remove valve (11).
2) Remove snap ring (121, then remove U-pack-
ing (13) and ring (14).
PC300, 350-6 30-73

0
RING DISASSEMBLY
RECOIL AND ASSEMBLY
ASSEMBLY OF RECOIL SPRING

SSEMBLY
M2
1. Assembly of piston assembly
1) Assemble ring(14) andU-packing(13) to
piston (91,and secure with snap ring (12).
2) Tightenvalve(11)temporarily,and secure
with lock plate ( I O ) .
2.Assembly of recoilspringassembly
1) Usingtool M2, assembledust seal (8)to
cylinder (7).
2) Assemble cylinder (7A), collar (7B), and yoke CEP00062
(6) to spring (51,then set to tool MI.
* Collar (7B):
Sliding portion of cylinder:
Grease (G2-LI)
3) Apply hydraulic pressure slowly to compress
spring, and tighten nut (4) so that instalied
length of spring is dimension "a", then se-
cure with lock plate (3)
* Installed length "a" of spring: 648 mm
4) Remove recoil spring assembly (1) from tool
MI.
DJP00848
3. Assemblepistonassembly (2) to recoilspring
assembly (1).
6 Piston sliding portion and wear ring:
Grease (G2-LII
* Assemble the cylinder assembly so that the
mounting position of the valve is 90" to the
side.
* Fill the inside of thecylinderwith approx.
200cc of grease (G2-LI), then bleed the air
and check that grease comesout of the
grease hole.
30-74 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY ROLLER TRACK
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Lower work equipment to ground, then loosen
lubricator (11, and relieve track tension.
A The adjustment cylinder is under extremely
high pressure, so never loosen the lubrica-
tor more than one turn. If the grease does
not come out easily, move the machine back-
wards and forwards. 1
I
2. Remove mounting boltsof track roller guard(2),
then swing work equipment go", jack up ma- CEP00534 CEP00051
chine with work equipment, and remove track
roller guard (2) towards outsideof machine.=
Track roller guard: 35 kg
3. Lower chassiscompletely,removemounting
bolts of track roller assembly (31, then jack up
machine with work equipment, and remove track
roller assembly (3)to outside of machine. a
& Track roller assembly: 55 k g
2 CEPOOOB2
INSTALLATION OF TRACK
I
ROLLER ASSEMBLY
removal.
* Adjust the track tension.

Testing and adjusting track tension.
I 3 CEP00083
m Roller guard mounting bolt:

Roller guard mounting bolt:
926.7 2 103 Nm (94.5 2 10.5 kgm)
JT?p
Track roller mounting bolt:
Track roller mounting bolt:
1st pass: 1S.1 z 19.6 Nm (20 2 2 kgm}
2nd pass:
Tighten an additional105 2 5"
PC300, 350-6 30-75

0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY OF TRACK ROLLER ASSEMBLY
P ..
CEP00084
1. Remove pin (11, then remove collar (2).

1 3
2. Remove floatingseal (3)from collar (2) and roller \
(4).
3. Pull out roller (4) from shaft (5).

A !t is filled with 250 - 280 CE. of oil, SO drain
the oil at this point or lay a cloth to prevent
the area from becoming dirty.
1 2 CEP00085 CEPOOOBB
4. Remove ffoating seal ( 6 ) on opposite side from

roller (4) and collar (8).
I CEP00087 I CEPOOO88
5. Removepin (71, thenremovecollar(8)from

shaft (5). =fl
6. Remove bushings (9) and (10) from roller (4). 5
4
7 CEW0089 CEW0090
30-76 PC300, 350-6

0
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Usingpush tool @, press fit bushings (9) and H
(10) to roller (4).
2. Assemble collar ( 8 ) t o shaft (51,and install pin

(7).
3. Using tool L3, installfloating seal (6) t o shaft

(5).
* When assembling the floating seal, clean the
contactsurface of O-ring (6c) and floating CEW0091 CEW0092
seal (6a), remove all grease and oil, and dry
it. Make sure that no dirt or dust sticks to ~
the contact surface of the floating seal.

* After inserting the floating seal, check that
Remove all oil and
grease from Protrusion of seal
the angle of the seal is less than 1 mm and hatched portion.
that the protrusion of the seal is within a
range of 5 - 7 mm. 5-7mm
CEWW93 CEW0094
4. Using tool L3, install floating seals (6) and (3)to

roller (4).
-k For details of the precautions when install-
ing floating seals (6b) and (6d), and I3b) and
*
(3d), see the precautions marked for Step
3.
5. Assembte shaft (5)to roller (4).
CEP00095 CEW0096
6. Turn over roller (4) and shaft (5) assembly.
7. Using tool L 3, installfloating seal (3)t o collar

(2).
* For details of the precautions when install-
ing floating seals (3a) and (313, see the pre-
*
cautions marked for Step 3;
CEP00097 CEP00098
PC300, 350-6 30-77

0
8. Assemble collar (2) t o shaft (51, and install pin

(1). 1
CEP00099
9. Using tool L4, apply standard pressure to roller

oil filler port, and check for leakage of air from
sea I.
I L4
* Standardpressure: 0.1 MPa {I kg/cm2}
* Methodofchecking
The standard pressure shall be maintained
for 10 seconds and the indicator of the gauge
shall not go down.
I CEPOOlOO
10. Using tool L4, fill track roller assembly with oil, I
then tighten plug (11).
I
L4 I
& Track roller oil: 250 - 280 cc (E030-CD)
Plug: 14.7 t 4.9 Nm (1.5 2 0.5 kgm)
i
To oil pump
To vacuum tank
CEW0201
CEP00202
30-78 PC300, 350-6

0
ROLLERDISASSEMBLY AND ASSEMBLY
CARRIER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
1. Lower work equipment to ground, then loosen
lubricator (11, and relieve track tension.
A The adjustment cylinder is under extremely
high pressure, so never loosen the lubrica-
tor more than one turn. If the grease does
not comeout, move themachine backwards
and forwards. 1
I 1
CEP00534 CEPD0051
2. Using hydraulic jacks 0, push up track to a po-

sition where carrier roller assembly can be re-
.
moved, then remove carrier roller assembly (2).
& Carrier roller assembly: 35 kg
1- 2 a CEP00203
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
Carry outinstallationinthe reverseorder to
removal.
+r Adjust the track tension.

Testing and adjusting track tension.
PC300, 350-6 30-79

0
AND DISASSEMBLY ROLLER CARRIER
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY

I 9
6
CEW0231
1. Remove plug (1) and drain oil.

b 3
- 500 cc
@
Carrier roller assembly: 450
2. Set carrier roller assembly on stand 0.

4. Remove ring (3).
CEP00232 CEP00233
5. Using tool L5, remove nut (4).
6. Using push tool @, pull out shaft assembly (5)

from roller (St withpress,thenremoveinner L5
7
race (7).
CEP00234 CEW0235
7. Remove outer races ( 8 ) and (9) from roller (6). I 1 1 I
6 8
8. Disassembly of shaft assembly.
1) Usingpuller 0, remove innerrace (10).
10
‘9
CEP00236 ~~~00237
30-80 PC300,350-6
0
ROLLER DISASSEMBLY
CARRIERAND ASSEMBLY
2) Remove floating seals (1 1).

3) Using push tool 0,
n
remove collar (12) from P l
ll
shaft (13).
1
1
1 la
1
I CEP00238
- +CEP00239
-
PC300, 350-6 30-81

0
AND DISASSEMBLY CARRIER ROLLER
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
1. Using push tool 0, press fit outer races ( 8 ) and
n
(9) to roller (6).
L7
2. Assembly of shaft assembly. 8
1) Using tool L7, press fit collar (12) to shaft
(13). 12
Ir When press fitting, be careful that there
9
is no scuffing.
-6 Fitting portion nf shaft:
Engine oil (EOBO-CD) CEP00240
- +
'
--
CEW0211
2) Using tool 16,assemble floating seals (11).

* When assembling the floating seal, clean
the contact surface of O-ring ( I l c ) and
floating seal (Ila), remove all grease and
oil, and dry it. Make sure that no dirt or
dust sticks to the contact surface of the
floating seal.
* Afterinsertingthefloating seal, check
that the angle of the seal is less than 1 11
mm and that the protrusion of the seal
is within a range of 5 - 7 mm.
3) Assemble floating seals (1 11, then using push U
tool 8, press fit inner race (10). CEW0242 CEW0243
* For details of the precautions when in-
stalling floating seals (11b) and(1Id), see
the precautions marked * for Step 2).
Remove all oil and Protrusion of seal
grease from
hatched portion.
5-7mm
L CEPOO093 CEW0094
3. Assembie roiier iSj to shait assembiy i5j,
4. Using push tool 0, press fit inner race (7). 7 L5

Jr When press fitting the bearing,rotate the
roller,andpress fit to a pointwherethe
rotation becomes slightly heavier.
5. Using tool L5, tighten nut (4) to a point where

drill hole in shaft is aligned with drill hole in
nut.
CEP00244 CEW0234
30-82 PC300,350-6
0
DISASSEMBLY
CARRIERAND ASSEMBLY ROLLER
6. installring (3).
3,
7. Usingpush-pull scale 8,check thatrollerro-
tates smoothly.
CEP00233 CEW0247
8. Fit O-ring and install cover (2).
k-=? CEP00248
9. Using tool L8, apply standard pressure t o roller

oil filler port, and check for leakage of air from
seal.
-k Standard pressure: 0.1 MPa (4 kg/cm2}
.?r Method of checking
The standard pressure shall be maintained
for 10 seconds and the indicatorof the gauge
shall not go down.
I CEW0249
10. Using tool L8, fill carrier roller assembly with

oii, then tighten piug i i j .
& Carrier roller oil: 450 - 500 cc (E030-CD)

Plug: 14.7 f 4.9 Nm I1.5 e 0.5 kgm}
I u
To oil O U ~ D I
To vacuum pump
CEW0250
PC300,350-6 30-83
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
1. Positioning track shoe
* Stop the machine at a point where it is easy
to set master pin removal toolR, and where
master pin is in the middleof the track frame,
thenloosenlubricator (l), andrelieve the
ion. track [y(1I
A The adjustment cylinder is under extremely 1
high pressure, so never loosen the tubrica-
tcr mwe than one t x n . If the grease does
not comeout, move the machine backwards CEP00534 I CEP00051
and forwards.
2. Using tool R, pull out master pin (2).

2
3. Lay out track as follows.
1) Movemachineforward so thatposition of
temporary pin is at front of idler, set block
@ in position, then remove temporary pin
0, and remove
dust seal.
2) Drive machine in reverse to. lay out track.
a
CEP00296
INSTALLATION OF TRACK
SHOE ASSEMBLY
removal.
3
Adjust the track tension.

For details, see TESTING AND ADJUSTING, Test-
ing and adjusting track tension.
* Use tool R and press fit so that the protru-

CEP00297
sion of the master pin is dimension "a".

Protrusion "a" of master pin: 4.2 r 2 mm
Whenassemblingthedust seal,coat a
t h eb u s h i n gc o n t a c ts u r f a c e with
grease (G2-LI).
I I I
'' CDW0230
38-84 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY TANK HYDRAULIC
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
Swing the upper structure to set the position of
the hydraulic tank drain and mounting bolt out-
side the track.
A Loosen the hydraulic tank oil fillercap slowly t o

1
& Hydraulic tank: Approx. 200
2. Remove operator'scabassembly.
For details, see REMOVAL OF OPERATOR'S CAB
ASSEMBLY.
3. Remove control valve top cover, hydraulic tank
undercover, and main pump undercover.
4. Open main pump side cover, then remove parti-
tions (1) and (2).
5. Remove covers (3)and (4).
6. Remove air conditioner air suction port (5).
I CEP00406
7. Disconnect drain hoses (61, (71, and (8).
8. Disconnect hydraulic oil filter inlet hose (9) and

oirilei hose (19).
\ - I
10 CEFUO408
PC300, 350-6 30-85

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
I
9. Disconnect hydraulic oil cooler returnhose (11).
I O . Disconnect drain hoses (121, (13), and (14).
11. Disconnect hydraulic oil level sensor connector
(15) (CN-PO9).
12. Remove main pump suction tube (16).

-k A box wrench cannot be fitted on the center
rear mount bolt, so disconnect both sides of
tube (16) and offset them.
13. Remove mounting bolts, and lift off hydraulic

tank assembly (17).
& Hydraulic tank assembly: 230kg
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
removal.
Hydraulic tank mounting bolt:

=
277 t 31.9 Nm (28.25 3.25 kgm}
* Add oil through the oil filler to thespecified
level.
Bleeding air
* Bleedthe air.
Bleeding air.
30-86 P6300,350-6
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REMOVAL OF MAIN PUMP

ASSEMBLY
ground and stop theengine. Then loosen the oil
the hydraulic tank.
I . Remove hydrauiic tank strainer, and using tooi
SI,stop oil.
* Whennotusingtool SI, removethedrain
plug, and drain the oil from the hydraulic CEP00268
tank and inside the system.

6
Hydraulic tank: Approx. 200 Q
2. Drain coolant.
3. Removemainpumpundercoverandengine
undercover.
5 . Remove mainpumptopcover (11, andparti-

tions (2) and (3).
PC300-E Serial No.: 33001 - 33465. PC350-6 Serial No.: 12001 - 12283
6. Remove muffler drain tube (4).

7. Disconnect chassis g r o m d cable !SI.
8. Remove bracket ( 6 ) sf pump branch hose.
k Do not disconnect the branch hose.
9. Disconnect suction tube (7).
IO. Disconnect cooling hose (8).
PC300-6 Serial No.: 33466 and up, PC350-6 Serial No.: 12284 and up
PC300, 350-6 30-87

0
DISASSEMBLY PUMP MAIN
11. Disconnect LS control hose (9).

12. Disconnectrear pump LS pressuredetection
hose ( I O ) .
13. Disconnect rear pump delivery pressure detec-
tion hose (11).
14. Disconnect TVC wiring connectors (12) (C13, 14).
15. Disconnect TVC wiring clamp (13).
96. Disconnect front pump LS pressuredetection
hose (14).
17. Disconnect front pump delivery pressure detec-
tion hose (15).
* After disconnecting the hoses, fit tags to dis-
tinguish them.
PC300-6 Serial No.: 33001 - 33465. PC350-6 Serial No.: 12001 - 12283
I
to self- reducing valve.
* Spacer (16B):
13. Disconnect hose (17A) and spacer (77Bj going
t o control valve.
* Spacer (17B):
21. Sling main pump assembly(19). remove mount-
ing bolts, then lift off.
PC300-6 Serial No.: 33466 and up, PC350-6Serial No.: 12284 and up
Main pump assembly: 250 kg
16 CWPO7205
1
30-87- PC300, 350-6
0
DISASSEMBLY AND ASSEMBLY PUMP MAIN
INSTALLATION OF MAIN
PUMP ASSEMBLY
Carry outinstaiiation inthe reverse orderto
removal.
& Involute spline of main pump:

Anti-frictioii @ompoiSnd;ee\lr-c;
Mating surface of main pump case:
Refilling with oil (dampercase)

level. Run the engine, then stop the engine,
wait for 15 minutes, and check the oil level
again.

A Ada oii through the oii fiiier to the specified
!eve!. Run the engine to circulatethe oil
through the system. Then check the oii ievei
again.
Bleeding
air
*
0
Bleed the air.

