Professional Documents
Culture Documents
PC300LC-6
PC300HD-6
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC300LC-6 - A83001 and up
SERIAL NUMBERS PC300HD-6 - A83001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to mak e
changes or add improvements at any time without incurring any obligation to install such changes on products sol d
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
00 FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
0-2 PC300LC-6
PC300HD-6
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following marks. It is requested that necessary actions
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PC300LC-6
PC300HD-6 0-5
CEBM002901 LIST OF ORIGINAL, NEW AND REVISED PAGES
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0-6 PC300LC-6
PC300HD-6
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVICE
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIGN
LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM002901
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM000601
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,
USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTEM
(PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D
IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
PUBINFOK.WPT 121297
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO
ATTN.
ORDER DATE
STREET ADDRESS
TYPE or PRINT
ONLY CITY, STATE, ZIP CODE
COUNTRY
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
0-6
00 FORWARD
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-4
PC300LC-6
PC300HD-6 00-1
FORWARD SAFETY
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation.
Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
Mistakes in operation are extremely dangerous. Read the 7. Before adding oil or making repairs, park the ma-
OPERATION & MAINTENANCE MANUAL carefully chine on hard, level ground, and block the wheels or
BEFORE operating the machine. tracks to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower blade, ripper, bucket or
the precautions given on the decals which are fixed to any other work equipment to the ground. If this is not
the machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure
2. When carrying out any operation, always wear safety to lock all the control levers and hang warning signs
shoes and helmet. Do not wear loose work clothes, on them.
or clothes with buttons missing.
9. When disassembling or assembling, support the
Always wear safety glasses when hitting parts machine with blocks, jacks or stands before starting
with a hammer. work.
Always wear safety glasses when grinding parts 10. Remove all mud and oil from the steps or other
with a grinder, etc. places used to get on and off the machine. Always
use the handrails, ladders or steps when getting on or
3. If welding repairs are needed, always have a trained, off the machine. Never jump on or off the machine.
experienced welder carry out the work. When carry- If it is impossible to use the handrails, ladders or
ing out welding work, always wear welding gloves, steps, use a stand to provide safe footing.
apron, glasses, cap and other clothes suited for
welding work. PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more 11. When removing the oil filler cap, drain plug or hy-
workers, always agree on the operating procedure draulic pressure measuring plugs, loosen them
before starting. Always inform your fellow workers slowly to prevent the oil from spurting out. Before
before starting any step of the operation. Before disconnecting or removing components of the oil,
starting work, hang UNDER REPAIR signs on the water or air circuits, first remove the pressure com-
controls in the operator's compartment. pletely from the circuit.
5. Keep all tools in good condition and learn the correct 12. The water and oil in the circuits are hot when the
way to use them. engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out
6. Decide a place in the repair workshop to keep tools any work on the oil or water circuits.
and removed parts. Always keep the tools and parts
in their correct places. Always keep the work area 13. Before starting work, remove the leads from the
clean and make sure that there is no dirt or oil on the battery. ALWAYS remove the lead from the negative
floor. Smoke only in the areas provided for smoking. (-) terminal first.
Never smoke while working.
PC300LC-6
00-2 PC300HD-6
FORWARD SAFETY
14. When raising heavy components, use a hoist or When installing hoses and wires, be sure that they
crane. Check that the wire rope, chains and hooks will not be damaged by contact with other parts when
are free from damage. Always use lifting equipment the machine is being operated.
which has ample capacity. Install the lifting equipment
at the correct places. Use a hoist or crane and 20. When installing high pressure hoses, make sure that
operate slowly to prevent the component from hitting they are not twisted. Damaged tubes are dangerous,
any other part. Do not work with any part still raised so be extremely careful when installing tubes for high
by the hoist or crane. pressure circuits. Also check that connecting parts
are correctly installed.
15. When removing covers which are under pressure or
under pressure from a spring, always leave two bolts 21. When assembling or installing parts, always use the
in position on opposite sides. Slowly release the specified tightening torques. When installing protec-
pressure, then slowly loosen the bolts to remove. tive parts such as guards, or parts which vibrate
violently or rotate at high speed, be particularly
16. When removing components, be careful not to break careful to check that they are installed correctly.
or damage the wiring, Damaged wiring may cause
electrical fires. 22. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a
17. When removing piping, stop the fuel or oil from hole.
spilling out. If any fuel or oil drips on to the floor, wipe
it up immediately. Fuel or oil on the floor can cause 23. When measuring hydraulic pressure, check that the
you to slip, or can even start fires. measuring tool is correctly assembled before taking
any measurements.
18. As a general rule, do not use gasoline to wash parts.
In particular, use only the minimum of gasoline when 24. Take care when removing or installing the tracks of
washing electrical parts. track-type machines. When removing the track, the
track separates suddenly, so never let anyone stand
19. Be sure to assemble all parts again in their original at either end of the track.
places. Replace any damaged part with new parts.
PC300LC-6
PC300HD-6 00-3
FORWARD GENERAL
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 sections. These sections are further divided into each
main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel,
coolant and lubricant specification charts.
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.
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.
This section explains the order to be followed when removing, installing, disassembling or assembling each
component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.
PC300LC-6
00-4 PC300HD-6
FORWARD HOW TO READ THE SHOP MANUAL
10-4-2 A
10-4-1
Added pages
10-5
PC300LC-6
PC300HD-6 00-5
FORWARD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES 4) Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load
1) Use adequate ropes depending on the weight of parts with two or more ropes, the force subjected to each
to be hoisted, referring to the table below: rope will increase with the hanging angles. The table
below shows the variation of allowable load (kg)
when hoisting is made with two ropes, each of which
Wire ropes is allowed to sling up to 1000 kg vertically, at various
(Standard "Z" or "S" twist ropes without galvanizing hanging angles. When two ropes sling a load verti-
cally, up to 2000 kg of total weight can be
Rope diameter (mm) Allowable load (tons) suspended. This weight becomes 1000 kg when two
ropes make a 120E hanging angle. On the other
10.0 1.0 hand, two ropes are subject to an excessive force as
11.2 1.4 large as 4000 kg if they sling a 2000 kg load at a
12.5 1.6 lifting angle of 150E.
14.0 2.2
16.0 2.8
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0
PC300LC-6
00-6 PC300HD-6
FORWARD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
PC300LC-6
PC300HD-6 00-7
FORWARD COATING MATERIALS
PC300LC-6
00-8 PC300HD-6
FORWARD STANDARD TIGHTENING TORQUE
Use these torques for metric bolts and nuts. (Always use torque wrench)
mm mm kgm NCm
mm mm kgm NCm
PC300LC-6
PC300HD-6 00-9
FORWARD STANDARD TIGHTENING TORQUE
mm mm kgm NCm
PC300LC-6
00-10 PC300HD-6
FORWARD STANDARD TIGHTENING TORQUE
mm mm kgm NCm
PC300LC-6
PC300HD-6 00-11
FORWARD STANDARD TIGHTENING TORQUE
mm kgm NCm
6 1.02 0.20 10 2
8 2.45 0.41 24 4
10 4.38 0.61 43 6
12 7.85 1.22 77 12
mm kgm NCm
6 0.81 0.20 8 2
8 1.02 0.20 10 2
10 1.22 0.20 12 2
12 2.45 0.41 24 4
14 3.67 0.51 36 5
mm kgm NCm
PC300LC-6
00-12 PC300HD-6
FORWARD ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table
will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cross Cable Current rating
Number of Dia. Of strand Applicable circuit
number section O.D. (mm) (A)
strands (mm)
(mm)
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
Priority Classification Circuits Charging Ground Starting Lighting Instrument Signal Other
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR --- BW RW YR GW LW
2
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
Code WL --- BR RY YG GY LY
4 Auxiliary
Color White/Blue --- Black/Red Red/Yellow Yellow/Green Green/Yellow Blue/Yellow
PC300LC-6
PC300HD-6 00-13
FORWARD CONVERSION TABLE
CONVERSION TABLES
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
PC300LC-6
00-14 PC300HD-6
FORWARD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
mm 0 1 2 3 4 5 6 7 8 9
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
kg 0 1 2 3 4 5 6 7 8 9
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
PC300LC-6
PC300HD-6 00-15
FORWARD CONVERSION TABLE
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
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
PC300LC-6
00-16 PC300HD-6
FORWARD CONVERSION TABLE
kgm to lbf ft
1 kgm = 7.233 lbf ft
kgm 0 1 2 3 4 5 6 7 8 9
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
PC300LC-6
PC300HD-6 00-17
FORWARD CONVERSION TABLE
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
PC300LC-6
00-18 PC300HD-6
FORWARD CONVERSION TABLE
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center 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.
1EC = 33.8EF
EC EF EC EF EC EF EC EF
PC300LC-6
PC300HD-6 00-19
01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
PC300LC-6
PC300HD-6 01-1
GENERAL SPECIFICATION DRAWINGS
PC300LC-6
01-2 PC300HD-6
GENERAL SPECIFICATION DRAWINGS
PC300LC-6
PC300HD-6 01-3
GENERAL SPECIFICATION DRAWINGS
WORK EQUIPMENT
PC300LC-6
01-4 PC300HD-6
GENERAL SPECIFICATION DRAWINGS
E Max dig depth for 8' level 6130 mm 6520 mm 7180 mm 8045 mm
D Max vertical wall dig depth 4960 mm 5720 mm 6240 mm 6630 mm 7110 mm
E Max dig depth for 8' level 5900 mm 6290 mm 6940 mm 7810 mm 6940 mm
G Max dig reach ground level 9920 mm 10320 mm 10890 mm 10870 mm 11700 mm
Bucket dig force at power max 19100 kg 19100 kg 19100 kg 19100 kg 19100 kg
Arm crowd force at power max 19300 kg 16900 kg 14300 kg 15705 kg 12200 kg
PC300LC-6
PC300HD-6 01-5
GENERAL SPECIFICATIONS
SPECIFICATIONS
Overall width
Track gauge
PC300LC-6
01-6 PC300HD-6
GENERAL SPECIFICATIONS
Performance
PC300LC-6
PC300HD-6 01-7
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling component.
Unit: kg
Machine model PC300LC-6 PC300HD-6
Engine 675
Damper 14.7
Operators seat 29
Counterweight 6320
Swing motor 81
Carrier roller 31 x 4
Track roller 52 x 16 72 x 14
PC300LC-6
01-8 PC300HD-6
GENERAL WEIGHT TABLE
Boom pin 76 + 15 x 2 + 56 + 17 + 42
Arm pin 13 + 17 10 x 2
Bucket pin 30 x 2 20 x 2
Link pin 27 x 2 13 x 2
PC300LC-6
PC300HD-6 01-9
GENERAL FUEL COOLANT AND LUBRICANTS
SAE 15W-40
0.75 R
Damper case --
0.20 gal
Swing 13 R 13 R
SAE 30
machinery case 2.9 gal 2.9 gal
Engine oil
Final drive 10 R 9.5 R
See page
(each) 2.6 gal 2.5 gal
1-10.
Track front idler 0.34 to 0.36 R 0.34 to 0.36 R
(each) .09 to .1 gal .09 to .1 gal
Track roller 0.28 to 0.31 R 0.28 to 0.31 R
SAE 30
(each) .07 to .08 gal .07 to .08 gal
Top carrier roller 0.45 to 0.5 R 0.45 to 0.5 R
(each) .12 to .13 gal .12 to .13 gal
SAE10W
Hydraulic SAE 10W-30 380 R 205 R
system 100.3 gal 54.2 gal
SAE 15W-40
All lube fittings Grease Komatsu Super Grease or NLGI No.2 Multi-purpose Fill as instructed
lithium grease with 3% molybdenum disulfide
ASTM: American Society of Testing and Materials SAE: Society of Automotive Engineers
Specified Capacity: Total amount of oil including oil for components and piping.
Refill Capacity: Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20EC, therefore consult
your distributor for your specific needs.
PC300LC-6
01-10 PC300HD-6
GENERAL FUEL COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS C Special "break-in" lubricating oils are not recom-
mended for a new or rebuilt engine. Use the same
NORMAL OPERATION type of oil during the "break-in" as specified for
normal operation.
Oil performance recommendations are as follows:
C Additional information regarding lubricating oil avail-
C The use of a quality engine lubricating oil combined ability throughout the world is available in the "E.M.A.
with appropriate oil and filter change intervals are Lubricating Oils Data Book for Automotive and
critical factors in maintaining engine performance and Industrial Engines. The data book may be ordered
durability. from the Engine Manufacturers Association, 401
North Michigan Ave., Chicago, Il U.S.A. 60611. The
C Komatsu Engine Oil or multi-viscosity engine oil telephone number is (312) 644-6610.
meeting American Petroleum Institute (API) perfor-
mance classification CF-4, CG-4, CF-4/SG or CG- ARCTIC OPERATION
4/SH or MIL-L-2104D or E is recommended.
If an engine is operated in ambient temperatures consis-
NOTICE: tently below -23EC and there are no provisions to keep
Classification CD, CE, CD/SF or CE/SF oils may be the engine warm when it is not in operation, use a
used in areas where CF-4, CG-4, CF-4/SG or CG- synthetic engine oil API performance classification CF-4,
4/SH oil is not yet available. If API classification CC or CG-4, CF-4/SG or CG-4/SH with adequate low tempera-
CC/CD is used, reduce the engine oil change interval ture properties such as SAE 5W-20 or 5W-30.
by half.
The oil supplier must be responsible for meeting the
C A sulfated ash limit of 1.0 to 1.5 mass percent is performance service specifications.
suggested for optimum valve and piston deposit and
oil consumption control. The sulfated ash must not NOTICE:
exceed 1.85 mass percent. The sulfated ash limit of The use of a synthetic base oil does not justify ex-
1.85 mass percent has been placed on all engine tended oil change intervals. Extended oil change
lubricating oils recommended for use in the engine. intervals can decrease engine life due to factors such
Higher ash oils can cause valve and/or piston dam- as; corrosion, deposits and wear.
age and lead to excessive oil consumption.
DAMPER CASE, SWING MACHINERY CASE, TRACK
C The API service symbol displays the following infor- FRONT IDLERS, TRACK ROLLERS, TOP CARRIER
mation. The upper half of the symbol displays the ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFICA-
appropriate oil categories; the lower half may contain TIONS
words to describe oil energy conserving features. The
center section identifies the SAE oil viscosity grade. Komatsu Engine Oil or engine oil meeting American
Petroleum Institute (API) performance classification CF-4,
Oil viscosity recommendations are as follows: CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is
recommended.
C The use of a multi-grade lubricating oil has been
found to improve oil consumption control and im- NOTICE:
prove engine cranking in cold temperatures while Classification CD, CE, CD/SF or CE/SF oils may be
maintaining lubrication at high operating tempera- used in areas where CF-4, CG-4, CF-4/SG or CG-
tures. 4/SH oil is not yet available.
PC300LC-6
PC300HD-6 01-11
GENERAL FUEL COOLANT AND LUBRICANTS
PC300LC-6
01-12 PC300HD-6
GENERAL FUEL COOLANT AND LUBRICANTS
Never use water alone in the cooling system because table shows the approximate percentage of antifreeze
rust, scale deposits and corrosion will occur. solution required for various temperatures.
PC300LC-6
PC300HD-6 01-13
GENERAL FUEL COOLANT AND LUBRICANTS
occurs. NOTICE:
Mixing of DCA4 and other supplemental coolant
C Provides engine protection in the following areas: additives is not recommended because there is
- Solder corrosion/bloom currently no test kit available to measure
- Copper corrosion/erosion/stress cracking concentration levels with mixed chemical solutions.
- Oil fouling
- Cylinder liner cavitation corrosion Supplemental Coolant Additive Maintenance Guide
- Aluminum cavitation corrosion
- Seal and gasket degradation Use supplemental coolant additives to protect the engine
cooling system from corrosion. Antifreeze alone does not
Maintenance of Supplemental Coolant Additives provide enough corrosion protection for a heavy duty
diesel engine. Supplemental corrosion protection must be
Keeping the engine coolant properly inhibited will keep supplied through periodic additions of supplemental
the engine and radiator free of rust, scale deposits and coolant additives to the coolant. To protect against
corrosion. corrosion, a new coolant charge must be brought up to
0.26 SCA unit per liter of coolant (initial charge). Maintain
New machines are delivered with antifreeze protection. the correct SCA concentration by changing the service
Service at a regular scheduled interval specified with a coolant filter at each engine oil and filter change interval.
replacement coolant filter.
Each time the coolant is drained and replace, the coolant
Each time the coolant is drained and replaced, the must be recharged with supplemental coolant additives.
coolant must be recharged with supplemental coolant Use the appropriate replacement coolant filter listed in
additives. New coolant can be correctly charged with following tables. The coolant mixture must be drained and
coolant additives by using a replacement coolant filter replaced. The amount of a replacement inhibitor is
and/or concentrate. determined by the length of the service interval and the
cooling system capacity. Refer to the DCA4 Unit Guide for
If coolant is added between drain intervals, additional the selection of the correct filter to replenish the SCA. If
coolant additives may be required. coolant is added between drain intervals, additional SCA
will be required. Check the coolant DCA concentration
Coolant Testing for Conditioner Concentration level anytime make up coolant is added to the system.
The SCA concentration must not fall below 0.13 units per
When the cooling system is maintained as liter or exceed 0.5 units per liter.
recommended, the conditioner concentration should be
satisfactory. The SCA concentration must not fall below
DCA4 UNIT GUIDE
1.0 unit per 3.8 R or exceed 2 units per 3.8 R of coolant.
The only accurate method for testing chemical concen- Fleetguard Part No. DCA4 Units
trations in coolant with mixed chemical compounds is a
laboratory analysis.
DCA4 Coolant Filter
NOTICE: WF-2070 2
Inadequate concentration of the coolant additive can WF-2071 4
result in major corrosive damage to cooling system WF-2072 6
components. Over-concentration can cause WF-2073 8
formation of gel that can cause restriction, plugging WF-2074 12
of passages and overheating. WF-2075 15
WF-2076 23
Replenishing Coolant Conditioner WF-2077 0
DCA4 Liquid
Install a "precharge" coolant filter when the coolant is DCA60L 4
changed or a significant (more than 50%) coolant loss DCA80L 1760
occurs. Install a service coolant filter as specified. When
antifreeze is added, add coolant conditioner equal to 1.0 DCA4 Powder
unit per 3.8 R of antifreeze. DCA95 20
PC300LC-6
01-14 PC300HD-6
GENERAL FUEL COOLANT AND LUBRICANTS
System Capacity
Precharge Filter Service Filter
(See NOTE 1) (See NOTE 3)
Liters
19 to 26 WF-2072 WF-2070
30 to 38 WF-2073 WF-2071
42 to 57 WF-2074 WF-2071
61 to 76 WF-2075 WF-2071
80 to 114 WF-2076 WF-2072
118 to 190 (See NOTE 2) WF-2073
NOTE 1 - After draining and replacing coolant, always The answer represents the additional units required to
precharge the cooling system to maintain the precharge the cooling system. Four bottles of powder,
SCA concentration between 1.0 and 2.0 units part number DCA95, will provide a sufficient amount of
per 3.8 R. SCA units (80) to precharge the example cooling system.
NOTE 2 - To precharge cooling systems larger than 114 Maintain a nominal SCA concentration of 1.0 unit per 3.8
R do the following: R of coolant in the system. Less than 0.5 units per 3.8 R
indicates an under-concentrated coolant solution. More
C Install appropriate service filter listed in the above than 2.0 units per 3.8 R indicates an over-concentrated
table based on cooling system capacity. coolant solution.
Example: 360 R cooling system capacity To check the SCA concentration level, use coolant test
-15 Units (1) WF-2075 Filter kit, CC-2626. Instructions are included with the test kit.
80 Units
PC300LC-6
PC300HD-6 01-15
GENERAL FUEL COOLANT AND LUBRICANTS
The following cooling system test kit may be purchased from your
distributor.
PC300LC-6
01-16 PC300HD-6
10 STRUCTURE AND FUNCTION
PARTS RELATED TO ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
RADIATOR, OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
TRACK FRAME, RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
HYDRAULIC PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
HYDRAULIC TANK AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
SELF REDUCING PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
SUCTION SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PPC SAFETY LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . 10-140
LS-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
BOOM HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
ELECTRICAL WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
ELECTRICAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
PC300LC-6
PC300HD-6 10-1
STRUCTURE AND FUNCTION PARTS RELATED TO ENGINE
Outline
PC300LC-6
10-2 PC300HD-6
STRUCTURE AND FUNCTION ENGINE AND RELATED PARTS
PC300LC-6
PC300HD-6 10-3
STRUCTURE AND FUNCTION ENGINE AND RELATED PARTS
PC300LC-6
10-4 PC300HD-6
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
PC300LC-6
PC300HD-6 10-5
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
PC300LC-6
10-6 PC300HD-6
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER
3. Radiator 9. Shroud
Specifications
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CWX-4
PC300LC-6
PC300HD-6 10-7
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
PC300LC-6
10-8 PC300HD-6
STRUCTURE AND FUNCTION FINAL DRIVE
PC300LC-6
PC300HD-6 10-9
STRUCTURE AND FUNCTION FINAL DRIVE
PC300LC-6
10-10 PC300HD-6
STRUCTURE AND FUNCTION FINAL DRIVE
PC300LC-6
PC300HD-6 10-11
STRUCTURE AND FUNCTION FINAL DRIVE
PC300LC-6
10-12 PC300HD-6
STRUCTURE AND FUNCTION FINAL DRIVE
8. Cover 8. Cover
14. No. 2 planetary gear . . . . . . . . . . . 38 tooth 14. No. 2 planetary gear . . . . . . . . . . . 32 tooth
SPECIFICATIONS SPECIFICATIONS
PC300LC-6
PC300HD-6 10-13
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
PC300LC-6
10-14 PC300HD-6
STRUCTURE AND FUNCTION SWING MACHINERY
PC300LC-6
PC300HD-6 10-15
STRUCTURE AND FUNCTION SWING MACHINERY
PC300LC-6
10-16 PC300HD-6
STRUCTURE AND FUNCTION SWING MACHINERY
2. Cover
3. Case
4. Coupling
8. Cover
9. Swing motor
Specifications
19+92
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . 19 X 19+92
19 = 34.130
PC300LC-6
PC300HD-6 10-17
STRUCTURE AND FUNCTION TRACK FRAME AND RECOIL SPRING
1. Idler 1. Idler
PC300LC-6
10-18 PC300HD-6
STRUCTURE AND FUNCTION TRACK FRAME, RECOIL SPRING
PC300LC-6
PC300HD-6 10-19
STRUCTURE AND FUNCTION TRACK FRAME, RECOIL SPRING
PC300LC-6
10-20 PC300HD-6
STRUCTURE AND FUNCTION TRACK SHOE
TRACK SHOE
Unit: mm
Standard shoe PC300LC-6 PC300HD-6
Rocky ground, normal C Travel in Lo speed when traveling on rough ground with obstacles such as
A
river soil large boulders and fallen trees.
C Cannot be used on rough ground where there are large obstacles such as
large boulders and fallen trees.
B Normal soil, soft land
C Travel in Hi speed only on flat ground; when it is impossible to avoid
traveling over obstacles, lower the travel speed to approx half of Lo speed.
C Use only for ground where A and B sink and are impossible to use.
C Cannot be used on rough ground where there are large obstacles such as
Extremely soft ground
C large boulders and fallen trees.
(swampy ground)
C Travel in Hi speed only on flat ground; when it is impossible to avoid
traveling over obstacles, lower the travel speed to approx half of Lo speed.
j When selecting the shoe width, select the narrowest j Categories B and C are wide shoes, so there are
shoe possible within the range that will give no restrictions on their use. Therefore, before using,
problem with flotation and ground pressure. If a wider check the restrictions and consider carefully the
shoe than necessary is used, there will be a large conditions of use before recommending a suitable
load on the shoe, and this may lead to bending of the shoe width. If necessary, give the customer guidance
shoe, cracking of the links, breakage of the pins, in their use.
loosening of the shoe bolts or other problems.
PC300LC-6
PC300HD-6 10-21
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
PC300LC-6
10-22 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PIPING DRAWING
PC300LC-6
PC300HD-6 10-23
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
PC300LC-6
10-24 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
5. Sight gauge
PC300LC-6
PC300HD-6 10-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
PC300LC-6
10-26 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
MAIN PUMP
PC300LC-6
PC300HD-6 10-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC300LC-6
10-28 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION C Rocker cam (4) has flat surface A, and shoe (5) is
always pressed against this surface while sliding in a
C The rotation and torque transmitted to the pump shaft circular movement. Rocker cam (4) brings high pres-
is converted into hydraulic energy, and pressurized oil sure oil at cylindrical surface B with cradle (2), which is
is discharged according to the load. secured to the case, and forms a static pressure
C It is possible to change the delivery amount by changing bearing when it slides.
the swash plate angle. C Piston (6) carries out relative movement in the axial
direction inside each cylinder chamber of cylinder block
STRUCTURE (7).
C The cylinder block seals the pressure oil to the valve
C Cylinder block (7) is supported to shaft (1) by spline S, plate (8) and carries out relative rotation. This surface
and shaft (1) is supported by the front and rear bear- is designed so that the oil pressure balance is main-
ings. tained at a suitable level. The oil inside each cylinder
C The tip of piston (6) is a concave ball, and shoe (5) is chamber of cylinder block (7) is sucked in and dis-
caulked to it to form one unit. Piston (6) and shoe (5) charged through valve plate (8).
form a spherical bearing.
PC300LC-6
PC300HD-6 10-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Operation of pump
C Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface A. When this happens, rocker cam (4)
moves along cylindrical surface B, so angle " between center line
X of rocker cam (4) and the axial direction of cylinder block (7)
changes. (Angle " is called the swash plate angle.)
1) Center line X of rocker cam (4) maintains swash plate angle "
in relation to the axial direction of cylinder block (7), and flat
surface A moves as a cam in relation to shoe (5). In this way,
piston (6) slides on the inside of cylinder block (7), so a
difference between 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) rotates and the volume
of chamber E becomes smaller, the oil is discharged during
that stroke. On the other hand, the volume of chamber F
becomes larger, and as the volume becomes bigger, the oil is
sucked in.
2) If center line X of rocker cam (4) is in line with the axial direc-
tion of cylinder block (7) (swash plate angle = 0), the difference
between volumes E1 and F1 inside cylinder block (7) becomes
0, so the pump does not carry out any suction or discharge of
oil.
PC300LC-6
10-30 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C If swash plate angle " becomes larger, the difference is different on the left and right, so main pump discharge
in volumes E and F becomes larger and discharge pressure (self pressure) PP is always connected to the
volume Q increases. chamber receiving the pressure on the small diameter
C Swash plate angle " is changed by servo piston (12). piston side (the self pressure is brought in). Output
C Servo piston (12) moves in a reciprocal movement pressure Pen of the LS valve is brought to the chamber
according to the command from the control valve. receiving the pressure at the large diameter piston end.
C This straight line movement is transmitted through rod The relationship in the size of self pressure PP and the
(13) to rocker cam (4), and rocker cam (4), which is pressure at the small diameter piston end, and the ratio
supported by the cylindrical surface to the cradle (2), between the area receiving the pressure at the small di-
moves in a rocking movement on the cylindrical sur- ameter piston end and the large diameter piston end
face in a direction. controls the movement of servo piston (12).
C With servo piston (12), the area receiving the pressure
PC300LC-6
PC300HD-6 10-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
TVC, LS VALVE
PP2 Pump pressure No. 2 port Pa2 Rear pump delivery pressure inlet port
PLS1 Control valve LS pressure inlet port Pen1 Signal pressure output
Pa1 Front pump delivery pressure inlet port Psig1 LS-EPC pressure inlet port
PC300LC-6
10-32 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC300LC-6
PC300HD-6 10-33
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
LS Valve
C The LS valve detects the load and controls the discharge amount.
This valve controls main pump discharge amount Q according to
differential pressure ) PLS (=PP2-PLS) (the difference between
main pump pressure PP2 and control valve outlet port pressure
PLS is called the LS differential pressure).
C Main pump pressure PP2 coming from the control valve inlet port,
pressure PLS (called the LS pressure) coming from the control
valve output, and pressure Psig (called the LS selector pressure)
from the proportional solenoid valve enter this valve. The relation-
ship between discharge amount Q and differential pressure ) PLS,
(the difference between main pump pressure PP2 and LS pres-
sure PLS) (=PP2-PLS) changes as shown in the diagram on the
right according to LS selector pressure Psig.
C When Psig changes between 0 to 30 kg/cm2, the spring load
changes according to this, and the point for switching the pump
discharge amount changes at the rated central value between 10
to 25 kg/cm2.
TVC Valve
C When pump discharge pressure Pa1 (self pressure) and Pa2
(other pump pressure) are high, the TVC valve controls the pump
so that no more oil than the constant flow (in accordance with the
discharge pressure) flows even if the stroke of the control valve
becomes larger. In this way it carries out equal horsepower control
so that the horsepower absorbed by the pump does not exceed
the engine horsepower.
C In other words, if the load during the operation becomes larger
and the pump discharge pressure rises, it reduces the discharge
amount from the pump; and if the pump discharge pressure
drops, it increases the discharge amount from the pump. The rela-
tionship between the average of the front and rear pump dis-
charge pressures (PF + PR)/2 and pump discharge amount Q is
shown on the right, with the current given to the TVC valve
solenoid shown as a parameter.
C However, in the heavy duty operation mode, there are cases
where it is given the function of sensing the actual speed of the
engine, and if the speed drops because of an increase in the load,
it reduces the pump discharge amount to allow the speed to re-
cover. In other words, when the load increases and the engine
speed drops below the set value, the command to the TVC valve
solenoid from the controller increases according to the drop in the
engine speed to reduce the pump swash plate angle.
PC300LC-6
10-34 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION - LS VALVE
1) When Control Valve Is at Neutral Position
C The LS valve is a three way selector valve, with pressure PLS (LS
pressure) from the outlet port of the control valve brought to spring
chamber I, and main pump discharge pressure PP2 brought to
chamber j of plug (6).
C The size of the force of this LS pressure PLS + force F of spring
(3) and the main pump pressure (self pressure) PP2 determines
the position of spool (4). However, the size of the output pressure
Psig (the LS selection pressure) of the EPC valve for the LS valve
entering port e also changes the position of spool (4). (The set
pressure of the spring changes.) Before the engine is started,
servo piston (1) is pushed to the right by spring (7) installed to rod
(2).
When the engine is started and the control lever is at the enters the large diameter end of the piston from port h,
neutral position, LS pressure PLS is 0 kg/cm2. (It is and the same pump pressure PP also enters the small
interconnected with the drain circuit through the control diameter end of the piston g, so the swash plate is moved
valve spool.) At this point, spool (4) is pushed to the left, to the minimum angle by the difference in area of piston
and port d and port c are connected. Pump pressure PP 1.
PC300LC-6
PC300HD-6 10-35
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C When the difference between main pump pressure PP2 C For this reason, the pressure at the large piston diame-
and LS pressure PLS, in other words, LS differential ter end of servo piston (1) becomes drain pressure PT,
pressure ) PLS, becomes smaller (for example, when and pump pressure PP enters the small diameter end,
the area of opening of the control valve becomes larger so servo piston (1) is pushed to the right. Therefore, rod
and pump pressure PP drops), spool (4) is pushed to (2) moves to the right and moves the swash plate in the
the right by the combined force of LS pressure PLS and direction to make the discharge amount larger.
the force of spring (3). C If the output pressure Psig of the LS-EPC valve enters
C When spool (4) moves, port b and port c are joined and port e, this pressure creates a force to move piston (5)
connected to the TVC valve. When this happens, the to the left. If piston (5) is pushed to the left, it acts to
TVC valve is connected to the drain port, so circuit c - make the set pressure of spring (3) weaker, and the
h becomes drain pressure PT. (The operation of the difference between PLS and PP2 changes when ports
TVC valve is explained later.) b and c of spool (4) are connected.
PC300LC-6
10-36 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C The following explains the situation if servo piston (1) piston diameter end.
moves to the left (the discharge amount becomes C Main pump pressure PP also enters the small piston
smaller). When LS differential pressure ) PLS be- diameter end, but because of the difference in area
comes larger (for example, when the area of opening between the large piston diameter end and small piston
of the control valve becomes smaller and pump pres- diameter end of servo piston (1), servo piston (1) is
sure PP rises), main pump discharge pressure PP2 pushed to the left. As a result, rod (2) moves in the
pushes spool (4) to the left. direction to make the swash plate angle smaller.
C When spool (4) moves, main pump pressure PP flows C If LS selection pressure Psig enters port e, it acts to
from port d to port c, and from port h, it enters the large make the set pressure of spring (3) weaker.
PC300LC-6
PC300HD-6 10-37
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C Let us take the area receiving the pressure at the large pump pressure PP.
piston diameter end as A1, the area receiving the C At this point, the relationship between the area receiving
pressure at the small diameter end as A0, and the the pressure at both ends of piston (1) is A0 : A1 = 2 :
pressure flowing into the large piston diameter end as 5, so the pressure applied to both ends of the piston
Pen. If main pump discharge pressure PP2 of the LS when it is balanced becomes PP : Pen = 5 : 2.
valve and the combined force of force F of spring (3) C The position where spool (4) is balanced and stopped
and LS pressure PLS are balanced, and the relation- is the standard center, and the force of spring (3) is
ship is A0xPP=A1xPen, servo piston (1) will stop in that adjusted so that it is determined when PP2 - PLS = 25
position, and the swash plate will be kept at an interme- kg/cm2. However, if Psig (the output pressure of 0 to 30
diate position. It will stop at a position where the open- kg/cm2 of the EPC valve of the LS valve) is applied to
ing of the throttle between port b and port c and be- port e, the balance stop position will change in pro-
tween port d and port c of spool (4) is approximately portion to pressure Psig between PP2 - PLS = 25 - 10
the same. At this point, the pressure of port c is ~ 2/5 kg/cm2.
PC300LC-6
10-38 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC300LC-6
PC300HD-6 10-39
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C The size of command current x is determined by the band the small piston diameter end of servo piston (9),
nature of the operation (lever operation), the selection and the other main pump pressure Pa2 enters port a.
of the working mode, and the set value and actual C When pump pressures Pa1 and Pa2 are small, piston
value for the engine speed. (2) is on the right. At this point, port c and port d are
j Other Pump Pressure: This is the pressure of the connected, and the pressure entering the LS valve
pump at the opposite end. For the front pump, it is the becomes drain pressure PT. If port h and port e of the
rear pump pressure. For the rear pump, it is the front LS valve are connected (see LS valve), the pressure
pump pressure. entering the large piston diameter end from port f
Action of spring becomes drain pressure PT, and servo piston (9)
C The spring load of springs (3) and (4) in the TVC valve moves to the right. In this way, the pump discharge
is determined by the position of the swash plate. amount moves in the direction of increase.
C When servo piston (9) moves, cam (7), which is con- C As servo piston (9) moves further, piston (5) is moved
nected to rod (8), also moves. When this happens, to the left by rod (8), cam (7), and lever (6). Springs (3)
lever (6) is rotated by the angle of cam (7), and piston and (4) expand and the spring force becomes weaker.
(5) moves to the right or left. When the spring force becomes weaker, piston (2)
C If piston (5) moves to the right, spring (3) is moves to the left, so the connection between port c and
compressed; and if it moves further to the right, spring port d is cut, and the pump discharge pressure port b
(4) contacts seat (10), so both spring (3) and spring (4) is connected to port c. As a result, the pressure at port
function. In other words, the spring load is changed by c rises, and the pressure at the large piston diameter
piston (5) extending or contracting springs (3) and (4). end also rises, so the movement of piston (9) to the
C If command current x input to solenoid (1) changes right is stopped. In other words, the stop position for
further, the pushing force of solenoid push pin (11) piston (9) (= pump discharge amount) is decided at the
changes, and the spring load of springs (3) and (4) also point where the force of springs (3) and (4) and the
changes according to the value of the solenoid com- pushing force from the solenoid and the pushing force
mand current. created by pressures Pa1 and Pa2 acting on piston (2)
C Port c of the TVC valve is connected to port e of the LS are in balance.
valve (see LS valve). Self pressure Pa1 enters port
PC300LC-6
10-40 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C When the load is large and pump discharge pressures Pa1 and
Pa2 are high, the force pushing piston (2) to the left becomes
larger and piston (2) moves to the position shown in the diagram
above. When this happens, as shown in the diagram above, with
the pressurized oil flowing from port c to the LS valve, part of the
pressurized oil from port b flows out to port d and becomes
approximately 2/5 main pump pressure Pa1.
C When port h and port e of the LS valve are connected (see LS
valve), the pressure from port f enters the large piston diameter
end of servo piston (9), and servo piston (9) stops.
PC300LC-6
PC300HD-6 10-41
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C If main pump pressures Pa1 and Pa2 increase further and piston
(2) moves further to the left, main pump pressure Pa1 flows to
port c and acts to make the discharge amount the minimum.
When piston (9) moves to the left, piston (5) is moved to the right
by cam (7) and lever (6). For this reason, springs (3) and (4) are
compressed and push back piston (2). Because of this force,
piston (2) cuts off the connection from port b to port c, and port c
and port d are connected. As a result, the pressure at port c (= f)
drops, and piston (9) stops moving to the left. The position in which
piston (9) stops when this happens is further to the left than the
position when main pump pressures Pa1 and Pa2 are low.