Bleeding air.
PC300, 350-6
P ' w
m
E!tJJ
V
0 \
m
W
P
\w
m
LS valve
i) Removelocknut (231, thenremoveplug
(249, seat (251, spring (261, and seat (27).
* Measure the dimension between the
end face of locknut (23) and the end
face of plug (24).
ii) Remove plug 1281, thenremovesieeve

(29), piston (301, and spool (31).
Remove filter (321, then remove spacer (33)

and orifice (34).
5. Valve plate, end cap

1) Remove valve plate (36) from end cap (35).
2) Remove 8 mounting bolts (37).then lift off
end cap (35).
* The valve plate may be stuck to the end
cap, so be careful not to drop it.
.ir Measureprotrusion L o i maximum
swash plate angle adjustment screw(38).
3) Remove valve plate (39) from end cap (35).
1
-
I 38 CKPOO655
Disassembly of end cap

i) Loosen locknut (40), then remove screw
(38) and washer (42).
ii) Remove bearing (51) from end cap (35).
iii) Remove bearing (49) frominsideend
cap.
I 35 51 CUP06351
6. Cylinder block, piston assembly

Remove cylinder block and pistonassem bly (53)
from pump case (54).
t The cylinder block and piston assembly may
come off separately, so becareful not to
drop them.
I CLPOO657
30-88-2 PC300, 350-6

0
Disassembly of cylinder block, piston assembly

Pull out piston assembly (56) from cylinder block
(55), andremoveretainerguide(57)and 3
I 57, ,56
preload pins (58). 55

* Whenremovingthepiston assembly from
\ - 58
thecylinder block, thepreloadpinsmay
come out, so be careful not to lose them.
Disassembly of piston assembly

Pull out piston (60) from retainer shoe (59).
60
59
CKP00659
Disassembly of cylinderblock
1) Set tool S4 to cylinder block (55).
2) Hold bolt of tool S4 with wrench, tighten nut

to compress spring, and remove snap ring
(56).
3) Loosen nut of tool S4 slowly to release ten-

sion of spring (831,then remove tool S4.
41 Remove seat (58). spring (83), and seat (59)

from cylinder block (55). 56 DVP00751
* Check the assembiy direction of seat (59j.
7; Servo pistonassembly
1) Remove mounting screws with tool S5, then
remove cover (60). (Front pump only)
PC300, 350-6 30-88-3

0
DISASSEMBLY AND ASSEMBLY PUMP MAIN
2) Remove plug (61), then remove spring (62).

62
61
ri- CLPOO662
3) Using bolt (6 mm), remove stopper (63).
CLPOO663
4) Set'tool S6 in position, and assemble spacers

@ to both ends of rod (64). 64
5) Move to side and loosen piston (651 so that

width across flats of rocker cam comes off
from width across flats of cradle.
* Be careful not to let the bolt portion of 64
tool S6 come off the rod.
0 65
6 ) Remove piston (65), then remove rod (64).
*Check the assembly direction of rod (64). 56
I CLPOO664 CLP00665
8. Shaft, cradle assembly

1) Remove rocker cam (66) from shaft and cra-
dle assembly (67).
I CLPO0666
30-88-4 PC300, 350-6

0
2) Remove 6 bolts, then remove shaft and cra-

dle assembly (67)from front pumpcase (54).
Disassembly of shaft, cradleassembly

1) Push cradle (69) with push tool @ t o remove
it from shaft (68).When removing, be care-
ful to keep cradle (69) straight. 69
71-
2) Remove snap ring (701, then remove washer
(711.
ti CKP00668 CLPOD669
3) Using push tool 0, remove bearing (72) from I

shaft (68). I I
* Bearing (72) divides into the flange ring
0
I I
and the bearing, so becarefulnot to
lose either part.
* Check theinstallationdirectionofthe
bearing.
72
68
9. DIsassemb!y nf ptrmp cese

1) Loosen locknut (74) of minimum swash plate
angleadjustmentscrew (73),and remove
screw (73).
* Beforelooseningthelocknut,measure
dimension L betweenthe end face sf
the case and the end face of the screw.
2) Rotate tool S3 90", remove snap ring(75)

fromfrontpump case (541, thenremove
spacer (76).
CKP00671
3) Remove oil seal (77).
PC300, 350-6 30-88-5

0
10. If above disassembly operation is not needed,

and only oil seal is to be replaced, replace oil
seal as follows.
1) Remove snap ring (75) and spacer (76).
2) Using bar @ (hit end face with hammer), hit

through to core of oil seal (771, then twist to
remove.
* Hit at a pointmidwaybetweenthe in-
side andoutsidecircumferenceofthe
oil seal, and twist at two places on op-
posite sides (A and B in diagram) to re-
move.
* Be careful not to damage the shaft and
pump case.
Disassembly of rearpumpassembly
11. Rear pump assembly
Set rear pump assembly (3) to tool S3.
12. Servo valve assembly

Same operation as in Item 4.

14. Servo piston assembly


16. Disassembly of pump case

Loosenlocknut (82) of minimum swashplate '81
angle adjustment screw(811, then remove screw
(81).
I 82 CKPOO674
I D-Z--,. I-..n....:-- +h.. I..-ir-,.+ +I-.-

A DGIUIG I U U ~ G I I I I I ~ LIIG Iu\rnlIuL, IllcaauIC: IIIG
dimensionbetweentheendfaceofthe
locknut and the end face of the screw.
30-88-6 PC300, 350-6

0
ASSEMBLY OF MAIN PUMP

ASSEMBLY
* Clean all parts, remove all burrs, and check for c
dirt or damage.Coat the rotating and sliding
surfaces of all parts with engine oil (E010-CD)
before installing.
Always check the following parts beforeassem-
bling.
i) Check contact of cradle and rocker cam (for
details; see PROCEDURE FOR C.!-!ECK!NG
CONTACT).
ii) Check contactbetweencylinderblockand
valve plate (for details, see PROCEDURE FOR
CHECKING CONTACT).
iii) Check contact between valve plate and end
cap(fordetails, seePROCEDURE FOR
CHECKING CONTACT).
Assembly of front pump assembly

FI
Assembly of shaft and cradleassembly
1) Assemble flange ring to shaft (68),then use
tool S7 t o press fit bearing (72).
Press-fitting surface of bearin:
Grease (G2:LI)
I I OVP00752

tool s7.
2 ) Assemble washer (711, and install snap ring

(70).
Method of selectinglock washer (71)

i) After press fittingbearing (72)t o shaft
(681, assemble washer (71) (removed dur-
ing disassembly).
ii) Measure clearance dimension a between
end face of assembled washer (71) and
snap ring groove. I
DVPOO753
-ir Ciearance dimension a:
1.45 - 1.60 mm
iii) If clearance "a" isnot within above
standard value, select washer from table
below and assemble.
Washer
G
Part No. 708-17-12750708-17-12760 708-17-12770
!Ai,.
3.0 3.1 3.2
""CZSh€i (mm)
thickness
-
PC300, 350-6 30-88-7

0
DISASSEMBLY MAIN PUMP
3) Using push tooi 0, press fit cradle (69) to

shaft (68) to make shaft and cradle assem-
bly (67).
6 Press-fitting surface of bearing:
Grease (G2-LI)
end face of the bearing: outer race with
push tool 0.
4) Set pump case (54) to tool S3-3.
DVP00754
5) Fit dowel pin and O-ring to bottom surface I

of inside ofpump case (54, then install shaft
and cradle assembly (67).
Cradle mounting bolt:
110.3 z 12.3 Nm 111.25 2 1.25 kgrn}
* Check that there is no risingand that the
pin does not fall out.
* Be extremely careful that the O-ring does '67
not come out or get caught.
<
CLW0667
2. Rockercam I
Assemble rocker cam (66) to shaft and cradle
assembly (67).
38-88-8 PC300, 350-6

0
3. Servopistonassembly
1) Assemblespherical portionofrod (64) to
rocker cam.
* When assembling the rod, assemble with
the spring seat surface facing in the di-
rection of assembly of the spring.
S6
2) Fit piston (651,set tool S6 on opposite side
from when !nosening, set spacer 0GI? f r m t
end of rod (641, and tighten piston (65). 0
* Before tighteningpiston (651, moveto
the side so that the width across flats of
the rocker cam comesout from the width
CLPOO678 1
across flats of the cradle.
(This i s to prevent damage to the rocker
cam and cradle when tightening the pis-
ton.)
Near $$ area of piston thread in Coat wrth three drops near a r e a #
diagram on right: Coat with three \\
drops of adhesive (Loctite 648)
Piston:
475.6 34.3 Nm I48.5 2 3.5 kgm)
4. Positioning minimum swash plate angle

1) Remove 2 dowel pins from servo valve as- DVP00755
sembly mounting surface.
2) Set tool S8 in position.

sa
I 105. 5f0. 05mm I 1
3) Assemble O-ring and tighten screw (73) un-
til it contacts piston (65). 7
Screw:
12.3 * 2.5 Nm {1.25 = 0.25 kgm}
4) Tightenlocknut(74) tohold screw(73) in
position.
Locknut:
*
254.9 29.4 Nm I26 2 3 kgm}
After completion of assembly, carry out
I 73
65
DVP00756
a bench test to check the minimum flow.

t .Assemb!ethe spring after measuring the
rotating torque of the pump assembly.
5) Assemble backup ring and O-ring to stopper

(631, and install to case.
CLPoo663
PC300, 350-6 30-88-9

0
5. Cylinderblock, pistonassembly
Assembly of cylinder block
1) Assemble seat (59), spring (831, and seat (58)
to cylinder block (55).
* Assemble with thetaperedportionon
the inside of seat (59) facing down.
2i Set tool $4 to cylinder block (55).
3) Hold bolt of toolS4 with wrench, tighten nut

to compressspring (831,theninstall snap
ring (56). 56 DVPOO751
* Check that the snapring is fitted securely
in the groove.
4) Remove tool S4.
Assembly of piston assembly 60

5) Assemble piston (60) t o retainer shoe (59).
59
CKW0659
Assembly of cylinder blockandpiston assem-

bly
6 ) Assemble 3 preloadpins(58)tocylinder
block (55). 5
It To prevent the preloads pin from com- 58
ing out, coat the pins with grease (G2-
LI).
7) Assembleretainerguide(57)tocylinder
block (551, then install piston assembly (56)
to make cylinder block and piston assembly I
(53). CKP00658
It Alignthesplineforthecylinder block
-.-.A -.,.+
:.,.- "..:A,.
a l l u lcLalllct YUIUG.
Installation ~f cylinder block and piston assem-

bly
8 ) Installcylinderblockandpistonassembly
(53)to pump case (54).
* Before assembling the cylinder block and
pistonassembly,assemblethewidth
across flats of the rocker cam to thecra-
dle securely.
CLPOO657
30-88-10 PC300, 350-6

0
AND DISASSEMBLY MAIN PUMP
6. Endcap
1) Using tool S9, press fit bearing (51) until it
comes into contact with front pump end of
end cap (35).
Press-fitting surface of bearing :
Grease (G2-LI)
* After installing the bearing on one side,
insert coupling (49) inside the end cap.
2) !!'!S?a!! CBSP dQSi'e! B R d V B ! W ?!a%
dowel pins (2 each) to end cap.
h CUP06353
7 . Positioning maximum swash plate angle I

1) Installscrew (381, locknut (401, and washer
(42) to end cap.
* Install so that protrusion L of screw (38)
from mating surface of case of end cap
(35) is as shown below.
Protrusion L: 8.0 mm
2) Tighten locknut (40) to hold in position.
Locknut:
=
254.9 29.4 N m (26 3 kgm}
L
4
4240384042
CKP00772
8. Endcapassembly
1) Assemble valve plate (39)to end cap (35).
* Align the dowel pin and pin hole to in-
stall.
* Check that the end cap and valve plate
port holes are aligned.
(There is danger that this will damage
I CKW0681
PC300, 350-6 30-88-11

0
2) Slingend capassembly (35)and installto

front pump case (54).
t Wheninstallingtheend cap assembly,
insert a screwdriver through the bearing
hole, support the coupling with the han-
dle of the screwdriver, and install cou-
pling (49) to the front pump drive shaft.
A- Check that there is no rising and thai the
pin does not fall out.
Sr Be extremely careful that the O-ring does 54
not come out orget caught.
aMating surface of pump case: CUP06354
Gasket sealant (LG-7 or LG-5)
Mounting bolt:
*
384.9 41.7 Nm f39.25 2 4.25 kgm)
9. Measuring rotating torque of pump assembly

1) Set tool SI0 to pump shaft.
2j Set torque wrench to tooi 540, rotate shaft

a t low speed (3 - 5 sed1 turn) and measure
rotating torque.
* When checking the rotating torque, check
that the shaft rotates smoothly without
any variation.
Variation range:
Max. 2.9 Nm (0.3kgm)
0 Rotating torque:
Max. 24.5 Nm (2.5 kgm) 62
.k If there is any abnormality in the rotat-
ing torque, disassemble again andcheck.
10. Servo piston spring

1) Assemblespring (62). 61
2) Fit O-ring and install plug (61).

Plug:
151.9 c 24.5 Nm i15.5 2 2.5 kgm}
CLPO0662
3) Using tool S5, tighten mounting screws for

cover (60).
Mounting screw:
30.9 2 3.4 Nm j3.15 = 0.35 kgml
GtP00661
I2
30-88- PC300,350-6
0

1) Assembly of servo valve assembly
LS valve
i) Assemble spool (311, piston 1301, and
sleeve (29) t o body, then fit O-ring and
install plug (28).
Plug (28):
110.3 c 12.3 Nm (11.25 a 1.25 kgm)
* Check thatthe relative movements
ofthebodyandspool (311, and
sleeve(29)andpiston(30)are
smooth.
ii) Assemble seat (271, spring (26), and seat

(251, then fit backup ring and O-ring and
install plug (24).
iii) Tighten locknut (23).

Locknut (23):
=
68.6 9.8 Nrn I7 2 1 kgm)
* Install so that the dimension between
the end face of locknut (23) and the
end face of plug (24) is the dimen-
CLPOO600
sion measured during disassembly.
iv) After completion of assembly, carry out

a benchtestoftheperformanceand
make final adjustment of plug (24).
* TVC
valve
i) Fit O-ring and assemble plug (221, then
install snap ring (21).
ii) Install pin (191, washer (171, bearing (18),

and nut (16) to lever (20)to make lever
assembly (15).
Nut (?e!:
10.8 0.98 Nm 11.1 2 0.1 kgm}
-a
Nut (16):
Thread tightener (Loctite 648)
Sr Check that the movementoflever

(20)and bearing (18) is smooth.
PC300, 350-6 30-88-13

0
DISASSEMBLY ASSEMBLY MAIN PUMP
iii) Fit O-ring to plug (141, theninstall to

lever assembly (45) and body.
* Tighten to a point where the tip of
plug (14)is in contact with plug (221, D i r e c t i o n to
0'-180'position loosen
then turn back at least 180" in the after adjusting
plug
direction of loosening and move the

mark to the position O=O in the dia-
gram on the right. 0"
* If the position of themark is between
0)
the 6 180" and 360" positions i n the 2jO'
diagramon the right at thepoint
where the tip of plug (14)contacts DVP00757
plug (22), turn back at least 1 turn to
thetemporaryassemblyposition
(e=o).
iv) Tighten locknut (13).
Locknut (13):
29.4 2 4.9 Nm (3 +. 0.5 kgm)
ir Check thatthemovement of lever
(20)and plug (22) and plug (14)is
smooth.
v) Assemble piston (121,then fit O-ring and

install plug (11).
Plug (1 I):
11.3 2 1.5 Nm 11.15 2 0.15 kgm}
vi)Assemblespool (7) to sleeve (6), then

install together withseat (81, and springs
(9)and (IO)to body.
* Check that the relative movement of
sleeve (7)and spool ( 6 ) is smooth.
vii)Install O-ring, theninstallsolenoid as-

sembly (5).
Solenoid assembly mounting bolt:
13.2 z 1.5 Nm i1.35 2 0.15 kgm}
Mating surfaceof solenoid assembly:
G=sk& se=!=nt (LG=l LG-5
(Loctite 572/5751j
viii)Using tool S11, checkthat there is no

leakage of oil or air from mating surface
*
with solenoid assembly.
Air pressure : 0.5 MPa (5 kg/cm2) w
ix) After completion of assembly, carry out
a bench test to check performance, and
make final adjustment of plug (14).
SI 1
CLW0645
I J
14
30-88- PC300, 350-6
0
Assemble orifice (34), and install spacer (331,

filter (32), and O-ring.
Orifice (34):
9.8 2 1.9 Nm Il.0 f 0.2 kgm)
Aftercompletion of assembly,carry out
bench test of servo valve assembly (4) as an
individualpartto checkperformanceand
carry cut adjustment.
Fit O-ring and filter t o servo valve assembly

(4) and install to pump case.
* Install the filter so that the mesh end is
at the front face endof the valve body.
Sr Be extremely careful that the O-ring and c
filter do not fall out.

Ir Tighten the mounting bolts gradually in
turn on opposite sides.
Mounting bolt:
66.2 A 7.4 Nm I6.75 = 0.75 kgm}
6 Mating surface of servo valve:
Gasketsealant (LG-7 or LG-5
(Loctite 572/575\1 /
4
Assembly of rearpump assembly CLW0646

12. Shaft, cradle assembiy
Same operation as in Item 1. (Set pump case to
tool s3-4.)
13. Rocker cam

14. Servo piston assembly

15. Positioning minimum swash plate angle


Same operation as in item 5.
17. Positioning maximum swash plate angle

18. Servo piston spring


PC300, 350-6 15
30-88-
0
20. Rear p u m p assembly

1) Assemble dowel pin, valve ptate, and O-ring
to end cap.
2) Sling rear pump assembly (3).
* Whenslinging,becarefulnottodrop
the cylinder block, piston assembly, or
other parts.
* Align the rear pump drive shaft with the
spline of coupling (49) and install.
3) Tightenmountingbolts of rearpump as-
sembly.
Mounting bolt : f
384.9 2 41.7 Nm (39.25 2 4.25 kgrn}
Mating surface of pump case :
Gasket sealant ILG-7 or LG-5)
21. Measuring rotating torque of pump assembly

1) Set tool S10 to pump shaft.
2) Set torque wrench to tool S10, rotate shaft

at low speed (3 - 5 sed1 turn) and measure
rotating torque.
* When checking the rotating torque, check
that the shaft rotates smoothly without
any variation.
Variationrange:Max. 2.9 Nm (0.3kgm)
Rotating torque: Max. 4.9 Nm (5.0 kgm)
* If there is any abnormality in the rotat-
ing torque, disassemble again and check.
16
30-88- PC300, 350-6
0
22. Oil seal

1) Check that there are no burrs or flashesat
corners of shaft.
2) Using tool S12, press fit oil seal (77).
3) Assemble spacer (76), and install snap ring
(75).
I CKP00686 I CKP00687
23. Hose
Install elbow, tee, and hose (2).
Hose: 24.5 t 4.9 Nm 12.5 r 0.5 kgm)
I
24. Pump assembly

Remove pump assembly (1) from tool S3.
CUP06347
PC300, 350-6 17
30-88-
0
2. Checking contact between rocker cam and cra-

dle
* This check is unnecessary if both the rocker
cam and cradle are replacement parts (new
parts).
* This check applies if one of the parts is a
replacement part or a restored part.
I! R e m ~ V ea!! oi! and grease fmm the parts to

be checked.
* Do not wipe with a cloth.
2) Paint the cradle with inspection paint.

*Coat thinly with paint.
3) Put the rocker cam on top, push with a force

of 39 - 49 N (4 - 5 kg}, and move it between
themaximum swash plateangleandthe
position where it contacts the stopper. Re-
peat this process 2 or 3 times.
4) Remove the rocker cam, transfer the contact

surface t o a tape, and check the contact sur-
face.
k The standard for the contact surface is
as given below.
i) Contact within central portion (36 - 50

mm) must be at least 90%.
R o c k e r cam
ii) Contact in rangebetweencentral por-

tion (36- 50 mm) and 67 mm must be
50 - 90%.
iii) Contactof area outside 67 mm width
(outside) must be less than 50%.
(It is not permitted t o have contact only
attheoutsideand nocontactatthe
center.)
[Reference] " * .,,/..

DVP00760
if rne contact is not wirnin the stanaara
value, and lapping is carried out, it must
always be carried out for both parts to-
gether.
* Parts with any scratches or damage must

not be used.
PC300, 350-6 19
30-88-
0
3. Checking contact between valve plate and end

cap
This check is unnecessary if both the valve P
plate andend capare replacement parts (new
parts).
This check applies if one of the parts is a
replacement part or a restored part.
16 the contact is defective, use a surface plate
and correct by lapping.
I
Remove all oil and grease from the parts to
be checked.
Ir Do not wipe with a cloth.
P DVP0076l
Paint the end cap with inspection paint.

j , Coat thinly with paint.
Push thevalveplate with aforce of 39 -

49 N 14 - 5 kg) against the endcap, turn the
valve plate 90°, then turnit back to the arigi-
ma0 position. 8epeat this process 2 or 3 times.
Remove the valve plate, transfer the contact

surface to a tape, and check the contact sur-
face.
* The contact of the planesurface between
the valve plate and end cap must cover
at least 80% without any variation.
* For details of the operation, see the Parts
Judgement Guide.
30-88-20 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL OF MAIN PUMP

INPUT SHAFT OIL SEAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP AS-
SEMBLY.
2. Remove snap ring ( l ) ,then remove spacer (2).
3. Lever up oil seal (3)with a screwdriver to re-

move.
* When removingthe oil seal, beextremely
a
careful not to damage the shaft. CEWOaOO
INSTALLATION OF MAIN
PUMP INPUT SHAFT OIL SEAL
Carry out installation in the reverseorder to
removal.
6 Lip of oil seal: Grease (G2-LI)
6 Coat the outside circumferenceof the oil

seal with grease (G2-LI) thinly, then press
fi?.
3 4 CEP00401
* Using tool S2, press fit oil seal (3).
PC300, 350-6 30-89

0
CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
ground and stop the engine. Then loosen theoil
the hydraulic tank.
A Release the remaining pressurein the hydraulic
circuit.
For details, see TESTiNG AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
* Make match marks befored i s c ~ n n ~ t i nthe
g PPC \ 0 4-
circuit hoses. 3
* Fitblindplugs in thedisconnected hosesand
CEW0127
tubes.

2. Remove control valve top cover.
3. Disconnect turbochargeroutlet port hose (I), and
remove inlet port hose (2).
4. Disconnect air cleaner clogging sensor hose (3).
5, Disconnect air cleaner assernbly !4! tcgetber with
bracket.
6. Disconnect wiring harness (51, and remove par-
tition (6).
7. Disconnect 9 bottom PPC hoses (7).

8. Disconnect pump rnerge/divider solenoid hose
(8).
7 CEP00129
^Y.Disconnect pressure sensor connectors (9) and

(IO)(CN-C08 and CN-C07).
10. Disconnectmain pump outlet hoses (11) and
(12).
30-90 PC300, 350-6

0
VALVE DISASSEMBLY
CONTROL
AND ASSEMBLY
11. Disconnect hoses (131,(141, (15), (161,U7), and

(18).
* Hose (13): For arm boost PPC
Hoses (14)and (15):For R.H. straight travel
Hoses (16)and (17): For L.H. straight travel
Hose (18):For drain circuit
12. Disconnect hoses (19) and (20).

* Hose (19):For drain circuit
Hose (20):For high-pressure circuit
13. Remove elbows (21).(221, and (23).
14. Set hose mounts of elbows (24)and (25) facing

down.
15. Disconnect control valve return hose (26).
17. Disconnect 1@top PPC hoses (28).
18. Disconnect safety valve hose (29).
19. Disconnect high-pressure circuit hose (30)and

LS pressure hoses (31).
I 31 CEW0134
PC300, 350-6 30-91

0
DISASSEMBLY
CONTROL
AND ASSEMBLY VALVE
20. Disconnect swing motor suction hose 132).
2% Disconnect bucket hoses (33).
22. Disconnect 2 R.H. travel hoses (34).
23. Disconnect arm hoses (35).
24. Disconnect L.H. travel hoses (36).
25. Remove swing motor hoses (37).
26. Remove boom tubes (38)and (39).
27. Disconnect LS select valve hose (40).
28. Sling control valve assembly (411, then remove

mounting bolts, and lift off control valve assem-
bly.
* Move slightly to the front and pass through
the bracket to lift off.
Control valve assembly: 260 kg
INSTALLATlON OF CONTROL
VALVE ASSEMBLY
Carry outinstallationinthe reverseorder to
removal.
e Refilling with oil (hydraulic tank)

It Add oil through the oil filler to thespecified
level.
30-92 PC300, 350-6

0
I.
N
DISASSEMBLY AND ASSEMBLY VALVE CONTROL
15
BO OS^
13 arm-hioh
Bucket
11
R. H. t r a v e i
9
Boom- I ow
7
Swine
5 L. H. travel
Arm- i ow
3
2
A-A 6-6
27 28
30
26
23 24
21
29
19 20
17 18 32
31
c-c J-J
I
I 2 i i
39
33 31
34 37
L- L K-K 35 €E-EE 36
DWP'0071 7
30-94 PC300, 350-6

0
0
w
m
,/ 0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
* The set pressure of the safety valve cannot be

adjusted when it is installed on the machine, so
do not disassemble.
P The following procedure is for the 7-spool valve.
1. Main relief valve

1) Remove main relief valve (2).
2. Unload valve, safety-suction valve, suction valve,

Plug
? f Remwe unlcad valve (1).
2) Remove safety-suction valves (17L(181, (221,
and (26).
3) Remove suction valves (191,(201, (231,and
(24).
4) Remove plugs (27) and (28).
3. Pressure compensation valves

* Before removing anypressurecompensa-
tion valve, check and mark its mounting po-
siticn.
1) Remove arm Hi IN pressurecompensation
valve (151, bucket DUMP pressure compen-
sation valve (13),R.H. travel REVERSE pres-
sure compensation valve (1 1 ), boom RAISE
pressure compensation valve (91,right swing
pressure compensation valve (71, L.H. travel
REVERSE pressure compensation valve (51,
and arm OUT pressure compensation valve
(31.
2) Remove boom Hi RAISE pressurecompen-
sation valve(16), bucket CURL pressure com-
pensation valve (141,R.H. travel FORWARD
pressurecompensationvalve (12), boom
LOWER pressure compensation valve (101,
left swing pressure compensation valve (81,
L.H. travel FORWARD pressurecompensa-
tion valve (61, and arm IN pressure compen-
sation valve (4).
* After removing the pressure compensa-
tion valves, remove check valve (88)from
eachpressurecompensationvalve
mount.
4. LS select valve
Remove LS select valve (29).
30-96 PC300, 350-6

0
ASSEMBLY
DISASSEMBLY AND CONTROL VALVE
5. LS shuttle valves, pump merge/divider valve, 9. Boom control valve

boom regeneration valve, block 1) Remove case(68), thenremovespring
1) Remove LS shuttle valves (30) and (31). (69) and retainer (70).
2) Remove pump merge/divider valve (321, 2) Remove plug (711, thenremovepiston
then remove boom regeneration spring (72) and spring (73).
(85) and boom regeneration valve (86). 3) Remove case (741, thenremovespring
3) Removemerge/dividervalvebody(35) (75) and retainer (76).
andplugs (37) and (38), then remove 4) Removespoolassembly (77).
spools (33) and (341, andsprings(36) * Do not disassemble spool assembly
and (39). (771.
4) Removeblock (87).
10. Bucket control valve
6. Armcontrol valve I)Remove case (781,thenremovespring
1) Removeplug (401, thenremovepiston (79) and retainer (80).
(42) and spring (411. 2) Remove case (811, thenremovespring
2)Remove case (431, thenremovespring (82) and retainer (83).
(44) and retainer (45). 3) Remove spool assembly (84).
3) Remove case (461, thenremovespring * Do not disassemble spool assembly
(47) and retainer (48). (84).
4) Removespoolassembly (49).
* Do not disassemble spool assembly 11. Arm regeneration valve
(49). Removeplate (911, then remove arm re-
generationspring(92)andarmregen-
7. Swing control valve eration valve (93).
1) Remove case (50),thenremovespring
(51) and retainer (52).
2) Removeplug (531, thenremovepiston
(54).
3)Remove case (551, thenremovespring
4) Remove plug !58!; then remove piston
(59).
5) Removespool assembly (60).
*Do not disassemble spool assembly
(60).
8. R.H. travel control valve, L.H. travel control

valve
1) Remove case(61), thenremovespring
2) Remove case !64!, spring (651, and re-
tainer (66).
3) Remove spool assembly (67).
* Do notdisassembiespooiassembiy
(67).
PC300, 350-6 30-97

0
12. Boom Hi, arm Hi control valves

Arm Hi control valve
* Mark with tags t o preventmistakesin
the mounting position when assembling
the springs and spools.
1) Remove case (1031, then pull out spool as-
semblytopositionshown in, diagramon
right.
2) T3 p : ~ e n tdamage to S ~ O Oassembiy,
~ hoid
position @) shown in diagram on right with
a wrench (width across flats: 24mm), remove
plug (951, then disassemble into retainer(961, I CWPOG 1 5 3
springs (97a1 and (97b),retainer (981, and
spool (94).
Boom Hi control valve

* Markwithtagstopreventmistakesin
the mounting position when assembling
the springs and spools.
3) Remove case (104), then remove spring (105)
and plate (99).
4) i o prevent damage to spool assembly, hold
position @ shown in diagram on right with
a wrench (widthacross flats: 24mm1, remove
plug (1001, then disassemble into vaive (IOI),
plate (991, and spool (102).
13. Removecovers (89) and(98)and valve (106)

from valve body.
I CWPOGI 5 4
30-98 PC300,350-6
0
N
0
cn
VALVEDISASSEMBLY
CONTROL
AND ASSEMBLY
Boom.
13 arm-high
I4
Bucket
I1 12
R. !. t r2v3
Y IO B o o m - I ow
7 8 s.i j
5 6 L. H. t r a v e
Arm-law
3 4
2 I
A-A B-B
27I I28
30
26
23 24
21
'22
29
19 20
17 18 \ 32
3 I'
c-c J-J
! !
39
33 38
34 37
L- L K-K 35 EE-EE 36
DWPO 0 7 1 7
30-1 00 PC300, 350-6

0
58 51 60 F-F 54 53
N-N (For swine)
( F o rb o o m .a r m - h i o h )
61 78
64 E5 66 m 67 63 62 E1
[For b u c k e t )
25 87
E-E
(For t r a v e I )
65 66 67 63 62
c
i I!
,42
AA-AA
(For travel) 41
71
,?2
75 71
76 73
(For boom) DWP00718
PC300, 350-6 30-1 01

0
* Check the spools and valves for dirt, damage, or I

burrs. Coat the sliding surfaces of all parts with
engine oil before instailing. A\ I I /
B
1. Covers
Install valve (106), and covers (89) and (90)to
valve body.
*-=
Ir Check that there is no damage to theO-ring,
then installsecurely to the mating surface of
the cover ana vaive.
* Tightenthemounting bolts ofcovers(89)
and (90) in the order shown in the diagram
on the right. CDPW544
Cover mounting bolt:
166.6 2 9.8 Nm 117 t 1 kgm)
2. Boom Hi, arm Hi control valve spools

Boom Hi control valve spool-
Check the mounting position of the spring
and spool assembly carefully before install-
ing.
Fit seal to spool 11021, and install seal to
valve (101).
Assemble spool (102) to position shown in
diagram on right, install plate (99) and valve
(101) to spool (102), then hold position @
shown in diagram on right with a wrench
(width across flats: 24mm), and tighten plug
(41).
Plug: 13.2 t 1.5 Nm I1.35 z 0.15 kgm)
Push spool assembly into body, fit spring
(1051, then fit O-ring to case (104) and in-
stall.
Case mounting bolt:
=
30.9 3.4 Nm I3.15 0.35 kgm}
Arm Hi control valve spool

Check the mounting position of the spring
I
f
and spool assembly carefully before install- d
ing.
Assemble spool (94) to position shown in CWPOG 154
diagram on right, install retainer(981, springs
(97a)and (97b), andretainer (96), then in-
stali piug (951.
Hold spool (94) at position @ shown in dia-
gram on right with a wrench (width across
flats: 24mm), and tighten plug (32).
Plug: 17.2 2.5 Nm f1.75 0.25kgm}
Push spool assembly into body, then fit 0-
ring to case (103) and install.
Case mounting bolt:
30.9 2 3.4 Nm 13.15 r 0.35 kgm}
I CWP06f53
30-1 02 PC300, 350-6