C The relation of average main pump pressure Pa1 + Pa2 and the
position of servo piston (9) forms a bent line because of the
double spring effect of springs (4) and (6). The relationship
between average main pump pressure Pa1 + Pa2 and the pump
discharge amount Q is shown in the figure on the right.
PC300LC-6
10-42 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC300LC-6
PC300HD-6 10-43
STRUCTURE AND FUNCTION HYDRAULIC PUMP
C In the same way as in the previous item, when the TVC prolix
switch is ON, the command current x sent to solenoid (1) be-
comes constant. For this reason, the force of solenoid push pin
(11) pushing piston (2) is constant.
C If main pump pressures Pa1 and Pa2 increase, piston (2) moves
further to the left than when the main pump load is light, and is
balanced at a position towards the left.
C In this case, the pressure from port b flows to port c, so servo
piston (9) moves to the left (to make the discharge amount
smaller) and stops at a position further to the left than when the
load on the pump is light. In other words, even when the TVC
prolix switch is ON, the curve for the pump pressure P and
discharge amount Q is determined as shown in the diagram for
the value of the current sent to the solenoid through the resistor.
PC300LC-6
10-44 PC300HD-6
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PC300LC-6
PC300HD-6 10-45
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
10-46 PC300HD-6
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
PC300HD-6 10-47
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
10-48 PC300HD-6
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
PC300HD-6 10-49
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
10-50 PC300HD-6
STRUCTURE AND FUNCTION CONTROL VALVE
1. LS shuttle valve
2. LS divider valve
4. Return spring
6. Return spring
7. LS by pass valve
PC300LC-6
PC300HD-6 10-51
STRUCTURE AND FUNCTION CONTROL VALVE
PC300LC-6
10-52 PC300HD-6
STRUCTURE AND FUNCTION CONTROL VALVE
7. Suction valve
PC300LC-6
PC300HD-6 10-53
STRUCTURE AND FUNCTION SELF REDUCING PRESSURE VALVE
T : To hydraulic tank
PC300LC-6
10-54 PC300HD-6
STRUCTURE AND FUNCTION SELF REDUCING PRESSURE VALVE
PC300LC-6
PC300HD-6 10-55
STRUCTURE AND FUNCTION SELF REDUCING PRESSURE VALVE
FUNCTION
C This valve reduces the discharge pressure of the main pump and
supplies it as the control pressure for the solenoid valve and PPC
valve.
OPERATION
WHEN ENGINE IS STOPPED
C Poppet (5) is pushed against the seat by spring (6), and the
passage from port PR T is closed.
C Valve (9) is pushed to the left by spring (8), and the passage from
port P1PR is open.
C Valve (2) is pushed to the left by spring (3), so the passage
between port P1 P2 is closed.
PC300LC-6
10-56 PC300HD-6
STRUCTURE AND FUNCTION SELF REDUCING PRESSURE VALVE
REMARK
When load pressure P2 is lower than output pressure PR of the
self-reducing pressure valve.
C Valve (2) receives force in the direction to close the passage from
P2 from spring (3) and pressure PR (when the engine is
port P1
stopped, the pressure is 0 kg/cm2. However, when hydraulic oil
flows in from port P1, the pressure is balanced so that pressure
P1 force of spring (8) + (area id x pressure PR), and the
opening from port P1 P2 is adjusted so that pressure P1 is kept
at a certain value above pressure PR.
C When pressure PR goes above the set pressure, poppet (5) opens
and the hydraulic oil flows in the following circuit, port PR hole
a inside spool (9) opening of poppet (5) tank port T.
C As a result, a pressure difference is created on both sides of hole
a inside spool (9), so spool (9) moves in the direction to close the
opening from port P1 PR. Pressure P1 is reduced to a certain
pressure (set pressure) by the amount of opening at this point, and
is supplied as pressure PR.
C If pressure PR goes above the set pressure, 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.
PC300LC-6
PC300HD-6 10-57
STRUCTURE AND FUNCTION SELF REDUCING PRESSURE VALVE
PC300LC-6
10-58 PC300HD-6
STRUCTURE AND FUNCTION SUCTION SAFETY VALVE
3. Piston 8. Sleeve
PC300LC-6
PC300HD-6 10-59
STRUCTURE AND FUNCTION MEMORANDA
MEMORANDA
PC300LC-6
10-60 PC300HD-6
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE OF CLSS
OUTLINE STRUCTURE
C CLSS stands for Closed center Load Sensing System, C The CLSS consists of a main pump (2 pumps), control
and has the following features. valve, and actuators for the work equipment.
C The main pump consists of the pump itself, the TVC
FEATURES valve and LS valve.
C Fine control not influenced by load.
C Control enabling digging even with fine control.
C Ease of compound operation ensured by flow divider
function using area of opening of spool during com-
pound operations.
C Energy saving using variable pump control.
PC300LC-6
PC300HD-6 10-61
STRUCTURE AND FUNCTION CLSS
BASIC PRINCIPLE
CONTROL OF PUMP SWASH PLATE ANGLE
PC300LC-6
10-62 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PRESSURE COMPENSATION (inlet port) and downstream (outlet port) of the spool of
each valve the same regardless of the size of the load
A pressure compensation valve is installed to the outlet (pressure).
port side of the control valve to balance the load. In this way, the flow of oil from the pump is divided
When two actuators are operated together, this valve acts (compensated) in proportion to the area of openings S1
to make pressure difference ) P between the upstream and S2 of each valve.
PC300LC-6
PC300HD-6 10-63
STRUCTURE AND FUNCTION CLSS
2. Main relief valve, arm . . . . . . . . . 355 5 kg/cm 20 Check valve - for arm regeneration circuit
6. Variable type pressure compensation valve 24. Merge flow divider valve
1st stage . . . . . . . . . . 290 5 kg/cm
2nd stage . . . . . . . . . 150 5 kg/cm 25. Main pump
8. Safety suction valve . . . . . . . . . . 365 5 kg/cm 27. To swing stroke switch valve
9. Safety suction valve, large flow . 365 5 kg/cm 28. Arm cylinder
16. Check valve - for boom regeneration circuit 36. Test port
17. Swing spool 37. Service valve - up to two with a 3rd possible
PC300LC-6
10-64 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-65
STRUCTURE AND FUNCTION CLSS
SYSTEM DIAGRAM
j This shows actuator (6A) at stroke end relief in the merge mode.
PC300LC-6
10-66 PC300HD-6
STRUCTURE AND FUNCTION CLSS
FUNCTION
C When all the control valves are at neutral, the oil discharged when
the pump is at the minimum swash plate angle is drained. When
this happens, the pump pressure becomes a pressure that
matches the set load of springs (11A, 11B) inside the valve (P1
pressure). The LS pressure is drained from LS bypass valve (12),
so LS pressure tank pressure 0 kg/cm2.
C When operated (for operations in the discharge range for the
minimum swash plate angle), the discharge pressure of the oil dis-
charged with the pump at the minimum swash plate angle is LS
pressure + P1 pressure. In other words, the LS control differential
pressure () )PLS) of the oil discharged at the minimum swash plate
angle is the P1 pressure.
OPERATION
C The pressure in pump passages (7A, 7B) is received by the end
face of valves (10A, 10B). The control valve is at neutral, so the
pressure in LS circuits (8A, 8B) is 0 kg/ cm2.
C The pressurized oil in pump passages (7A, 7B) is stopped by
valves (10A, 10B). There is no way for the pressurized oil dis-
charged by the pump to escape, so the pressure rises. When this
pressure becomes larger than the force of springs (11A, 11B),
valves (10A, 10B) move to the left, ports B and C are connected
and the pump pressure flows to tank passages (9A, 9B). In
addition, the pressurized oil in LS circuits (8A, 8B) passes from
orifice A through port C, and is drained to tank passages (9A, 9B).
Therefore, when the valve is actuated, LS pressure tank pres-
sure.
C When the unload operation is carried out, the differential pressure
(pump discharge pressure - LS circuit pressure) is greater than the
pump LS control pressure, so a signal is sent to move the pump
swash plate to the minimum angle.
PC300LC-6
PC300HD-6 10-67
STRUCTURE AND FUNCTION CLSS
Function
C When cut-off control is being carried out on the pump by the TVC
valve, the pump swash plate angle is at the minimum.
C The relief valve acts to relieve the oil flow when the pump is at the
minimum swash plate angle in order to maintain the overall
balance.
Operation
C When the cylinder reaches the end of its stroke, main relief valves
(2A, 2B) open and pump discharge amount Q is relieved to tank
passages (9A, 9B).
C When pump delivery pressure PP comes close to the relief
pressure, the governor, pump controller sends a signal to the
solenoid of the TVC valve and carries out the cut-off function to
make pump discharge amount Q the minimum.
C The spool is at the end of its stroke, so there is no flow of oil
upstream or downstream from the spool. As a result, the pump
delivery pressure PP and LS pressure PLS are almost the same
pressure, and LS differential pressure ) PLS becomes 0.
C LS differential pressure )PLS 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, because of the structure,
the action of the TVC valve is given priority over the action of the
LS valve, so the pump is held at the minimum swash plate angle
by the cut-off function of the TVC valve.
CUT-OFF CANCELED
(Power Max. Mode, Fine Control Mode, Travel)
Function, operation
C In the power max. mode, fine control mode, or travel mode, the
torque cut-off signal is not given, so the torque moves on the
pump output curve.
C When this happens, the pump discharge amount is relieved from
the relief valve, so the overall balance is maintained.
PC300LC-6
10-68 PC300HD-6
STRUCTURE AND FUNCTION CLSS
INTRODUCTION OF LS PRESSURE
j The diagram shows the condition for arm IN.
FUNCTION OPERATION
The upstream pressure (= spool meter-in downstream When spool (2) is operated, the pump pressure passes
pressure) of pressure compensation valve (3) is intro- through introduction hole a, enters port C, and is taken to
duced and goes to shuttle valve (7) as the LS pressure. the LS circuit. When the pump pressure rises and
When this happens, it is connected to port B of the reaches the load pressure of port B, ball valve (5) opens.
actuator through valve (4), and LS pressure actuator
load pressure. Introduction hole a inside the spool has a
small diameter, so it also acts as a throttle.
PC300LC-6
PC300HD-6 10-69
STRUCTURE AND FUNCTION CLSS
LS BYPASS VALVE
FUNCTION
C The residual pressure in LS circuit (6) is released from orifices a
and b.
C This reduces the speed of the rise in the LS pressure, and
prevents any sudden change in the oil pressure. Furthermore, a
pressure loss is generated by the circuit resistance between
throttle c of main spool (2) and LS shuttle valve (4) according to
the bypass flow from LS bypass valve (5). As a result, the effective
LS differential pressure drops, and the dynamic stability of the
actuator is increased.
PC300LC-6
10-70 PC300HD-6
STRUCTURE AND FUNCTION CLSS
FUNCTION
1) During independent operation and at maximum load
pressure during compound operations, when load pressure
is higher than other work equipment
C The pressure compensation valve acts as a load check valve.
OPERATION
C If the pump pressure (LS pressure) is lower than the load pressure
at port C, shuttle valve (3) inside pressure compensation valve pis-
ton (4) moves to interconnect spring chamber E and port C. From
this condition, the force of spring (5) acts to move piston (4) and
valve (2) in the direction of closing.
Reference: Integrated pressure compensation valve
C When high peak pressure is generated in the actuator circuit or
when peak pressure is generated repeatedly over a continuous
period (such as when using a breaker), valve (2) may hit valve
chamber seat s and generate a high stress. To prevent this, an
integrated pressure compensation valve combining valve (2) and
piston (4) is used. On this machine, this is employed for the bucket
valve (at the cylinder bottom) and service valve. With the
integrated compensation valve, as a basic rule, port C and spring
chamber E are not interconnected, so even if a high peak
pressure is generated at port C, valve (7) does not hit the valve
chamber. (However, the system is designed so that port C and
spring chamber E are interconnected just before the bucket valve
is seated.)
PC300LC-6
PC300HD-6 10-71
STRUCTURE AND FUNCTION CLSS
PC300LC-6
10-72 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-73
STRUCTURE AND FUNCTION CLSS
2. Valve 4. Piston
FUNCTION
When holding pressure at port A > LS pressure in spring
chamber B.
C Shuttle valve (3) is pushed to the right by the pressure of port A,
and the circuit between ports A and C is shut off. In this condition,
the holding pressure 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.
PC300LC-6
10-74 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-75
STRUCTURE AND FUNCTION CLSS
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)
PC300LC-6
10-76 PC300HD-6
STRUCTURE AND FUNCTION CLSS
FUNCTION
1) Cylinder head pressure < cylinder bottom pressure (free
fall, etc.)
C A return flow circuit is provided from the cylinder bottom to the
cylinder head so that when the boom is lowered, the return flow
can be used to increase the flow of oil from the pump to the
cylinder bottom.
OPERATION
C When the cylinder head pressure < cylinder bottom pressure, part
of the pressurized oil from the cylinder bottom passes through the
notch in spool (2), goes through port B, and enters drain circuit
(7). The rest of the oil goes from port C, enters regeneration circuit
(8), opens check valve (5), and passes through ports C and D to
flow back to the cylinder head.
PC300LC-6
PC300HD-6 10-77
STRUCTURE AND FUNCTION CLSS
PC300LC-6
10-78 PC300HD-6
STRUCTURE AND FUNCTION CLSS
FUNCTION
Cylinder head pressure > cylinder bottom pressure
C A return flow circuit is provided from the cylinder head to the
cylinder bottom so that when the arm is moved IN, the flow of oil
to the cylinder becomes the pump discharge amount + the return
flow. This covers for any negative pressure at the cylinder bottom,
and, as a result, increases the cylinder speed.
OPERATION
C When the cylinder head pressure > cylinder bottom pressure, the
pressurized oil from the cylinder head passes through the notch
in spool (2), enters port C and opens check valve (8), then passes
through ports D and E to flow back to the cylinder bottom.
PC300LC-6
PC300HD-6 10-79
STRUCTURE AND FUNCTION CLSS
PC300LC-6
10-80 PC300HD-6
STRUCTURE AND FUNCTION CLSS
C When pilot pressure PS is ON, main spool (1) is moved to the right
by the PS pressure, and ports E and F are disconnected.
Therefore, the pressurized oil discharged from each pump is sent
to its own control valve group.
C In the same way, LS spool (3) is also moved to the right by the PS
pressure, and the ports are connected as follows.
C Therefore, LS circuits (5), (6), (7), and (8) are all connected to
their own control valve group.
PC300LC-6
PC300HD-6 10-81
STRUCTURE AND FUNCTION CLSS
LS SELECT VALVE
j The diagram shows the situation when the swing and left travel
are operated at the same time. (BP pressure ON).
4. Piston 9. LS circuit
5. Swing spool
FUNCTION
C This valve is used to increase the ease of operating the work
equipment. It prevents high pressure from being generated when
the swing is operated. It also prevents the high LS pressure from
the swing circuit from flowing into any other LS circuit when the
swing is operated together with the work equipment.
OPERATION
PC300LC-6
10-82 PC300HD-6
STRUCTURE AND FUNCTION CLSS
FUNCTION
C The set pressure of the safety valve can be 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 control lever. This makes it possible to carry out
operations with high efficiency and with little vibration of the
chassis.
OPERATION
PC300LC-6
PC300HD-6 10-83
STRUCTURE AND FUNCTION CLSS
2A. Main pump (front) 19. 2 stage safety-suction valve (boom LOWER)
5A. Merge flow divider valve (main) 25. LS shuttle valve (arm)
5B. Merge flow divider valve (for LS) 26. Check valve (for boom regeneration circuit)
14. Pressure compensation valve (with shuttle valve) 33. Suction valve
15. Pressure compensation valve (with shuttle valve) 34. Service spool
16. Pressure compensation valve (w/o shuttle valve) 35. Variable type pressure compensation valve
Bucket group: Bucket, Right travel, boom Lo, boom Hi, Arm Hi
PC300LC-6
10-84 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-85
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-87
STRUCTURE AND FUNCTION CLSS
C When the boom RAISE is operated, unload valves (29A, 29B) are
closed.
PC300LC-6
10-88 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-91
STRUCTURE AND FUNCTION CLSS
C When the arm OUT is operated, unload valves (29A, 29B) are
closed.
C When this happens, the oil from the cylinder bottom is divided,
sent to the Lo and Hi spools, and then returned, so it is possible
to keep the pressure loss in the circuit small.
PC300LC-6
10-92 PC300HD-6
STRUCTURE AND FUNCTION CLSS
Step 1
Step 2
C From the condition in Step 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 operated in the opposite direction (the direction
of travel is reversed), the oil flow from the pump is being divided,
so the left and right travel circuits are controlled independently
and the machine is steered.
PC300LC-6
PC300HD-6 10-95
STRUCTURE AND FUNCTION CLSS
WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-97)
Step 1
C When this happens, the load pressure at the boom RAISE side
is higher than at the arm side, so the LS pressure passes thru
ports E and F of boom Lo spool (8), 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 (14), and acts to
increase the set pressure of the pressure compensation valve.
Because of this, the pressure between port H of arm Lo spool
(11) and port I of pressure compensation valve (14) rises, and the
spool meter in LS differential pressure (pump pressure LS
pressure = ) PLS) becomes the same as that at the boom end.
Step 2
PC300LC-6
10-96 PC300HD-6
STRUCTURE AND FUNCTION CLSS
WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-98)
C When this happens, the LS divider valve is shut off, and the high
pressure generated when the swing is operated does not flow to
the LS circuit, so the LS circuit pressure becomes the boom
pressure.
PC300LC-6
PC300HD-6 10-99
STRUCTURE AND FUNCTION CLSS
WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-101)
PC300LC-6
10-100 PC300HD-6
STRUCTURE AND FUNCTION CLSS
PC300LC-6
PC300HD-6 10-103
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
KMF160ABE-3
MB : From control valve Safety valve set pressure . . . . . . . 293 +50 kg/cm2
PC300LC-6
10-104 PC300HD-6
STRUCTURE AND FUNCTION SWING MOTOR
8. Housing
PC300LC-6
PC300HD-6 10-105
STRUCTURE AND FUNCTION SWING MOTOR
SUCTION-SAFETY VALVE
FUNCTION
C 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 becomes abnormally high and there is danger
that the motor will be damaged.
OPERATION
C When this happens, the pressure at port MA 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 to the tank.
PC300LC-6
10-106 PC300HD-6
STRUCTURE AND FUNCTION SWING MOTOR
SWING BRAKE
OPERATION
PC300LC-6
PC300HD-6 10-107
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
PC300LC-6
10-108 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
TRAVEL MOTOR
HMV160ADT-2
PC300LC-6
PC300HD-6 10-109
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
PC300LC-6
10-110 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
OPERATION OF MOTOR
AT LOW SPEED
PC300LC-6
PC300HD-6 10-111
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
AT HIGH SPEED
C When the solenoid valve is energized, the pilot pressure oil from
the main pump flows to port P, and pushes regulator valve (21)
to the left.
C Because of this, main pressure oil from the control valve passes
through passage d in regulator valve (21), enters regulator piston
(13), and pushes regulator piston to the right.
C As a result, rocker cam (3) moves in the minimum swash plate
angle direction, the motor capacity becomes minimum, and the
system is set to high travel speed.
PC300LC-6
10-112 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
C When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (17), opens the circuit
to the parking brake, and flows into chamber a of brake piston
(10). It overcomes the force of spring (9), and pushes brake
piston (10) to the right.
C When this happens, the force pushing plate (11) and disc (12)
together is lost, so the plate and disc separate and the brake is
released.
PC300LC-6
PC300HD-6 10-113
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
C The pressurized oil at the supply side flows from orifice E1 in the
spool (19) and orifice E2 in the piston to chamber S1. When the
pressure in chamber S1 goes above spool switching pressure,
spool (19) is pushed to the right. As a result, port MB and port PB
are connected, the outlet port side of the motor is opened, and
the motor starts to rotate.
PC300LC-6
10-114 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
SAFETY VALVE
FUNCTION
C If the pressure goes above the set pressure, the force produced
by the difference in area between D1 and D2 [B4 (D12 - D22 ) x
pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MA in the circuit on
the opposite side.
PC300LC-6
PC300HD-6 10-115
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
C If the pressure goes above the set pressure, the force produced
by the difference in area between D1 and D3 [B/4(D32 - D12 ) x
pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MB in the circuit on
the opposite side.
C When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (19), and opens the
pilot circuit to the safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes the piston to the
right, and compresses the spring to make the set load larger.
Because of this, the set pressure of the safety valve is switched
to the high pressure setting, and a large drawbar pull is made
available.
PC300LC-6
10-116 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300LC-6
PC300LC-6
PC300HD-6 10-117
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
TRAVEL MOTOR
KMV280ADT
PC300LC-6
10-118 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
PC300LC-6
PC300HD-6 10-119
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
OPERATION OF MOTOR
AT LOW SPEED
C The main pressure oil from the control valve pushes slow return
valve (17), goes to end cover (6), and acts on chamber a of
regulator piston (9).
C At the same time, the main pressure oil passes through orifice c
in regulator valve (17) and acts also on chamber b.
C As a result, valve plate (5) and cylinder block (4) move in the
maximum swash plate angle direction, the motor capacity
becomes maximum, and the system is set to low speed.
PC300LC-6
10-120 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
AT HIGH SPEED
C When the solenoid valve is energized, the pilot pressure oil from
the main pump flows to port P, and pushes regulator valve (17)
down.
C When this happens, chamber b and the main pressure oil are
shut off at regulator valve (17), and the oil at chamber b is
drained inside the case.
C As a result, valve plate (5) and cylinder block (4) move in the
minimum swash plate angle direction, the motor capacity
becomes minimum, and the system is set to high travel speed.
PC300LC-6
PC300HD-6 10-121
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
C When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (11), opens the circuit
to the parking brake, and flows into chamber e of brake piston
(20). It overcomes the force of spring (19), and pushes brake
piston (20) to the right.
C When this happens, the force pushing plate (10) and disc (11)
together is lost, so plate (10) and disc (11) separate and the
brake is released.
PC300LC-6
10-122 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
PC300LC-6
PC300HD-6 10-123
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
SAFETY VALVE
FUNCTION
C If the pressure goes above the set pressure, the force produced
by the difference in area between D1 and D2 [B4 (D12 - D22 ) x
pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MA in the circuit on
the opposite side.
PC300LC-6
10-124 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
C If the pressure goes above the set pressure, the force produced
by the difference in area between D1 and D3 [B/4(D32 - D12 ) x
pressure] overcomes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MB in the circuit on
the opposite side.
C When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (19), and opens the
pilot circuit to the safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes the piston to the
right, and compresses the spring to make the set load larger.
Because of this, the set pressure of the safety valve is switched
to the high pressure setting, and a large drawbar pull is made
available.
PC300LC-6
PC300HD-6 10-125
STRUCTURE AND FUNCTION TRAVEL MOTOR - PC300HD-6
PC300LC-6
10-126 PC300HD-6
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
Components
1. Travel PPC valve 5. Right equipment lever 9. Control valve 13. Left equipment lever
2. Left travel lever 6. Active solenoid valve 10. Hydraulic pump 14. PPC safety lock valve
3. Right travel lever 7. Accumulator 11. LS-EPC valve 15. Left PPC valve
4. Right PPC valve 8. Solenoid block 12. PPC shuttle valve 16. Safety lock lever
Lever Positions
a. NEUTRAL e. Bucket CURL I. Swing right m. Travel FORWARD
b. Boom RAISE f. NEUTRAL j. Swing left n. LOCK
c. Boom LOWER g. Arm IN k. NEUTRAL p. FREE
d. Bucket DUMP h. Arm OUT l. Travel REVERSE
PC300LC-6
PC300HD-6 10-127
STRUCTURE AND FUNCTION WORK EQUIPMENT PPC VALVE
PC300LC-6
10-128 PC300HD-6
STRUCTURE AND FUNCTION WORK EQUIPMENT PPC VALVE
1. Spool 7. Joint
PC300LC-6
PC300HD-6 10-129
STRUCTURE AND FUNCTION WORK EQUIPMENT PPC VALVE
OPERATION
AT NEUTRAL
PC300LC-6
10-130 PC300HD-6
STRUCTURE AND FUNCTION WORK EQUIPMENT PPC VALVE
C If the pressure at port P1 drops too far, spool (1) is pushed down
by metering spring (2), and fine control hole f is shut off from
drain chamber D. At almost the same time, it is connected to
pump pressure chamber PP, and the pump pressure is supplied
until the pressure at port P1 recovers to a pressure that
corresponds to the lever position.
C When the spool of the control valve returns, oil in drain chamber
D flows in from fine control hole f in the valve on the side that is
not working. The oil passes through port P2 and enters chamber
B to fill the chamber with oil.
AT FULL STROKE
C When disc (5) pushes down piston (4), and retainer (9) pushes
down spool (1), fine control hole f is shut off from drain chamber
D and is connected with pump pressure chamber PP. Therefore,
the pilot pressure oil from the main pump passes through the fine
control hole f and flows to chamber A from port P1, and pushes
the control valve spool. The oil returning from chamber B passes
from port P2 through fine control hole f and flows to drain
chamber D.
PC300LC-6
PC300HD-6 10-131
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
T : To tank
PC300LC-6
10-132 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
PC300LC-6
PC300HD-6 10-133
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
OPERATION
AT NEUTRAL
C The relationship of the position of spool (1) and body (10) (fine
control hole f is in the middle between drain hole D and pump
pressure chamber PP) does not change until retainer (9)
contacts spool (1).
PC300LC-6
10-134 PC300HD-6
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
AT FULL STROKE
C Disc (5) pushes down piston (4), and retainer (9) pushes down
spool (1). Fine control hole f is shut off from drain chamber D,
and is 5 connected to pump pressure chamber PP. Therefore,
the pilot pressure oil from the main pump passes through fine
control hole f and flows to chamber A from port P1 to push the
control valve spool. The return oil from chamber B passes from
port P2 through fine control hole f and flows to drain chamber D.
PC300LC-6
PC300HD-6 10-135
STRUCTURE AND FUNCTION 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 : To service valve P1
B : To service valve P2
T : To tank
PC300LC-6
10-136 PC300HD-6
STRUCTURE AND FUNCTION SERVICE PPC VALVE
OPERATION
AT NEUTRAL
C The pressurized oil from the main pump enters from port P and
is blocked by spool (9). Ports A and B of the control valve and
ports a and b of the PPC valve are connected to drain port T
through fine control hole X of spool (9).
WHEN OPERATED
C As a result, fine control hole X is shut off from the drain circuit. At
almost the same time, fine control portion Y is connected with
port a, and the pressurized oil from port P flows from port a to
port A of the control valve.
PC300LC-6
PC300HD-6 10-137
STRUCTURE AND FUNCTION PPC SAFETY LOCK VALVE
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
PC300LC-6
10-138 PC300HD-6
STRUCTURE AND FUNCTION PPC ACCUMULATOR
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
PC300LC-6
PC300HD-6 10-139
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
PC300LC-6
10-140 PC300HD-6
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
FUNCTION
C The PPC shuttle valve sends the PPC valve output pressure to
the control valve and travel junction valve. It is provided with a
port for the pressure switch for detecting the pilot pressure.
PC300LC-6
PC300HD-6 10-141
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
PC300LC-6
10-142 PC300HD-6
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
1. Body
2. Plug
3. Ball
PC300LC-6
PC300HD-6 10-143
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
PC300LC-6
10-144 PC300HD-6
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
STRAIGHT-TRAVEL SYSTEM
FUNCTION
C A travel junction valve is installed between the travel valve and
travel motor to compensate for any difference in the oil flow to
the left and right travel circuits when traveling in a straight line.
C Because of this, the flow of oil to the left and right travel motors
when traveling in a straight line is almost the same, so there is no
travel deviation.
C The travel junction valve interconnects the travel circuits when
the straight travel is operated independently or when the straight
travel + another actuator are operated simultaneously.
C When steering, if the difference in the movement of the travel
levers is more than ~ 10 mm, the travel junction valve is switched,
and the left and right travel circuits are shut off.
PC300LC-6
PC300HD-6 10-145
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
OPERATION
PC300LC-6
10-146 PC300HD-6
STRUCTURE AND FUNCTION LS-EPC VALVE
LS-EPC VALVE
4. Push pin
PC300LC-6
PC300HD-6 10-147
STRUCTURE AND FUNCTION LS-EPC VALVE
FUNCTION
C The EPC valve consists of the proportional solenoid portion and
the hydraulic valve portion.
C When it receives signal current I from the controller, it generates
the EPC output pressure in proportion to the size of the signal,
and outputs it to the LS valve.
OPERATION
WHEN SIGNAL CURRENT IS 0 (COIL DE-ENERGIZED)
PC300LC-6
10-148 PC300HD-6
STRUCTURE AND FUNCTION LS-EPC VALVE
C When a very small signal current flows to coil (5), coil (5) is
energized, a propulsion force is generated, and this pushes
plunger (6) to the left.
C Push pin (4) pushes spool (2) to the left, and pressurized oil flows
from port P to port C. When the pressure at port C rises and the
load of spring (3) + the force acting on surface a of spool (2)
becomes greater than the propulsion force of plunger (6), 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.
C When the signal current flows to coil (5), coil (5) is energized.
When this happens, the signal current is at its maximum, so the
propulsion force of plunger (6) is also at its maximum. For this
reason, spool (1) is pushed fully to the left by push pin (4).
PC300LC-6
PC300HD-6 10-149
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
FOR ACTIVE MODE, PUMP MERGE DIVIDER, BOOM HI 2 STAGE SAFETY VALVE, TRAVEL SPEED,
SWING BRAKE SOLENOID VALVE
PC300LC-6
10-150 PC300HD-6
STRUCTURE AND FUNCTION SOLENOID VALVE
OPERATION
WHEN SOLENOID IS DEACTIVATED
C When the signal current does not flow from the PPC lock switch
or swing lock switch, solenoid (3) is deactivated. For this reason,
spool (5) is pushed fully to the right by spring (6).
C When the signal current flows from the PPC lock switch or swing
lock switch to solenoid (3), solenoid (3) is excited. For this reason,
spool (5) is pushed to the left in the direction of the arrow.
C 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 stops the
oil from flowing to the tank.
PC300LC-6
PC300HD-6 10-151
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
5. Poppet
PC300LC-6
10-152 PC300HD-6
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
OPERATION
AT BOOM RAISE
C When the boom is raised, the main pressure from the control
valve pushes 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 cylinder.
PC300LC-6
PC300HD-6 10-153
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
AT BOOM LOWER
PC300LC-6
10-154 PC300HD-6
STRUCTURE AND FUNCTION WORK EQUIPMENT
WORK EQUIPMENT
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
PC300LC-6
PC300HD-6 10-155
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
REMARK
PC300LC-6
10-156 PC300HD-6
STRUCTURE AND FUNCTION ACTUAL ELECTRICAL WIRING DIAGRAM
PC300LC-6
PC300HD-6 10-157
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM
PC300LC-6
10-158 PC300HD-6
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM
PC300LC-6
PC300HD-6 10-159
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM
PC300LC-6
10-160 PC300HD-6
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
PC300LC-6
PC300HD-6 10-161
STRUCTURE AND FUNCTION ENGINE CONTROL
OPERATION OF SYSTEM
STARTING ENGINE
C The fuel control dial sends a signal to the governor and pump
controller according to the position of the dial. The governor and
pump controller calculates the angle of the governor motor
according to this signal, and sends a signal to drive the governor
motor so that it is at that angle. When this happens, the operating
angle of the governor motor is detected by the potentiometer,
and feedback is sent to the governor and pump controller, so that
it can observe the operation of the governor motor.
STOPPING ENGINE
PC300LC-6
10-162 PC300HD-6
STRUCTURE AND FUNCTION ENGINE CONTROL
COMPONENTS OF SYSTEM
FUEL CONTROL DIAL
PC300LC-6
PC300HD-6 10-163
STRUCTURE AND FUNCTION ENGINE CONTROL
GOVERNOR MOTOR
Function
C The motor is rotated and the governor lever of the fuel injection
pump is controlled by the drive signal from the governor and
pump controller. A stepping motor is used for the motor which
provides the power.
C In addition, a potentiometer for giving feedback is installed to
allow observation of the operation of the motor.
C The rotation of the motor is transmitted to the potentiometer
through a gear.
Operation
MOTOR STATIONARY
C Both A phase and B phase of the motor are continuous, and a
holding torque is generated in the motor.
MOTOR ROTATING
C A pulse current is applied to the A phase and B phase from the
governor and pump controller to give synchronous rotation with
the pulse.
PC300LC-6
10-164 PC300HD-6
STRUCTURE AND FUNCTION ENGINE CONTROL
PC300LC-6
PC300HD-6 10-165
STRUCTURE AND FUNCTION ENGINE CONTROL
5 NC 5 NC CN-C17
13 NC 3 GND Input
14 NC 4 GND Input
21 PGND Input
PC300LC-6
10-166 PC300HD-6
STRUCTURE AND FUNCTION MEMORANDA PAGE
MEMORANDA PAGE
PC300LC-6
PC300HD-6 10-167
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
PC300LC-6
10-168 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
PC300LC-6
PC300HD-6 10-169
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C There are five modes available for selection with the C The governor and pump controller detects the actual
working mode switch on the monitor panel. These engine speed and the speed set by the engine
modes are the heavy-duty operation mode (H/O), governor through the fuel control dial in accordance
general operation mode (G/O), finishing operation with the pump absorption torque set for each mode,
mode (F/O), lifting operation mode (L/O), and the and carries out control so that the pump absorbs all of
breaker mode (B/O). It is possible to select the most the torque at each output point of the engine.
suitable engine torque and pump absorption torque to
match the nature of the work.
PC300LC-6
10-170 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
C When the load on the pump rises and the pressure rises, the
engine speed goes down. When this happens, the pump
discharge amount is reduced, and the engine speed is controlled
so that it becomes near the rated output point. If the reverse
happens and the pressure 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 always be used at near the rated output
point.
Matching point
Mode G/O B/O F/O C When the load on the pump rises and the pressure
rises, the engine speed goes down. When this
Partial output point 90% 85% 80% happens, mutual control of the engine and pump is
used to control the system so that the pump
absorption torque follows the equal horsepower curve
of the engine, and the engine speed is lowered while
G/O mode . . . . . . . . . . . . . . . . . 205.9 kW @ 1850 rpm keeping the torque constant. In this way, the engine is
B/O mode . . . . . . . . . . . . . . . . . . 194.9 kW @ 1850 rpm used in a range which provides good fuel efficiency.
F/O mode . . . . . . . . . . . . . . . . . . 183.9 kW @ 1700 rpm
PC300LC-6
PC300HD-6 10-171
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Matching point in lifting operation mode: When the lifting operation mode is selected, the engine
60% partial output point speed is automatically lowered to the partial position. In
this condition, control is carried out in the same way as for
L/O mode . . . . . . . . . . . . . . . . . . 143.4 kW @ 1400 rpm the general operation, finishing, and breaker operation
modes to match the load on the pump. In this way, the
fuel consumption is reduced and the fine control ability is
improved.
Matching point in power max. mode: When the pump load increases, the engine speed drops.
Rated output point When this happens, the pump discharge is reduced to
prevent the engine speed from going down and to ensure
Power max. mode . . . . . . . . . . . . 228 kW @ 1950 rpm that the engine is used at near the rated output point. The
cut-off at relief is canceled and the oil flow at relief is
increased.
Even if any abnormality should occur in the controller or maintain its functions. In this case, it is designed to allow
sensor, the TVC prolix switch can be turned ON to provide a constant current to flow from the battery to the TVC
an absorption torque more or less equivalent to the gen- valve, so oil pressure sensing is carried out only by the
eral operation mode, thereby allowing the machine to TVC valve.
PC300LC-6
10-172 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
LS CONTROL FUNCTION
C The switching point (LS set differential pressure) for the pump
discharge amount inside the LS valve is changed by changing the
output pressure from the LS-EPC valve to the LS valve according
to the operating condition of the actuator.
C Because of this, the timing for starting the discharge amount from
the pump can be optimized, to give excellent ease of compound
operation and fine control.
PC300LC-6
PC300HD-6 10-173
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
C If the load becomes large during the operation and the pump
discharge pressure rises to a point close to the relief pressure,
the pump pressure sensor detects this, and the controller sends
a signal to the TVC valve to reduce the discharge amount in
order to reduce the relief loss.
C The cut off cancel function stops the actuation of the cut off
function in order to ensure the flow of oil from the pump near the
relief pressure, thereby preventing any drop in speed.
C The relief pressure when the cut off function is actuated is 345
kg/cm2, but when the cut off is canceled, the relief pressure rises
to approx. 355 kg/cm2. Because of this, the hydraulic pressure is
increased by one stage.
j When the swing lock switch is set to ON, hydraulic oil is quickly
warmed, also when the swing lock switch is set to ON, the func-
tion is canceled. Under these conditions, when work equipment
is relieved, hydraulic oil temperature goes up more quickly, and
warming time is shortened.
PC300LC-6
10-174 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
j In each working mode, the full flow of the pump at the set engine
speed is taken as 100%.
PC300LC-6
PC300HD-6 10-175
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C This function provides an increase in the digging power for a
certain time or switches the working mode to the fine operation
to reduce the speed. It is operated using the left knob switch to
momentarily match the operating conditions.
j The power max. function and swift slowdown function are
operated with the same switch. Only one of these functions can
be selected at any time; they cannot both be operated together.
PC300LC-6
10-176 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
PC300LC-6
PC300HD-6 10-177
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C If all the control levers are at neutral when waiting for work or
waiting for a dump truck, the engine speed is automatically
reduced to a mid range speed to reduce fuel consumption and
noise. If any control lever is operated, the engine speed returns
immediately to the set speed.
PC300LC-6
10-178 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
OPERATION
PC300LC-6
PC300HD-6 10-179
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
PC300LC-6
10-180 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
C This function protects the engine by lowering the pump load and
engine speed to prevent overheating when the engine coolant
temperature has risen too far. This system is actuated when the
coolant temperature is 105EC and above.
Cancel condition
Coolant temperature Below 105EC
R e t u r n
temporarily to
Fuel control dial
low idle
position
C When the above conditions are met, the
system returns to the condition before
the overheat prevention function was
actuated (manual reset)
PC300LC-6
PC300HD-6 10-181
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C The system is provided with a swing lock and swing holding brake
function.
PC300LC-6
10-182 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
j Even when the swing lock prolix switch is turned ON, the swing
lock switch stays ON and the swing brake is not canceled.
j When the swing brake 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.
C When the swing lock switch is turned ON, the pump cut off is
canceled. If the work equipment is relieved in this condition, the
hydraulic oil temperature will rise more quickly and the warm up
time can be reduced.
Swing lock prolix switch ON (when controller is abnormal) OFF (when controller is normal)
Swing brake Swing lock applied Swing lock canceled Swing lock applied Swing brake applied
PC300LC-6
PC300HD-6 10-183
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C When traveling, the pump control is carried out, and the travel
speed can be selected manually or automatically to give a travel
performance that suits the nature of the work or the job site.
PC300LC-6
10-184 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
C 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.
Lo Mi Hi
Travel speed switch
PC300LC-6 PC300HD-6 PC300LC-6 PC300HD-6 PC300LC-6 PC300HD-6
PC300LC-6
PC300HD-6 10-185
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
FUNCTION
C When the active mode switch on the monitor panel is ON (lit up),
the work equipment speed is increased. The bucket lift is also
increased during swing plus boom RAISE operations, so it is
effective in loading dump trucks.
C 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. position,
the load sensing function is actuated but the pump discharge
increase function is not actuated.
PC300LC-6
10-186 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
C When the active mode switch is ON, the stroke of the boom
LOWER spool is switched 9 mm 11.5 mm, to increase the
lowering speed.
PC300LC-6
PC300HD-6 10-187
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
COMPONENTS OF SYSTEM
ENGINE SPEED SENSOR
Function 1. Wire
C The engine speed sensor is installed to the ring gear portion of 2. Magnet
the engine flywheel. It counts electrically the number of gear
teeth that pass in front of the sensor, and sends the results to the 3. Terminal
governor and pump controller.
4. Housing
C This detection is carried out by a magnet, and an electric current
is generated every time the gear tooth passes in front of the 5. Connector
magnet.
1. Plug
2. Switch
3. Connector
Specifications
Composition of points:
Function
PC300LC-6
10-188 PC300HD-6
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Sensor
2. Connector
Function
C This sensor is installed to the inlet port circuit of the control valve.
It converts the pump discharge pressure to a voltage and sends
this to the governor and pump controller.
Operation
V = 0.008 x P + 1.0
PC300LC-6
PC300HD-6 10-189
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Resistor 2. Connector
Specification
Resistance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 S
Function
C This resistor acts to allow a suitable current to flow to the TVC
solenoid when the TVC prolix switch is ON.
C No current flows when the TVC prolix switch is OFF.
FUEL CONTROL DIAL, GOVERNOR MOTOR, GOVERNOR AND
PUMP CONTROLLER
j See ENGINE CONTROL
MONITOR PANEL
j See MONITORING SYSTEM
TVC VALVE
j See HYDRAULIC PUMP
LS-EPC VALVE
j See LS-EPC VALVE
SOLENOID VALVE
C Active solenoid valve (boom)
C Boom Hi 2-stage safety valve solenoid valve
C Merge flow divider valve solenoid valve
C Travel speed solenoid valve
C Swing brake solenoid valve
j See SOLENOID VALVE
PC300LC-6
10-190 PC300HD-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
PC300LC-6
PC300HD-6 10-191
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MONITOR PANEL
OUTLINE
C The monitor panel consists of the time display, monitor display,
and mode selector switches.
C It has a built in CPU (Central Processing Unit), and processes,
displays, and outputs the data from the sensors and controllers.
C The monitor display and monitor display panels use a liquid
crystal display (LCD) and LED lamp. The mode switches are flat
sheet switches.
PC300LC-6
10-192 PC300HD-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MONITOR DISPLAY
4. Fuel level caution lamp 12. Engine oil pressure caution lamp
5. Engine oil level caution lamp 13. Coolant level caution lamp
6. Hydraulic oil level caution lamp 14. Coolant temperature caution lamp
PC300LC-6
PC300HD-6 10-193
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
CONTENT OF DISPLAY
Symbol Display item Display range With engine stopped With engine running
Engine oil level Below low level Flashes when abnormal OFF
Hydraulic oil level Below low level Flashes when abnormal OFF
PC300LC-6
10-194 PC300HD-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
C To enter the change interval setting mode, keep the time switch
and active mode switch (swing priority switch) pressed simulta-
neously for 2.5 seconds.
C To save the change interval time, set the monitor panel display
to the desired time (mode), then keep the time switch and active
mode switch (swing priority switch) pressed simultaneously for
2.5 seconds.
PC300LC-6
PC300HD-6 10-195
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
C During the oil change interval display and the elapsed time
display, for 10 seconds after all lamps light up (during the
elapsed time display), if the buzzer cancel switch is pressed and
held for 3 seconds, the elapsed time is reset. When the elapsed
time is reset, the elapsed time shows [0h] for 1 second.
C When the set time is changed, the elapsed time is reset to 0h.
DEMO MODE
C The set time in the demo mode is 250h and the elapsed time is
set to 240h. When the key is turned ON, the oil change display is
given. However, the elapsed time does not increase.
C In the demo mode, after the key is turned ON three times, the
interval setting is automatically set to [no setting] from the 4th
time. In addition, the elapsed time is reset to Oh and the elapsed
time count starts.
PC300LC-6
10-196 PC300HD-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
2. Auto-deceleration switch
C The bold letters indicate the default position of the switch when the starting switch is turned ON.
Item Action
TRAVEL SPEED Hi Mi Lo
Note 1: If the working mode is operated F/O G/O or L/O B/O, the auto deceleration switch is automatically turned
ON if it is OFF. If it is already ON, it stays ON. Conversely, if it is operated G/O F/O or B/O L/O, the auto
deceleration switch is automatically 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.
PC300LC-6
PC300HD-6 10-197
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
SENSORS
C The signals from the sensors are input directly to the monitor
panel.
C The contact type sensors are always connected at one end to the
chassis GND.
1. Sub-tank 3. Sensor
2. Float 4. Connector
PC300LC-6
10-198 PC300HD-6
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. Connector 3. Float
2. Bracket 4. Switch
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
1. Connector 3. Thermistor
2. Plug
PC300LC-6
PC300HD-6 10-199
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. Float 3. Cover
PC300LC-6
10-200 PC300HD-6
20 TESTING AND ADJUSTING
WARNING! 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.
WARNING! When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator cap i s
removed while the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
PC300LC-6
PC300HD-6 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLES
Engine SA6D114E-1
Item Measurement condition Unit New machine value Service limit valve
Warm the machine up to operating temperature and record all of the following engine speeds using the machine monitor panel Code 10. Compare
these with the specified values. Adjust the engine speed if necessary. Touch means slight PPC operation to close PPC switch.
Intake manifold pressure At full power and rated speed mm Hg 1143 57 1143 57
20-2 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING STANDARD VALUE TABLES
Arm Lo valve
Arm Hi valve
mm
Bucket valve 9 to 10 9 to 10 9 to 10 9 to 10
Swing valve
Boom Lo Boom Lo
Left travel valve LOWER LOWER
Right travel valve 11 to 12 11 to 12
Boom control lever C Center of lever knob 75 to 95 75 to 95
Travel of control levers
PC300LC-6
PC300HD-6 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLES
Seconds
from starting point
Work equipment posture Max reach
Swing
50 70 49 70
Lo to to to to
72 102 74.9 106
Seconds
37 49.8 37 49.8
Travel
Travel speed 1 MI to to to to
C Engine at full throttle
49 58.4 51.1 62.7
C Hyd oil temp: 45 to 55EC
C In H/O mode
C Raise track one side at a time, rotate 30.4 39.3 30.4 39.3
one turn, then measure time taken for Hi to to to to
next five turns with no load 37.8 46.7 41.5 50.4
20-4 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING STANDARD VALUE TABLES
Seconds
14.5 18.6 14.4
Travel speed 2 MI to to to N/A
C Engine at full throttle
18.9 22.6 21.0
C Hyd oil temp: 45 to 55EC
C In H/O mode
12.1 15.4 12.1
C Run up for at least 10 m and mea-
Hi to to to N/A
sure time taken to travel next 20 m on
14.1 17.4 15.1
flat ground
Measure dimension X
PC300LC-6
PC300HD-6 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLES
Boom cylinders
RAISE
3.5 to 4.3 Max 4.7
Bucket teeth in
contact with ground
LOWER
C Engine at full throttle
Cylinders fully 2.7 to 3.3 Max 3.5
C Hyd oil temp: 45 to 55EC
extended
C In H/O mode
Work equipment speed
IN
Fully retracted
Work equipment
OUT
Fully retracted
Seconds
DUMP
20-6 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING STANDARD VALUE TABLES
Seconds
Time lag
Work equipment
cc/min
C Hyd oil temp: 45 to 55EC
Center swivel joint C Relieve circuit to be measured Max 10 Max 50
C Hyd oil temp: 45 to 55EC
Performance in compound operation
Measure dimension X
PC300LC-6 and PC300HD-6; Discharge amount of piston pump
Piston pump performance
PC300LC-6
PC300HD-6 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLES
resistance
Measure
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . 0.25 to 7 kS
1 Start switch off
Fuel control dial E06 male Between 2 and 3 . . . . . . . . . . . . . . . . . . . . . 0.25 to 7 kS 2 Disconnect E06
Between 1 and 3 . . . . . . . . . . . . . . . . . . . . . . . 4 to 6 kS
resistance
Measure
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . 0.25 to 7 kS
1 Start switch off
Potentiometer E04 male Between 2 and 3 . . . . . . . . . . . . . . . . . . . . . 0.25 to 7 kS 2 DisconnectE04
Between 1 and 3 . . . . . . . . . . . . . . . . . . . . . . . 4 to 6 kS
Governor motor
resistance
Measure Between 3 and 4 . . . . . . . . . . . . . . . . . . . . . 0.25 to 7 kS
1 Start switch off
Motor E05 male Between 1 and 3 . . . . . . . . . . . . . . . . . . . . No continuity 2 Disconnect E05
Between 1 and chassis . . . . . . . . . . . . . . . No continuity
Between 3 and chassis . . . . . . . . . . . . . . . No continuity
1 Start engine
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 3 V 2 Insert T-adapter
Control system
20-8 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING STANDARD VALUE TABLES
resistance
Measure
Travel speed solenoid
V06 male Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 60 S 1 Start switch off
valve 2 Disconnect V06
Between 1, 2 and chassis . . . . . . . . . . . . . . . Min 1 MS
resistance
Measure
LS select solenoid
V02 male Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 60 S 1 Start switch off
valve 2 Disconnect V02
Between 1, 2 and chassis . . . . . . . . . . . . . . . Min 1 MS
resistance
Measure
Pump merge divider
V03 Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 60 S 1 Start switch off
solenoid valve 2 Disconnect V03
Between 1, 2 and chassis . . . . . . . . . . . . . . . Min 1 MS
resistance
Machine push up so-
V05 Measure Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . 20 to 60 S 1 Start switch off
lenoid valve 2 Disconnect V05
Between 1, 2 and chassis . . . . . . . . . . . . . . . Min 1 MS
Measure
1 Start switch on
Fuel control dial C03 Between 4 and 17, low idle . . . . . . . . . . . . . . 4 to 4.75 V 2 Insert T-adapter
Between 4 and 17, high idle . . . . . . . . . . . . . 0.25 to 1 V
PC300LC-6
PC300HD-6 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLES
Measure
Between
voltage
or Mi; solenoid on and trave l 4 Operate lever slightly,
Travel speed sole-
C01 motor swash plate angle min 9 and 6, 12 . . . 20 to 30 V but not enough to move
noid machine
With travel speed switch at Lo; To check that solenoid
Between is off, measure with fuel
solenoid off and travel motor
swash plate angle max 9 and 6, 12 . . . . . 0 to 3 V control dial at low, 1200
rpm or lower
Measure
off; solenoid on and boom
voltage
Active [boom] so- lower spool stroke 9 mm 8 and 6, 12 . . . 20 to 30 V 1 Start switch on
C01
lenoid 2 Insert T-adapter
Whe n active mode switch is
Between
on; solenoid off and boom
lower spool stroke 11.5 mm 9 and 6, 12 . . . . . 0 to 3 V
Measure
1 Start switch on
S-NET C17 Between 4, 12 and GND . . . . . . . . . . . . . . . . . . 4 to 8 V 2 Insert T-adapter
20-10 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING STANDARD VALUE TABLES
System Component Connector Inspection Judgement table Measurement
If within range shown below, it is normal
Continuity
1 Start engine
Air cleaner clogging P11 male Air cleaner normal Between P1 Continuity 2 Disconnect P11
sensor P12 female and P12
Air cleaner clogged No continuity and P12
resistance
Measure
Between 1 and 2 . . . . . . . . . . . . . . . . . . . 500 to 1000 S 1 Start switch off
2 Disconnect E07
Between 2 and chassis . . . . . . . . . . . . . . . . . Min 1 MS
Measure
Engine speed sensor E07 Measure with AC range
voltage
1 Start engine
Between 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 3 V 2 Insert T-adapter
Adjust
back 1 1/6 turns.
2 It must work normally when adjusted as above
If within range shown below, it is normal
resistance
1 Start switch off
Coolant level sensor P08 male Measure Above LOW level in sub tank . . . . . . . . . . . . . . Max 1 S 2 Disconnect P08
3 Insert T-adapter
Below LOW level in sub tank . . . . . . . . . . . . Min 1 MS
into sensor end
If within range shown below, it is normal
resistance
Engine oil level sensor P05 male Raise float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max 1 S 2 Disconnect P05
3 Drain oil, then
remove sensor
resistance
terminal
Engine oil pressure Oil pressure below 0.3 kg/cm 2 . . . . . . . . . . . . . Max 1 S
--- 3 Start engine
sensor
High end pressure 4 Put tester in con-
tact between sen-
Oil pressure above 1.7 kg/cm 2 . . . . . . . . . . . Min 1 MS
sor terminal screw
Oil pressure below 1.3 kg/cm 2 . . . . . . . . . . . . . Max 1 S and chassis
2 Disconnect P09
Hydraulic oil level sen-
P09 male Raise float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max 1 S 3 Drain oil, then re-
sor move sensor
4 Insert T-adapter into
sensor end
Lower float . . . . . . . . . . . . . . . . . . . . . . . . . . Min 1 MS
PC300LC-6
PC300HD-6 20-11
TESTING AND ADJUSTING STANDARD VALUE TABLES
resistance
Measure
Air cleaner clogged . . . . . . . . . . . . . . . . . . No continuity
Monitor
P12
Air cleaner clogging
P11 P12 3 Put tester in con-
sensor
tact with connec-
tor at sensor end
to measure
or measure the
7 3.422 to 3.804 kS resistance of the
sensor
Measure resistance between 6 3.600 to 4.125 kS
Display
engine coolant temperature
portion 5 4.015 to 5.122 kS 2 Check the display
gauge C03-1 and C03-16
with start switch
4 4.728 to 5.899 kS ON
3 6.294 to 7.910 kS
7
2 9.946 to 36.535 kS
Left
side 1 33.725 kS
or measure the
6 25.82 to 31.85 kS resistance of the
sensor
Measure resistance between 5 29.18 to 39.91 kS
Display
fuel level gauge C03-2 and
portion 4 37.00 to 44.60 kS 2 Check the display
chassis
with start switch
3 41.77 to 55.15 kS ON
2 50.42 to 77.07 kS
7
1 72.98 to 691.5 kS
Left
side All off 10 638 kS
Level 1 flashes
20-12 PC300LC-6
PC300HD-6
TESTING AND ADJUSTMENT
PC300LC-6
PC300HD-6 20-101
TESTING AND ADJUSTING TOOLS
79A-264-0020 0 to 294N
79A-264-0090 0 to 490N
Work equipment
L Commercially available Stop watch
speed
Troubleshooting of wiring
harnesses and sensors
N 799-601-7070 For SWP14P
2 Adapter
20-102 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING ENGINE SPEED
2. Start the engine, and measure the engine speed when it is set
to the conditions for measuring.
a) Measuring low idle and high idle speeds.
Measure the engine speed with the fuel control dial set t o
low idle and high idle.
i Measure in the H/O mode with the auto deceleration off.
b) Measure the speed at near the rated speed.
1) Set the working mode to the H/O mode.
2) Set the power max. swift slow down switch to the power
max. position.
3) Run the engine at full throttle, set the knob switch to the
on position, operate the arm lever, and measure th e
speed when the arm IN circuit is relieved.
i Even if the left knob switch is kept pressed, the power max.
function is automatically turned off after . eight seconds, so
measure during the first eight seconds.
i Measure speed when travel is operated: Knob switch on.
c) Measure speed at two pump relief:
1) Set the working mode the H/O mode.
2) Run the engine at full throttle, operate the arm lever ,
and measure the engine speed when the arm IN circuit
is relieved.
PC300LC-6
PC300HD-6 20-103
TESTING AND ADJUSTING ENGINE MEASUREMENTS
20-104 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING ENGINE MEASUREMENTS
BLOW BY PRESSURE
i Refer to the ENGINE SHOP MANUAL for tools and the proper
procedure.
COOLANT TEMPERATURE
i Refer to the ENGINE SHOP MANUAL for tools and the proper
procedure.
VALVE CLEARANCE
i Refer to the ENGINE SHOP MANUAL for tools and the proper
procedure.
PC300LC-6
PC300HD-6 20-105
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
2. Insert the exhaust gas intake port into the exhaust pipe, acceler-
ate the engine suddenly, and at the same time operate th e
handle of tool H1 to catch the exhaust gas on the filter paper.
3. Remove the filter paper and compare it with the scale provided
to judge the condition.
1. Insert the probe of tool H2 into the outlet port of exhaust pipe ,
then tighten the clip to secure it to the exhaust pipe.
2. Connect the probe hose, accelerator switch plug, and air hose
to tool H2.
Air supply pressure . . . . . . . . . . . . . less than 15 kg/cm2
3. Connect the power cord to the AC power source socket.
i When connecting the port, check first that the power switch o f
tool H2 is off.
4. Loosen the cap nut of the suction pump, then fit the filter paper.
i Fit the filter paper securely so that the exhaust gas does no t
leak.
7. Lay the filter paper used to catch the exhaust gas color on top
of unused filter papers, 10 sheets or more, inside the filter paper
holder, and read the indicated value.
20-106 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
1. Preparatory work
a) Keep the monitor panel time switch (1) and travel spee d
[right] switch (2) and working mode [right] switch (3) pressed
for 2.5 seconds.
b) Set the fuel control dial to MAX, and the auto deceleration
switch (4) to off.
ADJUSTING
1. Turn the starting switch OFF, then remove the nut and discon-
nect joint (1) from governor lever (2).
4. From the above position, shorten joints (1) and (4) a total of 2
turns [. 2.5 mm], and secure in position with the locknut.
CAUTION
PC300LC-6
PC300HD-6 20-107
TESTING AND ADJUSTING HYDRAULIC PRESSURE
20-108 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
ADJUSTING
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 39 NCm
i Adjust the safety valve at the high pressure end first, then adjust
the low pressure end.
PC300LC-6
PC300HD-6 20-109
TESTING AND ADJUSTING HYDRAULIC PRESSURE
20-110 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
1. Remove pressure measurement plugs (1), (2), (3) and (4), then
install nipple C2 and oil pressure gauge C1.
3. Set the working mode to H/O mode and set the knob switch
function to POWER MAX.
4. Run the engine at full throttle, turn the left knob switch on, and
measure the oil pressure when the arm IN circuit is relieved.
i For the front pump, measure the oil pressure 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.
i Check that the servo piston input pressure is 2/5 of the pump
discharge pressure.
[Reference]
PC300LC-6
PC300HD-6 20-111
TESTING AND ADJUSTING HYDRAULIC PRESSURE
Adjusting
i If the load becomes larger, the engine speed will drop. Or if the
engine speed remains normal, the work equipment speed will
drop. In such cases, if the pump discharge pressure and L S
differential pressure are normal, adjust the TVC valve as
follows.
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 34 NCm
20-112 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
1. Remove pressure measurement plugs (1), (2), (3) and (4) and
install nipple C2 and oil pressure gauge C1.
2. Set the working mode to H/O mode, and turn the travel speed
switch to Hi.
Table 1
PC300LC-6
PC300HD-6 20-113
TESTING AND ADJUSTING HYDRAULIC PRESSURE
MEASURING LS DIFFERENTIAL PRESSURE
b) Set the working mode to H/O mode, and turn the travel
speed switch to Hi.
Table 2
LS differential pres-
Working mode Travel lever Remarks
sure
2
H/O mode Neutral 40 10 kg/cm Note
Half, travel circuit
H/O mode 25 1 kg/cm2
under no load
20-114 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
ADJUSTING LS VALVE
1. Loosen locknut (1) and turn screw (2) to adjust the differential
pressure.
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 to 78 NCm
PC300LC-6
PC300HD-6 20-115
TESTING AND ADJUSTING HYDRAULIC PRESSURE
MEASURING
3. Start the engine and measure with the engine at full throttle.
20-116 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
Table 1
PC300LC-6
PC300HD-6 20-117
TESTING AND ADJUSTING HYDRAULIC PRESSURE
1. Disconnect outlet hoses (1), (2), (3), (4), (5) and (6) of th e
solenoid valve to be measured.
2. Install adapter C3 and nipple C2, and install oil pressure gauge
C1, 60 kg/cm2
20-118 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
Table 2
Condition of
Hose Solenoid Measurement conditions Operating conditions Oil pressure
solenoid
Boom under spool stroke 9
Active mode switch off ON Min 28 kg/cm2
mm
1 Active
Boom under spool stroke 11.5
Active mode switch on OFF 0 kg/cm2
mm
When machine push up switch is at high pres- Safety valve at high pressure
OFF 0 kg/cm2
sure setting setting
2 Machine push up
When machine push up switch is at low pres- Safety valve at low pressure
ON Min 28 kg/cm2
sure setting setting
Flow from front and rear
Travel operated independently ON Min 28 kg/cm2
Pump merge pumps divided
3
divider valve Flow from front and rear
All levers at neutral OFF 0 kg/cm2
pumps merged
When operate travel lever with travel spee d Motor swash plate angle at
ON Min 28 kg/cm2
switch at Hi or Mi MIN
4 Travel speed
Motor swash plate angle at
Travel speed switch at Lo OFF 0 kg/cm2
MAX
Swing or work equipment lever operated Brake canceled ON Min 28 kg/cm2
Swing holding
5 All levers except travel at neutral, 5 sec afte r
brake Brake actuated OFF 0 kg/cm2
returning to neutral
Active mode switch off Swing spool stroke 9.5 mm OFF 0 kg/cm2
6 Active, swing Active mode switch on, boom raise lever FULL,
Swing spool stroke 7.0 mm ON Min 28 kg/cm2
during operation
i With monitoring code [23], check at the same time that the solenoid is switched ON/OFF electrically. The machine
push up solenoid is not displayed.
i The measurement conditions in the table are typical conditions for measuring the output pressure. The solenoid
valve may be actuated [ON/OFF] under conditions other than the measurement conditions given above.
PC300LC-6
PC300HD-6 20-119
TESTING AND ADJUSTING HYDRAULIC PRESSURE
i If the output pressure at the control valve end is low, check for
leakage of oil from the PPC shuttle valve as follows.
1. Disconnect hose (1) between the PPC valve and the shuttl e
valve of the circuit to be measured. Disconnect the hose fro m
the shuttle valve together with the nipple.
20-120 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
2. Run the engine at full throttle, operate the applicable lever, and
measure the output pressure.
PC300LC-6
PC300HD-6 20-121
TESTING AND ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
i With the above adjustment, the clearance between disc (3) and
piston (4) becomes 0.
20-122 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
TRAVEL DEVIATION
i When traveling on level ground.
i For the travel posture, extend the bucket and arm cylinder rods
fully, and hold the boom angle at 45 E.
i Set to H/O mode and measure with the engine at full throttle.
2. Make a mark
3. 10 m midway point
PC300LC-6
PC300HD-6 20-123
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
a) Operate the arm cylinder to m ove the arm in fully, then stop
the engine.
b) Operate the control lever to arm IN.
20-124 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING HYDRAULIC DRIFT OF WORK EQUIPMENT
1. Disconnect pilot hose (1) of the boom lock valve and drain hose
(2), and install a blind plug in the hose.
2. Start the engine, charge the accumulator, then stop the engine.
i If any oil leaks from the port that is left open, the boom loc k
valve is defective.
PC300LC-6
PC300HD-6 20-125
TESTING AND ADJUSTING OIL LEAKAGE
2. Disconnect piping (1) at the head end, then block the piping at
the chassis end with a blind plug.
3. Start the engine and apply the relief pressure to the bottom end
of the cylinder with the engine at full throttle.
C Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAISE
C Arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN
C Bucket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CURL
20-126 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING OIL LEAKAGE
SWING MOTOR
1. Disconnect drain hose (1) from the swing motor, then install a
blind plug at the tank end.
3. Start the engine and operate the swing relief with the engine at
full throttle.
TRAVEL MOTOR
1. Disconnect drain hose (1) from the travel motor, then fit a blind
plug at the hose end.
PC300LC-6
PC300LC-6
PC300HD-6 20-127
TESTING AND ADJUSTING OIL LEAKAGE
PC300HD-6
2. Fit block (1) under the track shoe grouser, or fit block (2 )
between the sprocket and frame to lock the track.
3. Start the engine and operate the travel relief with the engine at
full throttle.
20-128 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
1. Loosen the oil filler cap slowly to release the pressure inside the
tank.
i When the levers are operated two to three times, the pressure
stored in the accumulator is removed.
3. Start the engine, run at low idling for . five minutes, then stop
the engine and operate the control levers.
i Repeat the above operation two to three times to release all the
remaining pressure.
PC300LC-6
PC300HD-6 20-129
TESTING AND ADJUSTING CLEARANCE OF SWING CIRCLE BEARING
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 wit h
the inner circle or outer circle. Set the dial gauge at the front or
rear.
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 til t
forward, so the front will go down and the rear will rise.
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
ground. When this is done, the upper structure will tilt back, so
the front will rise and the rear will go down.
C Dimension A . . . . . . . . . . . . . . . . . . . . . . . . 150 to 200 mm
5. Read the value on the dial gauge at this point. The value on the
dial gauge is the clearance of the swing circle bearing.
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 the zero
point, repeat Steps 3 to 5.
20-130 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING WEAR OF SPROCKET
WEAR OF SPROCKET
i If the sprocket wave pattern has reached the wear limit line,
replace the sprocket with a new part.
PC300LC-6
PC300HD-6 20-131
TESTING AND ADJUSTING TRACK SHOE TENSION
1. Raise the track frame on one side using the arm and boom.
ADJUSTING
i If the track shoe tension is not within the standard value, adjust
as follows.
WARNING! There is danger that the plug may fly out unde r
the high internal pressure of the grease, so never loosen plug
(1) more than one turn. If the grease does not come out
easily, move the machine backwards or forwards slowly.
20-132 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
1. Loosen air bleed plug (1), and check that oil oozes out from the
plug.
3. Leave plug (1) loosened and remove drain hose (2) and elbow
(3).
4. Pour in oil through the elbow mount hole until oil oozes out from
plug (1).
PC300LC-6
PC300HD-6 20-133
TESTING AND ADJUSTING BLEEDING AIR
2. Run the engine at low idling, then raise and lower the boom four
to five times in succession.
i Operate the piston rod to . 100 mm before the end of its stroke.
Do not relieve the circuit under any circumstances.
3. Run the engine at full throttle and repeat Step 2. After that, run
the engine at low idling, and operate the piston rod to the end of
its stroke to relieve the circuit.
4. Repeat Steps 2 and 3 to bleed the air from the arm and bucket
cylinders.
i When the cylinder has been replaced, bleed the air befor e
connecting the piston rod. Be particularly careful not to operate
the cylinder to the end of its stroke when the piston rod has been
connected to the LOWER end of the boom cylinder.
1. Inside motor case Run the engine at low idling for five minutes.
i This operation will bleed the air inside the motor case automati-
cally.
Loosen the sleeve nut of brake hose (1), start the engine, and
operate the swing prolix switch ON/OFF repeatedly. When oi l
oozes out, tighten the sleeve nut.
1. Run the engine at low idling, loosen air bleed plug (1), an d
check that oil oozes out from the plug.
2. When oil oozes out, tighten air bleed plug (1) again.
PC300LC-6
20-134 PC300LC-6
PC300HD-6
TESTING AND ADJUSTING BLEEDING AIR
PC300HD-6
PC300LC-6
PC300HD-6 20-135
TROUBLESHOOTING
PC300LC-6
PC300HD-6 20-201
TROUBLESHOOTING POINTS TO REMEMBER
20-202 PC300LC-6
PC300HD-6
TROUBLESHOOTING SEQUENCE OF EVENTS
Step 1
Examination, Confirmation of Symptoms
Ring! Ring!
1) When a request for repairs is received, first ask the following points.
C Name of customer
C Type, PIN of machine
C Details of job site, etc.
2) Ask questions to gain an outline of the problem
C Condition of failure
C Work being carried out at time of failure
C Operating environment
C Past history, details of maintenance, etc.
Breakdown!
Step 2
Determining probable location of cause
Step 8 Step 8
Step 4
Go to job site
Step 7
C Pinpoint locations of failure
C Decide action to take
Step 6
Re-enact failure
C Drive and operate the machine to confirm the condition before the failure
occurred
PC300LC-6
PC300HD-6 20-203
TROUBLESHOOTING POINTS TO REMEMBER
20-204 PC300LC-6
PC300HD-6
TROUBLESHOOTING POINTS TO REMEMBER
3) Disconnections in Wiring
PC300LC-6
PC300HD-6 20-205
TROUBLESHOOTING POINTS TO REMEMBER
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES
Disconnecting Connectors
20-206 PC300LC-6
PC300HD-6
TROUBLESHOOTING POINTS TO REMEMBER
Connecting Connectors
PC300LC-6
PC300HD-6 20-207
TROUBLESHOOTING POINTS TO REMEMBER
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 connecto r
must be washed in water, do not use high pressure water or steam
directly on the wiring harness. If water gets directly on the connec-
tor, do as follows.
1) Disconnect the connector and wipe off water with a dry cloth.
i Hot air from the dryer can be used, but regulate the time that
the hot air is used in order not to make the connector o r
related parts too hot, as this will cause deformation or dam -
age to the connector.
20-208 PC300LC-6
PC300HD-6
TROUBLESHOOTING POINTS TO REMEMBER
6) Do not place the control box on oil, water, or soil, or in any hot
place, even for a short time, place it on a suitable dry stand.
PC300LC-6
PC300HD-6 20-209
TROUBLESHOOTING POINTS TO REMEMBER
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
1) Always turn the power OFF before disconnecting or connect-
ing connectors.
20-210 PC300LC-6
PC300HD-6
TROUBLESHOOTING POINTS TO REMEMBER
SEALING OPENINGS
Be careful not to let any dirt or dust get in when refilling wit h
hydraulic oil. Always keep the oil filler and the area around i t
clean, and also use clean pumps and oil containers. If an oi l
cleaning device is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more effective method.
FLUSHING OPERATIONS
PC300LC-6
PC300HD-6 20-211
TROUBLESHOOTING POINTS TO REMEMBER
CLEANING OPERATIONS
20-212 PC300LC-6
PC300HD-6
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level --- Add fuel
2. Check for impurities --- Clean, drain
Lubricating oil, coolant
1. Check for looseness, corrosion of battery terminal, wiring --- Tighten or replace
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring --- Tighten or replace
3. Check for looseness, corrosion of starter motor terminal, wiring --- Tighten or replace
mechanical
equipment
PC300LC-6
PC300HD-6 20-213
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
No. Type Pins Mounting location Locale No. Type Pins Mounting location Locale
AC1 --- 20 Air conditioner, external Q2 M17 --- 1 Horn, low tone A3
AC2 --- 4 Air conditioner, control system Q2 M18 M 4 Wiper, washer switch P4
C01 MIC 13 Governor, pump controller D1 M20 --- --- Cigar lighter O4
C02 MIC 21 Governor, pump controller C2 M21 PA 9 Radio Q2
C03 040 20 Governor, pump controller E1 M22 M 2 Intermediate connector F1/R7
C04 X 2 Rear pump TVC solenoid valve I5 M23 M 2 Left knob switch F2/Q6
C05 S 10 Pump prolix circuit switch O1 M23 M 2 Horn switch Q5
C06 M 2 TVC prolix resistor P2 M26 --- 6 Air conditioner E1
C07 X 3 Rear pump pressure sensor D9 M28 KES0 2 Window washer motor I4
C08 X 3 Front pump pressure sensor D8 M34 250 X Magnetic clutch for AC compressor K2
C09 S 8 Model selector connector R2 M35 --- 2 AC condenser B2
C10 X 2 LS-EPC solenoid valve I5 M38 M 2 Machine push up switch P5
C13 X 2 Front pump TVC solenoid valve I5 M45 M 3 Network bus N1
C16 MIC 17 Governor, pump controller E1 M46 M 3 For troubleshooting M3
C17 040 16 Governor, pump controller D1 M62 X 2 Blind ---
D01 KES1 2 Window washer circuit --- M71 --- 1 Intermediate connector, cab light N7
D02 KES1 2 Active, swing solenoid circuit --- P01 040 20 Monitor N3
D03 KES1 2 Active, boom solenoid circuit --- P02 040 16 Monitor N3
D04 KES1 2 Pump merge divider solenoid circuit --- P03 M 2 Buzzer cancel switch P5
D05 KES1 2 Swing holding brake solenoid circuit --- P04 M 2 Alarm buzzer N3
D06 KES1 2 Machine push up solenoid circuit --- P05 X 1 Engine oil level sensor K1
D07 KES1 2 Travel speed selector solenoid circuit --- P06 X 1 Fuel level sensor A6
D08 KES1 2 Heater circuit --- P07 X 2 Engine coolant temperature sensor I3
D11 KES1 2 Alarm buzzer circuit --- P08 X 2 Radiator coolant level sensor E9
D13 KES1 2 Battery relay drive circuit --- P09 X 1 Hydraulic oil level sensor I4
D14 KES1 2 Diode --- P11 --- 1 Air cleaner clogging sensor ---
D17 KES1 2 Diode --- P12 --- 1 Air cleaner clogging sensor ---
D26 KES1 2 Swing holding brake solenoid --- R04 Shinagawa 6 Light relay P1
E04 X 3 Governor potentiometer F8 R05 Shinagawa 6 Light relay, option P1
E05 X 4 Governor motor F9 S01 X 2 Travel pressure switch G3/L7
E06 M 3 Fuel control dial O4 S02 X 2 Boom RAISE pressure switch G2/L6
E07 X 2 Engine speed sensor L3 S03 X 2 Arm OUT pressure switch D9/L7
E08 SWP 14 Intermediate connector I6 S04 X 2 Boom LOWER pressure switch E9/L8
E10 --- 3 Shut off valve --- S05 X 2 Arm IN pressure switch F9/L8
E11 X 2 Air heater relay L2 S06 X 2 Bucket CURL pressure switch F9/L9
F01 X 2 Travel alarm, option A3 S07 X 2 Bucket DUMP pressure switch E9/L9
H12 S 16 Intermediate connector F2 S08 X 2 Swing pressure switch E9/K9
H13 S 16 Intermediate connector C8 S09 X 2 Service pressure switch G2
H14 M 6 Intermediate connector C8 SW1 --- 20 Air conditioner control panel R2
H15 L 2 Intermediate connector F2 V02 X 2 LS select solenoid valve A5/H8
M02 X 2 Starting motor J4 V03 X 2 Pump merge divider solenoid valve B7/H8
M06 M 3 Heater fan switch --- V04 X 2 Swing holding brake solenoid valve C8/I8
M07 M 2 Light switch P4 V05 X 2 Machine push up solenoid C8/H8
M08 M 1 Right front light A4 V06 X 2 Travel speed selector solenoid valve B8/I8
M09 M 1 Working light, boom B8 V07 X 2 Active, swing solenoid I6
M10 M 1 Intermediate connector C2 W04 M 6 Wiper motor N6/M2
M11 L 2 Fusible link --- W08 070 18 Wiper motor controller P1
M12 KES1 3 Heater E1 X01 MIC 21 Intermediate connector C2/Q5
M13 KES0 2 Speaker D8/R4 X05 M 4 Swing lock switch O4
M14 L 2 Fusible link --- X07 MIC 17 Intermediate connector R3
M16 --- 1 Horn, high tone B3
20-214 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
PC300LC-6
PC300HD-6
20-215
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-216 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connectors
Pins
Male (female housing) Female (male housing)
PC300LC-6
PC300HD-6 20-217
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
14
16
20-218 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connectors
Pins
Male (female housing) Female (male housing)
PC300LC-6
PC300HD-6 20-219
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connectors
Pins
Male (female housing) Female (male housing)
10
12
16
20-220 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
13
17
21
PC300LC-6
PC300HD-6 20-221
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
12
16
20
20-222 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
14
18
PC300LC-6
PC300HD-6 20-223
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connectors
Pins
Male (female housing) Female (male housing)
20-224 PC300LC-6
PC300HD-6
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Automobile connector
Pins
Male (female housing) Female (male housing)
PC300LC-6
PC300HD-6 20-225
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Relay connector
Pins
Male (female housing) Female (male housing)
20-226 PC300LC-6
PC300HD-6
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM
PC300LC-6
PC300HD-6 20-227
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
2) Types of user code and system; E02 (TVC system), E03 (Swing holding brake system), E05 (Governor moto r
system)
i For details of the service codes included in the user code, see the action taken by the controller when a n
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.