0
3.Bucket
- control valve
1) Assemble spoolassembly(84) to valve
body.
2) Assemble retainer(83)and spring (821,
then fit O-ring to case (81) and install.
Case mounting bolt:
30.9 z 3.4 N m (3.15 3 0.35 kgm}
3) Assembleretainer(80) and spring (79),
Case mounting bolt:
30.9 F 3.4 Nm (3.15 t 0.35 kgm}
6. Swingcontrol valve
1) Assemble spool assembly(60) t o valve
body.
2) Assemble piston (59), and installplug
(58).
Plug:
107.8 z 14.7 Nm (11.0 t 1.5 kgm)
3) Assembleretainer (57) and spring (561,
Case mounting bolt:
30.9 2 3.4 Nm 13.15 z 0.35 kgml
4) Assemble piston (541, and install plug (53).
4. Boom control valve Plug:
1) Assemblespoolassembly(77) to valve 107.8 F 14.7 Nm (11.0 % 1.5 kgm)
body. 5) Assembleretainer (52) and spring (511,
2)Assemble retainer(76)and spring (75), 'then fit O-ring to case (50) and install.
then fit O-ring to case (74) and install. Case mounting bolt:
Case mounting bolt: =
30.9 2 3.4 Nm (3.15 0.35 kgml
-
=
30.9 t 3.4 Nm (3.15 0.35 kgml
3) Assemble spring (73) and piston (721, and 7. Arm control valve
install plug (71). 1) Assemble spool assembly(49) t o valve
Plug: body.
107.8 t 14.7 Nm (11.0 c 1.5 kgm) 2)Assembleretainer(48)and spring (471,
4) Assembleretainer (70) and spring (691, then fit O-ring to case (46) and install.
then fit O-ring to case (68) and install. Qiix~ Case mounting bolt:
Case mounting bolt: 30.9 +: 3.4 Nm I3.15 2 0.35 kgm}
30.9 t 3.4 Nm (3.15 t 0.35 kgm} 3) Assembleretainer(45) and spring (441,
then fit O-ring t o case (43) and install.
5. RH. travel control valve, L.H. travel control Case mounting bolt:
valve 30.93.4 Nm (3.15
0.35 kgm)
-I) P,sseR?b!e spec! assemb!y (67)to valve 4) Assemble spring (41: afid piston (42), arid
body. install plug (40).
2) Assemble retainer (66) and spring (651, Plug:
then fit O-ring to case (64) and install. 107.8 z 14.7 Nm i11.0 z 1.5 kgm)
Case mounting bolt:
30.9 f 3.4 Nm (3.15 f 0.35 kgm)
3) Assembleretainer(63)and spring (62),
Case mounting bolt:
30.9 2 3.4 Nm (3.150.35 kgm}
PC300, 350-6 30-1 03

0
8. LS shuttle valve, pump merge/divider valve,

boom regeneration valve, block
1) Assemble springs (36)and (39)and spools
(33)and (34)in mergeldivider valve (35),then
install plugs (37)and (38).
Plug (38):
=
39.2 2 4.5 Nm (4.0 0.5 kgm)
Plug (37):
=
151.9 24.5 Nm (15.5 c 2.5 kgm}
2) Assemble boom regeneration valve (86)and
spring !55) In va!ve body, thel? IRsta!! merge/ I I
divider valve assembly (32). I
* Tighten the mounting bolts in the order
CWPO6155
shown in the diagram on the right.

Mounting bolt:
166.6 2 9.8 Nm I17 t 1 kgm)
3) Install LS shuttle valves (30)and (31).
Mounting bolt:
66.2 2 7.4 Nm I6.75.z 0.75 kgm)
4) Installblock (87).
Mounting bolt:
30.9 2 3.4 Nm I3.15 2 0.35 kgm)
9.LS select valve

Install LS select valve (29).
LS select valve: CDP00544
127.4 t 19.6 Nm I13 2 2 kgm)
10.Pressure compensation valves

Check themarksmadeoneachpressure
compensation valve during disassembly,and
install in the correct position.
1) Beforeinstallingpressurecompensation
valves below, install check valve (88).
2) Fit O-rings and install arm IN pressure com-
pensationvalve (41, L.H. travel FORWARD
pressure compensation valve (61, left swing
pressurecompensationvalve (81, boom
LOWER pressurecompensationvalve (101,
R.H. travel FORWARD pressure compensa-
tion valve (121, bucket CURL pressure com-
pensationvalve (141, and boom Hi RAISE
pressure Compensation valve (16).
Pressure compensation valve:
392 19.6 Nm (40 2 2 kgm}
3) Fit O-ringsandinstall arm OUTpressure
compensationvalve (31, L.H. travel FOR-
WARD pressure compensation valve(5),right
swingpressurecompensationvalve (7),
boom RAISE pressure compensationvalve
(91, R.H. travel REVERSE pressure compen-
sationvalve ( I l ) , bucket DUMP pressure
compensation valve (131,and arm Hi IN pres-
sure compensation valve (15).
Pressure compensation valve:
392 2 19.6 Nm (40z 2 kgm)
30-104 PC300, 350-6
0
11. Arm regeneration valve

Assemble arm regeneration valve (93)and
spring (921, then install plate (91).
* Tighten the mounting bolts in the order
shown in the diagram on the right.
Plate mounting bolt:
66.2 2 7.4 Nm (6.75 t 0.75 kgm}
12. Unload valve, safety-suction valve,suction valve

ii Fit O-rings and instaii plugs (271 ana iZSi.
Plug: 49 t 9.8 Nm i5 I 1 kgml
2) Fit O-rings and install suction valve assem-
blies (191, (201,(21), (231,and (24).
Suction valve:
147 2 9.8 Nm (15 I1 kgm)
3) Fit O-rings and install safety-suction valves
(17L(181, (22Land (26).
Safety-suction valve assembly:
147 F 9.8 Nm (15 2 1 kgm}
4) Fit O-ring and install unload valve assembly
(11.
Unload valve assembly:
166.6 2 19.6 Nm (17 i 2 kgm)
13. Main relief valve

Fit O-ringandinstallmainreliefvalve as-
sembly (2).
Main relief valve assembly:
53.9 z 4.9 Nm (5.5 0.5 kgm}
PC300,350-6 30-105
0
DISASSEMBLY AND ASSEMBLY PUMP MERGE/DIVIDER
VALVE
DISASSEMBLY OF PUMP MERGEIDWIDER VALVE ASSEMBLY
1 P2
0
s
s
g--3
1
4
/& I
CEP00547
1. Remove plug ( 2 ) from valve body (11, then re-

move spring (3)and spool (4).
2. Remove plate (5).
3. Remove plug (61, thenremovespring (7) and
spool (8).
4. Remove plug (9).
* After disassembling, if there is any abnormality
in body (1) or spools (4) or (8),replace the whole
pump merge/divider valve assembly.
ASSEMBLY OF PUMP MERGE/

DIVIDER VALVE ASSEMBLY
Before assembling, coat the sliding surface with
engine oil.
1. Fit O-ring to plug (9)and install to valve body

(1).
=
Plug (9):39.2 5.9 Nm 14.0 t 0.6 kgml
2. Assemble spool ( 8 ) and spring (7}, then fit 0-

ring to plug (6) and install.
Plug (6):39.2 2 5.9 Nm 14.0 2 0.6 kgml
3. Fit O-ring to plate (5) and install valve body.
4. Assemble spool (4) and spring (3), then fit 0-

ring to plug (2) and install.
Plug (2):
152 2 24.5 Nm (15.5 f: 2.5 kgrn)
30-1 06 PC300,350-6
0
'DISASSEMBLYAND ASSEMBLY PRESSURE COMPENSATION VALVE
DISASSEMBLY OF PRESSURE COMPENSATION VALVE

ASSEMBLY
A
F
CEW0548
The structure of the parts for pressure compen- Pressure compensation valves
sationvalves A - I isthe same, but the part A: Arm IN Hi
numbers for the component parts is different, B: Boom RAISE Hi
so be careful when assembling. C: Boom LOWER
1. Remove piston sub-assembly (2) and piston (3) D: R.H. travel REVERSE, L.H. travel
from sleeve (11, then remove seal (4). REVERSE
* Sub-piston assembly (2) is assernbled to R.H. travel FORWARD, L.H. travel
FORWARD
pressure compensation valves A-C, E-I, and
piston (3) is assembled to pressure cornpen- E. Boom RAISE
sation valves D. F: Arm OUT
2. Remove spring (51, then remove ring (6) and 0- G: Bucket CURL
rings (7) and ( 8 )from sleeve (1). H: Arm IN
* Afterdisassembling, if there is any abnor- I: Right swing,leftswing,bucket dump
mality in sleeve (11, seal (41, piston sub-as-
sembly (2), or piston (31, replace the whole
pressure compensation valve assembly.
ASSEMBLY OF PRESSURE
COMPENSATION VALVE
ASSEMBLY
%&re assembling; coat the sliding surface with
engine oil.
1. Install O-rings ( 8 ) and (71 and ring ( 6 ) t o sleeve
(11.
2. Assemble spring (51, thenassemble seal (4) to
piston sub-assembly (2) and piston (3),and in-
stall t o sleeve.
PC300, 350-6 30-1 07

0
DISASSEMBLY AND ASSEMBLY SERVO VALVE H)R FRONT PUMP
REMOVAL OF SERVO VALVE

ASSEMBLY FOR FRONT PUMP
1. Disconnect TVC solenoid connector (1) (CN-C13).
2. Disconnectclamp (2).
3. Disconnect LS-EPC nose i3j, is pressurenose
(41, and pump circuit pressure hose (5).
* Fit blind plugs in the disconnected hoses.
4. Remove servo valve assembly(6)for front pump.
a
INSTALLATION OF SERVO
VALVE ASSEMBLY FOR FRONT
PUMP
Carry outinstallation in the reverseorderto
removal.
pTJ
* Be careful not to let the O-ring or filter fall
out when installing.
* Tighten the mounting bolts gradually on op-
posite sides in turn.
Servo valve mounting bolt:
=
66.2 t 7.4 Nm I6.75 0.75 kgm)
* Check the performance of the work equip-
ment, travel, and swing.
For details, see TESTING AND ADJUSTING.

level.
30-108 PC300, 350-6

0
DISASSEMBLY AND VALVE
ASSEMBLY
SERVO REAR FOR PUMP
REMOVAL OF SERVO VALVE

ASSEMBLY FOR REAR PUMP
A Disconnect the cable from the negative ter- (4
A Loosen the oil filler cap slowly t o release the
1. Disconnect TVC solenoid connector I1 1 (CN-CO4).

2. Disconnectconnector bracket (2) f r o m servo
va he.
3. Disconnect LS-EPC hoses (3)and (41, LS pres-
sure hose (51, and pump circuit pressure hose
(6).
4. Remove servo valve assembly (7)for rear pump.
J
p
-
INSTALLATION OF SERVO
VALVE ASSEMBLY FOR REAR
PUMP
Carry outinstallationinthereverseorderto
removal.
* Be careful not to let the O-ring or filter fall

out when installing.
* Tighten the mounting bolts gradually on op-
posite sides in turn.
Servo valve mounting bolt:
66.2 2 7.4 Nm (6.75 t 0.75 kgml
* Check the performance of the work equip-
ment, travel, and swing.
For details, see TESTING AND ADJUSTING.
Refilling with oil (hydraulictank1

* Add oil through the oil fillerto the specified
level.
RUE the engine t O clrcu!ats the el! thmugh
PC300, 350-6 30-1 09

0
DISASSEMBLY AND ASSEMBLY LS-EPC SOLENOID VALVE
REMOVAL OF LS-EPC
SOLENOID VALVE ASSEMBLY
Disconnect the cable from the negative (-1 ter-
minai of the battery.
A Loosen the hydraulic tank oil filler
cap slowly to
1. Open main pump side cover.
2. Disconnect wiring connector (CN-ClO).

* It is installed at the bottom of the EPC sole-
noid valve mounting bracket.
3. Disconnect hose (1) going to main pump.
4. Disconnect hose (2) going to hydraulic tank.
5. Disconnect hose (3)coming from solenoid valve.

6. Remove LS-EPC solenoid valve assembly (4).
INSTALLATION OF LS-EPC
SOLENOID VALVE ASSEMBLY
removal.
30-110 PC300, 350-6

0
VALVE
DISASSEMBLY
SOLENOID
AND ASSEMBLY
REMOVAL OF SOLENOID
VALVE ASSEMBLY
Disconnect the cable from the negative ( 4 ter-
Loosen the hydraulic tank oil filler cap slowly to
* Makematchmarks on the hosesandcon-
nectors.
1. Disconnectsolenoid wiring connectors (1).

* Disconnectallconnectors (V02,03,04, 05,
06, and 07).
2. Disconnect hose (2) coming from PPC.

3. Disconnect hose (3) going to control valve.
4. Disconnectdrainhose (4).
5. Disconnect hose (5) coming from accumulator.
6. Disconnecthose(6)comingfromself-pressure
reducing valve.
7. Disconnectoutlethoses (7) coming from each
solenoid valve.
8 . Remove mounting bolts, then remove solenoid
valve assembly (8).
e Whenremovingsolenoidvalve as anindividual
part
1) Remove mounting bolts (91, then remove coil
(10).
2)Remove msvab!e Iron core !ll! and O-ring
(12).
3) Remove cage !13! and spool !14!.
.Irt Cage (13):
PC300-6 Serial No.: 33001 - 33465
PC350-6 Serial No.: 12001 - 12283
4) Removewasher (151, spring (16). and stop-
per (17), then clean valves.
i 1 = I'6 0
CWPOG
INSTALLATION OF SOLENOID
VALVE ASSEMBLY IO
11
0 Carry outinstallation in the reverse orderto 9 !2

removal.
13
14
- Mounting bolt: 15
3.92 = 0.4 Nrn 10.4 2 0.04 kgml
16
CWPO6161 17 CWPOG 1 6 2
PC300, 350-6 30-1 11

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
REMOVAL OF WORK
EQUIPMENT PPC VALVE
1
ASSEMBLY
Lower the work equipment completely t o the
ground and stop the engine. Then loosen the oil
the hydraulic tank.
1.
3 2 CEPO0419
2. Disconnect wiring connector (1).
3. Remove joint bolt (21, and disconnect hose (3).

*Make match marks on the hoses. a
4. Remove mounting bolts, raise PPC valve assem-
bly (41, then disconnect hoses (5) and (61, and
remove.
INSTALLATION OF WORK
EQUIPMENT, PPC VALVE \ I CEP00420
ASSEMBLY
Carry outinstallation inthe reverse orderto
removal.
w Hose mount joint bolt:

29.4 z 4.9 Nrn 13.0 = 0.5 kgrn}
Hose mount joint bolt:

39.2 4.9 Nrn t4.0 2 0.5 kgrn}
IC If thereis excessive play in thecontrol le-

vers, Idlust the PPC \./?!\le.
Adjusting PPC valve.
30-112 PC300,350-6
0
DISASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Remove nut (I),
then remove disc (2) and boot
(3).
2. Remove bolts, then remove plate (5).

j , Do notremovejoint (4) unless it is to be
replaced.
3. Remove seal ( 6 ) and collar (7).
4. Pulloutpiston (8),andremoveretainer (91,

springs ( I O ) and (1I), and shim (12).
* Spring ( I O ) consists of two springs each of
two types with different installed loads, so
check the mounting position (hydraulic port)
and markwith tags to prevent mistakeswhen
installing.
5. Pull out valve (13) from body (14).
PC300, 350-6 30-113

0
ASSEMBLY OF WORK
EQUIPMENT PPC VALVE
ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) tovalve(13).
* Whenassemblingspring (111, setthe end
withthesmallcoildiameter(insidediam-
eter) a t shim (12) end.
3. Assemblespring (IO), retainer (91, andpiston
!8!.
The number of loops in the coil for spring
(IO) is differentfor each of thehydraulic
ports below, so be careful when installing.
Position of port Free length of spring (mm)

PI, P2 44.4
P3, P4 1 42.4
* The position of each port is marked at the

bottom of the valve body.
-
6Piston: Grease (G2-LI)
* Whenassemblingpiston (81, coat theout-
side of the piston and the inside of the hole
in the body with grease.
4. Fit O-ring tocollar (7) andassemble inbody
(141, then install seal (6).
5. Installplate (5).
Mounting bolt:
=
13.2 1.5 Nm (1.35 F 0.15 kgm}
-
6. Installjoint (4).
Sliding portion of joint: Grease (G2-LI)
6Female thread of body:
* Coat two places on the female thread with
one drop of Loctite each as shown in the
diagram on the right.
Joint: 44.1 t 4.9 Nm (4.5 2 0.5 kgm}
* Keep strictly to the tightening torque.
CEP00425 I
7. Assemble boot (3) and disc (21, and tighten with
nut ( I ) .
.I...-
pdiii: I IL.C)n = ".._
1 4 I Iwn 1 1 1.3 t i.5 icgmj
C l l r
* After assembling the disc, adjust the height

of the disc.
Adjusting PPC valve.
30-114 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
REMOVAL OF TRAVEL PPC