CActual display, Example: Disconnection in the cancel solenoid system for the swing holding brake
4) Display of trouble data; The monitor panel records both service codes which are included in the user code, and
service codes which are not included. This data can be displayed on the time display as follows.
i For details of the service codes that are not included in the user code, see ACTION TAKEN BY CONTROLLE R
WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGEMENT TABLE
20-228 PC300LC-6
PC300HD-6
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
METHOD OF DISPLAYING TROUBLE DATA
Operation
1. To set to the trouble data display mode, Keep the time switch and the left travel speed switch pressed for 2.5 sec-
onds.
2. To go to the next service code display, press the time switch and the right working mode switch.
3. To go back to the previous service code display, press the time switch and the left working mode switch.
4. To finish with the trouble data display mode, k eep the time switch and the left travel speed switch pressed for 2.5
seconds.
5. To erase the memory, keep the time switch pressed, turn the start switch from off to on, and keep the time switch
pressed for 5 seconds.
Display
1. On the time display and service meter display, the service code and number of hours, service meter hours, that
have elapsed since the occurrence of the abnormality are displayed.
C Example of display: When E212 has occurred 12 hours before (service meter)
i If there is an abnormality or the controller is carrying out self diagnosis, the output is shut off and E is displayed.
PC300LC-6
PC300HD-6 20-229
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
3. MACHINE DATA MONITORING FUNCTION
The input signals from the sensors and the output signals to drive the solenoid are displayed on the time display and
service meter display.
Operation
1. To set to the machine data monitoring mode, do as follows. Keep the time switch and the knob button function
switch pressed for 2.5 seconds.
2. To go to the next monitoring code display, press the time switch and the right working mode switch.
3. To go back to the previous monitoring code display, press the time switch and the left working mode switch.
4. To finish with the machine data monitoring code mode, keep the time switch and the knob button function switch
pressed for 2.5 seconds.
Display
1. On the time display and service meter display, the monitoring code and data are displayed.
Example of display
20-230 PC300LC-6
PC300HD-6
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
B) When displaying bit pattern
C For monitoring codes 08, 20 through 24, 36, 37, 47 49, 4A, display the bit pattern.
C Example of monitoring code 20
C The code No. is displayed in the monitoring code portion, and the display lights up to display bit patterns
1 through 6.
PC300LC-6
PC300HD-6 20-231
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
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 bein g
transmitted. For details, see Method of Displaying Monitoring Code.
20-232 PC300LC-6
PC300HD-6
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
Code Content Bit Details, condition when illuminated
1
2
3
36 Input condition of governor, pump controller
4
5 Start switch on
6
1 Battery relay, actuated
2
Output condition of governor, pump control- 3
37
ler 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
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 Preheat switch Off
5 Start C Sometimes turns On
6 LED lighting output Off, monitor panel
1 Time switch Off
2 PPC selector switch Off
3 Overload selector switch Off
4A Monitor panel input condition 3
4 STD/DLX selection Std
5 Swing lock switch Off
6 Buzzer cancel switch Off
1
2 Wiper motor normal rotation relay output *
3 Wiper motor reverse rotation relay output *
4C Monitor panel input condition 4
4 Window washer motor drive output
5
6 * When specified voltage is abnormal
PC300LC-6
PC300HD-6 20-233
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
4) GOVERNOR MOTOR ADJUSTMENT MODE
This is used when adjusting the linkage between the governor motor and the injection pump. For details of th e
procedure, see Testing and Adjusting.
Operation
1. To set to the governor motor adjustment mode, press the time switch and the right travel speed switch and the
right working mode switch.
2. To return to the time display mode use the same procedure as in Step 1 .
Display
Displays g-SET
Operation
1. To set to the time adjustment mode, keep the time switch depressed for 2.5 seconds.
4. To return to the time display mode use the same procedure as in Step 1.
Display
20-234 PC300LC-6
PC300HD-6
TROUBLESHOOTING DISPLAY AND FUNCTION OF MONITORING PANEL
6) WORKING MODE DEFAULT SETTING MODE
The default, initial position, for the working mode can be changed as follows, the default can be changed for the
working mode only.
a) Keep the time switch and working mode switch [M switch] pressed at the same time for at least 2.5 seconds.
a) Use the working mode switch [H switch] or working mode switch [M switch] to change the working mode and
set the working mode to the default to be changed.
b) Keep the time switch and working mode switch [M switch] pressed at the same time for at least 2.5 seconds.
c) When the setting is completed, the buzzer beeps, when the system returns to the normal mode, the working
mode LED lights up.
i Note that if the start switch is turned OFF when the normal mode LED is flashing, default setting mode, the
content of the working mode default is not changed.
C) Check that the working mode default has changed to the new setting.
i When the start switch is turned on, the auto deceleration setting changes according to the working mode.
PC300LC-6
PC300HD-6 20-235
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
[Judgement]
1. If a service code is being displayed on the monitor panel
Go to troubleshooting [E3: ] for the governor, pump controller, governor control system.
2. If no service code is displayed on the monitor panel, and the engine does not start:
a) Check that starting motor rotates
b) Starting motor rotates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to troubleshooting S-2 of mechanical system
c) Starting motor does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . Go to troubleshooting E-8 of electrical system
20-236 PC300LC-6
PC300HD-6
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR
CONTROL SYSTEM] AND HYDRAULIC RELATED PARTS
C 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.
C 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.
C If it is displayed normally, go to the troubleshooting code on the right of the judgement table, H- .
C If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottom of th e
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 governor, pump controller, pump control system.
2. If no service code is displayed on the monitor panel, and the upper structure does not swing
a) Check governor, pump controller input signal. Check in monitoring mode.
b) There is a signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to troubleshooting H-25 of mechanical system
c) There is no signal . . . . . . . . . Go to troubleshooting F- of governor, pump controller input signal system
F mode for applicable system
PC300LC-6
PC300HD-6 20-237
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
1. The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode, problem with
the machine. <See Example 1>
DISTINGUISHING CONDITIONS
1. Even with the same failure mode, problem, the method of troubleshooting may differ according to the model ,
component, or problem. In such cases, the failure mode, problem, is further divided into sections marked with small
letters, for example a, so go to the appropriate section to carry out troubleshooting. <See Example 2> If th e
troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode.
1. Check or measure the item inside , and according to the answer follow either the YES line or the NO line
to go to the next .
Note: The number written at the top right corner of the is an index number; it does not indicate the order to follow.
2. Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause
column. Check the cause and take the action given in the Remedy column on the right. <See Example 3>
3. Below the there are the methods for inspection or measurement, and the judgement values. If the judgement
values below the are correct or the answer to the question inside the is YES, follow the YES line; if the
judgement value is not correct, or the answer to the question is NO, follow the NO line.
4. Below the is given the preparatory work needed for inspection and measurement, and the judgement values.
If this preparatory work is neglected, or the m ethod of operation or handling is mistaken, there is danger that it may
cause m istaken judgement, or the equipment may be damaged. Therefore, before starting inspection o r
measurement, always read the instructions carefully, and start the work in order from Item 1.
GENERAL PRECAUTIONS
1. When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at
the top of the page and marked with i <See Example 4>.
2. The precautions marked i are not given in the , but must always be followed when carrying out the check inside
the .
20-238 PC300LC-6
PC300HD-6
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING TOOLS
1. When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR
TESTING, ADJUSTING, AND TROUBLESHOOTING.
1. A diagram or chart is given for the connector type, installation position, a nd connector pin number connection. When
carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and
measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode,
problem.
[Example]
1. M-9 When start switch is turned on [engine stopped], check item for previous troubleshooting flashes
3.
Cause Remedy
YES Defective coolant le-
vel sensor system, ---
1 see M-26
Does display go out
when short connec-
tor is connected to
P08
1. Disconnect P08 YES Defective governor,
2. Start switch on Replace
4 pump controller
YES Is bit 3 of monitoring
code 24 illuminated
1. Start switch on
Defective monitor
2. Set to monitoring Replace
3 code 24 NO panel
4. i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
i Check that the coolant is at the specified level before carrying out troubleshooting
PC300LC-6
PC300HD-6 20-239
TROUBLESHOOTING
MEMORANDA
20-240 PC300LC-6
PC300HD-6
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
YES
E02, TVC system Carry out troubleshooting for engine, S mode
YES
E03, Swing holding brake system
Go to Item 2
E05, Governor motor system
1 6
E2 group: Troubleshooting for gov- YES
Is user code displayed on monitor Is engine electrical system for whic h
ernor, pump controller, pump controller
panel there is no failure code display normal
system, C mode
Carry out troubleshooting in applicable 1. Go to flow chart for section where
YES mode. there is no abnormality display o n
NOTE: For E218, carry out trouble - judgement table.
shooting of the communication abnor- Carry out troubleshooting for engine electrical system, E
mality system, N mode. 5 mode. Use flow chart for items where there is no display,
E3 group: Troubleshooting for gov- YES NO E11 through E15
Is problem in engine system of hydrau-
ernor, pump controller, governor con-
lic [mechanical] system
troller system, E mode
1. After adjusting oil pressure, judge Hydraulic [mechanical] system. Carry
from engine speed. out troubleshooting for hydraulic [me -
2 4 2. Is all work equipment slow and does NO chanical] system, H mode
engine speed drop under heavy load
Is service code displayed on monitor YES Are governor, pump controller input
NO panel 3 and output signals normal
i For details, see governor, pump controller; governor control system, pump control system in the JUDGEMEN T
TABLE.
PC300LC-6
PC300HD-6
20-241
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING
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 governor, pump controller
Table 1
. 2220<during operation>
H/O 1950
. 2050 <idle>
20-242 PC300LC-6
PC300HD-6
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER
Check the input signals for each controller as follows.
Table 2 Pump merge flow logic and pumps actuated by control levers
Left travel
Swing
Arm
Boom
Bucket
Right travel
PC300LC-6
PC300HD-6 20-243
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING
2. No. 2 throttle signal
a) Set to the monitoring mode, and display monitoring code 16.
b) Use the procedure in Item 2 for checking the monitor panel output signal, and measure the engine speed.
3. Checking ON OFF solenoid condition
a) Set to the monitoring mode, and display monitoring code 23.
b) Refer to Table 3 and check that the applicable bit lights up.
20-244 PC300LC-6
PC300HD-6
TROUBLESHOOTING SERVICE CODE TABLE
E313 Option
PC300LC-6
PC300HD-6 20-245
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
N MODE
PC300LC-6
PC300HD-6 20-301
TROUBLESHOOTING N-1
Cause Remedy
YES
Has been reset ---
1
Is monitoring code
02, 03 display normal
1. Disconnect C17 YES
2. Start switch on Monitoring panel Replace
4
3. See Table 1
YES Is resistance between
P01-4, 11 and chas-
sis or P01-4,11 and
P01-12 normal
1. Disconnect C17, Disconnected between
P01 and install T- P01-4, 11 and P01-12 or Repair
3 adpater to P01 NO chassis
2. Min 1 MS
YES When C17 is discon-
nected, do bits 1 and
2 light up in monitor-
ing code 08
1. Disconnect C17 Governor pump controller Replace
2 2. Start switch on NO
Do bits 1 and 2 light
up in monitoring code
NO 08
1. See Table 2 YES
2. Start switch on Governor pump controller Replace
5
Is voltage between
C17 -4, 12 and
NO chassis normal
1. Start switch on YES
2. Min 7.5 V Monitor panel Replace
6
3. Disconnect C17
and measure volt- Is resistance between
age at harness P01-4, 11 and C17-4,
end NO 12 normal
1. Disconnect P01, Disconnection in harness
C17 between P01-4, 11 and Replace
2. Max 1S NO C17-4, 12
Table1
Display
Monitoring code
Network connection
08 condition
C Checks can be carried out with code 08 only whe n C Light up when connected
there is a disconnection. The display does not change
1) Governor, pump controller
when there is a short. Therefore, checks when there is
a short should be carried out basically using Table 1. 2) Governor, pump controller
20-302 PC300LC-6
PC300HD-6
TROUBLESHOOTING N-1
C17 H14
female female
PC300LC-6
PC300HD-6 20-303
TROUBLESHOOTING OF GOVERNOR,
PUMP CONTROLLER
GOVERNOR CONTROL SYSTEM
E MODE
E-1 Abnormality in governor, pump controller power source, controller LED is OFF . . . . . . . . . . . . . . . . 20-357
E-2 [E308] Abnormality in fuel control dial input value is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
E-4 [E318] Abnormality, short circuit in motor drive system is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
E-6 [E315] Abnormality, short circuit in battery relay output system is dis-played . . . . . . . . . . . . . . . . . . 20-362
E-12 Defective operation of battery relay system, engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
PC300LC-6
PC300HD-6 20-351
TROUBLESHOOTING POINTS TO REMEMBER
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 an d
Adjusting.
20-352 PC300LC-6
PC300HD-6
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
3. Disconnection in wiring harness between C02-4 to E05-3 3 to 4 4 to 5 0.25 to 7 kS 2. When there is a disconnection in only one of A
Disconnection, in motor drive phase or B phase
E317 1 to 3 2 to 4 Min 1 MS
Takes no particular action
system
4. Disconnection in wiring harness between C02-3 to E05-2 1) Engine does not stop
1 to 4 2 to 5 Min 1 MS
5. Disconnection in wiring harness between C02-5 to E05-4 2) Stops moving at position immediately
Pins 1, 2, Pins 2, 3, before failure, so engine speed cannot be
3, 4 & 4, 5 & Min 1 MS
6. Defective contact of E05 connector chassis chassis controlled
Motor drive current Hold . . . . . . . . 0.7 A 3) There are cases of hunting
Start . . . . . . . 0.84A
1. If during operation
1. Short circuit inside governor motor E05 C02
Resistance
value 1) Set to low idling
2. Wiring harness between C02-2 to E05-1 and between C02- 1 to 2 2 to 3 0.25 to 7 kS
2) Engine does not stop
4 to E05-3 short circuiting with wiring harness between C02-
3 to 4 4 to 5 0.25 to 7 kS
3 to E05-2 3) There are cases of hunting
Short circuit, in motor drive
E318 1 to 3 2 to 4 Min 1 MS Sets motor drive current to 0
system
3. Wiring harness between C02-4 to E05-3 and between C02- 2. When stopped
1 to 4 2 to 5 Min 1 MS
2 to E05-1 short circuiting with wiring harness between C02-
1) Engine starts, but stays at low idling
5 to E05-4 Pins 1, 2, Pins 2, 3,
3, 4 & 4, 5 & Min 1 MS
chassis chassis
2) Engine does not stop after starting
4. Wiring harness in Items 2 and 3 short circuiting with ground
Motor drive current Hold . . . . . . . . 0.7 A 3) There are cases of hunting
Start . . . . . . . . . . . . . . . . . 0.84A
PC300LC-6
PC300HD-6
20-353
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
Service Action by controller when abnormality Is Problems that appear on machine when there is
User code code
Abnormal system Nature of abnormality Conditions when normal
detected abnormality
1. Short circuit in wiring harness between C03-7 to 14, 7 to 17,
14 to 17 1. Precision of engine speed control may be
Resistance reduced.
2. Short circuit in wiring harness between E04-1 to 2, 1 to 3, 2 C03 E04
value
to 3 For example:
7 to 14 1 to 2 0.25 to 7 kS 1) Engine does not rise to high idle speed, a
3. Short circuit in wiring harness between E06-1 to 2, 1 to 3, 2 little too low
to 3
7 to 17 2 to 3 0.25 to 7 kS 2) Engine does not go down to low idle
Calculates position of motor and carries out control speed, a little too high
Abnormality in feedback 4. Short circuit in wiring harness between C03-7 to 4, 4 to 17
--- E306 from value of voltage immediately before abnor -
potentiometer system 3) Defective engine speed for auto dece -
5. Disconnection in wiring harness between C03-7 to E04-1 14 to 17 --- 2 to 3 kS mality occurred
leration or automatic warming up
6. Disconnection in wiring harness between C03-14 to E04-2 4) Engine may not stop
--- 1 to 3 4 to 6 kS
i The governor motor moves in the direction to
7. Disconnection in wiring harness between C03-17 to E04-3 stop the engine, but the motor may not move
Each pin
--- Min 1 MS
& chassis completely to the position to stop the engine.
8. Defective governor motor potentiometer
5) There are cases of hunting
9. Defective contact of C03, E04 connectors
1. Defective adjustment of rod or scuffing of loose spring 1. Linkage adjustment correct 1. Displays when returning from high idle to lo w
idle
2. Must move lightly when con- i Starts again, repeats step out Engine speed cannot be controlled, particularly at
--- E316 Step out in motor 2. Abnormality in governor motor
nector is removed high idle, so there is hunting
2. In some cases it may not display when return-
3. Abnormality in governor, pump controller 3. Normal ing from partial speed to low idle
PC300LC-6
20-354 PC300HD-6
TROUBLESHOOTING JUDGEMENT TABLE
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND ENGINE RELATED PARTS
Governor, pump controller Checking, monitoring,
Machine
engine related parts check items
monitor
Self diagnostic display check
item
105EC or above
User code E05 Monitoring code
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 idle and does not follow accelerator or engine pick up is poor S-3
4 Engine stops during operation S-4
When idle speed is irregular E-9a, S-5
5 Engine rotation is irregular
When there is hunting E-9a, S-5
6 Lack of output, engine high idle speed is too low E-10, S-6
7 Auto deceleration does not work E-3 @ E-4
8 Engine does not stop E-11
9 Warm 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 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 --- --- --- --- --- --- --- --- --- ---
PC300LC-6
PC300HD-6
20-355
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR E MODE
PC300LC-6
20-356 PC300HD-6
TROUBLESHOOTING E-1
Cause Remedy
1 YES Defective governor, pump
Replace
Is voltage between C01-7, 13 and C02-11, controller
21 normal
1. Start switch on
2. 20 to 30 V Defective contact or discon-
YES nection in wiring harness
Repair or replace
between fuse #1 and C01-7,
2 13
Is voltage between fuse #1 and chassis
NO normal
1. Start switch on Defective contact or discon-
2. 20 to 30 V nection in wiring harness
Repair or replace
NO between fuse #1 to H15-2 to
M14-2, 1 to battery relay M
PC300LC-6
PC300HD-6 20-357
TROUBLESHOOTING E-2
i If E306 also occurs at the same time, check the wiring harness as follows;
C Wiring harness between C03-7 to E04-1 short circuiting with ground or contact with other wiring harness.
20-358 PC300LC-6
PC300HD-6
TROUBLESHOOTING E-3
PC300LC-6
PC300HD-6 20-359
TROUBLESHOOTING E-4
20-360 PC300LC-6
PC300HD-6
TROUBLESHOOTING E-5
i If [E308] also occurs at the same time, check the wiring harness as follows;
C Wiring harness between C03-7 to X07-6 to E06-1 short circuiting w ith ground or contact with other wiring harness.
PC300LC-6
PC300HD-6 20-361
TROUBLESHOOTING E-6
E-6 [E315] Abnormality, short circuit in battery relay output system is dis-
played
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-
adapter, or when removing the T-adapter and returning the connector to its original position, if an E service code is not displayed,
the problem has been removed.
WARNING! Check with the engine stopped, push the fuel control lever of the fuel injection pump to the NO INJECTIO N
position.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any disconnected
connectors before going on the next step.
i This only occurs when the engine is stopped and the start switch is turned off.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
X07 X07
male female
20-362 PC300LC-6
PC300HD-6
TROUBLESHOOTING E-7
Cause Remedy
YES Go to applicable failure
---
1 mode
Are E306, E317 and
E318 displayed
1. Start switch on YES Defective governor,
Replace
3 pump controller
PC300LC-6
PC300HD-6 20-363
TROUBLESHOOTING E-8
X07 X07 M2 M2
male female male female
20-364 PC300LC-6
PC300HD-6
TROUBLESHOOTING E-8
Cause Remedy
YES
4 Defective starting motor Replace
PC300LC-6
PC300HD-6
20-365
TROUBLESHOOTING E-9
X07
female
PC300LC-6
20-366 PC300HD-6
TROUBLESHOOTING E-9
b) There is hunting
X07
female
PC300LC-6
PC300HD-6
20-367
TROUBLESHOOTING E-10
E-10 Lack of output, engine high idle speed is to low
i Before carrying out troubleshooting, check that all the related c onnectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Table 1 Cause Remedy
Controller model code YES
See N mode ---
2
YES
Is E218 displayed
X07
female
PC300LC-6
20-368 PC300HD-6
TROUBLESHOOTING E-11
PC300LC-6
PC300HD-6
20-369
TROUBLESHOOTING E-12
E-12 Defective operation of battery relay system, engine does not stop
i This only occurs when the engine is stopped and the start switch is turned Off.
WARNING! Check with the engine stopped, push the fuel control lever of the fuel injection pump to the N O
INJECTION position.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES
See E-6 ---
1
Is E315 displayed
1. Start switch on YES Defective governor, pump
Replace
Relay drive signal 2 controller
Is display of monitoring
code 35 as shown in Table
NO 1
1. Start switch off YES
2. 20 to 30 V Defective battery relay Replace
3
Is resistance between C01-
1 and battery relay terminal
BR and between wiring har-
NO ness and chassis normal
1. Between C01-1 and bat-
tery relay terminal BR,
Max 1 S 1. Disconnection in wiring
2. Between wiring harness harness C01-1 to bat-
Replace
and chassis, Max 1 S NO tery relay BR
3. Turn start switch off 2. When light is connected
4. Disconnect C01-1 and
battery relay BR
Table 1
Note 1 When the start switch is On, the controller end is Off, but a voltage of . 20 to 30 V is always flowing from start
switch BR, so if the voltage is measured at C01-1, there is a voltage of 20 to 30 V.
M11 M11
male female
20-370 PC300LC-6
PC300HD-6
TROUBLESHOOTING E-12
PC300LC-6
PC300HD-6 20-371
TROUBLESHOOTING OF ENGINE SYSTEM
S MODE
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down . . . . . . . . . . . . . . . . . . . . . . . . 20-415
S-12 Oil pressure caution lamp lights up, drop in oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-415
PC300LC-6
PC300HD-6 20-401
TROUBLESHOOTING METHOD OF USING CHARTS
Questions
Sections A plus B in the chart on the right corresponds to th e
items where answers can be obtained from the user. The items in
B are items that can be obtained from the user, depending on the
user's level.
Check items
The serviceman carries out simple inspection to narrow down the
causes. The items under C in the chart on the right correspond to
this.
The serviceman narrows down the causes from information A that
he has obtained from the user and the results of C that he has
obtained from his own inspection.
Troubleshooting
Troubleshooting is carried out in the order of probability, starting
with the causes that have been marked as having the highes t
probability from information gained from Questions and Check
items.
20-402 PC300LC-6
PC300HD-6
TROUBLESHOOTING METHOD OF USING CHARTS
The basic method of using the troubleshooting chart is as follows.
Items listed for Questions and Check items that have a relationship
with the Cause items are marked with , and of these, causes that
have a high probability are marked with .
Check each of the Questions and Check items in turn, and marked
the or in the chart for items where the problem appeared. The
vertical column, Causes, that has the highest number of points i s
the most probable cause, so start troubleshooting for that item t o
make final confirmation of the cause.
PC300LC-6
PC300HD-6 20-403
TROUBLESHOOTING METHOD OF USING CHARTS
MEMORANDA
20-404 PC300LC-6
PC300HD-6
TROUBLESHOOTING METHOD OF USING CHARTS
Example of troubleshooting when exhaust gas is black S-7 Exhaust gas is black, incomplete combustion
Let us assume that [Clogged air cleaner] is taken to be the c ause of black exhaust gas. Three symptoms have causal General causes why exhaust gas is black
relationship with this problem: [Exhaust gas slowly became black], [P ower slowly became weaker], and [Dust indicator C Insufficient intake of air
is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. C Improper condition of fuel injection
Let us explain here the method of using this causal relationship to pinpoint the most probable cause. C Excessive injection of fuel
PC300LC-6
PC300HD-6
20-405
TROUBLESHOOTING S-1
20-406 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-2
PC300LC-6
PC300HD-6 20-407
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out, fuel is not being injected
i Check that the monitor panel does not display any abnormality i Standards for use of fuel, per ASTM
in the governor control system.
Ambient temperature EC
General causes why engine turns but no exhaust smoke comes out Fluid type
C Supply of fuel impossible -30 -20 -10 0 10 20 30 40
20-408 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not start, fuel is being injected
i General causes why exhaust smoke comes out but engine does
not start.
C Lack of rotating force due to defective electrical system
C Insufficient supply of fuel
C Insufficient intake of air
C Improper selection of fuel and oil
PC300LC-6
PC300HD-6 20-409
TROUBLESHOOTING S-3
20-410 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-4
PC300LC-6
PC300HD-6 20-411
TROUBLESHOOTING S-5
20-412 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-6
PC300LC-6
PC300HD-6 20-413
TROUBLESHOOTING S-7
20-414 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-8 TO S-12
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
SEE ENGINE SHOP MANUAL
S-12 Oil pressure caution lamp lights up, drop in oil pressure
SEE ENGINE SHOP MANUAL
PC300LC-6
PC300HD-6 20-415
TROUBLESHOOTING S-13
20-416 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-14
PC300LC-6
PC300HD-6 20-417
TROUBLESHOOTING S-15
20-418 PC300LC-6
PC300HD-6
TROUBLESHOOTING S-16
PC300LC-6
PC300HD-6 20-419
TROUBLESHOOTING OF GOVERNOR, PUMP
CONTROLLER, PUMP CONTROL SYSTEM
C MODE
PC300LC-6
PC300HD-6 20-451
TROUBLESHOOTING POINTS TO REMEMBER
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 n o
longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the user code from memory.
There are cases where mistaken operation or abnormalities that occur when the connector is disconnected ar e
recorded by the memory retention function. Erasing the data in this way saves any wasted work.
20-452 PC300LC-6
PC300HD-6
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
PC300LC-6
PC300HD-6
20-453
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
1. Short circuit with ground, short circuit inside travel spee d 1. Makes output to solenoid 0.
Short circuit in tra- solenoid i If the abnormality is restored by the vibration of th e
Even if the travel speed is switched, th e
--- E206 vel speed solenoid 2. Short circuit with ground in wiring harness between controlle r Solenoid resistance . . . . . . . . . 20 to 60 S machine, it resets the power source to restore to th e
travel speed does not change, remains at Lo
system C01-9 and solenoid V06-2 side
PO
S proper condition. However, the service code display does
3. Defective governor, pump controller not go out.
1. Short circuit with ground, short circuit inside active mode, boom 1. Makes output to solenoid 0.
Short circuit in ac- solenoid i If the abnormality is restored by the vibration of th e
When mode is STD, active mode OFF, the
--- E207 tive mode boom 2. Short circuit with ground in wiring harness between controlle r Solenoid resistance . . . . . . . . . 20 to 60 S machine, it resets the power source to restore to th e
boom lower speeds become faster
solenoid system C01-8 and solenoid V02-2 side
PO
S proper condition. However, the service code display does
3. Defective governor, pump controller not go out.
1. Disconnection, defective contact, short circuit with ground i n Detects abnormality in input 1. Engine stalls, or
Model selection C17-6, 13 and chassis . . . . . . . . Max. 1 S
--- E217 model selection wiring harness C17-5, 6, 7, 13, 14 1) Retains data when starting switch is ON 2. Work equipment, swing, travel speeds
input error C17-5, 7, 14 and chassis . . . . Min. 1 MS
2. Defective governor, pump controller 2) Functions as PC100 when nonset conditions are input are all slow, and there is no power
PC300LC-6
20-454 PC300HD-6
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
1. Short circuit, with ground inside front pu mp pressure sensor or rear pump 1. Takes front pump and rear pump pressure as 0 kg/cm 2 when
1. The travel speed does not automatically shift, it
Abnormality in pres- pressure sensor actuating.
Voltage does not change from Hi to Lo.
--- E226 sure sensor power 2. Short circuit, with ground in wiring harness between controller C03-6 and 2. When abnormality is detected, it switches the output OFF, an d
Between C03-6 and 16 . . . . . . . . . . 18 to 28 V i If the button is operated manually, the pane l
source system front pressure sensor C08-2 or rear pressure sensor C07- 2 POS side when all levers are returned to neutral, it outputs again.
display is switched.
3. Defective governor, pump controller i This automatic resetting is repeated up to 3 times .
PC300LC-6
PC300HD-6
20-455
TROUBLESHOOTING ACTIONS TAKEN BY CONTROLLER
Ser-
User Problems that appear on machine when
vice Abnormal system Nature of abnormality Conditions when normal Action by controller when abnormality is detected
code there is abnormality
code
1. Short circuit with ground, short circuit inside active mode, swing 1. Makes output to solenoid 0.
Short circuit in ac- solenoid i If the abnormality is restored by the vibration of th e In active mode and heavy duty mode, the rise
--- E231 tive mode, swing 2. Short circuit with ground in wiring harness between controlle r Solenoid resistance . . . . . . . . . 20 to 60 S machine, it resets the power source to restore to th e in the bucket edge is the same in swing plus
solenoid system C01-10 and solenoid V07-2 sidePO
S proper condition. However, the service code display does boom RAISE. There is no priority.
3. Defective governor, pump controller not go out.
PC300LC-6
20-456 PC300HD-6
TROUBLESHOOTING JUDGEMENT TABLE
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
Governor, pump controller -E2:XX system- Self diagnositc display Check items in monitoring mode
Boom LOWER - 3
Bucket DUMP - 2
Bucket CURL - 1
Boom RAISE - 4
Travel speed - 6
Knob switch - 6
M36 Mode - 5
Arm OUT - 6
Model code
Arm IN - 5
Travel - 2
Swing - 1
Failure mode User code LED E02 --- E03 --- Bit pattern Monitoring code
Service code off 232 233 236 237 207 208 203 213 204 214 206 216 217 222 223 231 235 224 225 226 227 20 21 22 23 02 10 11 12 13 14 15
Speed of all work equipment, swing, travel are slow or lack power H-1
All work equipment,
PC300LC-6
PC300HD-6
20-457
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR C MODE
PC300LC-6
20-458 PC300HD-6
TROUBLESHOOTING
MEMORANDA
PC300LC-6
PC300HD-6 20-459
TROUBLESHOOTING C-1
Cause Remedy
1 YES Defective governor, pump
Replace
controller
Is voltage between C01-7, 13 and C02-11,
21 normal
1. Start switch on
2. 20 to 30 V Defective contact or discon-
YES
nection in wiring harness
Repair or replace
between fuse #1 and C01-7,
2 13
20-460 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-2
C-2 [E232] Short circuit in front pump TVC solenoid system is displayed Table 1
Troubleshooting No.2 Troubleshooting No.3 Troubleshooting No.4 Resistance value
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d Between C13-1 and 2 Between C02-8 and 18 Between C05-3 and 4 10 to 22 S
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an
Between C13-1 and chassis Between C02-8 and chassis Between C05-3 and chassis Min 1 MS
E service code is not displayed, the problem has been removed.
i If the start switch is turned OFF after an abnormality occu rs, turn the start switch ON and check if an E service code Table 2
is displayed. If it is not displayed, the problem has been removed. Troubleshooting No. 5 Resistance value
i Always turn the TVC prolix switch OFF. Between C05-1 and 3, 2 and 4 Max 1 S
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect Between C05-1, 2, 3, 4 and chassis Min 1 MS
any disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
1. Start switch off 1. Start switch off Short circuit with ground or short
2. Disconnect C13 2. Disconnect C05 circuit with power source in wir-
ing harness between C05-3 to
H12-3 to C13-1 or short circui t Repair or replace
NO with po-wer source in wiring har-
ness between C05-4 to H12-4 to
1 C13-2
Interchange connector with rear pump
TVC solenoid, is E232 displayed
1. Start switch off NO Defective front pump TVC sole-
2. Interchange C04 with C13 noid, internal short circuit or short Replace
3. Turn start switch on NO circuit with ground
PC300LC-6
PC300HD-6
20-461
TROUBLESHOOTING C-3
C-3 [E233] Disconnection in front pump TVC solenoid system is displayed
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an Table 1
E service code is not displayed, the problem has been removed. Troubleshooting No.2 Troubleshooting No.3 Troubleshooting No.4 Resistance value
i If the start switch is turned OFF after an abnormality occu rs, turn the start switch ON and check if an E service code Between C13-1 and 2 Between C02-8 and 18 Between C05-3 and 4 10 to 22 S
is displayed. If it is not displayed, the problem has been removed. Between C13-2 and chassis Between C02-18 and chassis Between C05-4 and chassis Min 1 MS
i If there is a disconection in the solenoid or wiring harness, no current flows to the solenoid. If the #2 pin of th e
Table 2
solenoid is short circuiting with the ground, the current, . 1A, continues to flow to the solenoid.
i Always turn the TVC prolix switch OFF. Troubleshooting No. 5 Resistance value
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect Between C05-1 and 3, 2 and 4 Max 1 S
any disconnected connectors before going on the next step. Between C05-1, 2, 3, 4 and chassis Min 1 MS
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
PC300LC-6
20-462 PC300HD-6
TROUBLESHOOTING C-4
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed Table 1
Troubleshooting No.2 Troubleshooting No.3 Troubleshooting No.4 Resistance value
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d Between C04-1 and 2 Between C02-9 and 19 Between C05-8 and 9 10 to 22 S
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an
Between C04-1 and chassis Between C02-9 and chassis Between C05-8 and chassis Min 1 MS
E service code is not displayed, the problem has been removed.
i If the start switch is turned OFF after an abnormality occu rs, turn the start switch ON and check if an E service code Table 2
is displayed. If it is not displayed, the problem has been removed. Troubleshooting No. 5 Resistance value
i Always turn the TVC prolix switch OFF. Between C05-6 and 8, 7 and 9 Max 1 S
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect Between C05-6, 7, 8, 9 and chassis Min 1 MS
any disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
1. Start switch off 1. Start switch off Short circuit with ground or short
2. Disconnect C04 2. Disconnect C05 circuit with power source in wir-
ing harness between C05-8 to
H12-1 to C04-1 or short circui t Repair or replace
NO with po-wer source in wiring har-
ness between C05-9 to H12-2 to
1 C04-2
Switch connector with front pump TVC
solenoid, is E236 displayed
1. Switch C13 with C04 NO Defective rear pump TVC sole-
2. Start switch on noid, internal short circuit or short Replace
NO circuit with ground
PC300LC-6
PC300HD-6
20-463
TROUBLESHOOTING C-5
C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an Table 1
E service code is not displayed, the problem has been removed. Troubleshooting No.2 Troubleshooting No.3 Troubleshooting No.4 Resistance value
i If the start switch is turned OFF after an abnormality occu rs, turn the start switch ON and check if an E service code Between C04-1 and 2 Between C02-9 and 19 Between C05-8 and 9 10 to 22 S
is displayed. If it is not displayed, the problem has been removed. Between C04-2 and chassis Between C02-19 and chassis Between C05-9 and chassis Min 1 MS
i If there is a disconection in the solenoid or wiring harness, no current flows to the solenoid. If the #2 pin of th e
Table 2
solenoid is short circuiting with the ground, the current, . 1A, continues to flow to the solenoid.
i Always turn the TVC prolix switch OFF. Troubleshooting No. 5 Resistance value
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect Between C05-6 and 8, 7 and 9 Max 1 S
any disconnected connectors before going on the next step. Between C05-6, 7, 8, 9 and chassis Min 1 MS
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
PC300LC-6
20-464 PC300HD-6
TROUBLESHOOTING C-6
Cause Remedy
YES Defective governor, pump
Replace
2 3 controller
Table 1
PC300LC-6
PC300HD-6 20-465
TROUBLESHOOTING
MEMORANDA
20-466 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-7
Cause Remedy
YES Defective governor, pump con-
Replace
5 troller
PC300LC-6
PC300HD-6
20-467
TROUBLESHOOTING C-8
i If the start switch is turned OFF after an abnormality occu rs, turn the start switch ON and check if an E service code C-8 [E203] Short circuit in swing brake solenoid system is displayed
is displayed. If it is not displayed, the problem has been removed.
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an
any disconnected connectors before going on the next step.
E service code is not displayed, the problem has been removed.
i Always turn the swing lock prolix switch off, then turn swing lock switch off before checking.
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
PC300LC-6
20-468 PC300HD-6
TROUBLESHOOTING C-9
C-9 [E213] Disconnection in swing brake solenoid system is displayed i Before carrying out troubleshooting, check that all the related c onnectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
i Always turn the swing lock prolix switch off, then turn swing lock switch off before checking.
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an
NOTE If swing prolix switch is operated, this error [213] is detected, but it does not indicate a failure
E service code is not displayed, the problem has been removed.
NOTE When the swing prolix switch is operated, if error [213] occurs, carry out troubleshooting, F-9 for the swing lock
i If the start switch is turned off after an abnormality occurs, turn the start switch on and check if an E service code
signal input system
is displayed. If it is not displayed, the problem has been removed.
Cause Remedy
YES Defective governor, pump con-
Replace
3 troller
PC300LC-6
PC300HD-6
20-469
TROUBLESHOOTING C-10
C-10 [E204] Short circuit in pump merge divider solenoid system is displayed
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E
service code is not displayed, the problem has been removed.
i If the start switch is turned off after an abnormality occurs, turn the start switch on and check if an E service code
is displayed. If it is not displayed, the problem has been removed.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
3 controller
YES Is resistance between C01-
2 and chassis normal
1. Start switch off Short circuit with chassis
2. Disconnect C01 ground in wiring harness Repair or replace
2 3. 20 to 60 S NO between C01-2 and V03-2
YES Is resistance between V03-1
and 2, 2 and chassis as in
Table 1
1
1. Start switch off
Switch connector with other 2. Disconnect V03
solenoid, is E204 displayed
1. Switch V03 with other Defective pump merge di-
connector NO vider solenoid, internal short
Replace
2. Start engine circuit or short circuit with
3. Operate travel NO ground
Table 1
20-470 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-11
Cause Remedy
YES Defective governor, pump con-
Replace
5 troller
YES Is voltage between C01-2 to V03-2 to chassis
normal
1. Disconnect C01 and V03 Short circuit with power source in
2. Start switch on wiring harness between C01-2 Repair or replace
4 3. Max 1 V NO and V03-3
YES Wh en V03-2 is grounded to chassis, i s
resistance between C01-2 and chassis
normal
1. Start switch off Defective contact or disconnec-
2. Disconnect V03 tion in wiring harness between Repair or replace
3 3. Max 1 S NO C01-2 and V03-2
YES Is resistance between V03-1 and chassi s
nornal
1. Start switch off Defective contact or disconnec-
2. Disconnect C02 tion in wiring harness between Repair or replace
2 3. Max 1 S NO V03-1 and chassis
YES Is resistance between V03-1 and 2 normal
1
1. Start switch off
Switch connector with other solenoid, i s 2. Disconnect V03
E214 displayed 3. 20 to 60 S
1. Switch V03 with other connector NO
Defective pump merge divider
2. Start switch on Replace
NO solenoid, internal disconnection
PC300LC-6
PC300HD-6
20-471
TROUBLESHOOTING C-12
Cause Remedy
YES Defective governor, pump
Replace
3 controller
YES Is resistance between C01-
9 and chassis normal
1. Start switch off Short circuit with chassis
2. Disconnect C01 ground in wiring harness Repair or replace
2 3. 20 to 60 S NO between C01-9 and V06-2
YES Is resistance between V06-1
and 2, 2 and chassis as in
Table 1
1
1. Start switch off
Switch connector with other 2. Disconnect V06
solenoid, is E206 displayed
1. Switch V06 with other
connector
2. Start engine
NO Defective travel speed sole-
3. Travel speed switch at
noid, internal short circuit or Replace
Mi or Hi
short circuit with ground
4. Operate lever slightly
but not enough to move NO
machine
Table 1
20-472 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-13
Cause Remedy
YES Defective governor, pump con-
Replace
5 troller
YES Is voltage between C01-9 to V06-2 to chassis
normal
1. Start switch off Short circuit with power source in
2. Disconnect C01 and V06 wiring harness between C01-9 Repair or replace
4 3. Max 1 V NO and V06-2
YES Wh en V06-2 is grounded to chassis, i s
resistance between C01-9 and chassis
normal
1. Start switch off Defective contact or disconnec-
2. Disconnect V06 tion in wiring harness between Repair or replace
3 3. Max 1 S NO C01-9 and V06-2
YES Is resistance between V06-1 and chassi s
nornal
1. Start switch off Defective contact or disconnec-
2. Disconnect C01 and V06 tion in wiring harness between Repair or replace
2 3. Max 1 S NO V06-1 and chassis
YES Is resistance between V06-1 and 2 normal
1
1. Start switch off
Switch connector with other solenoid, i s 2. Disconnect V06
E216 displayed 3. 20 to 60 S
1. Switch V06 with other connector NO
Defective travel speed solenoid ,
2. Start switch on Replace
NO internal disconnection
PC300LC-6
PC300HD-6
20-473
TROUBLESHOOTING C-14
C-14 [E217] Short circuit in active mode, swing, solenoid system is displayed
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if an E
service code is not displayed, the problem has been removed.
i If the start switch is turned off after an abnormality occurs, turn the start switch on and check if an E service code
is displayed. If it is not displayed, the problem has been removed.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
3 controller
YES Is resistance between C01-
10 and chassis normal
1. Start switch off Short circuit with chassis
2. Disconnect C01 ground in wiring harness Repair or replace
2 3. 20 to 60 S NO between C01-10 and V07-2
YES Is resistance between V07-1
and 2, 2 and chassis as in
Table 1
1
1. Start switch off
Switch connector with other 2. Disconnect V07
solenoid, is E231 displayed
1. Switch V07 with other
connector
2. Start engine
NO Defective LS select sole-
3. Swing lock switch off
noid, internal short circuit or Replace
4. Active mode switch on NO short circuit with ground
5. Operate swing plus
boom raise lever slight-
ly at the same time
Table 1
20-474 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-15
Cause Remedy
YES Defective governor, pump con-
Replace
5 troller
YES Is voltage between C01-10 to V07-2 to chas-
sis normal
1. Disconnect C01 and V07 Short circuit with power source in
2. Start swich on wiring harness between C01-10 Repair or replace
4 3. Max 1 V NO and V07-2
YES Wh en V07-2 is grounded to chassis, i s
resistance between C01-10 and chassis
normal
1. Start switch off Defective contact or disconnec-
2. Disconnect V07 tion in wiring harness between Repair or replace
3 3. Max 1 S NO C01-10 and V07-2
YES Is resistance between V07-1 and chassi s
normal
1. Start switch off Defective contact or disconnec-
2. Disconnect C01 tion in wiring harness between Repair or replace
2 3. Max 1 S NO V07-1 and chassis
YES Is resistance between V07-1 and 2 normal
1
1. Start switch off
Switch connector with other solenoid, i s 2. Disconnect V07
E235 displayed 3. 20 to 60 S
1. Switch V07 with other connector NO
Defective active mode [swing]
2. Start switch on Replace
NO solenoid, internal disconnection
PC300LC-6
PC300HD-6
20-475
TROUBLESHOOTING C-16
Cause Remedy
YES Defective governor, pump
Replace
1 YES controller
i The diagram shows monitoring code 02. Check the bit pattern display marked with $
C17 5 and chassis 6 and chassis 7 and chassis 13 and chassis 14 and chassis
Voltage 20 to 30 V Max 1 V Max 1 V Max 1 V 20 to 30 V
C09 H14
female female
20-476 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-16
PC300LC-6
PC300HD-6 20-477
TROUBLESHOOTING C-17
Cause Remedy
YES Defective governor, pump
Replace
2 controller
YES Is resistance between C02-7 and 17, 7 and
chassis as shown in Table 1
1. Start switch off Short circuit with ground or
2. Disconnect C02 short circuit with power
source in wiring harness
between C02-7and C10-1 or Repair or replace
NO short circuit with power
source in wiring harness
1 between C02-17 and C10-2
Is resistance between C10-1 and 2, 1 and
chassis as shown in Table 1
1. Start switch off Defective LS-EPC solenoid,
2. Disconnect C10 internal short circuit with
Replace
ground or short circuit with
NO power source
Table 1
20-478 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-18
Cause Remedy
YES Defective governor, pump
Replace
2 controller
YES Is resistance between C02-7 and 17, 17
and chassis as shown in Table 1
1. Start switch off Defective contact or short
2. Disconnect C02 circuit with chassis ground
in wiring harness between
C02-7 and C10-1 or defec-
Repair or replace
NO tive contact, short circuit
with ground or disconnec-
tion in wiring harness be-
1 tween C02-17 and C10-2
Is resistance between C10-1 and 2, 2 and
chassis as shown in Table 1
1. Start switch off Defective LS-EPC solenoid,
2. Disconnect C10 internal disconnection, de-
Replace
fective contact or short cir-
NO cuit with ground
Table 1
PC300LC-6
PC300HD-6 20-479
TROUBLESHOOTING C-19
Cause Remedy
YES Defective governor, pump
Replace
3 controller
YES Is voltage between C03-3
and 16 normal
1. Engine at high idle Short circuit with power
2. Operate repeatedly source, defective contact or
arm IN relief lever disconnection in wiring har- Repair or replace
NEUTRAL NO ness between C03-3 and
2 3. 0.5 to 4.5 V C08-3
YES Is voltage between C08-2
and 1 normal
1. Start switch on Short circuit with ground,
2. 18 to 28 V YES defective contact or discon-
Repair or replace
nection in wiring harness
4 between C03-16 and C08-1
Is voltage between C08-2
NO and chassis normal
1. Disconnect C08 Short circuit with ground,
2. Start switch on defective contact or discon-
Repair or replace
3. 18 to 28 V NO nection in wiring harness
1 between C03-6 and C08-2
Switch connector with rear
pump pressure sensor, is
E224 displayed
1. Start switch off Defective front pump pres-
2. Switch C07 with C08 sure sensor, internal
3. Engine at high idle disconnection, defective Replace
NO contact, short circuit or
short circuit with ground
20-480 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-20
Cause Remedy
YES Defective governor, pump
Replace
3 controller
YES Is voltage between C03-3
and 16 normal
1. Engine at high idle Short circuit with power
2. Operate repeatedly source, defective contact or
arm IN relief lever disconnection in wiring har- Repair or replace
NEUTRAL NO ness between C03-13 and
2 3. 0.5 to 4.5 V C07-3
YES Is voltage between C07-2
and 1 normal
1. Start switch on Short circuit with ground,
2. 18 to 28 V YES defective contact or discon-
Repair or replace
nection in wiring harness
4 between C03-16 and C07-1
Is voltage between C07-2
NO and chassis normal
1. Disconnect C08 Short circuit with ground,
2. Start switch on defective contact or discon-
Repair or replace
3. 18 to 28 V NO nection in wiring harness
1 between C03-6 and C07-2
Switch connector with front
pump pressure sensor, is
E225 displayed
1. Start switch off Defective rear pump pres-
2. Switch C08 with C07 sure sensor, internal
3. Engine at high idle disconnection, defective Replace
NO contact, short circuit or
short circuit with ground
PC300LC-6
PC300HD-6 20-481
TROUBLESHOOTING C-21
Cause Remedy
Defective front pump pres-
YES sure sensor, internal shor t
Replace
circuit or short circuit with
2 ground
YES Is voltage between C03-6
and 16 normal
1. Start switch on Defective rear pump pres-
2. Disconnect C08 YES sure sensor, internal shor t
Replace
3. 18 to 28 V circuit or short circuit with
3 ground
Is voltage between C03-6
NO and 16 normal
1. Disconnect C07 Defective governor, pump
2. Start switch on Replace
1 NO controller
3. 18 to 28 V
Is resistance between C03-
6 and 16, 16 and 6 and
chassis normal
1. Start switch off Short circuit or short circui t
2. Disconnect C03, C07 with ground in wiring har-
Repair or replace
and C08 NO ness of system where
3. Min 1 MS resistance value is defective
20-482 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-22
Cause Remedy
YES Defective governor, pump
Replace
2 controller
YES Is resistance between C16-1 and 2 normal
E08 E07
female female
PC300LC-6
PC300HD-6 20-483
TROUBLESHOOTING C-23
a) If solenoid is not actuated, turned on, when machine push up switch is set to low
pressure setting
i Check that fuse #2 is not blown.
i Carry out troubleshooting with the machine push up switch at the low pressure setting position.
Cause Remedy
YES Defective contact or discon-
nection in wiring harness Repair or replace
2 between V05-1 and chassis
YES Is resistance between V05-1
and 2 normal
1. Start switch off Defective machine push up
2. Disconnect V05 solenoid, internal discon- Replace
1 3. 20 to 60 S NO nection or defective contact
Is voltage between V05-2
and chassis normal
1. Start switch on Short circuit with ground,
2. 20 to 30 V YES defective contact or discon-
nection in wiring harness Repair or replace
between M38-1 to X01-16 to
4 H13-3 to V05-2
YES Is resistance between M38-
1 and 2 normal
1. Start switch off Defective machine push up
2. Disconnect M38 solenoid, internal discon-
Replace
3. Switch on . . . . Max 1 S NO nection, defective contact or
3 4. Switch off . . . Min 1 MS short circuit with ground
Is voltage between M38-2
NO and chassis normal
1. Start switch on Defective fuse #2 or short
2. 20 to 30 V circuit with ground,
defective contact or
Repair or replace
NO disconnection in wiring
harness between fuse #2 to
X01-12 to M38-2
20-484 PC300LC-6
PC300HD-6
TROUBLESHOOTING C-23
b) If solenoid is not canceled, turned off, when machine push up switch is set to high
pressure setting
i Carry out troubleshooting with the machine push up switch at the high pressure setting position.
Cause Remedy
YES Defective machine push up
solenoid, internal short Replace
1 circuit with power source
Is voltage between V05-2 and chassis nor-
mal
1. Start switch on YES Defective machine push up
2. Max 1 V switch, internal short circuit Replace
2 with power source
Is voltage between M38-1 and chassis nor-
NO mal
1. Start switch on Short circuit with power
2. Max 1 V source in wiring harness be-
Repair or replace
tween M38-1 to X01-16 to
NO H13-3 to V05-2
PC300LC-6
PC300HD-6 20-485
TROUBLESHOOTING OF GOVERNOR, PUMP
CONTROLLER, INPUT SIGNAL SYSTEM
F MODE
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] Mode connection does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
F-11 Bit pattern 22-[6] Left knob switch does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
PC300LC-6
PC300HD-6 20-501
TROUBLESHOOTING
MEMORANDA
20-502 PC300LC-6
PC300HD-6
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR F MODE
PC300LC-6
PC300HD-6
20-503
TROUBLESHOOTING F-1
F-1 Bit pattern 20-[1] Swing oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! Turn the swing lock switch ON before operating the swing lever.
i 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.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C16-5
and chassis normal
1. Start engine
Defective contact or discon-
2. Swing lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S08-1 and chassis
3. Swing lever operated;
ground
Max 1 V 3
Is resistance between C16-
YES 5 and S08-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
2. Disconnect C16 and S08 Defective contact, short cir-
3. Between C16 and S08; cuit with ground or discon-
Repair or replace
Max 1 S NO nection in wiring harness
4. Between harness and between C16-5 and S08-2
2 chassis; Min 1 MS
Is resistance between S08-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S08
Defective swing oil pressure
2. Start engine
switch
3. Swing lever at neutral;
If the condition does not re-
Min 1 MS Replace
NO turn to normal even when
4. Swing lever operated;
the switch is replaced, go to
Max 1 S
H-5
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 betwee n
C16-5 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
20-504 PC300LC-6
PC300HD-6
TROUBLESHOOTING F-2
F-2 Bit pattern 20-[2] Travel oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! Before operating the travel lever, check that the surronding area is safe.
i If there is no display when the travel lever is operated on one sid e, the PPC shuttle valve is defective. See H-5. When
measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C16-13
and chassis normal
1. Start engine
Defective contact or discon-
2. Travel lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S01-1 and chassis
3. Travel lever operated;
ground
Max 1 V 3
Is resistance between C16-
YES 13 and S01-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
2. Disconnect C16 and S01 Defective contact, short cir-
3. Between C16 and S01; cuit with ground or discon-
Repair or replace
Max 1 S NO nection in wiring harness
4. Between harness and between C16-13 and S01-2
2 chassis; Min 1 MS
Is resistance between S01-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S01
Defective travel oil pressure
2. Start engine
switch
3. Travel lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Travel lever operated;
the switch is replaced, go to
Max 1 S
H-5
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 betwee n
C16-13 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
PC300LC-6
PC300HD-6 20-505
TROUBLESHOOTING F-3
F-3 Bit pattern 20-[3] Boom LOWER oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-10
and chassis normal
1. Start engine
Defective contact or discon-
2. Boom lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S04-1 and chassis
3. Boom lever operated to
ground
LOWER; Max 1 V 3
Is resistance between C17-
YES 10 and S04-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
Defective contact, short cir-
2. Disconnect C17 and S04
cuit with ground or discon-
3. Between C17 and S04;
nection in wiring harness Repair or replace
Max 1 S NO between C17-10 to H13-
4. Between harness and
11to S04-2
2 chassis; Min 1 MS
Is resistance between S04-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S04
Defective boom LOWER oil
2. Start engine
pressure switch
3. Boom lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Boom lever operated to
the switch is replaced, go to
LOWER; Max 1 S
H-5
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 betwee n
C17-10 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
S04 H13
female female
20-506 PC300LC-6
PC300HD-6
TROUBLESHOOTING F-4
F-4 Bit pattern 20-[4] Boom RAISE oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-2
and chassis normal
1. Start engine
Defective contact or discon-
2. Boom lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S02-1 and chassis
3. Boom lever operated to
ground
RAISE; Max 1 V 3
Is resistance between C17-
YES 2 and S02-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
Defective contact, short cir-
2. Disconnect C17 and S02
cuit with ground or discon-
3. Between C17 and S02;
nection in wiring harness Repair or replace
Max 1 S NO between C17-2 to H13-9 to
4. Between harness and
S02-2
2 chassis; Min 1 MS
Is resistance between S02-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S02
Defective boom RAISE oil
2. Start engine
pressure switch
3. Boom lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Boom lever operated to
the switch is replaced, go to
RAISE; Max 1 S
H-5
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 betwee n
C17-2 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
S02 H13
female female
PC300LC-6
PC300HD-6 20-507
TROUBLESHOOTING F-5
F-5 Bit pattern 20-[5] Arm IN oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-3
and chassis normal
1. Start engine
Defective contact or discon-
2. Arm lever at neutral; 20 YES nection in wiring harness
to 30 V Repair or replace
between S05-1 and chassis
3. Arm lever operated to
ground
IN; Max 1 V 3
Is resistance between C17-
YES 3 and S05-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
Defective contact, short cir-
2. Disconnect C17 and S05
cuit with ground or discon-
3. Between C17 and S05;
nection in wiring harness Repair or replace
Max 1 S NO between C17-3 to H13-10 to
4. Between harness and
S05-2
2 chassis; Min 1 MS
Is resistance between S05-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S05
Defective arm IN oil pres-
2. Start engine
sure switch
3. Arm lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Arm lever operated to
the switch is replaced, go to
IN; Max 1 S
H-5
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 betwee n
C17-3 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
S05 H13
female female
20-508 PC300LC-6
PC300HD-6
TROUBLESHOOTING F-6
F-6 Bit pattern 20-[6] Arm OUT oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-11
and chassis normal
1. Start engine
Defective contact or discon-
2. Arm lever at neutral; 20 YES nection in wiring harness
to 30 V Repair or replace
between S03-1 and chassis
3. Arm lever operated to
ground
OUT; Max 1 V 3
Is resistance between C17-
YES 11 and S03-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
Defective contact, short cir-
2. Disconnect C17 and S03
cuit with ground or discon-
3. Between C17 and S03;
nection in wiring harness Repair or replace
Max 1 S NO between C17-11 to H13-12
4. Between harness and
to S03-2
2 chassis; Min 1 MS
Is resistance between S03-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S03
Defective arm OUT oil pres-
2. Start engine
sure switch
3. Arm lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Arm lever operated to
the switch is replaced, go to
OUT; Max 1 S
H-5
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 betwee n
C17-11 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
S03 H13
female female
PC300LC-6
PC300HD-6 20-509
TROUBLESHOOTING F-7
F-7 Bit pattern 21-[1] Bucket CURL oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C16-11
and chassis normal
1. Start engine
Defective contact or discon-
2. Bucket lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S06-1 and chassis
3. Bucket lever operated
ground
to CURL; Max 1 V 3
Is resistance between C16-
YES 11 and S06-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
2. Disconnect C16 and S06 Defective contact, short cir-
3. Between C16 and S06; cuit with ground or discon-
Repair or replace
Max 1 S NO nection in wiring harness
4. Between harness and between C16-11 and S06-2
2 chassis; Min 1 MS
Is resistance between S06-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S06
Defective bucket CURL oil
2. Start engine
pressure switch
3. Bucket lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Bucket lever operated
the switch is replaced, go to
to CURL; Max 1 S
H-5
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 betwee n
C16-11 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
20-510 PC300LC-6
PC300HD-6
TROUBLESHOOTING F-8
F-8 Bit pattern 21-[2] Bucket DUMP oil pressure switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
WARNING! When measuring with the engine running, operate the lever slightly and make sure that the wor k
equipment does not move. When measuring with the engine stopped, charge the accumulator first.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C16-12
and chassis normal
1. Start engine
Defective contact or discon-
2. Bucket lever at neutral; YES nection in wiring harness
20 to 30 V Repair or replace
between S07-1 and chassis
3. Bucket lever operated
ground
to DUMP; Max 1 V 3
Is resistance between C16-
YES 12 and S07-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
2. Disconnect C16 and S07 Defective contact, short cir-
3. Between C16 and S07; cuit with ground or discon-
Repair or replace
Max 1 S NO nection in wiring harness
4. Between harness and between C16-12 and S07-2
2 chassis; Min 1 MS
Is resistance between S07-1
and 2 normal and is circuit
NO insulated from chassis
1. Disconnect S07
Defective bucket DUMP oil
2. Start engine
pressure switch
3. Bucket lever at neutral;
If the condition does not
Min 1 MS Replace
NO return to normal even when
4. Bucket lever operated
the switch is replaced, go to
to DUMP; Max 1 S
H-5
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 betwee n
C16-12 and the chassis. If it is 20 to 30 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to YES
If it is less than 1 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Go to NO
PC300LC-6
PC300HD-6 20-511
TROUBLESHOOTING F-9
F-9 Bit pattern 21-[3] Swing lock switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
i If the panel display is normal, if the swing lock lamp does not light up, go to M-21.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-16
and chassis normal
1. Start engine Defective contact, short cir-
2. Swing lock switch; YES cuit with ground or discon-
On . . . . . . . . . Max 1 V nection in wiring harness Repair or replace
Off . . . . . . . 20 to 30 V between X05-2 to X01-5 to
3 H14-6 to chassis ground
Is resistance between C17-
YES 16 and X05-2 normal and is
circuit insulated from chas-
sis
1. Start switch off
2. Disconnect C17 and Defective contact, short cir-
X05 cuit with ground or discon-
3. Between C16 and S07; nection in wiring harness Repair or replace
Max 1 S NO between C17-16 to X01-4 to
4. Between harness and X05-1
2 chassis; Min 1 MS
Is resistance between X05-1
and 2 normal and is circuit
NO insulated from chassis
1. Start switch off
2. Disconnect X05
3. Swing lock switch; Defective swing lock switch Replace
On . . . . . . . . . Max 1 V NO
Off . . . . . . . 20 to 30 V
20-512 PC300LC-6
PC300HD-6
TROUBLESHOOTING F-11
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C17-15 and chassis
normal
1. Start switch on YES Defective contact or discon-
2. M36 connector; nection in wiring harness
Repair or replace
Connected . . . . . . . . . . . Max 1 V between M36-1 and chassis
Open . . . . . . . . . . . . . 20 to 30 V 2 ground
Is resistance between C17-15 and M36-1
NO normal
1. Start switch off Defective contact in wiring
2. Disconnect C17 and M36 harness between C17-15 Repair or replace
3. Max 1 S NO and M36-1
C17
female
PC300LC-6
PC300HD-6 20-513
TROUBLESHOOTING F-11
F-11 Bit pattern 22-[6] Left knob switch does not light up
i This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector an d
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the
monitor code display returns to normal, the problem has been removed.
i When fuse #5 is not blown.
i Before carrying out troubleshooting, check tha t all the related connectors are properly inserted. Always connect any
disconnected connectors before going on the next step.
Cause Remedy
YES Defective governor, pump
Replace
1 controller
Is voltage between C03-9
and chassis normal
1. Start switch on YES Defective contact or discon-
2. Knob switch; nection in wiring harness
Repair or replace
On . . . . . . . 20 to 30 V between knob switch outlet
Off . . . . . . . . . Max 1 V 3 M23-2 to M22-2 to C03-9
YES Is resistance between ter-
minals of knob switch nor-
mal
1. Start switch off
2. Disconnect switch
terminal
Left knob switch Repair or replace
3. Knob switch
On . . . . . . Max 1 S NO
2 Off . . . . . Min 1 MS
Is voltage between knob
switch inlet terminal and
NO chassis normal
1. Start switch on Faulty contact, short circuit
2. 20 to 30 V with ground or disconnec-
tion in harness between Replace
NO fuse #5 to H12-16 to M22-1
to H23-1 to knob switch inlet
H12 M22
female M23
female
20-514 PC300LC-6
PC300HD-6
TROUBLESHOOTING OF MACHINE
MECHANICAL SYSTEM
H MODE
PUMP MERGE DIVIDER LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
SOLENOID ACTUATION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
TABLE OF FAILURE MODES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
H-1 Speeds of all work equipment, swing, travel are slow or lack power . . . . . . . . . . . . . . . . . . . . . . . . 20-555
H-2 There is excessive drop in engine speed, or engine stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
H-3 No work equipment, travel, swing movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
H-4 Abnormal noise generated around pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
H-5 Auto deceleration does not work, when PPC shuttle valve is cause . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
H-6 Fine control ability is poor or response is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
H-7 Boom is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-558
H-8 Arm is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
H-9 Bucket is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-560
H-10 Work equipment; boom, arm, bucket, does not move, but travel and swing are normal . . . . . . . . . 20-561
H-11 Excessive hydraulic drift, boom, arm, bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-561
H-12 Excessive time lag, engine at low idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-562
H-13 Other equipment moves when single circuit is relieved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-562
H-14 In L/O, F/O modes, work equipment speed is faster than specified speed . . . . . . . . . . . . . . . . . . . . 20-563
H-15 Malfunction of machine push up function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-563
H-16 In compound operations, work equipment with larger load is slow . . . . . . . . . . . . . . . . . . . . . . . . . . 20-563
H-17 In swing plus boom RAISE, boom RAISE is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
H-18 In swing plus arm, arm is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
H-19 In swing plus travel, travel speed drops excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
H-20 Travel deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
H-21 Travel speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-567
H-22 Steering does not turn easily or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
H-23 Travel speed does not switch or is faster than specified speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-569
H-24 Travel does not move, one side only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-569
H-25 Does not swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-570
H-26 Swing acceleration is poor or swing speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-571
H-27 Excessive overrun when stopping swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-572
H-28 Excessive shock when stopping swing, one direction only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-573
H-29 Excessive abnormal noise when stopping swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-573
H-30 Excessive hydraulic drift of swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-574
H-31 Swing speed is faster than specified swing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-574
PC300LC-6
PC300HD-6 20-551
TROUBLESHOOTING
Divide, pump merge divider solenoid ON Merge, pump merge divider solenoid OFF
20-552 PC300LC-6
PC300HD-6
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES (1/2)
Parts causing failure Piston pump Control valve Solenoid valve Swing motor
Machine push up
Main relief valve
LS shuttle valve
This shows item that needs only checking with monitor
LS select valve
Engine system
Holding brake
Suction valve
Pump proper
Pump proper
Unload valve
Unload valve
Servo piston
Servo piston
PPC shuttle
Swivel joint
Main pump
PPC valve
This shows item to check with monitoring or machine monitor
TVC valve
TVC valve
LS pump
LS valve
LS valve
Damper
Strainer
LS-EPC
Boom
Spool
Arm
Failure mode
Speed of all work equipment, swing, travel are slow or lack power H-1
All work equipment,
i In the failure modes, modes for multi operations are used when independent operations are normal.
PC300LC-6
PC300HD-6
20-553
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES (2/2)
Parts causing failure Travel motor Pressure switch Pressure
Counterbalance valve
This shows applicable item for service code
Hydraulic cylinder
Swing machinery
Safety valve
Check valve
Front pump
Rear pump
Final drive
This shows item to check with monitoring or machine monitor
LOWER
RAISE
DUMP
Travel
CURL
Swing
OUT
IN
Failure mode
Speed of all work equipment, swing, travel are slow or lack power H-1
There is excessive drop in engine speed or engine stalls H-2
All work equipment,
travel, swing
i In the failure modes, modes for multi operations are used when independent operations are normal.
PC300LC-6
20-554 PC300HD-6
TROUBLESHOOTING H-1
H-1 Speeds of all work equipment, swing, travel are slow or lack power
i Carry out troubleshooting in the HO mode.
i Check that no abnormal noise is being generat ed from the main pump before carrying out troubleshooting. If there
is any abnormal noise, carry out troubleshooting for H-4.
Cause Remedy
YES Defective adjustment of TVC
Adjust
5 valve
The oil pressure in the control circuit is reduced by the self pressure reducing valve.
PC300LC-6
PC300HD-6
20-555
TROUBLESHOOTING H-2, H-3
Cause Remedy
YES Clogged throttle or filter in -
Clean
1 side servo
Is throttle inside servo or fil-
ter inside servo clogged
YES Defective TVC valve or op- Adjust or replace
3 eration of LS valve servo valve
Note 1: Replace the servo valve on the defective side with a new part, and if the engine speed is lower than th e
reference value below, carry out troubleshooting for S Mode engine. If it is higher, it can be judged that the TVC
valve [servo valve] is defective, so replace it.
i Engine speed [reference] at arm IN relief when engine and pump are normal
Cause Remedy
YES Defective self reducing
valve, control circuit or main Replace
2 piston pump
YES When main pump pressure pickup plug is
removed, does oil come out
1
1. Crank with starter motor Defective damper Replace
NO
Is safety lock valve working properly
20-556 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-4, H-5, H-6
Cause Remedy
NO Change hydraulic
Improper hydraulic oil
3 oil
YES Do bubbles disappear when engine is
stopped
YES
2 4 Clogged by external object Remove
YES YES Is suction strainer clogged by external
Are there bubbles inside hydraulic tank
NO object
YES
1 5 Defect inside pump Repair or replace
H-5 Auto deceleration does not work when PPC shuttle valve is cause H-6 Fine control ability is poor or response is poor
i The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied to the pressure
switch.
Cause Remedy
YES Clogged throttle in LS
Clean
Cause Remedy 2 circuit
YES Defective pressure YES
Replace Is throttle in LS circuit clogged
1 switch
Does condition become normal when pressure switch Defective servo valve, LS
is replaced valve or defective servo Replace
1 NO piston
Defective operation of
PPC shuttle valve in ap- Is output pressure of LS-EPC normal
Repair or replace
plicable system, swing or
NO travel 1. Output pressure, 30 2 kg/cm2 Defective LS-EPC valve Repair or replace
NO
PC300LC-6
PC300HD-6
20-557
TROUBLESHOOTING H-7
Cause Remedy
YES Defective operation of boom lock
Repair or replace
7 High valve
YES Is operating pressure normal
when boom RAISE operated
1. 160 10 kg/cm2 Low Defective boom cylinder piston
2. Engine at high idle Repair or replace
6 NO packing
3. At max reach, no load
YES Does LS shuttle valve
move smoothly
1. Check LS shuttle for Defective operation of LS shuttle
right travel and bucket Repair or replace
5 NO valve, right travel or bucket
Is relief pressure of front and rear
pumps normal when boom
RAISE circuit is relieved
YES 1. 330 to 365 kg/cm2 Defective boom lock valve or suc-
2. Engine at high idle tion valve for boom in control Replace
4 NO valve
YES Is pressure compensation valve
for boom normal or does pres-
sure compensation piston move
smoothly
1. It is also possible to inter YES Defective operation of boom lock
change with other valve Repair or replace
3 8 High valve
2. See Note 2
YES Does control valve spool for Is operating pressure normal
boom move smoothly when boom LOWER is operated
1. 50 30 kg/cm2 Low Defective operation of boom re-
2. Engine at high idle Repair or replace
2 NO generation valve
Note 1 If auto deceleration is canceled when boom RAISE or LOWER is operated, system is normal.
Note 2 After inspection, do not forget to return the interchanged valves to the original position.
PC300LC-6
20-558 PC300HD-6
TROUBLESHOOTING H-8
Center Remedy
YES Defective operation of arm regen-
Repair or replace
7 eration valve
YES Is leakage from arm cylinder nor-
mal
1. Max 20 cc/min Defective arm cylinder piston
2. Engine at high idle Repair or replace
6 NO packing
YES Does LS shuttle valve move
smoothly
1. Check LS shuttle for Defective operation of LS shuttle
left travel, boom, right valve, left travel, boom, right tra- Repair or replace
5 travel and bucket NO vel or bucket
YES Is relief pressure of front and rear
pumps normal when arm circuit
is relieved
1. 330 to 365 kg/cm2 Defective safety suction valve for
2. Engine at high idle Replace
4 NO arm
Note 1 If auto deceleration is canceled when arm IN or OUT is operated, the system is normal.
Note 2 After inspection, do not forget to return the interchanged valves to the original position.
PC300LC-6
PC300HD-6
20-559
TROUBLESHOOTING H-9
Cause Remedy
YES Defective operation of safety suc-
Repair or replace
5 tion valve for bucket
YES Is leakage from bucket cylinder normal
1. Min 28 kg/cm2
2. Engine at high idle Defective PPC valve Replace
1 3. Operate bucket NO
Is pressure switch for bucket CURL, DUMP
normal
1. See Judgement Table, Bit pattern 21, 1,
Defective bucket CURL or DUMP
2 Repair or replace
NO pressure switch
2. See Note 1
Note 1 If auto deceleration is canceled when bucket CURL or DUMP is operated, the system is normal.
Note 2 After inspection, do not forget to return the interchanged valves to the original position.
PC300LC-6
20-560 PC300HD-6
TROUBLESHOOTING H-10, H-11
H-10 Work equipment; boom, arm, bucket, does not move, but travel and swing
are normal
i When boom, arm and bucket are each operated independently. Cause Remedy
YES Defective control valve
Repair or replace
1 spool
Is output pressure of PPC valve normal
1. Min 28 kg/cm2
Defective PPC valve Replace
2. Engine at high idle NO
Note 1 After inspection, do not forget to return the switched valves to the original position.
PC300LC-6
PC300HD-6 20-561
TROUBLESHOOTING H-12, H-13
Cause Remedy
Defective safety suction
Boom, arm valve or defective regenera- Replace
tion valve
YES
30 2 kg/cm2 is output from the LS-EPC solenoid when all the levers are at neutral.
Note 2 After inspection, do not forget to return the switched valves to the original position.
Cause Remedy
Defective operation of the
pressure compensation
valve slipper seal. The
slipper seal in the pres- Replace
sure compensation valve
of the circuit that moved
is defective.
20-562 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-14, H-15, H-16
H-14 In L/O, F/O modes, work equipment speed is faster than specified speed
Cause Remedy
YES
1 Defective LS valve Repair or replace
Cause Remedy
YES
1 Defective safety valve Repair or replace
Table 1
PC300LC-6
PC300HD-6 20-563
TROUBLESHOOTING H-17, H-18, H-19
20-564 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-20
Cause Remedy
YES
3 Defective travel motor Repair or replace
Note 1 C Remove the PPC shuttle block inlet hose, fit an adapter and block the tip.
C If the adapter for blocking the circuit is not available, 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.
Cause Remedy
Defective operation of travel counterbalance valve Correct or replace
Clogging of throttle inside servo of front or rear pump Correct or replace
PC300LC-6
PC300HD-6 20-565
TROUBLESHOOTING
MEMORANDA
20-566 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-21
Cause Remedy
YES Defective operation of LS shuttle
Repair or replace
3 valve, for bucket
YES Is output pressure of LS-EPC
solenoid valve normal
1. See Note 2 Defective operation of LS-EPC
Repair or replace
2 NO solenoid valve
Note 1 C Measure the travel speed under no load or measure the time taken to travel 20 m. See Maintenanc e Note 3 After inspection, do not forget to return the interchanged valves to the original position.
Standard for Chassis Related Parts. Note 4 C Remove the PPC shuttle block inlet hose, fit an adapter and block the tip.
C When measuring the speed of the travel motor under no load Remove connector of LS control EPC C If the adapter for blocking the circuit is not available, interchange the travel PPC hoses with the PPC hoses
solenoid, and measure travel speed in Lo and Hi. for the bucket, CURL/DUMP, boom, LOWER, or arm, IN at both the inlet and outlet ports of the shuttle block
Note 2 Output pressure of LS-EPC solenoid and check operation.