VALVE ASSEMBLY
Lower the work equipment completely to the
ground and stop theengine. Then loosen the oil
the hydraulic tank.
1. Remove travel PPC valve undercover.
2. Removefioormat.
3. Remove pedals (1) and levers (2). 1 / I / CEW0426
4.
cover
Remove (3). a
5. Remove covers (4), then remove springs (5).
6. Disconnect 6 PPC hoses (71,and remove travel

PPC valve assembly (8).
INSTALLATION OF TRAVEL
PPC VALVE ASSEMBLY
I
Carryoutinstallation in thereverseorderto
removal.
Cover mounting bolt:

19.6 f 2.0 N m (2.0 t 0.2 kgm}
5 CEW0428
-1
Hcse mcunting ;=ifit bolt;
(width across flats: 30mm):
=
39.2 4.9 Nm (4.0 2 0.5 kgml
Hose mounting joint bolt

(width across flats: 22mm):
29.4 z 4.9 Nm (3.0 t: 0.5 kgm}
8
PC300, 350-6 30-115

0
DISASSEMBLY
TRAVEL
AND ASSEMBLY PPC VALVE
DISASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Remove screw (11, then remove lever (2).
2. Remove mounting bolts (31, then remove case

and shaft assembly (4).
3. Remove mounting bolts (5), then remove plate

(6) together with damper assembly (7).
L 3 *
1 i
* Check the thicknessand mounting position
sf washer (l$)*
4. Remove mounting bolts (81, then remove damper

assembly (7) from plate (6).
5. Remove seal (9) and collar (10).
6. Pulloutpiston (ll), andremoveretainer (121,

springs (13) and (141, and shims (1.5).
*Check thenumberand thickness of shims
(15) for each mounting position, and keep in
a safe place.
7. Pull out valve (16) from body (17).
14
15
16
17
CEW0533
30-11 6 PC300,350-6
0
DISASSEMBLY
TRAVEL
AND ASSEMBLY PPC VALVE
ASSEMBLY OF TRAVEL PPC

VALVE ASSEMBLY
1. Assemble valve (16) in body (17).
2. Assembleshim (15) and spring (14) tovalve
(16).
* Assemblethe same number and thickness
of shim (15) as was removed during disas-
sem bly.
Standard shim thickness: 0.3 m m
it Spring ( i 4 j isnorsymmetricai at therop
and bottom, so assemble with the small coil
diameter (inside diameter)a t the shim end.
3. Assemblespring (13),retainer (12), and piston
(11).
Outside circumference of piston, body
hole: Grease (62- LI)
4. Fit O-ringtocollar ( I O ) and assemble in body
(171, then install seal (9).
5. Installdamperassembly(7) to plate (6), then
tighten mounting bolts (8).
Mounting bolt: Thread tightener (LT-2)
Mounting bolt:
*
4.4 0.5 Nm (0.450.05 kgm]
6. Install plate (6) and damper assembly (7) as one
unit, then tighten mounting bolts (5).
* Temporarily assemble standard washer (1.6
mm) forwasher (18).
After completing theassembly, measure the
difference in the angle whenthe feft and
right levers areoperated fully. If the angle is
greater than 0.7", change the thickness of
washer (18) to make the difference less than
0.7".
* Washer thickness: 1.0, 1.3, 1.6 m m
Ir If the washer is thinner by 0.3 mm, the
angle of the fullstroke is 0.39" greater.
Mounting bolt:
*
30.9 i 3.4 Nm 13.15 0.35 kgm}
7. Install case and shaft assembly (4), then tighten
mounting bolts (3).
Rocking portionof shaft, contact portion
of lever and piston: Grease (G2-LI)
Mounting bolt:
*
27.9 3.4 : hii2.85 t 3.35 kgm]
8. Install lever (2),then tighten screw 11).
Rocking portion of lever pin and plate:
Grease (G2-LI)
*
Screw: 8.8 1.0 Nm (0.9 2 0.1 kgm)
CEP00533
PC300, 350-6 30-117

0
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
REMOVAL OF PPC SHUTTLE

VALVE ASSEMBLY
ground and stop the engine. Then loosen theoil
the hydraulic tank.
A Make match ma'rks at the male and female ends
of the oil pressure switch connectors.
* Before disconnecting any hosesi check the dis-
tinguishingtapestucktothe hose, ormake
match marks.
I. Disconnect 8 oil pressure switch connectors (1).
2. Disconnect 12 PPC hoses (2).
3. Disconnect 15 control valve hoses (3)(quick joint

connection). a
4. Disconnect 4 straight-travei noses (4j.

*The elbows on the front two hoses are long,
so hold the elbow witha wrench when dis-
connecting the hoses.
30-118 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
5. Disconnectclamp (5).
6. Remove mounting bolts, then removePPC shut-

tle valve assembly (6).
INSTALLATION OF PPC
SHUTTLE VALVE ASSEMBLY
removal.
Check thatthequickjointdoesnot come out

when the hose is pulled.
Refilling with oil (hydraulictank)

level.
PC300, 350-6 30-1 19

0
BLY AND
DISASSEMBLY PPC SHUlTLE VALVE
DISASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
SDPOOBlO
1. Disconnection of valve
Remove mounting bolts(11, and disconnectshut-
tle valve assembly (2),travel junction valve as-
sembly (3) and plate (4).
2. Disassembly of shuttle valve assembly

1) Remove 8 oil pressure switches (5).
2) Remove 2 slow return valves (6).
3) Removeshuttlevalve (7).
4) Remove plugs (81, then remove balls (9).
* There are 6 plugs and 6 balls.
3. Disassembly of travel junction valve assembly

1) Remove 2 each of plug (IO),spring (1I), and
retainer (12).
?\ .Remnve
-, ."..._." -r--.
cnnnl (73).
3) Remove 2 plugs (14).
30-1 20 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY VALVE
PPC SHUTTLE
ASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
SOP00610
1.
Assembly of travel junction
valve
assembly. 4) Install 8 oil pressureswitches (5).
1) Fit O-ring and install 2 plugs (14).
Plug: 3. Connection of valve
*
17.2 2.5 Nm (1.75 z 0.25 kgml FitO-ringandassembleshuttle valve as-
2) Assemble spool (131, andinstall 2 re- sembly (21, travel junction valve assembly
tainers (12) and springs (11). (3) and plate (41, then tighten mountingbolts
3) O-ring
Fit and
install 2 plugs (10). (1).
Plug: Q Z E I Mounting bolt:
107.9 r 14.7 Nm (11.0 t 1.5 kgm) 66.2 2 7.4 Nm (6.75 2 0.75
kgm}
2.Assembly of shuttle valve assembly

1) Fit O-ringand assemble balls (91, then
install plugs (8).
* There are 6 plugs and 6 balls.
Plug:
*
34.3 2 4.9 Nm (3.5 0.5 kgml
2) Fit O-ring and Instal! shutt!e valve !7L
* If the shuttle valve has been disas-
sembled, be careful of the direction
of installation of the poppet when
assembling.
3) Fit O-ring and install 2 slow return valves
(6).
* If the slow return valvehas been dis-
assembled, be careful of the direc-
tion of installation of thepoppet
when assembling.
PC300,350-6 30-121
0
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
REMOVAL OF BOOM LOCK

VALVE ASSEMBLY
ground and stop theengine. Then loosenthe oil
the hydraulic tank.
1. Drain hydraulic oif.

4
Hydraulic oil: Approx. 200
63
I
2. Disconnect drain hose (1) and PPC hose (2).
* Install blind plugs in the disconnected hoses.
3. Remove tube clamp (3).
4. Disconnect tube (4) coming from control valve.
5. Disconnect tube (5) coming from boom cylin-

der,
6. Remove mounting bolts (6), then remove boom

lock valve assembly (7).
INSTALLATION OF BOOM
LOCK VALVE ASSEMBLY
Carry outinstallation in thereverse order to
removal.
Refilling with oil

Irr Add oil through the oil filler to the specified
level.
Bleeding air
* Bleedthe air.
Bleeding air.
30-122 PC3Q0, 350-6

0
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
DISASSEMBLY OF BOOM
LOCK VALVE ASSEMBLY
1. Remove safety valve assembly (1).
*The safetyvalveassemblycannotbead-
9
justed when it is mounted on the machine,
so do not disassemble it.
2. Remove body (2).thenremovespring (3)and

check valve (4).
ASSEMBLY OF BOOM LOCK

VALVE ASSEMBLY
* Coat theslidingpartswithengineoilbefore
assembling.
1. Assemblespool (9), seat (81, spring (7), and CEP00471

washer (6) to body (Z), then fit O-ring and install
plug (5).
Plug: 39.2 2 4.9 Nm f4.0?: 0.5 kgm}
2. Assemble check valve(4) and spring (3)to body

(7Gj, rnen fit O-ring ana instaii body (2j.
3. Fit O-ring and install safety valve assembly ( I ) .

Safety valve:
225.5 2 9.8 Nm (23 1 kgm)
PC300, 350-6 30-1 23

0
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM
CYLINDER ASSEMBLY I
a Extend the arm and bucket fully, lower the work

equipment completely to the ground, and put
the safety lock lever in the LOCK position.
1. Disconnectgreasehose (1).
2. Sling boom cylinder assembly (21, and remove

lock bolt (3).
I I
3. Remove plate (41, then remove head pin ( 5 1 . m
Ilr Thereareshimsinstalled, so check the
number andthickness, and keep in a safe
place.
4. Startengine,andretract piston rod, thentie

piston rod with wire to prevent it from coming
out.
* Set stand @ underthecylinder assembly,
and adjust the position for slinging the cy!-
inder assembly.
A Release the remaining pressure in the hy-
draulic circuit.
Releasing remainingpressure in hydraulic 1 CEP00057
circuit.
5. Disconnecthoses (6).
6. Remove plate, then using forcing screws 0, re-

move bottom pin (7), and remove boom cylin-
der assembly (2).
* Thereareshimsinstalled, so check the
number and thickness, and keep in a safe
place.
& Boom cylinder assembly: 300 kg
30-1 24 PC300, 350-6

0
CYLINDER DISASSEMBLY
BOOM AND ASSEMBLY
CYLINDER ASSEMBLY
Carryoutinstallation in the reverse order to
removal.
* When tightening the locknut, tighten so that

the clearance between the plate and nut is
-
0.5 1.5 mm.
Inside surface of bushing whenassem-

bling pin: Anti-friction compound (LM-PI
I CEP00059
Greasing after assembling pin:

Grease (LM-GI
A When aligning the position of the pin hole,
never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clear-
ance between theendface of therodof
cylinder (2) and plate (4) is less than 1.0
mm.
Standard shim thickness:
1.0 mm, 1.5 m m
a& Inside surface of bushing when assem-

6 Greasing after assembling pin: I
Grease (LM-G)
never insen your fingers in the pin hole.
A Adjust the shim thickness so that the clear-
ance between the end dace of the b ~ t h ~ nof?
cylinder (2)and bracket (8) is less than 1.0
mm.
Standard shim thickness:
1.0 mm, 1.5 m m
Heeding air
* Bleed the air.
1 Max. I mm CDP00061
Bleeding air.
Reiiiiing with oii ihybrauiic iankj

.k Add oil through the oil filler to the specified
level.
PC300, 350-6 30-1 25

0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
I 3
A Extend the arm cylinder piston rod to a point
approx. 200 m m before the end of the INstroke,
lower the work equipment completely to the
ground, then set the remaining safety lock lever
to the LOCK position.
I. Set block 0between arm cylinder and boom. 2
2. R ~ ~ Qplate
w !I!, then rernwe head pin !2!.
I
3. Start engine,and retract piston rod, then tie
out.
draulic circuit.
Releasingremainingpressure in hydraulic
circuit,
4. Disconnect hoses (3).
5. Disconnect greasehose (4).
6. Raise arm cylinder assembly (51,removeplate

(6), thenremovebottompin (71, andremove
arm cylinder assembly (5).
* Thereareshimsinstalled, so checkthe
place.
Arm cylinder assembly: 430 kg (PC3001

440 kg (PC3501
30-126 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY
Carryoutinstallation in the reverseorderto
removal.
Inside surface of bushing when assem-

bling pin: Anti-friction compound (LM-P)
Grease (LM-G)
Inside surface. of bushing when assem-

Grease (LM-GI
a When aligning the position of the pin hole,
ance between the end face of the bottom of
cylinder (5) and bracket ( 8 ) is less than 1.0 -8
mm.
0 Standardshim thickness: 7.0 mrn
CDP00066
Bleeding air
*
0
Bleedthe air.
Bleeding air.

ir Add oil through the oii filler to the specified
level.
PC300, 350-6 30-127

0
CYLINDER
DISASSEMBLY
BUCKET
AND ASSEMBLY
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
A Extend the bucket cylinder piston rod to a point
approx. 200 m m before the end of the DUMP
stroke, lower the work equipment completely to
the ground, then set the safety lock lever to the
LOCK position.
1. Set block @ under arm top, block @ between

link and arm, and block 0 between bucket cyl-
inder and arm.
i 5
2. Remove lock bolt (1).
3. Remove plate (21, then remove head pin (3).
4. Start engine, andretractpiston rod, thentie

out.
Release the remaining pressure :I the hy-
draulic circuit.
Releasing remaining pressure in hydraulic
circuit.
5. Disconnecthoses (4).
6. Raise bucket cylinder assembly (51, remove plate

(61, thenremovebottompin (71, and remove
bucket cylinder assembly (5).
* Thereare shimsinstalled, so check the
place.
& Bucket cylinder assembly: 270 kg
30-1 2% PC300, 350-6

0
CYLINDER
DISASSEMBLY
BUCKETAND ASSEMBLY
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
Carry outinstallation in the reverse order t o
removal.
a* When tightening the locknut, tighten so that

0.5 - 1.5 mm.
6 Inside surface of bushing when assem-

Grease after assembling pin:
-
Max. 1 m m
Grease (LM-G)
a When aligning the position of the pin hole,
ance betweenlink ( 8 ) andlink (9) is less
than 1.0 mm.
Standardshim thickness: 0.8 m m 9
CDP00078
p g
bling pin:Antifriction compound IhM-B)
6 Grease after assembling pin:
Grease (LM-G)
aWhen aligning the position of the pin hole,
*
Adjust the shim thickness so that the clear-
ance between the endface of the bottom of
cylinder (5) and bracket (10) is less than 1.0
mm.
Standard shim thickness: 1.0 m m
Bleedingair
ir B i e d the air.
Bleeding air.

* Add Gi! through the ei! fI!!er k?the specified
level.
Run the engine t~ circulate the oil through
PC300,350-6 30-1 29
0
AND DISASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts,anddisconnect
head assembly (1).
3) Pull out piston rod assembly (2).
* Place a container under the cylinder to
catch the oil.
CLPO3941
4) Disassemble piston rod assembly as follows.

i) Set piston rod assembly (2) to tool U1.
t CLP03 179
ii) Remove piston assembly stopper screw

(3).
Screw size:
MI2 x pitch 1.75: Boom, Arm, Bucket
CLPO3779
R if screw i3i has been caulked strongly

and cannot be removed, screw it in
fully, then fit a tap to thethread and
pull it out.
I
1 DKP00498
I
30-1 30 P630, 350-6

0
E
0
p
w
Ih
8
n
I--
-n
0
W
-1
DISASSEMBLY
CYLINDER AND ASSEMBLY
HYDRAULIC
3. Disassembly of cylinderheadassembly
1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust 20
seal (17).
3) Remove rodpacking (18).
4) Remove buffer ring (19). 19
5 ) Remove bushing (20).
18
CLPO2322
30-1 32 PC300, 350-6

0
DISASSEMBLY
CYLINDERHYDRAULIC
AND ASSEMBLY
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY I
Jr Be carefulnotto damage the packings, dust

seals, and O-rings.
Jr Do not try t o force the backup ring into position.
Warm it in warm water (50 - SOOC) before fitting 0
it.
1. Assembly of cylinderheadassembly
I j using tooi u4, press fit busning i2Oi.
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
IIlzzull
CWP06181
CWPOG 1 8 2
4) Using toot U5, install dust seal (171, and se-
cure with snap ring (16).
5) Install backup ring and O-ring (15). I
17
CLP02322
2. Assembly of piston assembly

1) Using tool U2, expand piston ring (13). u3
*set the piston ring on tool ua, and turn
the handle 8 - 10 times to expand the
ring.
2) Set tool U3 in position, and compress piston
ring (13).
CWPO6 I83 CWPOGI 84
3) Install backup ring and O-ring (14).