Travel speed Lo Mi Hi
2 2
LS-EPC output pressure 2 2 kg/cm 18.4 2 kg/cm 2 2 kg/cm2
C Engine at high idle
Remarks
C Operate travel lever slightly, auto deceleration cancel position
PC300LC-6
PC300HD-6
20-567
TROUBLESHOOTING H-22
Cause Remedy
YES Defective operation of pump
merge divider valve or LS pump Repair or replace
4 merge divider valve
Is output pressure of pump
Both front and rear high merge divider solenoi d
valve normal
Defective operation of main
pump merge divider solenoid Repair or replace
3 NO valve
How is relief pressure o f
Both left and right front and rear pump when
relieved on one side
Pressure high only on side
Defective operation of travel junc-
being relieved, oil pressure Repair or replace
tion valve
2 normal
YES Is it difficult to turn to bot h
left and right or is it difficult
to turn in one direction only
Defective operation of LS circui t
Both front and rear high Repair or replace
check valve
PC300LC-6
20-568 PC300HD-6
TROUBLESHOOTING H-23, H-24
H-23 Travel speed does not switch or is faster than specified speed
Table 1
Travel speed Lo Mi Hi
2 2
LS-EPC output pressure 2 2 kg/cm 18.4 2 kg/cm 2 2 kg/cm2
C Engine at high idle
Remarks
C Operate travel lever slightly, auto deceleration cancel position
Cause Remedy
YES
1 Defective final drive Repair or replace
PC300LC-6
PC300HD-6 20-569
TROUBLESHOOTING H-25
Cause Remedy
YES
3 Defective swing machinery Repair or replace
Cause Remedy
YES Defective swing motor safe-
Replace
2 ty valve or suction valve
YES Does control valve spool for swin g
move smoothly
20-570 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-26
Cause Remedy
YES
2 Defective swing motor Repair or replace
One direction only, left or right Is PPC valve output pressure normal
1. Min 28 kg/cm2
2. Engine at high idle Defective PPC valve Replace
3. Operate swing NO
Note 1 C Remove the PPC shuttle block inlet hose, fit an adapter, and block the tip.
C If the adapter for blocking the circuit is not available, interchange the swing PPC hoses with the PPC hoses
for the bucket; CURL, DUMP, at both the inlet and outlet ports of the shuttle block, and check operation.
Note 2 After inspection, do not forget to return the switched valves to the original position.
PC300LC-6
PC300HD-6
20-571
TROUBLESHOOTING H-27
Cause Remedy
YES Defective swing PPC slow
Repair or replace
3 return valve
YES Is problem reversed when
left & right swing PPC slow
return valves are switched
Defective PPC valve Replace
2 NO
YES Is problem reversed when
left or right output hoses of
PPC valve are switched
Defective swing motor safe-
Replace
1 NO ty valve
Does control valve spool for
swing move smoothly
Defective operation of con-
Repair or replace
NO trol valve spool for swing
b) Both directions
Cause Remedy
Defective swing motor Repair or replace
20-572 PC300LC-6
PC300HD-6
TROUBLESHOOTING H-28, H-29
Cause Remedy
YES Defective swing PPC slow
Repair or replace
1 return valve, check valve
Does condition become normal when left and
right swing PPC slow return valves are switched
Defective PPC valve Replace
NO
Cause Remedy
YES Defective operation of swing
Clean
1 motor safety suction valve
Does condition become nor-
mal when swing motor safe-
ty suction valve is cleaned
YES Defective swing motor safe-
Replace
2 ty suction valve
Does condition become nor-
mal when swing motor safe-
NO ty suction valve is replaced
YES
3 Defective swing machinery Repair or replace
PC300LC-6
PC300HD-6 20-573
TROUBLESHOOTING H-30, H-31
Cause Remedy
YES Defective swing motor safe-
Repair or replace
2 ty suction valve
Cause Remedy
YES Defective operation of swing
Repair or replace
1 holding brake
Is output pressure of swing holding brake solenoid valve normal
1. 2 2 kg/cm2
Defective operation of swing
2. When five seconds have passed after all swing and work Repair or replace
NO holding brake solenoid valve
equipment control levers have been returned to neutral
Cause Remedy
YES Defective operation of LS
Replace servo
1 valve
20-574 PC300LC-6
PC300HD-6
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
M MODE
ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE . . . . . 20-603
ELECTRIC CIRCUIT DIAGRAM FOR M MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604
M-1 [E101] Abnormality in error data is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605
[E101] Error in clock data is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605
M-2 [E103] Short circuit in buzzer output or 24V wiring harness contact with buzzer harness is displayed . . . . . . . 20-606
M-3 [E104] Air cleaner restriction detected is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
M-4 [E106] Drop in engine oil Hi pressure detected is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
M-5 [E108] Engine coolant temperature 105EC detected is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
M-6 When start switch is turned ON, no lamps on monitor panel light up for three seconds . . . . . . . . . . . . . . . . . . . . 20-608
M-7 When start switch is turned ON, monitor panel lamps all stay illuminated and do not go out . . . . . . . . . . . . . . . . 20-610
M-8 When start switch is turned ON, items illuminated on monitor panel are different from actual machine . . . . . . . . 20-610
M-9 When start switch is turned ON, engine stopped, basic check items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
M-10 Preheating is not used but on monitor panel lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
M-11 When start switch is turned ON and engine is started, basic check items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
M-12 When start switch is turned ON, engine speed, caution items, emergency items flash. Battery, engine
oil pressure lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
M-13 When start 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
M-14 When start switch is turned ON, engine stopped, buzzer does not sound for one second, Caution items
flash but do not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
M-15 No abnormality is displayed on monitor panel but buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
M-16 Night light on monitor panel does not light up, liquid crystal display is normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
M-17 Coolant temperature gauge does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
M-18 Coolant temperature gauge does not give any display, no gauge lamps light up during operation . . . . . . . . . . . . 20-626
M-19 Fuel level gauge always displays FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-627
M-20 Fuel level gauge does not give display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-628
M-21 Swing lock switch is turned ON, but on monitor panel does not light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-629
M-22 Swing prolix switch is turned ON, but on monitor panel does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-630
M-23 Service meter does not advance while engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-631
M-24 When start switch is at 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 E112, E113] . . . . . . . . . . . . . . . 20-637
M-31 Wiper does not work or switch is not being used but washer motor is actuated [include E114] . . . . . . . . . . . . . . 20-641
PC300LC-6
PC300HD-6 20-601
TROUBLESHOOTING
MEMORANDA
20-602 PC300LC-6
PC300HD-6
TROUBLESHOOTING ACTIONS TAKEN BY MONITOR PANEL
ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
1. Short circuit with ground, short circuit inside wiper motor C Voltage between W04-3 and 5
2. Short circuit with ground, short circuit inside relay box Max. 3 V
Short circuit in wiper motor drive normal rota- 1. Sets output to relay box
--- E112 3. Short circuit with ground, short circuit in wiring harness between ; 1. Operation of wiper stops
tion system to 0
monitor P02-11 and relay box W08-2 or between W08-6 an d 20 to 30 V
wiper motor W04-1 Repeats in regular cycle
1. Short circuit with ground, short circuit inside wiper motor C Voltage between W04-1 and 5
2. Short circuit with ground, short circuit inside relay box Max. 3 V
Short circuit in wiper motor drive reverse ro- 1. Sets output to relay box
--- E113 3. Short circuit with ground, short circuit in wiring harness between ; 1. Operation of wiper stops
tation system to 0
monitor P02-3 and relay box W08-3 or between W08-7 and wiper 20 to 30 V
motor W04-1 Repeats in regular cycle
PC300LC-6
PC300HD-6
20-603
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
PC300LC-6
20-604 PC300HD-6
TROUBLESHOOTING M-1
Cause Remedy
YES Defective monitor panel Replace
2
YES Is voltage between P02-8, P02-14 and
chassis normal
1. Start switch off Disconnection, defective
2. 20 to 30 V contact, short circuit with
ground in wiring harness
Repair or
between battery to battery
NO replace
relay B to M11-1, M11-2 to
H14-1 to fuse #13 to P02-8
1 and P02-14
Does the service code display ap-
pear again after system has been
reset
1. After resetting system, carry out
normal operations for a short
time and watch the condition, NO
Normal ---
See Note 1
Note 1 Resetting operation; Turn the start switch OFF. Then keep the time switch at the back of the monitor pane l
depressed, turn the start switch ON again, and keep the time switch depressed for five seconds to return the
system to normal. With this operation, all the service codes in the internal memory are erased.
P02 M11 M11 H14
female male female male
H14
female
PC300LC-6
PC300HD-6 20-605
TROUBLESHOOTING M-2
M-2 [E103] Short circuit in buzzer output or 24V wiring harness contact with
buzzer harness is displayed
i If the start switch is turned OFF after an abnormality occurs, turn the start switch ON and check if an E service code
is displayed. If it is not displayed, the system has been reset.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
2 Defective monitor panel Replace
YES Is voltage between P04-2 and chassis nor-
mal
1. Start switch on Short circuit with power
2. Buzzer ON Max 1V source in wiring harness
3. Buzzer OFF 20V to 30V between P01-7 and P04-2 Repair or
NO or short circuit in wirin g replace
harness between P04-1
1 and P04-2
Is resistance between P04-1 and
P04-2 and P04-2 to chassis as
shown in the table
1. Start switch off
Defective buzzer Replace
2. Disconnect P04 NO
Table
P04 (male) Resistance value
Between (1) and (2) 200 to 300 S
Between (2) and chassis Min. 1 MS
D11
female
20-606 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-3, M-4, M-5
Note 1 The monitor panel display has returned to normal, but the air cle aner restriction sensor has detected symptoms
of restriction in the past, so carry out troubleshooting of the engine to remove the problem.
Note 1 The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has detecte d
symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of the engine to remove th e
problem.
Note 1 The monitor panel display has returned to normal, but the coolant temperature sensor has detected symptoms
of the coolant temperature reaching 105 EC in the past, so carry out troubleshooting of the engine to remove
the problem.
PC300LC-6
PC300HD-6 20-607
TROUBLESHOOTING M-6
M-6 When start switch is turned ON, no lamps on monitor panel light up for
three seconds
i Check that fuses #10 and #13 are not blown.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective monitor panel Replace
2
YES Is voltage between P01-9
and chassis normal
H14 H14
male female
20-608 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-6
Cause Remedy
PC300LC-6
PC300HD-6 20-609
TROUBLESHOOTING M-7, M-8
M-7 When start switch is turned ON, monitor panel lamps all stay illuminated
and do not go out
Cause Remedy
M-8 When start switch is turned ON, items illuminated on monitor panel are
different from actual machine
i Immediately after replacing the monitor panel, turn the start switch OFF, then turn it ON again and check.
Cause Remedy
YES
Defective monitor panel Replace
1
Table
20-610 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-9
M-9 When start switch is turned ON, engine stopped, basic check items flash
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
PC300LC-6
PC300HD-6 20-611
TROUBLESHOOTING M-9
i Check that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective engine oil level
---
1 sensor system, see M-27
Does display go out when
P05-1 is connected to
chassis ground
1. Disconnect P05 YES Defective governor, pump
2. Start switch on Replace
3 controller
YES Is bit 4 of monitoring
code 24 illuminated
1. Start switch on
2. Set to monitoring code Defective monitor panel Replace
2 24 NO
Is continuity between C16-
16 and chassis as shown
NO in table
1. Start switch off
Defective contact or dis-
2. Disconnect C16, P05
connection in wiring har-
3. Connect disconnect Repair or replace
NO ness between C16-16 to
short connector to
E08-5 to P05-1
P05-1
Table
20-612 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-9
i Check that the hydraulic oil is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective engine oil leve l
---
1 sensor system, see M-29
Does display go out when
P09-1 is connected to
chassis ground
1. Disconnect P09 YES Defective governor, pump
2. Start switch on Replace
3 controller
YES Is bit 5 of monitoring
code 24 illuminated
1. Start switch on
2. Set to monitoring code Defective monitor panel Replace
2 24 NO
Is continuity between C16-
9 and chassis as shown in
NO table
1. Start switch off
Defective contact or dis-
2. Disconnect C16, P09
connection in wiring har-
3. Connect disconnect Repair or replace
NO ness between C16-9 and
short connector to
P09-1
P09-1
Table
C16
female
PC300LC-6
PC300HD-6 20-613
TROUBLESHOOTING M-10
Cause Remedy
YES
2 Defective monitor panel Replace
YES Is voltage between P01-18 and chassis
normal
1. Start switch on Short circuit with power
2. Max 1V source in wiring harness
Repair or
between start switch R1 to
NO replace
X07-3 to H13-6 to P01-18
1 or E11-1 to E08-3 to H13-6
Is voltage between start switch ter-
minal R1 and chassis normal
1. Disconnect terminal R1
2. Start switch off Defective start switch Replace
3. Max 1 V NO
E11
female
20-614 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-11
M-11 When start switch is turned ON and engine is started, basic check items
flash
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on to the next step.
i Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy
YES Defective governor, pump Replace
3 controller
YES Does monitoring code 43
show a value greater than
100
1. Start engine and run at
mid idle or above
Defective monitor panel Replace
2. Set to monitoring code
2 43 NO
PC300LC-6
PC300HD-6 20-615
TROUBLESHOOTING M-11
20-616 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-12
M-12 When start switch is turned ON, engine speed, caution items, emergency
items flash. Battery, engine oil pressure lamps do not light up
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on to the next step.
i Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy
YES Defective governor, pump
Replace
3 controller
PC300LC-6
PC300HD-6 20-617
TROUBLESHOOTING M-12
20-618 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-13
M-13 When start 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
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on to the next step.
See M-11 b
See M-9 a
See M-11 a
PC300LC-6
PC300HD-6 20-619
TROUBLESHOOTING M-13
P07
female
C03
female
20-620 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-13
i Check that the air cleaner is not restricted before carrying out troubleshooting Cause Remedy
YES
1 Defective air cleaner Replace
YES Is continuity
between C16-17 and
chassis as in table
1. Start switch off
2. Disconnect C16, Defective contact or dis-
P11 and P12 connection in wiring har- Repair or
3. Connect dis- ness between C16-17 replace
connect P11 to NO and P11
2 P12
Is there continuity
between P12 and
NO chassis
1. Start switch off Defective contact or dis-
2. Disconnect P12 connection in wiring har- Repair or
ness between P12 and replace
NO chassis ground
Table
C16
female
PC300LC-6
PC300HD-6 20-621
TROUBLESHOOTING M-14
M-14 When start switch is turned ON, engine stopped, buzzer does not sound
for one second, Caution items flash but do not sound
i Of the caution items, the buzzer will not sound even if there is an abnormality in the battery charge or fuel level.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective monitor panel Replace
2
YES Wh en P01-7 and chassis
are connected, does buzzer
sound
1. Disconnect P01 YES Defective contact or discon-
2. Start switch on nection in wiring harness Repair or replace
3 between P01-7 and P04-2
D11
female
20-622 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-15
Cause Remedy
Contact of chassis ground
YES with wiring harness between
Repair or replace
P01-7 and P04-2 or defective
1 buzzer
PC300LC-6
PC300HD-6 20-623
TROUBLESHOOTING M-16
M-16 Night light on monitor panel does not light up, liquid crystal display is
normal
i When the front light and working light are illuminated.
Cause Remedy
YES Replace bulb or
Blown bulb or defective con-
clean defective
tact of bulb
1 contact
Is bulb blown or is there
defective contact
1. Remove bulb YES YES
2. Check visually for Defective monitor panel Replace
blown bulb 2
Does bit 3 of monitoring
NO code 49 go out
1. Start switch on
2. Set to monitoring code
49 3
Is voltage between P01-8
NO and 12 normal
M07
female
20-624 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-17
Cause Remedy
YES Defective coolant tempera-
ture sensor system, see M- ---
1 26
Wh en short connector is
connected to P07, do level
lamps on gauge go up in
turn and then all lamps go
out
1. Disconnect P07 YES
2. Start switch on Defective monitor panel Replace
3
YES Does monitoring code 41
show a value of less than 50
P07
female
PC300LC-6
PC300HD-6 20-625
TROUBLESHOOTING M-18
M-18 Coolant temperature gauge does not give any display, no gauge lamps
light up during operation
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES Defective coolant tempera-
ture sensor system, see M- ---
1 26
When P07 is disconnected,
does coolant temperature
gauge display appear
1. Disconnect P07 YES Contact of chassis ground
2. Start switch on with wiring harness between Repair or replace
2 C03-1 to E08-6 to P07-1
1. Start switch on
2. Set to monitoring code Defective monitor panel Replace
41 NO
P07
female
20-626 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-19
Cause Remedy
YES Defective fuel level sensor
---
1 system, see M-25
C03
female
PC300LC-6
PC300HD-6 20-627
TROUBLESHOOTING M-20
Cause Remedy
YES Defective fuel level sensor
---
1 system, see M-25
C03
female
20-628 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-21
M-21 Swing lock switch is turned ON, but on monitor panel does not light
i Carry out this troubleshooting only if swing lock is actually being actuated.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
1 Defective monitor panel Replace
Table
PC300LC-6
PC300HD-6 20-629
TROUBLESHOOTING M-22
M-22 Swing prolix switch is turned ON, but on monitor panel does not flash
i Carry out this troubleshooting only if swing prolix actually being actuated.
i Before carrying out troubleshooting, check that all the related connectors are properly inserted.
i Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
2 Defective monitor panel Replace
Table
C17
female
20-630 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-23, M24
Cause Remedy
YES
See M-13 d ---
1
Does battery charge caution lamp flash
YES
1. Start engine and run at mid range or 2 Defective monitor panel Replace
above
Does monitoring code 43 show a value
NO greater than 100
1. Start engine and run at mid range or
Defective governor, pump
above Replace
NO controller
2. Set to monitoring code 43
M-24 When start switch is at OFF and time switch is pressed, time and service
meter are not displayed
Cause Remedy
YES
1 Defective monitor panel Replace
PC300LC-6
PC300HD-6 20-631
TROUBLESHOOTING M-25
Cause Remedy
YES Interference with sensor Replace, see
3 inside tank Note 2
YES Is there any large crack,
chip or damage to float
Note 2 There is the possibility of defective installation or interference with the sensor inside the tank, so be careful when
installing.
Note 3 Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
20-632 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-26
Cause Remedy
Table
Note 1 If the problem occurs again, the female connector at the chassis end is probably defective, so check th e
connector and wiring harness at the chassis end.
Note 2 Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
PC300LC-6
PC300HD-6 20-633
TROUBLESHOOTING M-27
Float UP Max 1 S
Float DOWN Min 1 MS
Note 2 If the problem occurs again, the female connector at the chassis end is probably defective, so check th e
connector and wiring harness at the chassis end.
Note 3 Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
Note 4 Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for
any vibration of the mount, and if there is excessive vibration, take the appropriate action.
20-634 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-28
Float UP Max 1 S
Float DOWN Min 1 MS
Note 2 If the problem occurs again, the female connector at the chassis end is probably defective, so check th e
connector and wiring harness at the chassis end.
Note 3 Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
Note 4 Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for
any vibration of the mount, and if there is excessive vibration, take the appropriate action.
PC300LC-6
PC300HD-6 20-635
TROUBLESHOOTING M-29
Float UP Max 1 S
Float DOWN Min 1 MS
Note 2 If the problem occurs again, the female connector at the chassis end is probably defective, so check th e
connector and wiring harness at the chassis end.
Note 3 Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
Note 4 Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check for
any vibration of the mount, and if there is excessive vibration, take the appropriate action.
20-636 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-30
M-30 Wiper does not work or switch is not being used but wiper is actuated
[include E112, E113]
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. Cause Remedy
i Always connect any disconnected connectors before going on to the next step. YES
4 Defective wiper motor Replace
a) Wiper does not work YES Is voltage between pins of W04 as shown in
Table 1
1. Turn start switch off YES
i Check that fuse 7 is normal. Carry out this troubleshooting if service code [E112] or [E113] is displayed. 5 Defective relay box Replace
11
10
PC300LC-6
PC300HD-6
20-637
TROUBLESHOOTING M-30
OFF Max 3 V
ON 20 to 30 V
Table 2 Table 3
Resistance Wiper switch M18 Female P02 Female Resistance
value Between 1 and 2 Between 1 and 4 Min 1 MS
Between W04-1 female and W08-7 female INT mode Between 1 and 4 Between 1 and 12 Max 1 S
Between W04-3 female and W08-6 female Between 2 and 4 Between 4 and 12
Between W04-4 female and P02-5 female Max 1 S Between 1 and 2 Between 1 and 4
Min 1 MS
Between W04-5 female and P02-1 female OFF mode Between 1 and 4 Between 1 and 12
Between W04-6 female and P02-6 female Between 2 and 4 Between 4 and 12
Between W04-1, 3 , 4, 5, 6 and ground Min 1 MS Between 1 and 2 Between 1 and 4 Max 1 S
Between W08-2 female and P02-11 female ON mode Between 1 and 4 Between 1 and 12
Max 1 S Min 1 MS
Between W08-3 female and P02-3 female Between 2 and 4 Between 4 and 12
PC300LC-6
20-638 PC300HD-6
TROUBLESHOOTING
Cause Remedy
YES
4 Defective monitor panel Replace
PC300LC-6
PC300HD-6 20-639
TROUBLESHOOTING
MEMORANDA
20-640 PC300LC-6
PC300HD-6
TROUBLESHOOTING M-31
M-31 Wiper does not work or switch is not being used but washer motor is
actuated [include E114]
i Before carrying out troubleshooting, check that all the related connectors are properly inserted. P02 M28 M28 W08
i Always connect any disconnected connectors before going on the next step. female male female female
Is resistance between relay box W08-16 and Is voltage between H12-16 and chassis
17 normal NO normal
PC300LC-6
PC300HD-6
20-641
TROUBLESHOOTING M-31
b) Switch is not being operated but washer is actuated
i For this failure mode, E114 is not displayed Cause Remedy
YES Defective monitor panel Replace
1
Is resistance between P02-3, M18-3, W08-1 3
and chassis normal
1. Start switch off Short circuit with ground i n
2. Disconnect P02, M18, W08 wiring harness between Repair or replace
3. Min 1 MS NO P02-5 to M18-3 to W08-13
20-642 PC300LC-6
PC300HD-6
30 DISASSEMBLY AND ASSEMBLY
PC300LC-6
PC300HD-6 30-1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
1) When removing or installing a unit, the order of work and techniques used are given for the removal operation;
the order of work for the installation operation is not given,
2) Any special techniques applying only to the installation procedures are marked , and the same mark is
placed after the relevant step in the removal procedure to indicate which step in the installation procedure it
applies to.
[Example]
3. ~~~~~ (3)
......................................... Quantity of oil or water drained.
2. General Precautions
General precautions when carrying out installation o r removal, disassembly or assembly of units are given together
as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying
out the operation.
For details of the operation, part number and quantity of any tools [ A1, etc.] that appears in the operation procedure,
see the SPECIAL TOOLS LIST given in this manual.
30-2 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
i In the case of metric nuts and bolts for which there is no special instructions, tighten to th e
torque given in the table below.
mm mm NCm
6 10 13.2 1.4
8 13 31.4 2.9
10 17 65.7 6.8
12 19 112 9.8
14 22 177 19
16 24 279 29
18 27 383 39
20 30 549 58
22 32 745 78
24 36 927 98
27 41 1320 140
30 46 1720 190
33 50 2210 240
36 55 2750 290
39 60 3280 340
i In the case of flared nuts for which there is no special instructions, tighten to the torque
given in the table below.
i In the case of split flange bolts for which there is no special instructions, tighten to the torque given in table below.
PC300LC-6
PC300HD-6 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
i Precautions when handling piping during disassembly. Fit the following blind plugs into the piping afte r
disconnecting it during disassembly operations.
Nominal number Plug, nut end Sleeve nut, elbow end, use the two items as a set
30-4 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
IF THE PART IS NOT UNDER HYDRAULIC PRESSURE, THE FOLLOWING CORKS CAN BE USED.
Nominal Dimensions
Part Number
number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
i When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic
equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping th e
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder three to four times to the end of its stroke.
4) After doing this, run the engine at normal speed.
i When using the machine for the first time after repair or long storage, follow the same procedure.
PC300LC-6
PC300HD-6 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
30-6 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
i N/R -New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled for items already available for othe r
models.
Blank: Tools already available for other models, used without any modification.
i Tools marked in the sketch column are tools introduced in special sketches. See SKETCHES OF SPECIA L
TOOLS.
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
2 790-101-2510 Block 1
3 792-104-3940 Bolt 2
PC300LC-6
4 01580-11613 Nut 2
2 D&A Push of bearing inner race
Final drive J 5 790-101-2570 Washer 2
6 01642-31645 Washer 1
7 790-105-2100 Jack 1
8 790-101-1102 Pump 1
3 790-331-1110 Wrench 1 D&A Tightening of cover bolt
3 790-101-2550 Leg 2
PC300HD-6
4 709-101-2740 Adapter 2
2 Push of bearing inner race
Final drive J 5 790-101-2560 Nut 2
D&A
6 790-101-2570 Washer 4
7 790-101-2102 Jack 1
8 790-101-1102 Pump 1
PC300LC-6
PC300HD-6 30-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
791-685-8005 Compressor B 1
791-635-3160 Extension 1 Removal, installation of recoil
1 D&A
790-101-1600 Cylinder - 686 kN 1 spring
PC300LC-6
791-685-8005 Compressor B 1
791-635-3160 Extension 1 Removal, installation of recoil
1 D&A
spring
PC300HD-6
30-8 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
1 790-201-3610 Bolt 1
2 796-465-1110 Washer 1
Cylinder block
4 3 01643-33080 Washer 1 D&A of cylinder block
spring
4 01643-32060 Washer 2
5 01582-02016 Nut 1
1 796-720-2250 Screwdriver 1
MAIN PUMP
796-660-1400 Gauge 1
C796-660-1440 CPlate 1
Servo piston
Positioning servo piston swash
swash plate 8 C796-660-1450 CPlate 1
plate angle
angle
C01010-51030 CBolt 1
C01010-51835 CBolt 1
791-101-5201 Push tool kit 1
C01010-51225 CBolt 1
Drive shaft 10 01435-01016 Bolt 1 Measure rotating torque of shaft
Servo valve 11 799-301-1600 Oil leak tester 1 Leak test of servo valve
790-201-2700 Push tool kit 1
Oil Seal 12 Press fit of oil seal
C790-201-2740 CSpacer 1
PC300LC-6
PC300HD-6 30-9
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
3 790-401-1470 Plate 1
C790-101-1430 CCoupler 1
C796-660-1490 CNipple 1
C799-101-5130 CGauge 1
C799-101-5160 CNipple 1
1 Release brake to check drive
Brake release 15 C790-301-1190 CNipple 1
shaft rotating torque
C790-301-1660 CTee 1
C205-70-51390 CNipple 1
C790-301-1210 CJoint 1
C07002-01423 CO-ring 1
2 790-101-1102 Pump 1
SWING MOTOR
2 791-600-1120 Bolt 2
3 01643-31845 Washer 6
Drive shaft 19 Push out drive shaft
4 01580-11613 Nut 6
5 790-105-2100 Jack 1
6 790-101-1102 Pump 1
Drive shaft 20 01435-01220 Bolt 1 Measure shaft rotating torque
1 796T-660-1520 Plate 1
2 01010-51020 Bolt 2
Pump housing 22 Adjust valve plate angle
3 01010-51835 Bolt 4
4 01580-11815 Nut 4
30-10 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
3 790-901-1361 Plate 1
Brake piston 26 799-301-1600 Oil leak tester 1 Pulling out piston
1 796-465-1110 Washer 1
TRAVEL MOTOR - PC300LC-6
2 790-201-3610 Bolt 1
Cylinder block 27 3 01582-02016 Washer 1 Compress cylinder block spring
4 01643-32460 Nut 1
S
5 01643-32060 Nut 1
Main bearing 28 796-465-1120 Push tool 1 Press fit of main bearing
Cylinder block
1 796-465-1131 Push tool 1 Installation of cylinder block
29
and piston and piston
2 01010-51070 Bolt 1
2 01050-52035 Bolt 2
End cover 26 To raise end cover
3 04530-11222 Eye bolt 1
4 01580-11210 Nut 1
TRAVEL MOTOR - PC300HD-6
Sub bearing 790-201-2700 Push tool kit 1 Press fit of sub bearing inner
31
inner race C790-201-2750 CSpacer 1 race
1 796T-660-1320 Guide 1
2 01580-11008 Nut 1
1 796T-660-1330 Plate 1
Drive shaft 32 Drive shaft assembly
2 01580-11008 Nut 1
3
790-201-3200 Bolt kit 1
3
C790-201-3240 CBolt 1
PC300LC-6
PC300HD-6 30-11
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
1 796-660-1350 Positioner 1
2 796-660-1360 Plate 1
Brake plate 33 Positioning of brake plate
3 796-660-1370 Pin 1
4 796-660-1380 Pin 1
C790-101-1430 CCoupler 1
C796-660-1490 CNipple 1
S C799-101-5130 CGauge 1
C799-101-5160 CNipple 1
1
Brake 37 C790-301-1190 CNipple 1 Releasing brake
C790-301-1660 CTee 1
C205-70-51390 CNipple 1
D&A
C790-301-1271 CJoint 1
C07002-01023 CO-ring 1
2 790-101-1102 Pump 1
C790-101-2510 CBlock 1
C790-101-2520 CScrew 1
C791-112-1180 CNut 1
Center swivel
T C790-101-2540 CWasher 1 To disconnect shaft and rotor
joint
C790-101-2630 CLeg 2
C790-101-2570 CPlate 4
C790-101-2560 CNut 2
C790-101-2650 CAdapter 2
30-12 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Qty. N/R Sketch Nature of work, remarks
C01010-50816 CBolt 1
790-201-1500 Push tool kit 1
C790-101-5021 CGrip 1
Installation of dust seal
C01010-50816 CBolt 1
796-670-1100 Remover 1
C796-670-1110 CSleeve 1
C796-670-1120 CPlate 1
C796-670-1130 CScrew 1
C01803-13034 CNut 1
R&I
790-101-4000 Puller 1
790-101-1102 Pump 1
799-703-1200 Service tool kit 1
PC300LC-6
PC300HD-6 30-13
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note: Komatsu cannot accept any responsibility for specia l
tools manufactured according to these sketches.
F Push tool - Swing Machinery
30-14 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
PC300LC-6
PC300HD-6 30-15
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
30-16 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
PC300LC-6
PC300HD-6 30-17
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
30-18 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
PC300LC-6
PC300HD-6 30-19
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
30-20 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
PC300LC-6
PC300HD-6 30-21
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
ENGINE COMPONENTS
STARTING MOTOR
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
ALTERNATOR
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
30-22 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
WATER PUMP
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
NOZZLE HOLDER
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
TURBOCHARGER
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
THERMOSTAT
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
PC300LC-6
PC300HD-6 30-23
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
CYLINDER HEAD
i Refer to ENGINE SHOP MANUAL for proper tools and proce-
dure.
30-24 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
GOVERNOR MOTOR
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-25
DISASSEMBLY AND ASSEMBLY OIL COOLER
OIL COOLER
REMOVAL
WARNING! Loosen the oil filler cap slowly to release th e
pressure inside the hydraulic tank.
Engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 kg
Hydraulic cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
30-26 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
2. Drain coolant.
Engine hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 kg
PC300LC-6
PC300HD-6 30-27
DISASSEMBLY AND ASSEMBLY RADIATOR, OIL COOLER
12. Remove top two bolts of shroud (7) and move it towards engine.
13. Sling radiator and oil cooler (9), remove top and bottom mount
bolts, then lift off radiator and cooler.
i Check the direction of the holder plate at the bottom of the top
mount.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
30-28 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
of battery.
1. Remove hydraulic tank strainer, and using tool S1, stop oil.
i When not using tool S1, remove drain plug, and drain the oi l
from the hydraulic tank and inside the system.
3. Remove main pump top cover (1) and partitions (2 and 3).
PC300LC-6
PC300HD-6 30-29
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
10. Disconnect governor motor connectors (19) and (20) [E04 and
E05].
12. Disconnect the fuel return hose (22) at the injection pump.
15. Disconnect heater hose (25) at engine block behind air cleaner.
30-30 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
PC300LC-6
PC300HD-6 30-31
DISASSEMBLY AND ASSEMBLY ENGINE, MAIN PUMP
21. Remove the engine mounting bolts at the front (32) and th e
rear (33).
22. Make visual check of engine and pump for any remainin g
connected cables, clips, hoses etc.
23. Attach a chain hoist and leveler to engine front (34) and rea r
(35) lifting brackets, then remove from machine.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with coolant through the filler to the specified level. Run
the engine to circulate the coolant through the system. The n
check the coolant level again.
i Charging air conditioner with gas using tool X, charge the air
conditioner circuit with R134a refrigerant.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed the air. For details, see TESTING AND ADJUSTMENT.
30-32 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY DAMPER
DAMPER
REMOVAL
1. Remove main pump. For details, see REMOVAL OF MAIN
PUMP.
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-33
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal NE
G
of the battery.
4. Disconnect fuel supply hose (5), return hose (6), spill hose (7),
and clamp (8).
INSTALLATION
! Carry out installation in the reverse order to removal.
30-34 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
i Mark all the piping with tags to prevent mistakes in the mounting
position when installing.
1. Disconnect travel motor hoses (1) and (2), and speed selector
hose (3).
2. Disconnect drain hose (4), and remove elbow (5). Install a blind
plug in the drain hose.
3. Disconnect drain hoses (7) and (8) and install a blind plug in the
drain hose.
4. Disconnect travel hoses (9) and (10), and speed selector hose
(11). Pull out pin (12), and disconnect plate (13).
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed the air from the travel motor. For details, see TESTING
AND ADJUSTING.
PC300LC-6
PC300HD-6 30-35
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY
1. Remove cover (1).
3. Using puller T, pull out swivel rotor (4) and ring (3) from swivel
shaft (5).
4. Remove o-ring (6) and slipper seal (7) from swivel rotor.
ASSEMBLY
1. Assemble slipper seal (7) and o-ring (6) to swivel rotor.
2. Set swivel shaft (5) to block, then using push tool, tap swive l
rotor (4) with a plastic hammer to install.
30-36 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
7. Sling final drive (6), and remove mounting bolts, then remov e
final drive.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed the air from the travel motor [hydraulic tank]. For details,
see TESTING AND ADJUSTING.
PC300LC-6
PC300HD-6 30-37
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
DISASSEMBLY
1. Remove drain plug and drain oil from final drive case.
30-38 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
A) Push in pin (4), and knock out shaft (5) from carrier (6).
B) Remove thrust washer (7), gear (8), bearing (9), and thrus t
washer (10).
PC300LC-6
PC300HD-6 30-39
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
A) Push in pin (16) and pull out shaft (17) from carrier (18).
30-40 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
PC300LC-6
PC300HD-6 30-41
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
ASSEMBLY
! Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing.
A) Using push tool, press fit bearings (28) and (29) to hub.
i Remove all oil and grease from the o-ring and o-ring contac t
surface, and dry the parts before installing the floating seal.
i After installing the floating seal, coat the sliding surface thinl y
with engine oil.
2. Using tool J4, install floating seal (30) to travel motor (31).
3. Using eyebolts D, set hub (25) to travel motor, then using push
tool, tap to press fit bearing portion.
30-42 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
i Pushing force . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 to 19 kN
i Rotate the hub two to three times before applying the pushing
force to the bearing inner race.
PC300LC-6
PC300HD-6 30-43
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
i Do not coat the threaded portion of the nut with thread tightener
[LT-2].
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
A) Assemble bearing (21) to gear (20), fit top and bottom thrust
washers (19) and (22), and set gear in carrier (18).
i After inserting the pin, stake the pin portion of the carrier.
30-44 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
i Align the position so that the three tips of the gear shafts o f
carrier (15) enter the three hollows in the end face of the motor
case, then install.
11. Fit o-ring to hub end, then using eyebolts C, install ring gea r
(14).
i Install so that the side with two grooves machined in the outside
circumference of the ring gear is at the top [cover end].
i Remove all grease and oil from the mating surface of the ring
gear and hub.
i Do not put any gasket sealant on the mating surface of the ring
gear and hub under any circumstances.
PC300LC-6
PC300HD-6 30-45
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
A) Assemble bearing (9) to gear (8), fit top and bottom thrus t
washers (7) and (10) and set gear to carrier (6).
B) Align position of pin holes of shaft and carrier, then tap with a
plastic hammer to install shaft (5).
i After inserting the pin, stake the pin portion of the carrier.
30-46 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300LC-6
i Tighten drain plug and add engine oil through oil filler.
i Carry out a final check of the oil level at the determined position
after installing the final drive to the chassis.
PC300LC-6
PC300HD-6 30-47
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed the air from the travel motor. For details, see TESTIN G
AND ADJUSTING.
30-48 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
DISASSEMBLY
1. Remove drain plug and drain oil from final drive case.
PC300LC-6
PC300HD-6 30-49
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
A) Push in pin (5), and knock out shaft (6) from carrier (7).
B) Remove thrust washer (8), gear (9), bearing (10), and thrust
washer (11).
30-50 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
A) Push in pin (16) and pull out shaft (17) from carrier (18).
PC300LC-6
PC300HD-6 30-51
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
16. Remove floating seal and cage (27) from hub (32).
30-52 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
ASSEMBLY
! Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing.
1. Using push tool, press fit bearings (31 and 30) to hub (32).
i Remove all oil and grease from the o-ring and o-ring contac t
surface, and dry the parts before installing the floating seal.
i After installing the floating seal, coat the sliding surface thinl y
with engine oil.
PC300LC-6
PC300HD-6 30-53
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
i Remove all oil and grease from the o-ring and o-ring contac t
surface, and dry the parts before installing the floating seal.
i After installing the floating seal, coat the sliding surface thinl y
with engine oil.
5. Using eyebolts C, set hub (25) to travel motor, then using push
tool, tap to press fit bearing portion.
i Pushing force . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 to 25 kN
i Rotate the hub two to three times before applying the pushing
force to the bearing inner race.
30-54 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
E) Install lock plate (23); bring lock plate Z and spline into tigh t
contact.
PC300LC-6
PC300HD-6 30-55
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
A) Assemble bearing (21) to gear (20), fit top and bottom thrust
washers (19) and (22), and set gear in carrier (18).
i After inserting the pin, stake the pin portion of the carrier.
i Align the position so that the four tips of the gear shafts of carrier
(15) enter the four hollows in the end face of the motor case ,
then install.
i Assemble an o-ring to the face mating with the hub. 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.
30-56 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
A) Assemble bearing (10) to gear (9), fit top and bottom thrus t
washers (8) and (11) and set gear to carrier (7).
B) Align position of pin holes of shaft and carrier, then tap with a
plastic hammer to install shaft (6).
i After inserting the pin, caulk the pin portion of the carrier.
PC300LC-6
PC300HD-6 30-57
DISASSEMBLY AND ASSEMBLY FINAL DRIVE - PC300HD-6
16. Using eyebolts A, install cover (1), then using angle tightenin g
wrench J3, tighten mounting bolts.
17. Tighten drain plug and add engine oil through oil filler.
i Carry out a final check of the oil level at the determined position
after installing the final drive to the chassis.
30-58 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
TRAVEL MOTOR
DISASSEMBLY
1. Set travel motor (1) to tool S25.
2. Loosen plug (2) slowly and remove, then remove spring (3) and
piston (4).
3. Turn over tool S25 and remove safety valve (5). Loosen plug (6)
slowly. Lift off end cover (7).
i The valve plate may be stuck to the end cover, so be careful not
to drop it.
PC300LC-6
PC300HD-6 30-59
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
A) Loosen plug (6) slowly and remove, then remove spring (11),
piston (12), and spool (13).
B) Remove plug (14), then remove spring (15) and valve (16).
30-60 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
8. Blow in compressed air with tool S26, and remove brake piston
(26).
i Be careful that the air pressure is not too high. The brake piston
will fly out.
10. Rotate tool S25 90E, and remove cylinder block and piston (28)
from motor case (29).
11. Remove plate (30) and disc (31). Pull out piston (33) from cylin-
der block (32), and remove retainer guide (34) and preload pin
(35).
i When removing the piston from the cylinder block, the preload
pin may come out, so be careful not to lose it.
PC300LC-6
PC300HD-6 30-61
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
13. Set tool S27 to cylinder block (32). Hold bolt of tool with wrench,
tighten nut to compress spring, then remove snap ring (38) .
Loosen nut of tool slowly to relieve tension of spring (39), then
remove tool. Remove spacer (40), spring (39), and spacer (40)
from cylinder block (32).
14. Remove rocker cam (41) together with shaft (42) from motor
case (29).
15. Using push tooI C, remove bearing (44) from shaft (43).
30-62 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
16. Remove ball (45). Rotate tool S25 90E, remove snap ring (46)
from motor case (29), then remove spacer (47). Remove oil
seal (48) and outer race (49).
17. If above disassembly operation is not needed, and only oil seal
is to be replaced, replace oil seal as follows:
B) Using bar G [hit end face with hammer], hit through to core of
oil seal (48), then twist to remove.
PC300LC-6
PC300HD-6 30-63
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
ASSEMBLY
! Clean all parts, remove all burrs, and check for dirt or damage.
Coat rotating and sliding surfaces of all parts with oil befor e
installing. Always check the following parts before assembling.
i When pressing the bearing, push the end face of the bearin g
inner race with tool S28 and press until it is in tight contact with
the end face of the shaft.
4. Install rocker cam (41) to motor case (29) together with shaf t
(42).
i When installing the rocker cam, check contact with the ball, and
check that the rocker cam moves smoothly without interfering
with the motor case or shaft.
i Coat the ball hole in the rocker cam with grease [G2-LI]. T o
prevent the ball from coming out when the cylinder block an d
piston is assembled.
30-64 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
i Coat the preload pins with grease [G2LI] to prevent them from
coming out.
i Align the cylinder block and the spline of the retainer guide.
9. Secure shaft in position with tool S29. Rotate tool S25 90E and
set opening of motor case facing side.
PC300LC-6
PC300HD-6 30-65
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
10. Install cylinder block and piston (28) to motor case (29).
i Align the spline of the cylinder block and piston with the spline
of the shaft, then install.
12. Align cutout arc teeth areas G, H, and I of the discs. Protrusions
A, B, C, D, E, and F on the outside of the plates can be set a t
any position in relation to positions G, H, and I of discs.
13. Fit o-ring (c) and backup ring (a), and install brake piston (26).
30-66 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
14. Using tool S30 and puller E, press bearing (27) to shaft (43).
i When pressing the bearing, push the end face of the bearin g
inner race with tool S30 and press until it is in tight contact with
the end face of the shaft.
15. Assemble spacer (10) to end cover (7), and install outer rac e
(9).
16. Align with dowel pin and install valve plate (8) to end cover (7).
18. Fit dial gauge F to motor case (29), move shaft in axial direction,
and measure end play between shaft and bearing.
PC300LC-6
PC300HD-6 30-67
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
b = 12.95 - a
b mm 1.70 to 1.79 1.80 to 1.89 1.90 to 1.99 2.00 to 2.09 2.10 to 2.19 2.20 to 2.29 2.30 to 2.39
i Remove all oil and grease from the plug and female thread [end
cover], and dry completely. When coating with adhesive, coa t
with two drops [. 0.04 g] at a point (a) 2 to 3 mm from the tip of
the thread of the plug.
i Do not apply any pressure to the plug for thirty minutes afte r
tightening.
30-68 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
A) Assemble valve (24), then fit o-ring and install plug (23).
B) Assemble ball (22), then fit o-ring and install plug (21).
C) Assemble spool (20), spring (19), and seat (18) in order, then
fit o-ring and install ring (17).
D) Assemble valve (16) and spring (15) in order, then fit backup
ring and o-ring and install plug (14).
23. Align with dowel pin, and install valve plate (8) to end cover (7).
PC300LC-6
PC300HD-6 30-69
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
27. Fit backup ring and o-ring, and install safety valve (5).
28. Assemble piston (4) and spring (3), then fit o-ring and instal l
plug (2).
A) Remove all oil and grease from the plug and female threa d
[motor case], and dry completely.
i Press until the end face of the motor case contacts tool S31.
Clean the oil seal lip.
30-70 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300LC-6
1. Make a centering tool A for the cylinder block and valve plate.
i The tool can be made from plastic, bakelite or any other sof t
material.
2. Remove all oil and grease from the parts to be checked. Do not
wipe with a cloth.
3. Set the tool in position, then paint the cylinder block wit h
inspection paint. Coat thinly with paint.
i The contact of the plane surface of the valve plate and cylinder
block must fulfill the conditions below and must cover the whole
circumference without any break.
PC300LC-6
PC300HD-6 30-71
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
TRAVEL MOTOR
DISASSEMBLY
1. Set travel motor (1) to tool S25.
A) Remove plug (2), then remove spring (3) an d E) Remove plug (13).
check valve (4).
F) Remove plug (14), then remove ball (15).
B) Remove plug (5), then remove spring (6), pisto n
(7), and spool (8). G) Remove plug (16), then remove valve (17).
C) Remove safety valve (9). H) Remove plug (18), then remove valve (19).
D) Remove plug (10), then remove regulator valv e I ) Remove plugs (20), (21), and (22), then remov e
(11) and spring (12). sleeve (23) and bleeder (24).
30-72 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
i The valve plate may be stuck to the rear face, so be careful not
to drop it.
4. Remove screw (26), pull out pin (27), then remove regulato r
pistons (28).
PC300LC-6
PC300HD-6 30-73
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
10. Set tool S28 to port hole for brake piston. Apply pressur e
gradually until brake piston (37) comes up.
i Be careful that the air pressure is not too high. The brake piston
will fly out.
13. Turn over tool S25. Remove snap ring (40), then remove cover
(41).
30-74 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
15. Rotate tool S25 90E and set opening of motor case facing side.
Tap end face of drive shaft with plastic hammer to remove drive
shaft and bearing (43).
17. Set drive shaft and bearing (43) to tool S29. Set push tool A to
drive shaft, then push with press to remove drive shaft and main
bearing inner race.
18. Remove sub bearing inner race (46), outer race (47), retaine r
(48), and main bearing outer race (49).
PC300LC-6
PC300HD-6 30-75
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
19. Remove main bearing inner race (51) from drive shaft (50).
ASSEMBLY
Precautions when assembling
A) Clean all parts, remove all burrs, and check for dirt or dam-
age.
B) Coat the rotating and sliding surfaces of all parts with engine
oil before installing.
1. Using tool S30, press main bearing (51) to drive shaft (50).
i Press until the end face of the inner race is in tight contact with
the end face of the drive shaft.
i Press load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 kN
3. Using tool S31, press sub bearing inner race (46) to drive shaft
(50).
i Press until the roller of the inner race is in tight contact with the
outer race.
i Press load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 kN
30-76 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
7. Support main bearing outer race (49) with tool S29. Apply load
to drive shaft (50) until top surface of sub bearing inner rac e
(46), spacer (45), and snap ring (44) are all in tight contact with
each other.
i If the spacers can be rotated or are not fully in tight contact, ad-
just again.
PC300LC-6
PC300HD-6 30-77
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
i After tightening, wipe off any adhesive that has been squeezed
out.
i Check that the large ball of the piston and the center shaft move
smoothly.
30-78 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
12. Assemble spring (32) and center ring (33) in turn in center shaft
hole of cylinder block (31).
13. Turn over drive shaft (43), and use eyebolt B [10x1.5 mm,
length below head: . 85 mm] to raise drive shaft.
14. Align center shaft and piston with each hole in cylinder bloc k
(31), then install drive shaft (43).
15. Set motor case (52) to tool S25. Raise drive shaft and cylinder
block (53) with tool S32-2 and install motor case (52).
16. Set tool S32-1 in position and hold cylinder block (31) at center
position.
PC300LC-6
PC300HD-6 30-79
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
17. Install tool S32-3 to drive shaft, then press until end face of main
bearing outer race is in tight contact with case.
i Press load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 kN
i Number of plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
i Number of discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19. Fit o-ring (c) and backup ring (a) to brake piston (37).
30-80 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
20. Install brake piston (37) to motor case (52), and determin e
position with tool S33.
i Install tool S33 in the position shown in the diagram on the right
in relation to port hole a for the brake piston.
22. Using tool S34, press fit dowel pin (54) to end cover (25) t o
dimension z shown.
i Dimension z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 0.3 mm
PC300LC-6
PC300HD-6 30-81
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
25. Install valve plate (29) to end cover (25). Pass tool S35 through
plug hole and secure valve plate (29) in position.
i Align the hole in the valve plate exactly with pin (27) of th e
regulator piston.
i Check that the valve plate moves smoothly in the end cove r
mounting groove.
30-82 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
PC300LC-6
PC300HD-6 30-83
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR - PC300HD-6
B) Using tool S38, rotate drive shaft at low speed [5 sec/1 turn]
and measure rotating torque and variation.
31. Using tool S39, press oil seal (42) to cover (41).
32. Install cover (41), and secure with snap ring (40).
30-84 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SPROCKET
SPROCKET
REMOVAL
1. Remove track shoe. For details, see TRACK SHOE.
Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-85
DISASSEMBLY AND ASSEMBLY SWING MOTOR
SWING MOTOR
REMOVAL
WARNING! Release the remaining pressure in the hydraulic
circuit. For details, see TESTING AND ADJUSTING.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed the air from the swing motor. For details, see TESTING
AND ADJUSTING.
30-86 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR
DISASSEMBLY
1. Set swing motor (1) to tool S13.
2. Remove covers (2), then remove springs (3) and sleeves (4) .
Remove housing mounting bolts (5).
PC300LC-6
PC300HD-6 30-87
DISASSEMBLY AND ASSEMBLY SWING MOTOR
10. Using tool S24, pump in air through port B and remove brake
piston (15).
i Be careful that the air pressure is not to high. The brake piston
will fly out.
14. Remove case from tool S13 and turn over. Remove snap ring
(20), then remove cover (21).
16. Remove snap ring (23), then remove two spacers (24).
30-88 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR
17. Set case to press and remove shaft (25) from case (26).
19. Remove bearing inner race (29) from case. Remove bearin g
outer race (30). Remove seat (31) and belleville spring (32) .
Remove main bearing outer race (33).
ASSEMBLY
! Clean all parts, remove all burrs and check for dirt or damage.
Coat the rotating parts and sliding surfaces of all parts wit h
engine oil before installing. Using chromium oxide, remove al l
the lapping powder from the places that have been lapped.
i Press until the end face of the inner race is in tight contact with
the shaft.
i Press load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 39 kN
PC300LC-6
PC300HD-6 30-89
DISASSEMBLY AND ASSEMBLY SWING MOTOR
6. Using tool S18, press bearing (29). During the press operation,
rotate case (26) and check that the bearing rotates smoothly .
Press until seat (31) is in tight contact with case (26).
30-90 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR
i Check that the snap ring is fitted securely in the snap rin g
groove.
9. Set tool S19 to case (26), then push out drive shaft under load
given below until end face of bearing inner race (29) is in tigh t
contact with spacer (24) and snap ring (23).
11. Check clearance between case (26) and seat (31) as follows:
PC300LC-6
PC300HD-6 30-91
DISASSEMBLY AND ASSEMBLY SWING MOTOR
C) Set motor case to tool S13, then use tool S20 to measure
rotating torque of drive shaft.
12. Using tool S21, press oil seal (22) until it is in tight contact with
cover (21).
i Be careful not to damage the lip of the oil seal when installing
the cover.
14. Assemble plates (19) qty. two, then alternate disc (18) qty. three
and plate (17) qty. three to case, ending with plate (17).
30-92 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR
17. Set seven pistons (14) and center shaft in position. Using too l
S14, tighten 7 retainer mounting screws.
i Remove all oil and grease from the thread [male and female ]
and dry completely.
i Check that the large ball of piston (14) and center shaft (13 )
move smoothly.
18. Using dial gauge E, measure play of piston (14) in axial direc -
tion.
19. Set housing (6) to tool S13 together with tool S22, then adjust
angle so that valve plate mounting surface is horizontal. Install
valve plate (18).
PC300LC-6
PC300HD-6 30-93
DISASSEMBLY AND ASSEMBLY SWING MOTOR
21. Install six springs (7) to housing. Press dowel pin (34).
22. Using tool S23, knock in the dowel pin so that the dimension a
is the standard value.
Standard dimension a . . . . . . . . . . . . . . . . . 8 to 10 mm
24. Raise motor case, align with housing and lower slowly, alig n
seven center shaft pistons with holes in cylinder block, the n
install housing (6).
i Align the positions of the dowel pin and motor case exactly when
installing.
25. Set swing motor to tool S13. Install sleeves (4), springs (3) and
covers (2).
30-94 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MOTOR
i When checking the rotating torque, check that the shaft rotates
smoothly without any variations.
PC300LC-6
PC300HD-6 30-95
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
SWING MACHINERY
REMOVAL
1. Remove swing motor. For details, see SWING MOTOR.
INSTALLATION
! Carry out installation in the reverse order to removal.
30-96 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLY
1. Loosen drain plug and drain oil from swing machinery.
A) Push in pin (5), and knock out shaft (6) from carrier (7).
B) Remove thrust washer (8), gear (9), bearing (10), and thrust
washer (11).
PC300LC-6
PC300HD-6 30-97
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
7. Remove thrust washer (13) and collar (14), then remove # 1 sun
gear (15).
30-98 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
A) Push in pin (18), and knock out shaft (19) from carrier (17).
11. Remove bolt (24), then remove holder (25). Remove gear (26).
12. Turn over case and pinion, then remove mounting bolts (28) of
cover (27).
13. Turn over case and pinion (29), and set on press stand, the n
using push tool A, remove pinion shaft (30) with press.
PC300LC-6
PC300HD-6 30-99
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
14. Using push tool B, remove cover (27) and bearing (31) fro m
shaft (32). Remove oil seal (33) from cover (27).
15. Using push tool, remove bearing (34) from case (35).
ASSEMBLY
! Clean all parts, and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing.
2. Using push tool D, press fit oil seal (33) to cover (27).
i Be careful not to let the gasket sealant [LG-6] get on the oil seal
lip when press fitting.
30-100 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
3. Fit cover (27) to case (35), and tighten mounting bolts (28).
i Be careful not to let the gasket sealant [LG-6] get on the oil seal
lip when press fitting.
4. Set case (35) to shaft (32), then using push tool E, press fit
bearing inner race portion.
i Press the bearing inner race and outer race at the same tim e
when press fitting. Do not press only the inner race when press
fitting.
i After press fitting bearing, check that the case rotates smoothly.
6. Assemble gear (26), then fit holder (25) and tighten bolt (24).
PC300LC-6
PC300HD-6 30-101
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
7. Assemble bearing (22) to gear (21), fit top and bottom thrus t
washers (23) and (20) and set gear to carrier (17).
8. Align with position of pin holes of shaft and carrier, then tap with
a plastic hammer to install shaft (19).
i After inserting the pin, stake the pin portion of the carrier.
i Align the position so that the tip of the gear shaft enters at four
places, then install.
30-102 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
12. Install # 2 sun gear (15) to # 2 carrier, then install collar (14) and
thrust washer (13).
i There are the remains of the staking when the pin is inserted at
the end face of hole h at the side of the carrier, so remove the
staked metal from the inside diameter of the hole before starting
to assemble.
14. Assemble bearing (10) to gear (9), fit top and bottom thrus t
washers (8) and (11) and set gear to carrier (7).
15. Align position of pin holes of shaft and carrier, then tap with a
plastic hammer to install shaft (6).
i After inserting the pin, stake the pin portion of the carrier.
PC300LC-6
PC300HD-6 30-103
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
18. Assemble # 1 sun gear (3) to carrier. Install thrust washer (2).
20. Tighten drain plug and add engine oil through oil filler.
30-104 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REVOLVING FRAME
REMOVAL
1. Remove work equipment. For details, see WORK EQUIPMENT.
WARNING! When disconnecting the hydraulic hoses ,
release the remaining pressure in the hydraulic circuit. Fo r
details, see TESTING AND ADJUSTING.
3. Raise boom cylinder (2), then pull out foot pin (3) and lift off .
Remove the right cylinder in the same way.
5. Remove engine hood (4), cover (5), and frame (6). For details
of the method of removing the engine hood, see HYDRAULIC
COOLER.
8. Disconnect travel hoses (9) and (10), and speed selector hose
(11).
9. Pull out pin (12), and disconnect plate (13) from swivel joint.
PC300LC-6
PC300HD-6 30-105
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
10. Sling revolving frame (14), then remove mounting bolts, and lift
off revolving frame.
i Loosen the mounting bolts remaining at the front and rear and
adjust the center of gravity with the lever block while lifting off.
INSTALLATION
! Carry out installation in the reverse order to removal.
30-106 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
SWING CIRCLE
REMOVAL
1. Remove the revolving frame. For details, see REVOLVIN G
FRAME.
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-107
DISASSEMBLY AND ASSEMBLY IDLER AND RECOIL SPRING
2. Sling idler and recoil spring (2) and pull out to the front t o
remove.
i Fit wire to the idler and spring of the idler and recoil sprin g
assembly, and adjust the balance when removing.
INSTALLATION
! Carry out installation in the reverse order to removal.
i When installing the idler and recoil spring, assemble so that the
position of the greasing plug on t he idler is on the outside for the
right side of the machine and on the inside for the left side of the
machine.
30-108 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY IDLER AND RECOIL SPRING
2. Sling idler and recoil spring (2) and pull out to the front t o
remove.
i Fit wire to the idler and spring of the idler and recoil sprin g
assembly, and adjust the balance when removing.
INSTALLATION
! Carry out installation in the reverse order to removal.
i When installing the idler and recoil spring, assemble so that the
position of the greasing plug on t he idler is on the outside for the
right side of the machine and on the inside for the left side of the
machine.
PC300LC-6
PC300HD-6 30-109
DISASSEMBLY AND ASSEMBLY IDLER
IDLER - PC300LC-6
DISASSEMBLY
1. Remove pin (1), then remove support (2).
2. Remove floating seal (3) from support (2) and idler (4).
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 cc
5. Remove pin (8), then remove support (9) from shaft (7).
30-110 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY IDLER
ASSEMBLY
1. Press fit bushing (5) to idler (4).
2. Fit o-ring and install support (8) to shaft (7), then install pin (9).
i After inserting the pin, stake the pin portion of the support.
3. Using tool L1, install floating seal (6) to idler (4) and support.
PC300LC-6
PC300HD-6 30-111
DISASSEMBLY AND ASSEMBLY IDLER
5. Using tool L1, install floating seal (3) to idler (4) and support (2).
30-112 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY IDLER
6. Install o-ring, then assemble support (3) and install pin (2).
i After inserting the pin, stake the pin portion of the support.
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 cc
IDLER - PC300HD-6
DISASSEMBLY
1. Remove nut (1), pull out bolt (2), then remove support (3).
2. Remove floating seal (4) from support (3) and idler (5).
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 cc
PC300LC-6
PC300HD-6 30-113
DISASSEMBLY AND ASSEMBLY IDLER
5. Remove nut (8), pull out bolt, then remove support (10) fro m
shaft (11).
ASSEMBLY
1. Press fit bushing (6) to idler (5).
2. Fit o-ring and install support (10) to shaft (11), then install bolt
and tighten with nut (8).
3. Using tool L1, install floating seal (7) to idler (5) and support.
30-114 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY IDLER
5. Using tool L1, install floating seal (4) to idler (5) and support (3).
PC300LC-6
PC300HD-6 30-115
DISASSEMBLY AND ASSEMBLY IDLER
6. Install o-ring, then assemble support (3) and install bolt (2) and
tighten nut (1).
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 cc
30-116 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
RECOIL SPRING
DISASSEMBLY
PC300LC-6
PC300HD-6 30-117
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY
1. Assemble piston as follows:
A) Assemble ring (14) and U-packing (13) to piston (9), an d
secure with snap ring (12).
B) Tighten valve (11) and secure with lock plate (10).
30-118 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
TRACK ROLLER
REMOVAL
1. Lower work equipment to ground, then loosen lubricator (1), and
relieve track tension.
2. Remove the mounting bolts of track roller guard (2), then swing
the work equipment 90E, jack up the machine with work
equipment, and remove the track roller guard (2) the toward s
outside of machine.
PC300LC-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kg
PC300HD-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-119
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY
2. Remove floating seal (3) from collar (2) and roller (4).
5. Remove pin (7), then remove collar (8) from shaft (5).
30-120 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
ASSEMBLY
1. Using push tool A, press fit bushings (9) and (10) to roller (4).
4. Using tool L3, install floating seals (6) and (3) to roller (4) as per
preceding step.
PC300LC-6
PC300HD-6 30-121
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
7. Using tool L3, install floating seal (3) to collar (2) per preceding
step.
9. Using tool L4, apply standard pressure to roller oil filler port, and
check for leakage of air from seal.
10. Using tool L4, fill track roller with oil, then tighten plug (11).
PC300LC-6 Track roller . . . . . . . . . . . . . . 250 to 280 cc
PC300HD-6 Track roller . . . . . . . . . . . . . . 280 to 310 cc
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5 NCm
30-122 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
PC300LC-6
PC300HD-6 30-123
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
CARRIER ROLLER
REMOVAL
1. Lower work equipment to ground, then loosen lubricator (1), and
relieve track tension.
Carrier roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
30-124 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY
6. Using push tool B, pull out shaft (5) from roller (6) with press ,
then remove inner race (7).
PC300LC-6
PC300HD-6 30-125
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
ASSEMBLY
1. Using push tool E, press outer races (8) and (9) to roller (6).
30-126 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
i After inserting the floating seal, check that the angle of the seal
is less than 1 mm and that the protrusion of the seal a is within
a range of 5 to 7 mm.
4. Assemble floating seals (11), then using push tool F, press inner
race (10) per preceding step.
PC300LC-6
PC300HD-6 30-127
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
11. Using tool L8, apply standard pressure to roller oil filler port, and
check for leakage of air from seal.
12. Using tool L8, fill carrier roller with oil, then tighten plug (1).
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5 NCm
30-128 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRACK CHAIN
TRACK CHAIN
REMOVAL
1. Stop the machine at a point where it is easy to set master pi n
removal tool R, and where master pin is in the middle of th e
track frame, then loosen lubricator (1), and relieve the trac k
tension.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Use tool R and press fit so that the protrusion of the master pin
is dimension a.
PC300LC-6
PC300HD-6 30-129
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
HYDRAULIC TANK
REMOVAL
! Swing the upper structure to set the position of the hydrauli c
tank drain and mounting bolt outside the track.
WARNING! Loosen the hydraulic tank oil filler cap slowly to
release the pressure inside the hydraulic tank.
1. Drain oil from hydraulic tank.
4. Open main pump side cover, then remove partitions (1) and (2).
8. Disconnect hydraulic oil filte r inlet hose (9) and outlet hose (10).
30-130 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
13. Remove mounting bolts and lift off hydraulic tank (17).
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
PC300LC-6
PC300HD-6 30-131
DISASSEMBLY AND ASSEMBLY MAIN PUMP
MAIN PUMP
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal NE
G
3. Remove main pump top cover (1) and partitions (2) and (3).
30-132 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
10. Sling main pump (19), remove mounting bolts, then lift off.
Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
Involute spline . . . . . . Anti-friction compound [LM-G]
i Refill with oil [damper case] through the oil filler to the specified
level. Run the engine, then stop the engine, wait for 15 minutes
and check the oil level again.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
PC300LC-6
PC300HD-6 30-133
DISASSEMBLY AND ASSEMBLY MAIN PUMP
DISASSEMBLY
PUMP ASSEMBLY
1. Install pump (1) to tool S3. Remove hose (2) and fittings.
2. Sling rear pump (3). Remove 8 bolts at rear pump end, then re-
move rear pump (3).
i Leave the end cap at the front end.
i Be careful not to drop the rear pump valve plate, cylinder block,
piston, or other parts.
FRONT PUMP
Servo Valve
1. Remove servo valve (4).
TVC VALVE
A) Remove solenoid (5), then remove sleeve (6) and spool (7).
B) Remove seat (8), then remove springs (9) and (10).
C) Remove plug (11), then remove piston (12).
D) Remove locknut (13), then remove plug (14) and lever (15).
E) Remove nut (16) from lever (15), then remove washer (17) ,
bearing (18), pin (19) and lever (20).
F) Remove snap ring (21), then remove plug (22).
LS VALVE
i Measure the dimension between the end face of locknut (23 )
and the end face of plug (24).
A) Remove locknut (23), then remove plug (24), seat (25), spring
(26) and seat (27).
B) Remove plug (28), then remove sleeve (29), piston (30) and
spool (31).
2. Remove filter (32), then remove spacer (33) and orifice (34).
30-134 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
2. Remove 8 mounting bolts (37), then lift off end cap (35).
i If the valve plate is stuck to end cap, be careful not to drop it.
i Measure protrusion L of maximum swash plate angle adjust-
ment screw (38).
4. Loosen locknut (40) and remove screw (38) and washer (41) .
Remove bearings (42) from end cap (35). Remove couplin g
(43).
1. Remove cylinder block and piston (44) from pump case (45).
i The cylinder block and piston may come off separately, so b e
careful not to drop them.
2. Pull out piston (46) from cylinder block (47) and retainer guide
(48) and three preload pins (49).
i When removing the piston from the cylinder block, the preload
pins may come out, so be careful not to lose them.
PC300LC-6
PC300HD-6 30-135
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Servo Piston
1. Remove mounting screws with tool S5, then remove cover (56).
30-136 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
5. Move to side and loosen piston (61) so that width across flats of
rocker cam comes off from width across flats of cradle.
i Be careful not to let the bolt portion of tool S6 come off the rod.
2. Remove six bolts, then remove shaft and cradle (64) from front
pump case (45).
PC300LC-6
PC300HD-6 30-137
DISASSEMBLY AND ASSEMBLY MAIN PUMP
3. Push cradle (64) with push tool B to remove it from shaft (65).
When removing, be careful to keep cradle straight.
i Bearing (68) divides into the flange ring and the bearing, so be
careful not to lose either part. Check the installation direction of
the bearing.
Pump Case
2. Using bar D [hit end face with hammer], hit through to core of oil
seal (73), then twist to remove.
REAR PUMP
Servo Valve
30-138 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
TVC VALVE
A) Remove solenoid (75), then remove sleeve (76) and spoo l
(77).
B) Remove seat (78), then remove springs (79) and (80).
C) Remove plug (81), then remove piston (82).
D) Remove locknut (83), then remove plug (84) and lever (85).
E) Remove nut (86) from lever (55), then remove washer (87) ,
bearing (88), pin (89) and lever (90).
F) Remove snap ring (91), then remove plug (92).
LS VALVE
i Measure the dimension between the end face of locknut (93 )
and the end face of plug (94).
A) Remove locknut (93), then remove plug (94), seat (95), spring
(96) and seat (97).
B) Remove plug (98), then remove sleeve (99), piston (100) and
spool (101).
2. Remove filter (102), then remove spacer (103) and orifice (104).
2. Pull out piston (106) from cylinder block (107) and retaine r
guide (108) and three preload pins (109).
i When removing the piston from the cylinder block, the preload
pins may come out, so be careful not to lose them.
PC300LC-6
PC300HD-6 30-139
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Servo Piston
30-140 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
4. Move to side and loosen piston (121) so that width across flats
of rocker cam comes off from width across flats of cradle.
i Be careful not to let the bolt portion of tool S6 come off the rod.
2. Remove six bolts, then remove shaft and cradle (124) from front
pump case (74).
3. Push cradle (124) with push tool B to remove it from shaft (125).
When removing, be careful to keep cradle straight.
PC300LC-6
PC300HD-6 30-141
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Pump Case
30-142 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
ASSEMBLY
i Clean all parts, remove all burrs and check for dirt or damage.
Coat the rotating and sliding surfaces of all parts with engine oil
before installing.
! Always check the following parts before assembling.
A) Check contact of cradle and rocker cam [for details, se e
procedure for checking contact].
B) Check contact between cylinder block and valve plate [fo r
details, see procedure for checking contact].
C) Check contact between valve plate and end cap [for details,
see procedure for checking contact].
FRONT PUMP
Shaft and Cradle
1. Assemble flange ring (*) to shaft (65), then use tool S7 to press
fit bearing (68).
Press fit surface of bearing . . . . . . . . . . Grease [G2-LI]
i When press fitting the bearing, push the end face of the bearing
inner race with tool S7.
2. Assemble washer (67) and install snap ring (66).
i When press fitting the bearing, push the end face of the bearing
outer race with push tool G.
PC300LC-6
PC300HD-6 30-143
DISASSEMBLY AND ASSEMBLY MAIN PUMP
i Check that there is no rising and that the pin does not fall out.
Servo Piston
2. Fit piston (61), set tool S6 on opposite side from when loosen-
ing, set spacer A on front end of rod (60) and tighten piston (61).
i Before tightening piston (61), move to the side so that the width
across flats of the rocker cam comes out from the width across
flats of the cradle. This is to prevent damage to the rocker cam
and cradle when tightening the piston.
30-144 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
1. Remove two dowel pins from servo valve mounting surface. Set
tool S8 in position. Assemble o-ring and tighten screw (70) until
it contacts piston (61). Tighten locknut (69) to hold screw (70) in
position.
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3 NCm
1. Assemble seat (55), spring (53) and seat (54) to block (47).
PC300LC-6
PC300HD-6 30-145
DISASSEMBLY AND ASSEMBLY MAIN PUMP
End cap
1. Using tool S9, assemble one bearing (42) to end cap (35), then
turn over end cap.
i Press fit the bearing until it comes into contact with other end.
Press fit surface of bearing . . . . . . . . . . Grease [G2-LI]
4. Fit washer (41) and locknut (40) to screw (38), then install t o
end cap (35).
30-146 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
i Align the dowel pin and pin hole to install. Check that there is no
interference with the bearing and cap. Check that the end cap
and valve plate holes are aligned.
i Do not hit the valve plate or apply any impact when assembling.
There is danger that this will damage the sliding surface o r
cause distortion.
Servo Piston
PC300LC-6
PC300HD-6 30-147
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Servo Valve
1. Assemble servo valve.
LS VALVE
A) Assemble spool (31), piston (30) and sleeve (29) to body ,
then fit o-ring and install plug (28).
Plug (28) . . . . . . . . . . . . . . . . . . . . . . . . . . 110 12 NCm
i Check that the relative movements of the body and spool (31)
and sleeve (29) and piston (30) are smooth.
B) Assemble seat (27), spring (26) and seat (25), then fit backup
ring and o-ring and install plug (24).
C) Tighten locknut (23).
Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 10 NCm
i lnstall so that the dimension between the end face of locknu t
(23) and the end face of plug (24) is the dimension measure d
during disassembly.
D) After completion of assembly, carry out a bench test of th e
performance and make final adjustment of plug (24).
TVC VALVE
A) Fit o-ring and assemble plug (22), then install snap ring (21).
Install pin (19), washer (17), bearing (18) and nut (16) to lever
(20) to make lever (15).
Nut (16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 NCm
30-148 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
2. Assemble orifice (34) and install spacer (33), filter (32) and o-
ring.
Orifice (34) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 NCm
3. After completion of assembly, carry out bench test of serv o
valve (4) as an individual part to check performance and carry
out adjustment.
4. Fit o-ring and filter to servo valve (4) and install to pump case.
i Install the filter so that the mesh end is at the front face end of
the valve body.
i Be extremely careful that the o-ring and filter do not fall out.
i Tighten the mounting bolts gradually in turn on opposite sides.
PC300LC-6
PC300HD-6 30-149
DISASSEMBLY AND ASSEMBLY MAIN PUMP
REAR PUMP
i When press fitting the bearing, push the end face of the bearing
inner race with tool S7.
i When press fitting the bearing, push the end face of the bearing
outer race with push tool G.
30-150 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
i Check that there is no rising and that the pin does not fall out.
Servo Piston
2. Fit piston (121), set tool S6 on opposite side from when loosen-
ing, set spacer A on front end of rod (120) and tighten pisto n
(121).
i Before tightening piston (121), move to the side so that the width
across flats of the rocker cam comes out from the width across
flats of the cradle. This is to prevent damage to the rocker cam
and cradle when tightening the piston.
PC300LC-6
PC300HD-6 30-151
DISASSEMBLY AND ASSEMBLY MAIN PUMP
1. Remove two dowel pins from servo valve mounting surface. Set
tool S8 in position. Assemble o-ring and tighten screw (130) until
it contacts piston (121). Tighten locknut (129) to hold scre w
(130) in position.
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3 NCm
30-152 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
i To prevent the preload pins from coming out, coat the pins with
grease [G2LI].
i Align the spline for the cylinder block and retainer guide.
Servo Piston
PC300LC-6
PC300HD-6 30-153
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Servo Valve
1. Assemble servo valve.
LS VALVE
A) Assemble spool (101), piston (100) and sleeve (99) to body,
then fit o-ring and install plug (98).
Plug (98) . . . . . . . . . . . . . . . . . . . . . . . . . . 110 12 NCm
i Check that the relative movements of the body and spool (101)
and sleeve (99) and piston (100) are smooth.
B) Assemble seat (97), spring (96) and seat (95), then fit backup
ring and o-ring and install plug (94). Tighten locknut (93).
Locknut (93) . . . . . . . . . . . . . . . . . . . . . . . . . 69 10 NCm
i lnstall so that the dimension between the end face of locknu t
(93) and the end face of plug (94) is the dimension measure d
during disassembly.
C) After completion of assembly, carry out a bench test of th e
performance and make final adjustment of plug (94).
TVC VALVE
A) Fit o-ring and assemble plug (92), then install snap ring (91).
Install pin (89), washer (87), bearing (88) and nut (86) to lever
(90) to make lever (85).
Nut (86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1 NCm
Nut (86) . . . . . . . . . . . . Thread tightener [Loctite 648]
i Check that the movement of lever (90) and bearing (88) i s
smooth.
B) Fit o-ring to plug (84), then install to lever (85) and body.
30-154 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
D) Assemble piston (82), then fit o-ring and install plug (81).
Plug (81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2 NCm
E) Assemble spool (77) to sleeve (76), then install to bod y
together with seat (78) and springs (79) and (80).
i Check that the relative movement of sleeve (77) and spool (76)
is smooth.
F) Install o-ring, then install solenoid (75).
Solenoid mounting bolt . . . . . . . . . . . . . . . . . 13 2 NCm
2. Assemble orifice (104) and install spacer (103), filter (102) and
o-ring.
Orifice (104) . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2 NCm
3. After completion of assembly, carry out bench test of serv o
valve (74) as an individual part to check performance and carry
out adjustment.
4. Install 2 knock pins to pump end. Fit o-ring and filter to serv o
valve (74) and install to pump case.
i Install the filter so that the mesh end is at the front face end of
the valve body.
i Be extremely careful that the o-ring and filter do not fall out.
i Tighten the mounting bolts gradually in turn on opposite sides.
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . 66 7 NCm
Mating surface of servo valve . . . . . . . . . . LG-7 or LG-5
PC300LC-6
PC300HD-6 30-155
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Oil Seal
30-156 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP
CHECKING CONTACT
1. Make a centering tool (x) for the cylinder block and valve plate
(y).
i The tool can be made from plastic, bakelite or any other sof t
material.
2. Remove all oil and grease from the parts to be checked.
i Do not wipe with a cloth.
3. Set the tool in position, then paint the cylinder block wit h
inspection paint.
i Coat thinly with paint.
i This check is unnecessary if both the rocker cam and cradle are
replacement parts [new parts].