4) Assembie wear ring ii2j.
5) Assemblering (11).
-k Be carefulnot to opentheendgapof
the ring toowide.
a Ring groove : Grease (G2-LI)
I CLPO3784
PC300, 350-6 30-I 33

0
DISASSEMBLY
CYLINDERHYDRAULIC
AND ASSEMBLY
3. Piston rod assembly

1) Set piston rod assembly (2) to tool U1.
i w
2) Assemble head assembly (7).

3) Fit O-ring and backup ring to collar (61, then
assemble.
Boomandarmcylinderonly
4) Assemble plunger (5).
Boom and armcylinderonly
* Check that thereis a smallamount of
play at the tip of the plunger.
CLPD3782
5) Set cushion plunger ( I O ) to piston rod, then

assemble 12 balls (S),and secure with cap
(8). .IO
Armcylinderonly
6 ) Assemble piston assembly (4) as follows.

When using rod and piston assembly (2)
again
* Washthoroughlyandremoveall
metal particles and dirt.
i) Screw in piston assembly (41, then
use tool U6 to tighten piston assem- CWPO6I 66
bly (2) so that position of screw
thread hole matches.
ft Remove aii burrs ana iiasnes with
a file.
ii) Tightenscrew (3).
I U6
Screw (3):
=
66.2 7.35 Nm 16.75 2 0.75 kgm)
I OWPOO715
30-134 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
iii) Caulk thread at 2 places with punch.

When using a new part for either or both /3
of rod or piston assembly (2)
* For therodwithbottomcushion,
mark the cushion plug position on
the end face of the rod.
Armcylinderonly Punch
I
? DKP00500
i) Screw inuntilpistonassembly
contactsend face of rod, then use
(4)
I
tool U6 to tighten.
Piston assembly (4):
294 z 29.4 Nm (30 e 3.0 kgm)
* After tightening the piston, check
that there is play in plunger (5).
Boom,armcylinderonly
ii) Machineoneholeusedtoinstall
screw (3).
* Align a drillhorizontalwiththe I DKP00501
V-groove of the threadof rod (2)
andpiston (41, thencarryout
machining.
* Forthecylinderwithbottom
cl;~hior;(arm zyiinder), avoid:Re
cushion plug position when ma-
chining.
0 Screwmachiningdimension (mm)
Drill Bottom Tap Tap

diameter hole deoth used deDth
10.3 27 12~1.75 20
I CLPO3792
iii) After machining, wash thoroughly to

remove all metal particles and dust.
iv) Tighten screw (31.
Screw (3):
66.2 L 7.35 Nm I6.75 t 0.75 kgm)
v) Caulk thread at 2 places with punch.
CLPO377Q
PC300, 350-6 30-1 35

0
AND DISASSEMBLY
7) Assemble piston rod assembly (2).

6 Seal portion: Grease (G2-Ul
* Set the end gap of the ring at the hori-
zontal(side)position,alignthe axial
DD
center of shaft and cylinder tube, then
insert.
.k After inserting, check that the ring is not
broken and has not come out, then push
in fully.
End oaD i n r i n u
DLP00502
8 ) Tightenheadassembly (1) with mounting I

bolts.
Mounting bolt :
Cylinder Tightening torque
Bucket 373 t 54.0 Nm I38.0 2 5.5 kgm)
Arm 530 t 78.5 Nm 154.0 t 8.0 kgm)
Boom 373 t 54.0 Nm 138.0 t 5.5 kgm}
I CLPO3941
9) Install piping.
30-136 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
A Extend the armand bucket fully, lower the work
equipmenttotheground, and set the safety
lock lever to the LOCK position.
1. Disconnectgreasehose (I).
2. Sling boom cylinder assembly (2), and remove
lock bolt (3).
3. Remove piate (41, then remove head pin ( 5 j . m
* Thereareshimsinstalled, so check the
. ..
number and thickness, and keep in a safe I CEP0005t
place.
4. Start engine, andretract piston rod, thentie
out, and lower cylinder onto stand.
* Disconnect the boom cylinder on the oppo-
site side in the same way.
draulic circuit.
Releasing remainingpressureinhydraulic
circuit.
5. Disconnect armcylinder hoses (6) and bucket
cylinder hoses (71, and secure to valve withrope.
6. Disconnectwiringconnector ( 8 ) forworking
lamp.
I
7 . Remove plate, and set tool V to boom foot pin
(9).
8, Raise workequipment assembly ('IC% ther? re- Y 9
move boom foot pin (9) using tool V, and re-
moveworkequipmentassembly (IO). m
Sr Thereareshimsinstalled, so check the
place.
Work equipment assembly: 5700 kg
CDPOO280
281
PC300, 350-6 30-1 37

0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
Carry outinstallationinthereverseorderto
removal.
* When tightening thelocknut, tighten so that

-
8.5 1.5 mm.
p
J
& Inside surface of bushing whenassem- CEP00059
aGrease after assembling pin:
Grease (LM-GI
Sr Adjust the shim thickness so that the clear-
ance betweentheendface of the rod of
cylinder (2) andplate (4) is lessthan 1.0
mm,
Standardshim thickness:
1.0 mm, 1.5 m m
aa Inside surface of bushing whenassem-

a Grease after assembling pin:
Grease (LM-G)
A When aligning the position of the pin hole, Max. 1 mm
_I_
ance between the end faceof the foot of
boom (11) and bracket (12) is less than 1.0
mm.
0.8 rnm, 1.5 m m
Bleeding air 11 12
* Bleed the air. CDW0282
Bleeding air.

Jc Add oil through the oil fillerto the specified
level.
30-1 38 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY BUCKET
REMOVAL OF BUCKET
ASSEMBLY
A Set the back of the bucket facing down, lower
the work equipment completely to the ground,
and set the safety lock lever to the LOCK posi- 2
tion.
1
1. Remove lock bolt ( I ) .
2. Remove connectingpin (2) betweenlinkand

bucket.
*Thereareshimsinstalled, so checkthe CEP00285
number and thickness, and keep in asafe

place.
3. Start engine, and retract piston rod, then tie link

to arm with wire to prevent piston rod from
coming out.
4. Remove lock bolt (3).
5. Remove plate (4), thenremoveconnecting pin

(5) between
and
arm bucket. p
J
jc Thereareshimsinstalled, so checkthe
place.
6. Start engine, then raise workequipmentand

swing to remove bucket assembly (6).
Bucket assembly: 1050 kg
PC300, 350-6 30-139

0
DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION OF BUCKET
ASSEMBLY
removaf.
[Et, 113]
-
0.5 9.5 mm.
6 Inside surface of bushing whenassem-

i CEP00059
& Grease after assembling pin:

Grease (LM-G)
AWhen aligning the position of the pin hole,
*Adjust the shim thickness so that the clear-
ance between the end face of the boss of
bucket (6) and link (7) is less than 1.0 mm.
* Standardshimthickness: 0.8 mm
1x4)
bling pin: Anti-friction compound ILM-PI
& Grease after assembling pin:
Grease (LM-GI
I Max. 1 mm
CDP00288

*Insert the O-ring at the end face of the bucket
a b
boss securely.
*Adjusting bucket clearance.
1) Measureclearance a betweenarm ( 8 )
and bushing (9).
* It is easier to measure if the bucket 1
s4
is moved to one side so that all the
play is in one place.
2) Select shim thickness b so that clear-
ance a is 0.5 - 1.0 mm.
* Standardshimthickness: CDP00284
0.5 mm, 1.0 mrn

3) Installselected shim, then installplate
14.
30-140 PC300,350-6
0
DISASSEMBLY AND ASSEMBLY ARM
REMOVAL OF ARM ASSEMBLY

1. Remove bucket assembly.
For details, see REMOVAL OF BUCKET ASSEM-
BLY.
2
2. Secure link to armwith wire.
A Extend the arm cylinder piston rod atopoint
approx. 200 rnm before the end of the IN
stroke, then lower the arm on to block @
and stand 0.- and set the safety lock leverto
the LOCK position.
3. Set block @ between arm cylinder and boom.
4. Remove plate(I); then remove arm cylinder head

pin (2).
5. Startengine,andretractpiston rod, thentie

out.
draulic circuit.
Releasing remaining pressure in hydraulic
circuit.
6. Disconnect 2 bucket cylinder hoses (3).
7. Remove plate (4), then remove connecting pin

(5) between
boom.
and
arm
f Thereareshimsinstalled, so check the
a
number and thickness, ana keep in a safe
place.
a. Start engine, then raise boom and swing to re-

move arm assembly (6).
& Arm assembly: 1500 kg
PC300, 350-6 30-141

0
DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION OF ARM
ASSEMBLY
Carry Out installation inthe reverse orderto
removal.

bling pin:Anti-friction compound (LM-P)
Grease {LM-GI
Inside surfaceof bushing when assem-

bling pin: Anti-friction compound (LM-P) Max. 1 m m
-I-
Grease (LM-GI
never insert your fingers in the pinhofe.
arm (6) and boom ( 7 ) is below 1.0 mm.
* Standard shim thickness: 1.0 mm
Bleeding air
* Bleed the air.
CDP00292

Bleeding air.

leveI.
30-142 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY BUCKET, ARM
REMOVAL OF BUCKET, ARM

ASSEMBLY
Extend the bucket cylinder piston rod to the end
of the CURL stroke, and the arm cylinder piston
rod toa point approx. 200 mm before theend of
the IN stroke. Then lower the work equipment
completely to the ground, and set the safety
lock lever t o the LOCK position.
1. Set block @ t o bucket cylinder bottom mount-

ing boss portion of arm.
2. Remove plate (I), then remove arm cylinderhead

pin (2).
3. Start engine, andretract piston rod,then tie

out.
draulic circuit.
Releasing remainingpressure in hydraulic
circuit.
4. Disconnect 2 bucket cylinder hoses (3).
5. Removeplate (4), then remove connecting pin

(5) between arm and boom.
* There are shimsinstalled, so check the
place.
6. Start engine, then raise boom and swing to re-

move bucket and arm assembly ( 6 ) .
Bucket, arm assembly: 2600 kg
CEP00295
PC300, 350-6 30-143

0
DISASSEMBLY AND ASSEMBLY BUCKET, ARM
INSTALLATION OF BUCKET,
ARM ASSEMBLY
Carry outinstallation in the reverse order t o
removal.
p g
Inside surface of bushing whenassem-
Grease (LM-G)
When a!lgning the positinn of the pin hole,
1x2f
bling pin: Anti-friction compound (LM-PI Max. 1 mm
Grease (LM-G)
*Adjgst the s h h thickr?ess so that the clear-
arm (6) and boom (7) is less than 1.0 mm.
Standardshimthickness: 1.0 m m
Bleeding air cowo2a2

* Bleed the air.
Bleeding air.

Jr Add oil through the oil filler to the specified
level.
30-144 PC300,350-6
0
DISASSEMBLY AND ASSEMBLY BOOM
ASSEMBLY
removal.

0.5 - 1.5 mm.
a Inside surface of bushing when assern-

I
CEP00059
Grease (LM-GI
never insert your fingers in the pin hole,
*Adjust the shim thickness so that the clear-
ance between the end face of therodof
cylinder (2) andplate (4) is less than 1.0
rnrn.
1.0 mm, 1.5 rnm
a Inside surface of bushing when assern- 2' CDPOOOM)

Grease (LM-G)
A
*
When aligning the position of the pin hole,
Adjust the shim thickness so that the clear-
-4 Max. 1 mrn
ance between the end face of the foot of

boom (10) and bracket (11) is less than 1.0
mm.
0.8 mrn, 1.5 rnm
. Bleeding
air 10 11
* Bleed the air. CDwO300
Bleeding air.
. Refilling withoil (hydraulictank)

level.
30-146 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
REMOVAL OF OPERATOR‘S
CAB ASSEMBLY
1. Remove floor mat.
2. Remove operator’s seat (1).

* Be careful not to damage the covers.
d1l
CEW0438
3. Remove knob (2).
4. Remove 4 bolts and 1 clip, then remove panels

(3)and (4).
CEP00440
I CEW0441
7. Disconnect hose ( 8 ) and speaker wiring connec-

tor, then remove right cover (9).
* Lift up right cover (9) slightly before discon-
necting the speaker wiring connector.
\
CEW0442
PC300, 350-6 30-1 47

0
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB
8. Remove cover ( I O ) and duct (11).
9. Disconnect air conditioner cable (12).
10. Disconnect duct (13) a t front.
11. Disconnect 11 connectors (14).

* Panel:CN-X07 tMlC21)
* Controller: CN-CO1 (MIC13)
: CN-C02 (MIC21)
: CN-CQ3 (M16.20)
: CN-C16 (MIC17)
* Wiring harness intermediate
: CN-H12 (Sl6) White
: CN-HI3 6 1 6 ) Blue
: CN-HI4 (M6)
CN-HI5 (L2)
* Speaker: CM-MI3 (KES-2)
* Air conditioner: N o connector No.
12. Remove 4 mounting nuts and6 mounting bolts,

then lift off operator's cab assembly (15). a
Operator's cab assembly: 300 kg
%: Nut A: Bolt
* Check the length of the bolts.
CEP00445
iNSTALLATiON OF
OPERATOR'S CAB ASSEMBLY
removal.
Mounting nut:
=
277.0 31.9 Nm t28.25 2 3.25 kgml
I CEPW446
30-148 PC300, 350-6

0
D DISASSEMBLY
REMOVAL OF
COUNTERWEIGHT ASSEMBLY
1. Set lifting hook chains of counterweight assem-
bly in position, and sling.
2. Remove mounting bolts ( I ) .

* Check the location of the shims.
3. Lift off counteweight assembly (2).
Counterweight assembly: 5500 kg

I 1 CEP00536
INSTALLATION OF I
COUNTERWEIGHT ASSEMBLY
Carry outinstallation in thereverseorderto
removal.
*Adjust the stepped difference (top and bot-

t o m clearance) from the bodywork with
shims.
*Install so that the clearance between the door CEP00537
and counterweightandthe clearancebe-

tween the revolving frame and the counter-
weight are a uniform 10 & 5 mm.
& Thread of counterweight mounting bolt:
Thread tightener iLT-2j
Counterweight mounting bolt:
1814.1 t 98.1 Nm (185 2 10 kgm}
PC300, 350-6 30-1 49

0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
1. Open engine hood, then install tool X1 t o por-

tion @ of air cqnditioner compressor hose, and
collect refrigerant (R134a).
3. Loosen lock bolts (2) and (3).

I
4. Remove drive belt (4) from pulley.
5. Disconnect hose (6).
8; Remove lock bolts (2) and ( 3 , then remove air

conditioner compressor assembly(7).
ir it is difficuit to removethe C Q ~ ~ ~ W S S Q ~
mounting bolts, so remove together with the
bracket.
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Carry outinstallationinthereverseorder to
removal.
* Check that the O-rings are not damaged or 7 6 CWPO6169

deteriorated, then connect the hoses.
p g
For details, see.TESTING AND ADJUSTING,
Testing and adjusting belttension for air con-
ditioner compressor.
Chargingairconditioner with gas

* Using tool X1, charge theairconditioner
30-1 50 PC300,350-6
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
Collect refrigerant (R134a).
For details, see REMOVAL OF AIR CONDITIONER
COMPRESSOR ASSEMBLY.
1. Remove control valve top cover and disconnect

condenser wiring connector (1) (M35).
2. Open air conditioner condenser side cover.
3. Disconnect hose (2) coming from air conditioner

compressor.
4. Disconnect hose (3)going to receiver t a n k . m

* The connection at the condenser end breaks
easily, so alwaysuse 2 wrenches:one
wrench to hold the connection and the other
to loosen the hose.
5. Remove mounting bolts, then remove air condi-

tioner condenser assembly (4).
INSTALLATION OF
CONDENSER ASSEMBLY
removal.
* Check that the O-rings are not damaged or

deieiio:ated, then connect the hoses.