PC300LC-6
PC300HD-6 30-157
DISASSEMBLY AND ASSEMBLY MAIN PUMP
30-158 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MAIN PUMP OIL SEAL
INSTALLATION
! Carry out installation in the reverse order to removal using tool
S2.
PC300LC-6
PC300HD-6 30-159
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
REMOVAL
WARNING! Lower the work equipment completely to the
ground and stop the engine. Then loosen the oil filler ca p
slowly to release the pressure inside the hydraulic tank .
Release the remaining pressure in the hydraulic circuit. Fo r
details, see TESTING AND ADJUSTING.
i Make match marks before disconnecting the PPC circuit hoses.
Fit blind plugs in the disconnected hoses and tubes.
30-160 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
8. Disconnect drain hose (21), ten top PPC hoses (22) and safety
valve hose (23).
PC300LC-6
PC300HD-6 30-161
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
10. Disconnect swing motor suction hose (26), bucket hoses (27),
two right travel hoses (28), arm hoses (29) and left travel hoses
(30).
11. Remove swing motor hoses (31) boom tubes (32 and 33).
13. Sling control valve (35), then remove mounting bolts and lift off
control valve .
i Move slightly to the front and pass through the bracket to lift off.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through system. Then
check the oil level again.
30-162 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY
(1/3)
PC300LC-6
PC300HD-6 30-163
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(2/3)
30-164 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(3/3)
PC300LC-6
PC300HD-6 30-165
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
6. Remove plug (40), then remove piston (42) and spring (41) .
Remove case (43), then remove spring (44) and retainer (45).
Remove case (46), then remove spring (47) and retainer (48).
Remove spool (49).
i Do not disassemble spool (49).
7. Remove case (50), then remove spring (51) and retainer (52).
Remove plug (53), then remove piston (54). Remove case (55),
then remove spring (56) and retainer (57). Remove plug (58) ,
then remove piston (59). Remove spool (60).
i Do not disassemble spool (60).
8. Remove case (61), then remove spring (62) and retainer (63).
Remove case (64), spring (65) and retainer (66). Remove spool
(67).
i Do not disassemble spool (67).
30-166 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
9. Remove case (68), then remove spring (69) and retainer (70).
Remove plug (71), then remove piston (72) and spring (73) .
Remove case (74), then remove spring (75) and retainer (76).
Remove spool (77).
i Do not disassemble spool (77).
10. Remove case (78), then remove spring (79) and retainer (80).
Remove case (81), then remove spring (82)and retainer (83) .
Remove spool (84).
i Do not disassemble spool (84).
11. Remove plate (91), then remove arm regeneration spring (92)
and arm regeneration valve (93).
12. Remove case (103), then pull out spool to position shown i n
diagram on right. To prevent damage to spool hold positio n
shown @ with a wrench [width across flats: 24mm], remove plug
(95), then disassemble into retainer (96), springs (97a) an d
(97b), retainer (98) and spool (94).
13. Remove case (104), then remove spring (105) and plate (99).
To prevent damage to spool, hold position shown # with a
wrench [width across flats: 24mm], remove plug (100), then
disassemble into valve (101), plate (99) and spool (102).
14. Remove covers (89) and (90) and valve (106) from valve body.
PC300LC-6
PC300HD-6 30-167
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
ASSEMBLY
(1/3)
30-168 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(2/3)
PC300LC-6
PC300HD-6 30-169
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(3/3)
30-170 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
i Check the spools and valves for dirt, damage, or burrs. Coat the
sliding surfaces of all parts with engine oil before installing.
1. Install valve (106) and covers (89) and (90) to valve body.
2. Fit seal to spool (102) and install seal to valve (101). Assemble
spool (102) to position shown, install plate (99) and valve (101)
to spool (102), then hold position # with a wrench [width across
flats: 24mm] and tighten plug (41). Push spool into body, fi t
spring (105), then fit o-ring to case (104) and install.
PC300LC-6
PC300HD-6 30-171
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-172 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12. Fit o-rings and install arm out pressure compensation valve (3),
left travel forward pressure compensation valve (5), right swing
pressure compensation valve (7), boom raise pressur e
compensation valve (9), right travel reverse pressure compen-
sation valve (11), bucket dump pressure compensation valv e
(13) and arm Hi in pressure compensation valve (15).
Pressure compensation valve . . . . . . . . . . 392 20 NCm
13. Assemble arm regeneration valve (93) and spring (92), the n
install plate (91).
14. Fit o-rings and install plugs (27) and (28). Fit o-rings and install
suction valves (19), (20), (21), (23) and (24). Fit o-rings an d
install safety suction valves (17), (18), (22) and (26). Fit o-rin g
and install unload valve (1).
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 10 NCm
Suction valve . . . . . . . . . . . . . . . . . . . . . . . 147 10 NCm
Safety-suction valve . . . . . . . . . . . . . . . . . . 147 10 NCm
Unload valve . . . . . . . . . . . . . . . . . . . . . . . 167 20 NCm
PC300LC-6
PC300HD-6 30-173
DISASSEMBLY AND ASSEMBLY PUMP MERGE DIVIDER VALVE
3. Remove plug (6), then remove spring (7) and spool (8).
ASSEMBLY
! Before assembling, coat the sliding surface with engine oil.
2. Assemble spool (8) and spring (7), then fit o-ring to plug (6) and
install.
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6 NCm
4. Assemble spool (4) and spring (3), then fit o-ring to plug (2) and
install.
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 25 NCm
30-174 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
! The structure of the parts for pressure compensation valves A Pressure compensation valves
thru I is the same, but the part numbers for the component parts
A Arm IN Hi
are different, so be careful when assembling.
B Boom RAISE Hi
1. Remove piston (2) and piston (3) from sleeve (1), then remove
C Boom LOWER
seal (4).
D Right travel REVERSE
i Piston (2) is assembled to valves A thru C, E thru I and piston
Left travel REVERSE
(3) is assembled to valve D.
Right travel FORWARD
Left travel FORWARD
2. Remove spring (5), then remove ring (6) and o-rings (7) and (8)
from sleeve (1). E Boom RAISE
i After disassembling, if there is any abnormality in sleeve (1) , F Arm OUT
seal (4), piston (2), or piston (3), replace the whole pressur e
G Bucket CURL
compensation valve.
H Arm IN
ASSEMBLY I Right swing, left swing, bucket dump
1. Install o-rings (8) and (7) and ring (6) to sleeve (1).
PC300LC-6
PC300HD-6 30-175
DISASSEMBLY AND ASSEMBLY FRONT PUMP SERVO VALVE
INSTALLATION
! Carry out installation in the reverse order to removal.
i Be careful not to let the o-ring or filter fall out when installing.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
30-176 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY REAR PUMP SERVO VALVE
INSTALLATION
! Carry out installation in the reverse order to removal.
i Be careful not to let the o-ring or filter fall out when installing.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-177
DISASSEMBLY AND ASSEMBLY LS-EPC SOLENOID VALVE
of the battery. Loosen the hydraulic tank oil filler cap slowly to
release the pressure inside the hydraulic tank.
INSTALLATION
! Carry out installation in the reverse order to removal.
30-178 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
SOLENOID VALVE
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal NE
G
of the battery. Loosen the hydraulic tank oil filler cap slowly to
release the pressure inside the hydraulic tank.
i Make match marks on the hoses and connectors.
2. Remove movable the iron core (11) and o-ring (12). Remov e
sleeve (13) and spool (14). Remove washer (15), spring (16 )
and stopper (17), then clean valves.
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-179
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
INSTALLATION
! Carry out installation in the reverse order to removal.
30-180 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
DISASSEMBLY
1. Remove nut (1), then remove disc (2) and boot (3). Remov e
bolts, then remove plate (5).
i Do not remove joint (4) unless it is to be replaced.
2. Remove seal (6) and collar (7). Pull out piston (8) and remove
retainer (9), springs (10) and (11) and shim (12).
i Spring (10) consists of two springs each of two types wit h
different installed loads, so check mounting position [hydraulic
port] and mark with tags to prevent mistakes when installing.
3. Pull out valve (13) from body (14).
ASSEMBLY
1. Assemble valve (13) to body (14). Assemble shim (12) an d
spring (11) to valve (13).
i When assembling spring (11), set the end with the small coi l
diameter [inside diameter] at shim (12) end.
2. Assemble spring (10), retainer (9) and piston (8).
i The number of loops in the coil for spring (10) is different fo r
each of the hydraulic ports below, so be careful when installing.
Port Position Free length of spring
P1, P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4 mm
P3, P4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.4 mm
i The position of each port is marked at the bottom of the valv e
body.
i When assembling piston (8), coat the outside of the piston and
the inside of the hole in the body with grease.
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease [G2-LI]
3. Fit o-ring to collar (7) and assemble in body (14), then instal l
seal (6). Install plate (5).
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . 13 2 NCm
4. Install joint (4).
Sliding portion of joint . . . . . . . . . . . . . . Grease [G2-LI]
Female thread of body . . . . . . Thread tightener [LT-2]
i Coat two places on the female thread A [5 to 7 mm] with one
drop of Loctite each as shown in the diagram on the right.
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 5 NCm
i Keep strictly to the tightening torque.
5. Assemble boot (3) and disc (2) and tighten with nut (1).
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 15 NCm
i After assembling the disc, adjust the height of the disc. Fo r
details, see TESTING AND ADJUSTING.
PC300LC-6
PC300HD-6 30-181
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
6. Disconnect six PPC hoses (7) and remove travel PPC valve (8).
INSTALLATION
! Carry out installation in the reverse order to removal.
30-182 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY
1. Remove screw (1), then remove lever (2). Remove mounting
bolts (3), then remove case and shaft (4). Remove mounting
bolts (5), then remove plate (6) together with damper (7).
i Check the thickness and mounting position of washer (18).
2. Remove mounting bolts (8), then remove damper (7) from plate
(6). Remove seal (9) and collar (10). Pull out piston (11) an d
remove retainer (12), springs (13) and (14) and shims (15).
i Check the number and thickness of shims (15) for each
mounting position and keep in a safe place.
3. Pull out valve (16) from body (17).
ASSEMBLY
1. Assemble valve (16) in body (17). Assemble shim (15) an d
spring (14) to valve (16).
i Assemble the same number and thickness of shim (15) as was
removed during disassembly.
Standard shim thickness . . . . . . . . . . . . . . . . . . . 0.3 mm
i Spring (14) is not symmetrical at the top and bottom, so
assemble with the small coil diameter [inside diameter] at th e
shim end.
2. Assemble spring (13), retainer (12) and piston
Outside of piston, body hole . . . . . . . . . Grease [G2- LI]
3. Fit o-ring to collar (10) and assemble in body (17), then install
seal (9). Install damper (7) to plate (6), then tighten bolts (8).
Mounting bolt . . . . . . . . . . . . . . Thread tightener [LT-2]
Mounting bolt . . . . . . . . . . . . . . . . . . . . . . . 4.4 0.5 NCm
4. Install plate (6) and damper (7) as one unit, then tighten bolt s
(5).
i Temporarily assemble standard washer [1.6 mm] for washer
(18). Measure the difference in the angle when the left and right
levers are operated fully. If the angle is greater than 0.7 E,
change the thickness of washer (18) to make the difference less
than 0.7E. If the washer is thinner by 0.3 mm, the angle of th e
full stroke is 0.39E greater.
Washer thickness . . . . . . . . . . . . . . . . . 1.0, 1.3, 1.6 mm
PC300LC-6
PC300HD-6 30-183
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
i Make match marks at the male and female ends of the oil
pressure switch connectors. Before disconnecting any hoses ,
check the distinguishing tape stuck to the hose, or make match
marks.
i The elbows on the front two hoses are long, so hold the elbow
with a wrench when disconnecting the hoses.
30-184 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
INSTALLATION
! Carry out installation in the reverse order to removal.
i Check that the quick joint does not come out when the hose is
pulled.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
DISASSEMBLY
2. Remove eight oil pressure switches (5). Remove two slow return
valves (6). Remove shuttle valve (7). Remove plugs (8), the n
remove balls (9).
i There are six plugs and balls.
3. Remove two each of plug (10), spring (11) and retainer (12) .
Remove spool (13). Remove two plugs (14).
PC300LC-6
PC300HD-6 30-185
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
ASSEMBLY
1. Fit o-ring and install two plugs (14).
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3 NCm
2. Assemble spool (13) and install two retainers (12) and springs
(11). Fit o-ring and install two plugs (10).
3. Fit o-ring and assemble six balls (9), then install six plugs (8).
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5 NCm
7. Fit o-ring and assemble shuttle valve (2), travel junction valv e
(3) and plate (4), then tighten mounting bolts
30-186 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
6. Remove mounting bolts (6), then remove boom lock valve (7).
INSTALLATION
! Carry out installation in the reverse order to removal.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
PC300LC-6
PC300HD-6 30-187
DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE
DISASSEMBLY
1. Remove safety valve (1).
2. Remove body (2), then remove spring (3) and check valve (4).
3. Remove plug (5), then remove spacer (6), spring (7), seat (8 )
and spool (9).
ASSEMBLY
! Coat the sliding parts with engine oil before assembling.
1. Assemble spool (9), seat (8), spring (7) and washer (6) to body
(2), then fit o-ring and install plug (5).
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5 NCm
2. Assemble check valve (4) and spring (3) to body (10), then fit o-
ring and install body (2).
30-188 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
BOOM CYLINDER
REMOVAL
WARNING! Extend the arm and bucket fully, lower the work
equipment completely to the ground and put the safety loc k
lever in the LOCK position.
4. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out.
i Set stand A under the cylinder and adjust the position fo r
slinging the cylinder.
6. Remove plate, then using forcing screws (A), remove bottom pin
(7) and remove boom cylinder (2).
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-189
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
30-190 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
ARM CYLINDER
REMOVAL
WARNING! Extend the arm cylinder piston rod to a point .
200 mm before the end of the IN stroke, lower the wor k
equipment completely to the ground, then set the remaining
safety lock lever to the LOCK position.
3. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out.
5. Raise arm cylinder (5), remove plate (6), then remove botto m
pin (7) and remove arm cylinder (5).
i There are shims installed, so check the number and thickness
and keep in a safe place.
INSTALLATION
! Carry out installation in the reverse order to removal.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-191
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
BUCKET CYLINDER
REMOVAL
WARNING! Extend the bucket cylinder piston rod to a point
. 200 mm 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 A under arm top, block B between link and arm and
block C between bucket cylinder and arm.
4. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out.
6. Raise the bucket cylinder (5), remove plate (6), then remov e
bottom pin (7) and remove bucket cylinder (5).
INSTALLATION
! Carry out installation in the reverse order to removal.
30-192 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
i Adjust the shim thickness so that the clearance between link (8)
and link (9) is less than 1.0 mm.
i Adjust the shim thickness so that the clearance between the end
face of the cylinder bottom (5) and bracket (10) is less than 1.0
mm.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-193
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOLT ON TYPE PISTON
DISASSEMBLY
4. Remove screw (4), then remove eleven balls (5) and remov e
plunger (6).
8. Remove rings (12), wear rings (13) and piston ring (14).
30-194 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
9. Remove collar (15) and head (2) from piston rod (3).
10. Remove o-ring and backup ring (16). Then remove collar (18)
and ring (19) from collar (17).
11. Remove o-ring and backup ring (20). Remove snap ring (21) ,
then remove dust seal (22). Remove rod packing (23), buffe r
ring (24) and (25).
ASSEMBLY
i Do not try to force the backup ring into position. Warm it in warm
water [50 to 60EC] before fitting it.
1. Using tool U4, press fit bushing (25). Assemble buffer ring (24)
and rod packing (23).
2. Using tool U5, install dust seal (22) and secure with snap rin g
(21). Install o-ring and backup ring (20).
PC300LC-6
PC300HD-6 30-195
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3. Assemble ring (19) and collar (18) to collar (17). Install o-rin g
and backup ring (16).
i Assemble collar (15) for the boom and arm cylinders only.
i Set the piston ring on the tool U2 and turn the handle 8 to 1 0
times to expand the ring.
i Be careful not to open the end gap of the ring too wide.
30-196 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
9. Install piston (9) and spacers (8) and tighten with screws (7).
10. Set plunger (6) on piston rod, assemble twelve balls (5), the n
secure with set screw (4).
i Stake the rod end area after tightening the set screw.
i Set the end gap of the ring at the horizontal (side) position, align
the center of shaft and cylinder tube, then insert.
i After inserting, check that the ring is not broken and has no t
come out, then push in fully.
PC300LC-6
PC300HD-6 30-197
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
30-198 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
i When not using tool U6, use the drill holes [ i10: 4 places] and
loosen the piston.
7. Remove cap (8) and pull out 12 balls (9), then remove cushion
plunger (10).
8. Remove ring (11), wear ring (12), piston ring (13) and o-ring and
backup ring (14).
PC300LC-6
PC300HD-6 30-199
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
9. Remove o-ring and backup ring (15), snap ring (16), the n
remove dust seal (17), rod packing (18), buffer ring (19) an d
bushing (20).
ASSEMBLY
i Do not try to force the backup ring into position. Warm it in warm
water [50 to 60EC] before fitting it.
1. Using tool U4, press fit bushing (20). Assemble buffer ring (19)
and rod packing (18). Using tool U5, install dust seal (17) an d
secure with snap ring (16). Install backup ring and o-ring (15).
i Set the piston ring on tool U2 and turn the handle 8 to 10 times
to expand the ring.
30-200 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
4. Install backup ring and o-ring (14), wear ring (12) and ring (11).
i Be careful not to open the end gap of the ring too wide.
7. Fit o-ring and backup ring to collar (6), then assemble wit h
plunger (5).
PC300LC-6
PC300HD-6 30-201
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
10. Thread on piston (4), then use tool U6 to tighten piston (2) so
that position of screw thread hole matches.
12. Stake thread A at 2 places with punch when using a new part for
either or both rod and/or piston.
i For the rod with bottom cushion, mark the cushion plug position
on the end face of the rod.
13. Screw in until piston (4) contacts end face of rod A, then use
tool U6 to tighten.
10.3 27 12x1.75 20
30-202 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
16. Set the end gap A of the ring at the horizontal [side] position ,
align the axial center of shaft and cyl inder tube, then insert. After
inserting, check that the ring is not broken and has not com e
out, then push in fully.
PC300LC-6
PC300HD-6 30-203
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL
WARNING! Extend the arm and bucket fully, lower the work
equipment to the ground and set the safety lock lever to the
LOCK position.
4. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out and lower cylinder onto stand.
5. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (7)
and secure to valve with rope.
8. Raise work equipment (10), then remove boom foot pin (9)
using tool V and remove work equipment (10).
30-204 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION
! Carry out installation in the reverse order to removal.
i Adjust the shim thickness so that the clearance between the end
face of cylinder rod (2) and plate (4) is less than 1 mm ( B).
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-205
DISASSEMBLY AND ASSEMBLY BUCKET
BUCKET
REMOVAL
WARNING! Set the back of the bucket facing down, lower
the work equipment completely to the ground and set th e
safety lock lever to the LOCK position.
3. Start engine and retract piston rod, then tie link to arm with wire
to prevent piston rod from coming out.
5. Remove plate (4), then remove connecting pin (5) between arm
and bucket.
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 kg
30-206 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BUCKET
INSTALLATION
! Carry out installation in the reverse order to removal.
,
i When tightening the locknut, tighten so that the clearanc e
between the plate and nut is 0.5 to 1.5 mm (A).
! Insert the o-ring at the end face of the bucket boss securely.
PC300LC-6
PC300HD-6 30-207
DISASSEMBLY AND ASSEMBLY ARM
ARM
REMOVAL
1. Remove bucket. For details, see REMOVAL OF BUCKET.
5. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out.
7. Remove plate (4), then remove connecting pin (5) between arm
and boom.
8. Start engine, then raise boom and swing to remove arm (6).
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 kg
30-208 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY ARM
INSTALLATION
! Carry out installation in the reverse order to removal.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-209
DISASSEMBLY AND ASSEMBLY BUCKET AND ARM
2. Remove plate (1), then remove arm cylinder head pin (2).
3. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out.
5. Remove plate (4), then remove connecting pin (5) between arm
and boom.
6. Start engine, then raise boom and swing to remove bucket and
arm (6).
30-210 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BUCKET AND ARM
INSTALLATION
! Carry out installation in the reverse order to removal.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-211
DISASSEMBLY AND ASSEMBLY BOOM
BOOM
REMOVAL
1. Remove bucket and arm. For details, see REMOVAL OF
BUCKET, ARM.
5. Start engine and retract piston rod, then tie piston rod with wire
to prevent it from coming out and lower it onto stand.
6. Disconnect arm cylinder hoses (6) and bucket cylinder hoses (7)
and secure to valve with rope.
9. Raise boom (10), remove boom foot pin (9) using tool V, then
remove boom (10).
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 kg
30-212 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION
! Carry out installation in the reverse order to removal.
i Bleed air from the hydraulic system. For details, see TESTING
AND ADJUSTING.
i Refill with oil [hydraulic tank] through the oil filler to the specified
level. Run the engine to circulate the oil through the system .
Then check the oil level again.
PC300LC-6
PC300HD-6 30-213
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
OPERATORS CAB
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
4. Remove 4 bolts and 1 clip, then remove panels (3) and (4).
30-214 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY OPERATORS CAB
12. Remove four mounting nuts and six mounting bolts, then lift off
operators cab (15).
Nut
Bolt
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-215
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL
1. Set lifting hook chains of counterweight in position and sling.
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . 5500 kg
INSTALLATION
! Carry out installation in the reverse order to removal.
30-216 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY COMPRESSOR
COMPRESSOR
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
INSTALLATION
! Carry out installation in the reverse order to removal.
i When installing the hoses, check that the o-ring is not damaged
or deteriorated, then connect the hoses.
PC300LC-6
PC300HD-6 30-217
DISASSEMBLY AND ASSEMBLY CONDENSER
CONDENSER
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
INSTALLATION
! Carry out installation in the reverse order to removal.
30-218 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
RECEIVER TANK
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
3. Disconnect clamp (3) of hose (1). Remove two u-bolts (4) then
remove receiver tank (5).
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-219
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
of the battery.
30-220 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-221
DISASSEMBLY AND ASSEMBLY GOVERNOR, PUMP CONTROLLER
of the battery.
INSTALLATION
! Carry out installation in the reverse order to removal.
30-222 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
MONITOR PANEL
REMOVAL
WARNING! Disconnect the cable from negative [ ] terminal
NE
G
of the battery.
INSTALLATION
! Carry out installation in the reverse order to removal.
PC300LC-6
PC300HD-6 30-223
DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE
BOOT
1. Insert a thin flat headed screwdriver between boot (3) and upper
case (4), remove claw (5) at front of boot from upper case, then
raise front.
4. Push boot up, remove bolt (8), then remove lever (9) and boot
(3).
30-224 PC300LC-6
PC300HD-6
DISASSEMBLY AND ASSEMBLY CONTROL STAND CASE
UPPER CASE
2. Push bottom center of upper case (11) from both sides and lift
up to release claws at both sides.
INSTALLATION
! Carry out installation in the reverse order to removal.
i When installing the boot, insert the claw at the rear first.
i When installing the tray and upper case, insert the claws at the
front first.
PC300LC-6
PC300HD-6 30-225
40 MAINTENANCE STANDARD
PC300LC-6
PC300HD-6 40-1
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
PC300LC-6
40-2 PC300HD-6
MAINTENANCE STANDARD ENGINE MOUNT
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
PC300LC-6
PC300HD-6 40-3
MAINTENANCE STANDARD RADIATOR AND OIL COOLER MOUNT
PC300LC-6
40-4 PC300HD-6
MAINTENANCE STANDARD RADIATOR AND OIL COOLER MOUNT
Unit - mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
PC300LC-6
PC300HD-6 40-5
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
PC300LC-6
40-6 PC300HD-6
MAINTENANCE STANDARD SWING MACHINERY
Unit - mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
PC300LC-6
PC300HD-6 40-7
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
PC300LC-6
40-8 PC300HD-6
MAINTENANCE STANDARD SWING CIRCLE
Unit - mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
PC300LC-6
PC300HD-6 40-9
MAINTENANCE STANDARD FINAL DRIVE
PC300LC-6
40-10 PC300HD-6
MAINTENANCE STANDARD FINAL DRIVE
Unit - mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
PC300LC-6
PC300HD-6 40-11
MAINTENANCE STANDARD FINAL DRIVE
PC300LC-6
40-12 PC300HD-6
MAINTENANCE STANDARD FINAL DRIVE
Unit - mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
PC300LC-6
PC300HD-6 40-13
MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
Unit - mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
+3
Track frame 123 127
Top to bottom width of idler -1
1
guide
Idler support 120 0.5 118
Rebuild or
+4 replace
Track frame 266 271
Left to right width of idler -1
2
guide
Idler support 261 --- 259
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
40-14 PC300HD-6
MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
PC300HD-6
Unit - mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
+3
Track frame 148 152
Top to bottom width of idler -1
1
guide
Idler support 145 0.5 142
Rebuild or
+4 replace
Track frame 302 307
Left to right width of idler -1
2
guide
Idler support 297 --- 295
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
PC300HD-6 40-15
MAINTENANCE STANDARD IDLER
IDLER - PC300LC-6
PC300LC-6
40-16 PC300HD-6
MAINTENANCE STANDARD IDLER
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
-0.225 -0.085
7 Shaft and support clearance 80 -0.290 -0.195
0.03 to 0.205 --- Replace
Tolerance Standard Interference
Standard size
Shaft Hole interference limit
+0.087 -0.042
8 Idler and bushing interference 87.6 +0.037 -0.079
0.079 to 0.166 --- Replace bushing
PC300LC-6
PC300HD-6 40-17
MAINTENANCE STANDARD IDLER
IDLER - PC300HD-6
PC300LC-6
40-18 PC300HD-6
MAINTENANCE STANDARD IDLER
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
-0.120 +0.035
7 Shaft and support clearance 95 -0.207 0
0.120 to 0.242 --- Replace
Tolerance Standard Interference
Standard size
Shaft Hole interference limit
+0.087 -0.027
8 Idler and bushing interference 102.6 +0.037 -0.062
0.064 to 0.149 --- Replace bushing
Replace
9 Side clearance - both sides 0.46 to 0.86 1.5
bushing
PC300LC-6
PC300HD-6 40-19
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
PC300LC-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
+0.021 0
4 Idler and bearing interference 55 +0.002 -0.015
0.002 to 0.036 ---
Replace
0 -0.024
5 Roller and bearing interference 100 -0.015 -0.059
0.009 to 0.059 ---
Standard size Repair limit
PC300LC-6
40-20 PC300HD-6
MAINTENANCE STANDARD CARRIER ROLLER
PC300HD-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
PC300LC-6
PC300HD-6 40-21
MAINTENANCE STANDARD TRACK ROLLER
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
PC300LC-6
40-22 PC300HD-6
MAINTENANCE STANDARD TRACK ROLLER
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
PC300LC-6
PC300HD-6 40-23
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRACK CHAIN
PC300LC-6
40-24 PC300HD-6
MAINTENANCE STANDARD TRACK SHOE
PC300LC-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
When turned
Standard size
Normal load Impact load
2 Bushing outside diameter 66.5 --- 61 Reverse or replace
+0.235 -0.218
22 Pin and link interference 44.6 +0.085 -0.280
0.303 to 0.515 Replace
+0.030 -0.188
23 Master pin and link interference 44.6 0 -0.250
0.188 to 0.280
Tolerance Standard
Standard size
Shaft Hole clearance
+0.235 +0.915
24 Pin and bushing clearance 44.6 +0.085 +0.415
0.180 to 0.830
Adjust or replace
-0.030 +0.915
25 Master pin and bushing clearance 44.6 0 +0.415
0.418 to 0.915
PC300LC-6
PC300HD-6 40-25
MAINTENANCE STANDARD TRACK SHOE
PC300HD-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
When turned
Standard size
Normal load Impact load
2 Bushing outside diameter 71 --- 66 Reverse or replace
+0.235 -0.218
22 Pin and link interference 47 +0.085 -0.280
0.303 to 0.515 Replace
+0.030 -0.218
23 Master pin and link interference 47 0 -0.280
0.218 to 0.310
Tolerance Standard
Standard size
Shaft Hole clearance
+0.235 +0.915
24 Pin and bushing clearance 47 +0.085 +0.415
0.180 to 0.830
Adjust or replace
-0.030 +0.915
25 Master pin and bushing clearance 47 0 +0.415
0.418 to 0.915
PC300LC-6
40-26 PC300HD-6
MAINTENANCE STANDARD TRACK SHOE
PC300LC-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height 36 1 24
2 Thickness 11 0.8
Rebuild or replace
3 32 1
Length of base
4 26 1
5 24 1
6 Length at tip 18 1
7 18 1
PC300HD-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height 37 1 25
2 Thickness 13 0.8
Rebuild or replace
3 33 1
Length of base
4 27 1
5 25.5 1
7 22.5
PC300LC-6
PC300HD-6 40-27
MAINTENANCE STANDARD TRACK SHOE
PC300HD-6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height 46 1 34
Rebuild or replace
2 Thickness 25 0.75
4 26 0.5
Length at tip
5 26 0.5
PC300LC-6
40-28 PC300HD-6
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV160 + 160
PC300LC-6
PC300HD-6 40-29
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
9 SPOOL VALVE - 1/6
PC300LC-6
40-30 PC300HD-6
MAINTENANCE STANDARD CONTROL VALVE
i When tightening bolts marked, always use two washers on top of each other.
2/6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
PC300HD-6 40-31
MAINTENANCE STANDARD CONTROL VALVE
3/6
PC300LC-6
40-32 PC300HD-6
MAINTENANCE STANDARD CONTROL VALVE
4/6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
3 Piston return spring 48.1 x 10.8 28 1.78 kg --- 1.42 kg Replace spring if
there is damage
or deformation
4 Piston return spring 50.4 x 17.0 39 16.2 kg --- 14.5 kg
PC300LC-6
PC300HD-6 40-33
MAINTENANCE STANDARD CONTROL VALVE
5/6
PC300LC-6
40-34 PC300HD-6
MAINTENANCE STANDARD CONTROL VALVE
6/6
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
PC300HD-6 40-35
MAINTENANCE STANDARD CONTROL VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
1 Piston return spring 32.76 x 8.5 20.5 1.0 kg --- 0.8 kg Replace spring if
there is damage
2 Relief valve spring 17.1 x 9 15.5 7.6 kg --- 6.1 kg or deformation
PC300LC-6
40-36 PC300HD-6
MAINTENANCE STANDARD SELF REDUCING PRESSURE VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
2 Pilot valve spring 16.5 x 7.2 12.7 2.1 kg --- 1.9 kg Replace spring if
there is damage
3 Spring 71 x 18 59 20.4 kg --- 19 kg or deformation
PC300LC-6
PC300HD-6 40-37
MAINTENANCE STANDARD SUCTION SAFETY VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
1 Suction valve spring 16.3 x 21.3 9.5 0.21 kg --- 0.16 kg Replace spring if
there is damage
2 Pilot spring 20 x 7 14 0.21 kg --- 0.16 kg or deformation
PC300LC-6
40-38 PC300HD-6
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF160ABE-3
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
Replace spring if
1 Check valve spring 46.9 x 9.2 31 1.6 kg --- 1.28 kg there is damage
or deformation
PC300LC-6
PC300HD-6 40-39
MAINTENANCE STANDARD TRAVEL MOTOR
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
40-40 PC300HD-6
MAINTENANCE STANDARD TRAVEL MOTOR
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
PC300HD-6 40-41
MAINTENANCE STANDARD WORK EQUIPMENT SWING PPC VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
PC300LC-6
40-42 PC300HD-6
MAINTENANCE STANDARD TRAVEL PPC VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
1 Metering spring 26.5 x 8.15 24.9 1.7 kg --- 1.4 kg Replace spring if
there is damage
2 Centering spring 48.1 x 15.5 32.5 11 kg --- 8.8 kg or deformation
PC300LC-6
PC300HD-6 40-43
MAINTENANCE STANDARD SERVICE PPC VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
1 Centering spring 64.8 x 16.6 40.5 4.7 kg 62.9 4.5 kg Replace spring if
there is damage
2 Metering spring 26.0 x 10.5 25 2.6 kg 25.2 2.5 kg or deformation
PC300LC-6
40-44 PC300HD-6
MAINTENANCE STANDARD PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
Replace spring if
1 Spool return spring 23.6 x 13.3 20 1.5 kg --- 1.2 kg there is damage
or deformation
PC300LC-6
PC300HD-6 40-45
MAINTENANCE STANDARD PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE
LS-EPC VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
Replace EPC valve
if any damage or
1 Return spring 9.0 x 11.4 7.9 0.32 kg --- --- deformation are
found
PC300LC-6
40-46 PC300HD-6
MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PC300LC-6
PC300HD-6 40-47
MAINTENANCE STANDARD CENTER SWIVEL JOINT
Unit - mm
No. Check item Criteria Remedy
Standard size Standard Clearance Clearance limit
PC300LC-6
40-48 PC300HD-6
MAINTENANCE STANDARD BOOM HOLDING VALVE
Unit - mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x OD Installed length Installed load Free length Installed load
1 Pilot valve spring 26.5 x 11.2 25 0.48 kg --- 0.38 kg Replace spring if
there is damage
2 Check valve spring 37.2 x 16.2 30 3.6 kg --- 2.9 kg or deformation
PC300LC-6
PC300HD-6 40-49
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM, BUCKET CYLINDER - THREADED PISTON Boom shown, bucket similar
PC300LC-6
40-50 PC300HD-6
MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit - mm
No. Check item Criteria Remedy
Tolerance Standard Clearance
Cylinder Standard size
Shaft Hole clearance limit
-0.036 +0.257
Boom 100 -0.090 +0.047
0.083 to 0.347 0.447
-0.036 +0.261 Replace
1 Rod bushing Arm 110 -0.090 +0.047
0.083 to 0.351 0.451
bushing
-0.036 +0.257
Bucket 100 -0.090 +0.047
0.083 to 0.347 0.447
+0.457
Boom 100 --- +0.370 --- 1.0
+0.457
2 Pin bushing Arm 100 --- +0.370 --- 1.0
+0.457
Bucket 90 --- --- 1.0
+0.370 Replace pin,
+0.457 bushing
Boom 90 --- +0.370 --- 1.0
+0.457
3 Pin bushing Arm 100 --- +0.370 --- 1.0
+0.457
Bucket 90 --- +0.370 --- 1.0
PC300LC-6
PC300HD-6 40-51
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
PC300LC-6
40-52 PC300HD-6
MAINTENANCE STANDARD WORK EQUIPMENT
Unit - mm
No. Check item Criteria Remedy
Tolerance Standard Clearance
Standard size
Shaft Hole clearance limit
+0.100 +0.161
1 Boom mounting pin 110 0 +0.094
0.095 to 0.161 1.0
+0.100 +0.354
2 Boom to arm pin 110 0 +0.275
0.276 to 0.354 1.0
+0.100 +0.338
3 Link at arm pin 90 0 +0.272
0.273 to 0.338 1.0
Replace
+0.100 +0.337
4 Bucket at arm pin 90 0 +0.271
0.272 to 0.337 1.0
+0.100 +0.346
5 Link at link pin 90 0 +0.275
0.276 to 0.346 1.0
+0.100 +0.346
6 Link pin and bushing clearance 90 0 +0.275
0.276 to 0.346 1.0
PC300LC-6
PC300HD-6 40-53
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
PC300LC-6
40-54 PC300HD-6
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
Unit - mm
Item 2.2 m Arm 2.5 m Arm 3.2 m Arm 3.2 m HD Arm 4.0 m Arm
+0.1 +0.457 +0.1 +0.457 +0.1 +0.457 +0.1 +0.457 +0.1 +0.457
1 100 0 +0.370 100 0 +0.370 100 0 +0.370 100 0 +0.370 100 0 +0.370
+0.5 -0.3 +0.5 -0.3 +0.5 -0.3 +0.5 -0.3 +0.5 -0.3
3 320 0 -0.8 320 0 -0.8 320 0 -0.8 320 0 -0.8 320 0 -0.8
+0.1 +0.351 +0.1 +0.351 +0.1 +0.351 +0.1 +0.351 +0.1 +0.351
4 110 0 +0.277 110 0 +0.277 110 0 +0.277 110 0 +0.277 110 0 +0.277
11 731 0.2 731 0.2 731 0.2 731 0.2 731 0.2
12 728 0.5 728 0.5 728 0.5 728 0.5 728 0.5
16 345 0.5 345 0.5 345 0.5 345 0.5 345 0.5
+0.2 +0.346 +0.2 +0.346 +0.2 +0.346 +0.2 +0.346 +0.2 +0.346
17 90 0 +0.275 90 0 +0.275 90 0 +0.275 90 0 +0.275 90 0 +0.275
Max 3275 Max 3275 Max 3275 Max 3275 Max 3275
19 Min 1990 Min 1990 Min 1990 Min 1990 Min 1990
PC300LC-6
PC300HD-6 40-55
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
BUCKET
PC300LC-6
40-56 PC300HD-6
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
Unit - mm
1 512.2 0.5
2 37.9 0.5
3 94E19'
4 513.6
7 ---
8 50E
9 90 +0.2
0
10 346 +10
11 68
12 138
13 525.5 0.5
14 26
15 170
16 200
17 135.5
18 142
19 R115
20 R100
21 370 +20
22 60
PC300LC-6
PC300HD-6 40-57
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