* Usingtool X1, charge the air conditioner
PC300, 350-6 30-1 51

0
DISASSEMBLY
RECEIVER
AND ASSEMBLY TANK
REMOVAL OF RECEIVER TANK

ASSEMBLY
A Collect refrigerant (R134a).
2,
1. Open air conditioner condensersidecover.
Disconnect hose ! l ) corning from air cnndltIo.rler

condenser.
3. Disconnect hose (2) going to air conditioner unit.

MI 0 r
a
4. Disconnect clamp (3) of hose (1).
5. Remove 2 U-bolts (4), then remove receiver tank

assembly (5).
73
INSTALLATION OF RECEIVER
TANK ASSEMBLY
removal.
p
J
* Check that the O-rings are not damaged or
deteriorated, then connect the hoses.

* Usingtool X1, chargetheairconditioner
30-I 52 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY
a Disconnect the cable from the negative ( 4 ter-
1. Collect refrigerant (R134a).

2. Close heater warm water outlet valve at engine

end. I CEP00105
3. Remove operator’s seat.
4. Remove plate (11, then remove cover (2).

f The speaker is installed t o the cover, so dis-
connect the wiring connector (M73) of the
speaker.
6. Remove hose (4) from duct.
7. Remove cover (5) and duct (6).
8. Remove duct (7).
PC300, 350-6 30-1 53

0
DISASSEMBLY
ASSEMBLY AND AIR CONDITIONER UNIT
9. Disconnect wiring connector (8) (M26).
10. Disconnect wiring connector (9) (AC-I).
11. Disconnect cable (IO) from receiver.
12. Disconnect heater hose (1 ).

1
13. Disconnect air conditioner hose (12).
14. Remove air conditioner unit (13).

*
Check that all the connectors have been dis-
connected.
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY
9 Carry outinstallation in the reverseorderto
removal.
Refilling withwater
It Add water up to the water filler port.
Run the engineto circulate the water through
the system. Then checkthe water levelagain
at the reserve tank.

It Usingtool X1, charge theairconditioner
30-I 54 PC300, 350-6

0
DISASSEMBLY AND ASSEMBLY GOVERNOR, PUMP CONTROLLER
REMOVAL OF GOVERNOR,
PUMP CONTROLLER
ASSEMBLY
1. Slide operator’s seat fully forward.
2. Remove plate (1); then remove cover (2).

I CEP00105
* The speaker is installed to the cover, so dis-
connect the wiring connector (M73) of the
speaker.
4. Disconnect hose (4) from duct.
5. Disconnect 5 connectors (5).

* Connectors = (COI, 02, 03, 16, 17)
6. Remove governor and pump controller assem-

bly (6). m
INSTALLATION OF GOVERNOR,
PUMP CONTROLLER
ASSEMBLY
l Carry out installation in the reverse order to
rmwysl
‘V.I.” US.
pg
l Check the performance of the work equipment,
travel, and swing. For details, see TESTING AND
ADJUSTING.
PC300,350-6 30-155
0
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
REMOVAL OF MONITOR
PANEL ASSEMBLY
1. Remove 4 screws (I), and disconnect monitor

panel assembly (2)from bracket.
2. Disconnectconnectors (3),thenremovemoni-
tor panel assembly (2).
INSTALLATION OF MONITOR
PANEL ASSEMBLY
removal.
Check the mode settinganddisplayfunction.

For details, seeTESTING, ADJUSTING, AND
TROUBLESHOOTING.
I I - CEFO0437
30-1 56 PC300, 350-6

0
DISASSEMBLY AND
CONTROL
ASSEMBLY STAND CASE
REMOVAL OF CONTROL
STAND CASE
1. Tray
Inserta thin fiat-headedscrewdriverinto
notch at rear of tray (1) and lever up lightly
to release rear claw (2).
*The claw can only be released from the
rear.
I CEPOOB07 CEW608
Pull tray (1) to rear to remove.
2. Boot
1) Insert a thin flat-headed screwdriver between
boot (3)and (opper case (4,remove claw (Si
at front of boot from upper case, then raise
front.
2) Pull boot (3) to front to remove claw a t rear

of
3) Disconnectwiringconnector
for removed tray.
a
(7) fromhole
4) Push bcrot upi remove bo!t !8?,then IBrnCIVB

lever (9) and boot (3).
Ir Check the direction of the lever.
+ 5 CEW0604
PC300, 350-6 30-1 57

0
DISASSEMBLY
STANDAND
CONTROL
ASSEMBLY CASE
3. Upper case
1) Remove 4 upper case mounting screws (10).
i. 10
I CEP00421
1 CEW0422
2) Push bottom center of upper case (11) from I

both sides, and lift u p t o release claws at
both sides.
I CEW0423
3) Use a screwdriver from front of upper case

(11) to release claws (12) at front of case.
4) Removeupper case (11).
CEP00601 I I CfP00602
INSTALLATION OF CONTROL
STAND CASE
removal.
* When installing the boot, insert the claw at

the rear first.
* When installing the tray and upper case, in-

sert the claws at the front first.
30-158 PC300,350-6
0
40 MAINTENANCESTANDARD
Engine mount ............................................... 40-2

Swing machinery ........................................ 40-4
Swing circle ................................................. 40-6
Final drive .................................................... 40-8
Track frame and recoil spring ................... 40-10
Idler ............................................................... 40-12
Carrier roller ................................................ 40-14
Track roller ................................................... 40-15
Track shoe .................................................... 40-16
Hydraulic pump .......................................... 40-20
Control valve ............................................... 40-22
Self-reducing pressure valve ...................... 40-29
Suction-safety valve ................................... 40-30
Swing motor ................................................ 40-31
Travel motor ................................................ 40-32
Work equipment swing PPC valve ........ 40-33
Travel PPC valve ........................................ 40-34
Service PPC valve ...................................... 40-35
PPC shuttle valve, travel junction valve .. 40-36
LS-EPC valve ................................................ 40-37
Solenoid valve ............................................ 40-38
Center swivel joint ..................................... 40-39
Boom holding valve..................................... 40-41
Hydraulic cylinder ...................................... 40-42
Work equipment ........................................... 40-44
Dimensions of work equipment ................. 40-46
PC300. 350-6 40-1

0
m
I
I r---
a
l
a
w-
0
7
i i
MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
Check item Criteria Remedy
Backlash between swing

motor shaft and No. 1 sun
gear 0.18 - 0.29
3acklash between No. 1 sun 0.15 - 0.49

gear and No. 1 planet gear
3acklash betwee:: Nc. 1 0.17- 0.57 1.10

Aanet gear and ring gear
3acklash between No. 2 0.06 - 0.25 -

slanet carrier and coupling
3acklash between No. 1
Dlanet carrier and No. 2 0.38 - 0.66 1.20
sun gear Replace
Backlash between No. 2 sun 0.15- 0.49 0.90
afid NO.2 planet gear
Backlash between No. 2 0.17 - 0.57

p1ai;e: gear and ring gear
Backlash between coupling 0.07 - 0.23

and swing pinion
Backlash between swing 0 - 1.21

pinion and swing circle
Clearance between plate -

0.38 - 0.82
and coupling
Standard size Repair limit

Repair hard
Wear of swing pinion oil chrome plating
seal contact surface -
40 -:.loo or replace
PC300, 350-6 40-5

MAINTENANCE SWING CIRCLE
SWING CIRCLE
PC300-6 Serial No.: 33001 - 33465
PC358-6 Serial No.: 12801 - 12283
! I I
7
A
Unit: mm
I I
Check item
I Criteria I Remedy
Standard clearance Clearance limit

Clearance of bearing in
axial direction (when Replace
mounted on machine) 0.5- 1.6 3.2
I I I
40-5 PC300, 350-6

0
2
Z Z
P ?
.. ..
E
FINAL MAINTENANCE STANDARD
Unit: r n r n
-
i t eNo.
m Check I
I
Criteria
I t
Remedy
Standard ciearance Ciearance

iimit
Backlash between No. 1 I
1 sun gear and No. 1 planet
gear I 0.17 - 0.50 1.oo
Backlash between No. 1 0.24 - 0.64 1.oo

2 planet gear and ring gear
Backlash between No. 2 0.06 - 0.24 -

3 planet carrier and motor
-
Backlash between No. 2
4 sun gear and No. 2 planet 0.17 - 0.52 1.oo
sear I I I Fiepiace
I
I
Backlash between No. 2 0.21 - 0.64 1.oo
5 planet gear and ring gear ,
Backlash between No. 1
6 planet carrier and No. 2 sur 0.38 - 0.78 1 .oo
- gear
7 End play of sprocket shaft 8.10 - 0.15 -

I
8 Wear of sprocket teeth Repair limit: 6
I Standard size I Repair limit i Rebuild or

9 Sprocket tooth width replace
87 84
L
PC300, 350-6 40-9

MAINTENANCE
STANDARD FRAME
TRACK AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING

* The diagram shows the PC300-6
3
SAP00409
Unit: mm

1
/Standard size Tolerance 1 Repair limit
Top-to-bottom width of
idler guide
Track frame
I
I
123
I
I
+2
-1
4
I
I
127 1
I
Idler support 120 k0.5 118
Rebuild or
replace
Track frame 266 +3 27 1
Left-to-right width of idler -1
guide
support
Idler 1
I
261 1 -
I
259 1
Free length Installed Installed Installed
Free length
3ecoil spring x OD length load load Replace
40-1 0 PC300, 350-6

1
MAINTENANCE STANDARD IDLER
Unit: rnm
-
i
No Check item Criteria Remedy
Standard size I Repair limit

Outside diameter of
1 -
proruding portion 630
II
2 Outside diameter of tread 590 578
Rebul!c! c:
replace
3 Width of protrusion 10'1
-
4 Overall width 190

-
5 Width of tread 44.5 50.5
Tolerance Replace
Standard Standard Clearance
size Siiair Koie clearance limit bwhi!?.;
Clearance between shaft
6 and bushing
-0.225 +O. 130 0.21 5 -
80 -0,325 , -0,010 , 1.5
0,455 ,

7 and support Replace
I
Tolerance
Standard Standard Interference
l-&--L
1111Gl
^
^_^_^ L-&..,--A :AI-*
I G I G I I ~ GU G L V V G G I I I U I G I
size , shaft i ~ote , interference, limit
8
i 1 1 1
and bushing
-0.027
+0.087 0.064 -
87'6 +0.037 -0.079 0.166 Replace
bushing
Standard clearance Clearance limit
Side clearance of idler
9
[both sides) 0.68 - 1.22 2
-
PC300, 350-6 40-13

MAINTENANCE STANDARD ROLLER CARRIER
CARRIER ROLLER
2 1
Unit: mm
I I
No.1 Check i t e m Criteria Remedy

’ Outside diameter of flange
(outside) 200 -
I I I
Rebuild or
2 Outside diameter of tread 168 158 replace
I I
3
1 Widthoftread
I
I Interference between shaft
and bearing
Standard
size
Tolerance
1
Hole
Standard lnterferenct
interference
Shaft limit
+0.02 1 0
-0.0 15 I 0.002 -
0.036 1
,
Interference between roller
and bearing
1
-0.015 1
I
2:::; 1
I
0.009 -
0.059
I
Replace
0.01 - 0.24
40-14 PC300,350-6
MAINTENANCE STANDARD ROLLER TRACK
TRACK ROLLER
SBP00413
Unit: m m
i!
I
Standard
Repair size timit
Outside diameter of flange
216 -
(outside)
3ebuild or
168 180 -eplace
3 I Width of tread 49 55
27 -
Standard
Tolerance Standard
AI,-._.-.....A
I Clearance
and bushing 3eplace
15
-0.2 +O. 186 0.151 -
0.50 1 Iushing
Standard
size Shaft
interference between roiier
f
and bearing
72 +0.108 -0.006 0.014 - -
1 +0.008 -0.036 1 0.144 1
clearance
Standard
Clearance limit
Side clearance of idler leplace
(both sides) 0.41 - 0.95
I
I
1.5
PC300, 350-6 40-15

c
a .-0
E
L1
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
No. Check item Criteria Remedy

1 Link pitch
216.3 219.3
When turned Reverse or

Standard size replace
Normal load Impact load
2 Bushing outside diameter
66.9 — 61.9
Repair or
3 Link height replace
116 107
Thickness of link metal

4 (bushing press-fitting portion) 30.8
5 178.4
Replace
6 Shoe bolt pitch 76.2
7 19
8 Inside width 102
9 Link Overall width 47.8 Repair or

replace
10 Tread width 42.6
11 Protrusion of pin 4.2
12 Protrusion of regular bushing 5.25
13 Overall length of pin 242

Adjust or
replace
14 Overall length of bushing 148.3
15 Thickness of bushing metal 10.8
16 Thickness of spacer —
17 Bushing 98 – 264.6 kN {10 – 27 ton}

Press-fitting
18 force Regular pin 147 – 362.6 kN {15 – 37 ton} —
ª
19 Master 98 – 215.6 kN {10 – 22 ton}
ª : Dry type track link
PC300, 350-6 40-17

40-17
5
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
196.1±19.6
Triple shoe {20±2} 120±10
Shoe bolt Retighten
Tightening torque Additional tightening Lower limit torque
20 (Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
— — —
No. of shoes (each side) PC300, 350-6: 45 —

PC300, 350LC-6: 48
Standard Tolerance Standard
size Shaft Hole interference
Interference between
21 bushing and link
66.5 +0.464 +0.074 0.350 – 0.464
+0.424 0
Interference between +0.235 –0.188
22 44.6 0.273 – 0.485
regular pin and link +0.085 0
Clearance between size Shaft Hole clearance
23
regular pin and bushing
+0.235 +0.915 Adjust or
44.6 0.180 – 0.830 replace
+0.085 +0.415
size Shaft Hole interference
24 Interference between
master pin and link +0.03 –0.188
44.6 0.188 – 0.280
0 –0.250
ª Clearance between size Shaft Hole clearance
25 master pin and bushing
44.3 +0.050 +0.930 0.480 – 0.980
–0.050 +0.530
ª : Dry type track link
40-18 PC300, 350-6

TRIPLE GROUSER SHOE
Unit: mm

1 Height
36 21
2 Thickness 11
3 32
Length of base Rebuild or
replace
4 26
5 24
6 Length at tip 18
7 18
PC300, 350-6 40-19

40-19
5
MAINTENANCE VALVE
CONTROL VALVE
IO-spool valve (1/6) When tightening the bolts at the
* For details of the 9, 8, and 7-spool valves,see places marked *,
always use 2
10-SPOOL VALVE. washers onother.
top of each
30.9*3.4Nm 7.4Nm 66.2*
-*
G
30.9*3.4Nm
{3.15*0.35kornl
SWPO48 IO
40-22 PC300, 350-6

NDARD MAINTENANCE VALVE
B-B
SWPO48 1
Unit: mm
1
NO] Check item Criteria Remedy

Standard size
Installed
Installed
Free
Installed
length
Free length
1 Spool returnspring x O.D. load
ienath
54.5X 34.851.2 393 N - 314.6 N

{40.1 kg} {32.1 kg}
I
3 Spoolreturnspring 52.6 x 34.849.2
! 432.1 N
144.0 kg} 1 -
Replace
spring if there
is damage or
54.4 x 34.851.2 411.6 N - 333.2 N deformation
142.0 kg} 134.0 kg}
5 Spool returnspring 54.9 x 24.251.2 250.9 Pi - 200.9 Pi

{25.6kg) 120.5 kg}
5 Spoo!returnspring 53.3 x 37.? 49.5

358.7 N - 287.1 N
I36.6 kg} 129.3 kg}
7 Spool returnspring 40 x 12.3 38 50 N - 40.2 N

15.1 kg} (4.1 kg)
PC300, 350-6 40-23

\
MAINTENANCE STANDARD VALVE CONTROL
392.3* 19.6Nrn
{40*2ksrnl
392.3* 19.6Nm
{40*2ksrni
392.3* 19.6Nrn
PC300, 350-6 40-25

MAINTENANCE
147
15* 392.3t 19.6Nm
(40*2kernI
147. 392.3i 19.6Nm

(15-t {4O*2karnl
N A - N A
22.05 f 2.45Nm
{2.25*0.25ksd
/
147.1 i9.8Nm
i1 5 * 1 k r n l 392.3* 19.6Nm
\ (4O*Zbrnl
392.3t 19.6Nm
*
(40 Zkoml
392.3* I9.6Nm
(40*2koml
147.
N-N (15* NE-NB SWPO4814
Unit: mm
I
_I_

- I
Standard size Reoair limit
Free length Installed Installed Installed
Free
1A Regeneration valve spring x O.D. length load load
5.9 N - 4.4 N
31.5 x 10.3 19.5
fo.6 !0.45 kg!
1B Regeneration valve spring

10.53 kg)
Replace
17.4N 13.9 N spring if there
2 Piston return spring
11.78 kg) .4I kg}
{2 is damage or
- ~~~~ ~
deformation
3 Piston return spring 50.4 x 17 39
158.8 N - 142.1 N
- (16.2 kg} i14.5 kg1
- 29.4 N - -
4 Piston return spring X
I3 kg)
-
2N - 1.5 N
5 'Iston return spring 24.5 x 25.2 12
10.2 kg1 10.15 kg)
40-26 PC300, 350-6

DARD MAINTENANCE
f 5.4N rn
.0.5ksml
.55*3.95Nrn
I f 0.4ksmI
SWPO4815
Unit: rnm
PC300, 350-6 40-27

MAINTENANCE STANDARD CONTROL VALVE
VARIABLE PRESSURE COMPENSATION VALVE
2
SDPO1124
Unit: mm
Free length
Standard size Repair
Installed Free
Installed
limit
Installed
I Replace
1 Piston return spring x O.D. load load spring if any
length length damages or
9.8 N - 7.8 N deformations
32.76 x 8.5 20.5 I1.0 kg} 10.8 kg) are found.
2 Relief valve spring 17.1 x 9 15.5

74.5 N I
U . 6 kg} I - 59.8 N
(6.1 kg}
’I
40-28 PC300, 350-6

MAINTENANCE
PRESSURE
SELF-REDUCING
STANDARD VALVE
SELF-REDUCING PRESSURE VALVE
I I
4
SWPO4816

I
~~~~
Spring Free length Installed Installed Free Installed

1 (reducing pressure valve, X O.D. length load length load
main) I
19.6 N - 17.7 N I Replace
19.2 x 7.2 16.1 ii.8 kg] spring if any
i2 kgi
damages or
1 Spring
(reducing pressure
valve, pilot) 1 16.5 I x 72 1 I2.1 kg} I 18.6 N
{1.9k n l
deformations
are found.
199.8 N - 186.2 N
3 Spring 71 x 18 59 {20.4 kg1 I19 kg1
61.7 N - 58.8 N
4 Spring (safety valve) 16.1 x 7.8 13.4 i6.3 kg1 (6 kg}
PC300,350-6 40-29
ARD MAINTENANCE
SUCTION-SAFETY VALVE
FOR SERVICE VALVE
u k rn 140+22Nm
(14.25k2.25kgm)
SBP00430
No.1 Check item Criteria 1 Remedy

Wire Free length Installed Installed Free Installed
1 Suction valve spring diameter x O.D. length load length load
$’”
16.3 x
9.5
2.1 N - 1.6 N Replace
4 21.3 (0.21 kg} (0.16 kg}
2.1 N - 1.6 N
2 Piston spring $0.5 20x437 l4
(0.21 kg) I0.76 kg1
40-30 PC300, 350-6

DARD MAINTENANCE SWING MOTOR
SWING MOTOR
KMFI 60ABE-3
l 1 0 2 5 * 12.25Nm
( 1 1.25* 1.25kPmI
\
SWPO48 1 7
Unit: rnm
NO. Check item Criteria
PC300, 350-6 40-31

7 - i
R
r
i
K
0
-0
0
a
cn
c
MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
WORK EQUIPMENT SWING PPC VALVE
112.8.t 14.7Nrn
/ ( 1 1.5t 1.5kemI
44.1 +4.9Nm I kJ I
(4.5iO.5komI
3
A- A c-c
6.8i 1.9Nm D-D

f0.72 0.2koml
8-0
E-E SAP0275 1
Unit: mm
Check item
I
Repair sizeStandard limit I
Free length Installed
Installed
Installed Free length
Centering spring load load
x O.D. length
(for P3, P4) Replace
42.4 x 15.5 1 34
I
*-. ,?LE
11.0 I Y
U.8 kg} I -
I
*--I
13.1
{1.4 kg1
.I
IY
I spring if any
damages or
deformations
Centering spring are found.
2
(for P I , P2)
3 Metering spring 26.5 x 8.2 I 24.9 1 16.7 N

0 . 7 kg}
1 - 1 13.7 N
{1.4 kg}
I
PC300, 350-6 40-33
11
J
U
n
I 1
01
.-L
C
CL
v)
0
z
MAINTENANCE STANDARD VALVE PPC SERVICE
SERVICE PPC VALVE
SBP00436
Unit: m m
-
Free length Installed installed Installed
Free length Replace
1 Centering spring x O.D. length load load
I 64.8 x 16.6 1
I
40.5 1 46.1 N
(4.7 k g ~
1 (62m91 I 44.1 N
I4.5 kg)
~
spring if any
damages or
deformations
are found.
24.5 N
2 Metering spring X 10.5 25.0 26.0 (25.2)
(2.6 N
25.5kg)
- (2.5 kg1
PC300, 350-6 40-35

MAINTENANCE STANDARD PPC SHUTTLE VALVE,
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
34.3*4.9Nm
/!3.5*0.5ksm!
/
f
66.1 5 f 7.35Nm
(6.75i0.75ksml
I A-A SDPO 1353
Unit: m m

- Standard size Repair limit
Free length Installed Installed Installed Replace
Free length
1 Spool return spring x O.D. length load load spring ifthere
is damage or
14.7 N - 11.8 N deformation
23.5 x 13.3 20
(1.5 kg) (1.2 kg}
40-36 PC300, 350-6

:z
I?
C
2.
r!
3
3
n
W
c
l
f 7 n I .
-
u)
0
m
m
V
0
0
P
w
m
P
A
A
A
STANDARD
MAINTENANCE CENTER SWIVEL JOINT

\
- I
SJPO6565
Unit: mm
Check item
I Criteria Remedy
Standard size Standard clearance Clearance limit

Clearance between rotor
and shaft Replace
90 0.056- 0.105 0.1 11
40-40 PC300, 350-6

0
MAINTENANCE STANDARD VALVEBOOM HOLDING
BOOM HOLDING VALVE
/-2
(15-.lkgm)
t-"
I
I
SAP00440
Unit: mm
No.1 Check item I Criteria I Remedy

Free length Installed
Installed instaiied
Free length
1 Pilot valve spring x O.D. length load load
26.5 x 11.2 25.0

4.7 N
{o.48 kg}
- 3.7 ,
kg}
Replace
spring if there
is damage or
deformation
2
I Checkvalve spring
PC300, 350-6 40-41

RD MAINTENANCE HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
m ’ 3 7 2 * 54Nm
{38.0*5.5hml
ARM CYLINDER
2
5- 529t76Nm
~54.0i8.0bml
sm 294*29.4Nm
3
BUCKET CYLINDER
372254Nm
{38.0+5.5kaml
\ /
3
40-42 PC300, 350-6

w
-. -
m m m
F 0 C 0
0 0 0
x 7r
2 2 2 3
- I-
to CD (D
0
0 0 0 0
ic
++ ++
-I
I
++ ++
zg
4u1 -4u1
04 0-4
-t
I
-.L
C
rt
2.
3
3
m
n
d
w
w
I
LL
I
LL
'?
(3
c-
2
Y
Q
5
U
W
MAINTENANCE STANDARD WORK EQUIPMENT
Unit: rnm
I I
No./
1
Check item I Criteria Remedy
Standard Tolerance . Standard Clearance

Clearance between bushing size Shaft Hole clearance limit
1 and mounting pin of boom
and revolving frame +O. 161 -0.036
0.110 -
110 1.o
-0.090 +0.074 0.251
Clearance between bushing -0.036 +0.354 0.311 -

2 and mounting pin of boom 110 0.444 1.o
-0.090 +0.275
and arm
PI-..-..-..- ha&..,a-- h,.-h:--
weataslbc u c i l v v c o l l UUJIIIII~
-0.036 +0.338 0.308 -
3 and mounting pin of boom 90 0.428 1.o Replace
-0.090 t0.272
and link
PI-..-..--,.
\rleaIaIIbc
L.-**.,---
U G L V V ~ ~
h,.- l.:-.-.
I IU U J I I I I I ~
-0.036 +0.337 0.307 -
4 and mounting pin of boom 90 -0.090 +0.271 0.427 1 .O
and bucket
Clearance between bushing +0.346 0.311 -
-0.036
5 and mounting pin of link 90 1.o
-0.090 +0.275 0.436
and bucket
6
1 Clearance between bushing1
and mounting pin of link
and link
90
' 4.036
-0.090
I _ _ . _ I
tV.J40
+0.275 1 U.SI I-
0.436 1 lVo
7 Bucket clearance (a) 0.5 - 1.0

Adjust shims
8 Bucket clearance (b) 2.0
PC300, 350-6 40-45

X
I
X
w c
N
I
N
N
MAINTENANCE
STANDARD DIMENSIONS OF WORK EQUIPMENT
Unit: mm
I
PC300-6 PC350-6
1 0 100 +0.1/ -0.036 q 100+0.1/ -0.036

0 -0.090 0 -0.090
2 I qb 117.3c~5/116 1.2 * # 1 1 7 . 3 + ~ 5 / 1 1 61.2~

3 320 +0.5/ -0.3 320 +0.5/ -0.3
0 -0.8 0 -0.8
4 9 110+: 1 / -0.036 q 110 +0.1/ -0.036

-0.090 0 4.090
5 428.4 2 1.0 468 f 1
6 219 f 0.5 234.0 r 0.5
7 +. 1.0 1022.8 -c 1.0935.7
2 3 8 3179 2 3 3179
~
9 3095.7 * 1.0 3095.7 & 1.0
~~ ~
10
~
468 *1 472.5 1.0
11 731.0 k 0.2 731.0 & 0.2

-
12 728.0 0.5 728.0 2 0.5
~~ ~
13 513.6 513.6
14 1670 1670
15 90+:.2 14.036 q go+:.2 1-0.036

-0.090 -0.090
16
I 345.0 2 0.5
I 345.0 * 0.5
17 90+O.2 -0 036 # 90+:.2 1-0.036
0 /-0:090 -0.090
l8
I Arm.
nnrt
p.",
as individual
3381.5 330&
When press 345 345
fitting bushing
Min. 1990 1990

?9
Max. 3275 3275
PC300, 350-6 40-47

N
I I =I
U
I
a
MAINTENANCEDIMENSIONS
STANDARD OF WORK EQUIPMENT
Unit: mm
PC300-6 PC350-6
1 I 512.2 f 0.5 I 512.2 .c 0.5
2 37.9 & 0.5 37.9 * 0.5

3 94'1 9' 93" 12'
4 513.6 51 3.6
5 1663 1658
6 193 173
7 -
8 50" 42O
9 # go+;.* # go+;.*
10 346'; 346 A'
I? 68 88
12 138 I 138
13 525.5 f 0.5 525.5 2 0.5
14
15 # 170
16 4 200 cp 200
17 146.1 135.5
18 137.6 142.0
19 R115 R115
20 RlOO RIOO
~
21 3700
' 370 'f
22 60 60
PC300, 350-6 40-49

90 OTHERS
Hydraulic circuit diagram ........................... 90- 3

Electric circuit diagram (1/3)
with power window .............................. 90- 5
without power window ......................... 90-11
PC300, 350-6 90-1

0
BUCKET
C Y L i NDER
-I4
4I-t
I *--
-+t
"i
LCCUUUlAIOR
PPC LOCK
V A L V E r'
it
(
r SWIVEL CENTER
JOlNi
LEFT ?
L
Ji
t- (8.7kg/cm2i
C R A C K I N GP R E S S U R E '
ARM C Y 1 I NDER
LS-€PC
VALVE -
\
SAFE!Y VALVE 5 E l T l N G PRESSURt 2 8 7 M P a a t 2U4Q/m'
(293kq/cmz)
SUP05073
PC300,350-6 90-3
I
h
i
0
XU
t
.L
t
m
P
h
I I
L
ELECTRIC CIRCUIT DIAGRAM 13/31
,AUTO L U B R I C A T I O N ( 0 P T )
1
1 I
i11
I / I
0.5 1
o. gr 1lPRESSURE S W I T C H ( t )
2lPRESSURE S W I T C H ( - )
FUEL SUPPLY P U M P ( 0 P T )
7
I I
BATTERY
I TO BATTERY,
I
I
I RELAY
i
B I G SCUND HORN
r
I AIR I
r
1
1
I
r-
CONDITIONER UNIT
I------?
I
I
li
CONTROL
1
I
I
HORN
(
(HIGH TONE 1
348Hz3 1 1 6 d B 1 i
I
li
I
I
I
ii
I :I
a
i
PC300, 350-6 90-9

-1m
/I lllllwzEtt!k
a
F
P
tm
tr DD
cr-
I
I I Ij
.I ..
Ill
H
I- - - T
1
1 OPTlIlII -----> I
+ m >
-r-
z
II LLLL
- .
+
m
0
c
?=
I'
4
L I
0
W I
I I I 1
t
r
CnT
rnc
PRESSURE SWITCH /
7
II
t
I
I , -
I
I I
I
I
--. 0
-1-
-
--T -
I 1 1 0
ELECTRIC CIRCUIT DIAGRAM (3/3)
P C 4 0 0 - 6 : F O LR O A D I N G
SHOVEL
r-
--p----_______--____-___-----
I
/
/ R/H CASE \
LEFT WOE\
SWI T C H
1
/ B/H C A S E \
HORN
S W I TCH
\
I
M A I BN O D Y I
TO M23
mCN-MZ3
I H O R SN W I T C H I
I /I m m I/
1 HORN
(H I GH TONE)
I (348Hr)
I ( 1 16dB)
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AUTO LUBRI C A T I ON (OPT)

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CN-M37
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D LIMIT SWITCH
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CN-M38
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PC300, 350-6 90-15

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TO: Kornatsusubsidiary
: Kornatsu LiaisonOffice
PROPOSAL FOR MANUALREVISION

f f $ No. PMR-
iG E5
NAME OF COMPANY: INFORMATION No.:
v)
DEPARTMENT/SECTION: ISSUED ON:

0 -
NAME: BBFfiB :
MANUAL NAME:
Given in upper right hand corner Of C0ver.J

MANUAL No.:
I
MACHINE
1
I
1
l
1
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I
1. Details 2. Include your request oropinion? 3. Include user's opinion?
Artached photo or sketch.

I f you need more space, use anotner sheet.
I
I REPLY I
3. If there is no manual No., please write machine model, type and date of publication.
KS-90E 09-94 (03)30001

pc300 350 6NLC

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SEBM014307

MACHINE MODEL SERIAL NUMBER

PC300-6 33001 and up

• PC300, 350-6 mount the SAA6D108-2 engine.

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD ......................................... 40-1

00-2 PC300, 350-6

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 7 01- 1 10-14 10-45 10-75

PC300, 350-6 00-2-1

Time of Time of Time of Time of Time of

10-112 10-155 10-197 5 20-14 5 20-131 1

00-2-2 PC300, 350-6

Time of Time of Time of Time of Time of

20-233 5 20-372 1 20-457 1 20-501 5 20-577 1

PC300, 350-6 00-2-3

Time of Time of Time of Time of Time of

20-630 5 30-17 2 30-53-2 3 30-71 2 30-90 2

00-2-4 PC300, 350-6

Time of Time of Time of Time of Time of

30-130 2 40-12 90- 3

PC300, 350-6 00-2-5

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Item number (10. Structure

Example 2 (Engine volume):

• If a part cannot be smoothly removed from

ﬂ The allowable load value is estimated to

2) Sling wire ropes from the middle portion

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

• Used to prevent rubber gaskets, rubber

• Features: Resistance to heat and chemi-

790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

• Quick hardening type adhesive

• Quick hardening type adhesive

• Features: Resistance to heat, chemicals

• Used as adhesive or sealant for gaskets

• Features: Resistance to heat

• Features: Resistance to water, oil

• Features: Silicon based, resistance to heat,

• Features: Silicon based, quick hardening

Three bond • Used as heat-resisting sealant for repairing

• Used as lubricant for sliding portion (to pre-

SYG2-400LI • General purpose type

• Used for normal temperature, light load

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width

Thread diameter Width

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS