CEBM018701

Shop
Manual

PC300LC-8
PC300HD-8
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC300LC-8 A90001 and up
PC300HD-8 A87001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2008 Komatsu

Printed in U.S.A.
Komatsu America Corp.
February 2008
FOREWORD CONTENTS
12
CONTENTS 00

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 PC300LC/HD-8
FOREWORD

The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add

● Page to be replaced Replace

( ) Page to be deleted Discard

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FOREWORD

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PC300LC/HD-8 00-2-7 1
FOREWORD

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00-2-8 1 PC300LC/HD-8
FOREWORD SAFETY
12
SAFETY 00

SAFETY NOTICE 00

IMPORTANT SAFETY NOTICE 00

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.

GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00

Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.

1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
• Always wear safety glasses when hitting parts with 3. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before starting
• Always wear safety glasses when grinding parts work.
with a grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00

before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.

PC300LC/HD-8 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.

5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.

9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.

14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.

15. Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit.
A. Disconnection

WARNING! Collect the air conditioner refrigerant gas (R134a).

If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly,
when collecting or adding it, you must be qualified for handling the refrigerant and put on
protective goggles.

B. Connection

i. When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter
them.

ii. When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.

iii. Check that each O-ring is not damaged or deteriorated.

iv. When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.

00-4 PC300LC/HD-8
FOREWORD SAFETY
★ Example of O-ring (Fitted to every joint of hoses and tubes)
★ For tightening torque, see the precautions for installation in each
section of "Disassembly and assembly".

PC300LC/HD-8 00-5
FOREWORD GENERAL
12
GENERAL 00

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

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. In addition, this section gives the judgement standards
when inspecting disassembled parts.

STANDARD VALE TABLE

This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.

TROUBLESHOOTING

Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.

OTHER

This section has the foldout drawings for the machine.

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.

00-6 PC300LC/HD-8
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

VOLUMES 00

REVISIONS 00

Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00

Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00

Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2

10-5

REVISED EDITION MARK 00

When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.

PC300LC/HD-8 00-7
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00

HOISTING 00
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
can result. Hooks have maximum strength at the middle
WARNING! Heavy parts (25 kg or more) portion.
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.

● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WIRE ROPES 00

WARNING! Slinging with one rope may

cause turning of the load
1. Use adequate ropes depending on the weight of parts to during hoisting, untwisting of
be hoisted, referring to the table below:
the rope, or slipping of the
Wire ropes rope from its original winding
(Standard “Z” or “S” twist ropes without galvanizing) position on the load, which
can result in a dangerous
Rope diameter Allowable load accident
mm kN tons
4. Do not sling a heavy load with ropes forming a wide
10 9.8 1.0 hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
11.2 13.7 1.4 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
12.5 15.7 1.6 hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
14 21.6 2.2 hanging angles. When two ropes sling a load vertically,
16 27.5 2.8 up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120°
18 35.3 3.6 hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of
the breaking strength of the rope used.Sling wire ropes
from the middle portion of the hook.

PC300LC/HD-8 00-8
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00

WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.

WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.

TYPE 1 00

DISCONNECTION 00

1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.

CONNECTION 00

1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.

PC300LC/HD-8 00-9
FOREWORD PUSH PULL COUPLER

TYPE 2 00

DISCONNECTION 00

1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.

2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

00-10 PC300LC/HD-8
FOREWORD PUSH PULL COUPLER
12
TYPE 3 00

DISCONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.

2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.

PC300LC/HD-8 00-11
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00

● The maintenance standard values necessary for judgment of

products and parts are described by the following terms.

1. Standard Size And Tolerance

• To be accurate, the finishing size of parts is a little different
from one to another.
• To specify a finishing size of a part, a temporary standard size
is set and an allowable difference from that size is indicated.
• The above size set temporarily is called the “standard size” and
the range of difference from the standard size is called the
“tolerance”.
• The tolerance with the symbols of + or – is indicated on the
right side of the standard size.

Example:
Standard size Tolerance
–0.022
120
–0.126

★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and
different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

2. Standard Clearance And Standard Value

• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.

3. Standard Interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard
interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.

00-12 PC300LC/HD-8
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
4. Repair Limit And Allowable Value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance Limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts
cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.

6. Interference Limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.

PC300LC/HD-8 00-13
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00

BOLTS AND NUTS 00

● Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench)
★ The following table corresponds to the bolts in Figure A.
Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35

★ The following table corresponds to the bolts in Figure B.

Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52

Figure A Figure B

00-14 PC300LC/HD-8
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00

Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00

Use these torques for split flange bolts.

Thread diameter Width across flat Tightening torque
mm mm Nm lbf ft
10 14 59 - 74 43.51 - 54.57

12 17 98 - 123 72.28 - 90.72

16 22 235 - 285 173.32 - 210.20

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6

18 24 49 ± 19.6 36.1 ± 14.4

22 27 78.5 ± 19.6 57.8 ± 14.4

24 32 137.3 ± 29.4 101.2 ± 21.6

30 36 176.5 ± 29.4 130.1 ± 21.6

33 41 196.1 ± 49 144.6 ± 36.1

36 46 245.2 ± 49 180.8 ± 36.1

42 55 294.2 ± 49 216.9 ± 36.1

PC300LC/HD-8 00-15
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00

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

Thread diameter Width across flat Tightening torque Nm (lbf ft)

Norminal No.
mm mm Range Target
02 14 35 - 63 (25.81 - 46.46) 44 (32.45)
03, 04 20 84 - 132 (61.95 - 97.35) 103 (75.96)
Varies depending on
05, 06 24 128 - 186 (94.40 - 137.18) 157 (115.79)
type of connector.
10, 12 33 363 - 480 (267.73 - 354.02) 422 (311.25)
14 42 746 - 1010 (550.22 - 744.93) 883 (651.26)

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00

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

Thread diameter Width across flat Tightening torque Nm (lbf lb)

Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42)
10 10 17 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31)
12 12 19 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01)
14 14 22 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62)
16 16 24 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68)
18 18 27 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91)
20 20 30 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14)
24 24 32 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59)
30 30 32 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50)
33 33 _ 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75)
36 36 36 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03)
42 42 _ 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40)
52 52 _ 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52)

TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00

★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.

Taper seal
Tightening torque (Nm (lbf ft)) Face seal type
type
Nominal Width Nominal thread
size of hose across flats Thread size size - Threads per Root diameter (mm)
Range Target
(mm) inch, Thread (Reference)
series
34 - 54 (25.0 - 39.8) 44 (32.4) - 9/16 - 18UN 14.3
02 19
34 - 63 (25.0 - 46.4) 44 (32.4) 14 - -
22 54 - 93 (39.8 - 68.5) 74 (54.5) - 11/16 -16UN 17.5
03
24 59 - 98 (43.5 - 72.2) 78 57.5) 18 - -
04 27 84 - 132 (61.9 - 97.3) 103 (75.9) 22 13/16 - 16UN 20.6
05 32 128 - 186 (94.4 - 137.1) 157 (115.7) 24 1 - 14UNS 25.4
06 36 177 - 245 (130.5 - 180.7) 216 (159.3) 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 (130.5 - 180.7) 216 (159.3) 33 - -
(12) 46 197 - 294 (145.3 - 216.8) 245 (180.7) 36 - -
(14) 55 246 - 343 (181.4 - 252.9) 294 (216.8) 42 - -

00-16 PC300LC/HD-8
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00

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 00

Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (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

CLASSIFICATION BY COLOR AND CODE 00

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary

Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary

4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue

PC300LC/HD-8 00-17
FOREWORD ELECTRIC WIRE CODE
12
HOW TO READ ELECTRIC WIRE CODE 00

★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational
information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric
wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.

Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1. Type, Symbol, And Material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and
outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Using
Type Symbol Material temperature Example of use
range °C (°F)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for AV appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
–30 to +60
Thin-cover Annealed copper for electric (-22 to +140)
Conductor
low-voltage appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold
low-voltage appliance –50 to +110
AEX district, wiring at high-temperature
wire for Heat-resistant crosslinked (-58 to +230)
Insulator place
automobile polyethylene

00-18 PC300LC/HD-8
FOREWORD ELECTRIC WIRE CODE
2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
Diameter of
Conductor strand
Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D

AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

★ “f” of nominal No. denotes flexible”.

PC300LC/HD-8 00-19
FOREWORD ELECTRIC WIRE CODE
12
3. Color Codes Table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

● In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the
marking.
Example: “GW” means that the background is Green and marking is White.

★ Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –

00-20 PC300LC/HD-8
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00

METHOD OF USING THE CONVERSION TABLE 00

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.

EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.

B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.

C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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/HD-8 00-21
FOREWORD CONVERSION TABLES
12

Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-22 PC300LC/HD-8
FOREWORD CONVERSION TABLES
12

Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

PC300LC/HD-8 00-23
FOREWORD CONVERSION TABLES
12

kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-24 PC300LC/HD-8
FOREWORD CONVERSION TABLES
12

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 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/HD-8 00-25
FOREWORD CONVERSION TABLES
12
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 or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-26 PC300LC/HD-8
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00

★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
Adhesives

500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-alpha Polyethylene ● Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container ● Used mainly for adhesion of rubbers, plastics
and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tempera-
648-50 container
ture.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Gasket sealant

● Features: Resistance to heat

● Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
● Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

PC300LC/HD-8 00-27
FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
● Used as sealant for mating surfaces of final drive
case, transmission case.
● Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant

LG-5 790-129-9080 1 kg
tainer ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
● Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case, etc.
● Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum

squeaking).
disulphide
lubricant

● Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load bearing
Grease

G2-CA SYG2-400CA-A Various Various

at places in contact with water or steam.
SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum

400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)

00-28 PC300LC/HD-8
 01 GENERAL

SPECIFICATION DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
WORKING RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9

PC300LC/HD-8 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
SPECIFICATION DIMENSION DRAWINGS

DIMENSIONS
Item Unit PC300LC-8 PC300HD-8
kg
Operating weight 32,830 (72,380) 36,736 (80,989)
(lb)
Bucket capacity m3 (cu.yd) 1.4 (1.8)
Name of engine KOMATSU SAA6D114E-3 diesel engine
Engine horsepower kW (HP) /rpm 184 (247) /1,900
A Overall length mm (ft in) 11,140 (36' 7“) 11,140 (36’7”)
B Overall height mm (ft in) 3,285 (10' 9“) 3,383 (11’1”)
C Overall width mm (ft in) 3,290 (10' 10“) 3,440 (11’3”)
D Track width mm (ft in) 700 (2' 4“) 700 (2’4”)
E Height of cab mm (ft in) 3,100 (10' 2“) 3,233 (10’6”)
F Radius of upper structure mm (ft in) 3,450 (11' 4“) 3,450 (11’4”)
G Length of track mm (ft in) 4,955 (16' 3“) 5,356 (17’6”)
H Tumbler center distance mm (ft in) 4,030 (13' 3“) 4,350 (14’3”)
Min. ground clearance mm (ft in) 498 (1' 8“) 550 (2’0”)
Travel speed (Lo/Mi/Hi) km/h (MPH) 3.2/4.5/5.5 (2/2.8/3.4) 2.5/4.0/4.9 (1.6/2.5/3.1)
Swing speed rpm 9.5

01-2 PC300LC/HD-8
GENERAL SPECIFICATION DIMENSION DRAWINGS
12
WORKING RANGES
Working ranges Unit PC300LC-8 PC300HD-8
A Max. digging reach mm (ft in) 11,100 (36' 5“) 11,100 (36’4”)
B Max. digging depth mm (ft in) 7,380 (24' 3“) 7,277 (24’0”)
C Max. digging height mm (ft in) 10,100 (33' 2“) 10,313 (34’0”)
D Max. vertical wall depth mm (ft in) 6,400 (20' 12“) 6,377 (21’0”)
E Max. dumping height mm (ft in) 7,050 (23' 2“) 7,213 (23’6”)
F Min. dumping height mm (ft in) 2,640 (8' 8“) 2,743 (9’0”)
G Max. reach at ground level mm (ft in) 10,920 (35' 10“) 10,920 (35’8”)

PC300LC/HD-8 01-3
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Machine model PC300LC-8 PC300HD-8

Serial Number A90001 and up A87001 and up

Bucket capacity m³ 1.4 1.4

Operating weight kg 32,830 36,736

Max. digging depth mm 7,380 7,277

Max. vertical wall depth mm 6,480 6,377
Working ranges

Max. digging reach mm 11,100 11,100

Max. reach at ground level mm 10,920 10,920
Max. digging height mm 10,100 10,313
Performance

Max. dumping height mm 7,050 7,213

Max. digging force kN {kg} 211.8 {21,600} (226.5 211.8 (21.59)

(using power max. function) kN {kg} {23,100}) 226.5 (23.096)
Swing speed rpm 9.5 9.5
Swing max. slope angle deg. 21 21
Travel speed km/h Lo: 3.2 (Mi: 4.5) Lo: 2.5 (Mi: 4.0)
Hi: 5.5 Hi: 4.9
Grade ability deg. 35 35

Overall length (for transport) mm 11,140 11,1405

Overall width mm 3,190 3,440
Overall width of track mm 3,190 3,440
Overall height (for transport) mm 3,250 3,383
Overall height to chassis mm 3,110 3,233
Dimensions

Ground clearance to bottom of upper structure mm 1,185 1,300

Minimum ground clearance mm 498 550
Tail swing radius mm 3,450 3,450
Min. swing radius of work equipment mm 4,310 4,310
Height of work equipment at minimum swing radius mm 8,520 8,523
Length of track on ground mm 4,030 4,350
Track gauge mm 2,590 2,740
Height of machine cab mm 3,100 3,233

01-4 PC300LC/HD-8
GENERAL SPECIFICATIONS
12
Machine model PC300LC-8 PC300HD-8

Serial Number A90001 and up A87001 and up

Model SAA6D114E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection, with
turbocharger and aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement L {cc} 8.27 {8,270}

Flywheel horsepower kW/rpm {HP/rpm} 183.9/1,980 {250/1,980}

Performance

Max. torque Nm/rpm {kgm/rpm} 1,108/1,450 {113/1,450}

Engine

Max. speed at no load rpm 2,050

Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HPh} 205 {151}

Starting motor 24V, 7.5 kW

Alternator 24V, 60 A
Battery 12V, 126 Ah x 2

Radiator core type Aluminum wave type, 4 rows

Carrier roller 2 on one side

carriage
Under-

Track roller 8 on each side 8 on each side

Assembly-type triple Assembly-type triple

Track shoe
grouser, 48 on each side grouser, 49 on each side
Hydraulic

Type x No. HPV125+125, variable displacement, Piston type x2

pump

Delivery L/min. 267.5 x 2

Set pressure MPa (kg/cm²) 37.8 {380}
Control

Type x No. 6-spool type + 1-spool type x 1

valve

Control method Hydraulic

HMV160ADT-2, piston KMV200ADT-2, variable

type piston type
Travel motor
(with brake valve, parking (with brake valve, parking
Hydraulic
motor

brake): x 2 brake): x 2
Hydraulic system

KMF230ABE-5, Piston type

Swing motor (with safety valve, holding brake): x 1
reverse rotation check valve

Type Boom (*1) Arm (*1) (*2) Bucket

Double acting Double acting Double acting

Hydraulic cylinder

piston piston piston

Inside diameter of cylinder mm 140 160 140

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

Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)

PC300LC/HD-8 01-5
GENERAL SPECIFICATIONS
*1: Cushion is provided on head side
*2: Cushion is provided on bottom side

01-6 PC300LC/HD-8
GENERAL WEIGHT TABLE
12
WEIGHT TABLE

WARNING! This weight table is for use when handling components or when transporting the
machine.

Unit: kg

Machine model PC300LC-8 PC300HD-8

Serial Number A90001 and UP A87001 and UP

Engine assembly 1,148 1,148

• Engine 865 865

• Damper 14.3 14.3

• Hydraulic pump 178 178

Radiator oil cooler assembly 153 153
Hydraulic tank, filter assembly (excluding hydraulic oil) 176 176
Fuel tank (excluding fuel) 238 238
Revolving frame 2,723 2,723
Operator’s cab 570 292
Operator’s seat 35 35
Counterweight 5,480 5,470
Swing machinery 442 442
Control valve 242 242
Swing motor 88 88
Travel motor 164 x 2 208 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,979 11,934

• Track frame 4,441 7,096

• Swing circle 487 605

• Idler 169 x 2 230 x 2

• Idler cushion 287.5 x 2 338 x 2

• Carrier roller 28 x 4 32 x 4

• Track roller 52.2 x 16 72 x 16

• Final drive (including travel motor) 583 x 2 722 x 2

PC300LC/HD-8 01-7
GENERAL WEIGHT TABLE
12

Unit: kg

Machine model PC300LC-8 PC300HD-8

Serial Number A90001 and UP A87001 and UP

Track shoe assembly

• Standard triple grouser shoe (600 mm) 3,700 4,760

• Standard triple grouser shoe (700 mm) 4,300 5,210

• Wide triple grouser shoe (800 mm) 4,680 5,670

• Wide triple grouser shoe (900 mm) --- 6,130

Boom assembly 2,290 2,290

Arm assembly 1,105 1,105

Bucket assembly 1,015 1,015

Boom cylinder assembly 254 x 2 254 x 2

Arm cylinder assembly 382 382

Bucket cylinder assembly 228 228

Link assembly (large) 316 316

Link assembly (small) — —

Boom pin 76 + 15 x 2 + 56 + 17 + 42 76 + 15 x 2 + 56 + 17 + 42

Arm pin 13 +17 13 +17

Bucket pin 30 x 2 30 x 2

Link pin 27 x 2 27 x 2

01-8 PC300LC/HD-8
GENERAL FUEL, COOLANT, AND LUBRICANTS
12
FUEL, COOLANT, AND LUBRICANTS

• ASTM: American Society of Testing and Material

Swing Final drive case

Engine oil Damper Hydraulic Cooling
machinery (each) Fuel tank
pan case system system
case PC300LC-8 PC300HD-8
Specified liter 40 16.5 9.0 10.5 1.3 365 32 605
capacity US gal 10.57 4.36 2.38 2.77 0.34 96.43 8.45 159.84
Refill liter 35 16.5 9.0 10.5 1.3 188 32 -
capacity US gal 9.25 4.36 2.38 2.77 0.34 49.67 8.45 -

Remark
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this
machine uses an electronically controlled high-pressure fuel injection device. This device requires high
precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop
markedly.

PC300LC/HD-8 01-9
GENERAL FUEL, COOLANT, AND LUBRICANTS

Note 1: HTHS (High-Temperature High-Shear Viscosity 150°C), specified by ASTM D4741 must be equal to or higher
than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bush-
ings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)
1. Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.

2. For details of the ratio when diluting super coolant with water, Supercoolant AF-NAC may be supplied in premix. In this
case, always top off with premix solution. (never dilute with water)

3. To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30%
and 68%.

01-10 PC300LC/HD-8
 10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
RADIATOR, OIL COOLER AND AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
UNDERCARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
LC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
TRIPLE GROUSER SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
HYDRAULIC EQUIPMENT LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
HYDRAULIC TANK AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
TYPE: HPV125+125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
LS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
LS(PC)-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
VARIABLE VOLUME VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
VALVE FUNCTIONS AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
HYDRAULIC CIRCUIT DIAGRAM AND THE NAME OF VALVES . . . . . . . . . . . . . . . . . . . . . . . 10-82
UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86

PC300LC/HD-8 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
PRESSURE COMPENSATION VALVE INNER SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
BOOM REGENERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
ARM REGENERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
MERGE-DIVIDER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
LS SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
SELF PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
BOOM DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
ARM DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
2-STAGE SAFETY-SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
VARIABLE PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
ATTACHMENT CIRCUIT SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
SERVICE PPC VALVE (WITH EPC VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
RETURN OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
TRAVEL MOTOR - TYPE: HMV160ADT-2 - PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
PARKING BRAKE - PC300LC-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
TRAVEL MOTOR - Type: KMV200ADT-2 - PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
PARKING BRAKE - PC300HD-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
REVERSE PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
WORK EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
DIMENSION OF ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
DIMENSION OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
BOOST PRESSURE AND TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-209
WIF (WATER-IN-FUEL DETECTION) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
ENGINE OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211

10-2 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
ENGINE AND PUMP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
PUMP AND VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220
2-STAGE RELIEF FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221
POWER MAXIMIZING AND MACHINE PUSH-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-222
AUTO-DECELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
AUTO-WARM-UP AND OVERHEAT PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-226
SWING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-228
TRAVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
PPC OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-233
OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
PUMP PRESSURE SENSOR (HIGH PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-236
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-239
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-240
MONITOR CONTROL, DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-244
MONITOR ITEMS AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-246
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-267
KOMTRAX TERMINAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-270
KOMTRAX COMMUNICATION MODEM - TH300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-271

PC300LC/HD-8 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
ENGINE AND COOLING SYSTEM

ENGINE RELATED PARTS

1. Drive plate 5. Damper assembly Outline

2. Torsion spring 6. Muffler A wet type damper assembly is used.
3. Stopper pin 7. Rear engine mount Oil capacity: 1.3 L (0.343 US gal)
4. Friction plate 8. Front engine mount

10-4 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
12
RADIATOR, OIL COOLER AND AFTERCOOLER

1. Reservoir tank 4. Oil cooler 7. Radiator inlet hose

2. Radiator 5. Guard 8. Radiator outlet hose
3. Radiator cap 6. Aftercooler 9. Shroud

Specifications

Radiator: . . . . . . . . . . . . . . . . . . . . . . .Aluminum wave type, 4th row

Oil cooler: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CF40-1

PC300LC/HD-8 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN

POWER TRAIN

1. Idler 7. Hydraulic pump (HPV125+125)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor
• HMV160ADT-2 (PC300LC-8) 11. Swing motor (HMF230ABE-5)
• KMV200ADT (PC300HD-8)
6. Engine (SAA6D114E) 12. Swing circle

10-6 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

MEMORANDUM

PC300LC/HD-8 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
FINAL DRIVE
PC300LC-8

1. Level plug 6. No. 1 planetary carrier 11. Sprocket

2. Drain plug 7. No. 2 planetary carrier 12. Floating seal

3. No. 1 planetary gear (No. of teeth: 42) 8. Cover 13. Travel motor

14. No. 2 planetary gear

4. No. 1 sun gear (No. of teeth: 11) 9. Ring gear (No. of teeth: 97)
(No. of teeth: 38)

5. No. 2 sun gear (No. of teeth: 19) 10. Hub

Specifications

Reduction ratio: . . . . . . . . . . . . . -((11+97)/11)x((19+97)/19)=-58.943

10-8 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

Unit: mm
No. Check Item Criteria Remedy
Standard clearance Clearance limit
Backlash between No. 1 sun gear and No. 1 plane-
15 tary gear 0.12 - 0.44 0.9
16 Backlash between No. 1 planetary gear and ring 0.18 - 0.62 1.2
gear
17 Backlash between No. 2 planetary carrier and motor 0.06 - 0.25 -
18 Backlash between No. 2 sun gear and No.2 0.15 - 0.51 1.00 Replace
planetary gear
19 Backlash between No. 2 planetary gear and ring 0.19 - 0.66 1.3
gear
20 Backlash between No. 2 planetary carrier and No. 2 0.39 - 0.80 1.6
sun gear
21 Amount of wear on sprocket tooth Repair limit: 6
Build-up welding for
Standard size Repair limit rebuilding or replace
22 Width of sprocket tooth 87 84
Torque
Nm lbf ft
1st: 98 1st: 72.3
23 Bolt 2nd: 105±5° 2nd: 105±5°
24 Bolt 640 - 785 472 - 579
25 Bolt 49 - 74 36.1 - 54.6
26 Bolt 490 - 608 361 - 448

PC300LC/HD-8 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN

PC300HD-8

1. Level plug 6. No. 1 planetary carrier 11. Floating seal

2. Drain plug 7. No. 2 planetary carrier 12. Travel motor

13. No. 2 planetary gear (No.

3. No. 1 planetary gear (No. of teeth: 43) 8. Cover
of teeth: 38)

4. No. 1 sun gear (No. of teeth: 10) 9. Ring gear (No. of teeth: 98)

5. No. 2 sun gear (No. of teeth: 18) 10. Sprocket

Specifications
Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-10 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
Backlash between No. 1 sun gear and No. 1 planetary
14 gear 0.15 - 0.54 1.10
15 Backlash between No. 1 planetary gear and ring gear 0.18 - 0.66 1.30
16 Backlash between No. 2 planetary carrier and motor 0.06 - 0.24 -
Replace
Backlash between No. 2 sun gear and No. 2 planetary
17 gear 0.15 - 0.51 1.00

18 Backlash between No. 2 planetary gear and ring gear 0.17 - 0.60 1.20
Backlash between No. 2 planetary carrier and No. 2
19 sun gear 0.15 - 0.54 -

20 Amount of wear on sprocket tooth Repair limit: 6

Standard size Repair limit Rebuild or replace
21 Width of sprocket tooth 90 87
Torque
Nm lbf ft
22 Bolt 98 - 123 72.3 - 90.7
23 Bolt 59 - 74 43.5 - 54.6
24 Bolt 640 - 785 472 - 579
25 Bolt 490 - 608 361 - 448

PC300LC/HD-8 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
SPROCKET
PC300LC-8

Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip 336.5 324.5
2 Thickness of tooth root 20 14 Build-up welding for
rebuilding or replace
3 Width of tooth 87 84
Repair limit: 6 (measure with the full-size drawing of
4 Wear of tooth shape sprocket tooth shape)

10-12 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Full-size drawing of sprocket tooth shape.

★ The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy on an OHP sheet.

PC300LC/HD-8 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
PC300HD-8

Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip 355 343
2 Thickness of tooth root 20.8 14.8 Build-up welding for
rebuilding or replace
3 Width of tooth 90 87

4 Wear of tooth shape Repair limit: 6 (measure with the full-size drawing of
sprocket tooth shape)

10-14 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Full-size drawing of sprocket tooth shape.

★ The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy on an OHP sheet.

PC300LC/HD-8 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
SWING MACHINERY

10-16 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12

1. Swing pinion (No. of teeth: 13) 8. No. 1 planetary carrier

2. Cover 9. No. 1 planetary gear

3. Plate 10. Swing motor

4. No. 2 planetary carrier 11. Oil level gauge

5. Ring gear 12. No. 1 sun gear

6. No. 2 planetary gear 13. Case

7. No. 2 sun gear 14. Drain plug

Specifications

Reduction ratio: . . . . . . . . . . . . . . ((19+68)/19)x((24+68)/24)=17.553

Unit: mm
No. Check Item Criteria Remedy
Standard clearance Clearance limit
Backlash between swing motor shaft and No. 1
15 sun gear 0.18 - 0.28 -
16 Backlash between No. 1 sun gear and No.1 0.15 - 0.51 1.00
planetary gear
17 Backlash between No. 1 planetary gear and ring 0.17 - 0.60 1.10
gear

18 Backlash between No. 1 planetary carrier and No. 0.40 - 0.75 1.20
2 sun gear
Replace
19 Backlash between No. 2 sun gear and No.2 0.16 - 0.55 1.00
planetary gear

20 Backlash between No. 2 planetary gear and ring 0.17 - 0.60 1.10
gear

21 Backlash between No. 2 planetary carrier and 0.07 - 0.23 -

swing pinion
22 Backlash between swing pinion and swing circle 0 - 1.21 2.00
23 Clearance between plate and No. 2 planetary 0.57 - 1.09 -
carrier

Standard size Repair limit

Reapply hard chrome
0 plating or replace
Wear of swing pinion surface contacting with oil 145 -
24 seal -0.100
Torque
Nm lbf ft
25 Bolt 824 - 1030 607 - 759
26 Bolt 59 - 74 43.5 - 54.5
27 Bolt 343 - 427 253 - 314
28 Bolt 2.81 - 3.79 2.0 - 2.7
29 42.1 - 70.6 31 - 52

PC300LC/HD-8 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
SWING CIRCLE

1. Swing circle inner race (No. of teeth: 90) a. Inner race soft zone "S" position

2. Ball b. Outer race soft zone "S" position

3. Swing circle outer race

10-18 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
Specifications

Reduction ratio: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -90/13=-6.923

Amount of grease: . . . . . . . . . . . . . . . . . . . . . . . 33L (8.71 gal) G2-LI

Unit: mm
No. Check Item Criteria Remedy
Standard clearance Clearance limit
Axial clearance of bearing (when Replace
4 mounted on chassis) 0.5 - 1.6 3.2
Torque
Nm lbf ft
5 Bolt 824 - 1030 608 - 759

PC300LC/HD-8 10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
UNDERCARRIAGE AND FRAME
TRACK FRAME AND RECOIL SPRING
PC300LC-8

1. Idler 5. Track roller

2. Track frame 6. Track shoe
3. Carrier roller 7. Center guard
4. Final drive 8. Front guard

Number of track roller: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10-20 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Standard shoe

Model
Item PC300LC-8
Shoe width (triple shoe) (mm) 600
Link pitch (mm) 216
No. of shoes (one side) 48

Unit: mm
Criteria Remedy
No Check Item
Standard size Tolerance Rapair limit
Track +2
123 127
Vertical width of idler frame -1
9 Build-up
guide Idler 120 ±0.5 118 welding for
support rebuilding or
Track +3 replace
266 271
Horizontal width of idler frame -1
10 guide
Idler 261 - 259
support
Standard size Rapair limit
Free length Installation Installation Installation
x Free length
length load load
11 Recoil spring O.D. Replace
208.7 kN 167.0 kN
811 x 261 655 {21,290 - {17,030 kg}
kg}

PC300LC/HD-8 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC300HD-8

1. Idler 5. Track roller

2. Track frame 6. Track shoe
3. Carrier roller 7. Center guard
4. Final drive 8. Front guard

Number of track roller: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10-22 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Standard shoe

Model
Item PC300HD-8
Shoe width 700
Link pitch (mm) 228
No. of shoes (one side) 49

Unit: mm
Criteria Remedy
No Check Item
Standard size Tolerance Rapair limit
Track +3
148 -
Vertical width of idler frame -1
9 guide Idler 145 ±0.5 - Rebuild or
support replace
Track +4
302 -
Horizontal width of idler frame -1
10 guide
Idler 297 - -
support
Standard size Rapair limit
Free length Installation Installation Installation
x Free length
length load load
11 Recoil spring O.D. Replace
239 kN
845 x 262 690 {24,375 - -
kg}

PC300LC/HD-8 10-23
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
IDLER
PC300LC-8

10-24 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12

Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of protrusion 635 -
2 Outside diameter of tread 590 578
Build-up welding for
3 Difference of tread 22.5 28.5 rebuilding or replace
4 Thickness of tread - -
5 Total width 190 -
6 Width of tread 44 50

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

Clearance between shaft and 80 -0.225 +0.130 0.201-0.455 -

7 bushing -0.325 -0.024

Standard Tolerance Standard Interference

size interference limit Replace bushing
Shaft Hole
Interference between idler and +0.087 -0.027
87.6 0.064-0.166 -
8 bushing +0.037 -0.079
Clearance between bushing and Standard size Clearance limit
support
9 (Sum of clearance at both sides) 0.68 - 1.22 -

PC300LC/HD-8 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC300HD-8

10-26 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of protruding
704 ---
2 Outside diameter of tread 660 648
Rebuild or
3 Depth of tread 22 28 replace
4 Thickness of tread 21 15
5 Total width 202 ---
6 Width of tread 48.5 54.5
Clearance between bushing and
7 support 0.46 - 0.86 ---
(Sum of clearance at both sides)
Tolerance Standard
Standard size
Shaft Hole clearance
8 Clearance between shaft and bushing
Replace
-0.120 +0.360
95 0.340-0.507 bushing
-0.207 +0.220
Tolerance Standard
Standard size
Shaft Hole interference
9 Interference between idler and bushing
+0.087 -0.027
102.6 0.010-0.149
+0.037 -0.062
Torque Nm Torque lbf ft
10 Bolt
130 - 180 96 - 132

PC300LC/HD-8 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
CARRIER ROLLER
PC300LC-8

Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of flange 179 -
2 Outside diameter of tread 152 138
3 Width of tread 50.3 -
4 Thickness of tread 32 25
5 Width of flange 19 -

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit Replace
Clearance between shaft and -0.250 +0.074
54 0.250-0.354 -
6 bushing -0.280 +0.040

Standard Tolerance Standard Interference

size Shaft Hole interference limit

Interference between roller and +0.117 +0.030 0.057-

61 -
7 bushing +0.087 +0.040 0.117
Standard clearance Clearance limit
8 Axial clearance of roller 0.5 - 0.7 -

10-28 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
LC300HD-8

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange 179 ---
2 Outside diameter of tread 152 138
3 Width of tread 50.3 ---
4 Thickness of tread 32 25
5 Width of flange 19 ---

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit Replace
-0.250 +0.074
54 0.250 - 0.354 ---
6 Clearance between shaft and bushing -0.280 0

Standard Tolerance Standard Interference

size Shaft Hole interference limit

+0.117 +0.030
61 0.057 - 0.117 ---
7 Clearance between roller and bushing +0.087 0
Standard clearance Clearance limit
8 Axial clearance of roller 0.5 - 0.7 ---

PC300LC/HD-8 10-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
TRACK ROLLER
PC300LC-8

10-30 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12

Unit: mm
No Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange 216 -
Outside diameter of inner flange (Double
2 210 -
flange)
3 Outside diameter of tread 180 168
4 Thickness of tread 54 48
5 Overal width 250 - Build-up
Single welding for
49 rebuilding or
flange
6 Width of tread - replace
Double 47.7
flange
Single
flange
7 Width of flange 27 -
Double
flange
Width of inner frange
8 98 -
(Double frame)
Clearance between bushing and collar
9 0.44-0.97 -
(Sum of clearance at both sides)

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.250 +0.186 0.186- Replace

65 -
10 Clearance between shaft and bushing -0.350 -0.064 0.536 bushing

Standard Tolerance Standard Interference

size Shaft Hole interference limit
Interference between roller and +0.108 -0.006
72 0.014-0.144 -
11 bushing +0.008 -0.036
Torque
Nm lbf ft
12 Bolt 10 - 20 7.3 - 14.0
1st: 200±20 1st:147±14.75
13 Bolt 2nd: 105±5° 2nd:105±5°

PC300LC/HD-8 10-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC300HD-8

10-32 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12

Unit: mm
No Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange 240 -
Outside diameter of inner flange (Double
2 237 -
flange)
3 Outside diameter of tread 200 188
4 Thickness of tread 56.2 50.2
5 Overal width 278 - Build-up
welding for
Single rebuilding or
54.6
flange replace
6 Width of tread -
Double 51.6
flange
Single 34.4 -
flange
7 Width of flange
Double 34.4 -
flange
8 Width of inner frange (Double frame) 23.0 -
9 Axial play 0.4-1.0 -

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit

-0.250 +0.174
80 0.279-0.524 - Replace
10 Clearance between shaft and bushing -0.350 +0.029 bushing
Standard Tolerance Standard Interference
size Shaft Hole interference limit
Interference between roller and +0.087 +0.022
87.6 0.015-0.100 -
11 bushing +0.037 -0.013
Torque
Nm lbf ft
12 Bolt 10 - 20 7.3 - 14.0

PC300LC/HD-8 10-33
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
TRACK SHOE
PC300LC-8

★ P portion shows the link of bushing press fitting end.

Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch 216.3 219.3 Reverse or replace
2 Outside diameter of bushing 66.9 61.9
3 Thickness of bushing metal 10.8 5.8 Adjust or replace
4 Link height 116 107
Thickness of link metal Repair or replace
5 30.7 21.7
(bushing press-fitting portion)

10-34 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME

Unit: mm
No Check Item Criteria Remedy
6 178.4
7 Shoe bolt pitch 140.4 Replace
8 76.2
Inside
9 102
width
Overall
10 Link 47.8 Repair or replace
width
Tread
11 42.6
width
12 Protrusion of pin 4.2
13 Protrusion of regular bushing 5.25
14 Overall length of pin 242
Adjust or replace
15 Overall length of bushing 148.4
Standard size Reverse
16 Thickness of spacer 10.8 5.8
17 Bushing 98 - 264.6 kN (10 - 27 ton)
Regular
18 Press-fitting force 147 - 362.6 kN (15 - 37 ton)
pin -
19 Master 98 - 215.6 kN (10 - 22 ton)
(*) pin
Torque (Nm {kgm}) Retightening angle (deg.)
a.Regu-
lar link 393±39
Triple grouser shoe 120±10
{40±4}
20 Shoe bolt Retighten
Retightening angle Lower limit torque
b.Master Torque (Nm {kgm}) (deg.) (Nm {kgm})
link
- - -
Tolerance Standard
Standard size
Shaft Hole interference
Interference between bushing +0.464 +0.074
66.5 0.350-0.464
21 and link +0.424 0

22
Interference between regular 44.6 +0.235 -0.188 0.273-0.485
pin and link +0.085 -0.250
Standard
23
Clearance between regular pin 44.6 +0.235 +0.915 clearance Adjust or replace
and bushing +0.085 +0.415
0.180-0.830
Standard
24 Interference between master pin +0.03 -0.188 interference
44.6
(*) and link 0 -0.250
0.188-0.280
Standard
25 Clearance between master pin +0.050 +0.915 clearance
44.3
(*) and bushing -0.050 +0.415
0.365-0.965

* Dry type track link

PC300LC/HD-8 10-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC300HD-8

★ P portion shows the link of bushing press fitting end.

Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Link pitch 228.9 231.9 Reverse or replace
2 Outside diameter of bushing 71.5 66.5
3 Thickness of bushing metal 11.9 6.9 Adjust or replace
4 Link height 129 119
Thickness of link metal Repair or replace
5 34.5 24.5
(bushing press-fitting portion)

10-36 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12

Unit: mm
No Check Item Criteria Remedy
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
Inside
9 106
width
Overall
10 Link 51.6 Repair or replace
width
Tread
11 44.8
width
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer -
17 Bushing 118 - 304 kN (12 - 31 ton)
Regular
18 Press-fitting force 176 - 451 kN (18 - 46 ton)
pin -
19 Master 137 - 284 kN (14 - 29 ton)
(*) pin
Torque (Nm {kgm}) Retightening angle (deg.)
a.Regu-
lar link 393±39
Triple grouser shoe 120±10
{40±4}
20 Shoe bolt Retighten
Retightening angle Lower limit torque
b.Master Torque (Nm {kgm}) (deg.) (Nm {kgm})
link
- - -
Tolerance Standard
Standard size
Shaft Hole interference
Interference between bushing +0.494 +0.074
71 0.380-0.494
21 and link +0.454 0

22
Interference between regular 47 +0.235 -0.218 0.303-0.515
pin and link +0.085 -0.280
Standard
23
Clearance between regular pin 47 +0.235 +0.915 clearance Adjust or replace
and bushing +0.085 +0.415
0.180-0.830
Standard
24 Interference between master pin +0.03 -0.218 interference
47
(*) and link 0 -0.280
0.218-0.310
Standard
25 Clearance between master pin -0.2 +0.915 clearance
47
(*) and bushing -0.4 +0.415
0.615-1.315

* Dry type track link

PC300LC/HD-8 10-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
TRIPLE GROUSER SHOE
PC300LC-8

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
36 24
2 Thickness 11
3 32
Length at of base
4 26 Build-up welding for
5 24 rebuilding or replace

6 Length at tip 18
7 18
Standard size Repair limit
8 Thickness
47 35

10-38 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD UNDERCARRIAGE AND FRAME
12
PC300HD-8

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
37 22
2 Thickness 13
3 33
Length at of base
4 27 Build-up welding for
5 25.5 rebuilding or replace

6 Length at tip 17.5

7 23.5
Standard size Repair limit
8 Thickness
50 35

PC300LC/HD-8 10-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM

HYDRAULIC EQUIPMENT LAYOUT DRAW-

ING

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Work equipment lock lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Hydraulic drift prevention valve
19. Accumulator
20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Travel junction solenoid
20C. Pump merge/divider solenoid
20D. Travel speed solenoid
20E. Swing brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid

10-40 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

PC300LC/HD-8 10-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
HYDRAULIC TANK AND FILTER

Specifications

Tank capacity: 275 L (290.5 qts.)

Amount of oil inside tank: 188 L (199 qts.)
1. Oil filler cap Pressure valve
2. Bypass valve Relief cracking pressure:
3. Strainer 16.7 ± 6.9 kPa
4. Filter element (2.4 ± 1.0 psi)
5. Sight gauge Suction cracking pressure:
6. Hydraulic tank 0 - 0.49 kPa
(0 - 0.1 psi)
Bypass Valve set pressure:
150 ± 30 kPa
(22.0 ± 4.4 psi)

10-42 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

MEMORANDUM

PC300LC/HD-8 10-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
HYDRAULIC PUMP
TYPE: HPV125+125

10-44 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

Outline

● This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve and variable volume
valve.

BMP: Breather fitting port

IM: PC mode selector current
ISIG: LS set pressure selector current
OCP: Oil level detection port
PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Case drain port
PD1R: Air breeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure detection port
PENR: Rear control pressure detection port
PEPC: EPC basic pressure port
PEPB: EPC basic pressure detection port
PFC: Front pump delivery pressure detection port
PLSC: LS set selector pressure detection port
PLSF: Front load pressure input port
PLSFC: Front load pressure detection port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure detection port
PM: PC mode selector pressure detection port
PRC: Rear pump delivery pressure detection port
PS: Pump suction port

1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
7. Variable volume valve

Torque
Nm lbf ft
8. Plug 19.6 - 37.4 14.4 - 20.2
9. Plug 98 - 123 72.2 - 90.7
10. Plug 11.8 - 14.7 8.7 - 10.8
11. Screw 6.9 - 9.8 5.0 - 7.2
12. Screw 11.8 - 14.7 8.7 - 10.8
13. Drain plug 58.8 - 78.4 43.3 - 57.8
14. LS valve 132 - 157 97.3 - 115.7

PC300LC/HD-8 10-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Shaft (Front) 8. Valve plate

2. Cradle 9. End cap
3. Case (Front) 10. Shaft (Rear)
4. Rocker cam 11. Case (Rear)
5. Shoe 12. Servo piston
6. Piston 13. PC valve
7. Cylinder block

Torque
Nm lbf ft
14. Plug 7.8 - 9.8 5.7 - 7.2
15. Plug 58.8 - 78.4 43.3 - 57.8
16. Bolt 246.3 - 308.7 181.6 - 227.6
17. Bolt 245 - 309 180.7 - 227.9
18. Valve 637 - 764.4 469.8 - 563.7

10-46 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

Function

● The pump converts the engine rotation transmitted to the shaft to oil pressure and delivers pressurized oil corresponding to
the load.
● It is possible to change the discharge amount by changing the swash plate angle.
Structure

● Cylinder block (7) is supported to shaft (1) by spline (14).

● Shaft (1) is supported by front and rear bearings (15).
● Tip of piston (6) is shaped as a concave ball and shoe (5) is staked to it to form one unit.
● Piston (6) and shoe (5) constitute the spherical bearing.
● Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a circular
movement.
● Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms
a static pressure bearing when it slides.
● Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
● Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation.
● This surface is designed so that the oil pressure balance is maintained at a suitable level.
● The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).

PC300LC/HD-8 10-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation

● 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 (a) between center line (X) of rocker cam (4) and the
axial direction of cylinder block (7) changes.
● (a) is named the swash plate angle.

● With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
● In this way, piston (6) slides on the inside of cylinder block (7), so a
difference between volumes (E) and (F) is created inside cylinder
block (7).
● A single piston (6) sucks and discharges the oil by the amount
(F) – (E).
● As cylinder block (7) rotates and the volume of chamber (E)
becomes smaller, the pressurized oil is discharged.
● On the other hand, the volume of chamber (F) grows larger and, in
this process, the oil is suctioned.
● As center line (X) of rocker cam (4) matches the axial direction of
cylinder block (7) (swash plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7) becomes 0.
● Suction and discharge of pressurized oil is not carried out in this
state. Namely pumping action is not performed. (Actually, however,
the swash plate angle is not set to 0)

10-48 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Control of discharge amount

● If the swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and pump delivery (Q)
increases.
● Servo piston (12) is used for changing swash plate angle (a).
● Servo piston (12) carries out linear reciprocal movement according
to the signal pressure from the PC and LS valves.
● This linear movement is transmitted to rocker cam (4) via slider (13).
● Being supported by cradle (2) on the cylindrical surface, rocker cam
(4) slides on the surface while continuing revolving movement.
● Space of the pressure receiving area of servo piston (12) are not
identical on the left side and right side. Main pump discharge
pressure (self pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
● Output pressure (PEN) of the LS valve is brought to the chamber
receiving the pressure at the large diameter piston end.
● The relationship in the size of pressure (PP) at the small diameter
piston end and pressure (PEN) at the large diameter piston end, and
the ratio between the area receiving the pressure of the small
diameter piston and the large diameter piston controls the movement
of servo piston (12).

PC300LC/HD-8 10-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS VALVE

1. Sleeve PA : Pump port

2. Piston PDP : Drain port
3. Spool PLP : LS control pressure output port
4. Spring PLS : LS pressure input port
5. Seat PP : Pump port
6. Sleeve PPL : PC control pressure input port
7. Plug PSIG : LS mode selection pilot port
8. Locknut

Function

Front Pump
● The LS (load sensing) valve detects the load and controls the
discharge amount.
● This valve controls main pump delivery (Q) according to
differential pressure (ΔPLS)[= PP ~ LS], called the LS differential
pressure (the difference between main pump pressure PP and
control valve outlet port pressure PLS).
● Main pump pressure (PP), pressure (PLS) (called the LS pressure)
coming from the control valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional solenoid valve enter
this valve.

Rear Pump
● The relationship between the LS differential pressure between the
main pump pressure (PP) and LS pressure (PLS) (ΔPLS) [= (PP) -
(PLS)] and the pump delivery (Q) changes as shown in the diagram
according to LS selector current (ISIG) of the LS-EPC valve.
● If (ISIG) changes from 0 to 1A, setting force the spring changes,
too. As the result, the specified median of the pump delivery
volume switching point changes as shown in the diagram. As for
the front pump side, it will change in the range of 0.98 to 2.45 MPa
{in the range of 10 to 25 kg/cm2} and as for the rear pump side, it
will change in the range of 1.08 to 2.55 MPa {in the range of 11 to
26 kg/cm2}.

10-50 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation

1. Control valve is situated at neutral

● The LS valve is a 3-way selector valve, with pressure (PLS) (LS pressure) from the outlet port of the control valve
brought to spring chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8).
● Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (self
pressure) (PP) determine the position of spool (6).
● However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for the LS valve
entering port (G) also changes the position of spool (6). (Setting force of the spring is changed)
● Before the engine is started, servo piston (12) is pushed to the right. (See the figure)
● If the control lever is at the neutral position when the engine is started, LS pressure (PLS) will be set to 0 MPa {0 kg/
cm2}. (It is interconnected to the drain circuit via the control valve spool)
● Spool (6) is pushed to the right, and port (C) and port (D) will
be connected.
● Pump pressure (PP) is conducted to the larger diameter end
from the port (K).
● The same pump pressure (PP) is conducted to the smaller
diameter end from the port (J).
● According to the difference in the areas on servo piston (12),
the pressure moves in such that the swash plate angle may be
minimized.

PC300LC/HD-8 10-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Action for the direction of maximizing the pump delivery

● When the difference between the main pump pressure (PP) and LS pressure (PLS), in other words, LS differential
pressure (ΔPLS) becomes smaller (for example, when the area of opening of the control valve becomes larger and
pump pressure PP drops), spool (6) is pushed to the left by the combined force of LS pressure (PLS) and the force of
spring (4).
● When spool (6) moves, port (D) and port (E) are interconnected and connected to the PC valve.
● The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT).
(The operation of the PC valve is explained later.)
● The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT), and pump pressure (PP)
enters port (J) at the small diameter end, so servo piston (12) is pushed to the left side. Therefore, the swash plate is
moved in the direction to make the discharge amount larger.
● If the output pressure of the EPC valve for the LS valve enters port (G), rightward force is generated on piston (7).
● If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential pressure
(ΔPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6) are connected.

10-52 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. Action for the direction of minimizing the pump delivery

● When LS differential pressure (ΔPLS) becomes larger (for example, when the area of opening of the control valve
becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo
piston (12), pump pressure (PP) pushes spool (6) to the right.
● When spool (6) moves, main pump pressure (PP) flows from port (C) to port (D) and from port (K), it enters the large
diameter end of the piston.
● Main pump pressure (PP) also enters port (J) of the small diameter end of the piston, but because of the difference in
area between the large diameter end and the small diameter end on servo piston (12), it is pushed to the right. As the
result, servo piston (12) moves into the direction of reducing the swash plate angle.
● As LS selector pressure (PSIG) is input to port (G), setting force of spring (4) is reduced.

PC300LC/HD-8 10-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
4. When servo piston is balanced

● Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the
pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as
(PEN).
● If the main pump pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are
balanced, and the relationship is (A0) x (PP) = (A1) x (PEN), servo piston (12) will stop in that position.
● And the swash plate of the pump will be held in an intermediate position. [Spool (6) will be stopped at a position
where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the
same.]
● At this point, the relationship between the pressure receiving areas across servo piston (12) is (A0): (A1) = 3: 5, so the
pressure applied across the piston when it is balanced becomes (PP): (PEN) approximately 5: 3.
● Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (6) may be determined when
(PP) - (PLS) = 2.45 MPa {25 kg/cm2} on the front pump side and (PP) - (PLS) = 2.55 MPa {26 kg/cm2} on the rear
pump side at the median of the specified value.
● If (PSIG) [Output pressure of LS-EPC valve, 0 to 2.9 MPa {0 to 30 kg/cm2}] is input to port (G), the position of the
balanced stop is changed. The front pump side will be moved in the range of (PP) - (PLS) = 2.45 to 0.98 MPa {25 to
0 kg/ cm2} and the rear pump will be moved in the range of (PP) - (PLS) = 2.55 to 1.08 MPa {26 to 11 kg/cm2} in
proportion to (PSIG) pressure.

10-54 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PC VALVE

1. Plug
2. Servo piston assembly PA : Pump port
3. Pin PA2 : Pump pressure pilot port
4. Spool PDP : Drain port
5. Retainer PM : PC Mode selector pressure pilot port
6. Seat PPL : LS Control pressure output port
7. Cover
8. Wiring

Function

● When the pump discharge pressure (PP1) (self-pressure) and (PP2) (other pump pressure) are high, the PC valve controls
the pump so that the volume of oil beyond the discharge pressure-based specific flowrate may not be conducted however
you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it
may not exceed the engine hose power.
● If the pump discharge pressure increases due to increased load during operation, this valve decreases the pump delivery.
● And if the pump delivery pressure goes low, it increases the pump delivery.
● In this case, relation between the mean discharge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and the pump
delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter the current value (X) to
be given to PC-EPC valve solenoid.
● The controller continues counting the actual engine speed.
● If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to recover the speed.
● If the engine speed goes below the specified value because of
increased load, the controller sends a command current to PC-EPC
valve solenoid in order to reduce the slope angle in proportion to
reduction in the engine speed.

PC300LC/HD-8 10-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation

When Pump Controller Is Normal

1. When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low

★ Action of PC-EPC valve solenoid (1)

● Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller.
● This command current acts on PC-EPC valve to output the signal pressure in order to modify the force pushing piston
(2).
● Spool (3) stops at a position where the combined spool-pushing force is balanced by the setting force of springs (4)
and (6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure).
● The pressure [port (C) pressure] output from PC valve is changed depending on the above position.
● The size of command current (X) is determined by the nature of the operation (lever operation), the selected working
mode, and the set value and actual value of the engine speed.
● Other pump's pressure denotes the pressure of the pump situated on the opposite side.
● For the front pump pressure, the other pump's pressure is that of the rear pump.
● And for the rear pump pressure, the other pump's pressure is that of the front pump.

10-56 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Action of spring

● Load of springs (4) and (6) on the PC valve is determined by the swash plate position.
● As servo piston (9) moves to right, spring (6) is retracted.
● If the servo piston moves further, it will make contact against seat (5) and spring (6) will be fixed.
● After that, spring (4) alone will operate.
● The spring load is changed by servo piston (9) as it extends or compresses springs (4) and (6).
● If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2).
● Spring load of springs (4) and (6) is also affected by the command current (X) to PC-EPC valve solenoid.
● Port (C) of the PC valve is connected to port (E) of the LS valve.
● Self pressure (PP1) enters port (B) and the small diameter end of servo piston (9), and other pump pressure (PP2) enters
port (A).
● When pump pressures (PP1) and (PP2) are small, spool (3) will be positioned in the left side.
● Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
● If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port
(J) becomes drain pressure (PT), and servo piston (9) moves to the left side.
● The pump delivery will be set to the increasing trend.
● Accompanied with move of servo piston (9), springs (4) and (6) will be expanded and the spring force becomes weaker.
● As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and
the pump discharge pressure ports (B) and (C) are connected.
● As a result, the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the
leftward move of servo piston (9) is stopped.
● Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the
pressures (PP1) and (PP2) applied to spool (3), the pushing force of the solenoid in PC-EPC valve generates and the
pushing force of springs (4) and (6) are balanced.

PC300LC/HD-8 10-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When load on actuator is large and pump discharge pressure is high

Outline

• When the load is large and pump discharge pressures (PP1) and (PP2) are high, the force pushing spool (3) to the right
becomes larger and spool (3) will be moved to the position shown in above figure.
• Part of the pressure to be conducted from port (C) to LS valve flows from port (B) to port (C) and (D) via LS valve. At the
end this flow, level of this pressure becomes approximately half of the main pump pressure (PP2).

Operation

• When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of
servo piston (9), stopping servo piston (9).
• If main pump pressure (PP2) increases further and spool (3) moves further to the right, main pump pressure (PP1) flows to
port (C) and acts to make the pump delivery the minimum.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).
• When spool (3) moves to the left, the opening of port (C) and port (D) becomes larger.
• As a result, the pressure on port (C) (= J) is decreased and the rightward move servo piston (9) is stopped.
• The position in which servo piston (9) stops at this time is further to the right than the position when pump pressures (PP1)
and (PP2) are low.

10-58 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
● The relationship between the average pump pressure (PP1 + PP2)/2
and servo piston (9) in terms of their positions can be represented
by the broken line in the figure springs (4) and (6) form the double
springs.
● The relationship between the average pump pressure (PP1 + PP2)/2
and average pump delivery (Q) becomes as shown below.

● If command voltage (X) sent to PC-EPC valve solenoid (1)

increases further, the relationship between average pump pressure
(PP1 + PP2)/2, and pump delivery (Q) is proportional to the force
of the PC-EPC valve solenoid and moves in parallel.
● Namely, the force of PC-EPC valve solenoid (1) is added to the
pushing force to the right because of the pump pressure applied to
the spool (3), so the relationship between the average pump
pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A)
to (B) as the command current (X) is increased.

PC300LC/HD-8 10-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
When the main pump is under light load

3. As the emergency pump drive switch is turned on due to failure on the pump controller

• If there is a failure in the pump controller, the emergency pump drive switch is turned on to hand the control to the resistor
side.
• In this case, the power is directly supplied from the battery. The current, however, is too large as is, so the resistor is set in
between to control the current flowing to PC-EPC valve solenoid (1).
• The current becomes constant, so the force pushing piston (2) is also constant.
• If the main pump pressures (PP1) and (PP2) are low, the combined force of the pump pressure and the PC-EPC valve
solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left.
• At this point, port (C) is connected to the drain pressure of port (D), and the large diameter end of the piston of servo
piston (9) also becomes the drain pressure (PT) through the LS valve.
• Since the pressure on the small diameter end of the piston large, servo piston (9) moves in the direction to make the
discharge amount larger.

10-60 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
When the main pump is under heavy load

● If the emergency pump drive switch is turned on In the same way as in above, the command current (X) sent to PC-EPC
valve solenoid (1) becomes constant.
● For this reason, the force of piston (2) pushing spool (3) is constant.
● If main pump pressures (PP1) and (PP2) increase, spool (3) moves further to the right than when the main pump load is
light, and is balanced at the position in the diagram above.
● In this case, the pressure from port (B) flows to port (C), so servo
piston (9) moves to the right (smaller pump delivery) and stops at a
position to the further to the right then when the load on the pump is
light.
● When the emergency pump drive switch is turned on, too, the pump
pressure (PP) and pump delivery (Q) have a relationship as shown
with the curve in the figure corresponding to the current sent to the
PC-EPC valve solenoid through the resistor.
● The curve resulting when the emergency pump drive switch is ON
is situated further to the left (B) than when the pump controller is
normal (A).

PC300LC/HD-8 10-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS(PC)-EPC VALVE

1. Connector
2. Coil
3. Body C: To LS (PC) valve
4. Spring P: From self pressure reducing valve
5. Spool T: To tank
6. Rod
7. Plunger

Torque
Nm lbf ft
8. Screw 0.1 - 0.3 0.07 - 0.22
9. Bolt 9.8 - 12.7 7.2 - 9.3

10-62 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function

• The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
• 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 (PC) valve.

Operation

1. When signal current is 0 (coil is de-energized)

• When there is no signal current flowing from the controller to
coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left by spring (4).
• Port (P) closes and the pressurized oil from the self pressure
reducing valve does not flow to the LS (PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the
tank via port (C) and port (T).

PC300LC/HD-8 10-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When signal current is very small (coil is energized)
● When a very small signal current flows to coil (2), coil (2) is
energized, and a propulsion force is generated on the right side
of plunger (7).
● Rod (6) pushes spool (5) to the right, and pressurized oil flows
from port (P) to port (C).
● Pressures on port (C) increases and the force to act on spool (5)
surface and the spring load on spring (4) become larger than
the propulsion force of plunger (7).
● Spool (5) is pushed to the left, and port (P) is shut off from port
(C).
● Port (C) and port (T) are connected.
● Spool (5) moves up and down so that the propulsion force of
plunger (7) may be balance with pressure of port (C) + spring
load of spring (4).
● The circuit pressure between the EPC valve and the LS (PC)
valve is controlled in proportion to the size of the signal
current.

3. When signal current is maximum (coil is energized)

● As the signal current flows to coil (2), coil (2) is energized.
● When this happens, the signal current is at its maximum, so the
propulsion force of plunger (7) is also at its maximum.
● Spool (5) is pushed toward right side by rod (6).
● The maximum volume of pressurized oil is conducted from
port (P) to port (C), increasing the circuit pressure across EPC
valve and LS (PC) valve to the maximum level.
● Since port (T) is closed, pressurized oil does not flow to the
tank.

10-64 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
VARIABLE VOLUME VALVE

1. Plug
C1: To PC valve
2. Block
P1: From self pressure reducing valve
3. Piston
T1: To tank
4. Spring

Torque
Nm lbf ft
5. Plug 44.1 - 53.9 32.5 - 39.7

Function
• The variable volume valve stabilizes the EPC valve's output
pressure.
Operation
• Output pressure from EPC valve is conducted to port (C) and as the
result propulsion force of piston (3) is increased by the load of
spring (4).
• Piston (3) is pushed to the left, and volume of port (C) is increased.
• The propulsion force of piston (3) becomes smaller than the load of
spring (4).
• Piston (3) is pushed toward right, and volume of port (C) is
decreased.

PC300LC/HD-8 10-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
CONTROL VALVE
Outline

• The control valve consists of a 7-spool valve (6-spool valve + boom Hi, arm Hi valve) and a set of service valves. A
merge-divider valve, a back pressure valve, a boom drift preventive valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each other inside the
assembly, the assembly is compact and easy to maintain.

A1: To bucket cylinder bottom P-5: From service 2 and PPC valves
A2: To L.H. travel motor P-6: From service 2 and PPC valves
A3: To boom cylinder bottom PLS1: To front pump control
A4: To swing motor PLS2: To rear pump control
A5: To R.H. travel motor PP1: From front pump
A6: To arm cylinder head PP2: From rear pump
A-1: To boom cylinder bottom PP1S: Pressure sensor mounting port
A-2: To attachment 1 PP2S: Pressure sensor mounting port
A-3: To attachment 2 PPS1: To front pump control
B1: To bucket cylinder head PPS2: To rear pump control
B2: To L.H. travel motor PR: To solenoid valve, PPC valve, and EPC valve
B3: PS: From merge-divide solenoid valve
B4: To swing motor PST: From travel junction valve solenoid valve
B5: To R.H. travel motor PX1: From 2-stage relief solenoid valve
B6: To arm cylinder bottom PX2: From 2-stage relief solenoid valve
B-1: To arm cylinder bottom T: To tank
B-2: To attachment 1 T1: To tank
B-3: To attachment 2 TS: To tank
BP1: Boom raising PPC output pressure TSW: To swing motor S-port (suction side)
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve 1. 6-spool valve
P1: From bucket PPC and EPC valves 2. Cover A
P2: From bucket PPC and EPC valves 3. Cover B
P3: From L.H. travel PPC valve 4. Boom Hi and arm Hi valve
P4: From L.H. travel PPC valve 5. Service valve 1
P5: From boom PPC and EPC valves 6. Service valve 2
P6: From boom PPC and EPC valves 7. Merge-divider valve
P7: From swing PPC and EPC valves 8. Boom drift preventive valve
P8: From swing PPC and EPC valves 9. Quick return valve
P9: From R.H. travel PPC valve 10. Boom Hi valve check valve
P10: From R.H. travel PPC valve Torque
P11: From arm PPC and EPC valves Nm lbf ft
P12: From arm PPC and EPC valves 11. Bolt 156.9-176.5 115.7-130.1
P-3: From service 1 and PPC valves 12. Bolt 27.5-34.3 20.2-25.2
P-4: From service 1 and PPC valves 13. Bolt 58.8-73.6 43.3-54.2

10-66 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
General view

PC300LC/HD-8 10-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Sectional view (1/5)

10-68 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Pressure compensation valve (Arm out) 16. Pressure compensation valve (Arm in)
2. Pressure compensation valve (R.H. travel reverse) 17. Main relief valve
3. Pressure compensation valve (Left swing) 18. Unload valve
4. Pressure compensation valve (Boom raise) 19. Unload valve
5. Pressure compensation valve (L.H. travel reverse) 20. Main relief valve
6. Pressure compensation valve (Bucket dump) 21. Spool (Service 2)
7. Pressure compensation valve (Boom Hi raise) 22. Spool (Service 1)
8. Variable pressure compensation valve (Service 1) 23. Spool (Boom Hi)
9. Variable pressure compensation valve (Service 2) 24. Spool (Bucket)
10. Pressure compensation valve (Arm Hi in) 25. Spool (L.H. travel)
11. Pressure compensation valve (Bucket curl) 26. Spool (Boom)
12. Pressure compensation valve (L.H. travel forward) 27. Spool (Swing)
13. Pressure compensation valve (Boom lower) 28. Spool (R.H. travel)
14. Pressure compensation valve (Right swing) 29. Spool (Arm)
15. Pressure compensation valve (R.H. travel forward) 30. Spool (Arm Hi)

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
417 N 333 N
31 Spool return spring 54.2 x 34.8 51.2 {42.5 kg} - {34.0 kg} If damaged or
393 N 315 N deformed, replace
32 Spool return spring 54.5 x 34.8 51.2 - spring.
{40.1 kg} {32.1 kg}
421 N 336 N
33 Spool return spring 54.6 x 34.8 51.2 -
{42.9 kg} {34.3 kg}
251 N 201 N
34 Spool return spring 54.9 x 24.2 52.0 -
{25.6 kg} {20.5 kg}
Torque
Nm lbf ft
35 Valve 372.7 - 411.9 274.8 - 303.8
36 Plug 65.7 - 85.3 48.4 - 62.9
37 Plug 33.3 - 43.1 24.5 - 31.7

PC300LC/HD-8 10-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(2/5)

10-70 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

1. Safety-suction valve (Arm out) 13. Safety-suction valve (Arm in)

2. Suction valve (R.H. travel reverse) 14. LS shuttle valve (Arm)
3. Suction valve (Boom raise) 15. LS shuttle valve (R.H. travel)
4. Suction valve (L.H. travel reverse) 16. LS select valve
5. Safety-suction valve (Service 1) 17. LS shuttle valve (Boom)
6. Safety-suction valve (Service 2) 18. LS shuttle valve (L.H. travel)
7. 2-stage safety-suction valve (Service 1) 19. LS shuttle valve (Bucket)
8. Safety-suction valve (Arm Hi in) 20. LS shuttle valve (Service 1)
9. Safety-suction valve (Bucket curl) 21. LS shuttle valve (Service 2)
10. Suction valve (L.H. travel forward) 22. LS check valve
11. 2-stage safety-suction valve (Boom lower) 23. Pressure relief plug
12. Suction valve (R.H. travel forward)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed If damaged or
24 Suction valve spring Free length
Outside diameter length load load deformed,
46.8 x 7.5 40.6 5.5 N — 4.4 N replace spring.
25 Check valve spring 11.5 x 4.6 8.5 1.5 N — 1.2 N

Torque
Nm lbf ft
26. Plug 137.3 - 156.9 101.2 - 115.7
27. Plug 19.6 - 27.5 14.4 - 20.2
28. Valve 107.9 - 147.1 79.5 - 108.4
29. Plug 34.0 - 44.0 25.0 - 32.4

PC300LC/HD-8 10-71
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(3/5)

10-72 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

1. Unload valve R.H. travel valve

2. Safety valve (Boom raise)
12. LS shuttle valve
3. Main relief valve
13. Pressure compensation valve (Forward)
4. Lift check valve
14. Spool
15. Suction valve (Forward)
16. Suction valve (Reverse)
17. Pressure compensation valve (Reverse)

Arm valve Swing valve

5. LS shuttle valve 18. LS select valve

6. Pressure compensation valve (In) 19. Pressure compensation valve (R.H.)
7. Spool 20. Spool
8. Safety-suction valve (In) 21. Pressure compensation valve (L.H.)
9. Regeneration circuit check valve
10. Safety-suction valve (Out)
11. Pressure compensation valve (Out)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load If damaged or
19.6 N 15.7 N deformed, replace
50.0 x 14.4 42.0 - spring.
22 Spool return spring {2.0 kg} {1.6 kg}
5.9 N 4.71 N
23 Check valve spring 31.5 x 10.3 19.5 -
{0.6 kg} {0.48 kg}
Torque
Nm lbf ft
24 Valve 137 - 157 101.0 - 115.7
25 Valve/Plug 147.1 - 186.3 108.4 - 137.4
26 Valve 49 - 58.8 36.1 - 43.3

PC300LC/HD-8 10-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(4/5)

10-74 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. Return spring L.H. travel valve
2. Merge-divide valve (for LS)
15. Merge-divider valve (travel junction valve)
3. Valve (Sequence valve)
16. Return spring
4. Spring (Sequence valve)
17. LS shuttle valve
5. Merge-divide valve (Main)
18. Pressure compensation valve (Forward)
6. Return spring
19. Spool
20. Suction valve (Forward)
21. Suction valve (Reverse)
22. Pressure compensation valve (Reverse)

Boom valve Bucket valve

7. Drift preventive valve 23. LS shuttle valve

8. LS shuttle valve 24. Pressure compensation valve (Curl)
9. Pressure compensation valve (Lower) 25. Spool
10. Spool 26. Safety-suction valve (Curl)
11. 2-stage safety-suction valve (Lower) 27. Safety-suction valve (Dump)
12. Regeneration circuit check valve 28. Pressure compensation valve (Dump)
13. Suction valve (Raise)
14. Pressure compensation valve (Raise)

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
157 N 126 N
46.6 x 21.8 33.0 -
29 Spool return spring {16.0 kg} {12.8 kg}
250 N 200 N
30 Check valve spring 70.9 x 18.0 56.0 -
{25.5 kg} {20.4 kg}
178 N 142 N If damaged or
31 Spool return spring 64.5 x 32.3 63.0 -
{18.1 kg} {14.5 kg} deformed,
replace spring.
35.3 N 28.2 N
32 Check valve spring 33.0 x 12.0 26.0 -
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
33 Check valve spring 16.4 x 8.9 11.5 -
{1.4 kg} {1.12 kg}
Check valve spring 5.9 N 4.71 N
34 31.5 x 10.3 19.5 -
{0.6 kg} {0.48 kg}
Piston return spring 50.0 N 40.0 N
35 30.7 x 20.5 23.0 -
{5.1 kg} {4.08 kg}

PC300LC/HD-8 10-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
(5/5)

10-76 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

Boom Hi and arm Hi valve Service valve 2

13. LS shuttle valve
1. Boom Hi check valve 14. Pressure compensation valve
2. Quick return valve 15. Spool
3. Pressure compensation valve (Arm Hi in) 16. Safety-suction valve
4. Arm Hi spool 17. Unload valve
5. Safety-suction valve (Arm Hi in) 18. Main relief valve
6. Boom Hi spool 19. LS bypass plug
7. Pressure compensation valve (Boom Hi raise)

Service valve 1
8. LS shuttle valve
9. Pressure compensation valve
10. Spool
11. 2-stage safety-suction valve
12. Safety-suction valve

Torque
Nm lbf ft
20 End bolt 19.6 - 24.5 14.4 - 18.0
21 Plug 65.7 - 85.3 48.4 - 62.9
22 Plug 24.5 - 34.3 18.0 - 25.2
23 Valve 49 - 58.8 36.1 - 43.3
24 Valve 147.1 - 186.3 108.4 - 137.4
25 Valve 51.9 - 65.7 38.2 - 48.4
26 Valve 34.3 - 44.1 25.2 - 32.5

PC300LC/HD-8 10-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
Outline of CLSS

Features

CLSS stands for Closed Center Load Sensing System, which has the following characteristics:
● Fine control not influenced by load.
● Controllability enabling digging even with fine control.
● Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
● Energy saving using variable pump control.
Configuration

● CLSS is configured with variable capacity piston pumps, control valves, and respective actuators.
● The hydraulic pump is configured with pump body, PC valve and LS valve.

10-78 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
Basic principle

1. Control of pump swash plate

• The pump swash plate angle (pump discharge amount) is
controlled so that LS differential pressure ΔPLS (the difference
between pump pressure PP and control valve outlet port LS
pressure PLS) (load pressure of actuator) is constant.
• (LS pressure ΔPLS = Pump discharge pressure PP – S
pressure PLS)

• If LS differential pressure ΔPLS becomes lower than the set

pressure of the LS valve (when the actuator load pressure is
high), the pump swash plate moves towards the maximum
position;
• If it becomes higher than the set pressure of the LS valve
(when the actuator load pressure is low), the pump swash plate
moves towards the minimum position.

PC300LC/HD-8 10-79
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. Pressure compensation

• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When two actuators are operated together, this valve acts to make pressure difference ΔP between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
• In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of
each valve.

10-80 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
3. System Diagram

★ The illustration shows the actuator (7) in the merge mode with stroke end at the time of relief.

1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit

PC300LC/HD-8 10-81
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
VALVE FUNCTIONS AND OPERATION
HYDRAULIC CIRCUIT DIAGRAM AND THE NAME OF VALVES

10-82 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

1. Arm valve 35. Main relief valve (bucket side)

2. R.H. travel valve Set pressure:
3. Swing valve 36.1 ± 0.25 MPa (5236 ± 36 psi)
4. Boom valve 112 l/min (30 gal/min)
5. L.H. travel valve
6. Bucket valve When digging force increased:
7. Boom Hi valve 38.2 ± 0.25 MPa (5540 ± 36 psi)
8. Arm Hi valve 110 l/min (29 gal/min)
9. Service valve 1
10. Service valve 2 36. Main relief valve (arm side)
11. Arm spool Set pressure:
12. R.H. travel spool 36.1 ± 0.25 MPa (5236 ± 36 psi)
13. Swing spool 112 l/min (30 gal/min)
14. Boom spool
15. L.H. travel spool When digging force increased:
16. Bucket spool 38.2 ± 0.25 MPa (5540 ± 36 psi)
17. Boom Hi spool 110 l/min (29 gal/min)
18. Arm Hi spool
19. Service spool 1 37. Unload valve (bucket side)
20. Service spool 2 Cracking pressure:
21. Pressure compensation valve 3.1 ± 0.5 MPa (450 ± 73 psi)
22. Variable pressure compensation valve
23. Suction valve 38. Unload valve (arm side)
24. Check valve (for boom regeneration circuit) Cracking pressure:
25. Check valve (for arm regeneration circuit) 3.1 ± 0.5 MPa (450 ± 73 psi)
26. LS shuttle valve
27. LS select valve 39. Safety-suction valve
28. Merge-divider valve Set pressure:
29. Arm quick return valve 17.2 ± 0.5 MPa (2495 ± 73 psi)
30. Self pressure reducing valve
31. Travel junction valve 40. Safety-suction valve
32. Back pressure valve Set pressure:
33. Boom drift prevention valve 38.2 ± 0.5 MPa (5540 ± 73 psi)
34. Boom Hi check valve
41. 2-stage safety-suction valve
Set pressure:
1 stage: 21.1 ± 0.5 MPa (3060 ± 73 psi)
2 stage: 17.2 ± 0.5 MPa (2495 ± 73 psi)

42. 2-stage safety-suction valve

Set pressure:
1 stage: 28.4 ± 0.5 MPa (4119 ± 73 psi)
2 stage: 14.7 ± 0.5 MPa (2132 ± 73 psi)

43. Safety valve

Set pressure:
38.2 ± 0.5 MPa (5540 ± 73 psi)

PC300LC/HD-8 10-83
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
UNLOADER VALVE
When Valve Is Actuated

1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit

Function

● Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are in the holding.
● The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1).
● Since LS pressure is drained from the LS bypass valve, LS pressure approximately tank pressure 0 MPa{0 kg/cm2}.

Operation

● Pressure of pump circuit (3) is received by the end of valve (2).

● Since the control valve is in neutral position, pressure of LS circuit (1) is 0 MPa{0 kg/cm2}.
● Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
● When this pressure becomes larger than the force of spring (5), valve (2) moves to the left.
● Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (4).
● The pressurized oil of LS circuit (1) passes from orifice (a) via port (c) and is drained to the tank circuit (4).
● When actuated, LS pressure C tank pressure.
● Since the pump discharge pressure - LS circuit pressure during unloading is larger than the pump LS control pressure, the
signal is output to minimize the pump swash plate angle.

10-84 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
● During operation (a work within a scope of discharge by a
minimum swash plate angle), the discharge pressure for the portion
of minimum pump swash plate angle is set to LS pressure + P1
pressure.
● LS control differential pressure (EPLS) of discharge for the
portion of minimum swash plate angle will be equal to P1 pressure.

Operation Of Relief Valve

● When the cylinder reaches the stroke end, the main relief valve
opens.
● The pump delivery (Q) is relieved to the tank.(See the system
diagram)
● The pump discharge pressure (PP) and LS pressure (PLS) become
approximately the same as each has not flow at the upstream and
downstream of the spool, and LS differential pressure (EPLS)
becomes 0 kg/cm2.
● As LS differential pressure (EPLS) is lower than the LS set
pressure of LS valve, LS valve is actuated to maximize the pump
swash plate angle.
● Mechanically, operation of PC valve has priority over the LS valve.
● The pump is held at a minimum swash plate angle by the cut-off function of PC valve.

PC300LC/HD-8 10-85
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS PRESSURE

1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve

Function

● Introduces the upstream pressure (downstream pressure of the spool meter-in) of pressure compensation valve (3) and
leads to LS shuttle valve (7) as the LS pressure.
● Connected to actuator port (B) via valve (4), and makes LS pressure approximate actuator load pressure.
● Inlet pore (a) inside main spool (2) has a small diameter concurrently serving as a throttle.

Operation

● When main spool (2) is operated, the pump pressure enters port (c) via inlet port (a) and is led to the LS circuit.
● When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens.

10-86 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
LS bypass plug

1. Hydraulic pump 4. LS shuttle valve

2. Main spool 5. LS bypass valve
3. Pressure compensation valve 6. LS circuit

Function

● Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
● Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
● Bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the circuit resistance between throttle
(c) of main spool (2) and LS shuttle valve (4).
● Effective LS differential pressure drops to improve a dynamic stability of the actuator.

PC300LC/HD-8 10-87
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PRESSURE COMPENSATION VALVE

1. During independent operation and under maximum load pressure

★ If the load pressure is higher than other work equipment during a combined operation.

1. Hydraulic pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve

Function

● Pressure compensation valve works as the load check valve.

● If the pump pressure (LS pressure) is lower than the load at port (c), shuttle valve (3) in pressure compensation valve
piston (4) interconnects spring chamber (E) and port (C).
● The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated Pressure Compensation Valve

● High stress may occur when valve (2) collides with valve chamber
seat portion (C) if a high peak pressure is generated in the actuator
circuit or repetitive peak pressure occurs continuously (example:
when using the breaker).
● To prevent this, a pressure compensation valve with integrated valve
(2) and piston (4) is used.
● With the present machine, this device is adopted for the bucket valve
(cylinder bottom) and the service valve.
● As principle, port (C) and spring chamber (E) are not interconnected
in an integrated pressure compensation valve.
● If high peak pressure is generated at port (C), valve (7) does not col-
lide with the valve chamber.
● With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is seated.

10-88 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
2. When compensated
★ If the load pressure is lower than other work equipment during a combined operation.

Function

● The pressure compensation valve closes under LS pressure of port (D), and the spool meter-in downstream pressure of
port (B) becomes equivalent to the maximum pressure of other work equipment.
● Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meter-in differential pressure
[upstream pressure port (A) pressure] - downstream pressure [port (B) pressure] becomes equivalent to all the spools in
operation.
● Pump flow is divided according to the ratio of the meter-in opening area.

Operation

● Spring chamber (E) is interconnected to port (D).

● Piston (4) and valve (2) operate in the closing direction (to the right) under the LS circuit pressure from other work
equipment of port (F).
● Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with LS pressure.

PC300LC/HD-8 10-89
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. Pressure compensation valve area ratio

Function

● The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2). Area ratio =
(A2)/(A1)
● If area ratio = 1 : the spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure
will be divided according to the opening area ratio.
● If area ratio = 1 or over : the spool meter-in downstream pressure will be greater than the maximum load pressure, and the
pressure will be divided smaller than the opening area ratio.
● If area ratio = 1 or under : the spool meter-in downstream pressure will be smaller than the maximum load pressure, and
the pressure will be divided greater than the opening area ratio.

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STRUCTURE, FUNCTION AND
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12
PRESSURE COMPENSATION VALVE INNER SHUTTLE

1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)

1. Hydraulic pump 3. Pressure compensation valve inner shuttle valve

2. Valve 4. Piston

Function

● Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection between ports (A) and (C).
● Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) and valve (2)
will not be separated.

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12
2. In the case of travel

Outline

● Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve without shuttle
valve (3) is adopted.

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12
BOOM REGENERATION CIRCUIT

1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)

1. Hydraulic pump 5. Suction valve

2. Boom spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Safety-suction valve

Function

● Provides the regeneration circuit from the cylinder bottom to the cylinder head when the boom is lowered and increases
flow to the cylinder bottom.

Operation

● If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain
circuit (B) from the notch of boom spool (2).
● On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head
via circuit (D).
● Flow from regeneration circuit (C) and pump (1) merges in circuit (E).

PC300LC/HD-8 10-93
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2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)

Function

● Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.

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12
ARM REGENERATION CIRCUIT

1. If the cylinder head pressure is higher than the bottom pressure

1. Hydraulic pump 5. Suction valve

2. Arm spool 6. Check valve
3. Pressure compensation valve 7. LS shuttle valve
4. Safety-suction valve

Function

● During arm digging, regeneration circuit provided from the cylinder head to the bottom increases the cylinder speed as the
cylinder flow involves the pump delivery plus regenerated flow.

Operation

● If the cylinder head pressure is lower than the bottom pressure, pressurized oil (A) from the cylinder bottom flows to drain
circuit (B) from the notch of arm spool (2).
● On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder head
via circuit (D).
● Flow from regeneration circuit (C) and pump (1) merges in circuit (E).

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12
2. If the cylinder head pressure is lower than the bottom pressure

Function

● Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.

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12
MERGE-DIVIDER VALVE

1. When flows from the pumps merge [if pilot pressure (PS) is OFF]

1. Main spool 5. LS circuit (bucket side)

2. Spring 6. LS circuit (bucket side)
3. LS spool 7. LS circuit (arm side)
4. Spring 8. LS circuit (arm side)

Function

● Merges pressurized oil (P1) and (P2) discharged from the two pumps or divides (to respective control valve group).
● Merges and divides LS circuit pressure.

Operation

● Since pilot pressure (PS) is OFF, output pressure from PPC valve is 0 kg/cm2.
● Main spool (1) is pressed to the right by spring (2) and ports (E) and (F) are interconnected.
● Merges pressurized oil (P1) and (P2) discharged from the two pumps at ports (E) and (F) and sends to necessary control
valve.
● Since pilot pressure (PS) is OFF for LS spool (3), it is pressed to the right by spring (4), and ports (A) - (D) and ports (B)
- (C) are interconnected.
● Forwards LS pressure led from respective control valve spools to LS circuits (5), (6), (7) and (8) to all the pressure
compensation valves.

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STRUCTURE, FUNCTION AND
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2. When flows from the pumps are divided [if pilot pressure (PS) is ON]

Operation

● Pilot pressure (PS) turns ON, and output pressure from the PPC valve shifts main spool (1) to the left, and ports (E) and
(F) are divided.
● Pressurized oil discharged from the two pumps are sent to respective control valves.

● P1 pressure: To bucket, L.H. travel, and boom

● P2 pressure: To swing, R.H. travel, and arm

● LS spool (3) too shifts to the left under the output pressure from the PPC valve, interconnects ports (A) and (C) and
divides other ports.
● Forwards LS pressure led from each control valve spool to LS circuits (5), (6), (7) and (8) to respective control valves.

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LS SELECT VALVE
Function

● Prevents high LS pressure from the swing circuit from entering the
LS circuit of work valves while the swing and work equipment are in
combined operation.
● Prevents high pressure generated during swing operation and
improves operability of work equipment.

★ The illustration shows the state of simultaneous operation of

swinging and R.H. travel. [(BP) pressure ON]

1. Valve 6. L.H. travel spool

2. Spring 7. Arm spool
3. Piston 8. LS shuttle valve
4. Piston 9. LS circuit
5. Swing spool

Operation

1. If pilot pressure (BP) is OFF

● Since pilot pressure (BP) is OFF, piston (3) is pressed to the left
by spring (2).
● When swing-operated, swing LS pressure (P1) enters port (A)
after passing swing spool (5).
● Valve (1) is pressed to the left and ports (A) and (B) are
interconnected.
● Swing LS pressure (P1) flows to LS shuttle valve (8).

2. If pilot pressure (BP) is ON

● If pilot pressure (BP) is ON, BP pressure contracts spring (2),
and piston (3) shifts to the right.
● Valve (1) is pressed to the right and interconnection between
ports (A) and (B) is closed.
● Swing LS pressure (P1) stops flowing to LS shuttle valve (8).
● If swing LS pressure (P1) rises, other LS circuits are not
affected.

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12
SELF PRESSURE REDUCING VALVE
Function

Reduces the discharge pressure of the main pump and supplies it as

control pressure for the solenoid valves, EPC valves, etc.

Operation

1. While engine is stopped

● Poppet (11) is pressed by spring (12) against the seat and port
(PR) is not connected to (TS).

● Valve (14) is pressed by spring (13) against the left side and port
(P2) is connected to (TS).

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12 ● Valve (7) is pressed by spring (8) against the left side and port
(P2) is closed to (A2).

2. During neutral and when load pressure (P2) is low

★ When load pressure (A2) is lower than self pressure reducing
valve output pressure (PR)
● Valve (7) is pressed to the closing direction of circuit between
ports (P2) and (A2) by spring (8) and under pressure (PR) which
is 0 MPa (0 psi).
● When pressurized oil flows in from port (P2), a balance is
reached due to [(φd area x P2 pressure) = force of spring (8) +
(φd area x PR pressure)].
● Adjusts valve (7) opening to keep pressure (P2) at a constant
level over pressure (PR).
● When pressure (PR) rises above the set pressure, poppet (11)
opens.
● Pressurized oil flows from port (PR) to orifice (a) in spool (14),
then flows to seal drain port (TS) from poppet (11) opening.
● Differential pressure is generated before and after orifice (a) in
spool (14) and then spool (14) moves to close the pass between
ports (P2) and (PR).
● Pressure (P2) is reduced by the opening at this time and adjusted
to a constant pressure (the set pressure) and supplied as pressure
(PR).

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3. When load pressure (P2) is high
● Load pressure (A2) increases with the operation of digging, etc.,
and the pump discharge increases accordingly.
● Pressure (P2) increases to [(φd area x P2 pressure) = force of
spring (8) + (φd area x PR pressure)]., and valve (7) moves to
the right to the stroke end.
● As a result, opening between ports (P2) and (A2) increases, and
the pass resistance reduces, reducing the engine horsepower
loss.
● When pressure (PR) rises above the set pressure, poppet (11)
opens.
● Pressurized oil flows from port (PR) to orifice (a) in spool (14),
then flows to seal drain port (TS) from poppet (11) opening.
● Differential pressure is generated before and after orifice (a) in
spool (14) and then spool (14) moves to close the pass between
ports (P2) and (PR).
● Pressure (P2) is reduced by the opening at this time and adjusted
to a constant pressure (the set pressure) and supplied as pressure
(PR).

4. When abnormally high pressure is generated

● If pressure (PR) of self pressure reducing valve becomes
abnormally high, ball (16) contracts spring (15) and becomes
separated from the seat.
● Allows the pressurized oil to (TS) from port (PR) and lowers
pressure (PR).
● Protects PPC valve, solenoid valve and other devices from
abnormal pressure.

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TRAVEL JUNCTION VALVE
1. When pilot pressure is turned ON

Function

● This valve connects the L.H. and R.H. travel circuits via travel junction valve so that the hydraulic oil will be supplied
evenly to both travel motors to improve machine's straight travel performance.
● When the machine is steered, outside pilot pressure (PST) closes the travel junction valve to improve steering
performance.
Operation

● Pilot pressure from the travel junction solenoid valve contracts spring (1), and travel junction spool (2) moves to the left to
the stroke end.
● Junction circuit between port (PTL) (L.H. travel circuit) and port (PTR) (R.H. travel circuit) is closed.

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2. When pilot pressure is turned OFF

Operation

● If pilot pressure (PST) from the solenoid valve is 0, travel junction spool (2) is pressed by the force of spring (1) against
the right side and the pass between ports (PTL) and (PTR) is open.
● If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the oil flows through the route
between port (PTL), travel junction spool (2), and port (PTR) so that the oil flow rates to both motors will be equalized
again.

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TRAVEL PPC SHUTTLE VALVE

1. When travel lever is in neutral

Function

● Regulates flow to each cylinder by controlling the stroke of each spool of the boom, arm, and bucket using the pilot
pressure of travel PPC valve while climbing a steep grade, raising the boom, digging with arm, dumping, bucket-digging
or operating dump.
● When controlling the stroke of the boom, arm and/or bucket, pilot pressure of travel PPC valve passes through the circuit
inside the control valves to actuate the system.

Operation

● The oil in stroke regulation signal chamber (a) is drained through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case and the travel PPC valve.
● When operated for boom raising (or arm digging, dumping, bucket digging, dumping), spool (1) moves to the left until it
makes contact with the end face of spring casing (2) (st0).

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2. When traveling

Operation

● If the right travel lever is set in the reverse (or forward) direction, pilot pressure from the PPC valve presses spool (7) to
the left (or right).
● Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber (a) and the drain circuit of the
travel PPC valve.
● At this time, the right travel reverse (or forward) lever is set, PPC pressure is applied through orifice (6) of piston (4) to
the left end of piston (8) to push piston (8) to the right.
● When operated for boom raising (or arm IN, OUT, bucket CURL, DUMP), spool (1) moves to the left.
● Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.

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BOOM DRIFT PREVENTION VALVE

1. When raising boom

Function

● This valve prevents the oil in the boom cylinder bottom from leaking through spool (1) and the boom from lowering under
its weight while the boom lever is not operated.

Operation

● When the boom is raised, pressurized oil from the control valve works on the ring-shaped area (S)[= φ(d1) area – φ(d2)
area] caused by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the left.
● Contracts spring (4) and poppet (5) moves to the left.
● As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the bottom end of
the boom cylinder.

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2. When the boom is in neutral

Operation

● Moves the lever to neutral with the boom raised.

● Pressurized oil flows inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2).
● Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off.
● The holding pressure of boom cylinder bottom works on the ring-shaped area (S) caused by the difference between
outside diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right.
● The sum of this force and the force of spring (4) closes poppet (5).
● Pressurized oil from the control valve and the holding pressure of the boom cylinder bottom are shut off.

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3. When lowering boom

Operation

● When the boom is lowered, pilot pressure from the PPC valve presses pilot spool (2).
● Pressurized oil in chamber (b) inside the poppet is drained via orifice (c).
● Pressurized oil of the boom bottom flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressurized oil in
chamber (b) lowers.
● As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens.
● Pressurized oil from port (B) is led to port (A) and then flows to the control valve.

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ARM DRIFT PREVENTION VALVE
(if equipped)

1. When arm is OUT

Function

● This valve prevents the oil in the arm head from leaking through spool (1) and the boom from lowering under its weight
while the arm lever is not operated.

Operation

● When the arm OUT is operated, pressurized oil from the control valve works on the ring-shaped area
(S)[= φ(d1) area – φ(d2) area] caused by the difference between the outside diameter (d1) of poppet (5) and the seat
diameter (d2) to move it to the left.
● Contracts spring (4) and poppet (5) moves to the left.
● As a result, pressurized oil from the control valve passes through the opening of poppet (5) and flows to the arm cylinder
head.

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2. When the arm is in NEUTRAL

Operation

● Moves the lever to neutral with the arm dumped.

● Pressurized oil flows inside poppet (5) from orifice (a) of poppet (5) is closed by pilot piston (2).
● Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off.
● The holding pressure of arm cylinder head works on ring-shaped area (S) caused by the difference between outside
diameter (d1) of poppet (5) and seat diameter (d2) to move it to the right.
● The sum of this force and the force of spring (4) closes poppet (5).
● Pressurized oil from the control valve and the holding pressure of the arm cylinder head are shut off.

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3. When arm IN

Operation

● When the arm IN is operated, pilot spool (2) is pushed under the pilot pressure from the PPC valve.
● Pressurized oil in chamber (b) inside the poppet is drained via orifice (c).
● Pressurized oil of the arm head flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressurized oil in
chamber (b) lowers.
● As the pressure of chamber (b) lowers under the pressure of port (B), poppet (5) opens.
● Pressurized oil from port (B) is led to port (A) and then flows to the control valve.

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4. When abnormally high pressure is generated

● If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes
check valve (6) open, then safety valve (3) operates.
● If arm drift prevention valve (optional) is installed to the arm cylinder head circuit, the boom cylinder bottom circuit
pressure force or arm cylinder head circuit pressure force, whichever having higher pressurized oil, pushes check
valve (6) or (6A) open to actuate safety valve (3).

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QUICK RETURN VALVE

1. When arm OUT

Function

● When arm OUT, large volume of oil returns from the cylinder bottom.
● Reduces this pressure loss.

Operation

● When the arm OUT is operated, pilot spool (1) is pushed under the pilot pressure from the PPC valve.
● Pressurized oil in chamber (b) inside the valve is drained via orifice (c).
● Pressurized oil of the arm bottom side flows to orifice (a) ➡ chamber (b) ➡ orifice (c) ➡ drain (T), and the pressure in
chamber (b) lowers.
● If the pressure of chamber (b) drops lower than that of port (A), pressure receiving force of the pressure receiving portion
[φd2 area (S2) (seat diameter area)] on the side of port (A) increases by the sum of the pressure receiving force of pressure
receiving portion[φd1 area (S1)] on the chamber (b) side of valve (2) and the spring force.
● Or (φd2 pressure receiving force > φd1 pressure receiving force + spring force)
● Valve (2) is pressed to the left and pressurized oil is led from port (A) to (B).
● From port (B), pressurized oil is drained directly to the tank.

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2. When the arm is in NEUTRAL

Operation

• Returning the lever to neutral reduces the pilot pressure from the PPC valve to 0 kg/cm2.
• The pressurized oil that has flowed and been drained through orifice (a) in valve (2) is closed by pilot piston (1).
• The holding pressure on the arm bottom side works on the difference between areas (S2) and (S1) of valve (2) to the right.
• Valve (2) is closed by the total of this force and the force of spring (3), so ports (A) and (B) are shut off.

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LIFT CHECK VALVE
Function

● This valve applies back pressure to the drain circuit to prevent

generation of negative pressure on each actuator (motors, cylinders,
etc.).

Operation

1. While engine is stopped

● Pressurized oil is not fed to the self pressure reducing valve
from the pump, and valve (1) is pressed to the right by the force
of spring (2).
● Drain circuit (a) of the control valve is connected with port (T)
through orifice (b) of valve (1).

2. While engine is running

● Output pressure (PR) of the self pressure reducing valve is
applied via the control valve to spring chamber (c) of back
pressure valve (3).
● Output pressure (PR) applied to spring chamber (c) is applied to
the left end of valve (1) (area of fd) to push valve (1) to the right.
● At this time, pressure (PA) of drain circuit (a) of the control
valve is applied to the right end of valve (1) (area of φd1) to
push valve (1) to the left.
● Valve (1) strikes balance to make the back pressure equal to
(PA) in the equation below.

(Area of φd) x PR + force of spring (2)

PA =
Area of φd1

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MAIN RELIEF VALVE

1. Spring 2. Poppet

Function

● Set pressure of the relief valve is in two stages.

● When power is needed, pilot pressure (P) is turned ON and the set pressure becomes higher.

Operation

● The set pressure of relief valve is determined by spring (1) installed load. (1st stage)
● Respective setting is not required for both the 1st and 2nd stages. Setting the 1st stage completes the setting of the 2nd
stage.

1. If pilot pressure (P) is OFF: Low-pressure setting

Set pressure is determined by spring (1) installed load.

2. If pilot pressure (P) is ON: High-pressure setting

Spring (1) installed load is added with pilot pressure (P) applied to the area of poppet diameter (d1), raising the set
pressure to higher level.

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2-STAGE SAFETY-SUCTION VALVE
★ Installed to port (B) on the boom cylinder head side and port (B) of the service valve.

1. Spring 3. Spring
2. Piston 4. Holder

Function

● Enables to provide the safety valve set pressure in two stages, and make the low-pressure setting smaller.
● Enables to relieve a load without lever operation if high load is applied to the cylinder.
● Improves work efficiency and reduces machine body vibration.

Operation

● The safety set pressure is determined by spring (1) installed load.

1. If pilot pressure is OFF (high-pressure setting)

● Since pilot pressure (P) is OFF, piston (2) is pressed to the left
by spring (3). [Spring (1) installed load < spring (3) installed
load]
● Spring (1) installed load becomes maximum and the set
pressure rises.
● Passage (B) is interconnected to the drain circuit via passage (C)
and chamber (D).

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2. If pilot pressure is ON (low-pressure setting)
● If the pilot pressure (P) is ON, the pilot pressure is led to
section (A) via passage (B).
● Piston (2) works on the pressure-receiving bore portion
[(d2) − (d1)] of section A.
● This pilot pressure contracts spring (3), and piston (2) moves to
the right until making contact with holder (4).
● Spring (1) stretches, installed load is reduced, and the set
pressure lowers.
● Pressurized oil proportionate to the piston stroke is drained via
passage (C) and chamber (D).

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12
VARIABLE PRESSURE COMPENSATION VALVE
(Installed to the service valve)

A. Pump discharge pressure (P) (From service valve spool)

B. Cylinder port
C. Load pressure of other work equipment

1. Valve 5. Spring
2. Spring 6. Screw
3. Sleeve 7. Locknut
4. Poppet 8. Cap

Function

● Regulates flow distribution to the service valve when the service valve (attachment) and the work equipment valve (boom
raising, etc.) are operated together. (Equivalent surface area ratio variable)
● Pressurized oil from the service valve spool is applied to the left side of valve (1) and is led to chamber (g) via orifice (a).
● LS pressure is led to chamber (e) via orifice (d).
● Pressurized oil of cylinder port is led to chamber (h) via passage (c) and orifice (f).
● The force of spring (2) acts on valve (1), and the force of spring (5) acts on poppet (4).
● The force of spring (5) can be adjusted with screw (6).

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Operation

● Operation when jointly operated with a high-load work equipment

(such as the boom raising)
● Both of the pump discharge pressure (P) and LS pressures are
determined by other equipment's pressure, while cylinder port
pressure causes the attachment to operate.
● If the difference between the pump discharge pressure (P) and
cylinder pressure is smaller than the force of spring (5), the
balance of forces applying to valve (1) may be expressed with
the following equation:

P x A1 = P x A2 + LS(A2 – 1) + F

A1:Area of φd1
A2:Area of φd2
F:Force of spring
P:Pump discharge oil pressure

● If the difference between the pump discharge pressure (P) and

cylinder port pressure (B) is larger than the force of spring (5),
poppet (4) is pressed to the right.
● Pump discharge pressure (P) flows to orifice (a) and chamber
(g) and is interconnected to cylinder port via passages (b) and
(c).
● Differential pressure is generated between the upstream and
downstream of orifice (a), which reduces the pressure force in
chamber (g).
● Force that presses valve (1) to the left is reduced.
● A state is reached where the area ratio has become smaller.
● Valve (1) moves to the right, and the flow increases from the
pump to the cylinder.

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ATTACHMENT CIRCUIT SELECTOR VALVE

ACC: To accumulator T: To hydraulic oil tank 1. Spool

ATT: To attachment TS: To hydraulic oil tank 2. Spring
P1: From attachment selector solenoid valve V: To control valve

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
If damaged
Free length x Installed Installed Installed or
Free length
Outside diameter length load load deformed,
replace
834 N 667 N spring.
132 x 29 114.5
3 Spool return spring {85.0 kg} {68.0 kg}
Torque
Nm lbf ft
4 Bolt 59 - 74 43.5 - 54.5

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STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function

● When a breaker is installed, the return oil from the breaker does not
pass through the main valve, but returns directly to the hydraulic
tank.
● When other attachments (crusher, etc.) are installed, the attachment
and the main valve are interconnected.

Operation

1. When attachment other than breaker is installed

● Spool (1) is pressed to the left by the force of spring (2).
● Ports (ATT) and (V) are interconnected and ports (ATT) and (T)
are shut off. Attachment is thus interconnected to the
control valve.

2. When breaker is installed

● Pilot pressure from the attachment circuit selector solenoid
valve contracts spring (2), and spool (1) moves to the right to the
stroke end.
● Ports (ATT) and (V) are shut off and ports (ATT) and (T) are
interconnected.
● Pressurized oil returning from the breaker returns directly to the
hydraulic tank via port (T) without passing through the control
valve.

PC300LC/HD-8 10-123
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
DRIFT PREVENTION VALVE
(For the boom and arm)

10-124 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

1. Pilot spool CY: To work equipment cylinder

2. Spring (1st stage spool) PCY:For pressure pickup port and equalizer circuit

3. Spring (2nd stage spool) PI: From PPC valve

4. Safety valve T: To Tank

5. Check valve V: From control valve

6. Spring

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed Free length
Outside diameter length load load
12.7 N 10.2 N
20.8 x 12.2 13.5 -
7 Check valve spring {1.3 kg} {1.04 kg} If damaged or
58.8 N 47.1 N deformed, replace
8 Spool return spring 41.1 x 9.6 35.0 - spring.
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
9 Spool return spring 41.9 x 25.8 41.0 -
{8.0 kg} {6.4 kg}
181 N 145 N
10 Spool return spring 44.6 x 25.6 41.0 -
{18.5 kg} {14.8 kg}
Torque
Nm lbf ft
11 Screw 27 - 34 19.9 - 25.0
12 Plug 176.4 - 215.8 130.1 - 159.0
13 Valve 137 - 157 101.0 - 115.7

PC300LC/HD-8 10-125
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function

● Prevents the pressurized oil from reversing from the work equipment cylinder and the latter from a sudden drop if the
piping bursts between the control valve and the work equipment cylinder.
Operation

1. When the work equipment lever is in neutral

When the piping is free of burst:
● Check valve (5) is closed under the holding pressure of the
cylinder led from port (CY) to chamber (b).
● Pilot pressure led to port (PI) from the PPC valve when in
neutral is 0 MPa {0 kg/cm2}.
● Spool (1) is pressed to the left by the force of springs (2) and (3)
● Chambers (a) and (b) are shut off.
● No pressurized oil flows between the control valve and the work
equipment cylinder.
● Accordingly, the work equipment is held in position.
● If the work equipment cylinder has abnormally high pressure,
safety valve (4) is actuated by the holding pressure of the work
equipment cylinder.
● Chambers (b) of L.H. and R.H. hydraulic drift prevention valve
for the boom are interconnected by port (PCY).
● Chambers (b) will have the same pressure if the L.H. and R.H.
hydraulic drift prevention valves have a difference in leakage.

If the piping burst forth:

● If piping (A) bursts between the control valve and the work equipment cylinder, chambers (a) and (b) are shut off
same as when the piping has no burst.
● Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.

10-126 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. When pressurized oil flows from the main valve to the cylinder
When the piping is free of burst:
● Pressurized oil led to chamber (a) from the control valve
becomes higher than the combined force of pressure from work
equipment cylinder circuit chamber (b) and spring (6).
● Check valve (5) opens and chambers (a) and (b) are
interconnected.
● Pressurized oil flows from the control valve to the work
equipment cylinder.

If the piping burst forth:

● If piping (A) bursts between the control valve and the work
equipment cylinder, pressurized oil in chamber (a) flows outside
from the bursted portion.
● Pressure force in chamber (a) drops.
● Pressure force in chamber (a) drops lower than the combined
pressure force of chamber (b) and spring (6).
● Check valve (5) closes and chambers (a) and (b) are cut off.
● Pressure for the work equipment cylinder is held to prevent a sudden drop of the work equipment.

PC300LC/HD-8 10-127
STRUCTURE, FUNCTION AND
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12
3. When returning pressurized oil to the main valve from the work
equipment cylinder
When the piping is free of burst:
● Holding pressure of the work equipment cylinder is led to
chamber (b) and check valve (5) closes.
● Pilot pressure from the PPC valve is led to port (PI) and reaches
[Pilot Pressure > Force of Spring (3)] (area of d).
● Spool (1) moves to the right to the standby position. (1st stage
stroke)
● At this point, chambers (a) and (b) are not interconnected.
● Pilot pressure further rises, and reaches
[Pilot pressure > Force of spring (2)] (area of d).
● Spool (1) moves further to the right, and chambers (a) and (b)
are interconnected. (2nd stage stroke)
● Pressurized oil returns to the control valve from the work
equipment cylinder.

If the piping burst forth:

● If piping (A) bursts between the control valve and the work
equipment cylinder.
● Pressurized oil in chamber (a) flows out to the bursted portion
but resupplied from chamber (b).
● Since pressurized oil flows via opening (c) of spool (1), a
sudden drop of the cylinder is prevented.

10-128 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
VALVE CONTROL

1. Travel PPC valve 8. Solenoid block

2. Service PPC valve 9. Accumulator
3. Service pedal 10. Control valve
4. L.H. travel lever 11. Hydraulic pump
5. R.H travel lever 12. Junction box
6. R.H. PPC valve 13. L.H. work equipment control lever
7. R.H. work equipment control lever 14. L.H. PPC valve

Lever Positions G. Arm (IN)

A. Hold H. Arm (OUT)
B. Boom (RAISE) J. Swing (RIGHT)
C. Boom (LOWER) K. Swing (LEFT)
D. Bucket (DUMP) L. Neutral
E. Bucket (CURL) M. Travel (REVERSE)
F. Hold N. Travel (FORWARD)

PC300LC/HD-8 10-129
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PPC VALVE
WORK EQUIPMENT AND SWING PPC VALVE

P: From self pressure reducing valve P3: L.H. PPC: Swing left/R.H. PPC: Bucket curl
P1: L.H. PPC: Arm out/R.H. PPC: Boom lower P4: L.H. PPC: Swing right/R.H. PPC: Bucket dump
P2: L.H. PPC: Arm in/R.H. PPC: Boom raise T: To tank

10-130 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

1. Spool 4. Piston 7. Joint 10. Body

2. Metering spring 5. Disc 8. Plate 11. Filter
3. Centering spring 6. Nut (for lever connection) 9. Retainer

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
If damaged or
Centering spring 17.7 N 13.7 N
42.5 x 15.5 34.0 - deformed,
12 (for ports P3 and P4) {1.80 kg} {1.40 kg} replace
13 Centering spring 29.4 N 23.5 N spring.
44.5 x 15.5 34.0 -
(for ports P1 and P2) {3.0 kg} {2.40 kg}
14 Metering spring 16.7 N 13.7 N
26.5 x 8.15 24.9 -
{1.70 kg} {1.40 kg}
Torque
Nm lbf ft
15 Bolt 11.8 - 14.7 8.7 - 10.8
16 Nut 69 - 88 50.8 - 64.9
17 Nut 39 - 49 28.7 - 36.1
18 Plug 34 - 44 25.0 - 32.3
19 Plug 6 - 11 4.4 - 8.1
20 Plug 4-9 2.9 - 6.6

PC300LC/HD-8 10-131
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation

1. When in neutral
● Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) via fine
control hole (f) in spool (1).

2. During fine control

★ (Neutral ➡ fine control)
● When piston (4) is pushed by disc (5), retainer (9) is pushed,
spool (1) is also pushed by metering spring (2), and moves
down.
● When fine control hole (f) is shut off from drain chamber (D), it
is almost simultaneously interconnected to pump pressure
chamber (PP).
● Pilot pressurized oil of the control pump is led to port (A) from
port (P1) via fine control hole (f).

● When the pressure at port (P1) becomes higher, spool (1) is

pushed back and fine control hole (f) is shut off from pump
pressure chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the pressure at port
(P1).
● As a result, spool (1) moves up and down until the force of
metering spool (2) is balanced with the pressure at port (P1).
● The relationship of the position of spool (1) and body (10) [fine
control hole (f) is in the middle between drain chamber (D) and
pump pressure chamber (PP)] does not change until retainer (9)
contacts spool (1).
● Metering spring (2) contracts in proportion to the stroke of the
control lever.
● Pressure at port (P1) also rises in proportion to the stroke of the
control lever.
● In this way, the control valve spool moves to a position where
the pressure of chamber (A) (same as pressure at port (P1)) and
the force of the return spring of the control valve spool are
balanced.

10-132 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
3. During fine control
★ (When control lever is returned)
● When disc (5) starts to be returned, spool (1) is pushed up by the
force of centering spring (3) and the pressure at port (P1).
● Because of this, fine control hole (f) is connected to drain
chamber (D), and the pressurized oil at port (P1) is released.
● If the pressure of port (P1) is lowered excessively, spool (1) is
pushed down by metering spring (2).
● Fine control hole (f) is shut off from drain chamber (D), and it is
almost simultaneously interconnected to pump pressure
chamber (PP).
● Pump pressure is supplied until the pressure at port (P1)
recovers to the level equivalent to the lever position.
● When the spool of the control valve returns, the 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 replenish the chamber with pressurized
oil.

4. At full stroke
● 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
interconnected to pump pressure chamber (PP).
● Therefore, the pilot pressure oil from the self pressure reducing
valve passes through fine control hole (f) and flows to chamber
(A) from port (P1) to push 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/HD-8 10-133
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

MEMORANDUM

10-134 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
TRAVEL PPC VALVE

P: From self pressure reducing valve P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Steering signal
P3: R.H. reverse T: To tank

Torque

Nm lbf ft

1. Bolt 27 - 34 19.9 - 25.0

2. Screw 0.441 - 0.588 0.325 - 0.433

PC300LC/HD-8 10-135
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

10-136 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

12
1. Plate 6. Metering spring
2. Body 7. Valve
3. Piston 8. Dumper
4. Collar 9. Steering signal spool
5. Centering spring 10. Steering signal spool spring

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Installed
Free length
Outside diameter length load load
108 N 86.3 N If damaged or
47.6 x 15.5 32.5 —
11 Centering spring {11.0 kg} {8.8 kg} deformed,
16.7 N 13.7 N replace spring.
12 Metering spring 26.5 x 8.15 24.9 —
{1.7 kg} {1.4 kg}
8.8 N 7.1 N
13 Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}
Torque
Nm lbf ft
14 Bolt 25 - 31 18.4 - 22.8
15 Plug 34 - 44 25.0 - 32.4
16 Plug 24.5 - 34.3 18.0 - 25.2
17 Bolt 19.6 - 27.4 14.4 - 20.2

PC300LC/HD-8 10-137
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PRESSURE REDUCING VALVE
Operation

1. When in neutral
● Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) via fine
control hole (f) in spool (1).

2. During fine control

★ (Neutral ➡ fine control)
● When piston (4) is pushed by disc (5), retainer (9) is pushed,
spool (1) is also pushed by metering spring (2), and moves
down.
● When fine control hole (f) is shut off from drain chamber (D), it
is almost simultaneously interconnected to pump pressure
chamber (PP).

● Pilot pressurized oil of the control pump is led to port (A) from
port (P1) via fine control hole (f).
● When the pressure at port (P1) becomes higher, spool (1) is
pushed back and fine control hole (f) is shut off from pump
pressure chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the pressure at port
(P1).
● As a result, spool (1) moves up and down until the force of
metering spool (2) is balanced with the pressure at port (P1).
● The relationship of the position of spool (1) and body (10) [fine
control hole (f) is in the middle between drain chamber (D) and
pump pressure chamber (PP)] does not change until retainer (9)
contacts spool (1).
● Metering spring (2) contracts in proportion to the stroke of the
control lever.
● Pressure at port (P1) also rises in proportion to the stroke of the
control lever.
● In this way, the control valve spool moves to a position where
the pressure of chamber (A) (same as pressure at port (P1)) and
the force of the return spring of the control valve spool are balanced.

10-138 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
3. During fine control
★ (When control lever is returned)
● When lever (5) starts to be returned, spool (1) is pushed up by
the force of centering spring (3) and pressure at port (P1).
● Because of this, fine control hole (f) is connected to drain
chamber (D), and the pressurized oil at port (P1) is released.
● If the pressure of port (P1) is lowered excessively, spool (1) is
pushed down by metering spring (2).
● Fine control hole (f) is shut off from drain chamber (D), and it is
almost simultaneously interconnected to pump pressure
chamber (PP).
● Pump pressure is supplied until the pressure at port (P1)
recovers to the level equivalent to the lever position.
● When the spool of the control valve returns, the 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 replenish the chamber with pressurized
oil.

4. At full stroke
● Lever (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
interconnected to pump pressure chamber (PP).
● Therefore, the pilot pressure oil from the self pressure reducing
valve passes through fine control hole (f) and flows to chamber
(A) from port (P1) to push 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).

5. Travel signal/Steering function

★ Travel Signal
● Travel signal if either of the L.H. or R.H. travel levers is
operated, the higher PPC output pressure of both sides is
output as the travel signal.
● Accordingly, whether the machine is travelling is judged by the
signal of port (P5).
★ Steering Signal
● If the operation quantities of both levers are different from each other as in the steering operation, the higher one of
the PPC output pressures of both sides is output as the steering signal.
● Any signal is not output from port (P6) while the machine is travelling straight (forward or reverse) or in neutral.
● Accordingly, whether the machine is being steered is judged by the signal of port (P6).

PC300LC/HD-8 10-139
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Operation

1. When in NEUTRAl

● No output is made from respective output ports [from port (P1) to (P4)], travel signal [port (P5)] and steering signal
[port (P6)].

10-140 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. During straight travel

★ The Illustration shows the circuit for travelling straight forward.

● When operating L.H. motor forward [port (P2) output] and R.H. motor forward [port (P4) output], pressure of both
L.H. spring chamber (k) and R.H. spring chamber (l) rises high.
● Steering signal spool (j) remains at neutral position and does not output a steering signal to port (P6).

PC300LC/HD-8 10-141
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
3. When steered or pivot-turned

★ The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.

● If the operation quantities of both levers are different from each other as in the steering operation (if the difference of
the pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal.
● The pressure in left spring chamber (k) of steering signal spool (j) is (P2).
● The pressure in right spring chamber (l) is (P4).
● When the pressure state reaches [(P4 - P2) x (Spool section) > Spring set load], the spool is switched to the direction
of the arrow.
● Port (P4) pressure of the L.H. or R.H. PPC valves, whichever having a higher output pressure, is output to port (P6)
as the steering signal.

10-142 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
4. When counter-rotated

★ The illustration shows the circuit for travelling left reverse and right forward.

● When operating L.H. motor reverse [port (P1) output] and R.H. motor forward [port (P4) output], pressure of the
R.H. spring chamber (l) only rises high.
● Steering signal spool (j) strokes to the left to output the steering signal to port (P6).

PC300LC/HD-8 10-143
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
SERVICE PPC VALVE (WITH EPC VALVE)

★ For the details of operation, see the paragraph of "Work equipment swing PPC valve."

10-144 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

P: From self pressure reducing valve P2: To service valve

P1: To service valve T: To tank

1. Spool 5. Retainer
2. Piston 6. Block
3. Lever 7. Body
4. Plate 8. EPC valve

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free length Installation
Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 x 15.3 28.4 -
9 Centering spring {12.7 kg} {10.2 kg} spring.
16.7 N 13.3 N
10 Metering spring 22.7 x 8.10 22.0 -
{1.70 kg} {1.36 kg}
Torque
Nm Lbf ft
11 Screw 9.8 - 12.7 7.2 - 9.3
12 Bolt 11.76 - 14.7 8.6 - 10.8

PC300LC/HD-8 10-145
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
1. EPC valve

10-146 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

C: To control valve 3. Spool

P: From self pressure reducing valve 4. Push pin

T: To hydraulic tank 5. Coil

1. Body 6. Plunger

2. Plug 7. Connector

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Installation Installation Free Installation
Free length length load length load
If damaged or deformed,
3.1 N replace EPC valve
9.0 8.4 - -
8 Return spring {0.32 kg} assembly.
Torque
Nm lbf ft
9 Screw 0.98 - 1.96 0.72 - 1.44
10 Bolt 9.8 - 12.7 7.2 - 9.36
11 Plug 19.6 - 24.5 14.4 - 18.0
12 Plug 7.84 - 11.8 5.7 - 8.7

PC300LC/HD-8 10-147
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Function

● The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
● When it receives signal current (i) from the pump controller, it
generates the EPC output pressure in proportion to the size of the
signal, and outputs it to the control valve.

Operation

1. When signal current is 0.

(coil is de-energized)
● When there is no signal current flowing from the controller to
coil (14), coil (14) is de energized.
● Spool (11) is pushed to the right by spring (12).
● Port (P) closes and the pressurized oil from the front pump does
not flow to the control valve.
● The pressurized oil from the control valve is drained to the tank
via port (C) and port (T).

10-148 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When signal current is very small.
(coil is energized)
● When a very small signal current flows to coil (5), coil (5) is
energized, and a propulsion force is generated on the left side of
plunger (6).
● Push pin (4) pushes spool (2) to the left, and pressurized oil
flows from port (P) to port (C).
● Pressures on port (C) increases and the force to act on surface
(a) of spool (2) and the spring load on spring (3) become larger
than the propulsion force of plunger (6).
● Spool (2) is pushed to the right, port (P) is shut off from port (C)
and ports (C) and (T) are connected.
● Spool (2) moves up and down so that the propulsion force of
plunger (6) may be balance with pressure of port (C) + spring
load of spring (3).
● The circuit pressure between the EPC valve and the control
valve is controlled in proportion to the size of the signal current.

3. When signal current is maximum

(coil is energized)
● As 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.
● Spool (2) is pushed to the left by push pin (4).
● The maximum volume of pressurized oil is conducted from port
(P) to port (C), increasing the circuit pressure across EPC valve
and the control valve to the maximum level.
● Since port (T) is closed, pressurized oil does not flow to the
hydraulic tank.

PC300LC/HD-8 10-149
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
SERVICE PPC VALVE

★ For the details of operation, see the paragraph of "Work equipment swing PPC valve."

10-150 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

P: From self pressure reducing valve P2: To service valve

P1: To service valve T: To tank

1. Spool 4. Plate
2. Piston 5. Retainer
3. Lever 6. Body

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installation Free Installation
Outside length load length load
diameter If damaged or deformed,
125 N 100 N replace spring
33.9 x 15.3 28.4 -
7 Centering spring {12.7 kg} {10.2 kg}
16.7 N 13.3 N
8 Metering spring 22.7 x 8.10 22.0 -
{1.70 kg} {1.36 kg}
Torque
Nm lbf ft
9 Bolt 11.76 - 14.7 8.6 - 10.8

PC300LC/HD-8 10-151
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
SOLENOID VALVE
★ PPC lock, travel junction, merge-divider, travel speed, swing brake, machine push-up and 2-stage relief solenoid valves

1. PPC lock solenoid valve 5. Swing brake solenoid valve

2. Travel junction solenoid valve 6. Machine push-up solenoid valve
3. Merge-divider solenoid valve 7. 2-stage relief solenoid valve
4. Travel speed solenoid valve

T: To tank A5: To swing motor

A1: To PPC valve A6: To main valve (2-stage safety valve at boom cylinder head)
A2: To main valve (Travel junction valve) A8: To main valve (2-stage relief valve)
A3: To main valve (Merge-divider valve) P1: From main pump
A4: To both travel motors ACC: To accumulator

10-152 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring

Operation

★ When solenoid is de-energized

● Since the signal current does not flow from the controller,
solenoid (3) is de-energized. For this reason, spool (4) is
pushed to the left by spring (6). By this operation, the pass
from port (P) to port (A) is closed and the pressurized oil from
the main pump does not flow into the actuator. At this time, the
oil from the actuator is drained through ports (A) and (T) into
the tank.

★ When solenoid is energized

● The signal current flows from the controller to solenoid (3),
and the latter is energized. Accordingly, spool (4) is pressed
against to the right side. By this operation, the pressurized oil
from the main pump flows through port (P) and spool (4) to
port (A), then flows into the actuator. At the same time, port
(T) closes and stops the oil from flowing to the tank.

PC300LC/HD-8 10-153
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
PPC ACCUMULATOR

1. Gas plug 4. Holder

2. Shell 5. Bladder
3. Poppet 6. Oil port

Specifications

Gas capacity: . . . . . . . . . . . . . . . . . . . . . . . . .300 cc (for PPC)

10-154 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
RETURN OIL FILTER
FOR BREAKER

1. Drain plug 4. Head cover

2. Filter 5. Relief valve
3. Case

Specifications

Rated pressure: . . . . . . . . . . . . . . . . . . . . . . . 6.9 MPa (1,000.76 psi)

Flow: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 L/min (53 gal/min)
Relief valve cracking pressure: . . . . 0.34 ± 0.05 MPa (49 ± 7.24 psi)
Filter mesh size: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 µm
Filtering area: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,570 cm2

PC300LC/HD-8 10-155
STRUCTURE, FUNCTION AND
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12
CENTER SWIVEL JOINT

1. Cover 4. O-ring
2. Body 5. Shaft
3. Slipper seal

A1: To L.H. travel motor port PB C2: From control valve port A5
A2: From control valve port A2 D1: To R.H. travel motor port PB
B1: To L.H. travel motor port PA D2: From control valve port B5
B2: From control valve port B2 E: To L.H. and R.H. travel motors port P
C1: To R.H. travel motor port PA T1: From L.H. and R.H. travel motors port T
T2: To tank

Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 80 — —

10-156 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

MEMORANDUM

PC300LC/HD-8 10-157
STRUCTURE, FUNCTION AND
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12
TRAVEL MOTOR - TYPE: HMV160ADT-2 - PC300LC-8

MA: MA pressure detection port PA: From control valve

MB: MB pressure detection port PB: From control valve
P: From travel speed solenoid valve T: To tank

10-158 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
Specifications

Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HMV160ADT-2
Theoretical displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .(Min.):103.5 cm3/rev (Max.):160.8 cm3/rev
Rated pressure: . . . . . . . . . . . . . . . . . . . . . . . . 37.3 MPa (5,410 psi)
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Capacity min.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,638 rpm
(Capacity max.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,590 rpm
Brake release pressure: . . . . . . . . . . . . . . . . . .1.18 MPa {12 kg/cm2}
Travel speed selector pressure:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . (differential pressure):0.78 MPa (113.12 psi)

Torque

Nm lbf ft

1. Bolt 34.3 - 44.1 25.2 - 32.5

2. Bolt 431 - 490 317 - 361

3. Screw 27.47 - 35.32 20.2 - 26.0

PC300LC/HD-8 10-159
STRUCTURE, FUNCTION AND
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12

10-160 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

1. Output shaft 11. Plate

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

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length x Installation Installed Installed
Free length
20 Spool return spring Outside diameter length load load
427 N 341 N
58.43 x 30.0 42.0 —
(43.5 kg) (34.8 kg) If damaged or
1.27 N 0.98 N deformed,
21 Check valve spring 33.0 x 13.8 23.0 — replace spring.
(0.13 kg) (0.10 kg)
221 N 177 N
22 Regulator piston spring 61.1 x 23.2 43.9 —
(22.5 kg) (18.0 kg)
98.1 N 78.5 N
23 Regulator valve spring 29.6 x 9.0 26.0 —
(10.0 kg) (8.0 kg)
Torque
Nm lbf ft
24 Plug 324 - 402 238.9 - 296.4
25 Plug 123 - 155 90.7 - 114.3
26 Plug 19.6 - 27.5 14.4 - 20.2
27 Valve 372 - 421 274.3 - 310.5
28 Plug 373 - 466 275.1 - 343.7

PC300LC/HD-8 10-161
STRUCTURE, FUNCTION AND
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12
OPERATION OF MOTOR

1. At slow speed (motor swash plate angle at maximum)

● As the solenoid valve is de energized, the pilot pressurized oil from the self pressure reducing valve does not flow to
port (P).
● Regulator valve (21) is pushed to the right by spring (22).
● Pressurized oil being conducted from the control valve to end cover (7) by pressing slow return valve (8) is shut off
by regulator valve (21).
● Fulcrum (a) of rocker cam (3) is eccentric to the working point (b) of the combined force of the propulsion force of
cylinder (5).
● The combined force of the piston propulsion forces works as the moment of inclining rocker cam (3) toward the
maximum swash plate angle.
● The pressurized oil at regulator piston (13) passes through orifice (c) of regulator valve (21) and is drained to the
motor case.
● Rocker cam (3) is inclined in the maximum swash plate angle direction. The motor capacity becomes maximum,
turning on the low speed travel.

10-162 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. At high peed (motor swash plate angle at minimum)

● As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P).
● Regulator valve (21) is pushed to the left.
● The pressurized oil from the control valve passes through passage (d) in regulator valve (21) and enters regulator
piston (13).
● Regulator piston (13) is pushed to the right.
● Rocker cam (3) is inclined in the minimum swash plate angle direction. The motor capacity becomes minimum,
turning on the high speed travel.

PC300LC/HD-8 10-163
STRUCTURE, FUNCTION AND
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12
PARKING BRAKE - PC300LC-8

1. When starting travel

● As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (17), opening the
parking brake circuit.
● The pressurized oil is conducted to chamber (a) of brake piston (10) and compresses spring (9), pushing piston (10)
toward right.
● Since the pushing force to plate (11) and disc (12) disappears, plate (11) is separated from disc (12) and the brake is
released.

10-164 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. When travel is stopped

● As the travel lever is placed in neutral, counterbalance valve spool (17) returns to the neutral position and closing the
parking brake circuit.
● The pressurized oil in chamber (a) of brake piston (10) passes through orifice (f) of brake piston (10) and is drained to
the motor case.
● Brake piston (10) is pushed to the right by spring (9).
● Plate (11) and disc (12) are pushed together, and the brake is applied.
● As brake piston (10) returns, flow of pressurized oil is reduced with slow return valve (8).
● The time delay will be set to activate the brake only after the machine has stopped.

PC300LC/HD-8 10-165
STRUCTURE, FUNCTION AND
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12
BRAKE VALVE OPERATION

● The brake valve consists of check valves (14), counterbalance valve

(15) and safety valve (16).
● Functions and operations of respective components shall conform to
the following.

1. Counterbalance valve and check valve

Function

● When traveling downhill, the machine travel speed tends to get faster
than the motor (engine) speed because of the downward force
generated from its own weight.
● If the machine travels with the engine at low speed, the motor may
rotate without load, resulting in run away and inviting a very
dangerous situation.
● These valves are used to prevent above by controlling the machine to
travel according to the engine speed (pump delivery).

Operation When Pressurized Oil Is Supplied

● Operating the travel lever conducts the pressurized oil from the con-
trol valve to port (PA).
● The pressurized oil push-opens check valve (14A) and then flows to
motor outlet port (MB) via motor inlet port (MA).
● The motor outlet side is closed by check valve (14B) and spool (24),
so the pressure at the supply side rises.
● The pressurized oil on the supply side flows to chamber (S1) via
orifice (E1) and orifice (E2) of the spool (24).
● As the pressure in chamber (S1) goes above the spool selector
pressure, spool (24) is pushed toward right.
● Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.

10-166 PC300LC/HD-8
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12
● The pressurized oil on the supply side flows to chamber (S1) via ori-
fice (E1) and orifice (E2) of the spool (24).
● As the pressure in chamber (S1) goes above the spool selector pres-
sure, spool (24) is pushed toward right.
● Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.

Operation Of Brake During Travelling Downhill

● If indication of the machine runaway is sensed while travelling

downhill, the motor will be caused to rotate without load to decrease
the inlet side oil pressure.
● Pressure in chamber (S1) is released via orifices (E1) and (E2).
● As the pressure in chamber (S1) goes below the spool selector
pressure, spool (24) is returned to the left by spring (20) and outlet
port (MB) is throttled.
● The pressure at the outlet port side rises, generating rotation
resistance on the motor to prevent the machine from running away.
● The spool moves to a position where the pressure on outlet port
(MB) can be balanced against the machine's own weight and the inlet
port pressure.
● Oil flow from the outlet circuit is reduced to ensure the travel speed
corresponded to the pump delivery.

PC300LC/HD-8 10-167
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
TRAVEL MOTOR - Type: KMV200ADT-2 - PC300HD-8

10-168 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
PA: From control valve
PB: From control valve
PI: From travel speed solenoid valve
T: To tank

Specifications

Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMV200ADT-2
Theoretical displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . (Min.): 130 cm3/rev (0.0343 gal/rev)
. . . . . . . . . . . . . . . . . . . . . . . . . . (Max.): 200 cm3/rev (0.0528 gal/rev)
Rated pressure: . . . . . . . . . . . . . . . . . . . . . 380 kg/cm2 (5404.8 psi)
Rated speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Capacity min.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 rpm
(Capacity max.): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,550 rpm
Brake release pressure: . . . . . . . . . . . . . . . . . . 10 kg/cm2 (142.2 psi)
Travel speed selector pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . (differential pressure):8 kg/cm2 (113.7 psi)

Torque
Nm lbf ft
1 Bolt 490 - 608 361.4 - 448.4
2 Nut 294 - 343 216.8 - 252.9

PC300LC/HD-8 10-169
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

10-170 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
1. Output shaft 11. Check valve spring
2. Motor case 12. Check valve
3. Piston 13. Counter balance valve spool
4. Cylinder block 14. Spool return spring
5. Valve plate 15. Safety valve
6. End cover 16. Regulator valve
7. Slow return valve 17. Spring
8. Regulator piston 18. Brake spring
9. Plate 19. Brake piston
10. Disk 20. Check valve

Unit: mm
No Check item Criteria Remedy
Standard size Repair limit
Free length x Installed Installed Free Installed
Outside diameter length load length load
427 N 341 N If damaged or
62.5 x 32.0 42.0 -
21 Spool return spring {43.5 kg} {34.8 kg} deformed, replace
spring.
3.04 N 2.45 N
22 Check valve spring 62.5 x 20.0 39.0 -
{0.31 kg} {0.25 kg}

23 Regulator piston 98.1 N 78.5 N

55.0 x 9.0 50.0 -
spring {10.0 kg} {8.0 kg}
Torque
Nm lbf ft
24 Plug 24.5 - 34.3 20 - 25
25 Plug 19.6 - 27.5 15 - 20
26 Bolt 65.7 - 82.4 48 - 61
27 Bolt 324 - 407 239 - 300
28 Plug 147.1 - 186.3 108 - 137
29 Plug 373 - 466 265 - 344

PC300LC/HD-8 10-171
STRUCTURE, FUNCTION AND
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12
Operation of motor

1. At slow speed (motor swash plate angle at maximum).

● As the solenoid valve is de-energized, the pilot pressurized oil from the self pressure reducing valve does not flow to
port (P).
● Regulator valve (16) is being pushed down by spring (17).
● Pressurized oil conducted to end cover (6) by pressing check valve (20) is then conducted to chamber (b) via
regulator valve (16).
● Force is generated on regulator piston (8) that works in downward direction.
● Valve plate (5) and cylinder block (4) move in the maximum tilt and roll angle direction, increasing the motor
capacity to the maximum and thus turning on the low speed travel.

10-172 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. At high speed (motor swash plate angle at minimum).

● As the solenoid valve is energized, the pilot pressurized oil from the self pressure reducing valve flows to port (P).
● Regulator valve (16) is pushed upward.
● Pressurized oil in chamber (b) is drained to the case and oil is conducted to chamber a through regulator valve (16).
● Force is generated on regulator piston (8) that works in upward direction.
● Valve plate (5) and cylinder block (4) move in the minimum tilt and rotation angle direction, decreasing the motor
capacity to the minimum and thus turning on the high speed travel.

PC300LC/HD-8 10-173
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM

PARKING BRAKE - PC300HD-8

1. When starting travel.

● As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (13), opening the
parking brake circuit.
● The pressurized oil is conducted to chamber (e) of brake piston (19) and compresses spring (18), pushing piston (19)
toward right.
● Since the pushing force to plate (9) and disc (10) disappears, plate (9) is separated from disc (10) and the brake is
released.

10-174 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
2. When travel is stopped.

● As the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and closing the
parking brake circuit.
● Pressurized oil in chamber (e) of brake piston (19) keeps flowing through the orifice of slow return valve (7) until
counter balance valve spool (13) is returned to the neutral.
● As counter balance valve spool (13) is returned to the neutral, pressurized oil is drained to the case through orifice (f)
of brake piston (19).
● Brake piston (19) is pushed to the left by spring (18).
● Plate (9) and disc (10) are pushed together, and the brake is applied.
● As brake piston (19) returns, flow of pressurized oil is reduced with slow return valve (7).
● The time delay will be set to activate the brake only after the machine has stopped.

PC300LC/HD-8 10-175
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
BRAKE VALVE OPERATION

● The brake valve consists of check valves (1), counterbalance valve

(2) and safety valve (3).
● Functions and operations of respective components shall conform to
the following.

1. Counterbalance valve and check valve.

Function

● When traveling downhill, the machine travel speed tends to get faster
than the motor (engine) speed because of the downward force
generated from its own weight.
● If the machine travels with the engine at low speed, the motor may
rotate without load, causing the machine to run away, resulting in a
very dangerous situation.
● These valves are used to prevent above by controlling the machine to
travel according to the engine speed (pump delivery).

Operation when pressurized oil is supplied

● Operating the travel lever conducts the pressurized oil from the
control valve to port (PA).
● The pressurized oil push-opens check valve (12A) and then flows to
motor outlet port (MB) via motor inlet port (MA).
● The motor outlet side is closed by check valve (12B) and spool (13),
so the pressure at the supply side rises.

10-176 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
● The pressurized oil on the supply side flows to chamber (S1) via
orifice (E1) and orifice (E2) of the spool (13).
● As the pressure in chamber (S1) goes above the spool selector
pressure, spool (13) is pushed toward right.
● Port (MB) and port (PB) are connected, opening the motor outlet
port side and starting the motor rotating.

Operation of brake during travelling downhill

● If indication of the machine runaway is sensed while traveling

downhill, the motor will be caused to rotate without load to decrease
the inlet side oil pressure.
● Pressure in chamber (S1) is released through orifices (E1) and (E2).
● As the pressure in chamber (S1) goes below the spool selector
pressure, spool (13) is returned to the left by spring (14) and outlet
port (MB) is throttled.
● The pressure at the outlet port side rises, generating rotation
resistance on the motor to prevent the machine from running away.
● The spool moves to a position where the pressure on outlet port
(MB) can be balanced against the machine's own weight and the inlet
port pressure.
● Oil flow from the outlet circuit is reduced to ensure the travel speed
corresponded to the pump delivery.

PC300LC/HD-8 10-177
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
SAFETY VALVE
★ (bidirectional 2-stage set safety valve)

Function

● As long as the machine travel is stopped (or it is travelling

downhill), the counterbalance valve closes the inlet and outlet
circuits of the motor.
● Since the motor is rotated by inertial force, pressure in the motor
outlet port side is abnormally increased, potentially resulting in
damages on the motor and piping.
● The safety valve releases this abnormal pressure to the inlet port side
of the motor in order to prevent damages to the equipment.

Bidirectional Action

1. When pressure in chamber (MB) has become high (when rotating

clockwise)
● As long as the machine travel is stopped (or it is travelling
downhill), the check valve of counterbalance valve closes
chamber (MB) of the outlet port circuit.
● The motor tries to continue rotation resorting to inertial force,
thus pressure on the outlet port (MB) is increased.
● As the pressure goes above the set pressure, [Difference in areas
of circles (D1) and (D2) x Pressure] compresses spring (2).
● Poppet (1) is moved leftward and the pressurized oil flows into
chamber (MA) of the opposite circuit.

2. When pressure in chamber (MA) has become high (when rotating

counterclockwise)
● As long as the machine travel is stopped (or it is travelling
downhill), the check valve of counterbalance valve closes
chamber (MA) of the outlet port circuit.
● The motor tries to continue rotation resorting to inertial force,
thus pressure on the outlet port (MA) is increased.

10-178 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12 ● As the pressure goes above the set pressure, [Difference in areas
of circles (D1) and (D3) x Pressure] compresses spring (2).
● Poppet (1) is moved leftward and the pressurized oil flows into
chamber (MB) of the opposite circuit.

Operation Of Mechanism For Varying Set Pressure

1. When starting travel (high-pressure setting)

● As the travel lever is operated, the pressurized oil from the
pump moves spool (19) toward right.
● Above opens the pilot circuit to the safety valve, conducting the
pressurized oil to chamber (J) via chamber (G) and passage (H).
● Piston (3) is pushed rightward, spring (2) is compressed and the
set load is increased.
● High pressure is turned on the safety valve, providing a large
tractional force to the valve.

PC300LC/HD-8 10-179
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
2. When travel is stopped (low-pressure setting)
● When the travel lever is placed in neutral, the pressure in cham-
ber (PA) drops and spool (24) returns to the neutral
position.
● When spool (24) is in the process of returning to the neutral
position, the pressurized oil in chamber (J) flows to chamber
(PA) via passage (H) and chamber (G).
● Piston (3) moves to the left side, decreasing the set load.
● The safety valve is caused to the low pressure setting, thereby
attenuating the shocks when the speed is reduced.

Set Pressure Of Safety Valve

High pressure setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . 40.2 MPa (410 kg/cm2) (5,831 psi)
. . . . . . . . . . . . . . . . . . . . . (at start of travel and during travel)

Low pressure setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . 27.5 MPa (280 kg/cm2) (3,989 psi) (during stop)

10-180 PC300LC/HD-8
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12

MEMORANDUM

PC300LC/HD-8 10-181
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
SWING MOTOR
Type: KMF230ABE-5

10-182 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

B: From swing holding brake solenoid valve Specifications

MA: From control valve Type : KMF230ABE-5
MB :From control valve Theoretical displacement : 229.4 cm3/rev (0.0606 gal/rev)
S: From control valve Safety valve set pressure : 285 kg/cm2 (4053 psi)
T: To tank Rated speed : 1,413 rpm
Brake release pressure : 19 kg/cm2 (270.2 psi)
1. Reverse prevention valve
2. Safety valve

Torque
Nm lbf ft
3 Bolt 27 - 34 20 - 25
4 Bolt 98.1 - 122.6 72 - 90
5 Valve 294 - 392 217 - 289

PC300LC/HD-8 10-183
STRUCTURE, FUNCTION AND
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12

10-184 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
1. Brake spring 10. Cylinder block
2. Drive shaft 11. Valve plate
3. Spacer 12. Center shaft
4. Case 13. Center spring
5. Disc 14. Check valve
6. Plate 15. Check valve spring
7. Brake piston 16. Shuttle valve
8. Housing 17. Shuttle valve spring
9. Piston

Unit: mm
No Check item Criteria Remedy
Basic dimensions Repair limit
Free length x Installed Installed Free Installed
Outside length load length load
diameter If damaged or deformed,
6.96 N 5.59 N replace spring.
66.5 x 25.6 45.0 -
18 Check valve spring {0.71 kg} {0.57 kg}
7.45 N 5.98 N
19 Shuttle valve spring 24.5 x 11.6 14.5 -
{0.76 kg} {0.61 kg}
Torque
Nm lbf ft
20 Cap 294 - 392 217 - 289
21 Cap 490.5 - 608.2 362 - 449
22 Cap 98.1 - 122.6 72 - 90
23 Cap 176.5 - 215.8 130 - 160

PC300LC/HD-8 10-185
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
Swing holding brake

1. When solenoid valve is de-energized.

Operation

● As the swing holding brake is de-energized, the pressurized oil from

the self pressure reducing valve is shut off.
● Port (B) is connected to tank circuit (T).
● Brake piston (7) is pushed down by brake spring (1).
● Disc (5) and plate (6) are pushed together, and the brake is applied.

1. When solenoid valve is energized.

Operation

● As the swing brake solenoid valve is energized, the valve is

switched.
● The pressurized oil from the self pressure reducing valve is
conducted brake chamber (a) via port (B).
● After entering chamber a, the pressurized oil compresses brake
spring (1) and pushes brake piston (7) up.
● Disc (5) is separated from plate (6), releasing the brake.

10-186 PC300LC/HD-8
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12
RELIEF VALVE PORTION

Outline

● The relief valve portion consists of check valves (2) and (3), shuttle
valves (4) and (5), and relief valve (1).

Function

● When the machine is in the swing holding mode, control valve (6)
closes the motor outlet circuit, but the motor rotation is continued by
inertial force.
● The motor output, therefore, is abnormally increased, resulting in
damage to the motor.
● In order to prevent motor damage, the relief valve relieves the
abnormally high pressure to port (S) from the motor outlet side
(high-pressure side) of the motor.

Operation

1. When starting swing

● When the swing control lever is operated to the right- swing, the pressurized oil from the pump is supplied to port
(MA) via control valve (6).
● The pressure on port (MA) rises, the starting torque is generated in the motor, and the motor starts to rotate.
● The pressurized oil from the outlet port of the motor passes from port (MB) through the control valve (6) and returns
to the tank.

2. When swing is stopped

● When the swing control lever is returned to neutral, the supply
of pressurized oil from the pump to port (MA) is stopped.
● The pressurized oil from the motor outlet can't return to the tank
since the returning circuit to the tank is closed from
control valve (6). Thus, pressure on port (MB) increases.
● Rotation resistance is generated on the motor and hence the
brake tarts working.
● Shuttle valve (4) is pressed as pressure on port (MB) goes above
port (MA).
● The pressure on chamber (C) is increased to the set pressure of
relief valve (1) and becomes the same as that of port (MB).
● A high braking torque works on the motor, thereby stopping the
motor.
● When relief valve (1) is being actuated, the relieved
pressurized oil and the pressurized oil from port (S) are fed to
port (MA) via check valve (3).
● Above prevents cavitation on port (MA).

PC300LC/HD-8 10-187
STRUCTURE, FUNCTION AND
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12
REVERSE PREVENTION VALVE

10-188 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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MA: From control valve T1: To tank

MB: From control valve T2: To tank

1. Valve body 5. Spool (MB side)

2. Spool (MA side) 6. Spring (MB side)
3. Spring (MA side) 7. Plug (MB side)
4. Plug (MA side)

Explanatory Drawing Of Effects

PC300LC/HD-8 10-189
STRUCTURE, FUNCTION AND
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12
Function

● This valve reduces the swing back generation in the swing body by
the inertia of the swing body, the backlash and rigidity of the
machinery system, and the compression of the hydraulic oil when
the swing is stopped.
● The valve contributes in preventing collapsing of load when the
swing is stopped and also contributes in reducing cycle time
(enhances the positioning performance, enabling you to proceed to
the next work quicker than ever).

Operation

1. When port (MB) brake pressure is generated

● Pressure (MB) is conducted to chamber (d) via notch (g).
● The pressure compresses spring (6) by use of the difference in
areas of circles (φD1 > φD2) of spool (5) and moves spool (5)
to the left side.
● Port (MB) ➡ chamber (e) will be interconnected.
● Since pressure (MA) is lower than the set pressure of spring
(3), spool (2) does not move and the pressurized oil is kept in.
Thus the braking force is ensured.

2. When motor is stopped temporarily

● The motor rotation is reversed by the closing pressure
generated at port (MB). (1st time: reverse rotation)
● Reversing pressure is generated on port (MA). Pressure (MA)
is conducted to chamber (a).
● The pressure compresses spring (3) by use of the difference in
areas of circles (φD3 > φD4) of spool (2) and moves spool (2)
to the right side.
● Port (MA) ➡ chamber (b) will be interconnected.
● Then ports (b) and (f) will be interconnected through the
drilled hole (h) on spool (5). This interconnection bypasses the
reversing pressure on port (MA) to port (T), thereby preventing
the reverse rotation of the 2nd time.

10-190 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

MEMORANDUM

PC300LC/HD-8 10-191
STRUCTURE, FUNCTION AND
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12
HYDRAULIC CYLINDER
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-192 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

Unit: mm
No Check item Criteria Remedy

Standard Tolerance Standard Clearance

Cylinder size Shaft Hole clearance limit

-0.036 +0.035 0.041 -

Clearance between Boom 100 0.412
-0.090 +0.005 0.125
1 piston rod and Replace bushing
bushing -0.036 +0.261 0.083 -
Arm 110 0.412
-0.090 +0.047 0.351
-0.030 +0.257 0.083 -
Bucket 100 0.447
-0.076 +0.047 0.347
-0.030 +0.190 0.100 -
Boom 100 -
-0.060 +0.070 0.250
Clearance between -0.030 +0.190 0.105 -
2 piston rod support Arm 100 -
-0.076 +0.070 0.251
shaft and bushing
-0.030 +0.190 0.100 -
Bucket 90 -
-0.076 +0.070 0.246
Replace pin or bushing
-0.030 +0.190 0.075 -
Boom 90 -
-0.060 +0.070 0.225
Clearance between
cylinder bottom -0.030 +0.190 0.105 -
3 Arm 100 -
support shaft and -0.076 +0.070 0.251
bushing
-0.030 +0.190 0.100 -
Bucket 90 -
-0.060 +0.070 0.230
Torque
Nm lbf ft
4 Bolt 373±54 275±39.8
5 Sleeve 297±29.4 216±21.6
6 Bolt 490±49 361±36.1
7 Bolt 58.9 - 73.6 43.4 - 54.2

PC300LC/HD-8 10-193
STRUCTURE, FUNCTION AND
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12
WORK EQUIPMENT

WORK EQUIPMENT

10-194 PC300LC/HD-8
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12

Unit: mm
No Check item Criteria Remedy

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between pin
connecting boom and revolving -0.036 +0.157 0.115 -
110 1.0
1 frame and bushing -0.090 +0.079 0.247
Clearance between pin -0.036 +0.179 0.117 -
2 connecting boom and arm and 110 1.0
-0.090 +0.081 0.269
bushing
Clearance between pin -0.036 +0.165 0.108 -
3 connecting arm and link and 90 1.0 Replace
-0.090 +0.072 0.255
bushing
Clearance between pin -0.036 +0.145 0.119 -
4 connecting arm and bucket and 90 1.0
-0.090 +0.083 0.235
bushing
Clearance between pin -0.036 +0.165 0.108 -
5 connecting link and bucket and 90 1.0
-0.090 +0.072 0.255
bushing
Clearance between pin -0.036 +0.163 0.105 -
6 90 1.0
connecting links and bushing -0.090 +0.069 0.253
7 Bucket clearance (a) 0.5 - 1.0
Adjust shims
8 Bucket clearance (b) 2.0

PC300LC/HD-8 10-195
STRUCTURE, FUNCTION AND
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12
DIMENSION OF ARM

10-196 PC300LC/HD-8
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12

Unit: mm (in)
PC300LC/HD-8
Measuring
No. Tolerance
position Standard size
Shaft Hole
–0.036 (0.001) +0.1 (0.004)
1 – f100 (3.94)
–0.071 (0.003) 0 (0)
+1.5 (0.59)
Arm side 119.3 (4.69)
2 0 (0)
Cylinder head side 116 (4.56) ±1.2 (0.05)
+0.5 (0.02)
Boom side 320 (12.6)
0 (0)
3
–0.3 (0.012)
Arm side 316 (12.4)
–0.8 (0.031)
–0.036 (0.001) +1.0 (0.004)
4 – f110 (4.33)
–0.090 (0.004) 0 (0)
5 – 470.6 (18.5) ±1 (0.04)
6 – 236.5 (9.31) ±0.5 (0.02)
7 – 1022.4 (40.25) ±1 (0.04)
8 – 3178 (125.1) ±3 (0.12)
9 – 2975.6 (117.1) ±1 (0.04)
10 – 472.5 (18.6) –
11 – 731.0 (28.78) ±0.2 (0.01)
12 – 728.0 (28.66) ±0.5 (0.02)
13 – 513.6 (20.2) –
14 – 1670 (0.66) –
–0.036 (0.001) +0.2 (0.01)
15 – f90 (3.54)
–0.090 (0.004) 0 (0)
16 – 345.0 (13.58) ±0.5 (0.02)
–0.036 (0.001) +0.2 (0.01)
17 – f80 (3.15)
–0.090 (0.004) 0 (0)
0 (0)
Arm itself 330 (12.99)
18 –0.5 (0.02)
When press fitting bushing 345 (13.58) –
Min. 1870 (73.62) –
19
Max. 3155 (1.24) –

PC300LC/HD-8 10-197
STRUCTURE, FUNCTION AND
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12
DIMENSION OF BUCKET

10-198 PC300LC/HD-8
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Unit: mm
PC300LC/HD-8
No Measuring position
Standard size Tolerance
1 – 512.2 ±0.5
2 – 37.9 ±0.5
3 – 94°19' –
4 – 513.6 –
5 – 1658 –
6 – 193 –
7 – 50° –
+0.054
8 – ∅120
+0 (0)
+0.1
9 – ∅125
+0.1
+0.2
10 – ∅90
+0.0
+1
11 – 346
0
12 – 68 –
13 – 138 –
+0.5
14 – 525.5
–0.25
15 – ∅26 –
16 – ∅165 –
17 – ∅150 –
18 – ∅200 –
19 – 145.8 –
20 – 138.2 –
21 – R115 –
22 – R100 –
+2
23 – 382
0
24 – 60 –
25 – 56 –

PC300LC/HD-8 10-199
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD AIR CONDITIONER PIPING
12
AIR CONDITIONER PIPING

1. Hot water pickup piping 5. Air conditioner compressor

2. Receiver tank 6. Refrigerant piping
3. Hot water return piping 7. Air conditioner unit
4. Condenser 8. Duct

A: Fresh air B: Recirculated air C: Hot/cool air

10-200 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
ELECTRICAL SYSTEM

ENGINE CONTROL

1. Battery relay 5. Starting motor

2. Battery 6. Engine throttle controller
3. Starting switch 7. Pump controller
4. Fuel control dial

Outline

● The engine can be started and stopped with only starting switch (3).

PC300LC/HD-8 10-201
STRUCTURE, FUNCTION AND
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12
Operation Of System

Starting Engine

● When the starting switch is turned to the START position, the

starting signal flows to the starting motor. Then, the starting motor
turns to start the engine.
When it happens, the engine controller checks the signal voltage
from the fuel control dial and sets the engine speed to the speed set
by the fuel control dial.

Engine Speed Control

● The fuel control dial sends a signal voltage corresponding to the

rotation angle to the engine controller.
● The pump controller receives the fuel dial position information
from the engine controller through the network.
● The pump controller calculates the engine speed in accordance with
the working mode, the decelerate, and the like, and sends an
instruction to the engine controller.
● The engine controller determines the fuel injection quantity based
on the instruction received from the pump controller.

Stopping Engine

● When detecting that the starting switch is set to the “STOP”

position, the engine controller cuts the fuel injection to stop the
engine.

10-202 PC300LC/HD-8
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12
FUEL CONTROL DIAL

1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector

Function

● A potentiometer is installed under the knob. As the knob is turned,

the potentiometer shaft is turned.
● As the potentiometer shaft is turned, the resistance of the variable
resistor in potentiometer (5) changes and a throttle signal is sent to
the engine controller.
● The hatched area in the graph shown at right is the abnormality
detection area.

PC300LC/HD-8 10-203
STRUCTURE, FUNCTION AND
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12
ENGINE CONTROLLER

● Meanings of signal classes in the terminal table shown below are as follows.

A: Power Supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication

10-204 PC300LC/HD-8
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CN-CE01
Pin No. Signal name Input/output
1 Electric power supply for fuel feed pump D
2 Electric power supply for IMA D
3 Atmosphere sensor B
4 NC(*) –
5 NC(*) –
6 CAN(–) E
7 NC(*) –
8 CAN(+) E
9 NC(*) –
10 NC(*) –
*: Never connect to NC or malfunctions or failures will occur.
11 Fuel feed pump return C
12 NC(*) –
13 NC(*) B
14 WATER-IN-FUEL sensor B
15 Coolant temperature sensor B
16 5V electric power supply for sensor A
17 Oil pressure switch B
18 NC(*) –
19 NC(*) –
20 NC(*) –
21 NC(*) –
22 NC(*) D
23 Boost temperature sensor B
24 NC(*) –
25 Common rail pressure sensor B
26 Backup sensor B
27 NE sensor (+) B
*: Never connect to NC or malfunctions or failures will occur.
28 NC(*) –
29 NC(*) –
30 NC(*) –
31 NC(*) D
32 NC(*) C
33 GND A
34 NC(*) –
35 NC(*) A
36 NC(*) –
37 NC(*) A
38 NC(*) C
39 Key switch (ACC) –
40 Electrical intake air heater relay drive –
41 NC(*) –
42 Electrical intake air heater relay return C
43 NC(*) –
44 Boost pressure sensor B
45 Injector #1 (+) D
46 Injector #5 (+) D

PC300LC/HD-8 10-205
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM

CN-CE01
Pin No. Signal name Input/output
47 Sensor GND C
48 Ne sensor (–) C
49 NC(*) –
50 NC(*) –
51 Injector #2 (–) C
52 Injector #3 (–) C
53 Injector #1 (–) C
54 Injector #2 (+) D
55 Injector #3 (+) D
56 Injector #4 (+) D
57 Injector #6 (+) D
58 Injector #4 (–) C
59 Injector #6 (–) C
60 Injector #5 (–) C
*: Never connect to NC or malfunctions or failures will occur.

CN-CE02
Pin No. Signal name Input/output
1 NC(*) B
2 NC(*) B
3 NC(*) B
4 NC(*) B
5 NC(*) B
6 NC(*) B
7 NC(*) B
8 NC(*) B
9 Fuel control dial (+) B
10 NC(*) B
11 NC(*) B
12 NC(*) B
13 NC(*) B
14 NC(*) B
15 NC(*) B
16 NC(*) B
17 NC(*) B
18 NC(*) B
19 NC(*) B
20 NC(*) E
21 NC(*) A
22 Fuel control dial (+5V) A
23 Fuel control dial (–) C
24 NC(*) B
25 NC(*) B
26 NC(*) B
27 NC(*) B
28 NC(*) B
29 NC(*) C
30 NC(*) B
31 NC(*) B
10-206 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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CN-CE02
Pin No. Signal name Input/output
32 NC(*) C
33 GND C
34 NC(*) C
35 NC(*) B
36 NC(*) B
37 NC(*) C
38 NC(*) D
39 Key switch (ACC) A
40 Electrical intake air heater relay drive D
41 NC(*) D
42 Electrical intake air heater relay return C
43 NC(*) D
44 NC(*) D
45 NC(*) –
46 CAN(+) E
47 CAN(–) E
48 NC(*) D
49 PWM OUTPUT D
50 NC(*) D
*: Never connect to NC or malfunctions or failures will occur.

CN-CE03
Pin No. Signal name Input/output
1 GND C
2 NC(*) C
3 Electric power supply (+24V constantly) A
4 NC(*) A
*: Never connect to NC or malfunctions or failures will occur.

PC300LC/HD-8 10-207
STRUCTURE, FUNCTION AND
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12
SENSORS
COOLANT TEMPERATURE SENSOR

1. Connector
2. Sensor
3. O-ring

OIL PRESSURE SWITCH

1. Connector
2. Sensor
3. O-ring

10-208 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
ENGINE SPEED SENSOR

1. Connector
2. Sensor
3. O-ring

BOOST PRESSURE AND TEMPERATURE SENSOR

1. Connector
2. Sensor
3. O-ring

PC300LC/HD-8 10-209
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
WIF (WATER-IN-FUEL DETECTION) SENSOR

1. Connector
2. Tube
3. Sensor
4. O-ring

ENGINE OIL LEVEL SENSOR

1. Connector
2. Bracket
3. Float
4. Switch

10-210 PC300LC/HD-8
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12
ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTION

Engine and pump composite control function

Pump and valve control function

Power maximizing function

Machine push-up function

Auto-deceleration function

Auto-warm-up and overheat prevention function

Electronic control system

6

Swing control function

Travel control function

8
Attachment flow control and circuit selector function (if
equipped)

Self-diagnosis function

★ For the self-diagnosis function, see “Troubleshooting“.

PC300LC/HD-8 10-211
STRUCTURE, FUNCTION AND
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12
SYSTEM DIAGRAM

10-212 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

PC300LC/HD-8 10-213
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
ENGINE AND PUMP CONTROL

10-214 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12
Function

● This function allows the operator to select proper engine torque and
pump absorption torque according to the type of work. Four modes
are provided: P, E, B and L. Using the work mode switch on the
monitor panel, the operator is required to select one of them.
● The pump controller detects the speed of the engine governor set
with the fuel control dial and the actual engine speed (N) and
controls them so that the pump will absorb all the torque at each
output point of the engine, according to the pump absorption torque
set in each mode.

PC300LC/HD-8 10-215
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
12
1. Control method in each mode
P and E modes
Matching point in P mode: Rated speed

Mode Matching point

183.9 kW/1,950 rpm
P
{247 HP/1,950 rpm}
154.4 kW/1,750 rpm
E
{207 HP/1,750 rpm}

● If the pump load increases and the pressure rises, engine speed
(N) lowers. At this time, the controller lowers the pump
discharge so that the engine speed will be near the maximum
output point.
● If the pressure lowers, the controller increases pump discharge
(Q) so that the engine speed will be near the maximum output
point.
● By repeating these operations, the controller constantly uses
the engine near the maximum output point.

10-216 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12 B and L modes

Mode B mode L mode

Partial output point 82% 61%

Mode Matching point

147.1 kW/1,800 rpm
B
{197 HP/1,800 rpm}
110.3 kW/1,550 rpm
L
{148 HP/1,550 rpm}

● In B or L mode, the controller controls the pump absorption

torque through the pump and engine compound control func-
tion to decrease engine speed (N) while maintaining engine torque (T) constant along the constant horsepower curve.
This ensures reduced fuel consumption.

PC300LC/HD-8 10-217
STRUCTURE, FUNCTION AND
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12
2. Function to control pump during travel
● Traveling the machine in E or B mode leaves the working
mode unchanged, but raises the pump absorption torque and
engine speed (N) to values same as those in P mode.

● If the machine travels in L mode, the working mode and engine

speed (N) do not change, but the pump absorption torque is
increased.

10-218 PC300LC/HD-8
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12
3. Function to control when emergency pump drive switch is turned
on
● Even if any abnormality occurs in the controller or sensor,
setting emergency pump drive switch (1) to the “ON”
position activates the machine with an absorption torque
approximately equivalent to that in E mode.

● In this case, a constant current flows from the battery to the

EPC valve for PC and therefore, the oil pressure is sensed by
only the EPC valve for PC.

PC300LC/HD-8 10-219
STRUCTURE, FUNCTION AND
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12
PUMP AND VALVE CONTROL

★ The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force,
etc.

10-220 PC300LC/HD-8
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12
LS Control Function

● Depending on the operation condition of the actuator, this function

changes the pressure output from the LS-EPC valve to LS valve to
change the change point (LS set differential pressure (DLS)) of the
pump discharge in the LS valve.
● By this operation, the start-up time of the pump discharge is
optimized and the composite operation and fine control
performance is improved.

Cut-off Function

● This function increases PC-EPC current (J) to reduce the flow rate
in the relief state, improving fuel consumption.

Operating condition for turning on cut-off function

When the average value of the front and rear pressure sensors
is above 27.9 MPa (285 kg/cm2) (4,337 psi) with the power
maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in the
“ON” position.

2-STAGE RELIEF FUNCTION

● The relief pressure in the normal work is 34.8 MPa {355 kg/cm2}. If the 2-stage relief function is turned on, however, the
relief pressure rises to about 37.2 MPa (380 kg/cm2) (5,395 psi). By this operation, the hydraulic force is increased further.

Operating condition for turning on

Relief pressure
2-stage relief function
• During travel 34.8 MPa
• When swing lock switch is turned to the (355 kg/cm2)
ON position (5,047 psi)
• When boom is lowered ↓
• When power maximizing function is 37.2 MPa
turned on (380 kg/cm2)
• When L mode is operated (5,395 psi)

PC300LC/HD-8 10-221
STRUCTURE, FUNCTION AND
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12
POWER MAXIMIZING AND MACHINE PUSH-UP

● The power maximizing function allows the operator to increase power for a certain time by operating the left knob switch.
● The machine push-up function allows the operator to increase the boom pushing force by operating the machine push-up
switch.

10-222 PC300LC/HD-8
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12
1. Power maximizing function
● This function is used to increase digging force for a certain period of time (e.g., when digging up a large rock).
● If the left knob switch is pressed in P or E mode, the hydraulic force is increased about 7% to increase the digging
force. Each function is set automatically as shown below.

Function Setting
Engine and pump control Matching at rated ouptut point
34.8 MPa
(355 kg/cm2)
(5,047 psi)
2-stage relief function ↓
37.2 MPa
(380 kg/cm2)
(5,395 psi)
Software cut-off function Cancel

★ These settings are automatically reset after 8.5 seconds when the switch is pressed.

2. Machine push-up function

• The machine push-up function allows the operator to increase
the boom pushing force that is required for ditching or mass
excavation in hard ground by operating machine push-up
switch (1).

2-stage safety valve

Switch
function
Setting of safety valve at
boom cylinder head
OFF 14.7 MPa
(150 kg/cm2)
(2,132 psi)
Setting of safety valve at
boom cylinder head
ON 28.4 MPa
(290 kg/cm2)
(4,119 psi)

PC300LC/HD-8 10-223
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

AUTO-DECELERATION

Function

● The auto-deceleration function automatically reduces the engine

speed to its medium speed range when the all control levers are set in
NEUTRAL while waiting for a dump truck or work to reduce the
fuel consumption and noise.
● If any lever is operated, the engine speed instantly returns to the
speed set with the fuel control dial.
Operation

When control levers are set in neutral.

● If all the control levers are kept to NEUTRAL for 4 sec. during
operation at a engine speed above a decelerator operation level
(approximately 1,300 rpm), this function lowers the engine speed to the deceleration operation level (approximately
1,300 rpm) and keeps it until you operate any lever.
When any control lever is operated.
● If you operate any control lever while the engine speed is kept at the deceleration operation level, the engine speed
instantly rises to the level set with the fuel control dial.

10-224 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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12

MEMORANDUM

PC300LC/HD-8 10-225
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AUTO-WARM-UP AND OVERHEAT PREVENTION

Function

● The engine automatic warm-up function increases the engine speed to warm up the engine if coolant temperature is too
low after the engine starts.
● The overheat prevention function reduces the pump load when coolant or hydraulic oil temperature is too high during
operation to protect the engine from overheating.

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Warm-up

● After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up
the engine.

Operating condition (All) Operated

Coolant temperature: Below 30°C (86°F).
Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm

⇓
Resetting condition (Any one) Reset

⇒
Coolant temperature: Above 30°C (86°F).
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec.
Manual
or longer

Overheat Prevention

● If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to protect the
engine from overheating.
● This function is turned on when the coolant temperature rises above 95°C (203°F).

Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature: Below 95°C

⇒ ⇒
Hydraulic oil Work mode: Travel (203 °F)
temperature: Above Engine speed: Keep as is. • Under above condition, controller is
95°C (203 °F) Lower travel speed. set to condition before operation of
function. (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Hydraulic oil or coolant temperature:
Hydraulic oil or
⇒ Work mode: P or E mode
⇒
Below 100°C (212 °F)
coolant temperature: Engine speed: Keep as is. • Under above condition, controller is
Above 100°C ((212 °F) Lower pump discharge. set to condition before operation of
function. (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Hydraulic oil or coolant temperature:

⇒ ⇒
Work mode: P, E, B or L mode
Hydraulic oil or Below 102°C (216 °F)
Engine speed: Keep as is.
coolant temperature: • Under above condition, controller is
Monitor alarm lamp: Lights up.
Above 102°C (216 °F) set to condition before operation of
Lower pump discharge.
function. (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Hydraulic oil or coolant temperature:
Below 105°C (221 °F)

⇒ ⇒
Work mode: Any mode
Hydraulic oil or Fuel control dial: Return to low idle
Engine speed: Low idle
coolant temperature: position once.
Monitor alarm lamp: Lights up
Above 105°C (221 °F) • Under above condition, controller is
Alarm buzzer: Sounds
set to condition before operation of
function. (Manual reset)

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SWING CONTROL

Function

● The swing lock and swing holding brake function are provided as a swing control function.

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1. Swing lock and swing holding brake function
● The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake
function (automatic) is used to prevent hydraulic drift after the machine stops swinging.
● Operation of swing lock switch and swing lock/holding brake

Lock
Lock switch Function Operation
lamp
Swing holding If swing lever is set in neutral, swing brake operates in about 7 sec.
OFF OFF
brake If swing lever is operated, brake is released and machine can swing freely.
Swing lock operates and machine is locked from swinging.
ON ON Swing lock
Even if swing lever is operated, swing lock is not reset and machine does not swing.

Swing holding brake release switch

● If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing,
the swing lock can be reset with the swing holding brake release switch.
● Even if the swing holding brake release switch is turned on, if the swing lock switch is turned on, the swing brake is
not released.
● If the swing lock is reset, only the hydraulic brake is applied by the safety valve. Note that if swinging is stopped on a
slope, the upper structure may swing by its gravity.

Swing holding brake ON OFF

release switch (when controller has trouble) (when controller is normal)
Swing lock switch ON OFF ON OFF
Swing holding brake is
Swing brake Swing lock is turned on. Swing lock is canceled. Swing lock is turned on.
turned on.

2. Quick hydraulic oil warm-up function when swing lock switch is

turned on
● If swing lock switch (4) is turned on, the pump cut-off function
is cancelled and the relief pressure rises from 34.8 MPa (355 kg/
cm2) (5047 psi) to 37.2 MPa (380 kg/cm2) (5395 psi). If the
work equipment is relieved under this condition, the hydraulic
oil temperature rises quickly and the warm-up time can be short-
ened.

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TRAVEL CONTROL

Function

● The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by
controlling pumps during travel or allowing operator to change travel speed automatically or manually.

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1. Pump control function during travel
● If the machine travels in a work mode other than P mode, the work mode and the engine speed are kept as they are
and the pump absorption torque is increased.
● For details, see “Engine and pump composite control function.”

2. Travel speed change function

A. Manual change with travel speed switch

If one of Lo, Mi and Hi is selected with the travel speed switch, the pump controller controls the pump capacity and
motor capacity at each gear speed as shown below to change the travel speed.

Travel speed switch (PC300LC-7E0) Lo (Low speed) Mi (Mid. speed) Hi (High speed)
Pump capacity (%) 90 82 100
Motor capacity Max. Max. Min.
Travel speed: km/h (mph) 3.2 (2.0) 4.5 (3.0) 5.5 (3.4)

Travel speed switch (PC300HD-7E0) Lo (Low speed) Mi (Mid. speed) Hi (High speed)
Pump capacity (%) 90 80 100
Motor capacity Max. Max. Min.
Travel speed: km/h (mph) 2.5 (2.0) 4.0 (2.5) 4.9 (3.0)

B. Automatic change by engine speed

If the fuel control dial is used to set the engine speed to less
than 1,200 rpm, the travel speed changes to Lo when the
machine is travelling in Mi or Hi, and the travel speed will not
change to Mi or Hi.

C. Automatic change by pump discharge pressure

When traveling with the travel speed switch set to Hi or Mi, if
the load increases, such as when travelling uphill, and the
travel pressure goes above 32.3 MPa (330 kg/cm2) (4685 psi)
for more than 0.5 sec., the travel motor capacity will automati-
cally change to low speed (equivalent to Lo). (The travel speed
switch will stay at Hi or Mi.)
If the load decreases, such as when travelling on level ground
or travelling downhill, and the travel pressure goes below 18.6 MPa (190 kg/cm2) (2698 psi) for more than 0.5 sec.,
the travel motor capacity will automatically change and will return to Hi or Mi.

PC300LC/HD-8 10-231
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ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR
(if equipped)

Function

● This function is available only with the attachment specification.

● The function acts as follows according to the flow command and working mode from the monitor.

A. It throttles the attachment PPC pressure and controls the flow when the pedal is depressed fully.

B. In B mode and the other modes, it switches to attachment single acting (B) or double acting (other modes).

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SYSTEM COMPONENT PARTS
PPC OIL PRESSURE SWITCH

1. Plug
2. Switch
3. Connector

Specifications

Type of contacts: . . . . . . . . . . . . . . . . . . . . . Normally open contacts

Operating (ON) pressure: . . . . . . . . . . . 0.5 ± 0.1 MPa (73 ± 15 psi)
Resetting (OFF) pressure: . . . . . . . . . 0.3 ± 0.05 MPa (44 ± 7.25 psi)

Function

• The junction block has 6 PPC oil pressure switches.

• This sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the pump controller.

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OIL PRESSURE SENSOR

1. Sensor
2. Connector

Function

● The pump pressure sensor is installed to the input circuit of the control valve.
● It converts the pump discharge pressure into a voltage and transmits it to the pump controller.

Operation

● The oil pressure is applied to the diaphragm of the oil pressure

sensor from the pressure intake part, the diaphragm is deformed.
● The deformation in the diaphragm causes the resistance of the gauge
to change. This causes a change in the output voltage, which is
transmitted to the amplifier (voltage amplifier).

● The relationship between the pressure applied to sensors (P) and

output voltage (E) is shown in the figure below.
● The amplifier magnifies output voltage (E) and transmits it to the
pump controller.

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PUMP PRESSURE SENSOR (HIGH PRESSURE)

1. Sensor
2. Connector

Operation

• The relationship between the pressure applied to sensors (P) and

output voltage (E) is shown in the figure below.

PC300LC/HD-8 10-235
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PUMP CONTROLLER

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CN-C01 CN-C01
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 PWR_IN_BATT Input 52 Service switch Input
2 GND_PWR Input 53 Boom raise pressure switch Input
3 Washer motor output 54 NC(*) -
4 PWR_IN_BATT Input 55 Travel switch Input
5 GND_PWR Input 56 Wiper limit switch Input
6 NC(*) - 57 Window limit switch Input
7 NC(*) - 58 Machin select 4 Input
8 NC(*) - 59 NC(*) -
9 PWR_OUT_5V_0 output 60 Start switch Input
10 NC(*) Input 61 NC(*) -
11 NC(*) - 62 NC(*) Input
12 NC(*) - 63 NC(*) ó
Input/
13 NC(*) - 64 COMM_CAN_L_0
output
14 Boom lower switch Input 65 GND_SIG_A -
15 Arm dump switch Input 66 NC(*) -
16 Swing pressure switch Input 67 NC(*) -
17 Arm curl pilot sensor Input 68 R pump pressure sensor Input
18 GND_SIG_A Input 69 NC(*) -
19 Swing lock switch Input 70 NC(*) -
20 NC(*) - 71 NC(*) Input
21 Machin select 2 Input 72 NC(*) -
22 NC(*) - 73 Bucket curl pilot sensor Input
23 NC(*) - 74 Overload pressure sensor -
24 PWR_CTR_KEY Input 75 Wiper limit switch (P) Input
25 NC(*) - 76 NC(*) -
26 NC(*) - 77 Machin select 3 Input
Overload caution enable
27 NC(*) - 78 switch -

28 NC(*) - 79 Start switch (ACC) Input

29 Hydraulic-oil temperature Input 80 NC(*) -
30 NC(*) - 81 GND_SIG_D -
31 NC(*) - *: Never connect to NC or malfunctions or failures will occur.
32 NC(*) -
33 NC(*) -
34 Bucket dump pressure switch Input
35 NC(*) -
36 Travel steering switch Input
37 GND_SIG_D -
38 Swing prolix switch Input
39 Machin select 5 Input
40 Machin select 1 Input
41 Knob switch Input
42 NC(*) -
43 PWR_CTR_KEY Input
44 GND_SIG_P Input
Input/
45 COMM_CAN_H_0
output
46 GND_SIG_A Input
47 GND_SIG_A -
48 NC(*) -
49 F pump pressure sensor Input
50 NC(*) -
51 NC(*) -

PC300LC/HD-8 10-237
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CN-C02
Pin No. Signal name Input/output
82 NC(*) -
83 NC(*) -
84 NC(*) -
85 NC(*) -
86 Att circuit change solenoid output
87 Travel speed solenoid output
88 NC(*) output
89 NC(*) -
90 NC(*) -
91 NC(*) -
92 NC(*) -
93 NC(*) -
94 NC(*) -
95 NC(*) output
96 PCQñEPC (F) output
97 Att flux limit EPC output
98 NC(*) -
99 NC(*) -
100 NC(*) -
101 Swing brake solenoid output
102 NC(*) -
103 NC(*) -
104 NC(*) -
105 NC(*) -
106 NC(*) -
107 NC(*) -
108 Battery relay output
109 2-stage relief solenoid output
110 Travel valve solenoid output
111 NC(*) -
112 Merge-divider solenoid (Main) output
113 NC(*) -
114 Wiper motor (ñ) output
115 GND_ACT Input
116 Solenoid power supply Input
117 GND_ACT Input
118 Solenoid power supply Input
119 Wiper motor (+) output
120 GND_ACT Input
121 Solenoid power supply Input
*: Never connect to NC or malfunctions or failures will occur.

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MONITOR SYSTEM

● The monitor system notifies the operator of machine status. It monitors the condition of the machine with sensors installed
on various parts of the machine, processes and immediately displays the obtained information on the panel. The
information that appears on the panel is roughly divided as follows.

A. Alarms that are issued when the machine has troubles

B. Machine status, including coolant temperature, hydraulic oil temperature and fuel level
● The machine monitor also has various mode selector switches and functions to operate the machine control system.

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MACHINE MONITOR

Outline

● The machine monitor has the functions to display various items and the functions to select modes and electric parts.
● The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
● The monitor display employs an LCD (Liquid Crystal Display). The switches are flat sheet switches.

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Input and output signals
CN-CM01 CN-CM03
Pin No. Signal name Input/output Pin No. Signal name Input/output
Battery power (+24V con- RS232C CD for communica-tion
1 Input 1 Input
stantly) terminal
Battery power (+24V con- RS232C RXD for communication
2 stantly) Input 2 terminal Input

3 Battery power GND - 3 RS232C SG for communica-tion -

terminal
Signal GND for communication
4 Battery power GND - 4 -
terminal control
Communication terminal selection
5 Wake-up Input/Output 5 signal Input

6 Relay output Output 6 RS232C RTS for communication Output

terminal
RS232C TXD for communication
7 - - 7 Output
terminal
RS232C DTR for communication
8 NC(*) - 8 terminal Output

9 Fuel level Input 9 RS232C DSR for communication Input

terminal
RS232C CTS for communication
10 NC(*) - 10 Input
terminal
RS232C RI for communication
11 Charge amount Input 11 Input
terminal
Power GND for communication
12 Chassis analog signal GND - 12 terminal -

13 Light switch Input 13 Input CH1 for communication Input

terminal status
Output for communication terminal
14 Key switch (ACC) Input 14 Output
power control
Output CH1 for communication
15 Key switch (C) Input 15 terminal control Output

16 Preheating Input 16 Output CH2 for communication Output

terminal control
Input CH2 for communication
17 NC(*) - 17 Input
terminal status
Electric power supply for com-
18 NC(*) - 18 munication terminal Output

*: Never connect to NC or malfunctions or failures will occur.

CN-CM02 CN-CM04
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 NC(*) - 1 NC(*) -
2 Engine oil level sensor Input 2 NC(*) -
3 Coolant level sensor Input 3 NC(*) -
4 Air cleaner clogging sensor Input 4 NC(*) -
5 Swing lock Input 5 NC(*) -
6 NC(*) - 6 NC(*) -
7 NC(*) - 7 NC(*) -
8 CAN terminating resistance - 8 NC(*) -
9 CAN_H Input/Output 9 NC(*) -
10 CAN_L Input/Output 10 NC(*) -
11 NC(*) Input/Output 11 NC(*) -
12 NC(*) Input/Output 12 NC(*) -
*: Never connect to NC or malfunctions or failures will occur. *: Never connect to NC or malfunctions or failures will occur.

PC300LC/HD-8 10-241
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CN-CM05
Pin No. Signal name Input/output
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera -
6 Camera signal GND1 -
7 Camera signal GND2 -
8 Camera signal GND3 -

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MEMORANDUM

PC300LC/HD-8 10-243
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MONITOR CONTROL, DISPLAY PORTION

10-244 PC300LC/HD-8
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1. Hydraulic oil temperature monitor
2. Hydraulic oil temperature gauge
3. Engine coolant temperature monitor
4. Engine coolant temperature gauge
5. KOMTRAX message monitor
6. Air conditioner monitor
7. Wiper monitor
8. Swing lock monitor
9. Engine pre-heating monitor/power maximizing monitor
10. Time/service meter
11. Auto-deceleration monitor
12. Working mode monitor
13. Travel speed monitor
14. ECO indicator
15. Fuel gauge
16. Fuel level monitor
17. Maintenance interval monitor
18. Engine oil pressure monitor
19. Charge level monitor
20. Radiator coolant level monitor
21. Engine oil level monitor
22. Air cleaner clogging monitor
23. Water separator monitor

Precautions on the machine monitor display

● The liquid crystal display panel may have black spots (which do not light up) or bright spots (which stay on).
Products having 10 or less black or bright spots conform the product specification; such the condition is quite normal.
● Battery voltage may suddenly drop at engine start due to ambient temperature or the condition of the battery. The machine
monitor display may temporarily disappear if it happens; it is quite normal.
● Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is
quite normal. The screen normally displayed on the monitor has a blue or white background. For this reason, blue spots
will not cause any problem (since the liquid crystal lights up red, blue, and green spots when displaying white).

PC300LC/HD-8 10-245
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MONITOR ITEMS AND DISPLAY

Symbol Display item Display method

Swing lock switch Swing holding brake Display of symbol

release switch
OFF OFF OFF
ON OFF ON
Swing lock OFF ON Flashes
ON ON Flashes

Preheater operates at low temperature and symbol keeps

Automatic preheating lighting up for up to about 30 seconds and then goes off
after engine starts.
Time after setting Display of symbol
0 - 30 sec ON
Preheating
30 - 40 sec Flashes
Manual preheating

After 40 sec OFF

Power Max. switch Display of symbol

Keeps lighting up.
While pressed Goes off after about 9 sec. if switch is kept pressed.
While released Kept turned OFF.
Power Max.

Engine coolant
temperature
Hydraulic oil See gauge display on next page.
temperature
Fuel level

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The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot be obtained due to
disconnection of CAN.

Gauge Range Temperature or volume Indicator Buzzer sound

A1 105 Red ●
A2 102 Red
A3 100 Off
Engine coolant temperature (°C)
A4 80 Off
A5 60 Off
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Off
Hydraulic oil temperature (°C)
B4 85 Off
B5 40 Off
B6 20 White
C1 417 Off
C2 347.5 Off
C3 277.5 Off
Fuel level (L)
C4 199 Off
C5 100 Off
C6 62 Red

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Checks before starting (all symbols light up), when maintenance interval is exceeded.

If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature
gauge and the hydraulic oil temperature monitor disappear and the following symbols are displayed.

Symbols appear in the order in which they occur from the upper left. When symbols are displayed, if the hydraulic oil
temperature is high or low, only its symbol is displayed.

Condition of hydraulic oil Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 - B2) No display
High temperature (above B2) White on red background

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PC300LC/HD-8 10-249
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SWITCHES

1. Buzzer cancel switch 4. Function switch 7. Window washer switch

2. Auto-deceleration switch 5. Working mode selector switch 8. Wiper switch

3. Guidance icon 6. Travel speed selector switch 9. Air conditioner control switch

Buzzer cancel switch

Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer sounds.
Depending on the alarm buzzer type, it does not stop even if you press the buzzer cancel switch.
Auto-deceleration switch

The auto-deceleration switch toggles the auto-deceleration function on and off. When the working mode is switched, it is
automatically set to ON. When it is set to ON, the auto-deceleration monitor appears.
★ The auto-deceleration function does not work in L mode.
Guidance icon and function switch

The function switches differ depending on the screen display. Each guidance icon shows the function of the switch below it.
Switches with no guidance icon are disabled. The functions shown by the guidance icons are as shown in the table below.

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PC300LC/HD-8 10-251
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Working mode selector switch

Pressing working mode selector switch (5) switches among working

modes.
Check the working mode on the working mode monitor.

About B mode

● When you try specifying B mode as a working mode, the buzzer

sounds for safety's sake and the following confirmation message
appears.

F5: Returns to the working mode selector screen.

F6: Specifies the breaker mode.
● If B mode is specified as a working mode when you start the
monitor, the buzzer sounds and the following message appears.
F5: Starts up in E mode.
F6: Starts up in B mode.
Travel speed selector switch

Each time you press the travel speed selector switch, the travel speed
setting switches as shown below.
Lo ➡ Mi ➡ Hi ➡ Lo ….
The travel speed setting is confirmable on the travel speed monitor.
The relationship between the speed setting and the monitor display is
shown in the table below.
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
Crawler symbol + Hi High speed

Window washer switch

While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.

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Wiper switch

Each time you press the wiper switch, the wiper settings switch as follows.
OFF ➡ INT ➡ ON ➡ OFF ➡ ….
The wiper operation setting is confirmable on the wiper monitor.
The relationship between the wiper setting and the monitor display is shown in the table below.
Display Setting Wiper actuation status
None OFF Stowing stopped or now stowing
Wiper symbol + INT INT Intermittent actuation
Wiper symbol + ON ON Continuous actuation

Air conditioner control switch

To operate the air conditioner, use the air conditioner control switches.
9a: Specifies airflow
9b: Specifies temperature
9c: AUTO
9d: A/C
9e: Switches among air blowing modes
9f: Switches between inside air and outside air
9g: OFF
9a to 9c: Enables entered information simultaneously with switching to the
air conditioner control screen below.
9d to 9f: Switches to the air conditioner control screen below. Another
pressing switches among modes.
9g: Turns OFF the air conditioner function without switching to the air
conditioner screen.

If you do no operation at least 5 sec. with the air conditioner control

screen displayed, the window returns to the normal window.

★ When communication with the air conditioner is disconnected, or

“spurting-out damper”, “A/M damper”, or “refrigerant” has a
problem, the following screen appears.

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Camera screen display function

● For an optional-camera-equipped machine, pressing the F3 on the

normal screen switches to the camera image.
● For a machine with no camera equipped, the guidance icon for
switching to the camera screen does not appear; even if you press the
switch, the screen does not switch to the camera image.
● Up to three cameras are mountable.
F1: Displays the image of No. 1 camera full-screen.
F2: Displays the image of No. 2 camera full-screen.
F3: Displays the image of No. 3 camera full-screen.
F4: Displays the images of No. 1 and No. 2 cameras at the same
time.
F5: Returns to the normal screen.
● Making operation of air conditioner button (1) with the camera
screen displayed may switch to the air conditioner operation screen.

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F6, or no operation for 5 sec.: Returns to the camera screen.
● Even when the camera screen is displayed, the working mode
selector switch, travel speed selector switch, auto-deceleration
switch, buzzer cancel switch, wiper switch, and window washer
switch are enabled.
● Changing the working mode or travel speed returns to the normal
screen.
● If an abnormality corresponding to an alarm item with the camera
screen displayed, the alarm monitor appears on the upper left of the
screen. If it appears, return to the normal screen with F5 to check the
alarm display.
● If an abnormality corresponding to an error item with the camera
screen displayed, the error monitor appears on the upper left of the
screen. If it appears, you must move the machine to safe posture
immediately and make inspections.
● If you do not operate the lever at least 10 sec. after the error monitor
starts to blink, the screen switches to the normal screen.

Service meter/time selector function

● Pressing F4 on the normal screen when the service meter is

displayed in the top center of the screen switches the display to the
time, and doing so when the time is displayed switches the display to
the service meter.

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Maintenance function

● Pressing F5 on the normal screen switches to the maintenance

screen.

F1: Displays the next page.

Displays the top page when the last page is displayed.
F2: Displays the previous page.
Displays the last page when the top page is displayed.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the normal screen.
F6: Switches to the maintenance time reset screen.
No operation at least 30 sec.: Returns to the normal screen.
● If the remaining time on the maintenance table screen is less than 30
hours, the relevant items are highlighted in yellow, and if 0 hours,
they are done in red.
● On the maintenance time reset screen, reset the remaining time for
the selected item to return to the default.
F5: Cancels the reset to return to the maintenance table screen.
F6: Resets the remaining time to return to the normal screen.
No operation at least 30 sec.: Returns to the normal screen.

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12
The table shows the maintenance items and replacement intervals. The time remaining to maintenance is reduced as the
machine is operated.
Replacement interval
No. Item (Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor 1000(*)
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
*: If equipped (To be determined)

● The content of the caution display differs according to the remaining time. The relationship is as shown in the table below.

Display Condition
Remaining time for maintenance for all items is more than 30
None hours.
Notice display (black symbol displayed on yellow There is one or more items with less than 30-hour remaining
background) time for maintenance.

Warning display (white symbol displayed on red background) There is one or more items with less than 0-hour remaining time
for maintenance.

● You can lock the maintenance time by a password to prevent it from

carelessly being reset.
● The default password is “000000”.
● Enabling the password lock on an attachment equipped machine
locks the breaker/attachment setting screen at the same time.
★ For information on changing the attachment/ maintenance password,
see “Attachment/maintenance password change function” in the
Testing and adjusting section.

PC300LC/HD-8 10-257
STRUCTURE, FUNCTION AND
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12
User mode

● Pressing F6 on the normal screen enters the user mode, switching to

the user menu screen.
● In user mode, you can specify items relating to the machine monitor
and machine shown below.
Breaker/attachment setting
Message display
Screen adjustment
Time adjustment
Language setting
Economy mode adjustment

F3: Selects (highlights) an item one down.

F4: Selects (highlights) an item one up.
F5: Returns to the normal screen.
F6: Switches to the setting screen for the selected item.
No operation at least 30 sec.: Returns to the normal screen.
(In user mode, no switch operation at least 30 sec. returns to the
previous screen.)
Breaker/attachment setting

● For an attachment-equipped machine, this menu allows you to adjust

a flow rate in B mode and ATT mode.
● For a machine with no attachment, this menu does not appear.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels changes you made before confirming them with
F6 to return to the menu screen.
F6: Moves to the setup items of the selected (highlighted) item.
● Selecting B switches to the breaker setting menu, and selecting ATT
switches to the attachment setting menu.
● You can lock this menu with a password.
Enabling the password lock locks the maintenance reset screen at the
same time.

Changing breaker mode setting

● Selecting B on the breaker/attachment setting screen switches to the

breaker setting screen. On this screen, select the breaker setting
selection screen or breaker flow rate setting screen.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker/attachment setting screen.
F6: Switches to the setting screen for the selected (highlighted) item.

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1. Breaker setting selection screen.
● On this screen, you can allocate one of two set flow rates as a
flow rate in breaker mode.
● The B symbol is displayed before items specified to breaker
mode.
★ The defaults of both flow rates are 230 L/min.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker setting menu screen.
F6: Specifies the selected (highlighted) item as a flow rate in breaker
mode.

2. Breaker flow rate setting screen.

● On this screen, you can specify a flow rate.
● The B symbol is displayed before items specified to breaker mode.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker setting menu screen.
F6: Switches to the flow rate level setting screen for the selected (highlighted) item.
● On the flow rate level setting screen, change the set flow rate.
F3: Decreases the flow rate.
F4: Increases the flow rate.
F5: Returns to the flow rate setting screen without changing the flow
rate.
F6: Returns to the flow rate setting screen after specifying the flow
rate.
Flow level Flow rate (L/min) Remarks
15 273
14 250
13 240
12 230 Default
11 220
10 210
9 200
8 190
7 180
6 170
5 160
4 150
3 140
2 130
1 120

PC300LC/HD-8 10-259
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12
Changing attachment mode setting

● Selecting ATT on the breaker/attachment setting screen switches to

the 2-way attachment setting menu. On this screen, select the
attachment setting screen or breaker flow rate setting screen.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker/attachment setting screen.
F6: Switches to the setting screen for the selected (highlighted)
item.

1. Attachment setting selection screen.

● On this screen, you can allocate one of two set flow rates as a
flow rate in attachment mode.
● The ATT symbol is displayed before items specified to
attachment mode.
★ The defaults of both flow rates are 530 L/min.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the attachment setting menu.
F6: Specifies the selected (highlighted) item as a flow rate in
attachment mode.
● Selecting “No attachment” disables selection of attachment mode on
the working mode selection screen.

2. Attachment flow rate setting screen.

● On this screen, you can specify a flow rate.
● The ATT symbol is displayed before items specified to attachment mode.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the breaker setting menu screen.
F6: Switches to the flow rate level setting screen for the selected (highlighted) item.
● On the flow rate level setting screen, change the set flow rate.
F3: Decreases the flow rate.
F4: Increases the flow rate.
F5: Returns to the flow rate setting screen without changing the
flow rate.
F6: Returns to the flow rate setting screen after specifying the
flow rate.
Flow level Flow (L/min) Remarks
8 530 Default
7 430
6 370
5 300
4 230
3 165
2 100
1 30

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Message display

● For a KOMTRAX-equipped machine, you can view notification

from the sales representative.
When there is a message, the message monitor appears on the upper
left of the normal screen.
● The lighting green monitor indicates that there are messages to be
read.
● The lighting blue monitor appears when you have not sent replies yet
after opening messages which accept replies.

● Press F6 to enter user mode and select “Message display” and you
can view (open) the messages.
F6: Returns to the user mode screen.

● Under messages that accept replies, “Value to be entered with

10-key: [_]” appears.If it appears, enter the selected item number
provided in the message using the switches of the machine monitor,
and press F6.
● “Do you want to transmit the entered value?” appears under the
message. Press F6 and the entered value will be sent.
● Messages will be deleted when their validity expire or a new
message is received.
● When no message has not been received, “No message” appears at
the blue part of the top of the screen.
● Separately from the message display for users above, the service
menu is provided with message display for service.
Screen adjustment

● Selecting the Screen adjustment from the user menu and pressing F6
switches to the screen adjustment screen.
● From this menu, you can adjust the brightness, contrast, and
luminance of the machine monitor screen.
● When the light switch is in Night mode ON, the night mode screen is
adjustable.
● When the light switch is in Daytime mode ON or OFF, the daytime
mode screen is adjustable.
F2: Returns all adjusted values to the defaults.
F3: Decreases the value indicated by the indicator one graduation
left.
F4: Increases the value indicated by the indicator one graduation right.
F5: Cancels changes you made before confirming them with F6 to return to the menu screen.
F6: Confirms the changes and moves to the next item.

PC300LC/HD-8 10-261
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MONITOR SYSTEM
● For a camera-equipped machine, the brightness, contrast, and
illuminance of the camera screen are also adjustable.
● For a camera-equipped machine, selecting Screen adjustment from
the user menu switches to the screen for selecting a screen you want
to adjust.

F3: Selects (highlights) an item one down.

F4: Selects (highlights) an item one up.
F5: Cancels changes you made before confirming them with F6 to
return to the menu screen.
F6: Moves to the setup items of the selected (highlighted) item.
● The adjustment methods for the camera screen and normal screen are
the same.
● The background when adjusting the camera screen is the No. 1
camera image.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels changes you made before confirming them with F6 to
return to the menu screen.
F6: Moves to the setup items of the selected (highlighted) item.
Clock adjustment

● Selecting the Clock adjustment from the user menu and pressing F6
switches to the clock adjustment screen.
● On this screen, you can change the setting of the time displayed on
the normal screen.

1. Time setting
Set the clock time. If the time setting item is not highlighted, press
F6 to highlight it.

The time display part is highlighted.

F3: Advances the clock one hour.
F4: Sets the clock back one hour.
F5: Cancels changes you made before confirming them with F6 to return to the user menu.
F6: Confirms the changes and moves to minute setting.

The minute display part is highlighted.

F3: Advances the clock one min.
F4: Set the clock back one min.
F5: Cancels changes you made before confirming them with F6 to return to the use menu.
F6: Confirms the changes and moves to the 12/24 display mode.

2. 12/24 display mode

Specify time display to 12-hour display (AM/PM) or 24-hour display. If the item of 12/24 display mode is not highlighted,
press F6 to highlight it.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels the changes to return to the user menu.
F6: Confirms the changes and moves to summer time.
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STRUCTURE, FUNCTION AND
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3. Summer time.
Selecting ON for this sets the time forward one hour. Setting OFF returns to the ordinary time.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels changes you made before confirming them with F6 to return to the user menu screen.
F6: Confirms the changes and moves to the time setting.
★ Summer time (daylight saving time) is a system to lead a life according to the one-hour advanced time in order to
make efficient use of daylight time.
Language setting

● Selecting the Language from the user menu screen and pressing F6
switches to the language setting screen.
● From this menu, you can change the language to be displayed on the
monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish, Portuguese, Italian,
German, Russian, Turkish, Indonesian, and Thai.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels the changes to return to the user menu.
F6: Cancels the changes to return to the user menu.

Economy mode adjustment

● Selecting the Economy mode adjustment from the user menu and
pressing F6 switches to the Economy mode setting screen.
● From this menu, you can adjust engine output to improve fuel
consumption in E mode.
● The fuel consumption level is specified to one of four levels from E0
to E3. The larger the value, the better the fuel consumption, but the
smaller the work rate.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Cancels the changes to return to the user menu.
F6: Cancels the changes to return to the user menu.

PC300LC/HD-8 10-263
STRUCTURE, FUNCTION AND
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12
Idle stop guidance function

This function displays guidance to control unnecessary fuel consumption.

It is displayed only when all the following conditions are met.
● Energy saving guidance display of the service menu is specified to
ON.
● No operation is made at least 5 min. and the engine is running at idle.
● No error or caution (excluding low hydraulic oil temperature) is
occurring.
This screen switches to the normal screen if one of the following
conditions occurs.
● When the lever is operated.
● When F5 is pressed.
● When an error or caution occurs.
When you switch to the normal screen by pressing F5, this screen does not appear even if the engine continues to run at idle. If
the engine continues to run at least five min. after operating the lever, this screen appears again.

10-264 PC300LC/HD-8
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12
Service meter check function

● If you continuously pressing auto-deceleration switch (1) and buzzer

cancel switch (2) at the same time when setting the starting switch to
the OFF position, the service meter will appear on the screen in 3 to
5 sec.
● When these switches are released, the LCD goes out.
★ Continuous operation of the machine monitor may display blue
bright spots on this screen; it is quite normal.

Display LCD check function

● Continuously pressing the buzzer cancel switch (1) and F2 at the

same time on the password input screen or normal screen causes the
entire LCD to light in white. Release F2 and buzzer cancel switch in
order. If any part of the display is black, the LCD is broken.
● Pressing any function switch returns to the previous screen.

PC300LC/HD-8 10-265
STRUCTURE, FUNCTION AND
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12
User code/failure code display function

● If there is any problem in machine operation, the user code and

failure code are displayed on the monitor to advise the operator of
the steps to take.
● These codes appear on the normal screen.
● On the normal screen, user code (1) and failure code (2) are
displayed on the portion for the hydraulic oil temperature gauge.

● If multiple user codes or failure codes are issued, they are displayed
alternately every 2 sec. The drawing below shows the case two types
of user codes and failure codes are displayed.

● If the telephone number has been set in the service menu, the screen
shows the telephone symbol and telephone number simultaneously
with the user code/failure code. (For information on how to input
and set the telephone number, see “Special functions of monitor
panel” in the Testing and adjusting section.)

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SENSORS
● The signals from the sensors are input to the monitor panel directly.
● Either side of a sensor of contact type is always connected to the chassis ground.

Sensor name Type of sensor When normal When abnormal

Hydraulic oil level Contact ON (Closed) OFF (Open)
Hydraulic oil temperature Resistance - -
Coolant temperature Resistance - -
Fuel level Resistance - -
Air cleaner clogging OFF ON
Contact (Closed) (Open)

Hydraulic oil level sensor

1. Connector 3. Float

2. Bracket 4. Switch

PC300LC/HD-8 10-267
STRUCTURE, FUNCTION AND
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12
Hydraulic oil temperature sensor, coolant temperature sensor

1. Thermistor 4. Tube

2. Body 5. Wire

3. Tube 6. Connector

Fuel level sensor

1. Float 3. Cover

2. Connector 4. Variable resistor

10-268 PC300LC/HD-8
STRUCTURE, FUNCTION AND
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Air cleaner clogging sensor

PC300LC/HD-8 10-269
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD KOMTRAX TERMINAL SYSTEM
12
KOMTRAX TERMINAL SYSTEM

● The KOMTRAX terminal system consists of a KOMTRAX communication modem, communication antenna, machine
monitor, and GPS antenna.
● This system transmits various kinds of machine information wireless. Persons to operate the KOMTRAX can refer to the
information at office to provide various kinds of services for customers.
● Information transmittable from the KOMTRAX terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
★ To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

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KOMTRAX COMMUNICATION MODEM - TH300

1. Communication antenna connection

2. Connector A (14 poles)
3. Connector B (10 poles)
Outline

● The KOMTRAX communication modem is a wireless communication device to transmit various kinds of machine
information or GPS position information the monitor obtains from network signals or input signals in the machine. The
communication modem can transmit information via the communication antenna.
● The modem is provided with a LED lamp as a display unit. The LED is used for maintenance.
Input and output signals

Connector A Connector B
Pin No. Signal name Input/output Pin No. Signal name Input/output
A-1 Electric power supply Input B-1 Serial signal DCD Output
A-2 NC(*1) - B-2 Serial signal RXD Output
A-3 NC(*1) - B-3 Serial signal TXD Input
Electric power supply
A-4 Output B-4 Serial signal DTR Input
switching
A-5 NC(*1) - B-5 Serial signal SGND Input
A-6 NC(*1) - B-6 Serial signal DSR Output
A-7 GND Input B-7 Serial signal RTS (*2) Input
A-8 GND Input B-8 Serial signal CTS (*2) Output
Modem power control 1
A-9 Input B-9 Serial signal RI (*2) Output
(*2)
Modem power control 2
A-10 Input B-10 NC(*1) -
(*2)
A-11 Modem serial control (*2) Input *1: Never connect to NC or malfunctions or failures will occur.
Electric field intensity 1
A-12 (*2) Output *2: Signal used by TH200

Electric field intensity 2

A-13 Output
(*2)
A-14 NC(*1) -
*1: Never connect to NC or malfunctions or failures
will occur.
*2: Signal used by TH200

PC300LC/HD-8 10-271
STRUCTURE, FUNCTION AND
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12

MEMORANDUM

10-272 PC300LC/HD-8
 20 STANDARD VALUE TABLES

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

ENGINE RELATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
CHASSIS RELATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.

2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.

3. These standard values are not the standards used in dealing with claims.
.

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 water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.

WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.

PC300LC/HD-8 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
STANDARD VALUE TABLES

ENGINE RELATED
Applicable model PC300LC/HD-8
Engine SAA6D114E-3
Standard value table for new
Item Measurement condition Unit Service limit value
machine
High idling at operating temp. 2,050 ± 50 2,050 ± 50
Engine speed Low idling at operating temp. rpm 1,000 ± 25 1,000 ± 25
Rated speed at operating temp. 1,950 1,950
• Coolant at operating 147 - 187 Max. 120
Intake air pressure temperature kPa {1,100 - 1,400} {Max. 900}
(boost pressure) • Arm IN relief +Power Max. {mmHg} 135 - 175 Max. 100
{1,010 - 1,310} {Max. 750}
At sudden acceleration Max. 25 Max. 35
Exhaust gas color %
At high idling Max. 1.0 Max. 2.0
Valve clearance Intake valve 0.305 0.559
mm
(Normal temperature) Exhaust valve 0.559 0.813
MPa
⎯ ⎯
Compression pressure Oil temperature: 40 - 60º C {kg/cm2}
rpm 250 - 280 250 - 280
(Coolant temperature: operating kPa Max. 1.57 2.25
Blow-by pressure
range) At rated output {mmH2O} {Max. 160} {260}
Oil pressure: (Coolant temperature: operating
3.5 - 6.0 2.1
(SAE0W-30E0S) range)
2
(50 - 85) (30)
(SAE5W-40E0S) At high idling kg/cm
(SAE10W-30HD) (psi)
Min. 1.5 0.8
(SAE15W40HD) At low idling
(Min. 21) (11)
(SAE30HD)
Oil temperature Whole speed range (inside oil pan) °C (°F) 80 - 120 (176 - 248) 120 (248)
• Between fan pulley and
alternator pulley
Fan belt tension • Deflection when pressed with mm Auto-tensioner Auto-tensioner
finger force of approx. 98 N
(22lbf)
Deflection when pressed with
Air conditioner
finger force of approximately 98 N mm 5-8 5-8
compressor belt tension
(22lbf)

20-2 PC300LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
CHASSIS RELATED
Applicable model PC300LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value
• Engine coolant temperature:
Within operation range
• Hydraulic oil temperature: Within
2 pumps at relief 2,030 ± 100 2,030 ± 100
operation range
• Engine at high idling
• Arm in relief condition
• Engine coolant temperature:
Engine speed

Within operation range

• Hydraulic oil temperature: Within
rpm
At 2-pump relief + one touch power up operation range 1,930 ± 100 1,930 ± 100
• Engine at high idling
• Arm IN relief + Power max. switch
ON
• Engine at high idling
• Auto-deceleration switch in ON
Speed when auto-deceleration is
condition 1,400 ± 100 1,400 ± 100
operated
• All control levers in NEUTRAL
condition
Boom control valve
Spool stroke

Arm control valve

mm 9.5 ± 0.5 9.5 ± 0.5
Bucket control valve
(in) (0.4± 0.02) (0.4± 0.02)
Swing control valve
Travel control valve
85 ± 10 85 ± 10
Boom control lever
(3.3 ± 0.4) (3.3 ± 0.4)
85 ± 10 85 ± 10
Arm control lever
(3.3 ± 0.4) (3.3 ± 0.4)
Travel of control

• Engine stopped 85 ± 10 85 ± 10
Bucket control lever • At center of control lever grip (3.3 ± 0.4) (3.3 ± 0.4)
levers

mm
• Max. reading up to stroke end
(in) 85 ± 10 85 ± 10
Swing control lever (excepting lever play in
(3.3 ± 0.4) (3.3 ± 0.4)
NEUTRAL position)
115 ± 12 115 ± 12
Travel control lever
(5 ± 0.5) (5 ± 0.5)
Max. 10 Max. 15
Play of control lever
(Max. 0.4) (Max. 1.0)
15.7 ± 3.9 Max. 24.5
Boom control lever
(56 ± 18) (Max. 88)
15.7 ± 3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within (56 ± 18) (Max. 88)
of control levers
Operating force

operation range 12.7 ± 2.9 Max. 21.6

Bucket control lever
• Engine at high idling (46 ± 10) (Max. 78)
N (ozf)
• At center of control lever grip 12.7 ± 2.9 Max. 21.6
Swing control lever
• At tip in case of pedal (46 ± 10) (Max. 78)
• Max. reading up to stroke end 24.5 ± 5.9 Max. 39.2
Lever
(88 ± 21) (Max. 141)
Travel control lever
74.5 ± 18.6 Max. 107.6
Pedal
(268 ± 68) (Max. 387)

PC300LC/HD-8 20-3
STANDARD VALUE TABLES STANDARD VALUE TABLES

Applicable model PC300LC/HD-8

Permissible
Cat. Item Measurement condition Unit Standard value
value
• Hydraulic oil temperature: Within operation range
• Engine at high idling
3.9 ± 1.0 3.9 ± 1.0
Unload pressure • Working mode: P mode
(566 ± 145) (566 ± 145)
• Hydraulic pump output pressure with all control
levers in NEUTRAL position
34.81+1.47
-0.98
33.34 - 36.77
(37.27+1.47
-0.98 ) (35.80 - 39.23)
RAISE
{355+15
-10
{340 - 375
(365 - 400)}
(380+15
-10
)}
Boom
LOWER - At
• Hydraulic oil temperature: 18.13 ± 0.98 16.66 - 19.6
low-pressure
Within operation range (2630 ± 142) (2416 - 2843)
setting
• Engine at high idling
LOWER - At
• Working mode: P mode 31.36 ± 1.47 29.4 - 33.34
high-pressure
• Hydraulic pump output pressure (4548 ± 213) (4234 - 4836)
setting
with all measurement circuits
relieved 34.81+1.47
-0.98
• Values inside parenthesis: 33.34 - 37.23
Hydraulic pressure

(37.26+1.47
-0.98 ) (35.80 - 39.23)
Arm & Bucket Hydraulic oil pressure with
one-touch power max. switch in MPa {355+15
-10
{340 - 375
ON mode (reference only) {kg/cm2} (365 - 400)}
(380+15
-10
)}
(psi)
30.87+1.47
-2.45 28.42 - 32.85
Swing
{315+15 {285 - 335}
-25}

37.27+2.94
-0.98 35.80 - 40.70
Travel +3 }
{380-10 {365 - 415}
• Hydraulic oil temperature: Within operation range
Control circuit • Engine running at high idling 3.23 ± 0.2 2.84 - 3.43
source pressure • Self-reducing pressure valve output pressure with all {33 ± 2} {29 - 35}
control levers in NEUTRAL position
• Hydraulic oil temperature: Within When all control
operation range levers in 3.9 ± 1.0 4.2 ± 1.0
• Engine at high idling NEUTRAL {42 ± 10} {40 ± 10}
LS differential • Working mode: P mode position
pressure • Traveling speed: Hi When traveling
• Hydraulic oil pump pressure - LS at half stroke 2.45 ± 0.1 2.45 ± 0.1
pressure {25 ± 1} {25 ± 1}
(without load)
• Hydraulic oil temperature: Within operation range 2.9+0.6 2.9+0.6
PPC valve output -0.2 -0.2
• Engine at high idling
pressure {30+5.5 {30+5.5
• Control lever at full stroke -1.5 } -1.5

deg.
Swing

Max. 110 Max. 140

Swing brake angle [mm]
(Max. 4.0) (Max. 6.0)
• Hydraulic oil temperature: Within operation range (in)
• Engine running at high idling
• Working mode: P mode
• Swing circle misalignment amount when stopping
after one turn

20-4 PC300LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value

90° 3.3 ± 0.4 Max. 4.2

Time taken to start • Hydraulic oil temperature: Within sec.

swing operation range
• Engine running at high idling
• Working mode: P mode 180° 4.7 ± 0.5 Max. 5.7
• Time required for passing points
90 and 180 degrees from starting
point

Time taken to swing sec. 31.6 ± 2.9 Max. 38

• Hydraulic oil temperature: Within operation range
Swing

• Engine running at high idling

• Working mode: P mode
• Time required for 5 more turns after making initial
one turn

Hydraulic drift of mm 0 0
swing • Hydraulic oil temperature: Within operation range (in) (0) (0)
• Engine stopped
• Keeping upper structure transverse on slope of 15
degrees
• Notching a mating mark on inner and outer races of
swing circle
• Mating mark misalignment amount during 5 minutes
• Hydraulic oil temperature: Within operation range
Leakage from swing • Engine running at high idling L/m Max. 5.5 Max. 11
motor • Swing lock switch: ON (gpm) (Max. 1.5) (Max. 3.0)
• Leakage amount for one minute during swing relief

PC300LC/HD-8 20-5
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value

LC: 58.0 ± 11.5 LC: 45.0 - 74.5

Lo
HD: 80.4 ± 15.9 HD:64.5 ± 96.3

Travel speed
(idle travel) • Hydraulic oil temperature: Within LC: 41.5 ± 6.0 LC: 34.0 - 51.5
Mi
operation range HD: 50.3 ± 7.3 HD: 43 ± 57.6
• Engine running at high idling
• Working mode: P mode
• Time required for track shoes to LC: 34.0 ± 2.0 LC: 32.0 - 41.5
make 5 turns after making one Hi
HD: 41 ± 2.4 HD: 38.6 ± 43.4
initial idle turn
sec.

LC: 23.3 ± 4.4 LC: 18.9 - 31.0

Lo
HD: 28.8 ± 5.4 HD: 23.4 ± 34.2

Travel speed
(actual speed) • Hydraulic oil temperature: Within LC: 16.7 ± 2.2 LC: 14.4 - 21.0
Mi
operation range HD: 18 ± 2.4 HD: 15.6 ± 20.4
• Engine running at high idling
Travel

• Working mode: P mode Hi

• Flat ground LC: 13.1 ± 0.7 LC: 12.1 - 15.1
• Time required for traveling 20 m HD: 14.7 ± 0.8 HD: 13.9 ± 15.5
after 10 m trial run

• Hydraulic oil temperature: Within operation range

• Engine at high idling
• Working mode: P mode
• Travel speed: Lo mm Max. 200 Max. 300
Travel deviation
• Solid and flat ground (in) (Max. 8.0) (Max. 12.0)
• Swerving amount while traveling 20 m (X) after
initial 10 m trial run

20-6 PC300LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value

mm 0 0
Hydraulic drift of travel
• Hydraulic oil temperature: Within (in) (0) (0)
operation range
Travel

• Engine stopped
• Parking machine on slope of 12
degrees with sprocket facing up the
slope
• Sliding distance for 5 minutes
• Hydraulic oil temperature: Within
LC: Max. 15 LC: Max. 30
operation range
(Max.4.0) (Max. 8.0)
• Engine at high idling L/m
Leakage of travel motor
• Traveling with sprocket locked (gpm)
HD: Max. 20 HD: Max. 40
• Oil leakage amount for one minute
(Max.5.3) (Max.11.0)
with traveling in relief condition
Whole work equipment (tooth tip Max. 450 Max. 675
fall amount) (Max. 18) (Max. 27)
Boom cylinder (cylinder retraction Max. 25 Max. 38
amount) (Max. 1.0) (Max. 1.5)
Hydraulic drift of work equipment

Arm cylinder (cylinder extension Max. 135 Max. 203

amount) (Max. 5.3) (Max. 8.0)
Work equipment

• Hydraulic oil temperature: Within

operation range
mm
• Flat and level ground
(in)
• Work equipment in measurement
posture as illustrated above
Bucket cylinder (cylinder retraction • Bucket load: 3,060 kg Max. 20 Max. 30
amount) • Engine stopped (Max. 1.0) (Max. 1.2)
• Work equipment control lever in
NEUTRAL position
• Fall amount for 15 minutes as
measured every 5 minutes starting
immediately after initial setting

PC300LC/HD-8 20-7
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value

RAISE
3.7 ± 0.4 Max. 4.5

Boom
• Hydraulic oil temperature: Within operation
range

LOWER
• Engine running at high idling
• Working mode: P mode 2.9 +0.4 Max. 3.0
-0.1
• Time required from raise stroke end till bucket
touches ground

IN
3.8 ± 0.4 Max. 4.5
Work equipment speed

Arm
sec.
• Hydraulic oil temperature: Within operation
range
OUT
• Engine running at high idling 2.9 ± 0.3 Max. 3.5
• Working mode: P mode
Work equipment

• Time required from dumping stroke end to

digging stroke end
CURL

3.2 ± 0.3 Max. 3.8

Bucket
• Hydraulic oil temperature: Within operation
range
DUMP

• Engine running at high idling 2.3 ± 0.3 Max. 2.9

• Working mode: P mode
• Time required from dumping stroke end to
digging stroke end
Time lag

Boom sec. Max. 3.0 Max. 3.6

• Hydraulic oil temperature: Within operation range

• Engine running at low idling
• Working mode: P mode
• Time required from raise stroke end till bucket
touches ground and pushes up machine front

20-8 PC300LC/HD-8
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Permissible
Cat. Item Measurement condition Unit Standard value
value

Arm Max. 3.0 Max. 3.6

• Hydraulic oil temperature: Within operation range
• Engine running at low idling
• Working mode: P mode
• Time required from dumping stroke end till bucket
stops momentarily after control lever is tilted to
Time lag

digging and starts to move again

sec.
Work equipment

Bucket Max. 3.0 Max. 5.0

• Hydraulic oil temperature: Within operation range
• Engine running at low idling
• Working mode: P mode
• Time required from dumping stroke end till bucket
stops momentarily after control lever is tilted to
digging and starts to move again
Internal leakage

• Hydraulic oil temperature: Within operation range 4.5 (0.3) 20 (1.2)

Cylinders
• Engine running at high idling cc/mm
Center swivel • Leakage amount for one minute with cylinder or (c/in)
10 (1.0) 50 (3.1)
joint travel to be measured in relief condition

● Hydraulic oil temperature: Within operation range

● Engine at high idling
Performance in compound operation

● Working mode: P mode

● Traveling speed: Lo
● Flat and level ground
Swerving amount in ● Swerving amount (X) when traveling 20 m after
simultaneous initial trial run of 10 m mm Max. 400 Max. 440
operation of work (in) (Max. 16) (Max. 17)
equipment and travel
hydraulic pump
Performance of

Hydraulic pump
See next page L/min. See next page
delivery

PC300LC/HD-8 20-9
STANDARD VALUE TABLES STANDARD VALUE TABLES
12
Applicable model PC300LC/HD-8
Standard Permissible
Cat. Item Measurement condition Unit
value value
Performance of hydraulic pump

● Pump speed: At 1,950 rpm, PC current 280 mA

Test pump Discharge pressure
Standard value for
discharge of other pump Average pressure Judgement standard lower
Check point discharge amount Q
pressure MPa{kg/cm2} MPa{kg/cm2} limit Q (L/min.)
2
(L/min.)
MPa{kg/cm }

As desired P1 P2 P1 + P2- See graph See graph

-------------------
2
★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specified speed
with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurement, and use them
as a base for calculating the pump discharge amount at the specified speed.

20-10 PC300LC/HD-8
 30 TESTING AND ADJUSTING

CHASSIS SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
AIR BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
ENGINE RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
FUEL RETURN RATE AND LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
HANDLING DURING CYLINDER CUT-OUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
HANDLING DURING NO INJECTION CRANKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
AIR COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
SWING CIRCLE BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
CONTROL CIRCUIT OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
PUMP PC CONTROL CIRCUIT OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
PUMP LS CONTROL CIRCUIT OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
SOLENOID VALVE OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
PPC VALVE OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
WORK EQUIPMENT AND SWING PPC VALVES PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
HYDRAULIC DRIFT IN WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
BOOM AND BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
BOOM LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
OIL LEAKAGE AMOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
BLEEDING AIR FROM VARIOUS SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
DIODE INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
MACHINE MONITOR - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
ORDINARY FUNCTIONS AND SPECIAL FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . 30-40
OPERATOR MODE (OUTLINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
DISPLAY OF KOMATSU LOGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
DISPLAY OF INPUTTING PASSWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
DISPLAY OF CHECK OF BREAKER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
DISPLAY OF CHECK BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
DISPLAY OF WARNING AFTER CHECK BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
DISPLAY OF ENDING OF MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
DISPLAY OF CHECK OF WORKING MODE AND TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . 30-45
DISPLAY OF ORDINARY SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45

PC300LC/HD-8 30-1
TESTING AND ADJUSTING
DISPLAY OF END SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
SELECTION OF AUTO-DECELERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
SELECTION OF WORKING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
SELECTION OF TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
OPERATION TO STOP ALARM BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
OPERATION OF WINDSHIELD WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
OPERATION OF WINDOW WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
OPERATION OF AIR CONDITIONER/HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
OPERATION TO DISPLAY CAMERA MODE (IF CAMERA IS INSTALLED) . . . . . . . . . . . . . . . . 30-49
OPERATION TO DISPLAY CLOCK AND SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
CHECK OF MAINTENANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
SETTING AND DISPLAY OF USER MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
[KOMTRAX MESSAGE] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
DISPLAY OF ENERGY-SAVING GUIDANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
DISPLAY OF CAUTION MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
DISPLAY OF AUTOMATIC JUDGMENT OF BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
DISPLAY OF USER CODE AND FAILURE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
FUNCTION OF CHECKING DISPLAY OF LCD (LIQUID CRYSTAL DISPLAY) . . . . . . . . . . . . . 30-54
FUNCTION OF CHECKING SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
FUNCTION OF CHANGING ATTACHMENT/MAINTENANCE PASSWORD . . . . . . . . . . . . . . . . 30-55
SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
ABNORMALITY RECORD (MECHANICAL SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
ABNORMALITY RECORD (ELECTRICAL SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
ABNORMALITY RECORD (AIR-CONDITIONING SYSTEM/HEATER SYSTEM) . . . . . . . . . . . . 30-73
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
MAINTENANCE MODE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
PHONE NUMBER ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
DEFAULT (KEY-ON MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
DEFAULT (UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
DEFAULT (WITH/WITHOUT ATTACHMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
DEFAULT (ATTACHMENT/MAINTENANCE PASSWORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
DEFAULT (CAMERA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
DEFAULT (ECO DISPLAY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
DEFAULT (BREAKER DETECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
ADJUSTMENT (PUMP ABSORPTION TORQUE (F)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
ADJUSTMENT (PUMP ABSORPTION TORQUE (R)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
ADJUSTMENT (LOW SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89
ADJUSTMENT (ATTACHMENT FLOW ADJUSTMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
CYLINDER CUT-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
NO INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
FUEL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
KOMTRAX SETTINGS (TERMINAL STATUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95
KOMTRAX SETTINGS (GPS & COMMUNICATION STATUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
KOMTRAX SETTING (MODEM S/N: TH300) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
KOMTRAX SETTINGS (IP ADDRESS: TH200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
DISPLAY OF KOMTRAX MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . 30-101
PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106

30-2 PC300LC/HD-8
TESTING AND ADJUSTING CHASSIS SERVICE TOOLS
12
CHASSIS SERVICE TOOLS
Test and adjust item Symbol Part Number Part Name Qty. Remark
Clarence of swing Commercially
J Dial gauge 1
circle bearing available
Oil pressure in work Oil pressure gauge kit 2.5, 5.9, 39.2, 58.8 MPa (363,
799-101-5002 1
equipment, swing and (Analog) 856, 5,685, 8,528 psi)
travel circuits, basic 1
Oil pressure gauge kit
pressure of control L 790-261-1204 1 58.8 MPa (8,528 psi)
(Digital)
circuit and oil pressure
of pump PC control 799-101-5220 Nipple 1
2 10 x 1.25 mm
circuit 07002-11023 O-ring 1
Oil pressure gauge kit 2.5, 5.9, 39.2, 58.8 MPa (363,
799-101-5002 1
(Analog) 856, 5,685, 8,528 psi)
1
Oil pressure gauge kit
790-261-1204 1 58.8 MPa (8,528 psi)
Oil pressure of pump LS (Digital)
M
control circuit 799-101-5220 Nipple 1
2 10 x 1.25 mm
07002-11023 O-ring 1
Differential pressure
3 799-401-1340 1
gauge
Oil pressure gauge kit 2.5, 5.9, 39.2, 58.8 MPa (363,
799-101-5002 1
(Analog) 856, 5,685, 8,528 psi)
1
Oil pressure gauge kit
790-261-1204 1 58.8 MPa (8,528 psi)
(Digital)
Solenoid valve output
N 799-401-3100 Nipple 1 02 size
pressure
2
02896-11008 O-ring 1
799-401-3200 Nipple 1 03 size
3
02896-11009 O-ring 1
Oil pressure gauge kit 2.5, 5.9, 39.2, 58.8 MPa (363,
799-101-5002 1
(Analog) 856, 5,685, 8,528 psi)
1
PPC valve output Oil pressure gauge kit
P 790-261-1204 1 58.8 MPa (8,528 psi)
pressure (Digital)
2 799-401-3100 Nipple 1 02 size
3 799-401-3200 Nipple 1 03 size
Oil leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
Water and oil
temperature
æ 799-101-1502 Digital thermometer 1 -99.9 - 1,299oC (-148 - 2370oF)

Operating effort and 79A-264-0021 Push-pull scale 1 0 - 294 N (0 - 66 lbf)

æ
depressing force 79A-264-0091 Push-pull scale 1 0 - 490 N (0 - 110 lbf)
Stroke and hydraulic Commercially
æ Ruler 1
drift available
Commercially
Work equipment speed æ Stopwatch 1
available
Voltage and resistance Commercially
æ DVOM 1
values available

PC300LC/HD-8 30-3
TESTING AND ADJUSTING ENGINE
12
ENGINE
Remark
To tune, test and troubleshoot the following procedures you must refer to the ENGINE SHOP MANUAL for the
SAA6D114E-3 series engine for the tool requirements and proper procedures.

AIR BOOST PRESSURE

AIR FROM FUEL CIRCUIT

BLOW-BY PRESSURE

COMPRESSION PRESSURE

ENGINE OIL PRESSURE

ENGINE RPM

EXHAUST GAS COLOR

FUEL CIRCUIT FOR LEAKAGE

FUEL INJECTION TIMING

FUEL PRESSURE

FUEL RETURN RATE AND LEAKAGE

HANDLING DURING CYLINDER CUT-OUT OPERATION

HANDLING DURING NO INJECTION CRANKING OPERATION

VALVE CLEARANCE

30-4 PC300LC/HD-8
TESTING AND ADJUSTING ENGINE SPEED
12
ENGINE SPEED
★ Measure the engine speed with the monitoring function of the machine monitor.
★ Measure the engine speed under the following condition.
Engine coolant temperature: . . . . . . . . . . . . . . Within operating range
Hydraulic oil temperature: . . . . . . . . . . . . . . . . Within operating range

1. Preparation work.
Operate the machine monitor so that the engine speed can be monitored.
★ For the operating method of the machine monitor, see “Special functions of machine monitor”.
★ Monitoring code: 01002 Engine speed.

2. Measuring low idle speed.

A. Start the engine and set the fuel control dial to the low idle
(MIN) position.
B. Set all the control levers and pedals for work equipment, swing
and travel to the neutral and measure the engine speed.

3. Measuring high idle speed.

A. Start the engine and set the fuel control dial to the high idle
(MAX) position.
B. Set the working mode in the power mode (P) and turn the auto-
decelerator OFF.
C. Set all the control levers and pedals for work equipment, swing and travel to the neutral and measure the engine
speed.

4. Measuring the engine speed when 2-pumps are relieved.

A. Start the engine and move the arm cylinder to the IN stroke end.
B. Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P).
C. Operate the left work equipment control lever to relieve the arm circuit at the IN stroke end and measure the engine
speed.

5. Measuring the engine speed when 2-pumps relief and power maximizing (near rated speed).
A. Start the engine and move the arm cylinder to the IN stroke end.
B. Set the fuel control dial in the high idle (MAX) position and set the working mode in the power mode (P).
C. While operating the left work equipment control lever to relieve the arm at the IN stroke end and depressing the
power maximizing switch, measure the engine speed.
★ The power maximizing function is reset automatically in about 8.5 seconds even if the switch is being depressed.
Thus measurement of the engine speed must be completed within that period.

6. Measuring the speed when auto-deceleration speed is in operation.

A. Start the engine, set the fuel control dial in the high idle position (MAX), and turn the auto-decelerator ON.
B. Set all the control levers and pedals for work equipment, swing and travel to neutral and measure the engine speed
when the auto-decelerator is operated.
★ The engine speed is slowed down to a certain level in about 5 seconds from setting all the control levers and ped-
als to the neutral. This level is the engine speed when operation of the auto-deceleration is turned on.

PC300LC/HD-8 30-5
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION
12
AIR COMPRESSOR BELT TENSION
Inspection

Test belt deflection amount (a) when depressing the mid point between
the fan pulley and the compressor pulley with your finger.
Belt depressing force: . . . . . . . . . . . .98 N {10 kg} or equivalent

Adjustment

★ If the belt deflection amount is not proper, adjust it in the following

manner.

1. Loosen mounting bolt (2) and fixing bolt (3) of compressor bracket
(1).

2. Slide compressor bracket (1) using the bar, adjust the belt tension
and then tighten fixing bolt (3).

3. Tighten mounting bolt (2)of compressor bracket (1).

★ Check the belt tension again after the adjustment.

30-6 PC300LC/HD-8
TESTING AND ADJUSTING SWING CIRCLE BEARINGS
12
SWING CIRCLE BEARINGS
★ Follow the steps explained below when measuring clearance in the swing circle bearing on the actual machine.

WARNING! Be careful not to put a hand or foot under the undercarriage, while taking measurement.

1. Fasten dial gauge J to swing circle outer race (1) or inner race (2),
and contact the probe against the end surface of inner race (2) or
outer race (1) on the opposite side.
★ Set dial gauge J at the machine front or rear side.

2. Keep the work equipment in the max. reach posture and keep the
height of the bucket teeth tip level with the lower height of the
revolving frame.
★ The upper structure is lowered at the front and raised at the rear
at that time.

3. Set dial gauge to the zero point.

4. Hold the arm nearly perpendicular to the ground, and lower the
boom until the track shoes will be lifted at the machine front.
★ The upper structure is raised at the front and lowered at the rear
at that time.

5. Read the value indicated by dial gauge J in this condition.

★ The value indicated by dial gauge J represents the clearance in
the bearings.

6. Return the machine to the posture in Item 2 above, and confirm dial
gauge J reading returns to zero.
★ If zero value is not indicated, repeat the steps in Items 3 through
5.

PC300LC/HD-8 30-7
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
INSPECTION

1. Travel the machine forward by the length of track on ground with the
engine at low idle and then stop the machine slowly.

2. Place straight bar [1] on the track shoe between the idler and the 1st
carrier roller.
★ L beam is recommended for bar [1] because of its
deflection-free nature.

3. Measure maximum clearance (a) between bar [1] and the track shoe.
Standard clearance (a): . . . . . . . . . . . 10 ~ 30 mm (0.4 ~ 1.2 in)

ADJUSTMENt

★ If the track shoe tension is not correct, adjust it in the following

manner.

1. When The Tension Is Too Tight

Loosen valve (1) to discharge the grease.

WARNING! Do not loosen the valve more than 1

turn. Otherwise, the valve may jump out
because of the high-pressure grease
inside

2. When The Tension Is Too Loose

Push in grease through grease fitting (2).
★ If the normal track shoe tension is not restored even after greasing, move the machine slowly back and forth.

30-8 PC300LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
12
OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIR-
CUIT
★ Checkup of the oil pressure in the work equipment, swing, and travel circuits (pump discharge pressure) is also available
from the monitoring function of the machine monitor (Special functions of machine monitor).
Measurement

1. Preparation work.

WARNING! Lower the work equipment to the ground

and, after stopping the engine, release
residual pressure in the piping by
operating the control lever several times.
Then loosen the oil filler cap gradually to
release pressure inside the tank.

A. Remove hydraulic oil pressure measuring plugs (1) and (2).

• Plug (1): For the front pump circuit (situated in the rear side
of the machine)
• Plug (2): For the rear pump circuit (situated in the front side
of the machine)
B. Fit nipple L2 and connect it to oil pressure gauge [1] of
hydraulic tester L1.
★ Use the oil pressure gauge with capacity 60 MPa {600 kg/
cm2} (8,534 psi).

C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.

2. Combination of pump, actuator, and valve.

★ Care must be exercised when the oil from the pump is diverted
since, at this time, the actuators of the front pump and rear pump
work independently, relieving different valves.
★ When the work equipment circuit or swing circuit is relieved
singly, the oil of the pumps is diverted.
★ The actuators in the table are arranged in the order when the
control valve is seen from the front of the machine.

PC300LC/HD-8 30-9
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
12

Pump Actuator Valve to be relieved

(Unloader) (R) unload valve
Service Safety valve
Boom Hi Arm In (R) main relief valve
Front pump Bucket (R) main relief valve
L.H. travel (R) main relief valve
RAISE: (R) main relief valve
Boom Lo
LOWER: Safety valve
Swing Swing motor safety valve
R.H. travel (F) main relief valve
Rear pump
Arm Lo (F) main relief valve
(Unload) (F) unload valve

3. Measuring Unload Pressure.

A. Start the engine.
B. Measure hydraulic oil pressure, when the engine is running at high idle and all the control levers are moved to the
NEUTRAL position.
★ Hydraulic oil pressure when the unload valve unloads is displayed.

4. Measuring Work Equipment Relief Pressure.

A. Start the engine and move the cylinder to be measured to its stroke end.
B. Measure hydraulic oil pressure when the cylinder is relieved while the engine is running at high idle.
★ Except when the boom LOWER is selected, the pressure at which the main relief valve was relieved is displayed.
★ Except when the boom LOWER is selected, releasing the power max. switch introduces the low-pressure relief
pressure and pushing this switch introduces the high-pressure relief pressure.
★ Except when the boom LOWER is selected, keep the swing lock switch in the OFF position during the
inspection.
★ If it is moved to the ON position, hydraulic oil pressure is turned to high relief pressure, as the constant 2- stage
relief valve is moved to the ON position.
★ When the boom LOWER is selected, the pressure at which the safety valve was relieved is displayed.
★ When the boom LOWER is selected, the relief pressure is lower than the main relief pressure.
★ When the boom LOWER is selected, turning off the machine push-up switch introduces the low-pressure relief
pressure and turning it on introduces the high-pressure relief pressure.

30-10 PC300LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
12
5. Measuring Swing Relief Pressure
A. Start the engine and move the swing lock switch to the ON position.
B. Measure hydraulic oil pressure when the engine is running at high idle and the swing circuit is relieved.
★ Hydraulic oil pressure when the swing motor safety valve is relieved is displayed.
★ The relief pressure of the swing motor is lower than the main relief pressure.

6. Measuring Travel Circuit Relief Pressure.

A. Start the engine, and lock the travel.

WARNING! Insert pin [2] between the sprocket and

the track frame to positively lock the
travel circuit.

B. Measure the pressure when the engine is set to high idle and the
travel circuit is relieved.
★ Hydraulic oil pressure with the main relief valve in relief
condition is displayed. In the travel circuit relief, the
pressure is high pressure relief all the time.

ADJUSTING

★ Adjustment of the unload valve is not available.

1. Adjustment Of Main Relief Pressure

★ When the relief pressure of the work equipment circuit or travel
circuit is abnormal, adjust main relief valves (3) and (4)
according to the following procedure.
• (3): For the front pump circuit
• (4): For the rear pump circuit
★ As for the main relief valve, be sure to adjust its low-pressure
relief pressure alone (adjusting the low-pressure relief pressure
automatically sets the high-pressure relief pressure, too.).
★ When the low-pressure relief pressure is turned on, the 2-stage relief valve is OFF and thus the pilot pressure is not
applicable to the switching port.
A. Disconnect the pilot hose.
B. Loosen locknut (5) and turn holder (6) to adjust the relief
pressure.
★ Turning the holder clockwise increases the pressure.
Turning it counterclockwise decreases the pressure.
Quantity of adjustment per turn of holder: . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Approximately 20.5 MPa (2,973 psi)

Locknut: 49.0 ~ 58.8 Nm (36 ~ 43 lbf ft)

C. Check the pressure again after the adjustment, following the last
steps for measurement.
★ Connect the pilot hose when measuring the oil pressure.

PC300LC/HD-8 30-11
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
12
2. Adjusting Boom LOWER Relief Pressure (on the side where high
pressure is set)
★ When the high-pressure relief pressure for the boom
LOWER is not normal, adjust the high pressure side of the
safety and suction valve (7) for the boom LOWER in the
following procedure.
★ The the high-pressure relief pressure mode denotes the state
in which the machine push-up switch is turned on, disabling
to apply the pilot pressure to the switching port.

A. Disconnect the pilot hose.

B. Loosen locknut (8) and turn holder (9) to adjust the relief pres-
sure.
★ Turning the holder clockwise increases the pressure. Turn-
ing it counterclockwise decreases the pressure.
Pressure adjustable from a single turn of the holder: . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . Approximately 21.8 MPa (3,162 psi)

Locknut: 93 ~ 123 Nm (69 ~ 91 lbf ft)

C. Check the pressure again after the adjustment, following the

previous steps for measurement.
★ Connect the pilot hose when measuring the oil pressure.

3. Adjusting Boom LOWER Relief Pressure (on the side where low
pressure is set)
★ When low-pressure relief pressure of the boom LOWER is not
normal or when adjustment is made of the high pressure setting
side, adjust the low pressure side of the safety and suction valve
for the boom LOWER in the following procedure.
★ The low-pressure relief pressure mode denotes the state in
which the machine push-up switch is turned off, disabling to
apply the pilot pressure to the switching port.
A. Disconnect the pilot hose.
B. Loosen locknut (10) and turn holder (11) to adjust the relief
pressure.
★ Turning the holder clockwise increases the pressure. Turning it counterclockwise decreases the pressure.
Pressure adjustable from a single turn of the holder:. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . Approximately 21.8 MPa (3,162 psi)

Locknut: 78 ~ 93 Nm (58 ~ 69 lbf ft)

A. Check the pressure again after the adjustment, following the aforementioned steps for measurement.
★ Connect the pilot hose when measuring the oil pressure.

30-12 PC300LC/HD-8
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
12
1. Adjusting Swing Relief Pressure
★ If the swing relief pressure is not normal, adjust the swing motor
safety valve (12) in the following manner.

A. Loosen locknut (13) and turn adjustment screw (14) to adjust the
relief pressure.
★ Turning the holder clockwise increases the pressure.
Turning it counterclockwise decreases the pressure.
Quantity of adjustment per turn of adjusting screw: . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . Approximately 4.70 MPa (682 psi)

Locknut: 147 ~ 196 Nm (108 ~ 145 lbf ft)

B. Check the pressure again after the adjustment, following the

aforementioned steps for measurement.

PC300LC/HD-8 30-13
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
12
CONTROL CIRCUIT OIL PRESSURE
MEASURING

WARNING! Lower the work equipment to the ground

and, after stopping the engine, release
residual pressure in the piping by
operating the control lever several times.
Then loosen the oil filler cap gradually to
release pressure inside the tank.

1. Remove oil pressure measurement plug (1).

2. Install nipple L2 and connect it to oil pressure gauge to hydraulic

tester L1.
★ Use the oil pressure gauge with capacity 5.9 MPa (856 psi).

3. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.

4. Measure hydraulic oil pressure, when the engine is running at high

idle and all the control levers are moved to the NEUTRAL position.

5. Remove the measurement tool after the measurement, and make sure
that the machine is back to normal condition.
★ It is not allowed to adjust the relief valve of the control circuit
source pressure.

30-14 PC300LC/HD-8
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRES-
12
PUMP PC CONTROL CIRCUIT OIL PRESSURE
MEASURING

★ Measurement of the oil pressure in the pump PC control circuit shall

be conducted after making sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as basic pressure of the con-
trol circuit is normal.

WARNING! Lower the work equipment to the ground

and, after stopping the engine, release
residual pressure in the piping by
operating the control lever several times.
Then loosen the oil filler cap gradually to
release pressure inside the tank.

1. Measuring PC Valve Output Pressure

(servo piston inlet pressure)
★ PC valve output pressure (servo piston inlet pressure) is
measured along with that of the pump discharge pressure and
the result of the two is compared to each other.
A. Remove oil pressure measurement plugs (1), (2), (3) and (4).
(1): For the front pump discharge pressure (situated in the rear
side of the machine)
(2): For the rear pump discharge pressure (situated in the front
side of the machine)
(3): For the front pump PC valve output pressure
(4): For the rear pump PC valve output pressure
B. Install nipple L2 and connect it to oil pressure gauge [1] of
hydraulic tester L1.
★ Use the oil pressure gauge with capacity 58.8 MPa (8,529
psi).

PC300LC/HD-8 30-15
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRES-
12
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the pump discharge pressure and PC valve output pres-
sure (pressure at servo piston inlet) at the same time after setting
following conditions with the engine running at high idle.
Working mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-mode
Swing lock switch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ON
. . . . . . (Turning 2-stage relief ON induces high-pressure relief)
Work equipment, swing and travel: . . . . . . . . . . . . Arm IN relief
★ Judgement method: When the ratio between the pump
discharge pressure and PC valve output pressure (servo
piston output pressure) reaches the following values, both
pressures are judged normal.

Measured oil pressure Ratio between oil pressures

Pump discharge pressure 1
PC Valve output pressure Approximately 3/5

★ If there is any abnormality with PC valve or servo piston, the PC valve output pressure (servo piston output pres-
sure) becomes identical with the pump discharge pressure or comes to neighborhood of 0 pressure.

2. Measuring PC-EPC Valve Output Pressure

A. Remove oil pressure measurement plug (5).
★ The plug is installed in the front side of the machine.

B. Install nipple L2 and connect it to oil pressure gauge on

hydraulic tester L1.
Use the oil pressure gauge with capacity 5.9 MPa (856 psi)

30-16 PC300LC/HD-8
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRES-
C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the hydraulic oil pressure with all the control levers
kept in the NEUTRAL position and the engine running at high
idle and at low idle.

Engine speed Control lever Hydraulic oil pressure

Low idle 2.9 MPa (421 psi)
Neutral
High idle 0 MPa (0 psi)

★ You can assume that the PC-EPC valve output pressure is

normal when the following changes are observed.

ADJUSTING

★ When a problem on the PC valve is suspected because of the

following phenomena, adjust PC valves (6) and (7) in the following
manner.
• As workload increases, the engine rpm sharply drops.
• The engine rpm is normal but the work equipment speed is low.

1. Loosen locknut (8) and turn holder (9) to adjust the pump
absorption torque.
★ Turning the holder clockwise increases the pump absorption
torque. Turning the holder counterclockwise decreases the pump
absorption torque.
★ Following indicates the range of adjustment available from the
adjusting screw.
Counterclockwise: . . . . . . . . . . . . . . . . . . . . . . . . . Within 1 turn
Clockwise: . . . . . . . . . . . . . . . . . . . Within 1/2 turn (Within 180°)

Locknut: 27 ~ 34 Nm (20 ~ 25 lbf ft)

2. After the adjustment, make sure that the PC valve output pressure (servo piston inlet pressure) is normal using the mea-
surement steps explained earlier.

PC300LC/HD-8 30-17
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRES-
12
PUMP LS CONTROL CIRCUIT OIL PRESSURE
MEASURING

★ Measurement of the oil pressure in the pump LS control circuit shall

be conducted after making sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as basic pressure of the con-
trol circuit is normal.

WARNING! Lower the work equipment to the ground

and, after stopping the engine, release
residual pressure in the piping by
operating the control lever several times.
Then loosen the oil filler cap gradually to
release pressure inside the tank.

1. Measuring LS Valve Output Pressure

(servo piston inlet pressure)
★ PC valve output pressure (servo piston inlet pressure) is mea-
sured along with that of the pump discharge pressure and the
result of the two is compared to each other.
A. Remove oil pressure measurement plugs (1), (2), (3) and (4).
(1): For the front pump discharge pressure (situated in the rear
side of the machine)
(2): For the rear pump discharge pressure (situated in the front
side of the machine)
(3): For the front pump LS valve output pressure
(4): For the rear pump LS valve output pressure
B. Install nipple M2 and connect it to oil pressure gauge on hydrau-
lic tester L1.
★ Use the oil pressure gauge with capacity 58.8 MPa (8,528
psi).

30-18 PC300LC/HD-8
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRES-
12
C. Start the engine and lift the track shoe on the side to be
measured using work equipment.
• When measuring the front circuit: Left track shoe
• When measuring the rear circuit: Right track shoe

WARNING! Provide a working area of sufficient

space, as the raised track shoe will be
idly rotated.

D. Increase the hydraulic oil temperature to the operating range.

E. Measure the pump discharge pressure and LS valve output
pressure (pressure at servo piston output) at the same time after
setting following conditions with the engine running at high
idle.
• Working mode: P-mode
• Work equipment, swing and travel:
When all levers are at neutral and when travel lever is at half stroke (one side of travel is at idle)
★ Let the raised track shoe idly rotate, paying enough attention to the surroundings for safety.
★ Judgement method:
When the ratio between the pump discharge pressure and LS valve output pressure (servo piston output pressure)
reaches the following values, both pressures are judged normal.
Ratio between oil pressure
Measured oil pressure
At neutral Travel lever at half stroke
Pump discharge pressure 1
Almost the same pressure
LS valve output pressure Approximately 3/5

F. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

2. Measurement of LS differential pressure

★ LS differential pressure can be obtained by measuring the pump
discharge pressure and LS pressure (actuator load pressure) at
the same time and computing the difference between the two
pressures.
A. Remove oil pressure measurement plugs (1), (2), (5) and (6).
(1): For the front pump discharge pressure (situated in the rear
side of the machine)
(2): For the rear pump discharge pressure (situated in the front
side of the machine)
(5): For the front pump LS pressure (situated in the rear side of
the machine)
(6): For the rear pump LS pressure (situated in the rear side of
the machine)

PC300LC/HD-8 30-19
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRES-
12
B. Install nipple M2 and connect it to oil pressure gauge on
differential pressure gauge M3 of hydraulic tester M1.

★ When using a differential pressure gauge: Connect pump

discharge pressure to the high pressure side and LS pressure
to the low pressure side. A differential pressure gauge
requires DC 12V power. Connect it with one battery.
★ When using an oil pressure gauge: Use the oil pressure
gauge with capacity 58.8 MPa (8,528 psi) The max.
differential pressure is no more than approximately 3.9
MPa (566 psi) So the same gauge may be used throughout
the measurement.
C. Start the engine and push up the track shoe on the measurement
side using work equipment.
When measuring the front circuit: . . . . . . . . . . . Left track shoe
When measuring the rear circuit: . . . . . . . . . . . Right track shoe

WARNING! Provide a working area of sufficient space, as the raised track shoe will be idly rotated.

D. Increase the hydraulic oil temperature to the operating range.

E. Measure the pump discharge pressure and LS pressure (actuator
load pressure) at the same time after setting the following
conditions with the engine running at high idle.
Working mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-mode
Travel speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hi
★ Work equipment, swing and travel:
When all levers are at neutral and when travel lever is at
half stroke (one side of travel is at idle)
★ Let the raised track shoe idly rotate, paying enough
attention to the surroundings for safety.
★ Calculation of LS differential pressure: LS differential
pressure = Pump discharge pressure - LS pressure
★ If LS differential pressure is in the following conditions, it is judged normal.
Lever operation LS differential pressure
When all levers are set to neutral Unload pressure (refer to the standard value table)
Maximum LS
Travel lever set at half stroke
differential pressure (refer to the standard value table)

F. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

30-20 PC300LC/HD-8
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRES-
12
3. Measurement of LS-EPC valve output pressure
A. Remove oil pressure measurement plug (7).
★ The plug is installed on the rear pump.

B. Install nipple M2 and connect it to oil pressure gauge [1] of

hydraulic tester M1.
★ Use the oil pressure gauge with capacity 5.9 MPa (856 psi)

C. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.
D. Measure the oil pressure when the engine is running at high idle
and the travel speed switch and travel control lever are operated.
★ If LS-EPC valve output pressure changes to the following
values, the pressure is normal.
Travel
Travel control lever Oil pressure
speed
Lo Neutral Approximately 1.4 MPa (203 psi)
Fine operation
Hi 0 MPa (0 psi)
(Remark)

Remark
Operate the travel control lever slightly to the extent that the PPC oil pressure switch is turned ON
(Stop the operation short of starting the machine).
E. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

PC300LC/HD-8 30-21
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRES-
12
ADJUSTING

★ When the LS differential pressure is not normal, adjust LS valves (8)

and (9) in the following procedure.

1. Loosen locknut (10) and turn holder (11) to adjust the differential
pressure.
★ Adjustment screw
• Turned to the right, the differential pressure is increased.
• Turned to the left, the differential pressure is decreased.
★ Quantity of adjustment per turn of adjusting screw:
Quantity of pressure adjustment (LS differential pressure) 1.3
MPa (189 psi)

Lock nut: 49 ~ 64 Nm (36 ~ 47 lbf ft)

2. After the adjustment, confirm that LS differential pressure is normal, following the steps for measurement explained
earlier.

30-22 PC300LC/HD-8
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
SOLENOID VALVE OUTPUT PRESSURE
l Measure the solenoid valve output pressure after confirming that the
control circuit source pressure is normal.

WARNING! Lower the work equipment to the ground

and, after stopping the engine, release
residual pressure in the piping by
operating the control lever several times.
Then loosen the oil filler cap gradually to
release pressure inside the tank.

1. Disconnect the hoses of solenoid valve to be measured at the outlet

side.

No. Target solenoid values of measurement

1 PPC lock solenoid valve
2 Travel junction solenoid valve
3 Merge-divider solenoid valve
4 Travel speed switching solenoid valve
5 Swing holding brake solenoid valve
6 Machine push-up solenoid valve
7 2-stage relief solenoid valve

★ Hose (1) is installed in the back side of operator's cab, and hoses
(2) through (7) are installed at the center of
revolving frame.

2. Install adapter N2 or N3 and then connect hose currently

disconnected.

3. Install nipple [1] of hydraulic tester N1 and then connect it to oil

pressure gauge [2].
★ Use the oil pressure gauge with capacity 5.9 MPa (856 psi).

4. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.

PC300LC/HD-8 30-23
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
5. Run the engine at full throttle, then turn each solenoid valve ON or OFF by operating the control levers and switches, and
measure the pressure.
★ For conditions for turning each solenoid valve ON or OFF, refer to the ensuing
★ Table for functioning conditions for each solenoid valve.
★ You can check operation of the solenoid valves from the monitoring function of the monitor panel (Special Function
of Machine Monitor).

Solenoid valve Output pressure

OFF (De-energized) 0 MPa (0 psi)
ON (Energized) 3 MPa (435 psi)

★ When each output pressure shows the following values, it is judged normal.

6. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

Table for functioning conditions - PPC lock solenoid valve

Functioning conditions Function

Locked OFF
Lock lever
Released ON

Table for functioning conditions - Machine push up solenoid valve

Operating conditions Operations

ON ON
Machine push-up switch
OFF Off

Table for functioning conditions - Swing holding brake solenoid valve

Functioning conditions Function

When all signals are turned OFF OFF
Signal of work equipment, swing and travel
When one of the signals is turned ON ON

Table for functioning conditions - Travel junction solenoid valve

Functioning conditions Function

When the travel steering signal is ON
When travel steering is When F or R pump pressure is 34.3 MPa ON
When the travel steering independently operator (4,975 psi)
signal is OFF
Any other condition than above OFF

30-24 PC300LC/HD-8
TESTING AND ADJUSTING SOLENOID VALVE OUTPUT PRESSURE
12
Table for functioning conditions - Travel speed shifting solenoid valve

Functioning conditions Function

Overheat 2nd.setting is ON
When the fuel dial is at 1,200 rpm or lower
When the travel speed switch is at Lo
OFF
When signal of the travel is OFF
When F or R pump pressure is 32.3 MPa
When the travel speed switch
When signal of the travel (4,685 psi)
is at Mi or Hi
is ON When F or R pump pressure is 18.6 MPa
(2,698 psi) ON
Any other condition than above

Table for functioning conditions - 2-stage relief solenoid valve

Operating conditions Operation

Overheat 1st.setting is ON
OFF
All work equipment, swing and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L mode is selected
ON
Boom LOWER signal is ON
Signals other than swing independent signal
P or E mode is selected Left knob switch is ON are ON
Swing independent signal is ON
OFF
Other than above conditions

Table for functioning conditions - Merge-divider solenoid valve

Functioning conditions Function

When B mode is turned ON When the service signal is ON
When independent signal of the travel is ON
ON
When any When F or R pump pressure is 19.6 MPa
mode other (2,843 psi) or above
When
than L mode When F or R pump pressure is 14.7 MPa
signals of the OFF
is turned ON (2,132 psi) or above
When signal of the travel is work
OFF equipment When F or R pump pressure is 16.7 MPa
and swing ON
(2,422 psi) or lower
are ON L mode
When F or R pump pressure is 11.8 MPa
(1,711 psi) or lower OFF
Any other condition than above

PC300LC/HD-8 30-25
TESTING AND ADJUSTING PPC VALVE OUTPUT PRESSURE
12
PPC VALVE OUTPUT PRESSURE

★ Measure PPC valve output pressure after confirming that control

circuit original pressure is normal.

1. Remove PPC hydraulic switches (1) to (10) of the target circuit of

measurement.

No. Circuit to be measured No. Circuit to be measured

1 Boom RAISE 6 Bucket DUMP
2 Boom LOWER 7 Swing left
3 Arm IN 8 Swing right
4 Arm OUT 9 Travel (black)
5 Bucket CURL 10 Steering (red)

★ (1) through (8) are installed in the PPC relay block, and (9) and
(10) are installed in the back side of operator cab.

2. Install nipple [1] of the hydraulic tester P and then connect it to oil
pressure gauge.
★ Use the oil pressure gauge with capacity 5.9 MPa (856 psi).

3. Start the engine and keep it running until the hydraulic oil
temperature rises to the operating range.

4. Measure the pressure when the engine is running at high idle and the
control lever of the circuit to be measured is kept in the
NEUTRAL position and at the full stroke.
★ If PPC valve output pressure is at the level shown below, it is
judged normal.

Lever operation Hydraulic oil pressure

When set to NEUTRAL 0 MPa (0 psi)
Almost the same with the control circuit source pressure (refer to the
At full stroke
standard value table)

5. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

30-26 PC300LC/HD-8
TESTING AND ADJUSTING WORK EQUIPMENT AND SWING PPC
12
WORK EQUIPMENT AND SWING PPC VALVES PLAY ADJUST-
MENT
★ If there is excessive play in the work equipment or swing lever,
adjust it in the following manner.

1. Remove work the equipment and swing PPC valve assembly.

2. Remove boot (1).

3. Loosen locknut (2) and screw in disc (3) until it contacts the heads of
4 pistons (4).
★ Do not move the piston while doing this work.

4. Keep disc (3) in place and tighten locknut (2) to the specified
tightening torque.

Locknut: 98 - 127 Nm (72 - 94 lbf ft)

5. Install boot (1).

6. Install the work equipment and swing PPC valve assembly.

PC300LC/HD-8 30-27
TESTING AND ADJUSTING HYDRAULIC DRIFT IN WORK EQUIPMENT
12
HYDRAULIC DRIFT IN WORK EQUIPMENT
★ If hydraulic drift occurred on the work equipment (cylinder), check to see if the cause is on the cylinder packing side or
control valve side according to the following procedure.

BOOM AND BUCKET CYLINDERS

1. Set the work equipment in the same posture as when measuring
hydraulic drift, and stop the engine.
★ Fill the bucket with earth or apply the rated load to the bucket.

2. When inspecting the boom cylinder, shift the boom control lever to
RAISE side and when inspecting the bucket cylinder, shift the
bucket control lever to CURL side.
If, as the result, drifting speed increases, failure on the cylinder
packing should be suspected.
If the speed remains unchanged, failure on the control valve should
be suspected.
★ Operate the control lever with the engine ignition switch in the
ON position.
★ If pressure in the accumulator has dropped, run the engine for approximately 10 seconds to charge the accumulator
again.

ARM CYLINDER
1. Operate the arm cylinder to move the arm to the position 100 mm
before the digging stroke end, and stop the engine.

2. Shift the arm control lever to IN side.

If, as the result, drifting speed increases, failure on the cylinder
packing should be suspected.
If the speed remains unchanged, failure on the control valve should
be suspected.
★ Operate the control lever with the engine ignition switch in the
ON position.
★ If pressure in the accumulator has dropped, run the engine for
approximately 10 seconds to charge the accumulator again.

Remark
When the cause of the hydraulic drift is in the defective packing, following explains why such occurred.
If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the
bottom end leaks to the head end. However, the volume at the head end is small than the volume at the
bottom end by the volume of the rod end, so the internal pressure at the head end increases because of the
oil flowing in from the bottom end.

3. If the internal pressure of the head end increases, the pressure at the bottom end also rises in proportion to this and
balanced at certain level (this level depends on the volume of leakage). As the pressure is balanced, the drifting speed is
decreased.

4. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain
circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward
movement becomes faster.

30-28 PC300LC/HD-8
TESTING AND ADJUSTING HYDRAULIC DRIFT IN WORK EQUIPMENT
12
BOOM LOCK VALVE
1. Set the work equipment at the maximum reach and the boom top
horizontal. Then stop the engine.

WARNING! Lock the work equipment control levers

and release the pressure inside the
hydraulic tank. Do not allow anyone to
come under the work equipment during
the work.

2. Disconnect drain hose (1) of the control valve, and install an oil
stopper plug in the hose.
Oil stopper plug: . . . . . . . . . . . . . . . . . . . . . . . . . . .07376-70210
★ Leave the control valve end open.
★ If oil leaks out the opened port accompanying hydraulic drift of the work equipment, failure on the boom lock valve
should be suspected (loose contact).

PPC VALVE
1. Measure the amount of hydraulic drift of the work equipment when the accumulator is charged with pressure and the lock
lever is put to the LOCK and FREE positions.
★ Operate the control lever with the engine ignition switch in the ON position.
★ If pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again.
★ If the lock and free position cause any difference in the hydraulic drift volume, the PPC valve is defective (internal
failure).

PC300LC/HD-8 30-29
TESTING AND ADJUSTING HYDRAULIC CIRCUIT - RELEASING RE-
12
HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE

WARNING! When disconnecting the piping routed from the hydraulic cylinder and the hydraulic motor
to the control valve, release the residual pressure in the circuit according to the following
procedure.

★ The swing motor circuit and travel motor circuit are free from residual pressure. However, since these circuits are affected
by the pressure inside the hydraulic tank, the operation up to opening of the hydraulic tank cap must be implemented.

1. Stop the engine and then gradually loosen the oil filler cap of the hydraulic tank to release the pressure in the tank.

2. Turn the engine ignition switch to the ON position and operate the control levers several times.
★ Power must be conducted to PPC lock valve, thus the ignition switch must be set to ON position prior to the lever
operation.
★ When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed.

3. Start the engine, run at low idle for approx. 10 seconds to accumulate pressure in the accumulator, then stop the engine.

4. Repeat the steps in Item 2 to 3 above several times.

OIL LEAKAGE AMOUNT

Measuring Oil Leakage Amount From Boom Cylinder

1. Start the engine and keep it running until the hydraulic oil tempera-
ture rises to the operating range. Then extend the boom cylinder to
the stroke end.

WARNING! Release the pressure remaining in the

piping referring to “Releasing remaining
pressure in hydraulic circuit”.

2. Disconnect hose (1) on the cylinder head end and block the hose end
with a plate.

WARNING! Be careful not to disconnect the hose at

the cylinder bottom end.

3. Run the engine at high idle and relieve the boom circuit by raising the boom.

4. Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.

5. Remove the measurement tool after the measurement, and make sure that the machine is back to normal condition.

30-30 PC300LC/HD-8
TESTING AND ADJUSTING HYDRAULIC CIRCUIT - RELEASING RE-
12
Measuring Oil Leakage Amount From Arm Cylinder

1. Start the engine and keep it running until the hydraulic oil temperature rises to the operating range. Then extend the arm
cylinder to the IN stroke end.

WARNING! Release the pressure remaining in the piping referring to “Releasing remaining pressure
in hydraulic circuit”.

2. Disconnect hose (2) on the cylinder head end and block the hose end with a plate.

WARNING! Be careful not to disconnect the hose at the cylinder bottom end.

3. Run the engine at high idle and relieve the arm circuit by moving the arm IN.

4. Continue this condition for 30 seconds, then measure the oil leakage
amount for one minute.

5. Remove the measurement tool after the measurement, and make sure
that the machine is back to normal condition.

Measuring Oil Leakage Amount From Bucket Cylinder

1. Start the engine and keep it running until the hydraulic oil tempera-
ture rises to the operating range. Then extend the bucket cylinder to
the CURL stroke end.

WARNING! Release the pressure remaining in the

piping referring to “Releasing remaining
pressure in hydraulic circuit”.

2. Disconnect hose (3) on the cylinder head end and block the hose end
with a plate.

WARNING! Be careful not to disconnect the hose at the cylinder bottom end.

3. Run the engine at high idle and relieve the bucket circuit by moving the bucket CURL.

4. Continue this condition for 30 seconds, then measure the oil leakage amount for one minute.

5. After the measurement, make sure that the machine is back to normal condition.

PC300LC/HD-8 30-31
TESTING AND ADJUSTING HYDRAULIC CIRCUIT - RELEASING RE-
12
Measuring Oil Leakage Amount From Swing Motor

1. Disconnect drain hoses (4) and install the oil stopper plug in the
hoses.

2. Turn the swing lock switch to the ON position.

3. Run the engine at high idle, relieve the swing circuit, and measure
the oil leakage.
★ Start measuring the oil leakage 30 seconds after relieving is
started and measure for 1 minute.
★ After measurement 1 time, swinging 180°, and then measure
again.

4. After the measurement, make sure that the machine is back to normal condition.
Measuring Oil Leakage Amount From Travel Motor

1. Take off the travel motor cover.

2. Start the engine, and lock the travel.

WARNING! Insert pin [1] between the sprocket and

the track frame to positively lock the
travel circuit.

3. Disconnect drain hose (5) of the travel motor and fit an oil stopper
plug in the hose end.

4. Run the engine at high idle, relieve the travel circuit, and measure
the oil leakage.

WARNING! Wrong operation of the lever can cause

an accident. Accordingly, make signs
and checks securely.

★ Start measuring the oil leakage 30 seconds after relieving is

started and measure for 1 minute.
★ Measure several times, moving the motor a little (changing the
position of the valve plate and cylinder and that of the cylinder
and piston) each time.

5. After the measurement, make sure that the machine is back to normal condition.

30-32 PC300LC/HD-8
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
BLEEDING AIR FROM VARIOUS SYSTEMS
Air bleeding Air bleeding procedures
items
1 2 3 4 5 6
Hydraulic Starting Swing Travel
Cylinder Operation
Contents of work pump engine motor motor
● ●
• Replacement of hydraulic motor
● ● ● (see (see ●
• Cleaning of strainer
Remark) Remark
• Replacement of return filter element ● ➞ ➞ ➞ ●
• Replacement and repair of hydraulic pump
● ● ● ➞ ➞ ●
• Removal of suction piping
• Replacement and repair of control valve ● ● ➞ ➞ ●
• Replacement of cylinder
● ● ➞ ➞ ●
• Removal of cylinder piping
• Replacement of swing motor
● ➞ ● ➞ ●
• Replacement of swing motor piping
• Replacement of travel motor and swivel
● ➞ ➞ ● ●
• Removal of travel motor and swivel piping

Remark
Bleed air from the swing motor and travel motor only when oil in the casing is drained.

Bleeding Air From Hydraulic Pump

1. Loosen air bleeder (1) and check that oil oozes out through the air
bleeder.

2. If the oil seepage is confirmed, tighten air bleeder (1).

Air bleeder: 7.8 - 9.8 Nm (6 - 7 ft/lbs)

★ Precautions on starting engine: When starting the engine after

above operations, be sure to run the engine at low idle for 10
minutes. If the engine coolant temperature is low and an
automatic engine warming-up function is relied on, use the fuel
dial, when it becomes necessary to cancel it.

PC300LC/HD-8 30-33
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
Bleeding Air From Hydraulic Cylinder

1. Start the engine and keep running at low idle for 5 minutes.

2. Raise and lower the boom 4 to 5 times with the engine running at low idle.
★ Stop the piston approximately 100 mm (4 in) in front of the stroke end so that it may not be relieved.

3. While running the engine at high idle, perform step 2).

4. Set the piston rod to the stroke end at low idle and allow it to relieve.

5. For bleeding air from the arm cylinder and bucket cylinder, follow the same steps explained in Item 2) through 4) above.
★ In case a cylinder is replaced with new one, it is advised to bleed air from the new one before mounting the work
equipment. It is especially so with the boom cylinder, because its rod does not extend to the stroke end of LOWER
side, after the work equipment is mounted.
Bleeding Air From Swing Motor

1. Start the engine and run it at low idle.

2. Swing slowly to bleed air.

Bleeding Air From Travel Motor - PC300LC-8

1. Start the engine and run it at low idle.

2. Loosen air bleeder (2) and confirm that oil seeps out from the plug.

3. If the oil seepage is confirmed, tighten air bleeder (2).

Air bleeder: 27.5 - 35.3 Nm (20 - 26 lbf ft)

30-34 PC300LC/HD-8
TESTING AND ADJUSTING BLEEDING AIR FROM VARIOUS SYSTEMS
12
Bleeding Air From Travel Motor - PC300HD-8

1. Take off the travel motor cover.

2. Start the engine and run it at low idle.

3. Loosen bleeder (4) to make sure oil oozes out.

4. After making sure that the oil from bleeder (4) is free from mixed air,
tighten the bleeder.

Air bleeder: 9.8 – 12.74 Nm {1.0 – 1.3 kgm}

5. Using the work equipment, lift the track shoe of one side.

6. Gradually run the lifted track shoe at idle for approximately two
minutes.
★ Repeat the same for the opposite side track shoe.

PC300LC/HD-8 30-35
TESTING AND ADJUSTING DIODE INSPECTION PROCEDURES
12
DIODE INSPECTION PROCEDURES
★ Check an assembled-type diode (8 pins) and independent diode (2
pins) in the following manner.
★ The conduction direction of an assembled-type diode is as shown in
the diagram below.
★ The conduction direction of an independent diode is shown on the
diode surface.

When Using Digital Type Circuit Tester

1. Switch the testing mode to diode range and confirm the indicated
value.
★ Voltage of the battery inside is displayed with conventional
circuit testers.

2. Put the red probe (+) of the test lead to the anode (P) of and the black
probe (-) to the cathode (N) of diode, and confirm the
indicated value.

3. Determine acceptability of the diode from the indicated value.

• Indicated value remains unchanged:
• Conduction is absent (Failure)
★ Indicated value changes: Conduction is present (Normal) (Remark)
★ A value between 0.46 V to 0.60 V is indicated for silicon diodes.
★ A value between 460 to 600 is indicated for silicon diodes.
When Using Analog Type Circuit Tester

★ When the diode range is set, the testing method is the same as that
done by use of the digital type circuit tester.

1. Switch the testing mode to resistance range.

2. Apply the leads of the tester as explained below and check the
movement of the pointer.

A. Put the red probe (+) of the test lead to the anode (P) and the
black probe (-) to the cathode (N) of diode.

B. Put the red probe (+) of the test lead to the cathode (N) and the
black probe (-) to the anode (N) of diode.

3. Determine if a specific diode is good or no good by the way the pointer swings.
• With the connection A above, the pointer is not moved. It swings, however, when the connection B is employed.
Normal (However, magnitude of the pointer's move (indicating the resistance value) varies depending on the given
tester model and the measurement range selected).
• The pointer swings with both the connections of A and B: Defective (Internal short circuit)
• The pointer does not swing with both the connections of A and B: Defective (Internal breaking of wire)

30-36 PC300LC/HD-8
TESTING AND ADJUSTING DIODE INSPECTION PROCEDURES
12

MEMORANDUM

PC300LC/HD-8 30-37
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
MACHINE MONITOR - SPECIAL FUNCTIONS
Air conditioner specification

30-38 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
Upper section of machine monitor (Display section) Heater specification

(a): Multi-display
★ When the engine is started, the battery voltage may lower suddenly,
depending on the ambient temperature and the condition of the
battery. In this case, the machine monitor goes off for a moment.
This phenomenon is not a failure, however.
Upper section of machine monitor (Switch section)

[F1]: F1 function switch

[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
★ The function of each function switch is indicated by graphic mark in
the multi-display (a) above that function switch.
★ If the graphic mark of a function switch is not displayed, that
function switch is not working.
Lower section of machine monitor (Switch section)

[1]: Numeral 1 input switch/Auto-decelerator switch

[2]: Numeral 2 input switch/Working mode selector switch
[3]: Numeral 3 input switch/Travel speed shifting switch
[4]: Numeral 4 input switch/Alarm buzzer cancel switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer switch
[7]: Numeral 7 input switch/Air conditioner or heater switch Heaterless specification
[8]: Numeral 8 input switch/Air conditioner or heater
switch
[9]: Numeral 9 input switch/Air conditioner or heater
switch
[0]: Numeral 0 input switch/Air conditioner or heater
switch
Switch having no numerals: Air conditioner or heater switch
★ Each switch has the function indicated by graphic mark and the
function of inputting a numeral.
★ The machine monitor automatically judges which function of each
switch is currently effective, according to the display condition of
multi-display.
★ The difference between the air conditioner specification, heater spec-
ification, and heaterless specification is only the functions of the
switches in this section.

PC300LC/HD-8 30-39
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
ORDINARY FUNCTIONS AND SPECIAL FUNCTIONS OF MACHINE MONITOR
The machine monitor has the ordinary function and special functions and displays information of various types on the
multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed
according to the operation of the switches.

1. Ordinary functions: Operator mode

The items in this mode are displayed ordinarily. The operator can display and set them by operating the switches (Display
and setting of some items need special operations of the switches).

2. Special functions: Service mode

The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches
specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (Outline) Service mode
A Display of KOMATSU logo Monitoring
A Display of inputting password Mechanical Systems
Abnormality
A Display of check of breaker mode Electrical Systems
Record
A Display of check before starting Air-conditioning System/Heater System
A Display of warning after check before starting Maintenance Record
A Display of ending of maintenance interval Maintenance Mode Change
A Display of check of working mode and travel speed Phone Number Entry
A Display of ordinary screen Key-on Mode
A Display of end screen
↓ (Special operation)

Unit
B Selection of auto-deceleration With/Without Attachment
B Selection of working mode Default Attachment/Maintenance Password
B Selection of travel speed Camera
B Operation to stop alarm buzzer ECO Display
B Operation of windshield wiper Breaker Detect
B Operation of window washer Pump Absorption Torque (F)
B Operation of air conditioner/heater Pump Absorption Torque (R)
Operation to display camera mode Adjustment
B (if camera is installed) Low Speed

B Operation to display clock and service meter Attachment Flow Adjustment

B Check of maintenance information Cylinder Cut-Out
Setting and display of user mode
B (Including KOMTRAX messages for user) No Injection

C Display of energy-saving guidance Fuel Consumption

C Display of caution monitor Terminal Status
C Display of automatic judgment of breaker KOMTRAX GPS & Communication Status
C Display of user code and failure code Settings MODEM S/N (TH300)
↓ (Special operation) MODEM IP Address (TH200)
Function of checking display of LCD
D (Liquid Crystal Display) Display of KOMTRAX message

D Function of checking service meter

Function of changing attachment/maintenance
D password

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
★ Classification of operator mode:
A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and
display after starting switch is turned OFF.
B: Display/Function when switch of machine monitor is operated.
C: Display/Function when certain condition is satisfied.
D: Display/Function which needs special operation of switch.

PC300LC/HD-8 30-41
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12
OPERATOR MODE (OUTLINE)
★ Only outline of the operator mode is described in this section. For details of contents/operation of each function/display,
see the Structure, function and maintenance standard, or Operation and Maintenance Manual.
★ The following are the displays or functions of the operator mode explained in this section (including some items which
need special operations).
Display pattern
A B C D E
Display of KOMATSU logo 1 1 1 1 1
Display of inputting password 2 - - - -
Display of check of breaker mode - - 2 - -
Display of check before starting 3 2 3 2 2
Display of warning after check before starting - - - 3 -
Display of ending of maintenance interval - - - - 3
Display of check of working mode and travel speed 4 3 4 4 4
Display of ordinary screen 5 4 5 5 5
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner/heater

Operation to display camera mode (if camera is installed)

Operation to display clock and service meter

Check of maintenance information
Setting and display of user mode (including
KOMTRAX messages for user)
Display of energy-saving guidance
Display of caution monitor
Display of automatic judgment of breaker
Display of user code and failure code
↓ (Special operation)
Function of checking display of LCD (Liquid Crystal Display)
Function of checking service meter
Function of changing attachment/maintenance password

★ Display pattern of operator mode

The contents of display from the time when starting switch is turned ON to time when screen changes to ordinary screen
depends on the setting and condition of the machine.
A: When engine start lock is set effective
B: When engine start lock is set ineffective
C: When working mode at start is set to breaker mode (B)
D: When there is abnormal item in check before-starting items
E: When there is maintenance item which is not maintained after specified interval

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
DISPLAY OF KOMATSU LOGO
When the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds.
★ After the KOMATSU logo is displayed for 2 seconds, the screen
changes to “Display of inputting password”, “Display of check of
breaker mode (if B mode is set)”, or “Display of check before
starting”.

★ The following screen may be displayed instead of the above Display

of inputting password screen.
★ If this screen is displayed, call the person responsible to operation of
KOMTRAX in your Komatsu distributor and ask for remedy.

DISPLAY OF INPUTTING PASSWORD

After the KOMATSU logo is displayed, the screen
to input the engine start lock password is displayed.
★ This screen is displayed only when the engine start lock function is
set effective.
★ If the password is input normally, the screen changes to “Display of
check of breaker mode (if B mode is set)” or “Display of check
before starting”.
★ The machine monitor has some password functions other than the
engine start lock. Those functions are independent from one another.

PC300LC/HD-8 30-43
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12
DISPLAY OF CHECK OF BREAKER MODE
When the starting switch is turned ON, if the working mode is set to the
breaker mode [B], a message to inform the operator of starting in the
breaker mode is displayed on the screen.

WARNING! If an attachment other than the breaker is

used while the working mode is set to the
breaker mode [B], the machine may move
unexpectedly or may not operate normally
or the hydraulic components may be
damaged.

★ After operation to check of the breaker mode is finished, the screen

changes to “Display of check before starting”.
If No is selected: Working mode is set to economy mode [E]
If Yes is selected: Working mode is set to breaker mode [B]

DISPLAY OF CHECK BEFORE STARTING

When the screen changes to the check-before-starting screen, the check
before starting is carried out for 2 seconds.
★ If any abnormality is detected by the check before starting, the
screen changes to “Display of warning after check before starting” or
“Display of ending of maintenance interval”.
★ If no abnormality is detected by the check before starting, the screen
changes to “Display of check of working mode and travel speed”.
★ The monitors (6 pieces) displayed on the screen are the items under
the check before starting.

DISPLAY OF WARNING AFTER CHECK BEFORE STARTING

If any abnormality is detected by the check before starting, the warning
monitor is displayed on the screen.
★ The following figure shows that the engine oil level monitor (a) is
warning of low of engine oil level.

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
DISPLAY OF ENDING OF MAINTENANCE INTERVAL
When the check before starting is carried out, if a maintenance item is
near or after the end of the set interval, the maintenance monitor is
displayed for 30 seconds to urge the operator to maintenance.
★ This screen is displayed only when the maintenance function is
effective. The color of the maintenance monitor (yellow or red)
indicates the length of the time after the maintenance interval.
★ Set or change the maintenance function in the service mode.
★ After display of this screen is finished, the screen changes to
“Display of check of working mode and travel speed”.

DISPLAY OF CHECK OF WORKING MODE AND TRAVEL SPEED

If the check before starting is finished normally, the screen to check the
working mode and travel speed is displayed for 2 seconds.
★ After display of check of the working mode and travel speed is
finished, the screen changes to “Display of ordinary screen”.

DISPLAY OF ORDINARY SCREEN

If the machine monitor starts normally, the ordinary screen is displayed.
★ Service meter (a) or a clock is displayed at the center upper section
of the screen (The service meter or clock is selected with [F4]).
★ ECO gauge (b) is displayed at the right end of the screen (It is turned
ON and OFF in the service mode).

PC300LC/HD-8 30-45
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
DISPLAY OF END SCREEN
When the starting switch is turned OFF, the end screen is displayed for 5
seconds.
★ Another message may be displayed on the end screen, depending on
the message display function of KOMTRAX.

SELECTION OF AUTO-DECELERATION
While the ordinary screen is displayed, if the auto-deceleration switch is
pressed, large auto-deceleration monitor (a) is displayed for 2 seconds
and the setting of the auto-deceleration is changed.
★ Each time the auto-deceleration switch is pressed, the
auto-deceleration is turned ON and OFF alternately.
★ If the auto-deceleration is turned ON, large monitor (a) and
auto-deceleration monitor (b) are displayed simultaneously.
★ If the auto-deceleration is turned OFF, auto-deceleration monitor (b)
goes off.

SELECTION OF WORKING MODE

Select a working mode according to the following procedure.

1. While the ordinary screen is displayed, press the working mode

selector switch, and the working mode selection screen is displayed.
★ The following figure is the working mode selection screen
displayed when "With attachment" is set (If "With attachment"
is not set in the service mode, the attachment mode [ATT] is not
displayed).

2. Operate the function switches or working mode selector switch to

select and confirm the working mode which you will use.
Function switches

• [F3]: Move to lower working mode

• [F4]: Move to upper working mode
• [F5]: Cancel selection and return to ordinary screen
• [F6]: Confirm selection and return to ordinary screen
Working mode selector switch
• Press: Move to lower working mode
• Hold down: Confirm selection and return to ordinary screen
★ a If you do not touch any of the function switches and working
mode selector switch for 5 seconds, the selection is confirmed and the screen changes to the ordinary screen.

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
3. When the ordinary screen is displayed again, large working mode
monitor (a) is displayed for 2 seconds, and then the setting of the
working mode is changed.
★ When large monitor (a) is displayed, the display of working
mode monitor (b) is changed, too.

<Precautions for selecting breaker mode [B]>

• If breaker mode [B] is selected, both of the control of the hydraulic

pump and the setting of the hydraulic circuit are changed.
• If an attachment other than the breaker is used, the machine may
move unexpectedly or may not operate normally or the hydraulic
components may be damaged.
• After the breaker mode is selected, the screen to confirm the
selection of the breaker mode is displayed (The buzzer sounds
intermittently while this screen is displayed).
• If the setting is confirmed on this screen, the screen changes to the
ordinary screen.
If No is selected:
Screen returns to screen to select working mode.
If Yes is selected:
Working mode is set to breaker mode [B]

SELECTION OF TRAVEL SPEED

While the ordinary screen is displayed, if the travel speed shifting switch
is pressed, large travel speed monitor (a) is displayed for 2 seconds and
the setting of the travel speed is changed.
★ Each time the travel speed shifting switch is pressed, the travel speed
is changed to Lo, Mi, Hi, and Lo again in order.
★ When large monitor (a) is displayed, the display of travel speed
monitor (b) is changed, too.

OPERATION TO STOP ALARM BUZZER

While the alarm buzzer is sounding, if the alarm buzzer cancel switch is
pressed, the alarm buzzer stops.
★ Even if the alarm buzzer cancel switch is pressed, the screen does not change.

PC300LC/HD-8 30-47
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12
OPERATION OF WINDSHIELD WIPER
While the ordinary screen is displayed, if the wiper switch is pressed,
large wiper monitor (a) is displayed for 2 seconds and the windshield
wiper starts or stops.
★ Each time the wiper switch is pressed, the windshield wiper setting
is changed to INT, ON, OFF, and INT again in order.
★ When large monitor (a) is displayed, the display of wiper monitor (b)
is changed or turned OFF, too.
★ If the windshield wiper is turned OFF, large monitor (a) is not
displayed.

OPERATION OF WINDOW WASHER

While the ordinary screen is displayed, if the window washer switch is pressed, the washing liquid is splashed only while the
switch is held down.
★ Even if the window washer switch is pressed, the screen does not change.

OPERATION OF AIR CONDITIONER/HEATER

While the ordinary screen is displayed, press the air conditioner switch or heater switch, and the air conditioner adjustment
screen or heater adjustment screen is displayed.
★ While the air conditioner adjustment screen or heater adjustment screen is displayed, if you do not touch any switch for 5
seconds, the screen changes to the ordinary screen.
★ Air conditioner specification

★ Heater specification

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
OPERATION TO DISPLAY CAMERA MODE (IF CAMERA IS INSTALLED)
When a camera is installed, if [F3] is pressed, the multi-display changes
to the camera image (Set the connection of the camera in the service
mode).

★ Up to 3 cameras can be connected. If the camera mode is selected,

however, only the image of camera 1 is always displayed.
★ If a caution is generated in the camera mode, the caution monitor is
displayed at the left upper of the screen (The low hydraulic oil
temperature caution is not displayed there, however).
★ When an error that there is a user code occurs in the camera mode, if
you do not touch any control lever for 10 seconds, the screen
changes to the ordinary screen and displays the error information.
★ When two or more cameras are connected, the image of one of them
or the images of two of them can be displayed.
If 2-camera image display [F4] is selected, the image of camera 1 is
displayed on the left side of the screen and the image of camera 2 is
displayed on the right side. The image of camera 3 is displayed only
singly.
★ If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1 second on the right and left
screen.

OPERATION TO DISPLAY CLOCK AND SERVICE METER

While the ordinary screen is displayed, press [F4], and section (a)
changes to the service meter and clock alternately.
★ When the clock is selected, adjust the time, set 12-hour or 24-hour
display, and set the summer time with the user mode function.

PC300LC/HD-8 30-49
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
CHECK OF MAINTENANCE INFORMATION
While the maintenance monitor or ordinary screen is displayed, press
[F5], and the maintenance table screen is displayed.

★ To reset the time left after finishing maintenance, more operations

are necessary.

SETTING AND DISPLAY OF USER MODE

(INCLUDING KOMTRAX MESSAGES FOR USER)
While the ordinary screen is displayed, press [F6], and the user menu
screen is displayed.
★ There are following items in the user menu.

Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment

★ The breaker/attachment setting menu is displayed only when "With

attachment" is set in the service mode.

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
[KOMTRAX MESSAGE]
• There are 2 types of KOMTRAX message; 1 is for the user and the other is for the service.
• For user:
A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is
displayed on the ordinary screen. To see the contents of the message, operate "User Message" in the above user menu.
• For service:
A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed
on the ordinary screen. To see the contents of the message, operate "KOMTRAX message" display in the service
menu.

DISPLAY OF ENERGY-SAVING GUIDANCE

When the machine is set in a certain operating condition, the
energy-saving guidance screen is displayed automatically to urge the
operator to the energy-saving operation.
★ The energy-saving guidance is displayed when the following
condition is satisfied while the display setting is set effective in the
service mode.
★ Condition for display:
Engine is running + All levers have been in neutral for 5 minutes +
Caution (Note) or user code is not generated (Note)
Note: Excluding hydraulic oil low temperature caution
★ If any lever or pedal is operated, or [F5] is pressed, the screen returns
to the ordinary screen.

DISPLAY OF CAUTION MONITOR

If an abnormality which displays a caution monitor occurs on the
ordinary screen or camera mode screen, the caution monitor is displayed
large for a moment and then displayed at (a) in the screen.
★ On the camera mode screen, the caution monitor flashes at the left
upper of the screen when the caution is generated.

PC300LC/HD-8 30-51
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12
DISPLAY OF AUTOMATIC JUDGMENT OF BREAKER
If the operator performs breaker work in an improper working mode, the
breaker automatic judgment screen is displayed to urge the operator to
select a proper working mode.
★ The breaker automatic judgment is displayed when the following
condition is satisfied while the display setting is set effective in the
service mode.
★ Condition for display:
When the pump controller measures the rear pump pressure for a
certain time, the obtained value is similar to the pulsation wave form
of breaker operation which is held in the controller in advance.
★ The breaker automatic judgment function is set to Not used (Not
displayed) when delivered.
★ If this screen is displayed, check the setting of the working mode. If
the breaker is being used, select the breaker mode [B].
★ To return to the ordinary screen, press [F5].

DISPLAY OF USER CODE AND FAILURE CODE

If an abnormality which displays a user code and a failure code occurs on the ordinary screen or camera mode screen, all the
information of the abnormality is displayed.
(a): User code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
★ This screen is displayed only when an abnormality (failure code) for which a user code is set occurs.
★ The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode.
★ If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order.
★ Since the information of the displayed failure code is recorded in the
abnormality record in the service mode, check the details in the
service mode.

★ When the caution monitor is also displayed, the telephone mark is

not displayed.

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
★ Remedies given by displayed user codes to operator to take (The following table is an excerpt from the Operation and
Maintenance Manual)

User code Failure mode Action

When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not be
possible to release it. In any case, have inspection carried out
immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11 Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15 pressure, oil pressure) system error immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error out immediately.

PC300LC/HD-8 30-53
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
FUNCTION OF CHECKING DISPLAY OF LCD (LIQUID CRYSTAL DISPLAY)
While the ordinary screen is displayed, if the following numeral input
switch and function switch are operated as follows, all the LCD (Liquid
Crystal Display) lights up in white.
• Operation of switches (simultaneous): [4] + [F2]
★ When finishing the operation of the switches, release [F2] first.
★ If there is a display error in the LCD, only that part is indicated in
black.
★ The LCD panel sometimes has black points (points which are not
lighted) and bright points (points which do not go off) for the reason
of its characteristics. If the number of the bright points and black
points does not exceed 10, those points are not a failure or a defect.
★ To return to the former screen, press the function switch.

FUNCTION OF CHECKING SERVICE METER

To check the service meter while the starting switch is turned OFF,
operate the numeral input switches as follows. At this time, only the
service meter section displays.
• Operation of switches (simultaneous): [4] + [1]
★ Since there is some time lag in start of the LCD, hold down the
switches until the LCD displays normally.
★ After the machine monitor is used continuously, blue points (points
which do not go off) may be seen on this screen. This phenomenon
does not indicate a failure or a defect.

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TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
FUNCTION OF CHANGING ATTACHMENT/MAINTENANCE PASSWORD
When changing the attachment/maintenance password used for the
attachment setting function and maintenance setting function, follow
these procedures.

1. While the ordinary screen is displayed, perform the following

operation with the numeral input switches.
• Operation of switches (While pressing [4], perform the
operation in order):
[4] + [5] ➡ [5] ➡ [5]
★ This operation of the switches is not accepted until 10 minutes
pass after the starting switch is turned on.

2. After the Attachment/Maintenance PASSWORD screen is displayed,

input the current password with the numeral input switches and
confirm it with the function switch.
• [F5]: Reset input numeral/Return to ordinary screen
• [F6]: Confirm input numeral
• Default password: [000000]
• If the input password is correct, the screen changes to the next
screen.
• If the input password is incorrect, the message to input the
password again is displayed.

3. After the New password input screen is displayed, input a new

password with the numeral input switches and confirm it with the
function switch.
★ Set a new password of 4 – 6 digits (If it has only 3 or less digits
or has 7 or more digits, it is not accepted).
• [F5]: Reset input numeral/Return to ordinary screen
• [F6]: Confirm input numeral

4. After the New password input screen is displayed again, input a new
password again with the numeral input switches and confirm it with
the function switch.
• [F5]: Reset input numeral/Return to ordinary screen
• [F6]: Confirm input numeral
• If a password different from the password input before is input,
the message to input again is displayed.

PC300LC/HD-8 30-55
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
5. If the screen to notify completion of setting is displayed and then the
ordinary screen is displayed, the password is changed successfully.

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12

MEMORANDUM

PC300LC/HD-8 30-57
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
SERVICE MODE
To change the operator mode to the service mode, perform the following
operation.
This operation is always required when you use the service mode.

1. Check of display of screen and operation of switches

While the ordinary screen is displayed, perform the following
operation with the numeral input switches.
• Operation of switches (While pressing [4], perform the
operation in order): [4] + [1] ➡ [2] ➡ [3]
★ This operation of the switches is accepted only while the
ordinary screen is displayed.

2. Selection of service menu

When the Service menu screen is displayed, the service mode is
selected. Select a service menu you use with the function switches or
numeral input switches.
• [F3]: Move to lower menu
• [F4]: Move to upper menu
• [F5]: Return to ordinary screen (operator mode)
• [F6]: Confirm selection
★ You may enter a 2-digit code with the numeral input switches to
select the menu of that code and confirm it with [F6].

30-58 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 ★ The items which can be selected in the service menu are as follows (including some items which need special opera-
tions).

01 Monitoring
Mechanical Systems
02 Abnormality Record Electrical Systems
Air-conditioning System/Heater System
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Unit
With/Without Attachment
06 Default Attachment/Maintenance Password
Camera
ECO Display
Breaker Detect
Pump Absorption Torque (F)
Pump Absorption Torque (R)
07 Adjustment
Low Speed
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
GPS & Communication Status
11 KOMTRAX Settings
MODEM S/N (TH300)
MODEM IP Address (TH200)

PC300LC/HD-8 30-59
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
MONITORING
The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches,
sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling
switches, etc.

1. Selecting menu
Select “Monitoring” on the service menu screen.

2. Selecting monitoring items

After the “Monitoring selection menu screen” is displayed, select
items to be monitored with the function switches or numeral input
switches.
• [F1]: Move to next page (screen)
• [F2]: Move to previous page (screen)
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Reset input numeral/Return to service menu screen
• [F6]: Confirm selection
★ Selection with function switches: Select an item with [F3] or
[F4] and confirm it with [F6].
★ Selection with numeral input switches: Enter a 5-digit code, and
the item of that code is selected directly. Confirm that item with [F6].
★ If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed.
★ Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the
display form of those items.

3. Deciding monitoring items

After selecting monitoring items, execute monitoring with the func-
tion switch or numeral input switch.
★ Execution with function switch: Double click or hold down [F6]
(about 2 seconds).
★ Execution with numeral input switch: Input [99999] and press
[F6].
★ When monitoring only 2 items, for example, select them and
confirm with [F6]. If [F6] is pressed once more at this time,
monitoring is executed.
★ If monitoring items are selected up to the limit number, monitor-
ing is executed automatically.

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12
4. Executing monitoring
After the “Executing monitoring screen” is displayed, perform the
necessary operation of the machine and check the monitoring
information.
★ Monitoring information is indicated by value, ON/OFF, or
special display.
★ The unit of display can be set to SI unit, metric unit, or inch unit
with the Initialization function in the service mode.

5. Holding monitoring information

The monitoring information can be held and reset with the function
switches.
• [F3]: Reset holding
• [F4]: Hold information (displayed data)
• [F5]: Return to monitoring selection menu screen

6. Changing machine setting mode

To change the setting of the working mode, travel speed, or
auto-deceleration during monitoring, operate the corresponding
switch under the current condition, and the mode setting screen is
displayed.
While this screen is displayed, if the corresponding switch is
operated further, the corresponding mode is changed.
★ After finishing changing the setting, press [F6] to return to the monitoring information screen.
★ If the setting is changed during monitoring, the new setting is
held even after the screen returns to the ordinary screen after
monitoring is finished.

★ If the working mode is changed to breaker mode [B], the screen

to confirm the change of the setting is displayed as in changing
the working mode on the ordinary screen.

PC300LC/HD-8 30-61
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 Monitoring items table
Unit (Initial setting: ISO) Component in
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch charge
00200 Controller Model Select - PUMP
00201 Machine ID - ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
01101 R Pump Pressure MPa 2 psi PUMP
kg/cm
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa 2 psi PUMP
kg/cm
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01302 PC-EPC Sol. Curr.(R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr.(Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr.(LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value
36500 Boost Pressure kPa kg/cm2 psi ENG indication (including
atmospheric pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sensor Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode - ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP

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Unit (Initial setting: ISO) Component
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch in charge
Swing ON/OFF PUMP
Travel ON/OFF PUMP
Boom Lower ON/OFF PUMP
01900 Pressure Switch 1
Boom Raise ON/OFF PUMP
Arm Curl ON/OFF PUMP
Arm Dump ON/OFF PUMP
Bucket Curl ON/OFF PUMP
Bucket Dump ON/OFF PUMP
01901 Pressure Switch 2
Service ON/OFF PUMP
Travel Steering ON/OFF PUMP
Travel Junction ON/OFF PUMP
Swing Brake ON/OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON/OFF PUMP
2-Stage Relief ON/OFF PUMP
Travel Speed ON/OFF PUMP
02301 Solenoid Valve 2 Service Return ON/OFF PUMP
Lever Sw. ON/OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON/OFF PUMP
Swing Brake Sw. ON/OFF PUMP
Model Select 1 ON/OFF PUMP
Model Select 2 ON/OFF PUMP
Model Select 3 ON/OFF PUMP
02201 Switch Input 2
Model Select 4 ON/OFF PUMP
Model Select 5 ON/OFF PUMP
Overload Alarm ON/OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON/OFF PUMP
Window Limit SW. ON/OFF PUMP
02204 Switch Input 5 P Limit SW. ON/OFF PUMP
W Limit SW. ON/OFF PUMP
Key Switch ON/OFF MON
Start ON/OFF MON
04500 Monitor input 1 Preheat ON/OFF MON
Light ON/OFF MON
Rad. Level ON/OFF MON
Air cleaner ON/OFF MON
04501 Monitor Input 2 Eng. Oil Level ON/OFF MON
Battery Charge ON/OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON/OFF MON
F1 ON/OFF MON
F2 ON/OFF MON
Monitor Function F3 ON/OFF MON
04503 Switches F4 ON/OFF MON
F5 ON/OFF MON
F6 ON/OFF MON
SW1 ON/OFF MON
SW2 ON/OFF MON
Monitor 1st & 2nd SW3 ON/OFF MON
04504 Row Switches SW4 ON/OFF MON
SW5 ON/OFF MON
SW6 ON/OFF MON

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Unit (Initial setting: ISO) Component in
Code No. Monitoring item (Display on screen) Remarks
ISO meter inch charge
SW7 ON/OFF MON
SW8 ON/OFF MON
Monitor 3rd & 4th SW9 ON/OFF MON
04505
Row Switches SW10 ON/OFF MON
SW11 ON/OFF MON
SW12 ON/OFF MON
SW13 ON/OFF MON
04506 Monitor 5th Row SW14 ON/OFF MON
Switches
SW15 ON/OFF MON
18800 Water In Fuel ON/OFF ENG WIF: Water In Fuel
20216 ECM Build Version - ENG
20217 ECM CAL Data Ver - ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No - ENG
20227 Monitor Ass'y P/N - MON
20402 Monitor Serial No - MON
20228 Monitor Prog. P/N - MON
20229 Pump Con. Ass'y P/N - PUMP
20403 Pump Con. Serial No - PUMP
20230 Pump Con. Prog. P/N - PUMP

★ Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
★ Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit selecting in Initialization of the service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
★ Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.

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ABNORMALITY RECORD (MECHANICAL SYSTEMS)
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into
the mechanical systems, electrical systems, and air-conditioning system or heater system.
To check the mechanical system abnormality record, perform the following procedures.

1. Selecting menu
Select “Abnormality Record” on the “Service Menu” screen.

2. Selecting sub menu

After the “Abnormality Record” screen is displayed, select
“Mechanical Systems” with the function switches or numeral input
switches.
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to service menu screen
• [F6]: Confirm selection
★ You may enter a 2-digit code with the numeral input switches to
select the record of that code and confirm it with [F6].
★ The following figure shows the display of the air conditioner
specification. The heater specification and heaterless
specification are different from each other in the display of "03
Air-conditioning System", which may not be displayed in the heaterless specification.
3. Information displayed on “abnormality record” screen
On the “Mechanical Systems” screen, the following information is
displayed.
(a): Occurrence order of abnormalities from latest one/Total number
of records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time (Displayable range: 0 – 65,535
times)
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
• [F1]: Move to next page (screen) (if displayed)
• [F2]: Move to previous page (screen) (if displayed)
• [F5]: Return to abnormality record screen
★ If no abnormality record is recorded, "No abnormality record" is displayed.
★ If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at
the last occurrence are the same.
★ If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been
confirmed.
★ For all the failure codes that the machine monitor can record, see the failure codes table in “Abnormality Record
(Electrical Systems)”.

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4. Resetting abnormality record
The contents of the mechanical system abnormality record cannot be reset.

ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into
the mechanical systems, electrical systems, and air-conditioning system.
To check the electrical system abnormality record, perform the following procedures.

1. Selecting menu
Select “Abnormality Record” on the “Service Menu” Screen.

2. Selecting sub menu

After the “Abnormality Record” screen is displayed, select
“Electrical Systems” with the function switches or numeral input
switches.
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to service menu screen
• [F6]: Confirm selection
★ You may enter a 2-digit code with the numeral input switches to
select the record of that code and confirm it with [F6].
★ The following figure shows the display of the air conditioner
specification. The heater specification and heaterless
specification are different from each other in the display of "03
Air-conditioning System", which may not be displayed in the heaterless specification.

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3. Information displayed on “abnormality record” screen
On the “Electrical Systems” screen, the following information is
displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time (Displayable range: 0 – 65,535
times)
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
• [F1]:Move to next page (screen) (if displayed)
• [F2]:Move to previous page (screen) (if displayed)
• [F3]:Move to lower item
• [F4]:Move to upper item
• [F5]: Return to “abnormality record” screen
★ If no abnormality record is recorded, "No abnormality record" is displayed.
★ If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at
the last occurrence are the same.
★ If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been
confirmed.
★ For all the failure codes that the machine monitor can record, see the failure codes table.

4. Resetting abnormality record

A. While the “Electrical Systems” screen is displayed, perform the
following operation with the numeral input switches.
• Operation of switches (While pressing [4], perform the
operation in order): [4] + [1] ➡ [2] ➡ [3]

B. Check that the screen is set in the reset mode, and then reset the
items one by one or together with the function switches.
★ If the screen is set in the reset mode, [CLEAR] graphic
mark is indicated at [F2].
• [F2]: Reset all items
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to abnormality record screen
• [F6]: Reset selected item
★ To reset items one by one: Select the item to be reset with
[F3] or [F4] and press [F6].
★ To reset all items together: Press [F2], and all the items are
reset, regardless of selection of the items.
★ If [E] is displayed on the left of a failure code, the resetting operation is accepted but the information is not reset.

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12
C. After the “Electrical Sys. Error Reset” screen is displayed,
operate the function switches.
• [F5]: Return to “Electrical systems” screen (Reset mode)
• [F6]: Execute reset
★ The following figure shows the screen displayed when the
items are reset one by one (which is a little different from
the screen displayed when all the items are reset together).

D. If the screen to notify completion of reset is displayed and then

the “Electrical Systems” (reset mode) screen is displayed, the
reset of the abnormality record is completed.
★ After a while, the screen returns to the “Electrical Systems”
screen.

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★ Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
★ User code
Attached: If the failure code is detected, the user code, failure code, and telephone No. (if registered)
are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
★ Alarm buzzer
• When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the buzzer with the
alarm buzzer cancel switch).
▲ Since the caution monitor is also turned ON, its function sounds the buzzer.
★ Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
★ Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.

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ABNORMALITY RECORD (AIR-CONDITIONING SYSTEM/HEATER SYSTEM)
The machine monitor classifies and records the abnormalities which occurred in the past or which are occurring at present into
the mechanical systems, electrical systems, and air-conditioning abnormalities or heater abnormalities. To check the
air-conditioning abnormality record or heater abnormality record, perform the following procedures.
★ All the following figures show the air conditioner specification.

1. Selecting menu
Select “Abnormality Record” on the “Service Menu” screen.

2. Selecting sub menu

After the “Abnormality Record” screen is displayed, select
“Air-conditioning System” or “Heater System” with the function
switches or numeral input switches.
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to service menu screen
• [F6]: Confirm selection
★ You may enter a 2-digit code with the numeral input switches to
select the record of that code and confirm it with [F6].

3. Information displayed on “abnormality record” screen

On the “Air-conditioning System” or “Heater System” screen, the
following information is displayed.
(a): System/Component name
(b): Number of occurrence time
(c): Condition (Normal or abnormal)
• [F2]: Reset abnormality record
• [F5]: Return to abnormality record screen
★ If [E] is displayed on the left of a condition, the abnormality is
still occurring or resetting of it has not been confirmed.
★ If CAN disconnection is displayed in Communication condition,
communication cannot be carried out normally. Accordingly, the
conditions of other items are turned OFF.

4. Resetting abnormality record

While the “abnormality record” screen is displayed, press [F2], and the number of occurrence time of abnormality is reset.
If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
★ Heater specification
In the heater specification, the display of “Air-conditioning” is replaced with “Heater” and the items which are not
related to the heater are not displayed.
★ Heaterless specification
In the heaterless specification, the abnormality record menu and screen are not displayed.

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MAINTENANCE RECORD
The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by
the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times
of maintenance is recorded in this section.

1. Selecting menu
Select “Maintenance Record” on the “Service Menu” screen.

2. Selecting maintenance record item

After the “Maintenance Record” screen is displayed, select an item
to be checked with the function switches or numeral input switches.
• [F1]: Move to next page (screen)
• [F2]: Move to previous page (screen)
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to service menu screen
★ You may enter a 2-digit code with the numeral input switches to
select the item of that code.
★ The following items can be selected in the maintenance record.
01 Engine oil change
02 Engine oil filter change
03 Fuel main filter change
41 Fuel pre-filter change
04 Hydraulic oil filter change
05 Hydraulic tank breather change
06 Corrosion resistor change
07 Damper case service
08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change

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3. Items displayed on maintenance record screen
The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous replacement

MAINTENANCE MODE CHANGE

The operating condition for maintenance function in the operation mode can be set and changed with this menu.
• Set function effective or ineffective
• Change set replacement interval (by items)
• Initialize all set replacement intervals
1. Selecting menu
Select of “Maintenance Mode Change” on the “Service Menu”
screen.

2. Selecting sub menu

After the “Maintenance Mode Change” screen is displayed, select an
item to change the setting with the function switches or numeral
input switches.
• [F1]: Move to next page (screen)
• [F2]: Move to previous page (screen)
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to service menu screen
★ You may enter a 2-digit code with the numeral input switches to
select the item of that code and confirm it with [F6].

PC300LC/HD-8 30-75
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12 ★ The following items can be selected on the Change of maintenance mode screen.
00 Maintenance mode on/off
01 Engine oil change int.
02 Engine oil filter change int.
03 Fuel main filter change int.
41 Fuel pre filter change int.
04 Hyd oil filter change int.
05 Hyd tank breather change int.
06 Corrosion resistor change int.
07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Initialize all items

3. Contents of setting of Maintenance mode on/off

After selecting “Maintenance Mode On/Off”, if the screen is
displayed, set ON or OFF with the function switches.
• ON: Functions of all maintenance items are set effective in
operator mode
• OFF: Functions of all maintenance items are set ineffective in
operator mode
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to Maintenance mode change
screen
• [F6]: Confirm selection and return to Maintenance mode change
screen
★ Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.

4. Contents of setting of each maintenance item

After selecting each maintenance item, if the screen is displayed, set
the item with the function switches.
• Initial value: Maintenance interval set in machine monitor
(Recommended by manufacturer and not changeable).
• Set value: Maintenance interval which can be set freely.
Maintenance functions in operator mode operate on basis of this
set time (which is increased or decreased by 50 hours).
• ON: Maintenance function of this item is set effective in
operator mode.
• OFF: Maintenance function of this item is set ineffective in
operator mode.
• [F3]: Select Reduce set value (Upper) or OFF (Lower).
• [F4]: Select Increase set value (Upper) or ON (Lower).
• [F5]: Cancel setting before confirmation and return to Maintenance mode change screen.
• [F6]: Confirm setting of upper or lower line.
★ After the setting of the upper and lower lines is confirmed with [F6] and the screen changes to the Maintenance mode
change screen with [F5], the setting is effective.
★ If the set value of an item set to “ON” is changed after 1 or more operating hours since the start of setting, the change
is recognized as a resetting operation.

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5. Function of initializing all items
After selecting “All Default Value”, if the screen is displayed, set
with the function switches.
• If this operation is executed, the set values of all the
maintenance items are initialized.
• [F5]: Return to Maintenance mode change screen\
• [F6]: Execute initialization
★ A while after [F6] is pressed, the initialization completion
screen is displayed. Then, if the “Maintenance Mode Change”
screen is displayed, initialization is completed.

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PHONE NUMBER ENTRY
The telephone No. displayed when the user code/failure code is displayed in the operator mode can be input and changed
according to the following procedure.
If a telephone No. is not input with this function, no telephone No. is displayed in the operator mode.

1. Selecting menu
Select “Phone Number Entry” on the “Service Menu” screen.

2. Registering and changing telephone No.

After the “Phone Number Entry” screen is displayed, register or
change the telephone No.
• [F2]: Reset all input No.
• [F3]: Move to left position (if not blank)
• [F4]: Move to right position (if not blank)
• [F5]: Reset input digit/Return to service menu
• [F6]: Confirm input
★ Up to 14 digits can be input from the left. Input nothing in the
surplus positions.
★ If one of the input digits is wrong, move to that digit (orange
background) and overwrite it with the correct digit.
★ If [F6] is pressed without inputting a digit, there is not
information of telephone No. Accordingly, no telephone No. is
displayed in the operator mode.

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DEFAULT (KEY-ON MODE)
Check or change various settings related to the machine monitor and machine by "Default". The function of working mode
with key ON is used to set the working mode displayed on the machine monitor when the starting switch is turned ON.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select “Key-on Mode” with
the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting mode
After the “Key-on Mode” screen is displayed, select the mode to be
set with the function switches.
• Power Mode: [P] is displayed when key is ON
• Economy Mode: [E] is displayed when key is ON
• Lifting Mode: [L] is displayed when key is ON
• Breaker Mode: [B] is displayed when key is ON
• Attachment Mode: [ATT] is displayed when key is ON
• Mode at Previous Key-off: Final mode in previous operation is
displayed when key is ON
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to “Default” screen
• [F6]: Confirm selection and return to “Default” screen
★ When the machine is delivered, Mode at previous key-OFF is set.
★ If "With attachment" is not set, the attachment mode cannot be selected.
★ While Attachment mode [ATT] is selected, if "Without attachment" is set, Power mode [P] is displayed when the key
is turned ON.
★ If the engine is stopped while breaker mode [B] is selected in the operator mode, Breaker mode [B] is always
displayed, regardless of the above setting.

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DEFAULT (UNIT)
Check or change various settings related to the machine monitor and machine by "Default". The unit selecting function is used
to select the unit of the data displayed for monitoring, etc.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select “Unit” with the
function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting unit
After the “Unit” screen is displayed, select the unit to be set with the
function switches.
• [F3]: Move to lower unit
• [F4]: Move to upper unit
• [F5]: Cancel selection and return to “Default” screen
• [F6]: Confirm selection and return to “Default” screen
★ When the machine is delivered, the SI unit system is set.

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DEFAULT (WITH/WITHOUT ATTACHMENT)
Check or change various settings related to the machine monitor and machine by "Default". The "With/Without attachment"
function is used to set an installed or a remove attachment.

1. Selecting menu
Select "Default" on the “Service Menu” screen.

2. Selecting sub menu

After the "Default" screen is displayed, select “With/Without
Attachment” with the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting With/Without
After the “With/Without Attachment” screen is displayed, select the
setting with the function switches.
• Without Attachment: When attachment is not installed
• With Attachment: When attachment is installed
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to Default screen
• [F6]: Confirm selection and return to Default screen
★ When an attachment is installed, if this setting is not carried out
normally, the attachment cannot be set in the operator mode. As
a result, the attachment may not work normally or the hydraulic
components may have trouble.

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DEFAULT (ATTACHMENT/MAINTENANCE PASSWORD)
Check or change various settings related to the machine monitor and machine by "Default". The function of setting
attachment/maintenance password is used to set the display of the password screen when the functions related to the
attachment and maintenance are used in the operator mode.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select “Attachment/Mainte-
nance Password” with the function switches or numeral input
switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting Disable/Enable
After the Attachment/Maintenance Password screen is displayed,
select the setting with the function switches.
• Disable: Password screen is not displayed
• Enable: Password screen is displayed
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to "Default" screen
• [F6]: Confirm selection and return to "Default" screen
4. Displaying attachment/maintenance password screen
When the following operation is performed, the password screen is
displayed in the operator mode.
• Maintenance mode: The Maintenance table screen is changed to the Maintenance interval reset screen.
• User mode: On the User menu screen, the Breaker/Attachment setting menu is selected and the screen is changed to
the Attachment setting menu screen.
5. Changing attachment/maintenance password
The password can be changed by operating the switches specially in the operator mode.
★ See Attachment/Maintenance password changing function in the operator mode.
★ Default password: [000000]
★ If the password setting is changed from Enable to Disable, the password is reset to the default. When Enable is set
again, be sure to set a new password.
★ The attachment/maintenance password is different from the engine start lock password.

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DEFAULT (CAMERA)
Check or change various settings related to the machine monitor and machine by "Default". The camera setting function is
used to set installation and removal of a camera.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select “Camera” with the
function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
Screen.

3. Selecting camera setting

After the “Camera” setting screen is displayed, select the setting with
the function switches.
• OFF: Camera is not used
• Original Image: Image of connected camera is displayed in
original position (as in mirror, used as back monitor)
• Reverse Image: Image of connected camera is displayed in
reverse position (as seen directly, used as front or side monitor)
• [F3]: Move to left item
• [F4]: Move to right item
• [F5]: Cancel setting before confirmation and return to “Default”
screen
• [F6]: Confirm selection in each line
★ After “Camera” screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1
is set, the screen changes to setting of camera 2 automatically.
★ After confirming the setting of each line with [F6], return to the "Default" screen with [F5], and the setting is
effective.
★ If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in
the operator mode. Accordingly, the image of the camera cannot be used.
★ If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order.
★ The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set.
★ When a camera is installed, check that the displayed image is not inverted horizontally.

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DEFAULT (ECO DISPLAY)
Check or change various settings related to the machine monitor and machine by "Default". The ECO display setting function
is used to set the display of the ECO gauge and energy saving guidance.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select “ECO Display” with
the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting display setting

After the “ECO Display” screen is displayed, select the setting with
the function switches.
• ON: Display ECO
• OFF: Do not display ECO
• [F3]: Move to left item
• [F4]: Move to right item
• [F5]: Cancel setting before confirmation and return to "Default" screen
• [F6]: Confirm selection in each line
★ After confirming the setting of the upper and lower lines with [F6], return to the "Default" screen with [F5], and the
setting is effective.
★ If ECO display is turned ON, ECO is displayed when the screen
changes to the ordinary screen. Even if the energy saving guid-
ance is turned ON, however, it is not displayed if the condition
for display is not satisfied on the ordinary screen.

30-84 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
★ Display of ECO gauge (a)

★ Display of energy saving guidance

PC300LC/HD-8 30-85
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
DEFAULT (BREAKER DETECT)
Check or change various settings related to the machine monitor and
machine by "Default". The function of setting breaker automatic
judgment is used to set the display to give warning when the breaker is
used in an improper working mode.

1. Selecting menu
Select “Default” on the “Service Menu” screen.

2. Selecting sub menu

After the “Default” screen is displayed, select "Breaker Detect" with
the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service menu”
screen.

3. Selecting display setting

After the "Breaker Detect" screen is displayed, select the setting with
the function switches.
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Cancel selection and return to Default screen
• [F6]: Confirm selection and return to Default screen
★ When the machine is delivered, Disable is set.

★ Display of "Breaker Detect"

30-86 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
ADJUSTMENT (PUMP ABSORPTION TORQUE (F))
The operator can adjust various items related to the machine with the
machine monitor. The pump absorption torque (F) function is used to
finely adjust the absorption torque on the front side of the hydraulic
pump.

1. Selecting menu
Select “Adjustment” on the “Service Menu” screen.

2. Selecting sub menu

After the “Adjustment” screen is displayed, select “Pump
Absorption Torque (F)” with the function switches or numeral input
switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting absorption torque

After the "Pump Absorption Torque (F)" screen is displayed, select a
set value on the right side with the function switches.
• Set value: For actual torque adjustment value, see table
• [F3]: Increase set value
• [F4]: Decrease set value
• [F6]: Confirm setting and return to Adjustment menu screen
★ The 3 digits on the left side do not vary since they are the code
of this function.
★ Relationship between set value and torque adjustment value
Code Set value Torque adjustment value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}

PC300LC/HD-8 30-87
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
ADJUSTMENT (PUMP ABSORPTION TORQUE (R))
The operator can adjust various items related to the machine with the
machine monitor. The pump absorption torque (R) function is used to
finely adjust the absorption torque on the rear side of the hydraulic pump.

1. Selecting menu
Select “Adjustment” on the “Service Menu” screen.

2. Selecting sub menu

After the “Adjustment” screen is displayed, select “Pump
Absorption Torque (R)” with the function switches or numeral input
switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting absorption torque

After the "Pump Absorption Torque (R)" screen is displayed, select a
set value on the right side with the function switches.
• Set value: For actual torque adjustment value, see table
• [F3]: Increase set value
• [F4]: Decrease set value
• [F6]: Confirm setting and return to Adjustment menu screen
★ The 3 digits on the left side do not vary since they are the code
of this function.
★ Relationship between set value and torque adjustment value
Code Set value Torque adjustment value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}

30-88 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
ADJUSTMENT (LOW SPEED)
The operator can adjust various items related to the machine with the
machine monitor. The travel Low speed setting function is used to finely
adjust the travel Low speed.

1. Selecting menu
Select “Adjustment” on the “Service Menu” screen.

2. Selecting sub menu

After the “Adjustment” screen is displayed, select “Low speed” with
the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting travel Low speed

After the "Low Speed" setting screen is displayed, select a set value
on the right side with the function switches.
• Set value: For actual travel Low speed value, see table
• [F3]: Increase set value
• [F4]: Decrease set value
• [F6]: Confirm setting and return to Adjustment menu screen
★ The 3 digits on the left side do not vary since they are the code
of this function.
★ Relationship between set value and travel Low speed value

Code Set value Travel Low speed value

000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h

PC300LC/HD-8 30-89
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
ADJUSTMENT (ATTACHMENT FLOW ADJUSTMENT)
The operator can adjust various items related to the machine with the
machine monitor. The function of "Attachment Flow Adjustment" is used
to finely adjust the oil flow to the attachment in compound operation.

1. Selecting menu
Select “Adjustment” on the “Service Menu” screen.

2. Selecting sub menu

After the “Adjustment” screen is displayed, select “Attachment Flow
Adjustment” with the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Selecting distribution of oil flow

After the screen of "Attachment Flow Adjustment" is displayed,
select a set value on the right side with the function switches.
• Set value: For actual distribution of flow, see table
• [F3]: Increase set value
• [F4]: Decrease set value
• [F6]: Confirm setting and return to Adjustment menu screen
★ The 3 digits on the left side do not vary since they are the code
of this function.
★ Relationship between set value and distribution of flow to
attachment
Code Set value Distribution of flow to attachment
000 50 %
001 70 %
044
002 100 %
003 40 %

30-90 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
CYLINDER CUT-OUT
The operator can perform "Cylinder Cut-Out" operation with the machine
monitor.
"Cylinder Cut-Out" operation means to run the engine with 1 or more
fuel injectors disabled electrically to reduce the number of effective
cylinders. This operation is used to find out a cylinder which does not
output power normally (combustion in it is abnormal).

1. Selecting menu
Select “Cylinder Cut-Out” on the “Service Menu” screen.

2. Selecting cylinder to be disabled

After the "Cylinder Cut-Out" screen is displayed, select a cylinder to
be Cut-Out with the function switches.
• [F1]: Move selection mark (R) to left
• [F2]: Move selection mark (R) to right
• [F3]: Reset holding
• [F4]: Hold
• [F5]: Return to service menu screen
• [F6]: Confirm selection
★ This operation may be performed while the engine is running.
★ When [F6] is pressed, if background (a) of the selected cylinder
No. becomes white, the cylinder is Cut-Out.
★ If the machine monitor Cut-Out a cylinder but the engine controller cannot Cut-Out that cylinder, the background (a)
of the cylinder No. becomes yellow.
★ One or more cylinders can be Cut-Out.
★ In the cylinder Cut-Out operation, the auto-decelerate on function can be selected. If the auto-deceleration is turned
ON, auto-deceleration monitor (b) is displayed.

3. Resetting Cut-Out cylinder

When changing a cylinder to be Cut-Out or when Cylinder Cut-Out operation is finished, select a Cut-Out cylinder to be
reset with the function switches.
★ This operation may be performed while the engine is running.
★ When [F6] is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset.
★ If the machine monitor resets a Cut-Out cylinder but the engine controller cannot reset that Cut-Out cylinder, the
background (a) of the cylinder No. becomes red.
★ The Cut-Out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to
perform the resetting operation after the cylinder cut-out operation is finished.

4. Function of holding displayed information

If [F4] is pressed during the cylinder Cut-Out operation, the
displayed information is newly held (c) (The real-time information is
kept displayed on the left side). While the information is held, if [F3]
is pressed, the holding function is reset.
★ The holding function is effective, regardless of setting of the
reduced cylinder mode operation.

PC300LC/HD-8 30-91
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
[Reference]

• If a normally operating cylinder is Cut-Out, the following phenomena occur.

A. Lowering of engine speed
B. Increase of final injection rate command (quantity)
• If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control.
• In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.

NO INJECTION
If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with
oil. To prevent this, the function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set
the no-injection cranking while the engine is stopped.

1. Selecting menu
Select “No Injection” on the “Service Menu” screen.

2. Displaying check screen

If the "No injection" screen is displayed, the machine monitor asks
the operator if no injection cranking should be performed. Answer
with the function switch.
• [F5]: Do not perform (Return to Service menu screen)
• [F6]: Perform
★ While the screen is changing to the following screen, the screen
of "Communication between controllers is being checked" is
displayed.

3. Starting no injection cranking

If no injection cranking (Fuel injection in no cylinders) becomes
effective, that is displayed on the screen. Under this condition, crank
the engine with the starting motor.
★ While the screen is changing to the following screen, the screen
of "Setting is being prepared" is displayed.
★ Limit the cranking time to 20 seconds to protect the starting
motor.

30-92 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
4. Finishing no injection cranking
After completing the no injection cranking operation, press [F6], and
finish of no injection cranking is displayed and the screen returns to
the “Service Menu” screen automatically.

5. Prohibiting no injection cranking

If the operator tries to perform the no injection cranking while the
engine is running, the message that the engine is running is displayed
and the no injection cranking is not set effective.
★ This function can be selected even while the engine is running.
If the no injection cranking is performed, however, the message
of "Engine is running" is displayed on the screen.

PC300LC/HD-8 30-93
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
FUEL CONSUMPTION
This function calculates the hourly fuel consumption from the actual fuel
consumption in a measuring period and indicates it.

1. Selecting menu
Select “Fuel Consumption” on the “Service Menu” screen.

2. Starting measurement
After the screen of “Fuel Consumption” is displayed, start
measurement with the function switches.
• [F1]: Start
• [F2]: Clear
• [F5]: Return to Service menu screen
★ When the screen of Fuel consumption is displayed, if a data is
indicated, it is the data of the previous measurement. This data is
not an obstacle to new measurement and can be reset by
pressing [F2].
★ If [F1] is pressed, the data is displayed on the starting date and
time side and measurement starts.
★ The display unit of the fuel changes according to the unit set
with the default (unit setting) function.
SI and meter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L/h
inch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gal/h
3. Display and function during measurement
Clock mark (a) flashes during measurement.
★ While the fuel consumption is being measured, the operator can
work with the operator mode and other functions. Measurement
is not finished until this screen is displayed again and [F1] is
pressed (Even if the starting switch is turned OFF, this function
is kept effective, although fuel consumption is measured only
while the engine is running).
4. Finishing measurement
Press [F1], and measurement is finished and the data are displayed
on the finishing date and time side.

5. Displaying fuel consumption

If the measurement is finished, the hourly fuel consumption
calculated from the fuel consumption calculated by the engine
controller and the elapsed time are displayed.

30-94 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX SETTINGS (TERMINAL STATUS)
The setting condition and operating condition of KOMTRAX can be checked with Display of KOMTRAX setting. Setting
condition of terminal is used to check the setting condition of the KOMTRAX terminal.

1. Selecting menu
Select “KOMTRAX Settings” on the “Service Menu” screen.

2. Selecting sub menu

After the “KOMTRAX Settings” screen is displayed, select
“Terminal Status” with the function switches or numeral input
switches.
★ Select this item similarly to an item on the Service menu screen.
★ The following figure shows the display when Model TH300
KOMTRAX is installed. When TH200 is installed,
“03 IP Address” is displayed.

3. Contents of display of terminal status

On the “Terminal Status” screen, the following items are displayed.
• Terminal type: Model name of KOMTRAX communication
MODEM
• KOMTRAX communication: Executing condition of station
opening inspection
• GMT time: Greenwich Meant Time
• [F5]: Return to KOMTRAX settings screen

PC300LC/HD-8 30-95
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX SETTINGS (GPS & COMMUNICATION STATUS)
The setting condition and operating condition of KOMTRAX can be checked with “KOMTRAX Settings”. GPS &
communication status is used to check the condition of positioning and communication of the KOMTRAX terminal.

1. Selecting menu
Select “KOMTRAX Settings” on the “Service Menu” screen.

2. Selecting sub menu

After the “KOMTRAX Settings” screen is displayed, select GPS &
communication status with the function switches or numeral input
switches.
★ Select this item similarly to an item on the “Service Menu”
screen.
★ The following figure shows the display when Model TH300
KOMTRAX is installed. When TH200 is installed, “03 IP
Address” is displayed.

3. Contents of display of GPS & communication status

On the screen of “GPS & Communication Status”, the following
items are displayed.
• Positioning: Positioning condition of GPS.
• Communication: Communication environment of
communication MODEM and connecting condition of
communication MODEM.
• Number of message not yet sent: Number of mails which are
saved in machine monitor and not transmitted yet.
• [F5]: Return to KOMTRAX settings screen.

30-96 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX SETTING (MODEM S/N: TH300)
The setting condition and operating condition of KOMTRAX can be checked with Display of KOMTRAX setting. MODEM
S/N is used to check the serial No. of the KOMTRAX communication MODEM.

1. Selecting menu
Select “KOMTRAX Settings” on the “Service Menu” screen.

2. Selecting sub menu

After the “KOMTRAX Settings” screen is displayed, select “Modem
S/N” with the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Contents of display of Modem S/N

The serial No. of TH300 Modem is displayed.
• [F5]: Return to KOMTRAX settings screen.

PC300LC/HD-8 30-97
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
KOMTRAX SETTINGS (IP ADDRESS: TH200)
The setting condition and operating condition of KOMTRAX can be checked with Display of KOMTRAX settings. IP address
is used to check the IP address of the KOMTRAX communication MODEM.

1. Selecting menu
Select "KOMTRAX Settings" on the service menu screen.

2. Selecting sub menu

After the “KOMTRAX Settings” screen is displayed, select “IP
Address” with the function switches or numeral input switches.
★ Select this item similarly to an item on the “Service Menu”
screen.

3. Contents of display of IP address

The telephone No. and IP address (2 systems) of TH200 MODEM
are displayed.
• [F5]: Return to KOMTRAX setting screen.
★ The IP address is a No. specific to each MODEM which is
required when communication is made between the MODEM
and the server.

30-98 PC300LC/HD-8
TESTING AND ADJUSTING MACHINE MONITOR - SPECIAL FUNCTIONS
12
DISPLAY OF KOMTRAX MESSAGE
Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this
function. If there is setting in a message, a return mail can be sent by using numeral input switches.

1. Operation to display menu

Select "Service message" on the service menu screen.

2. Display of message (Read-only)

If there is a message, its contents are displayed. If there is not a
message, "No message" is displayed.
• [F5]: Return to service menu screen.
★ This message is different from a message transmitted to the
operator in the operator mode.
★ Since this message is special for the serviceman, the message
monitor is not displayed when it is received as in the operator
mode.

3. Display of message (with return mail function)

If a box to enter a value with the numeral keys is displayed under the
message, enter a proper number with the numeral input switches and
function switches and confirm it, and the information is returned to
the KOMTRAX base station.
• [F5]: Return to service menu screen.
• [F6]: Confirm and return input value.
★ This message is different from a message transmitted to the
operator in the operator mode.
★ Since this message is special for the serviceman, the message
monitor is not displayed when it is received as in the operator
mode.

PC300LC/HD-8 30-99
TESTING AND ADJUSTING HANDLING VOLTAGE CIRCUIT OF ENGINE
12
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
1. Before disconnecting or connecting a connector between the engine controller and engine, be sure to turn the starting
switch OFF.

2. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do
not start the engine.
★ You may turn the starting switch to the OFF or ON position but must not turn it to the START position.

30-100 PC300LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRI-
CAL SYSTEM
★ When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, pump
controller, or KOMTRAX communication MODEM, expose the related connectors according to the following procedure.
★ Disconnect and connect the connectors having special locking mechanisms according to the procedure shown below.

1. Machine monitor
A. Remove 2 mounting bolts and cover (1).
★ One of the mounting bolts is installed in the cover on the right of the daylight sensor.
★ While removing the mounting bolts, disconnect connector P31 of the daylight sensor.
B. Remove cover (2).
★ The cover is fixed with clips. Remove it by pull it up.
★ While removing the cover, disconnect connector M04 of
the cigarette lighter.

C. Remove 1 mounting bolt and duct (3).

D. Insert or connect troubleshooting T-adapters in or to connectors

CM01, CM02, and CM03 of machine monitor (4).
★ Connectors CM02 and CM03 are of the same type. When
returning them, check the mark plates of the mounting
brackets and take care not to make a wrong connection.

PC300LC/HD-8 30-101
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
2. Engine controller
★ The engine controller is installed in the left side of the engine.
A. Open the engine hood.
B. Insert or connect troubleshooting T-adapter in or to connectors
ENGINE, CE02 and CE03 of engine controller (3).
★ Connectors are fixed with screw.
Loosen the screws before disconnecting them.
★ When returning the connectors back to their position,
tighten them to the specified torque.

Screw: 2.82 Nm {0.288 kgm}

3. Pump controller
A. Slide the operator's seat and seat stand to the forward end.
B. Remove the 5 mounting bolts and cool & hot box (6).
★ While removing the cool & hot box, disconnect the drain
hose.
C. Remove the 2 mounting bolts, 1 fastener, and magazine box (7).
4) Remove the 3 mounting bolts and cover (8).
D. Remove fuse box cover (9) and cover (10).
★ Since the underside of cover (10) is clamped, pull it up.
E. Remove the 7 mounting bolts and cover (11).
F. Connect the troubleshooting adapters to connectors C01 and
C02 of pump controller (12).
★ Install the adapters to only the wiring harness side.

★ The connectors of the pump controller have a special

locking mechanism. Disconnect them according to steps
(a) – (c) and connect them according to steps (d) – (f) as
shown below.
Disconnection: (a) Unlock – (b) Slide lever – (c)
Disconnect connector.
Connection: (d) Position connector – (e) Slide lever – (f)
Lock.

30-102 PC300LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
4. KOMTRAX communication module
A. Slide the operator's seat and seat stand to the forward end.
B. Remove the 5 mounting bolts and cool & hot box (6).
★ While removing the cool & hot box, disconnect the drain
hose.
C. Remove the 2 mounting bolts, 1 fastener, and magazine box (7).
D. Remove the 3 mounting bolts and cover (8).
E. Remove fuse box cover (9) and cover (10).
★ Since the underside of cover (10) is clamped, pull it up.
F. Remove the 7 mounting bolts and cover (11).
G. Connect troubleshooting T-adapters to connectors CK01 and
CK02 of KOMTRAX communication module (13).
★ Cable (14) is for the communication antenna.

5. Atmospheric pressure sensor (AMBAIR PRESSURE)

Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE SWITCH)
★ Disconnection and connection of connectors
The connectors of the atmospheric pressure sensor, engine Ne
speed sensor, engine Bkup speed sensor, engine oil pressure
switch have a special locking mechanism. Disconnect them
according to steps (a) – (c) and connect them according to steps
(d) – (f) as shown below.
Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect
connector.
Connection: (d) Connect connector – (e) Lock – (f) Slide lever.
★ Removal and installation of sensor
A deep socket is necessary for removal and installation of the engine oil pressure switch. See "Tools for testing,
adjusting, and troubleshooting".

PC300LC/HD-8 30-103
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
6. Boost pressure and temperature sensor (BOOST PRESS & IMT)
★ Disconnection and connection of connector
The connector of the boost pressure and temperature sensor has
a special locking mechanism. Disconnect it according to steps
(a) – (b) and connect it according to steps (c) – (d) as shown
below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.
★ Removal and installation of sensor
A torque wrench is necessary for removal and installation of the
boost pressure and temperature sensor. See "Tools for testing,
adjusting, and troubleshooting".

7. Supply pump IMV solenoid (FUEL REGULATOR)

Electric priming pump (FUEL LIFT PUMP)
Water-in-fuel sensor intermediate connector (WIF)
★ Disconnection and connection of connector
The connector of the supply pump IMV solenoid has a special
locking mechanism. Disconnect it according to steps (a) – (b)
and connect it according to steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.

★ Precautions for connecting connector

Take care not to connect the connector reversely. Engage lock
(e) on the wiring harness side with triangular notch (f) on the
sensor side (Do not engage lock (e) with square guide (g) on the
opposite side of triangular notch (f)).

8. Common rail pressure sensor (FUEL RAIL PRESS)

★ Disconnection and connection of connector
The connector of the common rail pressure sensor has a special
locking mechanism. Disconnect it according to steps (a) – (b)
and connect it according to steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.

30-104 PC300LC/HD-8
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
9. Engine coolant temperature sensor (COOLANT TEMP)
★ Disconnection and connection of connector
The connector of the engine coolant temperature sensor has a
special locking mechanism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Disconnect connector.
Connection: (c) Connect connector – (d) Lock.
★ Removal and installation of sensor
A deep socket is necessary for removal and installation of
the engine coolant temperature sensor. See "Tools for
testing, adjusting, and troubleshooting".

PC300LC/HD-8 30-105
TESTING AND ADJUSTING PM CLINIC SERVICE
12
PM CLINIC SERVICE

30-106 PC300LC/HD-8
TESTING AND ADJUSTING PM CLINIC SERVICE
12
Items related to engine

PC300LC/HD-8 30-107
TESTING AND ADJUSTING PM CLINIC SERVICE
12
Items related to oil pressure

30-108 PC300LC/HD-8
TESTING AND ADJUSTING PM CLINIC SERVICE
12

PC300LC/HD-8 30-109
TESTING AND ADJUSTING PM CLINIC SERVICE
12

30-110 PC300LC/HD-8
 40 TROUBLESHOOTING

Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.

FAILURE CODES TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-5

FUSE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
LOCATION OF FUSE BOX AND FUSE NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . 40-15
CONNECTORS NEWLY USED FOR TIER 3 ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
CLASSIFICATION AND TROUBLESHOOTING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
CLASSIFICATION OF TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-35
T-ADAPTER BOX AND T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
FAILURE CODE (DISPLAY OF CODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
A000N1 - ENGINE HI OUT OF STD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
AA10NX - AIR CLEANER CLOGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-74
AB00KE - CHARGE VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-76
B@BAZG - ENGINE OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-78
B@BAZK - ENGINE OIL LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80
B@BCNS - ENGINE COOLANT OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-82
B@BCZK - ENGINE COOLANT LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-84
B@HANS - HYDRAULIC OIL OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-86
CA111 - EMC CRITICAL INTERNAL FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-88
CA115 - ENGINE NE AND BKUP SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-89
CA122 - CHARGE AIR PRESSURE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90
CA123 - CHARGE AIR PRESSURE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-92
CA131 - THROTTLE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-94
CA132 - THROTTLE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-96
CA144 - COOLANT TEMPERATURE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-98
CA145 - COOLANT TEMPERATURE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100
CA153 - CHARGE AIR TEMPERATURE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-102
CA154 - CHARGE AIR TEMPERATURE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104
CA187 - SENSOR POWER SUPPLY 2 VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-106
CA221 - AMBIENT PRESSURE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108
CA222 - AMBIENT PRESSER SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
CA227 - SENSOR SUPPLY 2 VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
CA234 - ENGINE OVERSPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-114
CA238 - NE SPEED SENSOR SUPPLY VOLTAGE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-115
CA271 - IMV/PCV1 SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-116
CA272 - IMV/PCV1 OPEN ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-118
CA322 - INJECTOR #1 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120

PC300LC/HD-8 40-1
TROUBLESHOOTING
CA323 - INJECTOR #5 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
CA324 - INJECTOR #3 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124
CA325 - INJECTOR #6 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
CA331 - INJECTOR #2 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
CA332 - INJECTOR #4 OPEN/SHORT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
CA342 - CALIBRATION CODE INCOMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132
CA351 - INJECTORS DRIVE CIRCUIT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
CA352 - SENSOR SUPPLY 1 VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
CA386 - SENSOR SUPPLY 1 VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
CA428 - WATER IN FUEL SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
CA429 - WATER IN FUEL SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142
CA441 - BATTERY VOLTAGE LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
CA442 - BATTERY VOLTAGE HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
CA449 - RAIL PRESSURE VERY HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
CA451 - RAIL PRESSURE SENSOR HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
CA452 - RAIL PRESSURE SENSOR LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
CA553 - RAIL PRESSURE HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156
CA559 - RAIL PRESSURE LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
CA689 - ENGINE NE SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160
CA731 - ENGINE BKUP SPEED SENSOR PHASE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162
CA757 - ALL PERSISTENT DATA LOST ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164
CA778 - ENGINE BKUP SPEED SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
CA1633 - KOMNET DATALINK TIMEOUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
CA2185 - THROTTLE SENSOR SUPPLY VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
CA2186 - THROTTLE SENSOR SUPPLY VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
CA2249 - RAIL PRESSURE VERY LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-173
CA2265 - ELECTRIC LIFT PUMP HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
CA2266 - ELECTRIC LIFT PUMP LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
CA2555 - GRID HTR RELAY VOLT HIGH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
CA2556 - GRID HTR RELAY VOLT LOW ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180
D110KB - BATTERY RELAY DRIVE S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
D196KA - SERVICE RETURN RELAY DISCONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
D196KB - SERVICE RETURN RELAY S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
DA25KP - PRESSURE SENSOR POWER ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
DA2RMC - PUMP COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
DA2SKQ - MODEL SELECTION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
DAFRMC - MONITOR COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
DHPAMA - F PUMP PRESSURE SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
DHPBMA - R PUMP PRESSURE SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
DHS3MA - ARM CURL PPC SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
DHS4MA - BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . 40-202
DW43KA - TRAVEL SPEED SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
DW43KB - TRAVEL SPEED SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
DW45KA - SWING BRAKE SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
DW45KB - SWING BRAKE SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
DW91KA - TRAVEL JUNCTION SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214
DW91KB - TRAVEL JUNCTION SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
DWJ0KA - MERGE-DIVIDER SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
DWJ0KB - MERGE-DIVIDER SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
DWK0KA - 2-STAGE RELIEF SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
DWK0KB - 2-STAGE RELIEF SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
DXA0KA - PC-EPC SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
DXA0KB - PC-EPC SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
DXE0KA - LS-EPC SOLENOID DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
DXE0KB - LS-EPC SOLENOID S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
DXE4KB - SERVICE CURRENT EPC S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-235
DY20KA - WIPER WORKING ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236

40-2 PC300LC/HD-8
TROUBLESHOOTING
DY20MA - WIPER PARKING ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
DY2CKB - WASHER DRIVE S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
DY2DKB - WIPER DRIVE (FOR) S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
DY2EKB - WIPER DRIVE (REV) S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
E-MODE (ELECTRICAL SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
E-2 AUTO-DECELERATOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-251
E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . 40-253
E-4 PREHEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE . . . . . . . . . 40-256
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
E-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM
APPLICABLE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING . . . . . . . . . . . . 40-263
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY . . . . . . . 40-264
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY . . . . . . . . . 40-266
E-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-267
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING . . . . . . . . . . . . 40-270
E-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE . . . . . . . . . . . . . . . . . . . 40-272
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . 40-276
E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE” NORMALLY . . . . . . . . . . . 40-278
E-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER” NORMALLY . . . . . . . . . . 40-280
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NORMALLY . . . . . . . . . . . . . . . . 40-282
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT” NORMALLY . . . . . . . . . . . . . . 40-284
E-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL” NORMALLY . . . . . . . . . . 40-286
E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET DUMP” NORMALLY . . . . . . . . . 40-288
E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NORMALLY . . . . . . . . . . . . . . . . . 40-290
E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NORMALLY . . . . . . . . . . . . . . . . 40-292
E-26 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL DIFFERENTIAL PRESSURE”
NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
E-27 MONITORING FUNCTION FAILS TO DISPLAY “SERVICE” NORMALLY . . . . . . . . . . . . . . . 40-296
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
E-29 AIR CONDITIONER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING . . . . . . . . . . . . . . . . 40-302
E-31 HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW . 40-310
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-313
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . 40-313
H-5 AUTO-DECELERATOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
H-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW . . . . . . . . . . . . . . . . . 40-314
H-7 BOOM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-315
H-8 ARM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
H-9 BUCKET MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-317
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION . . . . . . . . . . . . . . . . . . 40-317
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . 40-318
H-12 WORK EQUIPMENT HAS BIG TIME LAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT . . . . . . . . . . . 40-320
H-14 POWER MAX. SWITCH DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-321
H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD

PC300LC/HD-8 40-3
TROUBLESHOOTING
MOVES SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-321
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY . . . . . . . . . . . . . . . . . . . 40-322
H-17 IN SWING + TRAVEL OPERATION, TRAVEL SPEED DROPS SHARPLY . . . . . . . . . . . . . . . 40-322
H-18 MACHINE SWERVES IN TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-323
H-19 MACHINE TRAVELS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . 40-325
H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST . . . . . . . . . . . . . . . . . . . 40-326
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-327
H-23 MACHINE DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . 40-330
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-333
H-27 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING . . . . . . . . . . . . . . 40-333
H-28 SWING HYDRAULIC DRIFT IS TOO BIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334

★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and
is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as
a reference value when carrying out repairs.

2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various
tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.

3. These standard values are not the standards used in dealing with claims.

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 water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.

WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.

40-4 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODES TABLE
12
FAILURE CODES TABLE
Device in
Action code Failure code Trouble (Displayed on screen) Category of record
charge
- A000N1 Eng. Hi Out of Std MON Mechanical system
- AA10NX Air cleaner Clogging MON Mechanical system
- AB00KE Charge Voltage Low MON Mechanical system
- B@BAZG Eng. Oil Press. Low MON Mechanical system
- B@BAZK Eng Oil Level Low MON Mechanical system
- B@BCNS Eng. Water Overheat MON Mechanical system
- B@BCZK Eng. Water Lvl Low MON Mechanical system
E02 B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E11 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E15 CA221 Ambient Press Sens High Error ENG Electrical system
E15 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
- CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E11 CA271 IMV/PCV1 Short Error ENG Electrical system
E11 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error ENG Electrical system
E11 CA323 Inj #5 (L#5) Open/Short Error ENG Electrical system
E11 CA324 Inj #3 (L#3) Open/Short Error ENG Electrical system
E11 CA325 Inj #6 (L#6) Open/Short Error ENG Electrical system
E11 CA331 Inj #2 (L#2) Open/Short Error ENG Electrical system
E11 CA332 Inj #4 (L#4) Open/Short Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E15 CA428 Water in Fuel Sensor High Error ENG Electrical system
E15 CA429 Water in Fuel Sensor Low Error ENG Electrical system
E10 CA441 Battery Voltage Low Error ENG Electrical system
E10 CA442 Battery Voltage High Error ENG Electrical system
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 CA451 Rail Press Sensor High Error ENG Electrical system

PC300LC/HD-8 40-5
TROUBLESHOOTING FAILURE CODES TABLE

Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E15 CA553 Rail Press High Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E11 CA689 Ne Speed Sensor Error ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E15 CA2265 Electric Lift Pump High Error ENG Electrical system
E15 CA2266 Electric Lift Pump Low Error ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
- D110KB Battery Relay Drive S/C PUMP Electrical system
- D196KA Service Return Relay Disc. PUMP Electrical system
- D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
- DA2SKQ Model Selection Abnormality PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality PUMP Electrical system
- DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
- DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
- DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
- DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system
- DW43KA Travel Speed Sol. Disc. PUMP Electrical system
- DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C PUMP Electrical system
- DW91KA Travel Junction Sol. Disc. PUMP Electrical system
- DW91KB Travel Junction Sol. S/C PUMP Electrical system
- DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
- DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
- DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
- DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
- DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
- DXE0KB LS-EPC Sol. S/C PUMP Electrical system
- DXE4KA Service Current EPC Disc. PUMP Electrical system
- DXE4KB Service Current EPC S/C PUMP Electrical system
- DY20KA Wiper Working Abnormality MON Electrical system
- DY20MA Wiper Parking Abnormality MON Electrical system

40-6 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODES TABLE

Action code Failure code Trouble (Displayed on screen) Device in charge Category of record
- DY2CKB Washer Drive S/C MON Electrical system
- DY2DKB Wiper Drive (For) S/C MON Electrical system
- DY2EKB Wiper Drive (Rev) S/C MON Electrical system

★ This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.

PC300LC/HD-8 40-7
TROUBLESHOOTING FUSE LOCATIONS
12
FUSE LOCATIONS

CONNECTION TABLE OF FUSE BOX

★ This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is a
device which supplies power while the starting switch is in the OFF and ON positions).
★ When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if
the power is supplied normally.
Type of power supply Fusible link Fuse No. Fuse capacity Destination of power
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve

F04 3 20A Machine monitor

Switch power supply (65A) Wiper drive
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater
7 10A Rotary lamp
Right head lamp, working lamp (boom), working lamp
F04 8 10A
Switch power supply (rear)
(65A)
Radio, speaker
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
F04
Switch power supply 13 20A Head lamp
(65A)
14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 10A
Optional power supply (2)
Radio (backup power supply)
F05 16 10A
Constant power supply Room lamp
(30A)
Starting switch
17 10A
Machine monitor
18 10A (Spare)
19 30A Engine controller
Starting
Switch power supply 20 5A Engine controller (ACC signal)
switch ACC

40-8 PC300LC/HD-8
TROUBLESHOOTING FUSE LOCATIONS

LOCATION OF FUSE BOX AND FUSE NUMBERS

PC300LC/HD-8 40-9
TROUBLESHOOTING FUSE LOCATIONS
12
Troubles that occur when controller power supply of pump controller is defective

★ The controller power supply (F01-1) of the pump controller drives the controller system. Accordingly, if it is turned off,
the controller cannot control the system and the troubles shown below occur simultaneously (The following is an example
of the troubles).
• The working mode cannot be changed.
• The auto-decelerator does not work or is not reset.
• The travel speed does not change.
• The power maximizing function does not work.
• The swing holding brake cannot be reset automatically.
• The machine deviates during travel.
Troubles that occur when solenoid power supply of pump controller is defective

★ The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids and relays.
Accordingly, if the solenoid power supply is turned off, when the controller outputs the power to the solenoids or relays,
the power is not supplied to any of the solenoids and relays and all or some of the following failure codes are displayed
simultaneously.
• DW43KA, DW43KB: Travel speed solenoid system
• DW45KA, DW45KB: Swing holding brake solenoid system
• DW91KA, DW91KB: Travel junction solenoid system
• DWA2KA, DWA2KB: Service solenoid system
• DWK0KA, DWK0KB: 2-stage relief solenoid system
• DXA0KA, DXA0KB: PC-EPC (F) solenoid system
• DXE0KA, DXE0KB: LS-EPC solenoid system
• DXE4KA, DXE4KB: Service current EPC system (if attachment is installed)
• DWJ0KA, DWJ0KB: Merge-divider main solenoid system
★ If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
1) Disconnect connector CP03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2), and (12) and each of pins (27), (32), and (33).
* Pins (2) and (12) are the power supply and pins (27), (32), and (33) are the chassis ground.
* If the voltage is 20 – 30 V, it is normal.

40-10 PC300LC/HD-8
TROUBLESHOOTING FUSE LOCATIONS
★ Power supply connector (CP03) of pump controller

PC300LC/HD-8 40-11
TROUBLESHOOTING GENERAL INFORMATION
12
GENERAL INFORMATION

POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.

WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.

WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.

WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the failure occurred?

C. Did the failure occur suddenly, or were there problems with the machine condition before this?

D. Under what conditions did the failure occur?

E. Had any repairs been carried out before the failure? When were these repairs carried out?

F. Has the same kind of failure occurred before?

40-12 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
3. Check before troubleshooting.

A. Is there any sign of irregularities of the machine?

B. Make checks before starting day's work.

C. Make checks of other items.

D. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4. Confirming the failure.

Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.

5. Troubleshooting
Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
★ The basic procedure for troubleshooting is as follows.

A. Start from the simple points.

B. Start from the most likely points.

C. Investigate other related parts or information.

6. Measures to remove root cause of failure.

Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.

PC300LC/HD-8 40-13
TROUBLESHOOTING GENERAL INFORMATION
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING

40-14 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals
particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose,
it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic
oil).
Points to remember when handling electric equipment

1. Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and
disconnecting one wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases,
wiring harnesses are more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore, during inspection and
repair operations, they are frequently removed and installed again, so
they are likely to suffer deformation or damage. For this reason, it is
necessary to be extremely careful when handling wiring harnesses.

2. Main failures occurring in wiring harness

A. Defective contact of connectors (defective contact between male

and female)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female
connector, or because one or both of the connectors is deformed
or the position is not correctly aligned, or because there is
corrosion or oxidation of the contact surfaces. The corroded or
oxidized contact surfaces may become shiny again (and contact
may become normal) by connecting and disconnecting the
connector about 10 times.

B. Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the
crimped terminal or soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will
peel and cause improper connection or breakage.

PC300LC/HD-8 40-15
TROUBLESHOOTING GENERAL INFORMATION
12
C. Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or
components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping of the
connector may separate, or the soldering may be damaged, or
the wiring may be broken.

D. High-pressure water entering connector

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector,
depending on the direction of the water jet. Accordingly, take
care not to splash water over the connector. The connector is
designed to prevent water from entering, but at the same time, if
water does enter, it is difficult for it to be drained. Therefore, if
water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in, immediately
dry the connector or take other appropriate action before passing
electricity through it.

E. Oil or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray
it with a contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is oil or water in the compressed air, the contacts
will become even dirtier, so remove the oil and water from
the compressed air completely before cleaning with
compressed air.

40-16 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
3. Removing, installing, and drying connectors and wiring harnesses

A. Disconnecting connectors

i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors.
For connectors held by a screw, loosen the screw fully, then
hold the male and female connectors in each hand and pull
apart. For connectors which have a lock stopper, press
down the stopper with your thumb and pull the connectors
apart.
★ Never pull with one hand.

ii. When removing from clips

• Both of the connector and clip have stoppers, which are
engaged with each other when the connector is
installed.

• When removing a connector from a clip, pull the

connector in a parallel direction to the clip for
removing stoppers.
★ If the connector is twisted up and down or to the
left or right, the housing may break.

iii. Action to take after removing connectors

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
★ If the machine is left disassembled for a long time, it
is particularly easy for improper contact to occur, so
always cover the connector.

PC300LC/HD-8 40-17
TROUBLESHOOTING GENERAL INFORMATION
12
B. Connecting connectors

i. Check the connector visually.

Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
Check that there is no deformation, defective contact,
corrosion, or damage to the connector pins.
Check that there is no damage or breakage to the outside of
the connector.

★ If there is any oil, water, or dirt stuck to the connector,

wipe it off with a dry cloth. If any water has got inside
the connector, warm the inside of the wiring with a
dryer, but be careful not to make it too hot as this will
cause short circuits.
★ If there is any damage or breakage, replace the
connector.

ii. Fix the connector securely.

Align the position of the connector correctly, and then insert
it securely. For connectors with the lock stopper, push in the
connector until the stopper clicks into position.

iii. Correct any protrusion of the boot and any misalignment of

the wiring harness.
For connectors fitted with boots, correct any protrusion of
the boot. In addition, if the wiring harness is misaligned, or
the clamp is out of position, adjust it to its correct position.
★ If the connector cannot be corrected easily, remove
the clamp and adjust the position.
• If the connector clamp has been removed, be sure to
return it to its original position. Check also that there
are no loose clamps.

40-18 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
C. Heavy duty wire connector (DT 8-pole, 12-pole)
Disconnection (Left of figure)
While pressing both sides of locks (a) and (b), pull out
female connector (2).
Connection (Right of figure)

i. Push in female connector (2) horizontally until the lock

clicks.
Arrow: 1)

ii. Since locks (a) and (b) may not be set completely, push in
female connector (2) while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
★ Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely.

(1): Male connector

(2): Female connector
(a), (b): Locks

D. Drying wiring harness

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

i. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with compressed air,
there is the risk that oil in the air may cause defective
contact, so remove all oil and water from the
compressed air before blowing with air.

ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but regulate the
time that the hot air is used in order not to make the
connector or related parts too hot, as this will cause
deformation or damage to the connector.

PC300LC/HD-8 40-19
TROUBLESHOOTING GENERAL INFORMATION
12
iii. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, blow it with
contact restorer and reassemble.

4. Handling controller.

A. The controller contains a microcomputer and electronic control

circuits. These control all of the electronic circuits on the
machine, so be extremely careful when handling the controller.

B. Do not place objects on top of the controller.

C. Cover the control connectors with tape or a vinyl bag. Never

touch the connector contacts with your hand.

D. During rainy weather, do not leave the controller in a place

where it is exposed to rain.

E. Do not place the controller on oil, water, or soil, or in any hot

place, even for a short time. (Place it on a suitable dry stand).

F. Precautions when carrying out arc welding.

When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the controller. Fit an arc
welding ground close to the welding point.

5. Points to remember when troubleshooting electric circuits.

A. Always turn the power OFF before disconnecting or connecting

connectors.

B. Before carrying out troubleshooting, check that all the related

connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.

C. Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be
generated.

D. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the
related wiring and connectors several times and check that there is no change in the reading of the tester.
★ If there is any change, there is probably defective contact in that circuit.

40-20 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.

1. Be careful of the operating environment.

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

2. Disassembly and maintenance work in the field.

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

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

4. Do not let any dirt or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has collected during
storage, so this is an even more effective method.

5. Change hydraulic oil when the temperature is high.

When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and
from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.

PC300LC/HD-8 40-21
TROUBLESHOOTING GENERAL INFORMATION
12
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.

7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning
equipment is used to remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an
extremely effective device.

40-22 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
CONNECTORS NEWLY USED FOR TIER 3 ENGINES
1. Slide lock type.
(FRAMATOME-3, FRAMATOME-2)
• 107 – 170, 12V140 engines
• Various pressure sensors and NE speed sensor
Examples:
Intake air pressure in intake manifold: . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .PIM (125, 170, 12V140 engines)
Oil pressure sensor: . . . . . . . . . POIL (125, 170, 12V140 engines)
Oil pressure switch: . . . . . . . . . . . . . . . . . . . . . (107, 114 engines)
Ne speed sensor of flywheel housing: . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . NE (107 – 170, 12V140 engines)
Ambient pressure sensor: . . . PAMB (125, 170, 12V140 engines)

Disconnect connector (1) according to the following procedure.

A. Slide lock (L1) to the right.

B. While pressing lock (L2), pull out connector (1) toward you.
★ Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case,
float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.

2. Pull lock type (PACKARD-2).

• 107 – 170, 12V140 engine
• Various temperature sensors
Example:
Intake air temperature sensor in intake manifold: . . . . . . . . . TIM
Fuel temperature sensor: . . . . . . . . . . . . . . . . . . . . . . . . . . TFUEL
Oil temperature sensor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TOIL
Coolant temperature sensor: . . . . . . . . . . . . . . . . . . . TWTR, etc.
Disconnect the connector by pulling lock (B) (on the wiring harness side)
of connector (2) outward.

PC300LC/HD-8 40-23
TROUBLESHOOTING GENERAL INFORMATION
12
3. Push lock type.
• 107, 114 engines
Example:
Fuel pressure sensor in common rail (BOSCH-03)
Disconnect connector (3) according to the following procedure.

A. While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 engine

• 107 engine

★ If the lock is on the underside, use flat-head screwdriver [1]

since you cannot insert your fingers.

B. While pressing up lock (C) of the connector with flat-head

screwdriver [1], pull out connector (3) in the direction of the
arrow.
• 107, 114 engine
Example:
Intake air pressure/temperature sensor in intake manifold (SUMIT-
OMO-04)

40-24 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
C. While pressing lock (D), pull out connector (4) in the direction
of the arrow.

• 125 – 170, 12V140 engine

D. While pressing lock (E) of the connector, pullout connector (5)

in the direction of the arrow.
Example:
Fuel pressure in common rail: . . . . . . . . . . . PFUEL etc. (AMP-3)

Example:
Injection pressure control valve of fuel supply pump: . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCV (SUMITOMO-2)

Example:
Speed sensor of fuel supply pump: . . . . . . . . . G (SUMITOMO-3)
★ Pull the connector straight up.

PC300LC/HD-8 40-25
TROUBLESHOOTING GENERAL INFORMATION
12
4. Turn-housing type (Round green connector)
• 140 engine
Example:
Intake air pressure sensor in intake manifold (CANNON-04): . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIM etc.

A. Disconnect connector (6) according to the following procedure.

i. Turn housing (H1) in the direction of the arrow.

★ When connector is unlocked, housing (H1) becomes
heavy to turn.

ii. Pull out housing (H1) in the direction of the arrow.

★ Housing (H1) is left on the wiring harness side.

B. Connect the connector according to the following procedure.

i. Insert the connector to the end, while setting its groove.

ii. Turn housing (H1) in the direction of the arrow until it

“clicks”.

40-26 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
CHECKS BEFORE TROUBLESHOOTING
Item Criterion Remedy
1. Check of level and type of fuel - Add fuel
2. Check of fuel for foreign matter - Clean and drain
3. Check of hydraulic oil level - Add oil
4. Check of hydraulic oil strainer - Clean and drain
Lubricating oil/ 5. Check of swing machinery oil level - Add oil
Coolant
6. Check of level and type of engine oil (in oil pan) - Add oil
7. Check of coolant level - Add coolant
8. Check of dust indicator for clogging - Clean or replace
9. Check of hydraulic oil filter - Replace
1. Check of battery terminals and wiring for - Retighten or replace
looseness and corrosion
Electrical 2. Check of alternator terminals and wiring for - Retighten or replace
equipment looseness and corrosion
3. Check of starting motor terminals and wiring for - Retighten or replace
looseness and corrosion
1. Check for abnormal noise and smell - Repair
Hydraulic/
Mechanical 2. Check for oil leakage - Repair
equipment
3. Bleeding air - Bleed air
1. Check of battery voltage (with engine stopped) 20 - 30 V Replace
2. Check of electrolyte level - Add or replace
3. Check of wires for discoloration, burn, and - Replace
removal of cover
4. Check for released wire clamp and drooping wire - Repair
Electric, electrical 5. Check of wires for wetness (Check connectors Disconnect the
equipment -
and terminals for wetness, in particular) connectors and dry
6. Check of fuse for disconnection and corrosion - Replace
7. Check of alternator voltage (while engine speed After operating for several Replace
is at middle or higher) minutes: 27.5 - 29.5 V
8. Check of battery relay for operating sound (when - Replace
starting switch is turned ON or OFF)

PC300LC/HD-8 40-27
TROUBLESHOOTING GENERAL INFORMATION
12
CLASSIFICATION AND TROUBLESHOOTING STEPS
CLASSIFICATION OF TROUBLESHOOTING
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine

Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.

Troubleshooting steps

If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by performing the
following steps and proceed to the main body of troubleshooting.

1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [_] switch at panel switch section to display failure code. Carry
out the troubleshooting for the corresponding [Display of code] according to the displayed failure code.

2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality record function of the
machine monitor. If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
★ If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see if the trouble is
still detected.
★ An error code of the mechanical system cannot be deleted.

3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code is recorded in
abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnormality record, a
trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical
system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from the table of
“Phenomena looking like troubles and troubleshooting Nos.”, and then carry out troubleshooting corresponding to that
phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.

40-28 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

MEMORANDUM

PC300LC/HD-8 40-29
TROUBLESHOOTING GENERAL INFORMATION
12
INFORMATION IN TROUBLESHOOTING TABLE
★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble name displayed in abnormality record machine
Display on machine Trouble
machine monitor
monitor
monitor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine
machine moni-
controller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation

Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source
(24 V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are
state reference numbers, which do <Precautions for troubleshooting>
not indicate priority) (1) Method of indicating connector No. and handling of
T-adapter
Insert or connect T-adapter as explained below for
3 troubleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.

40-30 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION

Related circuit diagram

This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• “Connector No. and pin No.” from each branching/merging point: Shows the ends
of branch or source of merging within the parts of the same wiring harness.
• Arrow (⇔): Roughly shows the location on the machine.

PC300LC/HD-8 40-31
TROUBLESHOOTING GENERAL INFORMATION
12
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO.
Remark
Troubleshooting of engine electrical system (S-mode) is in the engine shop manual.

Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to action code/failure code
1 An action code is displayed on machine monitor.
According
When abnormality record is checked, failure code is displayed in
2 to
electrical system abnormality record
displayed
When abnormality record is checked, failure code is displayed in code
3
mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 a)
Engine does
6 Engine rotates, but exhaust gas does not come out S-2 b)
not start
7 Engine emits exhaust gas, but it does not start S-2 c)
8 Engine does not pick up smoothly (follow-up performance is poor) S-3
9 Engine stops during operations H-2 S-4
10 Engine rotation is unstable (it hunts). S-5
11 Engine lacks output or power H-1 S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil pressure drops S-12
18 Oil level rises (Entry of coolant or fuel) S-13
19 Coolant temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Auto-decelerator does not operate E-2 H-5
23 Automatic warm-up system does not operate E-3
24 Preheater does not operate E-4
Phenomena related to work equipment, swing, and travel
25 Speed or power of whole work equipment, travel, and swing is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment, swing, and travel mechanism do not move E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
Phenomena related to work equipment
30 Speed or power of boom is low E-18,19 H-7
31 Speed or power of arm is low E-20,21 H-8
32 Speed or power of bucket is low E-22,23 H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11

40-32 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION

Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
35 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of work
36 H-13
equipment move
37 Power maximizing function does not work. E-6, 18 - 23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part loaded
38 H-15
more is low
When machine swings and raises boom simultaneously, boom rising
39 H-16
speed is low
When machine swings and travels simultaneously, travel speed
40 H-17
lowers largely
Phenomena related to travel
41 Machine deviates during travel H-18
42 Travel speed is low E-25 H-19
43 Machine is not steered well or steering power is low E-25,26 H-20
44 Travel speed does not change or travel speed is low or high E-25 H-21
45 Travel system does not move (only one side) H-22
Phenomena related to swing
46 Upper structure does not swing E-24 H-23
47 Swing acceleration or swing speed is low H-24
48 Upper structure overruns remarkably when it stops swinging H-25
49 Large shock is made when upper structure stops swinging H-26
50 Large sound is made when upper structure stops swinging H-27
51 Hydraulic drift of swing is large H-28
Phenomena related to machine monitor (Operator menu: ordinary screen)
52 Machine monitor does not display any items E-7
53 Machine monitor does not display some items E-8
Contents of display by machine monitor are different from applicable
54 E-9
machine
Radiator coolant level monitor lights up in red during check before
55 B@BCZK
starting
56 Engine oil level monitor lights up in red during check before starting B@BAZK
Maintenance interval monitor lights up in red during check before See the Operation and Maintenance
57
starting Manual.
58 Charge level monitor lights up in red while engine is running AB00KE
59 Fuel level monitor lights up in red while engine is running E-10
60 Air cleaner clogging monitor lights up in red while engine is running AA10NX
Engine coolant temperature monitor lights up in red while engine is
61 B@BCNS
running
Hydraulic oil temperature monitor lights up in red while engine is
62 B@HANS
running
63 Engine coolant temperature gauge does not indicate normally E-11
64 Hydraulic oil temperature gauge does not indicate normally E-12
65 Fuel level gauge does not indicate normally E-13
66 Swing lock monitor does not indicate normally E-14

PC300LC/HD-8 40-33
TROUBLESHOOTING GENERAL INFORMATION

Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Machine monitor display anything even when operated on monitor
67 E-15
switch section
68 Windshield wiper and window washer do not operate E-16
69 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
70 Monitoring function does not display “Boom RAISE” normally E-18
71 Monitoring function does not display “Boom LOWER” normally E-19
72 Monitoring function does not display “Arm IN” normally E-20
73 Monitoring function does not display “Arm OUT” normally E-21
74 Monitoring function does not display “Bucket CURL” normally E-22
75 Monitoring function does not display “Bucket DUMP” normally E-23
76 Monitoring function does not display “Swing” normally E-24
77 Monitoring function does not display “Travel” normally E-25
78 Monitoring function does not display “Travel Steering” normally E-26
79 Monitoring function does not display “Service” normally E-27
Phenomena related to KOMTRAX
80 KOMTRAX system does not operate normally E-28
Other phenomena
81 Air conditioner does not operate E-29
82 Travel alarm does not sound or does not stop sounding E-30
83 Horn does not sound E-31

40-34 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.

X Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010

2 799-601-7020

Part number: 08055-00282 Part number: 08055-00292

3 799-601-7030

Part number: 08055-00381 Part number: 08055-00391

4 799-601-7040

Part number: 08055-00481 Part number: 08055-00491

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
• Wire size: 2.0 • Wire size: 2.0
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: red • Grommet: red

PC300LC/HD-8 40-35
TROUBLESHOOTING GENERAL INFORMATION

SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

6 799-601-7050

Part number: 08055-10681 Part number: 08055-10691

8 799-601-7060

Part number: 08055-10881 Part number: 08055-10891

12 799-601-7310

Part number: 08055-11281 Part number: 08055-11291

14 799-601-7070

Part number: 08055-11481 Part number: 08055-11491

40-36 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
SWP Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

16 799-601-7320

Part number: 08055-11681 Part number: 08055-11691

Terminal part number: Terminal part number:
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
• Wire size: 1.25 • Wire size: 1.25
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red

M Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080

2 799-601-7090

Part number: 08056-00271 Part number: 08056-00281

3 799-601-7110

Part number: 08056-00371 Part number: 08056-00381

PC300LC/HD-8 40-37
TROUBLESHOOTING GENERAL INFORMATION

4 799-601-7120

Part number: 08056-00471 Part number: 08056-00481

6 799-601-7130

Part number: 08056-00671 Part number: 08056-00681

8 799-601-7340

Part number: 08056-00871 Part number: 08056-00881

40-38 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 799-601-7140

Part number: 08056-10871 Part number: 08056-10881

10 (white) 799-601-7150

Part number: 08056-11071 Part number: 08056-11081

12 (white) 799-601-7350

Part number: 08056-11271 Part number: 08056-11281

16 (white) 799-601-7330

Part number: 08056-11671 Part number: 08056-11681

PC300LC/HD-8 40-39
TROUBLESHOOTING GENERAL INFORMATION
12
S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 (blue) —

— —

12 (blue) 799-601-7160

Part number: 08056-11272 Part number: 08056-11282

16 (blue) 799-601-7170

Part number: 08056-11672 Part number: 08056-11682

40-40 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
MIC Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
Body part number: 79A-222-2680 Body part number: 79A-222-2670
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —

5 799-601-2710

Body part number: 79A-222-2620 Body part number: 79A-222-2610

(Quantity: 5 pieces) (Quantity: 5 pieces)

9 799-601-2950

Body part number: 79A-222-2660 Body part number: 79A-222-2650

(Quantity: 5 pieces) (Quantity: 5 pieces)

13 799-601-2720

Body part number: 79A-222-2710 Body part number: 79A-222-2690

(Quantity: 2 pieces) (Quantity: 2 pieces)

PC300LC/HD-8 40-41
TROUBLESHOOTING GENERAL INFORMATION
12
MIC Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

17 799-601-2730

Body part number: 79A-222-2730 Body part number: 79A-222-2720

(Quantity: 2 pieces) (Quantity: 2 pieces)

21 799-601-2740

Body part number: 79A-222-2750 Body part number: 79A-222-2740

(Quantity: 2 pieces) (Quantity: 2 pieces)
Body part number: 79A-222-2770 Body part number: 79A-222-2760
— —
(Quantity: 50 pieces) (Quantity: 50 pieces)

40-42 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
AMP040 Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 799-601-7180

Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)

12 799-601-7190

— Housing part number: 79A-222-3440

(Quantity: 5 pieces)

16 799-601-7210

Housing part number: 79A-222-3450

—
(Quantity: 5 pieces)

20 799-601-7220

— Housing part number: 79A-222-3460

(Quantity: 5 pieces)

PC300LC/HD-8 40-43
TROUBLESHOOTING GENERAL INFORMATION

AMP070 Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 799-601-7510

— Part number: 08195-10210

12 799-601-7520

— Part number: 08195-12210

14 799-601-7530

— Part number: 08195-14210

18 799-601-7540

— Part number: 08195-18210

40-44 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION

20 799-601-7550

— Part number: 08195-20210

L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number

2 —

— —

PA Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number

9 —

— —

PC300LC/HD-8 40-45
TROUBLESHOOTING GENERAL INFORMATION
12
BENDIX (MS) Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 799-601-3460

— —

40-46 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
KES1 Automobile Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

2 —

Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part number: 08027-10310 Part number: 08027-10360

4 —

Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

PC300LC/HD-8 40-47
TROUBLESHOOTING GENERAL INFORMATION
12
KES1 Automobile Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 —

Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

Connector for relay (Socket)

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

5 799-601-7360

— —

6 799-601-7370

— —

40-48 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
Type F Type Connector
(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number

4 —

— —

PC300LC/HD-8 40-49
TROUBLESHOOTING GENERAL INFORMATION
12

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9210

Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)

799-601-9210

Part number: 08191-11201, 08191-12202 Part number: 08191-13101, 08191-13102

08191-11205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female terminal)

799-601-9220

Part number: 08191-21201, 08191-12202 Part number: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male terminal)

799-601-9220

Part number: 08191-22201, 08191-22202 Part number: 08191-23101, 08191-23102

08191-22205, 08191-22206 08191-23105, 08191-23106

40-50 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9230

18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male terminal)

799-601-9230

Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

Pin (male terminal) Pin (female terminal)

799-601-9240

18-21 Part number: 08191-41201, 08191-42202 Part number: 08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male terminal)

799-601-9240

Part number: 08191-42201, 08191-42202 Part number: 08191-43101, 08191-43102

PC300LC/HD-8 40-51
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9250

24-9 Part number: 08191-51201, 08191-51202 Part number: 08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male terminal)

799-601-9250

Part number: 08191-52201, 08191-52202 Part number: 08191-53101, 08191-53102

Pin (male terminal) Pin (female terminal)

799-601-9260

Part number: 08191-61201, 08191-62202 Part number: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male terminal)

799-601-9260

Part number: 08191-62201, 08191-62202 Part number: 08191-63101, 08191-63102

08191-62205, 08191-62206 08191-63105, 08191-63106

40-52 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9270

Part number: 08191-71201, 08191-71202 Part number: 08191-74101, 08191-74102

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male terminal)

799-601-9270

Part number: 08191-72201, 08191-72202 Part number: 08191-73102, 08191-73102

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female terminal)

799-601-9280

Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106

PC300LC/HD-8 40-53
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9290

Part number: 08191-91203, 08191-91204 Part number: 08191-94103, 08191-94104

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male terminal)

799-601-9290

Part number: 08191-92203, 08191-92204 Part number: 08191-93103, 08191-93104

08191-92205, 08191-92206 08191-93105, 08191-93106

40-54 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number

2 799-601-9020

Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

PC300LC/HD-8 40-55
TROUBLESHOOTING GENERAL INFORMATION
12
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number

8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080

Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR: 799-601-9140

Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)

DTM Series connector

Number of
Pins T-adapter Part
Body (plug) Body (receptacle) Number

2 799-601-9010

Part number: 08192-02200 Part number: 08192-02100

40-56 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
★ The pin No. is also marked on the connector (electric wire insertion end)

DTHD Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle) Number

1 —

Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

DTP4 Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number

4 799-601-4260

— Part number: 6261-81-2810

PC300LC/HD-8 40-57
TROUBLESHOOTING GENERAL INFORMATION
12

40-58 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-59
TROUBLESHOOTING GENERAL INFORMATION
12

40-60 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-61
TROUBLESHOOTING GENERAL INFORMATION
12

40-62 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-63
TROUBLESHOOTING GENERAL INFORMATION
12

40-64 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-65
TROUBLESHOOTING GENERAL INFORMATION
12

40-66 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-67
TROUBLESHOOTING GENERAL INFORMATION
12

40-68 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12
T-ADAPTER BOX AND T-ADAPTER TABLE
(REV. 2006. 11)
★ The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a
part number of harness checker assembly.

PC300LC/HD-8 40-69
TROUBLESHOOTING GENERAL INFORMATION
12

40-70 PC300LC/HD-8
TROUBLESHOOTING GENERAL INFORMATION
12

PC300LC/HD-8 40-71
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
FAILURE CODE (DISPLAY OF CODE)

A000N1 - ENGINE HI OUT OF STD

Action code Failure code Engine high idle out of standard
Trouble
— A000N1 (Mechanical system)
Contents of
• While the engine was running, engine speed exceeded 2,350 rpm for more than 10 seconds.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related • Input from the engine speed sensor (engine speed) can be checked with monitoring function.
information (Code 010: Engine speed)

Cause Standard value in normal state/Remarks on troubleshooting

Check for any internal or external factor that might cause the
Possible causes Defective engine
1 excessive engine high idle speed for troubleshooting of engine
and standard mechanical system
mechanical system.
value in normal
state Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective engine controller no visible error appears on the machine, the controller can be
continuously used as it is.)

40-72 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-73
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
AA10NX - AIR CLEANER CLOGGING
Action code Failure code Air cleaner clogging
Trouble
— AA10NX (Mechanical system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected with
trouble GND).
Action of
machine moni- • None in particular.
tor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• If an air cleaner clogging caution symbol appears on the machine monitor while the engine is
Related infor- running, this failure code will be recorded.
mation • Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code 046: Monitor Input 2)

Cause Standard value in normal state/Remarks on troubleshooting

Clogging of air cleaner ★ Check the air cleaner for clogging and then clean or replace it if
1
(when system is normal) clogged.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective air cleaner
2 clogging switch P23 (male) Air cleaner Resistance
(internal disconnection) Value in normal state Max. 1 Ω
Between (1) – (2)
Value when clogged Min. 1MΩ
Possible causes
and standard
★ Prepare with starting switch OFF, then start engine and carry out
Disconnection in wiring troubleshooting.
value in normal harness
state Wiring harness between P02 (female) (5) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
P23 (female) (1)
defective contact in
connector) Wiring harness between P23 (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
4 Defective machine monitor P02 Air cleaner Voltage
Between (5) – Value in normal state Max. 1 V
chassis ground Value when clogged 20 – 30 V

40-74 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to air cleaner clogging switch of machine monitor

PC300LC/HD-8 40-75
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
AB00KE - CHARGE VOLTAGE LOW
Action code Failure code Charge voltage low
Trouble
— AB00KE (mechanical system)
Contents of
• While engine is running, power generation signal from the alternator is not input.
trouble
Action of
machine • None in particular.
monitor
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
• If a charge level caution symbol appears on the machine monitor while the engine is running, this failure
Related
code will be recorded.
information
• Input from alternator (voltage) can be checked with monitoring function. (Code: 043 Charge voltage)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective alternator
1 Alternator Engine speed Voltage
(Low power generation)
R terminal – chassis
Min. medium speed 27.5 – 29.5 V
ground
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2 (Disconnection in wiring or
Wiring harness between P02 (female) (11) –
defective contact in Resistance Max. 1 Ω
Possible causes connector) J02 – Alternator R terminal
and standard
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
Ground fault in wiring
harness Wiring harness between P02 (female) (11) –
3 J02 – Alternator R terminal, between P02
(Short circuit with GND
circuit) (female) (11) – J02 – D01 (female) (6) and Resistance Min. 1MΩ
between P02 (female) (11) – J02 – M17
(female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
4 Defective machine monitor P02 Engine speed Voltage
Between (11) –
Min. medium speed 27.5 – 29.5 V
chassis ground

40-76 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to starting and charge of machine monitor

PC300LC/HD-8 40-77
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BAZG - ENGINE OIL PRESSURE LOW
Action code Failure code Engine oil pressure low
Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil
trouble pressure (sensor contact opened).
Action of • Displays engine oil pressure monitor on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine
Related
monitor.
information
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

Lowering of engine oil
★ Determine the cause and check the damage to the engine and then
1 pressure
modify it.
(when system is normal)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective engine oil pressure
2 sensor C2 (male) Engine Resistance
(Internal defect) When started Min. 1MΩ
Between (1) –
chassis ground When stopped Max. 1 Ω
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes harness without turning starting switch ON.
and standard 3 (Disconnection in wiring or
value in normal Wiring harness between CE01 (female) (17)
defective contact in Resistance Max. 1 Ω
state connector) – C2 (female) (1)

★ Prepare with starting switch OFF, then carry out troubleshooting

Ground fault in wiring without turning starting switch ON.
harness
4 Wiring harness between CE01 (female) (17)
(Short circuit with GND
circuit) – C2 (female) (1) and chassis ground (when Resistance Min. 1MΩ
engine is started)
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
5 Defective engine controller CE01 Engine Resistance
Between (17) – chas- When started Min. 1MΩ
sis ground When stopped Max. 1 Ω

40-78 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to starting and charge of machine monitor

PC300LC/HD-8 40-79
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BAZK - ENGINE OIL LEVEL LOW
Action code Failure code Engine oil level low
Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of
• Displays engine oil level monitor on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil level switch signal can be checked with monitoring function.
Related
(Code 04501: Monitor Input 2)
information
• Method of reproducing failure code: Turn starting switch ON.

Cause Standard value in normal state/Remarks on troubleshooting

Lowering of engine oil level ★ Check the engine oil level and add new oil.
1
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective engine oil level P44 (male) Engine oil level Resistance
2 switch
(Internal disconnection) Value in normal state Max. 1 Ω
Between (1) –
chassis ground Value when oil level is
Min. 1MΩ
Possible causes low
and standard Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON.
state 3 (Disconnection in wiring or
Wiring harness between P02 (female) (8) –
defective contact in Resistance Max. 1 Ω
connector) P44 (female) (1)

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P02 Engine oil level Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
Between (8) –
chassis ground Value when oil level is
20 – 30 V
low

40-80 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine oil level switch of machine monitor

PC300LC/HD-8 40-81
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BCNS - ENGINE COOLANT OVERHEAT
Action code Failure code Engine coolant overheat
Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating of
trouble engine coolant (above 102°C).
Action of
• Displays engine coolant temperature monitor with red on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine
monitor.
Related
• Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant
information
temperature)
• Method of reproducing failure code: Start engine

Cause Standard value in normal state/Remarks on troubleshooting

Overheating of engine ★ Determine the cause and check the damage to the engine and then
1
(when system is normal) modify it.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective engine coolant Engine coolant
C5 (male) Resistance
2 temperature sensor temperature
(Internal short circuit) Between (B) – (A) 90 – 3.5 kΩ
Possible causes Between (B) – 10 – 100°C
Min. 1MΩ
and standard chassis ground
value in normal
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state
harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CE01 (female) (15)
circuit) Resistance Min. 1MΩ
– C5 (female) (B) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Engine coolant
4 Defective engine controller CE01 (female) Resistance
temperature
Between (15) –
10 – 100°C 90 – 3.5 kΩ
chassis ground

40-82 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor of machine monitor

PC300LC/HD-8 40-83
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@BCZK - ENGINE COOLANT LEVEL LOW
Action code Failure code Engine coolant level low
Trouble
— B@BCZK (Mechanical system)
Contents of • While engine was running, signal circuit of radiator coolant level switch was opened (disconnected with
trouble GND).
Action of
machine • None in particular.
monitor
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• If radiator coolant level caution symbol appears on the machine monitor while the engine is running, this
Related failure code will be recorded.
information • Input from the radiator coolant level switch (ON/OFF) can be checked with monitoring function.
(Code 045: Monitor Input 1)

Cause Standard value in normal state/Remarks on troubleshooting

Lowering of radiator coolant
★ Check the coolant level and add coolant.
1 level
(If this phenomenon frequently occurs, investigate the cause.)
(when system is normal)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective radiator coolant P24 (male) Radiator coolant level Resistance
2 level switch (internal
disconnection) Value in normal state Max. 1 Ω
Between (1) – (2) Value when coolant
Min. 1MΩ
level is low
Possible causes
★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Disconnection in wiring without turning starting switch ON.
value in normal harness
state Wiring harness between P02 (female) (3) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
P24 (female) (1)
defective contact in
connector) Wiring harness between P24 (female) (2) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Engine coolant
P02 Voltage
4 Defective machine monitor temperature
Value in normal state Max. 1 V
Between (3) –
chassis ground Value when coolant
20 – 30 V
level is low

40-84 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to radiator coolant level switch of machine monitor

PC300LC/HD-8 40-85
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
B@HANS - HYDRAULIC OIL OVERHEAT
Action code Failure code Hydraulic oil overheat
Trouble
E02 B@HANS (Mechanical system)
Contents of
• While engine was running, signal of hydraulic oil temperature sensor input 102°C or higher.
trouble
Action of
machine • None in particular.
monitor
Problem that
appears on • If machine is operated as it is, hydraulic components may be seized.
machine
• If hydraulic oil temperature gauge enters red range on the machine monitor while the engine is
running, this failure code will be recorded.
Related
• Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring
information
function.
(Code 044:Engine oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

Overheating of hydraulic oil ★ Determine the cause and check the damage to the hydraulic
1
(when system is normal) components and then modify it.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective hydraulic oil Hydraulic oil
P22 (male) Resistance
2 temperature sensor temperature
(Internal short circuit) Between (1) – (2) 90 – 3.5 kΩ
Between (2) – 10 – 100°C
Possible causes Min. 1MΩ
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between P02 (female) (12) –
circuit) Resistance Min. 1MΩ
P22 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Hydraulic oil
P02 (female) Resistance
4 Defective machine monitor temperature
Between (12) – (13) 90 – 3.5 kΩ
Between (12) – 10 – 100°C
Min. 1MΩ
chassis ground

40-86 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to hydraulic oil temperature sensor of machine monitor

PC300LC/HD-8 40-87
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA111 - EMC CRITICAL INTERNAL FAILURE
Action code Failure code EMC critical internal failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Memory or power supply circuit in engine controller is defective.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start.
machine
Related
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Engine controller may be defective. (Since trouble is in system,
1 Defective engine controller
state troubleshooting cannot be carried out.)

40-88 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA115 - ENGINE NE AND BKUP SPEED SENSOR ERROR
Action code Failure code Engine Ne and Bkup speed sensor error
Trouble
E11 CA115 (Engine controller system)
Contents of
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Start engine
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard Connectors of Ne speed sensor and Bkup speed sensor may be
value in normal Defective connection of sensor
1 connected defectively (or connected to wrong parts). Check them
state connector
directly.

PC300LC/HD-8 40-89
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA122 - CHARGE AIR PRESSURE SENSOR HIGH ERROR
Action code Failure code Charge air pressure sensor high error
Trouble
E11 CA122 (Engine controller system)
Contents of
• Pressure signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA227] is also indicated, carry out troubleshooting for it
1
supply 2 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective boost pressure, C4 (male) Voltage
2 temperature sensor Between (1) – (4) Power supply 4.75 – 5.25 V
[pressure signal system]
Voltage is measured with wiring harness connected. Accordingly, if volt-
age is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
3 (Short circuit with 5V/24V
Possible causes Wiring harness between CE01 (female) (44)
circuit) Voltage Max. 1 V
and standard – C4 (female) (1) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE01 (female) (44)
(with another wiring harness) – C4 (female) (1) and between CE01 Min.
Resistance
100 kΩ
(female) (37) – C4 (female) (2)
Connecting parts between boost pressure, temperature sensor – engine
wiring harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V

40-90 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)

PC300LC/HD-8 40-91
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA123 - CHARGE AIR PRESSURE SENSOR LOW ERROR
Action code Failure code Charge air pressure sensor low error
Trouble
E11 CA123 (Engine controller system)
Contents of
• Pressure signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] is also indicated, carry out troubleshooting for it
1
supply 2 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective boost pressure, C4 (male) Voltage
2 temperature sensor Between (1) – (4) Power supply 4.75 – 5.25 V
[pressure signal system]
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
Possible causes (Short circuit with GND Wiring harness between CE01 (female) (44) Min.
and standard circuit) Resistance
– C4 (female) (1) and chassis ground 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE01 (female) (44)
(with another wiring harness) – C4 (female) (1) and between CE01 Min.
Resistance
100 kΩ
(female) (47) – C4 (female) (2)
Connecting parts between boost pressure, temperature sensor – engine
wiring harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V

40-92 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)

PC300LC/HD-8 40-93
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA131 - THROTTLE SENSOR HIGH ERROR
Action code Failure code Throttle sensor high error
Trouble
E14 CA131 (Engine controller system)
Contents of
• Signal circuit of fuel control dial detected high voltage.
trouble
Action of
• Action to be taken varies depending on applicable machine.
controller
Problem that
appears on • Action to be taken varies depending on applicable machine.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor If failure code [CA2185] is also indicated, carry out troubleshooting for it
1
power supply system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P20 (male) Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
3 (Short circuit with 5V/24V
Possible causes Wiring harness between CE02 (female) (9) –
circuit) Voltage Max. 1 V
and standard P20 (female) (2) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE02 (female) (9) –
(with another wiring harness) P20 (female) (2) and between CE02 (female) Min.
Resistance
100 kΩ
(22) – P20 (female) (1)
Connecting parts between fuel control dial – machine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE02 Voltage
Between (22) – (23) Power supply 4.75 – 5.25 V

40-94 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial

PC300LC/HD-8 40-95
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA132 - THROTTLE SENSOR LOW ERROR
Action code Failure code Throttle sensor low error
Trouble
E14 CA132 (Engine controller system)
Contents of
• Signal circuit of fuel control dial detected low voltage.
trouble
Action of
• Action to be taken varies depending on applicable machine.
controller
Problem that
appears on • Action to be taken varies depending on applicable machine.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective throttle sensor If failure code [CA2186] is also indicated, carry out troubleshooting for it
1
power supply system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P20 (male) Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
Possible causes (Short circuit with GND Wiring harness between CE02 (female) (9) – Min.
and standard circuit) Voltage
P20 (female) (2) and chassis ground 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE02 (female) (9) –
(with another wiring harness) P20 (female) (2) and between CE02 (female) Min.
Resistance
100 kΩ
(23) – P20 (female) (3)
Connecting parts between fuel control dial – machine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE02 Voltage
Between (22) – (23) Power supply 4.75 – 5.25 V

40-96 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial

PC300LC/HD-8 40-97
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA144 - COOLANT TEMPERATURE SENSOR HIGH ERROR
Action code Failure code Coolant temperature sensor high error
Trouble
E15 CA144 (Engine controller system)
Contents of
• Signal circuit of coolant temperature sensor detected high voltage.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
Overheat prevention function does not work.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective coolant without turning starting switch ON.
1
temperature sensor C5 (male) Resistance
Between (A) – (B) 0.18 – 160 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (15)
2 (Disconnection in wiring or Resistance Max. 10 Ω
– C5 (female) (B)
defective contact in
connector) Wiring harness between CE01 (female) (38)
Resistance Max. 10 Ω
– C5 (female) (A)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit in wiring without turning starting switch ON.
state 3 harness Between CE01 (female) (15) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between coolant temperature sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kΩ

40-98 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor

PC300LC/HD-8 40-99
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA145 - COOLANT TEMPERATURE SENSOR LOW ERROR
Action code Failure code Coolant temperature sensor low error
Trouble
E15 CA145 (Engine controller system)
Contents of
• Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not work.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective coolant C5 (male) Resistance
1
temperature sensor
Between (A) – (B) 0.18 – 160 kΩ
Between (B) – chassis ground Min. 100 kΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting without
harness turning starting switch ON.
2
(Short circuit with GND Wiring harness between CE01 (female) (15) Min.
circuit) Resistance
– C5 (female) (B) and chassis ground 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting without
and standard Short circuit in wiring turning starting switch ON.
value in normal 3 harness Between CE01 (female) (15) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between coolant temperature sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
5 Defective engine controller CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kΩ
Between (15) – chassis ground Min. 100 kΩ

40-100 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine coolant temperature sensor

PC300LC/HD-8 40-101
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA153 - CHARGE AIR TEMPERATURE SENSOR HIGH ERROR
Action code Failure code Charge air temperature sensor high error
Trouble
E15 CA153 (Engine controller system)
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective boost pressure, without turning starting switch ON.
1 temperature sensor
C4 (male) Resistance
[temperature signal system]
Between (3) – (4) 0.18 – 160 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (23)
2 (Disconnection in wiring or Resistance Max. 10 Ω
– C4 (female) (3)
defective contact in
connector) Wiring harness between CE01 (female) (47)
Resistance Max. 10 Ω
– C4 (female) (4)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit in wiring without turning starting switch ON.
state 3 harness Between CE01 (female) (23) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Min.
Resistance
100 kΩ
nectors disconnected)
Connecting parts between boost pressure, temperature sensor – engine
wiring harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (23) – (47) 0.18 – 160 kΩ

40-102 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)

PC300LC/HD-8 40-103
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA154 - CHARGE AIR TEMPERATURE SENSOR LOW ERROR
Action code Failure code Charge air temperature sensor low error
Trouble
E15 CA154 (Engine controller system)
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
• Engine protection function based on boost temperature does not work
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective boost pressure,
1 temperature sensor C4 (male) Resistance
[temperature signal system] Between (3) – (4) 0.18 – 160 kΩ
Between (3) – chassis ground Min. 100 kΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2
(Short circuit with GND Wiring harness between CE01 (female) (23) Min.
Resistance
circuit) – C4 (female) (3) and chassis ground 100 Ω

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (23) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between boost pressure, temperature sensor – engine
wiring harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller CE01 (female) Resistance
Between (23) – (47) 0.18 – 160 kΩ
Between (23) – chassis ground Min.100 Ω

40-104 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to boost pressure, temperature sensor (combination sensor)

PC300LC/HD-8 40-105
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA187 - SENSOR POWER SUPPLY 2 VOLT LOW ERROR
Action code Failure code Sensor power supply 2 voltage low error
Trouble
E15 CA187 (Engine controller system)
Contents of
• Low voltage was detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting switch
ON and carry out troubleshooting.

Boost pressure,
C4
Disconnect sensor and wiring temperature sensor
harness at right in order and
Defective sensor or wiring Common rail
1 carry out operation to C8
harness pressure sensor
reproduce trouble. If “E” of
Possible causes failure code goes off when
and standard sensor or wiring harness is Bkup sensor C13
value in normal disconnected, that sensor or
state wiring harness is defective. Engine wiring
CE01
harness

Connecting parts between each sensor – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
If causes 1 and 2 are not detected, engine controller may be defective.
3 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-106 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 2

PC300LC/HD-8 40-107
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA221 - AMBIENT PRESSURE SENSOR HIGH ERROR
Action code Failure code Ambient pressure sensor high error
Trouble
E15 CA221 (Engine controller system)
Contents of
• High voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine starting performance becomes deteriorated.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA386] is also indicated, carry out troubleshooting for it
1
supply 1 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C29 (male) Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3 5V/24V circuit) in wiring
Possible causes Wiring harness between CE01 (female) (3) –
harness Voltage Max. 1 V
and standard C29 (female) (3) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE01 (female) (3) –
(with another wiring harness) C29 (female) (3) and between CE01 Min.
Resistance
100 kΩ
(female) (33) – C29 (female) (1)
Connecting parts between ambient pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (33) – (38) Power supply 4.75 – 5.25 V

40-108 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to atmospheric pressure sensor

PC300LC/HD-8 40-109
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA222 - AMBIENT PRESSER SENSOR LOW ERROR
Action code Failure code Ambient pressure sensor low error
Trouble
E15 CA222 (Engine controller system)
Contents of
• Low voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine starting performance becomes deteriorated.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA352] is also indicated, carry out troubleshooting for it
1
supply 1 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C29 (male) Voltage
Defective ambient pressure
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
3
Possible causes (Short circuit with GND Wiring harness between CE01 (female) (3) – Min.
and standard circuit) Resistance
C29 (female) (3) and chassis ground 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE01 (female) (3) –
(with another wiring harness) C29 (female) (3) and between CE01 Min.
Resistance
100 kΩ
(female) (38) – JC03 – C29 (female) (2)
Connecting parts between ambient pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (33) – (38) Power supply 4.75 – 5.25 V

40-110 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to atmospheric pressure sensor

PC300LC/HD-8 40-111
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA227 - SENSOR SUPPLY 2 VOLT HIGH ERROR
Action code Failure code Sensor power supply 2 voltage high error
Trouble
E15 CA227 (Engine controller system)
Contents of
• High voltage was detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between each sensor – engine wiring harness – engine
Possible causes controller may be defective. Check them directly.
Defective wiring harness
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective. (Since
2 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

40-112 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 2

PC300LC/HD-8 40-113
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA234 - ENGINE OVERSPEED
Action code Failure code Engine overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded control upper speed limit.
trouble
Action of
• Stops injection until engine speed lowers to normal level.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
• Method of reproducing failure code: Run engine at high idle.
information

Cause Standard value in normal state/Remarks on troubleshooting

Possible causes 1 Use of improper fuel Fuel used may be improper. Check it directly.
and standard
value in normal 2 Improper use Machine may be used improperly. Teach operator proper using method.
state If cause 1 is not detected, engine controller may be defective. (Since
3 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

40-114 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA238 - NE SPEED SENSOR SUPPLY VOLTAGE ERROR
Action code Failure code Ne speed sensor supply power voltage error
Trouble
E15 CA238 (Engine controller system)
Contents of
• Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble
Action of
• Controls the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine does not start easily.
appears on
• Engine hunts.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.

Disconnect sensor and wiring

harness at right in order and Ne speed sensor C15
Defective sensor or wiring carry out operation to
1
Possible causes harness reproduce trouble. If “E” of
and standard failure code goes off when
value in normal sensor or wiring harness is
state disconnected, that sensor or Engine wiring har-
CE01
wiring harness is defective. ness

Connecting parts between each sensor – engine wiring harness – engine

controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation

Circuit diagram related to engine Ne speed sensor

PC300LC/HD-8 40-115
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA271 - IMV/PCV1 SHORT ERROR
Action code Failure code IMV/PCV1 short error
Trouble
E11 CA271 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of supply pump actuator.
trouble
Action of
• None in particular.
controller
Problem that • Engine speed does not rise from low idle.
appears on • Engine output lowers.
machine • Common rail fuel pressure rises above command value.
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective supply pump without turning starting switch ON.
1
actuator C17 (male) Resistance
Between (1) – chassis ground Min. 100 kΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2
(Short circuit with GND Wiring harness between CE01 (female) (2) – Min.
circuit) Resistance
C17 (female) (1) and chassis ground 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (2) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between supply pump actuator – engine wiring harness
– engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (2) – chassis ground Min. 100 kΩ

40-116 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to supply pump actuator (metering unit)

PC300LC/HD-8 40-117
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA272 - IMV/PCV1 OPEN ERROR
Action code Failure code IMV/PCV1 open error
Trouble
E11 CA272 (Engine controller system)
Contents of
• Opening was detected in drive circuit of supply pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
• Engine runs but its operation is unstable.
appears on
• Common rail fuel pressure rises above command value.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective supply pump without turning starting switch ON.
1
actuator C17 (male) Resistance
Between (1) – (2) Max. 5 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (2) –
2 (Disconnection in wiring or Resistance Max. 10 Ω
C17 (female) (1)
defective contact in
connector) Wiring harness between CE01 (female) (32)
Resistance Max. 10 Ω
– C17 (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness carry out troubleshooting.
Possible causes 3
and standard (Short circuit with 24V circuit) Wiring harness between CE01 (female) (2) –
Voltage Max. 3 V
value in normal C17 (female) (1) and chassis ground
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Between CE01 (female) (2) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between supply pump actuator – engine wiring harness
– engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
6 Defective engine controller
CE01 (female) Resistance
Between (2) – (32) Max. 5 Ω

40-118 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to supply pump actuator (metering unit)

PC300LC/HD-8 40-119
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA322 - INJECTOR #1 OPEN/SHORT ERROR
Action code Failure code Injector #1 open/short circuit error
Trouble
E11 CA322 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of
• None in particular.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine
1 Defective engine controller
controller: [CA322], [CA324], [CA331]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 1 injector C9 (male) Resistance
Between (3) – (4) Max. 2 Ω
Between (3) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (45)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C9 (female) (3)
defective contact in
connector) Wiring harness between CE01 (female) (53)
Resistance Max. 2 Ω
– C9 (female) (4)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (45)
and standard circuit) Resistance Max. 2 Ω
– C9 (female) (3) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (45) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (53) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 1 injector – engine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (45) – (53) Max. 2 Ω
Between (45) – chassis ground Min. 100 kΩ

40-120 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 1

PC300LC/HD-8 40-121
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA323 - INJECTOR #5 OPEN/SHORT ERROR
Action code Failure code Injector #5 open/short circuit error
Trouble
E11 CA323 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 5 injector.
trouble
Action of
• None in particular.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine
1 Defective engine controller
controller: [CA323], [CA325], [CA332]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 5 injector C11 (male) Resistance
Between (3) – (4) Max. 2 Ω
Between (3) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (46)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C11 (female) (3)
defective contact in
connector) Wiring harness between CE01 (female) (60)
Resistance Max. 2 Ω
– C11 (female) (4)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (46)
and standard circuit) Resistance Max. 2 Ω
– C11 (female) (3) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (46) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (60) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 5 injector – engine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (46) – (60) Max. 2 Ω
Between (46) – chassis ground Min. 100 kΩ

40-122 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
Circuit diagram related to injector No. 5

PC300LC/HD-8 40-123
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA324 - INJECTOR #3 OPEN/SHORT ERROR
Action code Failure code Injector #3 open/short circuit error
Trouble
E11 CA324 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 3 injector.
trouble
Action of
• None in particular.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller:
1 Defective engine controller
[CA322], [CA324], [CA331]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 3 injector C10 (male) Resistance
Between (3) – (4) Max. 2 Ω
Between (3) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (55)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C10 (female) (3)
defective contact in
connector) Wiring harness between CE01 (female) (52)
Resistance Max. 2 Ω
– C10 (female) (4)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (55)
and standard circuit) Resistance Max. 2 Ω
– C10 (female) (3) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (55) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (52) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 3 injector – engine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (55) – (52) Max. 2 Ω
Between (55) – chassis ground Min. 100 kΩ

40-124 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 3

PC300LC/HD-8 40-125
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA325 - INJECTOR #6 OPEN/SHORT ERROR
Action code Failure code Injector #6 open/short circuit error
Trouble
E11 CA325 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 6 injector.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Combustion becomes irregular or engine hunts.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller:
1 Defective engine controller
[CA323], [CA325], [CA332]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 6 injector C11 (male) Resistance
Between (1) – (2) Max. 2 Ω
Between (2) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (57)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C11 (female) (2)
defective contact in
connector) Wiring harness between CE01 (female) (59)
Resistance Max. 2 Ω
– C11 (female) (1)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (57)
and standard circuit) Resistance Max. 2 Ω
– C11 (female) (2) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (57) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (59) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 6 injector – engine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (57) – (59) Max. 2 Ω
Between (57) – chassis ground Min. 100 kΩ

40-126 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 6

PC300LC/HD-8 40-127
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA331 - INJECTOR #2 OPEN/SHORT ERROR
Action code Failure code Injector #2 open/short circuit error
Trouble
E11 CA331 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 2 injector.
trouble
Action of
• None in particular.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller:
1 Defective engine controller
[CA322], [CA324], [CA331]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 2 injector C9 (male) Resistance
Between (1) – (2) Max. 2 Ω
Between (2) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (54)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C9 (female) (2)
defective contact in
connector) Wiring harness between CE01 (female) (51)
Resistance Max. 2 Ω
– C9 (female) (1)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (54)
and standard circuit) Resistance Max. 2 Ω
– C9 (female) (2) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (54) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (51) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 2 injector – engine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (54) – (51) Max. 2 Ω
Between (54) – chassis ground Min. 100 kΩ

40-128 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 2

PC300LC/HD-8 40-129
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA332 - INJECTOR #4 OPEN/SHORT ERROR
Action code Failure code Injector #4 open/short circuit error
Trouble
E11 CA332 (Engine controller system)
Contents of
• Opening or short circuit was detected in drive circuit of No. 4 injector.
trouble
Action of
• None in particular.
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

Cause Standard value in normal state/Remarks on troubleshooting

If following failure codes are also displayed, trouble is in engine controller:
1 Defective engine controller
[CA323], [CA325], [CA332]
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
2 Defective No. 4 injector C10 (male) Resistance
Between (1) – (2) Max. 2 Ω
Between (2) – chassis ground Min. 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (56)
3 (Disconnection in wiring or Resistance Max. 2 Ω
– C10 (female) (2)
defective contact in
connector) Wiring harness between CE01 (female) (58)
Resistance Max. 2 Ω
– C10 (female) (1)
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 4
(Short circuit with GND Wiring harness between CE01 (female) (56)
and standard circuit) Resistance Max. 2 Ω
– C10 (female) (2) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE01 (female) (56) – each of CE01
Short circuit in wiring Min.
(female) pins (With all wiring harness Resistance
5 harness 100 kΩ
connectors disconnected)
(with another wiring harness)
Between CE01 (female) (58) – each of CE01
Min.
(female) pins (With all wiring harness Resistance
100 kΩ
connectors disconnected)
Connecting parts between No. 4 injector – engine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
6 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
7 Defective engine controller CE01 (female) Resistance
Between (56) – (58) Max. 2 Ω
Between (56) – chassis ground Min. 100 kΩ

40-130 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to injector No. 4

PC300LC/HD-8 40-131
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA342 - CALIBRATION CODE INCOMPATIBILITY
Action code Failure code Calibration code incompatibility
Trouble
E10 CA342 (Engine controller system)
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Normal operation, engine stopped, or start disabled
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
value in normal Engine controller may be defective. (Troubleshooting cannot be carried
state 2 Defective engine controller
out.)

40-132 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-133
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA351 - INJECTORS DRIVE CIRCUIT ERROR
Action code Failure code Injectors drive circuit error
Trouble
E10 CA351 (Engine controller system)
Contents of
• There is error in drive power circuit of injector.
trouble
Action of
• Limits output and continues operation.
controller
• Exhaust gas becomes black.
Problem that
• Combustion becomes irregular.
appears on
• Engine output lowers.
machine
• Engine cannot be started.
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective relay for engine
3 Replace relay (R23, R24) for engine controller with another relay and
controller power supply
perform reproducing operation. If “E” of failure code goes off at this time,
Possible causes replaced relay is defective.
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Disconnection in wiring Wiring harness between F01-19 – R23, R24 Max.
harness Resistance
(female) (3) 0.5 Ω
4 (Disconnection in wiring or
defective contact in Wiring harness between R23, R24 (female) Max.
Resistance
connector) (5) – CE03 (female) (3) 0.5 Ω
Wiring harness between CE03 (female) (1) – Max.
Resistance
chassis ground (T11) 10 Ω
If causes 1 – 4 are not detected, engine controller may be defective.
5 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-134 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine controller power supply

PC300LC/HD-8 40-135
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA352 - SENSOR SUPPLY 1 VOLT LOW ERROR
Action code Failure code Sensor power supply 1 voltage low error
Trouble
E15 CA352 (Engine controller system)
Contents of
• Low voltage was detected in sensor power supply 1 circuit.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.

Disconnect sensor and

wiring harness at right in Ambient pressure
C29
order and carry out sensor
Defective sensor or wiring
1 operation to reproduce
harness
trouble. If “E” of failure code
Possible causes
goes off when sensor or
and standard
wiring harness is Engine wiring har-
value in normal CE01
disconnected, that sensor or ness
state
wiring harness is defective.

Connecting parts between ambient pressure sensor – engine wiring

harness – engine controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
If causes 1 and 2 are not detected, engine controller may be defective.
3 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-136 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 1

PC300LC/HD-8 40-137
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA386 - SENSOR SUPPLY 1 VOLT HIGH ERROR
Action code Failure code Sensor power supply 1 voltage high error
Trouble
E15 CA386 (Engine controller system)
Contents of
• High voltage was detected in sensor power supply 1 circuit.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between ambient pressure sensor – engine wiring
Possible causes harness – engine controller may be defective. Check them directly.
Defective wiring harness
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective. (Since
2 Defective engine controller
trouble is in system, troubleshooting cannot be carried out.)

40-138 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to sensor power supply 1

PC300LC/HD-8 40-139
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA428 - WATER IN FUEL SENSOR HIGH ERROR
Action code Failure code Water-in-fuel sensor high error
Trouble
E15 CA428 (Engine controller system)
Contents of
• High voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective water-in-fuel without turning starting switch ON.
1
sensor P47 (male) Resistance
Between (1) – (2) Max. 10 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (14)
2 (Disconnection in wiring or Resistance Max. 10 Ω
– P47 (female) (1)
defective contact in
connector) Wiring harness between CE01 (female) (47)
Resistance Max. 10 Ω
– P47 (female) (2)
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal Short circuit in wiring without turning starting switch ON.
state 3 harness Between CE01 (female) (14) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between water-in-fuel sensor – engine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE01 (female) Resistance
Between (14) – (47) Max. 10 Ω

40-140 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to water-in-fuel sensor

PC300LC/HD-8 40-141
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA429 - WATER IN FUEL SENSOR LOW ERROR
Action code Failure code Water-in-fuel sensor low error
Trouble
E15 CA429 (Engine controller system)
Contents of
• Low voltage was detected in signal circuit of water-in-fuel sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective water-in-fuel P47 (male) Resistance
1
sensor
Between (1) – (2) Max. 10 Ω
Between (1) – chassis ground Min. 100 kΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2
(Short circuit with GND Wiring harness between CE01 (female) (14) Min.
circuit) Resistance
– P47 (female) (1) and chassis ground 100 kΩ

Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring without turning starting switch ON.
value in normal 3 harness Between CE01 (female) (14) – each of CE01
state (with another wiring harness) (female) pins (With all wiring harness Min.
Resistance
100 kΩ
connectors disconnected)
Connecting parts between water-in-fuel sensor – engine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller CE01 (female) Resistance
Between (14) – (47) Max. 10 Ω
Between (14) – chassis ground Min. 100 kΩ

40-142 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to water-in-fuel sensor

PC300LC/HD-8 40-143
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA441 - BATTERY VOLTAGE LOW ERROR
Action code Failure code Battery voltage low error
Trouble
E10 CA441 (Engine controller system)
Contents of
• There is low voltage in controller power supply circuit.
trouble
Action of
• None in particular.
controller
Problem that
• Engine stops.
appears on
• Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
★ Prepare with starting switch OFF, then keep starting switch OFF and
turn it to START and carry out troubleshooting in each case.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – OFF Min. 12 V
(–) terminals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective relay for engine
4 Replace relay (R23, R24) for engine controller with another relay and
controller power supply
perform reproducing operation. If “E” of failure code goes off at this time,
replaced relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
Wiring harness between F01-19 – R23, R24
Possible causes harness Resistance Max. 10 Ω
(female) (3)
and standard 5 (Disconnection in wiring or
Wiring harness between R23, R24 (female)
value in normal defective contact in Resistance Max. 10 Ω
connector) (5) – CE03 (female) (3)
state
Wiring harness between CE03 (female) (1) –
Resistance Max. 10 Ω
chassis ground (T11)
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between F01-19 – R23, R24 Min.
6 Resistance
(Short circuit with GND (female) (3) and chassis ground 100 kΩ
circuit) Wiring harness between R23, R24 (female) Max.
Resistance
(5) – CE03 (female) (3) and chassis ground 10 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between CE03 (female) (3) – CE03 (female) Min.
Resistance
(1) pins (With battery terminal disconnected) 100 kΩ
Short circuit in wiring harness Between CE03 (female) (3) – each of CE02
7 Min.
(with another wiring harness) (female) pins (With battery terminal Resistance
100 kΩ
disconnected)
Between CE03 (female) (1) – each of CE02
Min.
(female) pins (With battery terminal Resistance
100 kΩ
disconnected)

40-144 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between fuse No. 19 – machine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
8 • Looseness of connector, breakage of lock, or breakage of seal
Possible causes connector
• Corrosion, bend, breakage, push-in, or expansion of pin
and standard • Moisture or dirt in connector or defective insulation
value in normal
★ Prepare with starting switch OFF, then turn starting switch ON and
state
start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V

Circuit diagram related to engine controller power supply

PC300LC/HD-8 40-145
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA442 - BATTERY VOLTAGE HIGH ERROR
Action code Failure code Battery voltage high error
Trouble
E10 CA442 (Engine controller system)
Contents of
• There is high voltage (36 V or higher) in controller power supply circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine may stop.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes ★ Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator Alternator Engine speed Voltage
state
R terminal – chassis
Medium or higher 27.5 – 29.5 V
ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 Defective engine controller
CE03 (female) Voltage
Between (3) – (1) Max. 32 V

40-146 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to engine controller power supply

PC300LC/HD-8 40-147
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA449 - RAIL PRESSURE VERY HIGH ERROR
Action code Failure code Common rail pressure very high error
Trouble
E11 CA449 (Engine controller system)
Contents of
• There is high pressure error (2) in common rail circuit.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
There may be air in low pressure circuit. Check it directly according to the
following procedure.
1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
2 Air in low pressure circuit 3) Check pressure pickup plug for leakage of fuel and air.
• If this error occurs during air bleeding after the fuel filter was replaced,
air may remain in the fuel circuit. Keep running the engine at low idle for
about three minutes. As air is bled from the fuel circuit, the engine
speed will be stabilized, erasing the error indication.
★ For check of pressure in fuel low pressure circuit, see Testing and
adjusting, Checking fuel pressure.
• Measured in fuel filter outlet side.
During high idle
Pressure in fuel Max. 0.48 MPa
(if engine can be
low-pressure circuit {Max. 4.9 kg/cm2}
started)
Possible causes ★ For check of pressure in fuel low pressure circuit, see Testing and
and standard adjusting, Checking fuel pressure.
value in normal • Measured in fuel filter inlet and outlet sides.
state • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure —
Fuel filter outlet pressure
Defect in fuel low pressure Pressure drop in fuel Max. 0.14 MPa
3 During high idle
circuit parts low-pressure circuit {Max. 1.4 kg/cm2}
★ For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 33.9 kPa
pressure During high idle
{Max. 254 mmHg}
(gear pump side)
★ For check of fuel return circuit pressure, see Testing and adjusting,
Checking fuel pressure.
Fuel suction circuit
Max. 27.1 kPa
pressure During high idle
{Max. 203 mmHg}
(fuel connector side)
★ Directly check for fuel leakage from fuel tube of fuel cooler, O-ring,
4 Defective fuel cooler
seal washer damage, and check valve clogging or damage.

40-148 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective common rail Monitoring by machine
5 Monitoring code: 36400
pressure sensor monitor
0 ± 0.39 MPa
Common rail pressure While engine is stopped
{0 ± 4 kg/cm2}
Defective O-ring of supply
6 ★ Directly check that O-ring of supply pump actuator is not damaged.
pump actuator
★ Prepare with starting switch OFF (INSITE connection), then turn
starting switch ON and carry out troubleshooting.
Monitoring by machine
Monitoring code: 36400
monitor
0 ± 0.39 MPa
Common rail pressure While engine is stopped
Possible causes {0 ± 4 kg/cm2}
Defective supply pump
and standard 7
actuator ★ Prepare with starting switch OFF (INSITE connection), then start
value in normal engine and carry out troubleshooting.
state • Measured after one minute or more lapsed at idle.
Monitoring by machine
Monitoring code: 36400
monitor
1.96 MPa
Common rail pressure During low idle
{20 kg/cm2}
The common rail fuel pressure sensor connector and supply pump
actuator may be defective. Check them directly.
Defective wiring harness
8 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective engine controller without turning starting switch ON.
9
ground wiring harness CE03 (female) Resistance
Between (1) – chassis ground Max. 10 Ω
10 Defective supply pump If causes 1 – 10 are not detected, supply pump may be defective.

PC300LC/HD-8 40-149
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor and engine controller ground line

40-150 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-151
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA451 - RAIL PRESSURE SENSOR HIGH ERROR
Action code Failure code Common rail pressure sensor high error
Trouble
E11 CA451 (Engine controller system)
Contents of
• There is high voltage in signal circuit of common rail pressure sensor.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power
1 If failure code [CA227] is also indicated, carry out troubleshooting for it first.
supply 2 system
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
C8 (male) Voltage
Defective common rail
2 Between (3) – (1) Power supply 4.75 – 5.25 V
pressure sensor
Voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
★ Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short (Short circuit with out troubleshooting.
3 5V/24V circuit) in wiring
Possible causes Wiring harness between CE01 (female) (25)
harness Voltage Max. 1 V
and standard – C8 (female) (2) and chassis ground
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting without
Short circuit in wiring turning starting switch ON.
4 harness Wiring harnesses between CE01 (female)
(with another wiring harness) (25) – C8 (female) (2) and between CE01 Min.
Resistance
100 kΩ
(female) (37) – C8 (female) (3)
Connecting parts between common rail pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V

40-152 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor

PC300LC/HD-8 40-153
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA452 - RAIL PRESSURE SENSOR LOW ERROR
Action code Failure code Common rail pressure sensor low error
Trouble
E11 CA452 (Engine controller system)
Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] is also indicated, carry out troubleshooting for it
1
supply 2 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C8 (male) Voltage
Defective common rail
2 Between (3) – (1) Power supply 4.75 – 5.25 V
pressure sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Ground fault in wiring ★ Prepare with starting switch OFF, then turn starting switch ON and
harness carry out troubleshooting.
3
Possible causes (Short circuit with GND Wiring harness between CE01 (female) (25) Min.
and standard circuit) Resistance
– C8 (female) (2) and chassis ground 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Wiring harness between CE01 (female) (25)
(with another wiring harness) – C8 (female) (2) and between CE01 Min.
Resistance
100 kΩ
(female) (47) – C8 (female) (1)
Connecting parts between common rail pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective engine controller
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V

40-154 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to common rail pressure sensor

PC300LC/HD-8 40-155
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA553 - RAIL PRESSURE HIGH ERROR
Action code Failure code Common rail pressure high error
Trouble
E15 CA553 (Engine controller system)
Contents of
• There is high pressure error (1) in common rail circuit.
trouble
Action of
• None in particular.
controller
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Ground terminal may be connected defectively. Check following terminals
Possible causes directly.
and standard Defective connection of • Ground terminal of machine ((–) terminal of battery)
value in normal 2
ground terminal • Ground terminal of engine
state • Ground terminal of engine controller
• Ground terminal of starting motor
Defective O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator

40-156 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-157
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA559 - RAIL PRESSURE LOW ERROR
Action code Failure code Common rail pressure low error
Trouble
E15 CA559 (Engine controller system)
Contents of
• There is low pressure error (1) in common rail circuit.
trouble
Action of
• None in particular.
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Fuel may be leaking to outside. Check it directly (Check visually while
1 Fuel leakage to outside
running engine at low idle).
★ For check of pressure in fuel low pressure circuit, see Testing and
adjusting, Checking fuel pressure.
• Measured in fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Pressure in fuel low- Min. 0.14 MPa
During cranking
pressure circuit {Min. 1.4 kg/cm2}
★ For check of pressure in fuel low pressure circuit, see Testing and
adjusting, Checking fuel pressure.
• Measured in fuel filter outlet side.
Pressure in fuel Min. 0.48 MPa
During high idle
low-pressure circuit {Min. 4.9 kg/cm2}

Possible causes ★ For check of pressure in fuel low pressure circuit, see Testing and
and standard adjusting, Checking fuel pressure.
value in normal • Measured in fuel filter inlet and outlet sides.
state Defect in low pressure • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure —
2 Fuel filter outlet pressure
circuit parts
Pressure drop in fuel Max. 0.14 MPa
During high idle
low-pressure circuit {Max. 1.4 kg/cm2}
★ For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 33.9 kPa
pressure (gear pump During high idle
{Max. 254 mmHg}
side)
★ For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in fuel connector side.
Fuel suction circuit
Max. 27.1 kPa
pressure (fuel During high idle
{Max. 203 mmHg}
connector side)

40-158 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

★ For check of return rate from injector, see Testing and adjusting,
Checking fuel return rate and leakage.
During cranking
Defective injector
(if engine cannot be Max. 100 cc/30 sec.
3 (including high pressure
Return rate from started)
piping in head)
injector During low idle
(if engine can be Max. 300 cc/45 sec.
started)
★ For check of return rate from supply pump, see Testing and adjusting,
Checking fuel return rate and leakage.
During cranking
(if engine cannot be Max. 100 cc/30 sec.
4 Defective supply pump
Return rate from started)
Possible causes supply pump During low idle
and standard (if engine can be Max. 300 cc/45 sec.
value in normal started)
state
★ For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During cranking Max. 30 cc/min
pressure limiter
Defective supply pump ★ Remove the supply pump head, and directly check that the plunger is
6
plunger not damaged.
There may be air in low pressure circuit. Check it directly according to the
following procedure.
1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
7 Air in low pressure circuit 3) Check pressure pickup plug for leakage of fuel and air.
• If this error occurs during air bleeding after the fuel filter was replaced,
air may remain in the fuel circuit. Keep running the engine at low idle for
about three minutes. As air is bled from the fuel circuit, the engine
speed will be stabilized, erasing the error indication.

PC300LC/HD-8 40-159
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA689 - ENGINE NE SPEED SENSOR ERROR
Action code Failure code Engine Ne speed sensor error
Trouble
E11 CA689 (Engine controller system)
Contents of
• There is error in signal from engine Ne speed sensor.
trouble
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Problem that • Engine hunts.
appears on • Engine does not start easily.
machine • Engine output lowers.
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor If failure code [CA238] is also indicated, carry out troubleshooting for it
1
power supply system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C15 (male) Voltage
Defective engine Ne speed
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Breakage or improper
Engine Ne speed sensor may be broken or may have improper clearance.
3 clearance of engine Ne
Check it directly.
Possible causes speed sensor
and standard Breakage of rotation sensor
value in normal 4 Rotation sensor wheel may be broken. Check it directly.
wheel
state
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
5 (Disconnection in wiring or
Wiring harness between CE01 (female) (27)
defective contact in Resistance Max. 10 Ω
connector) – C15 (female) (3)

Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
6
(Short circuit with GND Wiring harness between CE01 (female) (27) Min.
circuit) Resistance
– C15 (female) (3) and chassis ground 100 kΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
7 5V/24V circuit) in wiring
harness Wiring harness between CE01 (female) (27)
Voltage Max. 1 V
– C15 (female) (3) and chassis ground

40-160 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CE01 (female) (27)
Short circuit in wiring Min.
– C15 (female) (3) and between CE01 Resistance
8 harness 100 kΩ
(female) (16) – C15 (female) (1)
(with another wiring harness)
Wiring harness between CE01 (female) (27)
Min.
Possible causes – C15 (female) (3) and between CE01 Resistance
100 kΩ
and standard (female) (48) – C15 (female) (2)
value in normal Connecting parts between engine Ne speed sensor – engine wiring
state harness – engine controller may be defective. Check them directly.
Defective wiring harness
9 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
10 Defective engine controller
CE01 Voltage
Between (16) – (48) Power supply 4.75 – 5.25 V

Circuit diagram related to engine Ne speed sensor

PC300LC/HD-8 40-161
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA731 - ENGINE BKUP SPEED SENSOR PHASE ERROR
Action code Failure code Engine Bkup speed sensor phase error
Trouble
E11 CA731 (Engine controller system)
Contents of
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of
• Controls the engine with signal from engine Ne speed sensor.
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Idle speed is unstable.
machine • Exhaust gas becomes black.
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. Check it directly.
speed sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor may be broken. Check it directly.
speed sensor
Rotation sensor wheel on crankshaft side may be installed defectively or
broken. Check it according to the following procedure.
Defective installation or
1) Set No. 1 cylinder at compression top dead center
3 breakage of rotation sensor
(Match stamped mark).
wheel on crankshaft side
2) If center of oblong hole of rotation sensor wheel is at tip of Ne speed
sensor, rotation sensor wheel is installed normally.
Possible causes Rotation sensor ring on camshaft side may be installed defectively or
and standard broken. Check it according to the following procedure.
value in normal Defective installation or 1) Set No. 1 cylinder at compression top dead center
state 4 breakage of rotation sensor (Match stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 crest) of rotation sensor ring are seen through sensor
mounting hole, rotation sensor ring is installed normally.
Defective timing of
5 Timing of crankshaft and camshaft may be defective. Check it directly.
crankshaft and camshaft
Ground terminal may be connected defectively. Check following terminals
directly.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6
ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor

40-162 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-163
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA757 - ALL PERSISTENT DATA LOST ERROR
Action code Failure code All persistent data lost error
Trouble
E10 CA757 (Engine controller system)
Contents of
• All data in engine controller are lost.
trouble
Action of
• None in particular.
controller
Problem that
• Engine may stop and may not be started again.
appears on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Looseness or corrosion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
★ Prepare with starting switch OFF, then keep starting switch OFF and
turn it to START and carry out troubleshooting in each case.
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective relay for engine
5 Replace relay (R23, R24) for engine controller with another relay and
controller power supply
perform reproducing operation. If “E” of failure code goes off at this time,
replaced relay is defective.
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Disconnection in wiring Wiring harness between F01-19 – R23, R24
harness Resistance Max. 10 Ω
(female) (3)
6 (Disconnection in wiring or
Wiring harness between R23, R24 (female)
defective contact in Resistance Max. 10 Ω
connector) (5) – CE03 (female) (3)
Wiring harness between CE03 (female) (1) –
Resistance Max. 10 Ω
chassis ground (T11)
Connecting parts between fuse No. 19 – machine wiring harness – engine
controller may be defective. Check them directly.
Defective wiring harness
7 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then turn starting switch ON and
start engine and carry out troubleshooting in each case.
8 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V

40-164 PC300LC/HD-8
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Circuit diagram related to engine controller power supply

PC300LC/HD-8 40-165
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA778 - ENGINE BKUP SPEED SENSOR ERROR
Action code Failure code Engine Bkup speed sensor error
Trouble
E11 CA778 (Engine controller system)
Contents of
• There is error in signal from engine Bkup speed sensor.
trouble
Action of
• Continues control with signal from engine Ne speed sensor.
controller
Problem that
• Engine does not start easily.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [CA187] is also indicated, carry out troubleshooting for it
1
supply 2 system first.
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
C13 (male) Voltage
Defective engine Bkup
2 Between (1) – (2) Power supply 4.75 – 5.25 V
speed sensor
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
Breakage or improper
Engine Bkup speed sensor may be broken or may have improper
3 clearance of engine Bkup
clearance. Check it directly.
speed sensor
Breakage of rotation sensor
4 Rotation sensor ring may be broken. Check it directly.
ring
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes harness without turning starting switch ON.
and standard 5 (Disconnection in wiring or
value in normal Wiring harness between CE01 (female) (26)
defective contact in Resistance Max. 10 Ω
state connector) – C13 (female) (3)

Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
6
(Short circuit with GND Wiring harness between CE01 (female) (26) Min.
circuit) Resistance
– C13 (female) (3) and chassis ground 100 kΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
7 5V/24V circuit) in wiring
harness Wiring harness between CE01 (female) (26)
Voltage Max. 1 V
– C13 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CE01 (female) (26)
Short circuit in wiring Min.
– C13 (female) (3) and between CE01 Resistance
8 harness 100 kΩ
(female) (37) – C13 (female) (1)
(with another wiring harness)
Wiring harness between CE01 (female) (26)
Min.
– C13 (female) (3) and between CE01 Resistance
100 kΩ
(female) (47) – C13 (female) (2)

40-166 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

Connecting parts between engine Bkup speed sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
9 • Looseness of connector, breakage of lock, or breakage of seal
Possible causes connector
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state ★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
10 Defective engine controller
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V

Circuit diagram related to engine Bkup speed sensor

PC300LC/HD-8 40-167
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA1633 - KOMNET DATALINK TIMEOUT ERROR
Action code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633 (Engine controller system)
Contents of • Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of • Action to be taken varies depending on applicable machine.
controller • If cause of failure disappears, system resets itself.
Problem that • Information may not transmitted normally by KOMNET communication and machine may not operate
appears on normally.
machine (Trouble phenomenon depends on failed section.)
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring
Wiring harness between P70 (female) (15) –
harness
K31 (female) (A) – CP02 (female) (32), Resistance Max. 1 Ω
1 (Disconnection in wiring or
– CE02 (female) (46), – K02 (female) (A)
defective contact in
connector) Wiring harness between P70 (female) (16) –
K31 (female) (B) – CP02 (female) (22), Resistance Max. 1 Ω
– CE02 (female) (47), – K02 (female) (B)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between P70 (female) (15) –
Ground fault in wiring K31 (female) (A) – CP02 (female) (32),
Resistance Min. 1 MΩ
harness – CE02 (female) (46), – K02 (female) (A) and
2
(Short circuit with GND chassis ground
circuit) Wiring harness between P70 (female) (16) –
Possible causes K31 (female) (B) – CP02 (female) (22),
and standard Resistance Min. 1 MΩ
– CE02 (female) (47), – K02 (female) (B) and
value in normal chassis ground
state
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between P70 (female) (15) –
K31 (female) (A) – CP02 (female) (32), Max.
Voltage
Hot short in wiring harness – CE02 (female) (46), – K02 (female) (A) and 5.5 V
3
(Short circuit with 24V circuit) chassis ground
Wiring harness between P70 (female) (16) –
K31 (female) (B) – CP02 (female) (22), Max.
Voltage
– CE02 (female) (47), – K02 (female) (B) and 5.5 V
chassis ground

Defective CAN terminal ★ Prepare with starting switch OFF, then carry out troubleshooting
resistance without turning starting switch ON.
4
(Internal short circuit or K31, K02 (male) Resistance
disconnection) Between (A) – (B) 47 – 67 Ω
If causes 1 – 4 are not detected, engine controller may be defective.
5 Defective pump controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-168 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to KOMNET communication

PC300LC/HD-8 40-169
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2185 - THROTTLE SENSOR SUPPLY VOLT HIGH ERROR
Action code Failure code Throttle sensor supply voltage high error
Trouble
E14 CA2185 (Engine controller system)
Contents of
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before
Action of detection of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage
at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Short circuit in wiring
Between CE02 (female) (22) – each of CE02 Min.
1 harness Resistance
(female) pins (With P20 disconnected) 100 kΩ
(with another wiring harness)
Possible causes Between CE02 (female) (22) – CE03 Min.
and standard Resistance
(female) (3) (With P20 disconnected) 100 kΩ
value in normal
Connecting parts between fuel control dial – machine wiring harness –
state
engine controller may be defective. Check them directly.
Defective wiring harness
2 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
If causes 1 and 2 are not detected, engine controller may be defective.
3 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-170 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial

PC300LC/HD-8 40-171
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2186 - THROTTLE SENSOR SUPPLY VOLT LOW ERROR
Action code Failure code Throttle sensor supply voltage low error
Trouble
E14 CA2186 (Engine controller system)
Contents of
• Low voltage was detected in throttle sensor power supply circuit.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before
Action of detection of trouble and continues operation.
controller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with voltage
at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
1
(Short circuit with GND Wiring harness between CE02 (female) (22) Min.
circuit) Resistance
– P20 (female) (1) and chassis ground 100 kΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Short circuit in wiring without turning starting switch ON.
and standard 2 harness
value in normal (with another wiring harness) Between CE02 (female) (9) – each of CE02 Resistance
Min.
(female) pins (With P20 disconnected) 100 kΩ
state
Connecting parts between fuel control dial – machine wiring harness –
engine controller may be defective. Check them directly.
Defective wiring harness
3 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
If causes 1 and 3 are not detected, engine controller may be defective.
4 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)

40-172 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to fuel control dial

CA2249 - RAIL PRESSURE VERY LOW ERROR

Action code Failure code Common rail pressure very low error
Trouble
E11 CA2249 (Engine controller system)
Contents of
• There is low pressure error (2) in common rail circuit.
trouble
Action of
• Limits output and continues operation.
controller
Problem that • Engine does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
Related
• Method of reproducing failure code: Start engine.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state

PC300LC/HD-8 40-173
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2265 - ELECTRIC LIFT PUMP HIGH ERROR
Action code Failure code Electric lift pump high error
Trouble
E15 CA2265 (Engine controller system)
Contents of
• Opening was detected in drive circuit of electric lift pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective electric lift pump without turning starting switch ON.
1 (Internal disconnection or
C18 (male) Resistance
short circuit)
Between (1) – (2) Max. 20 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (1) –
2 (Disconnection in wiring or Resistance Max. 10 Ω
C18 (female) (1)
defective contact in
connector) Wiring harness between CE01 (female) (11)
Resistance Max. 10 Ω
– C18 (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
Possible causes 3
and standard 12V circuit) in wiring harness Wiring harness between CE01 (female) (1) –
Voltage Max. 6 V
value in normal C18 (female) (1) and chassis ground
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
4 harness Between CE01 (female) (1) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resistance Min. 1 MΩ
nectors disconnected)
Connecting parts between common rail pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
6 Defective engine controller
CE01 (female) Resistance
Between (1) – (11) Max. 20 Ω

40-174 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to electric lift pump actuator

PC300LC/HD-8 40-175
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2266 - ELECTRIC LIFT PUMP LOW ERROR
Action code Failure code Electric lift pump low error
Trouble
E15 CA2266 (Engine controller system)
Contents of
• Opening was detected in electric lift pump actuator.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective electric lift pump C18 (male) Resistance
1
(Internal short circuit)
Between (1) – (2) Max. 20 Ω
Between (1) – chassis ground Min. 100 kΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2
(Short circuit with GND Wiring harness between CE01 (female) (1) – Max. 100
circuit) Resistance
C18 (female) (1) and chassis ground kΩ
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CE01 (female) (1) –
Possible causes Voltage Max. 6 V
and standard C18 (female) (1) and chassis ground
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state Short circuit in wiring without turning starting switch ON.
4 harness Between CE01 (female) (1) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Min.
Resistance
100 kΩ
nectors disconnected)
Connecting parts between common rail pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
6 Defective engine controller CE01 (female) Resistance
Between (1) – (11) Max. 20 Ω
Between (1) – chassis ground Min. 100 kΩ

40-176 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to electric lift pump actuator

PC300LC/HD-8 40-177
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2555 - GRID HTR RELAY VOLT HIGH ERROR
Action code Failure code Grid heater relay volt high error
Trouble
E15 CA2555 (Engine controller system)
Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of
• None in particular.
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below –4°C.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Troubleshooting for relay unit)
R18 (male) Resistance
Defective automatic Between (1) – (2) 300 – 600 Ω
1 preheater relay
★ Prepare with starting switch OFF, then turn starting switch ON and
(Internal disconnection).
carry out troubleshooting. (Troubleshooting by replacement)
Replace automatic preheater relay (R18) with another relay and perform
reproducing operation. If “E” of failure code goes off at this time, replaced
relay is defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE02 (female) (40)
Possible causes 2 (Disconnection in wiring or Resistance Max. 10 Ω
– R18 (female) (1)
and standard defective contact in
value in normal connector) Wiring harness between CE02 (female) (42)
Resistance Max. 10 Ω
state – R18 (female) (2)
★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
3 harness
(with another wiring harness) Between CE02 (female) (40) – each of CE02 Resistance
Min.
(female) pins (With R18 disconnected) 100 kΩ
Connecting parts between automatic preheater relay – machine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE02 (female) Resistance
Between (40) – (42) 300 – 600 Ω

40-178 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to preheating, starting and charging engine

PC300LC/HD-8 40-179
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
CA2556 - GRID HTR RELAY VOLT LOW ERROR
Action code Failure code Grid heater relay volt low error
Trouble
E15 CA2556 (Engine controller system)
Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of
• None in particular.
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below –4°C.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON. (Troubleshooting for relay unit)
R18 (male) Resistance
Defective automatic Between (1) – (2) 300 – 600 Ω
1 preheater relay
★ Prepare with starting switch OFF, then turn starting switch ON and
(Internal disconnection).
carry out troubleshooting. (Troubleshooting by replacement)
Replace automatic preheater relay (R18) with another relay and perform
reproducing operation. If “E” of failure code goes off at this time, replaced
relay is defective.
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
Possible causes 2
(Short circuit with GND Wiring harness between CE02 (female) (40) Min.
and standard Resistance
circuit) – R18 (female) (1) and chassis ground 100 kΩ
value in normal
state ★ Prepare with starting switch OFF, then carry out troubleshooting
Short circuit in wiring without turning starting switch ON.
3 harness
(with another wiring harness) Between CE02 (female) (40) – each of CE02 Min.
Resistance
(female) pins (With R18 disconnected) 100 kΩ
Connecting parts between automatic preheater relay – machine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
4 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective engine controller
CE02 (female) Resistance
Between (40) – (42) 300 – 600 Ω

40-180 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to preheating, starting and charging engine

PC300LC/HD-8 40-181
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D110KB - BATTERY RELAY DRIVE S/C
Action code Failure code Battery relay drive short
Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not stop.
machine
Related • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
information Code 03700: Controller Output)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Battery relay Resistance
Defective battery relay
1 Between R02 (terminal BR) –
(Internal defect) There is continuity
R01 (terminal E)
Between R02 (terminal BR) –
Min. 1 MΩ
chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
value in normal harness
state 2 Wiring harness between CP03 (female) (4) –
(Short circuit with GND
circuit) D01 – J01 – R02 (terminal BR) and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Turn starting switch
3 Defective pump controller CP03 (female) Voltage
OFF.
Between (4) – 20 – 30 V
ON ➡ OFF
chassis ground (4 – 7 sec.)

40-182 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to battery relay drive

PC300LC/HD-8 40-183
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D196KA - SERVICE RETURN RELAY DISCONNECTOR
Action code Failure code Service return relay disconnection
Trouble
— D196KA (Pump controller system)
Contents of • When service return relay circuit was disconnected with GND (when output was turned OFF), 24V was not
trouble generated.
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on monitor panel.)
★ This code detects only a trouble in the primary side (coil side) of service return relay.
Related When service return solenoid may be in defective operation, check the power supply, wiring harness,
information and solenoid in the secondary side (Limit SW side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
(Code 02301: Solenoid 2)

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No.2 If fuse is broken, circuit probably has ground fault.
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective service return relay without turning starting switch ON.
2
(Internal disconnection) R20 (male) Resistance
Between (1) – (2) 100 – 500 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP02 (female) (8) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
R20 (female) (2)
defective contact in
connector) Wiring harness between R20 (female) (1) –
Possible causes Resistance Max. 1 Ω
J03 – F01-2 outlet
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring without turning starting switch ON.
harness Wiring harness between CP02 (female) (8) –
4 Resistance Min. 1 MΩ
(Short circuit with GND R20 (female) (2) and chassis ground
circuit)
Wiring harness between R20 (female) (1) –
Resistance Min. 1 MΩ
J03 – F01-2 outlet and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
CP02 Working mode Voltage
5 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – selected
chassis ground When B-mode is
Max. 1 V
selected

40-184 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to service return relay and solenoid of pump controller

PC300LC/HD-8 40-185
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
D196KB - SERVICE RETURN RELAY S/C
Action code Failure code Service return relay short
Trouble
— D196KB (Pump controller system)
Contents of • When service return relay circuit was connected to GND (when output was turned ON), abnormal current
trouble flowed.
Action of • Turns output to service return relay circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on monitor panel.)
★ This code detects only a trouble in the primary side (coil side) of service return relay.
Related When service return solenoid may be in defective operation, check the power source, wiring harness, and
information solenoid in the secondary side (Limit SW side) of the relay.
• Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
(Code 02301: Solenoid 2)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting without
Defective service return relay turning starting switch ON.
1
(Internal short circuit) R20 (male) Resistance
Between (1) – (2) 100 – 500 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and carry
Possible causes Hot short (Short circuit with out troubleshooting.
2
and standard 24V circuit) in wiring harness Wiring harness between CP02 (female) (8) –
value in normal Voltage Max. 1 V
R20 (female) (2) and chassis ground
state
★ Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
CP02 Working mode Voltage
3 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – selected
chassis ground When B-mode is
Max. 1 V
selected

40-186 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to service return relay and solenoid of pump controller

PC300LC/HD-8 40-187
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA25KP - PRESSURE SENSOR POWER ABNORMALITY
Action code Failure code Pressure sensor power abnormality
Trouble
E02 DA25KP (Pump controller system)
Contents of
• Abnormal current flowed in pressure sensor power supply (5V) circuit.
trouble
Action of • Turns output to power supply (5V) circuit OFF.
controller • Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Signal of pressure sensor is not input normally.
appears on
• Pressure sensor failure code is displayed at the same time.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
F pump pressure
P25 connector
sensor
Disconnect sensor
Defective pressure sensor and wiring harness at R pump pressure
1 P26 connector
(Internal short circuit) right in order. If no sensor
failure code is Bucket curl pressure
displayed, that sensor P01 connector
sensor
is defective.
Arm IN pressure
P04 connector
sensor
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes
and standard Wiring harness between CP01 (female) (22)
value in normal – A03 – P25 (female) (3) and chassis ground Resistance Min. 1 MΩ
state [F pump pressure sensor system]
Ground fault in wiring Wiring harness between CP01 (female) (22)
harness – A03 – P26 (female) (3) and chassis ground Resistance Min. 1 MΩ
2
(Short circuit with GND [R pump pressure sensor system]
circuit) Wiring harness between CP01 (female) (22)
– A03 – P01 (female) (3) and chassis ground Resistance Min. 1 MΩ
[Bucket CURL pressure sensor system]
Wiring harness between CP01 (female) (22)
– A03 – P04 (female) (3) and chassis ground Resistance Min. 1 MΩ
[Arm IN pressure sensor system]
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 Defective pump controller
CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V

40-188 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to pressure sensor power supply of pump controller

PC300LC/HD-8 40-189
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA2RMC - PUMP COMMUNICATION ABNORMALITY
Action code Failure code Pump communication abnormality
Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine monitor
trouble and engine controller.
Action of • Fix engine output to E-mode, and limit pump absorption torque to about 80%.
controller • If cause of failure disappears, system resets itself.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P70 (female) (16) –
1 (Disconnection in wiring or Resistance Max. 1 Ω
CE02 (female) (47), – CP02 (female) (22)
defective contact in
connector) Wiring harness between P70 (female) (15) –
Resistance Max. 1 Ω
CE02 (female) (46), – CP02 (female) (32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between P70 (female) (16) –
harness CE02 (female) (47), – CP02 (female) (22), – Resistance Min. 1 MΩ
2
(Short circuit with GND other related circuit and chassis ground
circuit)
Wiring harness between P70 (female) (15) –
Possible causes CE02 (female) (46), – CP02 (female) (32), – Resistance Min. 1 MΩ
and standard other related circuit and chassis ground
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
Wiring harness between P70 (female) (16) –
Hot short (Short circuit with CE02 (female) (47), – CP02 (female) (22), – Voltage Max. 1 V
3
24V circuit) in wiring harness other related circuit and chassis ground
Wiring harness between P70 (female) (15) –
CE02 (female) (46), – CP02 (female) (32), – Voltage Max. 1 V
other related circuit and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective CAN terminal without turning starting switch ON.
4
resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 40 – 80 Ω
Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller, or
5 engine controller, or pump pump controller may be defective. (Since trouble is in system,
controller troubleshooting cannot be carried out.)

40-190 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to CAN communication of pump controller

PC300LC/HD-8 40-191
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DA2SKQ - MODEL SELECTION ABNORMALITY
Action code Failure code Model selection abnormality
Trouble
— DA2SKQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC300) and continues control.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • None in particular.
machine
• Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Related
• Input of model selection signal (ON/OFF) can be checked with monitoring function. (Code 02200: Switch
information
Input 2)

Cause Standard value in normal state/Remarks on troubleshooting

Defective model selection ★ Prepare with starting switch OFF, then carry out troubleshooting
connector without turning starting switch ON.
1
(Internal disconnection or S30 (female) Resistance
short circuit) Between (2), (3), (7) – (8) Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CP02 (female) (7) –
Resistance Max. 1 Ω
S30 (male) (4) and chassis ground
Disconnection in wiring Wiring harness between CP02 (female) (17)
harness Resistance Max. 1 Ω
– S30 (male) (3)
2 (Disconnection in wiring or
Wiring harness between CP02 (female) (27)
defective contact in Resistance Max. 1 Ω
connector) – S30 (male) (2)
Wiring harness between CP02 (female) (13)
Resistance Max. 1 Ω
– S30 (male) (7)
Possible causes Wiring harness between S30 (male) (8) –
Resistance Max. 1 Ω
and standard J05 – A01 – chassis ground
value in normal
★ Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Wiring harness between CP02 (female) (7) –
Resistance Min. 1 MΩ
Ground fault in wiring S30 (male) (4) and chassis ground
harness Wiring harness between CP02 (female) (13)
3 Resistance Min. 1 MΩ
(Short circuit with GND – S30 (male) (7) and chassis ground
circuit) Wiring harness between CP02 (female) (17)
Resistance Min. 1 MΩ
– S30 (male) (3) and chassis ground
Wiring harness between CP02 (female) (37)
Resistance Min. 1 MΩ
– S30 (male) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
CP02 Voltage
4 Defective pump controller Between (7), (13), (27), (37) –
20 – 30 V
chassis ground
Between (13), (17) (27) – chassis
Max. 1 V
ground

40-192 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to model selection connector of pump controller

PC300LC/HD-8 40-193
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DAFRMC - MONITOR COMMUNICATION ABNORMALITY
Action code Failure code Monitor communication abnormality
Trouble
E0E DAFRMC (Machine monitor)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump controller
trouble and engine controller.
Action of • Fix engine output to E-mode, and limit pump absorption torque to about 80%.
controller • If cause of failure disappears, system resets itself.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P70 (female) (16) –
1 (Disconnection in wiring or Resistance Max. 1 Ω
CE02 (female) (47), – CP02 (female) (22)
defective contact in
connector) Wiring harness between P70 (female) (15) –
Resistance Max. 1 Ω
CE02 (female) (46), – CP02 (female) (32)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between P70 (female) (16) –
harness CE02 (female) (47), – CP02 (female) (22), – Resistance Min. 1 MΩ
2
(Short circuit with GND other related circuit and chassis ground
circuit) Wiring harness between P70 (female) (15) –
Possible causes CE02 (female) (46), – CP02 (female) (32), – Resistance Min. 1 MΩ
and standard other related circuit and chassis ground
value in normal ★ Prepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
Wiring harness between P70 (female) (16) –
Hot short (Short circuit with CE02 (female) (47), – CP02 (female) (22), – Voltage Max. 1 V
3
24V circuit) in wiring harness other related circuit and chassis ground
Wiring harness between P70 (female) (15) –
CE02 (female) (46), – CP02 (female) (32), – Voltage Max. 1 V
other related circuit and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective CAN terminal without turning starting switch ON.
4
resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 40 – 80 Ω
Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller, or
5 engine controller, or pump pump controller may be defective. (Since trouble is in system,
controller troubleshooting cannot be carried out.)

40-194 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to CAN communication of machine monitor

PC300LC/HD-8 40-195
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHPAMA - F PUMP PRESSURE SENSOR ABNORMALITY
Action code Failure code F pump press sensor abnormality
Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be
Related broken. Accordingly, take extreme care when checking.
information • Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting for it
1
supply system first.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective F pump pressure
2 sensor P25 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (22)
harness Resistance Max. 1 Ω
– A03 – P25 (female) (3)
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (10)
defective contact in Resistance Max. 1 Ω
connector) – A06 – P25 (female) (1)
Possible causes
Wiring harness between CP01 (female) (8) –
and standard Resistance Max. 1 Ω
A06 – P25 (female) (2)
value in normal
state Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between CP01 (female) (8) –
circuit) Resistance Min. 1 MΩ
A06 – P25 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (22)
5 Voltage Max. 1 V
24V circuit) in wiring harness – A03 – P25 (female) (3) and chassis ground
Wiring harness between CP01 (female) (8) –
Voltage Max. 1 V
A06 – P25 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
6 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (8) – (10) 0.5 – 4.5 V

40-196 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to F pump pressure sensor of pump controller

PC300LC/HD-8 40-197
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHPBMA - R PUMP PRESSURE SENSOR ABNORMALITY
Action code Failure code R pump pressure sensor abnormality
Trouble
— DHPBMA (Pump controller system)
Contents of
• Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be
Related broken. Accordingly, take extreme care when checking.
information • Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting for it
1
supply system first.
★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
Defective R pump pressure
2 sensor P26 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (22)
harness Resistance Max. 1 Ω
– A03 – P26 (female) (3)
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (10)
defective contact in Resistance Max. 1 Ω
connector) – A06 – P26 (female) (1)
Possible causes
Wiring harness between CP01 (female) (2) –
and standard Resistance Max. 1 Ω
A06 – P26 (female) (2)
value in normal
state Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between CP01 (female) (2) –
circuit) Resistance Min. 1 MΩ
A06 – P26 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (22)
5 Voltage Max. 1 V
24V circuit) in wiring harness – A03 – P26 (female) (3) and chassis ground
Wiring harness between CP01 (female) (2) –
Voltage Max. 1 V
A06 – P26 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
6 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (2) – (10) 0.5 – 4.5 V

40-198 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to R pump pressure sensor of pump controller

PC300LC/HD-8 40-199
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHS3MA - ARM CURL PPC SENSOR ABNORMALITY
Action code Failure code Arm IN PPC pressure sensor abnormality
Trouble
— DHS3MA (Pump controller system)
Contents of
• Signal voltage from arm IN PPC pressure sensor is below 0.3 V or above 4.72 V.
trouble
Action of • Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be
Related broken. Accordingly, take extreme care when checking.
information • Input from arm IN PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm IN PPC pressure

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting for it
1
supply system first.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective arm IN PPC
2 pressure sensor (Internal P04 Voltage
defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (22)
harness Resistance Max. 1 Ω
– A03 – P04 (female) (3)
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (10)
defective contact in Resistance Max. 1 Ω
connector) – A06 – P04 (female) (1)
Possible causes
Wiring harness between CP01 (female) (19)
and standard Resistance Max. 1 Ω
– P04 (female) (2)
value in normal
state Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between P04 (female) (19) –
circuit) Resistance Min. 1 MΩ
P01 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (22)
5 Voltage Max. 1 V
24V circuit) in wiring harness – A03 – P04 (female) (3) and chassis ground
Wiring harness between CP01 (female) (19)
Voltage Max. 1 V
– A09 – P04 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
6 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (19) – (10) 0.5 – 4.5 V

40-200 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to arm IN PPC pressure sensor of pump controller

PC300LC/HD-8 40-201
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DHS4MA - BUCKET CURL PPC PRESSURE SENSOR ABNORMALITY
Action code Failure code Bucket CURL PPC press sensor abnormality
Trouble
— DHS4MA (Pump controller system)
Contents of
• Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • No automatic gear shifting
machine
★ If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be
Related broken. Accordingly, take extreme care when checking.
information • Input from bucket curl PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC pressure)

Cause Standard value in normal state/Remarks on troubleshooting

Defective sensor power If failure code [DA25KP] is also displayed, carry out troubleshooting for it
1
supply system first.
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective bucket curl PPC
2 pressure sensor (Internal P01 Voltage
defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP01 (female) (22)
harness Resistance Max. 1 Ω
– A03 – P01 (female) (3)
3 (Disconnection in wiring or
Wiring harness between CP01 (female) (10)
defective contact in Resistance Max. 1 Ω
connector) – A06 – P01 (female) (1)
Possible causes
Wiring harness between CP01 (female) (13)
and standard Resistance Max. 1 Ω
– P01 (female) (2)
value in normal
state Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between CP01 (female) (13)
circuit) Resistance Min. 1 MΩ
– P01 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP01 (female) (22)
5 Voltage Max. 1 V
24V circuit) in wiring harness – A03 – P01 (female) (3) and chassis ground
Wiring harness between CP01 (female) (13)
Voltage Max. 1 V
– P01 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
6 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (13) – (10) 0.5 – 4.5 V

40-202 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to bucket curl PPC pressure sensor of pump controller

PC300LC/HD-8 40-203
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW43KA - TRAVEL SPEED SOLENOID DISCONNECTION
Action code Failure code Travel speed solenoid disconnection
Trouble
— DW43KA (Pump controller system)
Contents of
• No current flows at output to travel speed solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
• Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW43KB].)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective travel speed without turning starting switch ON.
1 solenoid (Internal
V04 (male) Resistance
disconnection)
Between (1) – (2) 20 – 60 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (27)
Possible causes 2 (Disconnection in wiring or Resistance Max. 1 Ω
– A05 – V04 (female) (2)
and standard defective contact in
connector) Wiring harness between V04 (female) (1) –
value in normal Resistance Max. 1 Ω
state chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (27)
Voltage Max. 1 V
– A05 – V04 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
4 Defective pump controller
CP03 (female) Resistance
Between (27) – chassis ground 20 – 60 Ω

40-204 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel speed solenoid of pump controller

PC300LC/HD-8 40-205
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW43KB - TRAVEL SPEED SOLENOID S/C
Action code Failure code Travel speed solenoid short
Trouble
— DW43KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel speed solenoid circuit.
trouble
Action of • Turns output to travel speed solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
Related • Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective travel speed
1 solenoid (Internal short V04 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
Possible causes
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Short circuit with GND Wiring harness between CP03 (female) (27) –
circuit) Resistance Min. 1 MΩ
A05 – V04 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
3 Defective pump controller CP03 Travel speed Voltage
Between (27) – Lo Max. 1 V
chassis ground Hi + Travel operation 20 – 30 V

40-206 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel speed solenoid of pump controller

PC300LC/HD-8 40-207
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW45KA - SWING BRAKE SOLENOID DISCONNECTION
Action code Failure code Swing holding brake solenoid disconnection
Trouble
E03 DW45KA (Pump controller system)
Contents of
• No current flows at output to swing holding brake solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring
function. (Code 02300: Solenoid 1)
• If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake
Related release switch in release position (Swing holding brake does not work, however, when machine stops).
information • Turn both of swing lock and emergency swing release switches OFF during troubleshooting.
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW45KB].)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective swing holding without turning starting switch ON.
1 brake solenoid (Internal
V05 (male) Resistance
disconnection)
Between (1) – (2) 20 – 60 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective swing lock switch S04 (female) Switch Resistance
2
(Internal disconnection)
OFF Max. 1 Ω
Between (3) – (4)
LOCK Min. 1 MΩ
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
Defective assembled-type without turning starting switch ON.
value in normal
3 diode D01
state D01 (male) Digital circuit tester Continuity
(Internal disconnection)
Between (7) – (3) Diode mode There is continuity
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between CP03 (female) (37)
Disconnection in wiring Resistance Max. 1 Ω
– D01 (female) (7)
harness
Wiring harness between D01 (female) (3) –
4 (Disconnection in wiring or Resistance Max. 1 Ω
J02 – S04 (male) (3)
defective contact in
connector) Wiring harness between S04 (male) (4) –
Resistance Max. 1 Ω
A05 – V05 (female) (2)
Wiring harness between V05 (female) (1) –
Resistance Max. 1 Ω
CP03 (female) (3), (13), (23)

40-208 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Wiring harness between CP03 (female) (37)
Hot short (Short circuit with – D01 – H06 – S04 (male) (3) and chassis Voltage Max. 1 V
5
24V circuit) in wiring harness ground
Possible causes
and standard Wiring harness between V05 (female) (2) –
value in normal A05 – H06 – S04 (male) (4) and chassis Voltage Max. 1 V
state ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.

6 Defective pump controller CP03 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (37) – (7) on female side 20 – 60 Ω
chassis ground directly.

PC300LC/HD-8 40-209
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to swing holding brake solenoid of pump controller

40-210 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12

MEMORANDUM

PC300LC/HD-8 40-211
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW45KB - SWING BRAKE SOLENOID S/C
Action code Failure code Swing holding brake solenoid short
Trouble
E03 DW45KB (Pump controller system)
Contents of
• Abnormal current flowed at output to swing holding brake solenoid circuit.
trouble
Action of • Turns output to swing holding brake solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring function.
Related (Code 02300: Solenoid 1)
information • If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake
release switch in release position (Swing holding brake does not work, however, when machine stops).

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective swing holding
1 brake solenoid (Internal short V05 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective assembled-type without turning starting switch ON.
2 diode D01
D01 (male) Resistance
(Internal short circuit)
Between (3) – (7) Min. 1 MΩ
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Ground fault in wiring Wiring harness between CP03 (female) (37)
harness – D01 – J02 – H06 – S04 (male) (3) and Resistance Min. 1 MΩ
3
(Short circuit with GND chassis ground
circuit) Wiring harness between V05 (female) (2) –
A05 – H06 – S04 (male) (4) and chassis Resistance Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
4 Defective pump controller CP03 Swing lever Voltage
Between (37) – At neutral Max. 1 V
chassis ground At swing 20 – 30 V

40-212 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to swing holding brake solenoid of pump controller

PC300LC/HD-8 40-213
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW91KA - TRAVEL JUNCTION SOLENOID DISCONNECTION
Action code Failure code Travel junction solenoid disconnection
Trouble
— DW91KA (Pump controller system)
Contents of
• No current flows at output to travel junction solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Hard to turn when operating travel steering.
machine
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DW91KB].)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective travel junction without turning starting switch ON.
1 solenoid
V02 (male) Resistance
(Internal disconnection)
Between (1) – (2) 20 – 60 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between CP03 (female) (7) –
Resistance Max. 1 Ω
Possible causes 2 (Disconnection in wiring or A05 – V02 (female) (2)
and standard defective contact in
Wiring harness between V02 (female) (1) –
connector)
value in normal A05 – CP03 (female) (3), (13), (23) and Resistance Max. 1 Ω
state chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (7) –
Voltage Max. 1 V
A05 – V02 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
4 Defective pump controller
CP03 (female) Resistance
Between (7) – (3), (13), (23) 20 – 60 Ω

40-214 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel junction solenoid of pump controller

PC300LC/HD-8 40-215
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DW91KB - TRAVEL JUNCTION SOLENOID S/C
Action code Failure code Travel junction solenoid short
Trouble
— DW91KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of • Turns output to travel junction solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Hard to turn when operating travel steering.
machine
Related • Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
information Code 02300: Solenoid 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective travel junction without turning starting switch ON.
solenoid V02 (male) Resistance
1
(Internal short circuit or
ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
Possible causes
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Short circuit with GND Wiring harness between CP03 (female) (7) –
circuit) Resistance Min. 1 MΩ
A05 – V02 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
3 Defective pump controller CP03 Travel lever Voltage
Between (7) – (3), (13), At straight-travel Max. 1 V
(23) At steering 20 – 30 V

40-216 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to travel junction solenoid of pump controller

PC300LC/HD-8 40-217
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWJ0KA - MERGE-DIVIDER SOLENOID DISCONNECTION
Action code Failure code Merge-divider solenoid disconnection
Trouble
— DWJ0KA (Pump controller system)
Contents of
• No current flows at output to merge-divider solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DWJ0KB].)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective merge-divider without turning starting switch ON.
1 solenoid
V03 (male) Resistance
(Internal disconnection)
Between (1) – (2) 20 – 60 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between CP03 (female) (17)
Resistance Max. 1 Ω
Possible causes 2 (Disconnection in wiring or – A05 – V03 (female) (2)
and standard defective contact in
Wiring harness between V03 (female) (1) –
connector)
value in normal A05 – CP03 (female) (3), (13), (23) and Resistance Max. 1 Ω
state chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (17)
Voltage Max. 1 V
– A05 – V03 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
4 Defective pump controller
CP03 (female) Resistance
Between (17) – (3), (13), (23) 20 – 60 Ω

40-218 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to merge-divider solenoid of pump controller

PC300LC/HD-8 40-219
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWJ0KB - MERGE-DIVIDER SOLENOID S/C
Action code Failure code Merge-divider solenoid short
Trouble
— DWJ0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to merge-divider solenoid circuit.
trouble
Action of • Turns output to merge-divider solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related • Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective merge-divider without turning starting switch ON.
solenoid V03 (male) Resistance
1
(Internal short circuit or
ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
Possible causes Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
value in normal 2
(Short circuit with GND Wiring harness between CP03 (female) (17) –
state circuit) Resistance Min. 1 MΩ
A05 – V03 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
CP03 Travel lever Voltage
3 Defective pump controller
At neutral Max. 1 V
Between (17) – (3),
(13), (23) When either side is
20 – 30 V
operated

40-220 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to merge-divider solenoid of pump controller

PC300LC/HD-8 40-221
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWK0KA - 2-STAGE RELIEF SOLENOID DISCONNECTION
Action code Failure code 2-stage relief solenoid disconnection
Trouble
— DWK0KA (Pump controller system)
Contents of
• No current flows at output to 2-stage relief solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Power maximizing function does not work.
machine
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be sure
information
to turn output on. (For more information on how to turn output on/off, see troubleshooting for failure code
[DWK0KB].)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 2-stage relief without turning starting switch ON.
1 solenoid
V08 (male) Resistance
(Internal disconnection)
Between (1) – (2) 20 – 60 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (28)
Possible causes 2 (Disconnection in wiring or Resistance Max. 1 Ω
– A05 – V08 (female) (2)
and standard defective contact in
connector) Wiring harness between V08 (female) (1) –
value in normal Resistance Max. 1 Ω
state A05 – CP03 (female) (3), (13), (23)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (28)
Voltage Max. 1 V
– A05 – V08 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
4 Defective pump controller
CP03 (female) Resistance
Between (28) – chassis ground 20 – 60 Ω

40-222 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to 2-stage relief solenoid of pump controller

PC300LC/HD-8 40-223
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DWK0KB - 2-STAGE RELIEF SOLENOID S/C
Action code Failure code 2-stage relief solenoid short
Trouble
— DWK0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of • Turns output to 2-stage relief solenoid circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Power maximizing function does not work.
machine
Related • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
information (Code 02300: Solenoid 1)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective 2-stage relief without turning starting switch ON.
solenoid V08 (male) Resistance
1
(Internal short circuit or
ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
harness without turning starting switch ON.
and standard 2
value in normal (Short circuit with GND Wiring harness between CP03 (female) (28)
circuit) Resistance Min. 1 MΩ
state – A05 – V08 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
CP03 Working mode Voltage
3 Defective pump controller When L-mode is not
Max. 1 V
Between (28) – selected
chassis ground When L-mode is
20 – 30 V
selected

40-224 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to 2-stage relief solenoid of pump controller

PC300LC/HD-8 40-225
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXA0KA - PC-EPC SOLENOID DISCONNECTION
Action code Failure code PC-EPC solenoid disconnection
Trouble
E02 DXA0KA (Pump controller system)
Contents of
• No current flows to PC-EPC solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related
• If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate
information
the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed, but it is not
defective.)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective PC-EPC solenoid without turning starting switch ON.
1
(Internal disconnection) V11 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
S21 Switch Resistance
Defective emergency pump
2 drive switch (Internal OFF Max. 1 Ω
Between (2) – (3)
disconnection) ON Min. 1 MΩ
OFF Max. 1 Ω
Between (5) – (6)
ON Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Wiring harness between CP03 (female) (16)
and standard Disconnection in wiring Resistance Max. 1 Ω
– S21 (3)
value in normal harness
state Wiring harness between S21 (2) – V11
3 (Disconnection in wiring or Resistance Max. 1 Ω
(female) (1)
defective contact in
connector) Wiring harness between CP03 (female) (21),
Resistance Max. 1 Ω
(32), (33) – J05 – chassis ground
Wiring harness between S21 (5) – V11
Resistance Max. 1 Ω
(female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with Wiring harness between CP03 (female) (16)
4 Voltage Max. 1 V
24V circuit) in wiring harness – S21 (3) and chassis ground
Wiring harness between S21 (2) – V11
Voltage Max. 1 V
(female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective pump controller
CP03 (female) Resistance
Between (16) – (21), (32), (33) 7 – 14 Ω

40-226 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller

PC300LC/HD-8 40-227
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXA0KB - PC-EPC SOLENOID S/C
Action code Failure code PC-EPC solenoid short
Trouble
E02 DXA0KB (Pump controller system)
Contents of
• Abnormal current flowed to PC-EPC solenoid circuit.
trouble
Action of • Sets output to PC-EPC solenoid circuit to 0.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related • If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can operate
information the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed, but it is not
defective.)
★ Turn emergency pump drive switch OFF during troubleshooting.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective PC-EPC solenoid
1 (Internal short circuit or V11 (male) Resistance
ground fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
and standard Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
value in normal 2
state (Short circuit with GND Wiring harness between CP03 (female) (16) –
circuit) Resistance Min. 1 MΩ
S21 – V11 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective pump controller CP03 (female) Resistance
Between (16) – (21), (32), (33) 7 – 14 Ω
Between (16) – chassis ground Min. 1 MΩ

40-228 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller

PC300LC/HD-8 40-229
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE0KA - LS-EPC SOLENOID DISCONNECTION
Action code Failure code LS-EPC solenoid disconnection
Trouble
— DXE0KA (Pump controller system)
Contents of
• No current flows to LS-EPC solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Speed of work equipment and swing is high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC solenoid current)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective LS-EPC solenoid without turning starting switch ON.
1
(Internal disconnection) V19 (male) Resistance
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP03 (female) (6) –
harness Resistance Max. 1 Ω
A04 – V19 (female) (1)
Possible causes 2 (Disconnection in wiring or
Wiring harness between CP03 (female) (21),
and standard defective contact in Resistance Max. 1 Ω
connector) (32), (33) – J05 and chassis ground
value in normal
state Wiring harness between S21 (6) – V19
Resistance Max. 1 Ω
(female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
24V circuit) in wiring harness Wiring harness between CP03 (female) (6) –
Voltage Max. 1 V
A04 – V19 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
4 Defective pump controller
CP03 (female) Resistance
Between (6) – (21), (32), (33) 7 – 14 Ω

40-230 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller

PC300LC/HD-8 40-231
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE0KB - LS-EPC SOLENOID S/C
Action code Failure code LS-EPC solenoid short
Trouble
— DXE0KB (Pump controller system)
Contents of
• Abnormal current flowed to LS-EPC solenoid circuit.
trouble
Action of • Sets output to LS-EPC solenoid circuit to 0.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC solenoid current)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective LS-EPC solenoid
1 (Internal short circuit or V19 (male) Resistance
ground fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Short circuit with GND Wiring harness between CP03 (female) (6) –
circuit) Resistance Min. 1 MΩ
A04 – V19 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective pump controller CP03 (female) Resistance
Between (6) – (21), (32), (33) 7 – 14 Ω
Between (6) – chassis ground Min. 1 MΩ

40-232 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller

PC300LC/HD-8 40-233
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)

DXE4KA - SERVICE CURRENT EPC DISCONNECTION 1

Action code Failure code Service current EPC solenoid disconnection
Trouble
— DXE4KA (Pump controller system)
Contents of
• No current flows to service current EPC solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
information
(Code 01700: Service solenoid current)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective service current without turning starting switch ON.
1 EPC solenoid (Internal
V30 (male) Resistance
disconnection)
Between (1) – (2) 7 – 14 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (26)
Possible causes 2 (Disconnection in wiring or Resistance Max. 1 Ω
– V30 (female) (1)
and standard defective contact in
connector) Wiring harness between CP03 (female) (3),
value in normal Resistance Max. 1 Ω
state (13), (23) – V30 (female) (2)
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
2
24V circuit) in wiring harness Wiring harness between CP03 (female) (26)
Voltage Max. 1 V
– V30 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective pump controller
CP03 (female) Resistance
Between (26) – (3), (13), (23) 7 – 14 Ω

Circuit diagram related to service current EPC solenoid of pump controller

40-234 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DXE4KB - SERVICE CURRENT EPC S/C
Action code Failure code Service current EPC solenoid short
Trouble
— DXE4KB (Pump controller system)
Contents of
• Abnormal current flowed to service current EPC solenoid circuit.
trouble
Action of • Sets output to service current EPC solenoid circuit to 0.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
information
(Code 01700: Service solenoid current)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective service current
1 EPC solenoid (Internal short V30 (male) Resistance
circuit or ground fault) Between (1) – (2) 7 – 14 Ω
Between (1) – chassis ground Min. 1 MΩ
Possible causes
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Short circuit with GND Wiring harness between CP03 (female) (26)
circuit) Resistance Min. 1 MΩ
– V30 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Defective pump controller CP03 (female) Resistance
Between (26) – (3), (13), (23) 7 – 14 Ω
Between (26) – chassis ground Min. 1 MΩ

Circuit diagram related to service current EPC solenoid of pump controller

PC300LC/HD-8 40-235
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY20KA - WIPER WORKING ABNORMALITY
Action code Failure code Wiper working abnormality
Trouble
— DY20KA (Machine monitor system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of
• Turns working output to wiper motor OFF.
monitor panel
Problem that
appears on • Windshield wiper does not operate.
machine
Related • Input of W signal in wiper working area (ON/OFF) can be checked with monitoring function.
information (Code 04502: Monitor Input 3)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective wiper motor W04 (male) Wiper blade Resistance
1
(Internal disconnection) Operating range top Max. 1 Ω
Between (6) – (5) Other than operating
Min. 1 MΩ
range top
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness
Wiring harness between P01 (female) (5) –
value in normal 2 (Disconnection in wiring or Resistance Max. 1 Ω
state W04 (female) (6)
defective contact in
connector) Wiring harness between W04 (female) (5) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P01 Wiper blade Voltage
3 Defective machine monitor
Operating range top Max. 1 V
Between (5) –
chassis ground Other than operating
20 – 30 V
range top

40-236 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor

PC300LC/HD-8 40-237
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY20MA - WIPER PARKING ABNORMALITY
Action code Failure code Wiper parking abnormality
Trouble
— DY20MA (Machine monitor system)
Contents of
• When windshield wiper parks, P signal of storage area is not input.
trouble
Action of
• Turns parking output to wiper motor OFF.
monitor panel
Problem that
appears on • Windshield wiper does not park.
machine
Related • Input of P signal in wiper parking area (ON/OFF) can be checked with monitoring function.
information (Code 04502: Monitor Input 3)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective wiper motor W04 (male) Wiper blade Resistance
1
(Internal disconnection)
Storage area Max. 1 Ω
Between (4) – (5)
Working area Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness
Wiring harness between P01 (female) (12) –
value in normal 2 (Disconnection in wiring or Resistance Max. 1 Ω
state W04 (female) (4)
defective contact in
connector) Wiring harness between W04 (female) (5) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 Defective machine monitor P01 Wiper blade Voltage
Between (12) – Storage area Max. 1 V
chassis ground Working area 20 – 30 V

40-238 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor

PC300LC/HD-8 40-239
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2CKB - WASHER DRIVE S/C
Action code Failure code Window washer drive system short
Trouble
— DY2CKB (Machine monitor system)
Contents of
• When washer drive circuit was connected to GND (when output was turned ON), abnormal current flowed.
trouble
Action of
• Turns output to washer motor circuit OFF.
monitor panel
Problem that
appears on • Window washer operation stops.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
Defective washer motor without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Between (1) – (2) 5 – 20 Ω
★ Prepare with starting switch OFF, then turn starting switch ON and
Possible causes carry out troubleshooting.
and standard Hot short (Short circuit with
2
value in normal 24V circuit) in wiring harness Wiring harnesses between P01 (female) (3) –
state J04 – M06 (female) (2), – D02 (female) (8) and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
3 Defective machine monitor P01 Washer switch Voltage
Between (3) – chassis OFF 20 – 30 V
ground ON Max. 1 V

40-240 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to window washer motor of machine monitor

PC300LC/HD-8 40-241
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2DKB - WIPER DRIVE (FOR) S/C
Action code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive forward circuit.
trouble
Action of
• Turns output to wiper motor drive forward circuit OFF.
monitor panel
Problem that
appears on • Window washer operation stops.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective wiper motor
1 (Internal short circuit or W04 (male) Continuity/Resistance
ground fault) Between (3) – (1) There is continuity
Between (3) – chassis ground Min. 1 MΩ
Possible causes Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
value in normal 2
(Short circuit with GND Wiring harness between P01 (female) (9) –
state circuit) Resistance Min. 1 MΩ
W04 (female) (3) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P01 Wiper switch Voltage
3 Defective machine monitor
OFF Max. 3 V
Between (9) –
chassis ground Max. 3 V ⇔ 20 – 30 V
ON
(Constant cycle)

40-242 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor

PC300LC/HD-8 40-243
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
DY2EKB - WIPER DRIVE (REV) S/C
Action code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive reverse circuit.
trouble
Action of
• Turns output to wiper motor drive reverse circuit OFF.
monitor panel
Problem that
appears on • Window washer operation stops.
machine
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective wiper motor
1 (Internal short circuit or W04 (male) Continuity/Resistance
ground fault) Between (1) – (3) There is continuity
Between (1) – chassis ground Min. 1 MΩ
Possible causes Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard harness without turning starting switch ON.
value in normal 2
(Short circuit with GND Wiring harness between P01 (female) (10) –
state circuit) Resistance Min. 1 MΩ
W04 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P01 Wiper switch Voltage
3 Defective machine monitor
OFF Max. 3 V
Between (10) –
chassis ground Max. 3 V ⇔ 20 – 30 V
ON
(Constant cycle)

40-244 PC300LC/HD-8
TROUBLESHOOTING FAILURE CODE (DISPLAY OF CODE)
12
Circuit diagram related to wiper motor of machine monitor

PC300LC/HD-8 40-245
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-MODE (ELECTRICAL SYSTEM)

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.

Failure
Phenomenon occurring on machine
phenomenon
Relative
Information on the failure occurred as well as the troubleshooting
information

Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes Remarks
on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
Wiring harness which is not connected to chassis ground circuit
is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24 V)
circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are
state reference numbers, which do
not indicate priority) <Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for
3 troubleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male side
and female side.
• If connector No. has marks of “male” and “female”, disconnect
connector and connect T-adapter to only male side or female
side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise specified.
4 • Connect positive (+) lead to pin No. or wiring harness entered
on front side.
• Connect negative (–) lead to pin No. or harness entered on rear
side.

40-246 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram

which shows the portion where the failure
occurred.
• Connector No.: Indicates (Type – numbers of a
pin) (color)
• Arrow: Roughly indicates the location in the
machine where it is installed.

PC300LC/HD-8 40-247
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-1 ENGINE DOES NOT START
Trouble • Engine does not start (Engine does not turn).
• Engine starting circuit has following 2 start lock mechanisms:
Related 1) Start lock by the machine monitor password
information 2) Start lock by the lock lever
• In the case no error code for the engine controller mechanism is indicated

Cause Standard value in normal state/Remarks on troubleshooting

Battery voltage Specific gravity of battery
1 Low charge level of battery
Min. 24 V Min. 1.26
If fuse or fusible link is burnt out, the circuit probably has ground fault.
Defective fuse No. 3, No. 17
2 In the case the machine monitor does not light up, check the power circuit
or fusible link F04 and F05
between the battery and the fuse.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective starting switch H06 (male) Position Resistance
3
(Internal disconnection)
OFF Min. 1 MΩ
Between (1) – (4)
START Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective safety lock switch S14 (female) Lock lever Resistance
4
(internal short circuit)
Free Min. 1 MΩ
Between (1) – (3)
Lock Max. 1 Ω
Possible causes ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Defective starting motor cut-
out relay R06 or R07 R06 (male), R07 (male) Resistance
state
5
(Internal short circuit or Between (1) – (2) 100 – 500 Ω
ground fault) Between (3) – (5) Min. 1 MΩ
Between (3) – (6) Max. 1 Ω
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
(If power supply and starting input and output are normal but starting
motor does not turn, starting motor is defective.)
Defective starting motor Starting
6 (Internal disconnection or Starting motor Voltage
switch
breakage)
Power supply: Between terminal B
20 – 30 V
and chassis ground When
Starting input: Terminal C – chassis started
20 – 30 V
ground
★ Prepare with starting switch OFF, then turn starting switch ON or start
Defective alternator engine and carry out troubleshooting.
7
(Internal short circuit) Alternator Voltage
Terminal R – chassis ground Max. 1 V

40-248 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Cause Standard value in normal state/Remarks on troubleshooting
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01-17 – H06
Resistance Max. 1 Ω
(female) (1)
Wiring harness between H06 (female) (4) –
Resistance Max. 1 Ω
J01 – R06 (female) (5)
Disconnection in wiring Wiring harness between R06 (female) (3) –
harness Resistance Max. 1 Ω
M17 (female) (1)
8 (Disconnection in wiring or
Wiring harness between F01-3 outlet – S14
defective contact in Resistance Max. 1 Ω
connector) (female) (1)
Wiring harness between S14 (female) (3) –
Resistance Max. 1 Ω
R06 (female) (1)
Wiring harness between R06 (female) (2) –
Resistance Max. 1 Ω
R07 (female) (6)
Wiring harness between R07 (female) (3) –
Resistance Max. 1 Ω
J04 – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
without turning starting switch ON.
and standard
value in normal Wiring harness between battery relay
state terminal B (R04) – F05 – F01-16D and Resistance Min. 1 MΩ
chassis ground
Wiring harness between F01-17 – H06
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Ground fault in wiring Wiring harness between H06 (female) (4) –
harness Resistance Min. 1 MΩ
9 J01 – R06 (female) (5) and chassis ground
(Short circuit with GND
circuit) Wiring harness between R06 (female) (3) –
Resistance Min. 1 MΩ
M17 (female) (1) and chassis ground
Wiring harness between F01-3 – S14
Resistance Min. 1 MΩ
(female) (1) and chassis ground
Wiring harness between S14 (female) (3) –
Resistance Min. 1 MΩ
R06 (female) (1) and chassis ground
Wiring harness between R07 (female) (2) –
Resistance Min. 1 MΩ
J05 – P02 (female) (14) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
10
24V circuit) in wiring harness Wiring harness between P02 (female) (11) –
J02 – M17 (female) (2), – D01 (female) (6), – Voltage Max. 1 V
alternator terminal R and chassis ground

PC300LC/HD-8 40-249
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine start and battery charging

40-250 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-2 AUTO-DECELERATOR DOES NOT OPERATE
Trouble • Auto-decelerator does not operate.
• Set speed of auto-decelerator is 1,300 rpm. Accordingly, set the fuel control dial to a higher rpm than this
Related
speed. If set speed is under 1,300 rpm, the auto-decelerator will not operate.
information
• Check all the monitoring indications after starting the engine.

Cause Standard value in normal state/Remarks on troubleshooting

In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-21.
Defective boom RAISE
1 Monitoring code Item Normal display
signal
Operation of lever: ON
01900 Boom RAISE
Lever in neutral: OFF
In the case monitoring is not normally indicated, proceed to troubleshoot-
ing No. E-22.
Defective boom LOWER
2 Monitoring code Item Normal display
signal
Operation of lever: ON
01900 Boom LOWER
Lever in neutral: OFF
In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-23.
3 Defective arm IN signal Monitoring code Item Normal display
Operation of lever: ON
01900 Arm IN
Lever in neutral: OFF
Possible causes In the case monitoring is not normally indicated, proceed to
and standard troubleshooting No. E-24.
value in normal 4 Defective arm OUT signal Monitoring code Item Normal display
state
Operation of lever: ON
01900 Arm OUT
Lever in neutral: OFF
In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-26.
Defective bucket CURL
5 Monitoring code Item Normal display
signal
Operation of lever: ON
01901 Bucket CURL
Lever in neutral: OFF
In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-27.
Defective bucket DUMP
6 Monitoring code Item Normal display
signal
Operation of lever: ON
01901 Bucket DUMP
Lever in neutral: OFF
In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-28.
7 Defective swing signal Monitoring code Item Normal display
Operation of lever: ON
01900 Swing
Lever in neutral: OFF

PC300LC/HD-8 40-251
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)

Cause Standard value in normal state/Remarks on troubleshooting

In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-29.
8 Defective travel signal Monitoring code Item Normal display
Operation of lever: ON
01900 Travel
Possible causes Lever in neutral: OFF
and standard In the case monitoring is not normally indicated, proceed to
value in normal troubleshooting No. E-30.
state
9 Defective attachment signal Monitoring code Item Normal display
Operation of lever: ON
01901 Service
Lever in neutral: OFF
Since trouble is in system, troubleshooting cannot be carried out.
10 Defective pump controller (If causes 1 – 9 above are not detected, engine controller may be
defective.)

40-252 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE
Trouble • Automatic warming-up system does not operate
• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to 1,250
Related rpm.
information • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned ON or
after engine is started, automatic warm-up system is turned OFF.

Cause Standard value in normal state/Remarks on troubleshooting

In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-14.
Possible causes Defective engine coolant Monitoring code Item Normal display
1
and standard temperature signal Compare with actual
value in normal Engine coolant
04102 engine coolant
state temperature
temperature
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective pump controller causes stated above are not detected, engine controller may be
defective.)

PC300LC/HD-8 40-253
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-4 PREHEATER DOES NOT OPERATE
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Related Input of preheating signal (ON/OFF) can be checked with monitoring function.
information (Code 04500: Monitor Input 1)

Cause Standard value in normal state/Remarks on troubleshooting

Defective starting switch If preheating fails to operate (the heater does not warm up), refer to
1
system Trouble (2)
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
Possible causes harness without turning starting switch ON.
and standard 2 (Disconnection in wiring or
Wiring harness between P02 (female) (18) –
value in normal defective contact in Resistance Max. 1 Ω
connector) J02 (male) (7)
state
★ Prepare with starting switch OFF
P02 Starting switch Voltage
3 Defective machine monitor
Between (18) – OFF Max. 1 V
chassis ground HEAT 20 – 30 V

Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related • During low temperature (coolant temperature below 30°C), pump controller drives the heater relay for 100
information sec. after engine start to automatically preheat.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF
Defective starting switch H06 (male) Starting switch Resistance
1
(Internal disconnection) OFF Min. 1 MΩ
Between (1) – (3)
HEAT Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective heater relay Heater relay Resistance
2
Possible causes (Internal disconnection)
and standard Coil terminal – chassis ground
value in normal Between contact terminals Min. 1 MΩ
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective intake air heater without turning starting switch ON.
3
(Internal disconnection).
Between heater terminals Normal if conductive
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between H06 (female) (3) –
4 (Disconnection in wiring or Resistance Max. 1 Ω
J02 – Heater relay terminal R17
defective contact in
connector) Wiring harness between battery relay
Resistance Max. 1 Ω
terminal M (R03) – Heater relay terminal R15

40-254 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine preheater

PC300LC/HD-8 40-255
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-5
ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT
MOVE
Trouble • All travel, swing, and work equipment mechanism do not move.
Related
—
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 3 If fuse is burnt out, the circuit probably has ground fault.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective safety lock switch S14 (female) Lock lever Resistance
2
(internal disconnection)
Lock Min. 1 MΩ
Between (1) – (2)
Free Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective PPC lock solenoid
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective assembled-type without turning starting switch ON.
Possible causes
4 diode D01
and standard D01 (male) Resistance
(Internal short circuit)
value in normal
Between (8) – (4) Min. 1 MΩ
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between F01-3 outlet – J06 –
harness Resistance Max. 1 Ω
S14 (male) (1)
5 (Disconnection in wiring or
Wiring harness between S14 (male) (2) –
defective contact in Resistance Max. 1 Ω
connector) J02 – V01 (male) (2)
Wiring harness between V01 (female) (1) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring
Wiring harness between F01-3 outlet – J06 –
harness Resistance Min. 1 MΩ
6 S14 (male) (1) and chassis ground
(Short circuit with GND
circuit) Wiring harness between S14 (male) (2) –
J02 – V01(female) (2), – D01(female) (8) Resistance Min. 1 MΩ
and chassis ground

40-256 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to PPC lock solenoid

PC300LC/HD-8 40-257
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE
Trouble • Power maximizing function does not work.
• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed during
Related work equipment operation while the engine is running in P- or E-mode.
information • Input state of power maximizing switch (left knob switch) can be checked with monitoring function (Code
02200: Switch Input 1)

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 3 If fuse is burnt out, the circuit probably has ground fault.
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective power maximizing
2 switch (Internal S11(male) Switch Resistance
disconnection) Released Min. 1 MΩ
Between (1) – (2)
Pressed Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between F01-9 outlet – S11
3 (Disconnection in wiring or Resistance Max. 1 Ω
Possible causes (female) (1)
defective contact in
and standard connector) Wiring harness between S11 (female) (2) –
value in normal Resistance Max. 1 Ω
CP01 (female) (11)
state
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between F01-9 outlet – S11
4 Resistance Min. 1 MΩ
(Short circuit with GND (female) (1) and chassis ground
circuit) Wiring harness between S11 (female) (2) –
Resistance Min. 1 MΩ
CP01 (female) (11) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP01 Switch Voltage
Between (11) – Released Max. 1 V
chassis ground Pressed 20 – 30 V

40-258 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to power max. switch

PC300LC/HD-8 40-259
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL
Trouble • Machine monitor does not display at all when starting switch is turned ON
Related
—
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 3 If fuse is burnt out, the circuit probably has ground fault.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P01(female) (1) (2)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– J06 – F01-3 outlet
defective contact in
connector) Wiring harness between P01 (female) (6),
Resistance Max. 1 Ω
(7) – chassis ground
Possible causes
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 3
state (Short circuit with GND Wiring harness between P01(female) (1), (2)
circuit) Resistance Min. 1 MΩ
– J06 – F01-3 outlet and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P01 (female) Voltage/Resistance
4 Defective machine monitor Between (1), (2) – chassis
Voltage: 20 – 30 V
ground
Between (6), (7) – chassis
Resistance: Max. 1 Ω
ground

40-260 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to power source in monitor panel

PC300LC/HD-8 40-261
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS
Trouble • Machine monitor does not display some items when starting switch is turned ON
Related
—
information

Cause Standard value in normal state/Remarks on troubleshooting

When following switches are operated, if all LCD panel is lighted up (all
Possible causes Defective machine monitor
1 surface becomes white), LCD panel is normal.
and standard LCD
• Switch operation: [/] + [A] (Simultaneous operation)
value in normal
state Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective machine monitor causes stated above are not detected, engine controller may be
defective.)

E-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT

FROM APPLICABLE MACHINE

Trouble • Contents of display by machine monitor are different from applicable machine.
Related
—
information

Cause Standard value in normal state/Remarks on troubleshooting

In the case monitoring display is not normal, proceed to failure code
[DA2SKQ].
Possible causes Defective model code signal Monitoring code Item Normal display
1
and standard (Internal defect) 00200
value in normal Controller model code
300
state Select model
00201
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective machine monitor causes stated above are not detected, engine controller may
be defective.)

40-262 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-10FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUN-
NING
Trouble • Fuel level monitor was lighted in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
information
(Code 04200: Fuel level sensor voltage)

Cause Standard value in normal state/Remarks on troubleshooting

Low fuel level
1 ★ Add fuel
(When system is normal)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel level sensor P21 (male) Fuel level Resistance
2
(Internal disconnection)
Between (1) and FULL (Upper limit) Approx. 12 Ω
Possible causes chassis ground EMPTY (Lower limit) 85 – 110 Ω
and standard Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON.
state 3 (Disconnection in wiring or
Wiring harness between P02 (female) (2) –
defective contact in Resistance Max. 1 Ω
connector) P21 (female) (1)

★ Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
4 Defective machine monitor P02 (female) Fuel level Resistance
Between (2) and FULL (Upper limit) Approx. 12 Ω
chassis ground EMPTY (Lower limit) 85 – 110 Ω

Circuit diagram related to fuel level sensor

PC300LC/HD-8 40-263
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-11
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE
NORMALLY
• While engine coolant temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring function.
Related (Code: 04105: Engine coolant temperature)
information • Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated (if
yes, diagnose that failure first.)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective coolant Engine coolant
temperature sensor C5 (male) Resistance
1 temperature
(Internal disconnection or
short circuit) Between (B) – (A) 90 – 3.5 kΩ
Between (B) – 10 – 100°C
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CE01 (female) (15)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– C5 (female) (B)
defective contact in
Possible causes connector) Wiring harness between C5 (female) (A) –
Resistance Max. 1 Ω
and standard chassis ground
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring
state without turning starting switch ON.
harness
3
(Short circuit with GND Wiring harness between CE01 (female) (15)
circuit) Resistance Min. 1 MΩ
– C5 (female) (B) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CE01 (female) (15)
Voltage Max. 1 V
– C5 (female) (B) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Engine coolant
5 Defective engine controller CE01 (female) Resistance
temperature
Between (15) –
10 – 100°C 90 – 3.5 kΩ
chassis ground

40-264 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to engine coolant temperature sensor

PC300LC/HD-8 40-265
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-12
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NOR-
MALLY
• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
information (Code 04402: Hydraulic oil temperature)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective hydraulic oil Engine coolant tem-
temperature sensor P22 (male) Resistance
1 perature
(Internal disconnection or
short circuit) Between (1) – (2) 90 – 3.5 kΩ
Between (2) – 10 – 100°C
Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P02 (female) (12) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
P22 (female) (2)
defective contact in
connector) Wiring harness between P02 (female) (13) –
Possible causes Resistance Max. 1 Ω
P22 (female) (1)
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between P02 (female) (12) –
circuit) Resistance Min. 1 MΩ
P22 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between P02 (female) (12) –
Voltage Max. 1 V
P22 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Engine coolant
P02 Resistance
5 Defective machine monitor temperature
Between (12) – (13) 90 – 3.5 kΩ
Between (12) – 10 – 100°C
Min. 1 MΩ
chassis ground

Circuit diagram related to hydraulic oil temperature sensor

40-266 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)

E-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLY

• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F)
Related • Input signal (voltage) from the fuel level sensor can be checked with monitoring function. (Code 04200:
information Fuel level sensor voltage)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit)
Between (1) – FULL (Upper limit) Approx. 12 Ω
chassis ground EMPTY (Lower limit) 85 – 110 Ω
Disconnection in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
2 (Disconnection in wiring or
Wiring harness between P02 (female) (2) –
defective contact in Resistance Max. 1 Ω
connector) P21 (female) (1)
Possible causes
and standard Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
value in normal harness without turning starting switch ON.
3
state (Short circuit with GND Wiring harness between P02 (female) (2) –
circuit) Resistance Min. 1 MΩ
P21 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between P02 (female) (2) –
Voltage Max. 1 V
P21 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
5 Defective machine monitor P02 Fuel level Resistance
Between (2) – FULL (Upper limit) Approx. 12 Ω
chassis ground EMPTY (Lower limit) 85 – 110 Ω

Circuit diagram related to fuel level sensor

PC300LC/HD-8 40-267
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY
• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned OFF, swing lock monitor lights up.
Related • Input from swing lock switch (ON/OFF) can be checked with monitoring function.
information (Code 04502: Monitor Input 3)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective swing lock switch
1 (Internal disconnection or S04 (female) Swing lock switch Resistance
short circuit) OFF Min. 1 MΩ
Between (1) – (2)
ON Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P02 (female) (17) –
2 (Disconnection in wiring or Resistance Max. 1 Ω
J02 – S04 (male) (1)
defective contact in
connector) Wiring harness between S04 (male) (2) –
Possible causes Resistance Max. 1 Ω
J05 – chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between P02 (female) (17) –
circuit) Resistance Min. 1 MΩ
J02 – S04 (male) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between P02 (female) (17) –
Voltage Max. 1 V
J02 – S04 (male) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective machine monitor P02 Swing lock switch Voltage
Between (17) – OFF 20 – 30 V
chassis ground ON Max. 1 V

40-268 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to swing lock switch

PC300LC/HD-8 40-269
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTH-
ING
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related
—
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state

Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related
★ If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state

Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related
★ If travel speed selection fails, proceed with troubleshooting No. H-21.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state

Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related
★ If wiper fails to operate, proceed with troubleshooting No. E-16.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state

• When select switch is operated, adjust screen is not displayed.

Trouble (5) • When LCD monitor adjust switch is operated, adjust screen is not displayed.
• When maintenance switch is operated, maintenance item screen is not displayed.
Related
—
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state

40-270 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)

MEMORANDUM

PC300LC/HD-8 40-271
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE
Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
Related • Input from window limit switch (ON/OFF) can be checked with monitoring function.
information (Code 049: Monitor Input 3)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective swing lock switch W03 (female) Front window Resistance
1 (Internal disconnection or When installed to
short circuit) Min. 1 MΩ
front
Between (1) – (2)
When retracted to
Max. 1 Ω
rear
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective wiper motor W04 (female) Resistance
2 (Internal disconnection or
short circuit) Between (3) – (1)
Between (3), (1) – chassis
Min. 1 MΩ
ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between P01 (female) (9) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
Possible causes W04 (male) (3)
defective contact in
and standard Wiring harness between P01 (female) (10) –
connector)
value in normal Resistance Max. 1 Ω
W04 (male) (1)
state
Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
harness without turning starting switch ON.
4
(Short circuit with GND Wiring harness between P02 (female) (15) –
circuit) Resistance Min. 1 MΩ
W03 (male) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective machine monitor P02 Front window Voltage
(window limiter switch When installed to
system) 20 – 30 V
Between (15) – front
chassis ground When retracted to
Max. 1 V
rear
5
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
P02 Wiper switch Voltage
Defective machine monitor
(Wiper motor system) Between (9) – OFF Max. 3 V
chassis ground
Between (10) – Max. 3 V ⇔ 20 – 30 V
ON
chassis ground (Constant cycle)

40-272 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to windshield wiper motor

PC300LC/HD-8 40-273
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault (See cause 4).
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective washer motor
2 (Internal disconnection or M06 (male) Resistance
short circuit) Between (1) – (2) 5 – 20 Ω
Between (1) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between F01-4 – J03 – J06 –
3 (Disconnection in wiring or Resistance Max. 1 Ω
M06 (female) (1)
defective contact in
connector) Wiring harness between M06 (female) (2) –
Possible causes Resistance Max. 1 Ω
J04 – P01 (female) (3)
and standard
value in normal ★ Prepare with starting switch OFF, then carry out troubleshooting
state without turning starting switch ON.
Wiring harness between F01-4 – J03 – J06 –
Ground fault in wiring
M06 (female) (1), – D02 (female) (4), – other
harness Resistance Min. 1 MΩ
4 harnesses between related circuits and
(Short circuit with GND
chassis ground
circuit)
Wiring harness between M06 (female) (2) –
J04 – P01 (female) (3), – D02 (female) (8) Resistance Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective machine monitor Windshield washer
5 (window limiter switch P01 Voltage
switch
system)
Between (3) – OFF 20 – 30 V
chassis ground ON Max. 1 V

40-274 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to window washer motor of machine monitor

PC300LC/HD-8 40-275
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY
• Machine push-up function does not oper-
Trouble (1) Machine push-up function does not operate.
ate normally
Related
• When machine push-up function is set to high pressure, solenoid is de-energized.
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No.2 If fuse is broken, circuit probably has ground fault. (See Cause 6)
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective machine push-up Machine push-up
2 switch (Internal S05 (female) Resistance
switch
disconnection)
Low pressure set Max. 1 Ω
Between (1) – (2)
High pressure set Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective machine push-up without turning starting switch ON.
solenoid V06 (male) Resistance
3
(Internal disconnection or
short circuit or ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
★ Prepare with starting switch OFF, then carry out troubleshooting
Defective assembled-type without turning starting switch ON.
Possible causes
4 diode D02
and standard D02 (male) Resistance (Continuity)
(Internal short circuit)
value in normal
Between (3) – (7) Min. 1 MΩ (without continuity)
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between F01-2 outlet – S05
harness Resistance Max. 1 Ω
(male) (1)
5 (Disconnection in wiring or
Wiring harness between S05 (male) (2) –
defective contact in Resistance Max. 1 Ω
connector) J07 – V06 (female) (2)
Wiring harness between V06 (female) (1) –
Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring Wiring harness between F01-2 outlet – S05
harness (male) (1), – other harnesses between Resistance Min. 1 MΩ
6
(Short circuit with GND related circuits and chassis ground
circuit) Wiring harness between S05 (male) (2) –
J07 – V06 (female) (2), – D02 (female) (3) Resistance Min. 1 MΩ
and chassis ground

40-276 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
• Machine push-up function does not operate
Trouble (2) Machine push-up function does not release.
normally
Related
• When machine push-up function is set to low pressure, solenoid is energized.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Defective machine push-up Machine push-up
1 S05 (female) Resistance
Possible causes switch (Internal short circuit) switch
and standard Low pressure set Max. 1 Ω
value in normal Between (1) – (2)
High pressure set Min. 1 MΩ
state
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
2
24V circuit) in wiring harness Wiring harness between S05 (male) (2) – J07 –
V06 (female) (2), – D02 (female) (3) and chassis Voltage Max. 1 V
ground

Circuit diagram related to machine push-up solenoid

PC300LC/HD-8 40-277
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-18
MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE” NOR-
MALLY
Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Pressure Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective boom RAISE PPC troubleshooting.
oil pressure switch (Internal P06 (male) Boom lever Resistance
1
disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Boom RAISE Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (10)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P06 (female) (2)
defective contact in
connector) Wiring harness between P06 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP03 (female) (10)
circuit) Resistance Min. 1 MΩ
– P06 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP03 (female) (10)
Voltage Max. 1 V
– P06 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP03 Boom lever Voltage
Between (10) – Neutral 20 – 30 V
chassis ground Boom RAISE Max. 1 V

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Circuit diagram related to boom RAISE PPC oil pressure switch

PC300LC/HD-8 40-279
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-19
MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER” NOR-
MALLY
Trouble • Boom LOWER operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective boom LOWER troubleshooting.
PPC oil pressure switch P02 (male) Boom lever Resistance
1
(Internal disconnection or
short circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Boom LOWER Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (20)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P02 (female) (2)
defective contact in
connector) Wiring harness between P02 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP03 (female) (20)
circuit) Resistance Min. 1 MΩ
– P02 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP03 (female) (20)
Voltage Max. 1 V
– P02 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP03 Boom lever Voltage
Between (20) – chas- Neutral 20 – 30 V
sis ground Boom LOWER Max. 1 V

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12
Circuit diagram related to boom LOWER PPC oil pressure switch

PC300LC/HD-8 40-281
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NORMALLY
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective arm IN pressure troubleshooting.
sensor P04 (male) Voltage
1
(Internal disconnection or
short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP01 (female) (19)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P04 (female) (2)
defective contact in
connector) Wiring harness between P04 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP01 (female) (19)
circuit) Resistance Min. 1 MΩ
– P04 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP01 (female) (19)
Voltage Max. 1 V
– P04 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
Between (19) – (10) 0.5 – 4.5 V

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Circuit diagram related to arm IN PPC oil pressure switch

PC300LC/HD-8 40-283
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT” NORMALLY
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective arm OUT PPC oil troubleshooting.
pressure switch (Internal P08 (male) Arm lever Resistance
1
disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Arm OUT Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (40)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P08 (female) (2)
defective contact in
connector) Wiring harness between P08 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP03 (female) (40)
circuit) Resistance Min. 1 MΩ
– P08 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP03 (female) (40)
Voltage Max. 1 V
– P08 (female) (2) and chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP03 Arm lever Voltage
Between (40) – Neutral 20 – 30 V
chassis ground Arm OUT Max. 1 V

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Circuit diagram related to arm OUT PPC oil pressure switch

PC300LC/HD-8 40-285
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-22
MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL” NOR-
MALLY
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code:01901 (Output Switch 2)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective bucket CURL troubleshooting.
pressure sensor (internal P01 (male) Bucket lever Voltage
1
disconnection or short
circuit) Between (3) – (1) Neutral 4.5 – 5.5 V
Between (2) – (1) CURL 0.5 – 4.5V
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP01 (female) (13)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P01 (female) (2)
defective contact in
connector) Wiring harness between P01 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP01 (female) (13)
circuit) Resistance Min. 1 MΩ
– P01 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP01 (female) (13)
Voltage Max. 1 V
– P01 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP01 Voltage
Between (22) – (10) 4.5 – 5.5V
Between (13) – (10) 0.5 – 4.5V

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Circuit diagram related to Bucket CURL PPC oil pressure switch

PC300LC/HD-8 40-287
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-23
MONITORING FUNCTION FAILS TO DISPLAY “BUCKET DUMP” NOR-
MALLY
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 2)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective bucket DUMP PPC troubleshooting.
oil pressure switch (Internal P05 (male) Bucket lever Resistance
1
disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Bucket DUMP Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (19)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P05 (female) (2)
defective contact in
connector) Wiring harness between P05 (female) (1) –
Possible causes Resistance Max. 1 Ω
chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP03 (female) (19)
circuit) Resistance Min. 1 MΩ
– P05 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP03 (female) (19)
Voltage Max. 1 V
– P05 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP03 Bucket lever Voltage
Between (19) – Neutral 20 – 30 V
chassis ground Bucket DUMP Max. 1 V

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Circuit diagram related to bucket DUMP PPC oil pressure switch

PC300LC/HD-8 40-289
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NORMALLY
Trouble • Swing is not displayed normally by machine monitoring function (Special function)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective swing left PPC oil troubleshooting.
pressure switch (Internal P07 (male) Swing lever Resistance
1
disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Left Max. 1 Ω
★ Prepare with starting switch OFF, then start engine and carry out
Defective swing right PPC oil troubleshooting.
pressure switch (Internal P03 (male) Swing lever Resistance
2
disconnection or short
circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Right Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harnesses between CP03 (female)
harness Resistance Max. 1 Ω
(29) – P03 (male) (2), – P07 (female) (2)
Possible causes 3 (Disconnection in wiring or
Wiring harness between P03 (female) (1) –
and standard defective contact in Resistance Max. 1 Ω
connector) chassis ground
value in normal
Wiring harness between P07 (female) (1) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness
4 Wiring harnesses between CP03 (female)
(Short circuit with GND
circuit) (29) – P03 (female) (2), – P07 (female) (2) Resistance Min. 1 MΩ
and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
5
24V circuit) in wiring harness Wiring harnesses between CP03 (female)
(29) – P03 (female) (2), – P07 (female) (2) Voltage Max. 1 V
and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective pump controller CP03 Bucket lever Voltage
Between (29) – Neutral 20 – 30 V
chassis ground Left or Right Max. 1 V

40-290 PC300LC/HD-8
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Circuit diagram related to right and left swing PPC oil pressure switches

PC300LC/HD-8 40-291
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NORMALLY
Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective travel PPC oil troubleshooting.
pressure switch P09 (male) Travel lever Resistance
1
(Internal disconnection or
short circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Forward or reverse Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP03 (female) (39)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– J01 – P09 (female) (2)
defective contact in
connector) Wiring harness between P09 (female) (1) –
Resistance Max. 1 Ω
J05 – chassis ground
Possible causes
and standard ★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
value in normal harness
state 3 Wiring harness of CP03 (female) (39) – J01
(Short circuit with GND
circuit) – P09 (female) (2), – M14 (female) (2) and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
4
24V circuit) in wiring harness Wiring harness of CP03 (female) (39) – J01
– P09 (female) (2), – M14 (female) (2) and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP03 Travel lever Voltage
Between (39) – Neutral 20 – 30 V
chassis ground Forward or reverse Max. 1 V

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Circuit diagram related to travel PPC oil pressure switch and travel alarm

PC300LC/HD-8 40-293
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-26
MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL DIFFERENTIAL
PRESSURE” NORMALLY
Trouble • Travel differential pressure is not displayed normally by machine monitoring function (Special functions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left travel
Related
PPC circuits (during steering).
information
• Monitoring code: 01901 (Output Switch 2)

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective travel steering troubleshooting.
PPC oil pressure switch P10 (male) Travel lever Resistance
1
(Internal disconnection or
short circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Left or right only Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between CP02 (female) (16)
2 (Disconnection in wiring or Resistance Max. 1 Ω
– P10 (female) (2)
defective contact in
connector) Wiring harness between P10 (female) (1) –
Possible causes Resistance Max. 1 Ω
J05 – chassis ground
and standard
value in normal Ground fault in wiring ★ Prepare with starting switch OFF, then carry out troubleshooting
state harness without turning starting switch ON.
3
(Short circuit with GND Wiring harness between CP02 (female) (16)
circuit) Resistance Min. 1 MΩ
– P10 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CP02 (female) (16)
Voltage Max. 1 V
– P10 (female) (2) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective pump controller CP02 Travel lever Voltage
Between (16) – Neutral 20 – 30 V
chassis ground Left or right only Max. 1 V

40-294 PC300LC/HD-8
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Circuit diagram related to travel steering PPC oil pressure switch

PC300LC/HD-8 40-295
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-27 MONITORING FUNCTION FAILS TO DISPLAY “SERVICE” NORMALLY
Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01901 (Output Switch 2)
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with starting switch OFF, then start engine and carry out
Defective service (front) PPC troubleshooting.
oil pressure switch S10 (male) Service pedal Resistance
1
(Internal disconnection or
short circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Front Max. 1 Ω
★ Prepare with starting switch OFF, then start engine and carry out
Defective service (rear) PPC troubleshooting.
oil pressure switch S11(male) Service pedal Resistance
2
(Internal disconnection or
short circuit) Neutral Min. 1 MΩ
Between (1) – (2)
Rear Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring Wiring harness between CP02 (female) (35)
harness Resistance Max. 1 Ω
– S10 (female) (2), – S11 (female) (2)
Possible causes 3 (Disconnection in wiring or
Wiring harness between S10 (female) (1) –
and standard defective contact in Resistance Max. 1 Ω
connector) chassis ground
value in normal
Wiring harness between S11 (female) (1) –
state Resistance Max. 1 Ω
chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness
4 Wiring harness between CP02 (female) (35)
(Short circuit with GND
circuit) – S10 (female) (2), – S11 (female) (2) and Resistance Min. 1 MΩ
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
5
24V circuit) in wiring harness Wiring harness between CP02 (female) (35)
– S10 (female) (2), – S11 (female) (2) and Voltage Max. 1 V
chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
6 Defective pump controller CP02 Service pedal Voltage
Between (35) – Neutral 20 – 30 V
chassis ground Front or rear Max. 1 V

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Circuit diagram related to service PPC oil pressure switch

PC300LC/HD-8 40-297
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
Trouble • KOMTRAX system does not operate normally.
• If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry
Related
out following troubleshooting.
information
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.

Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch OFF, then carry out troubleshooting.
LED (1) Normal state
LED-A1 Lighted up

1 Defective power supply ★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
G01 Signal Voltage
Between (39), (40) –
Constant power supply 20 – 30 V
(37), (38)
★ Turn starting switch ON and carry out troubleshooting.
2 Defective GPS LED (2) Normal state
LED-A2 Lighted up
★ Start engine and carry out troubleshooting.
LED (6) Normal state
LED-C1 Lighted up

Defective starting switch

★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
3 ACC signal and alternator R
Possible causes signal G01 Signal Voltage
and standard
value in normal Between (36) –
Starting switch ACC 20 – 30 V
state (37), (38)
Between (28) –
Alternator R 20 – 30 V
(37), (38)
★ Turn starting switch ON and carry out troubleshooting.
LED (8) Normal state
LED-C3 Lighted up

Defective S-NET connection

★ Prepare with starting switch OFF, then turn starting switch ON and
4 carry out troubleshooting.
and starting switch C signal
G01 Signal Voltage
Between (10) – (9) S-NET 6–9V
Between (27) –
Starting switch C Max. 1 V
(37), (38)
★ Turn starting switch ON and carry out troubleshooting.
LED (9) Normal state
LED-C4 Lighted up
5 State of CAN connection
★ Prepare with starting switch OFF and carry out troubleshooting.
G01 Signal Resistance
Between (7) – (8) CAN 40 – 80 Ω

40-298 PC300LC/HD-8
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Cause Standard value in normal state/Remarks on troubleshooting

★ Turn starting switch ON and carry out troubleshooting.
Number of mails not
6 LED (12) Normal state
transmitted yet
Possible causes 7-segment 0–9
and standard ★ Turn starting switch ON and carry out troubleshooting (See *)
value in normal
state LED (13) Normal state

7 State of positioning with GPS Dot ON

* In an outdoor location within radio waves' penetration range, it
sometimes takes more than a minute from turning on of the starting switch
to completion of the positioning.

LED display unit

G01 connector

PC300LC/HD-8 40-299
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-29 AIR CONDITIONER DOES NOT OPERATE
Trouble • Air conditioner does not start.
Related • For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance stan-
information dard, “Air conditioner system.”

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 11 If fuse is burnt, circuit probably has ground fault.

Defective A/C Hi/Lo pressure ★ Prepare with starting switch OFF, then carry out troubleshooting with-
switch out turning starting switch ON.
2
(Internal disconnection or P17 (male) Resistance
defective contact) Between (1) – (2) Max. 1 Ω
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01-11 outlet – M26
Disconnection in wiring Resistance Max. 1 Ω
(male) (5)
harness
Wiring harness between M26 (male) (12) –
3 (Disconnection in wiring or Resistance Max. 1 Ω
P17 (female) (1)
Possible causes defective contact in
connector) Wiring harness between M26 (male) (8) –
and standard Resistance Max. 1 Ω
value in normal chassis ground
state Wiring harness between P17 (female) (2) –
Resistance Max. 1 Ω
J04 – A07 – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness Wiring harness between F01-11 outlet – M26
4 Resistance Min. 1 MΩ
(Short circuit with GND (male) (5) and chassis ground
circuit) Wiring harness between M26 (male) (12) –
Resistance Min. 1 MΩ
P17 (female) (1) and chassis ground
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (5) – (8) 20 – 30 V

40-300 PC300LC/HD-8
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Circuit diagram related to air conditioner

PC300LC/HD-8 40-301
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING
• Alarm does not sound during travel.
Trouble
• Alarm sounds in stopped state.
Related
—
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 15 If fuse is burnt out, the circuit probably has ground fault.
★ In the case monitoring is not normally indicated, proceed to
troubleshooting No. E-21.
Monitoring code Item Normal display
2 Defective travel signal Operation of lever: ON
019 Travel
Lever in neutral: OFF
When the monitoring display is not correct, proceed to diagnosis for
“'Travel is not normally indicated' in the monitoring function”
★ Prepare with starting switch OFF, then start engine and carry out
troubleshooting (insert T-adapter).

Defective travel alarm M14 Travel lever Voltage

3 (Internal disconnection or Neutral Max. 1 V
Possible causes Between (1) – (2)
short circuit)
and standard Operated 20 – 30 V
value in normal If above voltage is normal and travel alarm does not sound, travel alarm is
state defective.
★ Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring without turning starting switch ON.
harness
Wiring harness between F01-15 outlet – J03
4 (Disconnection in wiring or Resistance Max. 1 Ω
– A07 – M14 (female) (1)
defective contact in
connector) Wiring harness between M14 (female) (2) –
Resistance Max. 1 Ω
J01 (19)
★ Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring without turning starting switch ON.
harness
5 Wiring harness between F01-15 outlet – J03
(Short circuit with GND
circuit) – A07 – M14 (female) (1) and chassis Resistance Min. 1 MΩ
ground
Since trouble is in system, troubleshooting cannot be carried out. (If
6 Defective pump controller
causes 1 – 5 above are not detected, travel alarm may be defective.)

40-302 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to travel PPC oil pressure switch and travel alarm

PC300LC/HD-8 40-303
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
E-31 HORN DOES NOT SOUND
Trouble Horn does not sound
Related
information

Cause Standard value in normal state/Remarks on troubleshooting

1 Defective fuse No. 5 If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay If the horn sounds after replacing the relay, the relay was defective
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between M07 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
3 Defective high tone horn
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between M07 (female) (1) – chassis ground Resistance Max. 1 Ω
If above is normal, the horn is defective
★ Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Between M08 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
4 Defective low tone horn
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Possible causes Between M08 (female) (1) – chassis ground Resistance Max. 1 Ω
and standard If above is normal, the horn is defective
value in normal
state
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01 (5) – S10
Disconnection in wiring Resistance Max. 1 Ω
(female) – R08 (female) (3)
harness
Wiring harness between S10 (female) (2) –
5 (Disconnection in wiring or Resistance Max. 1 Ω
R08 (female) – A07 – M07 (female) (2)
defective contact in
connector) Wiring harness between R08 (female) (5) –
Resistance Max. 1 Ω
A07 – M08 (female) (2)
Wiring harness between R08 (female) (2) –
Resistance Max. 1 Ω
J04 (male) (18) – A07 – chassis ground
★ Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between F01 (5) – S10
Ground fault in wiring (female) – R08 (female) (3) and chassis Resistance Min. 1 MΩ
harness ground
6
(Short circuit with GND Wiring harness between S10 (female) (2) –
circuit) R08 (female) – A07 – M07 (female) (2) and Resistance Min. 1 MΩ
chassis ground
Wiring harness between R08 (female) (5) –
Resistance Min. 1 MΩ
A07 – M08 (female) (2) and chassis ground

40-304 PC300LC/HD-8
TROUBLESHOOTING E-MODE (ELECTRICAL SYSTEM)
12
Circuit diagram related to horn

PC300LC/HD-8 40-305
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM

40-306 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
★ This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference
material when troubleshooting the hydraulic and mechanical system.

PC300LC/HD-8 40-307
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
★ Troubleshooting table and related circuit diagram collectively carry the following information. Carry out troubleshooting
work after fully grasping their contents.
Failure
Phenomenon occurring on machine
phenomenon
Relative
Information on the failure occurred as well as the troubleshooting
information

Cause Standard value in normalcy and references for troubleshooting

2
Presumed Cause for presumed failure
cause and [Contents]
(The attached No. is for filing
standard value • The standard values in normalcy by which to judge “Good” or
3 and reference purpose only.
in normalcy “No Good” about presumed causes.
It does not stand for any
• References for making judgement of “good” or “No Good”
priority.)
4

40-308 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12

MEMORANDUM

PC300LC/HD-8 40-309
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING
SPEEDS ARE SLOW
Trouble • Speed or power of whole work equipment, travel, and swing is low
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
1 Malfunction of unload valve Control lever Unload pressure
3.9 ± 1.0 MPa
All lever in neutral
{40 ± 10 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Defective adjustment or Control lever Main relief pressure
2 malfunction of main relief 33.34 – 36.77 MPa
valve Arm IN
{340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief valve
may have malfunction or internal defect. Check main relief valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of self pressure
Possible causes 3 Control lever Control circuit basic pressure
reducing valve
and standard 2.83 – 3.43 MPa
All levers in neutral
value in normal {29 – 35 kg/cm2}
state
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Measured oil pressure Measurement condition Oil pressure ratio
Pump discharge
Defective adjustment or 1
4 pressure Swing lock: ON
malfunction of PC valve
PC valve output Arm IN relief
Approx. 3/5
pressure
If oil pressure does not become normal after adjustment, PC valve may
have malfunction or internal defect. Check PC valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
LS-EPC output
Travel speed Travel lever
5 Malfunction of LS-EPC valve pressure
Approx. 1.4 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Hi Lifting operation 0 MPa {0 kg/cm2}

40-310 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Oil pressure ratio

Measured oil pressure Travel with no load

All levers in neutral (Lever operated
Possible causes Defective adjustment or halfway)
6
and standard malfunction of LS valve Pump discharge
1
value in normal pressure
state Almost same pressure
LS valve output
Approx. 3/5
pressure
If oil pressure does not become normal after adjustment, LS valve may
have malfunction or internal defect. Check LS valve directly.
7 Malfunction of servo piston Servo piston may have malfunction. Check it directly.
If any cause above is detected, cause may be lowering of performance,
8 Defective piston pump
malfunction, or internal defect of piston pump.

PC300LC/HD-8 40-311
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS
Trouble • Engine speed lowers extremely or engine stalls.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Defective adjustment or Control lever Main relief pressure
1 malfunction of main relief 33.34 – 36.77 MPa
valve Arm IN
{340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief valve
may have malfunction or internal defect. Check main relief valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Measured oil pressure Measurement condition Oil pressure ratio
Pump discharge
Defective adjustment or 1
2 pressure Swing lock: ON
malfunction of PC valve
PC valve output Arm IN relief
Approx. 3/5
Possible causes pressure
and standard If oil pressure does not become normal after adjustment, PC valve may
value in normal have malfunction or internal defect. Check PC valve directly.
state
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Oil pressure ratio

Measured oil pressure Travel with no load

All lever in neutral (Lever operated
Defective adjustment or halfway)
3
malfunction of LS valve Pump discharge
1
pressure
Almost same pressure
LS valve output
Approx. 3/5
pressure
If oil pressure does not become normal after adjustment, LS valve may
have malfunction or internal defect. Check LS valve directly.
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check them
4
servo devices directly.
5 Malfunction of servo piston Servo piston may have malfunction. Check it directly.

40-312 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVE
Trouble • All work equipment, swing, and travel mechanism do not move.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of PPC lock Lock lever Solenoid output pressure
1
solenoid valve Lock 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Released
{29 – 35 kg/cm2}
Possible causes ★ Prepare with engine stopped, then run engine at high idle and carry
and standard out troubleshooting.
value in normal Malfunction of self pressure
2 Control lever Control circuit basic pressure
state reducing valve
2.83 – 3.43 MPa
All levers in neutral
{29 – 35 kg/cm2}
Piston pump may have malfunction or internal defect. Check it by
following method.
3 Defective piston pump
• Crank the engine with oil pressure measurement plug removed.
If oil flows out, the piston pump is normal.
Pump shaft may not revolve because of defect in damper. Check damper
4 Defective damper
directly.

H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP

Failure
• An abnormal noise is heard from around hydraulic pump.
phenomenon
Relative
information

Cause Standard value in normalcy and references for troubleshooting

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Presumed
cause and It is presumed that the cap of hydraulic tank is clogged, thereby causing
3 Hydraulic tank cap clogged
standard value negative pressure inside the tank. Make a visual check.
in normalcy It is presumed that the strainer in the hydraulic tank is clogged, thereby
4 Hydraulic tank strainer clogged
causing negative pressure in the suction circuit. Make a visual check.
The piston pump is suspected of an internal failure. Check the pump
5 Piston pump defective
itself.

PC300LC/HD-8 40-313
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-5 AUTO-DECELERATOR DOES NOT WORK
Trouble • Auto-decelerator does not operate.
• Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated. (Shuttle
Related
valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel circuit.)
information
• Set the working mode in P-mode before start.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
Possible causes out troubleshooting.
and standard
Malfunction of travel PPC Travel lever PPC valve output pressure
value in normal 1
state valve (shuttle valve) Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Operated
{Min. 28 kg/cm2}

H-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW

Trouble • Fine control performance or response is low.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
LS-EPC output
Travel speed Travel lever
1 Malfunction of LS-EPC valve pressure
Approx. 1.4 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Hi Lifting operation 0 MPa {0 kg/cm2}
2 Clogging of LS circuit orifice Orifice of LS circuit may be clogged. Check it directly.
Possible causes ★ Prepare with engine stopped, then run engine at high idle and carry
and standard out troubleshooting.
value in normal
Oil pressure ratio
state
Measured oil pressure Travel with no load
All levers in neutral (Lever operated
Defective adjustment or halfway)
3
malfunction of LS valve Pump discharge
1
pressure
Almost same pressure
LS valve output
Approx. 3/5
pressure
If oil pressure does not become normal after adjustment, LS valve may
have malfunction or internal defect. Check LS valve directly.
4 Malfunction of servo piston Servo piston may have malfunction. Check it directly.

40-314 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-7 BOOM MOVES SLOWLY OR LACKS POWER
Trouble • Speed or power of boom is low
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of right PPC valve Boom lever PPC valve output pressure
1
(boom circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Boom Raise or Boom Lower
{Min. 28 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of merge-divider Travel lever Solenoid output pressure
2
solenoid valve Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Either side operated
{29 – 35 kg/cm2}
Malfunction of merge-divider
3 Merge-divider valve (main/LS) may have malfunction. Check it directly.
valve (main/LS)
Malfunction of boom control Spool of boom control valve (Lo/Hi) may have malfunction. Check it
4
valve (spool) directly.
Malfunction of boom control
Possible causes Pressure compensation valve of boom control valve (Lo/Hi) may have
5 valve (pressure compensation
and standard malfunction. Check it directly.
valve)
value in normal
state Malfunction of boom control Regeneration valve of boom control valve (Lo) may have malfunction or
6
valve (regeneration valve) defective seal. Check it directly.
Malfunction of boom control Lock valve of boom control valve (Lo) may have malfunction. Check it
7
valve (lock valve) directly.
Malfunction of boom control Check valve of boom control valve (Hi) may have malfunction. Check it
8
valve (check valve) directly.
Malfunction or defective seal of Safety valve for lock valve may have malfunction or defective seal.
9
safety valve for lock valve Check it directly.
Malfunction or defective seal of
Suction valve of boom control valve (Lo) may have malfunction or
10 boom control valve (suction
defective seal. Check it directly.
valve)
Malfunction or defective seal of
Safety-suction valve of boom control valve (Lo) may have malfunction or
11 boom control valve
defective seal. Check it directly.
(safety-suction valve)
Malfunction of LS shuttle valve LS shuttle valve of left travel control valve, bucket control valve, or
12
(left travel, bucket, or service) service control valve may have malfunction. Check it directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
13 Defective boom cylinder
Boom lever Leakage from cylinder
Raise relief 20 cc/min

PC300LC/HD-8 40-315
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-8 ARM MOVES SLOWLY OR LACKS POWER
Trouble • Speed or power of arm is low
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of left PPC valve Arm lever PPC valve output pressure
1
(arm circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
IN or OUT
{Min. 28 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of merge-divider Travel lever Solenoid output pressure
2
solenoid valve Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Either side operated
{29 – 35 kg/cm2}
Malfunction of pump Pump merge-divider valve (main/LS) may have malfunction. Check it
3
merge-divider valve (main/LS) directly.
Possible causes Malfunction of arm control Spool of arm control valve (Lo/Hi) may have malfunction. Check it
and standard 4
valve (spool) directly.
value in normal
state Malfunction of arm control
Pressure compensation valve of arm control valve (Lo/Hi) may have
5 valve (pressure compensation
malfunction. Check it directly.
valve)
Malfunction of arm control Regeneration valve of arm control valve (Lo) may have malfunction or
6
valve (regeneration valve) defective seal. Check it directly.
Malfunction or defective seal of
Safety-suction valve of arm control valve (Lo/Hi) may have malfunction
7 arm control valve
or defective seal. Check it directly.
(safety-suction valve)
Malfunction of arm control Quick return valve of arm control valve (Hi) may have malfunction.
8
valve (quick return valve) Check it directly.
Malfunction of LS shuttle valve LS shuttle valve of right travel control valve, boom control valve, left
9 (right travel, boom, left travel, travel control valve, bucket control valve, or service control valve may
bucket, or service) have malfunction. Check it directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
10 Defective arm cylinder
Arm lever Leakage from cylinder
IN relief 20 cc/min

40-316 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-9 BUCKET MOVES SLOWLY OR LACKS POWER
Trouble • Speed or power of bucket is low
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of right PPC valve Bucket lever PPC valve output pressure
1
(bucket circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
CURL or DUMP
{Min. 28 kg/cm2}
Malfunction of bucket control
2 Spool of bucket control valve may have malfunction. Check it directly.
valve (spool)
Possible causes
and standard Malfunction of bucket control
Pressure compensation valve of bucket control valve may have
value in normal 3 valve (pressure compensation
malfunction. Check it directly.
state valve)
Malfunction or defective seal of
Safety-suction valve of bucket control valve may have malfunction or
4 bucket control valve
defective seal. Check it directly.
(safety-suction valve)
Malfunction of LS shuttle valve LS shuttle valve of service control valve may have malfunction. Check it
5
(service) directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
6 Defective bucket cylinder
Bucket lever Leakage from cylinder
CURL relief 20 cc/min

H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION

• Boom does not move singly.
Trouble • Arm does not move singly.
• Bucket does not move singly.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes Work equipment lever PPC valve output pressure
and standard 1 Malfunction of PPC valve
value in normal Neutral 0 MPa {0 kg/cm2}
state Min. 2.7 MPa
Operated
{Min. 28 kg/cm2}
Malfunction of control valve
2 Spool of control valve may have malfunction. Check it directly.
(spool)

PC300LC/HD-8 40-317
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT
Trouble (1) • Hydraulic drift of boom is large.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes 1 Defective boom cylinder
Boom lever Leakage from cylinder
and standard
value in normal RAISE relief 20 cc/min
state Defective seal of boom control Seal of lock valve of boom control valve (Lo) may be defective. Check it
2
valve (lock valve) directly.
Defective seal of safety valve
3 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve

Trouble (2) • Hydraulic drift of arm is large.

Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
1 Defective arm cylinder
Arm lever Leakage from cylinder
IN relief 20 cc/min
Seal of safety-suction valve of arm control valve (Lo/Hi) may be
Possible causes defective. Check it directly.
and standard
2
Defective seal of arm control ★ This safety-suction valve may be checked by replacing it with
value in normal valve (safety-suction valve) another one and seeing change of condition. (However, do not use
state
a safety-suction valve for lowering the boom or lock valve for this
purpose because its set pressure is different.)
Defective seal of arm control Seal of spool of arm control valve (Lo/Hi) may be defective. Check it
3
valve (spool) directly.
Defective seal of arm control
Seal of pressure compensation valve of arm control valve (Lo/Hi) may
4 valve (pressure compensation
be defective. Check it directly.
valve)

40-318 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12

Trouble (3) • Hydraulic drift of bucket is large.

Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
1 Defective bucket cylinder
Bucket lever Leakage from cylinder
CURL relief 20 cc/min
★ Seal of safety-suction valve of bucket control valve may defective.
Possible causes
Check it directly.
and standard Defective seal of bucket
This safety-suction valve may be checked by replacing it with
value in normal 2 control valve (safety-suction
another one and seeing change of condition. (However, do not use
state valve)
a safety-suction valve for lowering the boom or lock valve for this
purpose because its set pressure is different.)
Defective seal of bucket
3 Seal of bucket control valve spool may be defective. Check it directly.
control valve (spool)
Defective seal of valve control
Seal of pressure compensation valve of bucket control valve may be
4 valve (pressure compensation
defective. Check it directly.
valve)

PC300LC/HD-8 40-319
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-12 WORK EQUIPMENT HAS BIG TIME LAG
Trouble Time lag of work equipment is large.
Related
Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
LS-EPC output
Travel speed Travel lever
1 Malfunction of LS-EPC valve pressure
Approx. 1.4 MPa
Lo Neutral
{Approx. 14 kg/cm2}

Possible causes Hi Lifting operation 0 MPa {0 kg/cm2}

and standard Malfunction of control valve
Regeneration valve of control valve may have malfunction. Check it
value in normal 2 (regeneration valve)
directly.
state [boom and arm only]
Safety-suction valve of control valve may have malfunction. Check it
directly.
3
Malfunction of control valve ★ The safety-suction valve of the arm or boom may be checked by
(safety-suction valve) replacing it with another one and seeing change of condition.
(However, do not use a safety-suction valve for lowering the boom
or lock valve for this purpose because its set pressure is different.)
Malfunction of control valve Pressure compensation valve of control valve may have malfunction.
4
(pressure compensation valve) Check it directly.

H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIR-

CUIT
Trouble • When part of work equipment is relieved singly, other parts of work equipment move
Related
• Set the working mode in P-mode before start.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective seal of control valve Seal of pressure compensation valve of control valve may be defective.
1
state (pressure compensation valve) Check it directly.

40-320 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-14 POWER MAX. SWITCH DOES NOT OPERATE
Trouble • The power maximizing function does not work.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes
and standard Malfunction of 2-stage relief Swing lock switch Solenoid output pressure
1
value in normal solenoid valve OFF 0 MPa {0 kg/cm2}
state
2.84 – 3.43 MPa
ON
{29 – 35 kg/cm2}
2 Malfunction of main relief valve Main relief valve may have malfunction. Check it directly.

H-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER

LOAD MOVES SLOWLY
Failure
• In a compound operation, work equipment with larger load tends to move slowly.
phenomenon
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

The pressure compensation valve for the work equipment with smaller
load is presumed to malfunction. Check the valve itself.
Combination of compound
Presumed Work equipment with larger load
operation
cause and stan- Malfunctioning of pressure
dard value in 1 compensation valve for work Boom RAISE + arm IN Boom RAISE
normalcy equipment with smaller load Boom RAISE + arm OUT Arm OUT
Boom RAISE + bucket CURL Boom RAISE
Arm OUT + bucket CURL Arm OUT
Boom LOWER + arm OUT Arm OUT

PC300LC/HD-8 40-321
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related
• If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
information

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Malfunction or defective seal LS selector valve may have malfunction or defective seal. Check it
1
state of LS selector valve directly.

H-17 IN SWING + TRAVEL OPERATION, TRAVEL SPEED DROPS SHARPLY

Failure
• In a compound operation of swing + travel, the travel speed drops sharply.
phenomenon
Relative
• If the travel speed is slow in the single operation of travel, carry out the H-19 check first.
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control
1
in normalcy valve (left travel and swing) valve is presumed to malfunction. Check the valves themselves.

40-322 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-18 MACHINE SWERVES IN TRAVEL
Trouble • Machine deviates during travel.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.7 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left Within 0.4 MPa
outputs {Within. 4 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of self pressure
2 Control lever Control circuit basic pressure
reducing valve
2.83 – 3.43 MPa
All levers at neutral
{29 – 35 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Oil pressure ratio

Measured oil pressure Travel with no load

Defective adjustment or All lever in neutral (Lever operated
3
malfunction of LS valve halfway)
Possible causes
and standard Pump discharge
1
value in normal pressure
state Almost same pressure
LS valve output
Approx. 3/5
pressure
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of travel junction Travel lever Solenoid output pressure
4
solenoid valve Either side operated 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Both sides operated
{29 – 35 kg/cm2}
Malfunction of travel junction
5 Travel junction valve may have malfunction. Check it directly.
valve
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
7 Defective travel motor
Travel lever Leakage from travel motor
Travel relief Max. 30 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive ★ It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.

PC300LC/HD-8 40-323
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-19 MACHINE TRAVELS SLOWLY
Trouble • Travel speed is low.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.7 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left/ Within 0.4 MPa
forward and reverse outputs {Within. 4 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of self pressure
2 Control lever Control circuit basic pressure
reducing valve
2.83 – 3.43 MPa
All levers at neutral
{29 – 35 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
LS-EPC output
Travel speed Travel lever
Possible causes 3 Malfunction of LS-EPC valve pressure
and standard Approx. 1.4 MPa
Lo Neutral
value in normal {Approx. 14 kg/cm2}
state
Hi Lifting operation 0 MPa {0 kg/cm2}
Malfunction of travel control
4 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of travel control valve may have
5 valve (pressure compensation
malfunction. Check it directly.
valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of LS shuttle valve LS shuttle valve of bucket control valve may have malfunction. Check it
7
(bucket) directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
8 Defective travel motor
Travel lever Leakage from travel motor
Travel relief Max. 30 l/min
Final drive may have internal defect. Check it directly.
9 Defective final drive ★ It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.

40-324 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER
Trouble • Machine is not steered well or steering power is low
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
PPC valve output pressure
Malfunction of travel PPC Travel lever
1 (steering)
valve (steering spool)
Both sides in neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Either side operated
{Min. 28 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of travel junction Travel lever Solenoid output pressure
2
solenoid valve Both sides operated 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Either side operated
{29 – 35 kg/cm2}
Malfunction of travel junction
3 Travel junction valve may have malfunction. Check it directly.
valve
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of merge-divider Travel lever Solenoid output pressure
4
solenoid valve Both sides in neutral 0 MPa {0 kg/cm2}
Possible causes 2.84 – 3.43 MPa
and standard Either side operated
{29 – 35 kg/cm2}
value in normal
state Malfunction of merge-divider
5 Merge-divider valve may have malfunction. Check it directly.
valve
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
Malfunction of travel control
Pressure compensation valve of travel control valve may have
7 valve (pressure compensation
malfunction. Check it directly.
valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
8
valve (suction valve) directly.
Malfunction of LS shuttle valve LS shuttle valve of bucket control valve may have malfunction. Check it
9
(bucket) directly.
Defective seal of check valve Seal of check valve of LS pressure sensing part may be defective.
10
of LS pressure sensing part Check it directly.
Seal of safety valve of travel motor may have malfunction. Check it
directly.
Malfunction of travel motor
11
(safety valve)
★ Motors of same type on forward and reverse sides or on right and
left sides may be checked by replacing them with each other and
seeing change of condition.
Seal of check valve of travel motor may have malfunction. Check it
directly.
Malfunction of travel motor
12
(check valve)
★ Motors of same type on forward and reverse sides or on right and
left sides may be checked by replacing them with each other and
seeing change of condition.

PC300LC/HD-8 40-325
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL

H-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST

Trouble • Travel speed does not change or travel speed is low or high
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Travel
Travel lever Monitoring [15]
speed
Lo Fine control 690 mA
Mi (such as releasing 740 mA
Hi decelerator) 0 mA
1 Malfunction of LS-EPC valve
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes Travel
Travel lever LS-EPC output pressure
and standard speed
value in normal Approx. 1.4 MPa
state Lo Neutral
{Approx. 14 kg/cm2}
Hi Lifting operation 0 MPa {0 kg/cm2}
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Travel
Malfunction of travel speed Travel lever Solenoid valve output pressure
2 speed
selector solenoid valve
Lo Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operated
{29 – 35 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may have malfunction. Check it
3
(speed shifting section) directly.

40-326 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)

Trouble • Travel system does not move (only one side).

Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

Defective seal of travel control Suction valve of travel control valve may have defective seal. Check it
1
valve (suction valve) directly.
Defective seal of travel motor
2 Safety valve of travel motor may have defective seal. Check it directly.
(safety valve)

Possible causes Defective seal of travel motor

3 Check valve of travel motor may have defective seal. Check it directly.
and standard (check valve)
value in normal ★ Prepare with engine stopped, then run engine at high idle and carry
state out troubleshooting.
Lowering of travel motor
4
output Travel lever Leakage from travel motor
Travel relief Max. 30 l/min
Final drive may have internal defect. Check it directly.
5 Defective final drive ★ It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.

PC300LC/HD-8 40-327
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-23 MACHINE DOES NOT SWING
Trouble (1) • Upper structure does not swing in either direction.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of swing holding Swing Solenoid valve
1
brake solenoid valve Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check it
2
(holding brake section) directly.
★ Prepare with engine stopped, then run engine at high idle and carry
Possible causes out troubleshooting.
and standard
value in normal Defective adjustment or Swing lock switch Swing lever Swing relief pressure
state 3 malfunction of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
{285 – 335 kg/cm2}
If oil pressure does not become normal after adjustment, safety valve
may have malfunction or internal defect. Check safety valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
4 Defective swing motor
Swing lever Leakage from swing motor
Swing relief Max. 11 l/min
Swing machinery may have internal defect. Check it directly.
5 Defective swing machinery ★ It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.

40-328 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12

Trouble (2) • Upper structure swings only in one direction.

Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of swing PPC Left lever PPC valve output pressure
1
valve Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Possible causes Swing
{Min. 28 kg/cm2}
and standard
value in normal Malfunction of swing control
2 Spool of swing control valve may have malfunction. Check it directly.
state valve (spool)
Seal of suction valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
3
(suction valve)
★ Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.
Seal of check valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
4
(check valve)
★ Check valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.

PC300LC/HD-8 40-329
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW
Trouble (1) • Swing acceleration or swing speed is low in both directions.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

Malfunction of LS shuttle valve LS shuttle valves of all control valves may have malfunction. Check
1
(all control valves) them directly.
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check it
2
(holding brake) directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes
and standard Defective adjustment or Swing lock switch Swing lever Swing relief pressure
value in normal 3 malfunction of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
state {285 – 335 kg/cm2}
If oil pressure does not become normal after adjustment, safety valve
may have malfunction or internal defect. Check safety valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
4 Defective swing motor
Swing lever Leakage from swing motor
Swing relief Max. 11 l/min

40-330 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12

Trouble (2) • Swing acceleration or swing speed is low in only one direction.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of swing PPC Swing lever PPC valve output pressure
1
valve Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Left or Right
{Min. 28 kg/cm2}
Possible causes Malfunction of swing control
and standard 2 Spool of swing control valve may have malfunction. Check it directly.
valve (spool)
value in normal
Malfunction of swing control
state Pressure compensation valve of swing control valve may have
3 valve (pressure compensation
malfunction. Check it directly.
valve)
Seal of suction valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
4
(suction valve)
★ Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.
Seal of check valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
5
(check valve)
★ Check valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.

PC300LC/HD-8 40-331
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING
Trouble (1) • Upper structure overruns remarkably when it stops swinging in both directions.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Defective adjustment or Swing lock switch Swing lever Swing relief pressure
1 malfunction of swing motor 27.95 – 32.85 MPa
Possible causes ON Swing relief
(safety valve) {285 – 335 kg/cm2}
and standard
value in normal If oil pressure does not become normal after adjustment, safety valve
state may have malfunction or internal defect. Check safety valve directly.
★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
2 Defective swing motor
Swing lever Leakage from swing motor
Swing relief Max. 11 l/min

Trouble (2) • Upper structure overruns remarkably when it stops swinging in only one direction.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Malfunction of swing PPC Swing lever PPC valve output pressure
1
valve Neutral 0 MPa {0 kg/cm2}
Min. 2.7 MPa
Left or Right
{Min. 28 kg/cm2}
Possible causes Swing PPC slow return valve may be clogged. Check it directly.
and standard Clogging of swing PPC slow
2
return valve
★ Slow return valves on right side and left side may be checked by
value in normal replacing them with each other and seeing change of condition.
state
Malfunction of swing control
3 Swing control valve spool may be malfunctioning. Check it directly.
valve (spool)
Seal of suction valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
4
(suction valve section)
★ Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.
Seal of check valve of swing motor may be defective. Check it directly.
Defective seal of swing motor
5
(check valve)
★ Check valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.

40-332 PC300LC/HD-8
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING
Trouble • Large shock is made when upper structure stops swinging.
Related infor-
• Set the working mode in P-mode before start.
mation

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes Malfunction of swing PPC Swing lever PPC valve output pressure
1
and standard valve Neutral 0 MPa {0 kg/cm2}
value in normal
Min. 2.7 MPa
state Left or Right
{Min. 28 kg/cm2}
Swing PPC slow return valve may have malfunction. Check it directly.
Malfunction of swing PPC slow
2
return valve
★ Slow return valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.

H-27 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWING-

ING
Trouble • Large sound is made when upper structure stops swinging.
Related
• Set the working mode in P-mode before start.
information

Cause Standard value in normal state/Remarks on troubleshooting

Malfunction of back pressure Back pressure valve of control valve may have malfunction. Check it
1
valve directly.
Malfunction of swing motor
Possible causes 2 Safety valve of swing motor may have malfunction. Check it directly.
(safety valve)
and standard
value in normal Suction valve of swing motor may have malfunction. Check it directly.
Malfunction of swing motor
state 3
(suction valve)
★ Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.
Swing machinery may have internal defect. Check it directly.
4 Defective swing machinery ★ It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.

PC300LC/HD-8 40-333
TROUBLESHOOTING H-MODE (HYDRAULIC AND MECHANICAL
12
H-28 SWING HYDRAULIC DRIFT IS TOO BIG
Trouble (1) • Hydraulic drift of swing is large (when swing holding brake is applied).
Related • When swing emergency reset switch is turned OFF (normal position), swing holding brake operates and
information upper structure is fixed with disc brake.

Cause Standard value in normal state/Remarks on troubleshooting

★ Prepare with engine stopped, then run engine at high idle and carry
out troubleshooting.
Possible causes Swing lever Solenoid valve output pressure
Malfunction of swing holding
and standard 1
brake solenoid valve Neutral 0 MPa {0 kg/cm2}
value in normal
state 2.84 – 3.43 MPa
Left or Right
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction or internal
2
(holding brake) defect. Check it directly.

Trouble (2) • Hydraulic drift of swing is large (when swing holding brake is released).
Related • When swing emergency reset switch is turned ON (in an emergency), swing holding brake is released and
information upper structure is secured by only hydraulic pressure.

Cause Standard value in normal state/Remarks on troubleshooting

Malfunction of swing control
1 Seal of spool of swing control valve may be defective. Check it directly.
valve (spool)
Malfunction of swing control
Seal of pressure compensation valve section of swing control valve may
Possible causes 2 valve (pressure compensation
be defective. Check it directly.
and standard valve)
value in normal Defective seal of swing motor
state 3 Seal of safety valve of swing motor may be defective. Check it directly.
(safety valve)
Defective seal of swing motor
4 Seal of suction valve of swing motor may be defective. Check it directly.
(suction valve)
Defective seal of swing motor
5 Seal of check valve of swing motor may be defective. Check it directly.
(check valve)

40-334 PC300LC/HD-8
 50 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5

SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
Striping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
Insertion Of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-17
Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
ENGINE AND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59

PC300LC/HD-8 50-1 B
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
REVOLVING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-72
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-76
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-79
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-88
Oil Seal In Hydraulic Pump Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-88
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-88
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-94
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-104
Cab Glass (Stuck Glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-105
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-106
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-107
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120

50-2 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
Floor Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-129
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133
Komtrax Communication Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-134
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-136
Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-138
Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140

PC300LC/HD-8 50-3 B
DISASSEMBLY AND ASSEMBLY
12

MEMORANDUM

50-4 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
1. Removal and installation of assemblies
Special tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.

A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.

B. Distinction of new and existing special tools

N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank: Tools already available for other models. They can be used without any modification.

C. Circle mark ❍ in sketch column:

The sketch of the special tool is presented in the section of "Sketches of special tools".
This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).

Removal

• The [Removal] section contains procedures and precautions for implementing the work, know how and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.

WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.

★ : Know-how or precautions for work

[*1] :This mark shows that there are instructions or precautions for installing parts.

This mark shows the amount of oil or coolant to be drained.

Weight of part or component.

Installation

• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• Marks shown in the Installation Section stand for the following.

WARNING! Precautions related to safety in execution of work.

PC300LC/HD-8 50-5 B
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
★ :This mark gives guidance or precautions when doing the procedure.

Type of coating material.

Tightening torque.

Quantity of oil or coolant to be added.

Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.

1. Disassembly and assembly of assemblies

Special tools
• Special tools which are deemed necessary for disassembly or assembly of parts are described as A1, ••• X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.

A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.

B. Distinction of new and existing special tools

N : Tools newly developed for this model. They respectively have a new part number.
R : Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank : Tools already available for other models. They can be used without any modification.

C. Circle mark ❍ in sketch column:

• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).
Disassembly

• In Disassembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity
of the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• The meanings of the symbols used in Disassembly section are as follows.

WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.

★ Know-how or precautions for work

Quantity of oil or coolant drained.

50-6 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
Assembly

• In Assembly section, the work procedures, precautions and know-how for carrying out those procedures, and quantity of
the oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2] ••• etc. and their part names, part numbers and
quantities are not described.
• The meanings of the symbols used in Assembly section are as follows.

WARNING! Precautions related to safety in execution of work.

★ : This mark gives guidance or precautions when doing the procedure.

Type of coating material.

Tightening torque.

Quantity of oil or coolant to be added.

Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.

PC300LC/HD-8 50-7 B
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12
SPECIAL TOOLS LIST
★ Tools with part number 79❍T-❍❍❍-❍❍❍❍ cannot be supplied (they are items to be locally manufactured).
★ Necessity:
■ ...........Cannot be substituted, must always be installed (used).
● ...........Extremely useful if available or can be substituted with commercially available part.
★ New/Remodel:
N...........Tools with new part numbers, newly developed for this model.
R:...........Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: ...Tools already available for other models, can be used without any modification.
★ Tools marked ❍ in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special
tools).

New/remodel
Necessity

Sketch
Q'ty
Component Symbol Part number Part name Nature of work, remarks

Removal of fuel supply pump

Fuel supply pump assembly 1 795-799-1390 Remover ● 1 assembly
A
Installation of engine front
Engine front seal 2 795-799-8120 Installer ● 1 seal
Removal of fuel inlet
1 795-799-8150 Remover ● 1 connector
Removal of fuel injector
Cylinder head assembly B 2 795-799-6700 Puller ■ 1 assembly
Tightening of cylinder head
3 760-331-1110 Wrench ● 1 bolt

Engine and hydraulic pump 796-460-1210 Oil stopper ● 1

C Stopping oil flow
assembly 796-770-1320 Adapter ● 1
Wrench
796-627-1610 assembly ■ 1

796-627-1620 • Wrench 1 Removal and installation of

1 nut
796-427-1140 • Pin 3

01314-20612 • Screw 3
796T-627-1630 Push tool ■ 1 ❍
790-101-2510 Block ■ 1

Final drive assemby D

791-830-1320 Rod ■ 2
01580-11613 Nut ■ 2
2 Installation of bearing
790-101-2570 Washer ■ 2
01643-31645 Washer ■ 2
790-105-2100 Jack assembly ■ 1
790-101-1102 Pump ■ 1
3 790-580-1510 Installer ■ 1 Installation of floating seal
Tightening of cover mounting
4 790-331-1110 Wrench ■ 1 bolt

50-8 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST

New/remodel
Necessity
Symbol

Sketch
Q'ty
Component Part number Part name Nature of work, remarks

1 796T-626-1110 Push tool ● 1 ❍ Press fitting of bearing

3 790-201-2480 Push tool ■ 1 Press fitting of bearing
790-101-5401 Push tool kit ● 1
Swing motor and swing E 790-101-5521 • Plate 1
machinery assembly 4 Press fitting of oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 793T-815-1110 Push tool ■ 1 ❍ Press fitting of bearing
1 791-430-3230 Installer ■ 1
Carrier roller assembly F
2 791-601-1000 Oil pump ■ 1
1 796-670-1010 Installer ■ 1
Track roller assembly G Oil refilling
2 791-601-1000 Oil pump ■ 1
1 796-570-1020 Installer ■ 1
Idler assembly H
2 791-601-1000 Oil pump ■ 1
791-685-8006 Compressor ■ 1
791-635-3160 Extension ■ 1
Disassembly and assembly of
1 Cylinder
790-101-1600 ■ 1 recoil spring assembly
(686 kN {70 t})

Recoil spring assembly J 790-101-1102 Pump ■ 1

790-201-1500 Plate tool kit ■ 1
790-201-1620 • Plate 1
2 Installation of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-630-3000 Remover & installer ■ 1
Cylinder
Track shoe assembly K 790-101-1300 (980 kN {100 t}) ■ 1 Pulling out master pin

790-101-1102 Pump ■ 1
790-101-2501 Push puller ■ 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Center swivel joint Disassembly and assembly of
L 790-101-2540 • Washer 1
assembly center swivel joint assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2

PC300LC/HD-8 50-9 B
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12

New/remodel
Necessity
Symbol

Sketch
Q'ty
Component Part number Part name Nature of work, remarks

796-946-1310 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1810 Guide
■ 1
(For 723-46-43100, 723-46-43400)
1
796-946-2110 Guide
■ 1
(For 723-46-44100)
796-946-2210 Guide
■ 1
(For 723-46-45100)
796-946-1320 Guide
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1820 Guide
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2120 Guide
2 ■ 1
Control valve (For 723-46-44100) Replacement of pressure
M
assembly 796-946-2220 Guide compensation valve seal
■ 1
(For 723-46-45100)
796-946-1420 Guide
■ 1
(For 723-46-42800)
796-946-1330 Sleeve
■ 1
(For 723-46-40100, 723-46-40601)
796-946-1830 Sleeve
■ 1
(For 723-46-43100, 723-46-43400)
796-946-2130 Sleeve
3 ■ 1
(For 723-46-44100)
796-946-2230 Sleeve
■ 1
(For 723-46-45100)
796-946-1430 Sleeve
■ 1
(For 723-46-42800)

50-10 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12

New/remodel
Necessity
Symbol

Sketch
Q'ty
Component Part number Part name Nature of work, remarks

Disassembly and assembly of

1 790-502-1003 Cylinder repair stand ■ 1 hydraulic cylinder assembly
790-102-4300 Wrench assembly ■ 1 Removal and installation of piston
2
790-102-4310 Pin ■ 2 assembly

3 790-720-1000 Expander ● 1
796-720-1680 Ring ● 1 Installation of bearing
4
07281-01589 Clamp ● 1
790-201-1702 Push tool kit ■ 1
Hydraulic Push tool
790-201-1851 1
cylinder N (for bucket and boom)
assembly 5 Press fitting of bushing
790-201-1861 Push tool (for arm) 1
790-101-5021 Grip 1
01010-50816 Bolt 1
790-201-1500 Push tool kit ■ 1
790-101-5021 Grip 1

6 01010-50816 Bolt 1 Press fitting of dust seal

Push tool
790-201-1660 1
(for boom and bucket)
790-201-1670 Plate (for arm) 1
796-670-1100 Remover ■ 1
796-670-1110 • Sleeve 1
796-670-1120 • Plate 1
796-670-1130 • Screw 1
Work equipment 791-775-1150 • Adapter 1
P Removal of foot pin
assembly
01643-33080 • Washer 1
01803-13034 • Nut 1
Puller
790-101-4000 (490 kN {50 t} long) ■
790-101-1102 Pump (294 kN {30 t}) ■ 1

Cab glass (stuck 2 793-498-1210 Lifter (Suction cup) ■ 2

X Installation of cab glass (stuck glass)
glass) 3 20Y-54-13180 Stopper rubber ■ 2

PC300LC/HD-8 50-11 B
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
12
SKETCHES OF SPECIAL TOOLS
Remark
Komatsu does not accept any responsibility for special tools manufactured according to these sketches.
D2. Push tool

E1. Push tool

50-12 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
E5. Push tool

PC300LC/HD-8 50-13 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.

Contact Terminal Removal (HD30 Type)

1. Obtain the correct removal tool according to the wire size used in
the connector.

2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.

Remark
Using a removal tool that is too large or too small will
hinder wire removal and may damage the connector or
removal tool. Always use the correct removal tool size for
the wire gauge you are servicing.

3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.

Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or
connector may result.

4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.

5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.

50-14 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Striping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table

Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)

0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)

0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)

Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the "Strip Length" above.

Wire Inspection

After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.

PC300LC/HD-8 50-15 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Crimping Contact Terminal (HD30 Type)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.

50-16 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Insertion Of Contact Terminal (HD30 Type)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.

2. Holding connector with rear grommet facing you.

3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.

4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.

5. For unused wire cavities, insert sealing plugs for full environmental
sealing.

PC300LC/HD-8 50-17 B
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
Contact Terminal Removal (DT Type)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.

2. Pull the wedge lock straight out and save for reinstallation.

3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.

4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.

50-18 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
ENGINE COMPONENTS
Remark
To remove, install, disassemble and assemble these various engine items you must refer to the ENGINE
SHOP MANUAL for the tool requirements and the proper procedures.

Cylinder Head

Engine Front Seal

Engine Rear Seal

Fuel Injector

Fuel Supply Pump

50-19 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR

Removal
1. Open the engine hood and sling the radiator temporarily.

2. Pull out pin (1).

3. Remove bolt (2).

4. Set hole (3) to the position of bolt (2) to fix the engine hood.

5. Remove the bottom cover of the radiator.

6. Drain the coolant.

Coolant: 36 L (9.5 gal)

7. Disconnect hose (4) from the bottom of the radiator. [*1]

8. Remove seal (5).

9. Disconnect hoses (6) – (9) from the top of the radiator. [*1]

10. Remove 2 mounting bolts (10).

PC300LC/HD-8 50-20 B
DISASSEMBLY AND ASSEMBLY RADIATOR
11. Lift off radiator assembly (11).

Radiator assembly: 30 kg (66 lb)

Installation
• Carry out installation in the reverse order to removal.
[*1]

Apply ThreeBond 4324 or equivalent to the adapters of hoses (4), (7), (8), and (9).

• Refilling with coolant

Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.

Coolant: 36 L (9.5 gal)

50-21 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
12
HYDRAULIC OIL COOLER

Removal

WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure.

1. Drain the hydraulic oil.

Hydraulic oil: 248 L (65.6 gal)

2. Remove the bottom cover of the hydraulic oil cooler.

3. Open the cover at the front of the hydraulic oil cooler.

4. Open the engine hood and sling the hydraulic oil cooler temporarily.

5. Remove the mounting bolts of cover (1) and move the cover down.

6. Pull out pin (2).

7. Set hole (3) to the position of bolt (4) to fix the engine hood.

8. Remove drain plug (5) from the bottom of the hydraulic oil cooler to
drain the oil from the piping.

9. Disconnect tube (6).

10. Remove seal (7).

PC300LC/HD-8 50-22 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
11. Disconnect tube (8) from the top of the hydraulic oil cooler.

12. Remove 2 mounting bolts (9).

13. Remove mounting bolts (10).

14. Remove 2 wing screws (11) from the screen.

15. Lift off hydraulic oil cooler assembly (12).

Hydraulic oil cooler assembly: 50 kg (111 lb)

Installation
• Carry out installation in the reverse order to removal.
• Refilling with oil
Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the
oil level again.

Hydraulic oil: 248 L (65.6 gal)

50-23 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
12
AFTERCOOLER

Removal
1. Open the front cover of the aftercooler.

2. Disconnect connector M06 (1).

3. Disconnect hose (2) and remove reservoir tank (3).

4. Disconnect hoses (4) and (5). [*1]

5. Remove 4 mounting bolts (6) and aftercooler assembly (7).

Installation
• Carry out installation in the reverse order to removal.
[*1]

Apply ThreeBond 2720F or equivalent to the adapters

of hoses (4) and (5).

PC300LC/HD-8 50-24 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12
ENGINE AND HYDRAULIC PUMP

Removal

WARNING! Disconnect the negative terminal (–) of the battery.

WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure.

★ Attach an identification tag to each piping to avoid a mistake in the

position of installation later.

1. Remove the hydraulic tank strainer and stop the flow of oil using
tool C.
★ When not using tool C, remove the drain plug to drain oil from
the hydraulic tank and piping.

Hydraulic tank: Approximately 248 L (65.6 gal)

2. Drain the engine coolant.

Coolant: Approximately 36 L (9.5 gal)

3. Open the engine hood.

4. Remove clamps (1) and (2), U-bolt (3), and air intake tube (4). [*1]

5. Remove air intake connector (5).

6. Remove belt cover (6) and fan guard (7).

7. Disconnect hoses (8), (9), and (10) from the top of the radiator. [*2]

50-25 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
8. Disconnect connector M34 (11).

9. Loosen bolt (12) and remove air conditioner compressor belt (13).
[*3]

10. Remove air conditioner compressor (14) and bracket together and
move them to a place where they will not obstruct work.

11. Disconnect terminal M23 (15).

12. Disconnect fuel hoses (16) and (17).

13. Disconnect the following connectors.

• CE02 (18)
• CE03 (19)
• P44 (20)
• E06/WIF (21)

14. Remove clamps (22) and (23).

15. Disconnect ground wire (24).

16. Remove clamp (25). [*4]

17. Loosen clamp (26) and remove tube (27) and hose together. [*5]

PC300LC/HD-8 50-26 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
18. Disconnect heater hoses (28) and (29).

19. Disconnect B-terminal M21 (30), R-terminal M18 (31), and

E-terminal M22 (32).

20. Disconnect B-terminal M20 (33) and connector M17 (34).

21. Remove the bottom cover of the radiator and disconnect hose (35).
[*6]

22. Open cover (36).

23. Remove the divider board between the engine and hydraulic pump.

24. Remove covers (37) – (40).

50-27 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
25. Disconnect hoses (41) and (42) from the engine oil filter.

26. Disconnect connectors V19 (43) and V11 (44).

27. Disconnect hoses (45) – (52).

28. Disconnect tube (53).

★ Prepare a container to receive hydraulic oil which will leak.

PC300LC/HD-8 50-28 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
29. Remove 4 engine mounting bolts (54).

30. Lift off engine and hydraulic pump assembly (55).

★ Check that all the wires and pipes between the chassis and the
engine and hydraulic pump assembly are disconnected.
★ While removing the assembly, take care that it will not interfere
with the chassis.

Engine and hydraulic pump assembly:

1,200 kg (2,646 lb)

50-29 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12
Installation
• Carry out installation in the reverse order to removal.
[*1]
★ Tighten the hose clamps before and after the air intake tube to the following torque.

Hose clamp: 9.8 ± 0.5 Nm (7.2 ± 0.36 lbf ft)

[*2] [*6]
★ Apply ThreeBond 4324 or equivalent to the adapter of the hose.
[*3]
★ Adjust the belt tension. For details, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt”.
[*4]
★ Tighten the clamp to the following torque.

Clamp: 7 ± 1.1 Nm (5.16 ± 52.4 lbf ft)

[*5]
★ Tighten the clamp according to the following procedure.

A. Set bridge (83) under band (84).

B. Tighten the bolt so that dimension (a) will be 8 – 10 mm.

Bolt to 16 - 17 Nm (11.8 - 12.5 lbf ft)

• Refilling with oil and coolant

Add oil and coolant through the oil filler and coolant filler to the
specified level respectively. Run the engine to circulate the oil and
coolant through the system. Then, check the oil and coolant levels
again.

Hydraulic oil: 248 L (65.5 gal)

Coolant: 36 L (9.5 gal)

PC300LC/HD-8 50-30 B
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
12

MEMORANDUM

50-31 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE

Removal
1. Remove the sprocket, referring to the "Removal and installation of
sprocket" section in this manual.

WARNING! Lower the work equipment safely to the

ground. Stop the engine and loosen the
oil filler cap on the hydraulic tank to
release pressure inside.

2. Remove cover (1).

3. Disconnect drain hose (2), travel speed shifting hose (3) and motor
hoses (4) and (5).

4. Remove 21 mounting bolts and then lift off final drive assembly (6).
[*1]
★ Be careful so that the nipple sealing surface on the hose
mounting block may not be damaged.
★ When lifting off the final drive assembly, do not use a tapped
hole for lifting the cover.

Final drive assembly: 500 kg (1,103 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]

Mounting bolt: 490 - 608 Nm (361.4 - 448.4 lbf ft)

• Refilling with oil

Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding
Refer to the "Bleeding air from various parts" section in the Testing and adjusting chapter of this manual.

PC300LC/HD-8 50-32 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
Disassembly
1. Oil draining
Remove drain plug and drain oil from final drive case.

Final drive case: 8.5 L (2.25 gal)

2. Cover

A. Remove the mounting bolts.

Then, using forcing screws [1], separate cover (1) from the case.

B. Remove cover (1) using eyebolt [2].

3. Spacer
Remove spacer (2).

4. No.1 carrier assembly

A. Remove No.1 carrier assembly (3).

50-33 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
B. Disassemble No. 1 carrier assembly as follows.

i. Insert pin (4) and drive shaft (5) out of carrier (6).
★ After removing the shaft, remove pin (4).

ii. Remove thrust washer (7), gear (8), bearing (9), and thrust
washer (10).

5. No.1 sun gear shaft

Remove No. 1 sun gear shaft (11).

6. No.2 sun gear shaft

Remove No. 2 sun gear shaft (12).

7. Thrust washer
Remove thrust washer (13).

8. Ring gear
Remove ring gear (14) using eyebolt [3].

PC300LC/HD-8 50-34 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
9. No.2 carrier assembly

A. Remove No.2 carrier assembly (15).

B. Disassemble No. 2 carrier assembly as follows.

i. Insert pin (16) and drive shaft (17) out of carrier (18).
★ After removing the shaft, remove pin (16).

ii. Remove thrust washer (19), gear (20), bearing (21), and
thrust washer (22).

10. Nut

A. Remove lock plate (23).

B. Use tool D1 to remove nut (24).

50-35 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
11. Hub assembly

A. Using eyebolts [4], remove hub assembly (25) from travel

motor.

B. Disassemble the hub assembly as follows.

i. Remove floating seal (26).

ii. Remove bearings (27) and (28) from hub (29).

C. Remove floating seal (30) from travel motor (31).

PC300LC/HD-8 50-36 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
Assembly
★ Clean all parts and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before installing.

1. Hub assembly

A. Using the push tool, press-fit bearings (27) and (28) to hub (29).

B. Use tool D3 to install floating seal (26).

★ Remove all oil and grease from the O-ring and O-ring
contact surface and dry up these sections before installing
the floating seal.
★ After installing the floating seal, check that the angle of the
floating seal is within 1 mm.
★ After installing the floating seal, coat the sliding surface
thinly with engine oil (EO30).

C. Using tool D3, install floating seal (30) onto travel motor (31).
★ The procedure for installation is the same as in Step 2)
above.

D. Using eyebolts [4], set hub assembly (25) onto the travel motor.
Then tap the bearing using the push tool to press-fit it.

50-37 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
2. Nut

A. Install nut as follows.

i. Use tool D2 to press the inner lace of bearing (27).

Pressing force . . . . . . . . . . . . . . . . . 12.7 - 16.7 kN {1.3 - 1.7 ton}
★ Rotate the hub 2 - 3 turns before pressing the bearing
inner race.

ii. Under the above condition, measure dimension (a).

iii. Measure thickness (b) off the independent nut (24).

iv. Determine Calculate a - b = c

v. Using tool D1, tighten nut (24) until dimension (d) becomes
the value of (c) calculated above.

vi. Using push-pull scale [5], measure tangential force of the

hub to the motor case in the rotation direction.
Tangential force:. . . . . . . . . . . . . . . . . . . . . . . Max. 490 N {50 kg}
★ The tangential force denotes the maximum force at start
of the rotation.

PC300LC/HD-8 50-38 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
vii. Install lock plate (23).

★ When installing the lock plate, avoid notch (j) of the

travel motor and fit it to the spline totally (under the
condition of (k))

Thread of mounting bolt: Adhesive (LT-2)

Mounting bolt: 49 - 74 Nm (36.1 - 54.5 lbf ft)

★ Do not apply the adhesive (LT-2) to the tapped portion

of the nut.

3. No.2 carrier assembly.

A. Assemble No. 2 carrier assembly as follows.

★ Replace thrust washers (19) and (22) as well as pin (16)
with new ones.
★ There are traces of expansion on the end surface of carrier
side hole (e) which were originally caused when the pin
was inserted. Make such the end surfaces are smooth
enough before reassembly.

i. Assemble bearing (21) to gear (20), fit top and bottom

thrust washers (19) and (22) and then set the gear
assembly on carrier (18).

ii. Align the position of pin holes on the shaft and carrier, then
tap with a plastic hammer to install shaft (17).
★ Install the shaft, rotating the planetary gear. Take care so
that thrust washer is not damaged.

iii. Insert pin (16).

★ When inserting the pin, take care that the 3 claws (parts
(f)) on the periphery of the pin will not be placed on the
thin parts of the carrier (parts (g)).
Since the thin parts may be on the opposite side,
confirm them on each carrier.
If there is a groove, avoid placing the claws on that
groove.

50-39 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
★ After inserting the pin, caulk the pin portion of the
carrier.
★ After assembling the carrier assembly, check that gear
(20) rotates smoothly.

B. Install No.2 carrier assembly (15).

★ Align the position so that the 3 tips of the gear shafts of
carrier assembly (15) enter the 3 hollows in the end face of
the motor case, then install.

4. Ring gear
Fit the O-ring to the hub. Using eyebolts [3], sling ring gear (14) and
install it to the hub, matching their bolt holes to each other.
★ Remove all grease and oil from the mating surface of the ring
gear and hub.
★ Do not put any gasket sealant on the mating surface of the ring
gear and hub under any circumstances.

5. Thrust washer.
Install thrust washer (13).

6. No.2 sun gear.

Install No. 2 sun gear (12).

PC300LC/HD-8 50-40 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7. No.1 carrier assembly.

A. Assemble No. 1 carrier assembly as follows.

★ Replace thrust washers (7) and (10) as well as pin (4) with
new ones (For pin (4), see the next page).
★ There are remains of staking when the pin is inserted at the
end face of hole (h) at the side of the carrier. Remove the
staked metal from the inside diameter of the hole before
starting to assemble.

i. Assemble bearing (9) to gear (8), fit top and bottom thrust
washers (7) and (10) and then set the gear assembly on
carrier (6).

ii. Align the position of pin holes on the shaft and carrier, then tap with a plastic hammer to install shaft (5).
★ Install the shaft, rotating the planetary gear. Take care so that thrust washer is not damaged.

iii. Insert pin (4).

★ When inserting the pin, take care that the 3 claws (parts
(f)) on the periphery of the pin will not be placed on the
thin parts of the carrier (parts (g)). Since the thin parts
may be on the opposite side, confirm them on each
carrier. If there is a groove, avoid placing the claws on
that groove.

★ After inserting the pin, stake the pin portion of the

carrier.
★ After assembling the carrier assembly, check that gear
(8) rotates smoothly.

B. Install No.2 carrier assembly (3).

50-41 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
8. No.1 sun gear shaft.
Assemble No. 1 sun gear shaft (11).

9. Spacer.
Install spacer (2).
★ After installing the spacer, measure the dimension (i). If the
dimension (i) is 15 mm or greater, the assembly is not done
correctly. Check the assembly procedure again.

10. Cover.

A. Using eyebolts [2], install cover (1).

Cover mounting surface: Gasket sealant (LG-6)

PC300LC/HD-8 50-42 B
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
B. Tighten the mounting bolts according to the following
procedure.

Mounting bolt: 1st step : 98 Nm (72.2 lbf ft)

2nd step: Using tool D4, retighten each mounting bolt
by 100 - 110°.

★ If tool D4 is not available, make a match mark on the cover

and the bolt with paint and then tighten the bolt by 100 -
110°.

11. Refilling with oil.

Tighten the drain plug and fill engine oil through oil filler.

Final drive case: 12 L (3.17 gal)

★ Do a final check of the oil level at the determined position after installing the final drive assembly to the chassis.

50-43 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
SWING MOTOR AND SWING MACHINERY

Removal

WARNING! Release the remaining pressure in the

hydraulic circuit. For details, see Testing
and adjusting, "Release of remaining
pressure in hydraulic circuit".

WARNING! Lower the work equipment to the ground

for safety. After stopping the engine,
loosen the oil filler cap on the hydraulic
tank to release the residual pressure
inside the tank and move the work
equipment lock lever to the LOCK
position.

1. Disconnect 5 swing motor hoses (1) through (5).

• (1): Between the swing motor and control valve (port MA)
• (2): Between the swing motor and control valve (port MB)
• (3): Suction hose (port S)
• (4): Drain hose (port T)
• (5): Pilot hose for relieving swing brake (port B)

2. Disconnect arm cylinder hoses (6).

3. Remove the mounting bolts.

4. Tighten a forcing screw in position (a) shown in the following figure

to separate the swing motor and swing machinery assembly. [*1]

5. Lift and remove swing motor and swing machinery assembly (7).
★ When lifting off the swing motor and swing machinery
assembly for removal, do so slowly so that the hoses and other
parts may not be damaged.
★ Take care in the lift until you can pull out the pilot.

Swing motor and swing machinery assembly:

550 kg (1,212.5 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]

Mounting bolt: 824 - 1,030 Nm (608 - 759 lbf ft)

• Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting,
"Bleeding air from various parts".

PC300LC/HD-8 50-44 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
Disassembly
1. Oil drain.
Loosen the drain plug and drain oil from the swing machinery case.

Swing machinery: 13.4 L (3.53 gal)

2. Swing motor assembly.

A. Set the swing motor and swing machinery assembly on block

[1].

B. Remove the 6 mounting bolts to remove swing motor assembly (1).

3. No.1 sun gear.

Remove No. 1 sun gear shaft (2).

4. No.1 carrier assembly.

A. Remove No.1 carrier assembly (3).

B. Disassemble No. 1 carrier assembly as follows. Remove snap

ring (4) first, and then remove shaft (5), gear (6), bearing (7),
thrust washer (8) and plate (9).

50-45 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
5. Ring gear.
Remove the mounting bolts to remove ring gear (10).
Remove ring gear.

6. No.2 sun gear.

Remove No. 2 sun gear (11).

7. No.2 carrier assembly.

A. Remove mounting bolt (12) and No. 2 carrier assembly (13).

B. Disassemble No. 2 carrier assembly as follows.

i. Insert pin (14) and drive shaft (15) out of carrier (16).
★ After removing the shaft, remove pin (14).

ii. Remove thrust washer (17), gear (18), bearing (19), and
thrust washer (20).

iii. Remove plate (21).

PC300LC/HD-8 50-46 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
8. Shaft assembly.

A. Remove 12 mounting bolts (23).

B. Set the shaft and case assembly on the press and then, using
push tool [2], remove shaft assembly (24) from case assembly
(25).

C. Disassemble the shaft assembly as follows.

i. Using push tool [3], remove cover assembly (26) and

bearing (27) from shaft (28).

ii. Remove oil seal (29) from cover (30).

9. Bearing.
Using push tool, take bearing (31) out of case (32).

50-47 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
Assembly
★ Clean all related parts and check that there is no dust or damage on
the surface. Coat sliding surfaces with engine oil and then assemble
the parts.

1. Bearing.
Using push tool E3 [4], press fit bearing (27) to case (32).
★ Use a new bearing.
Press fitting force (Reference value):. . .0 - 26.4 kN (0 - 5,934 lbf)

2. Cover assembly.

A. Using push tool E4, press fit oil seal (29) to cover (30).
★ Use a new oil seal.
★ If push tool E4 is not available, use another push tool to
push the frame around the oil seal evenly.
★ Take care that oil seal (29) will not slant.

Periphery of oil seal: Gasket sealant (LG-6)

★ Make sure the (LG-6) does not get onto the oil seal lip and
shaft.

B. Install cover assembly (26) to case (32) and tighten mounting

bolts (23).
★ Match the oil passage of cover assembly (26) to hole (A) of
case (32).

Cover fitting face: Gasket sealant (LG-6)

★ Insure that gaskets sealant does not press into hole (A).

Mounting bolt: 59 - 74 Nm (43.5 - 54.5 lbf ft)

Oil seal lip: Grease (G2-LI)

3. Case assembly.

A. Reverse case assembly (25) and set it to shaft (28).

★ Be extremely careful not to damage the oil seal.

B. Using push tool E5 [5] and guide [7], press fit the bearing inner
race.
★ Be sure the bearing is centered and straight on the shaft then
first, using push tool E5 [5] , hit the bearing inner race with
a hammer so that the shaft will not fall, and then set it to the
press to press fit.
Press fitting force (Reference value):. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 110 kN (8,768 - 24,728 lbf)

PC300LC/HD-8 50-48 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Use guide [7] to prevent case assembly (25) from slanting.
★ Hit the flange of case assembly (25) frequently and lightly
to correct the lean of case assembly (25). In particular,
adjust the flange so that oil seal mating face (B) of the shaft
will be at the center oil seal (29).

C. Using push tool E1 [6], press fit bearing (31).

★ Use a new bearing.
★ Press the bearing inner race and outer race simultaneously.
Do not press only the inner race.
★ After press fitting the bearing, check that the case rotates
smoothly.
Press fitting force (Reference value):
Inner race side: . . . . . . . . . . . . . 15.3 - 43.2 kN (3,440 - 9,711 lbf)
Outer race side: . . . . . . . . . . . . . . . . . . .0 - 16.2 kN (0 - 3,641 lbf)

4. No.2 carrier assembly.

A. Assemble No. 2 carrier assembly as follows.

★ There are traces of expansion on the end surface of carrier
side hole (h) which were originally caused when the pin
was inserted. Make such the end surfaces are smooth
enough before reassembly.

i. Assemble plate (21) to carrier (16).

ii. Assemble bearing (19) to gear (18), fit top and bottom
thrust washers (17) and (20) and then set the gear assembly
on carrier (16).

50-49 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
12
iii. Match the pin hole of shaft (15) to that of the carrier and
install the shaft by hitting it lightly with a plastic hammer,
etc.
★ While rotating the planetary gear, install the shaft and
take care not to damage the thrust washer.

iv. Insert pin (14).

★ When inserting the pin, take care so that any of the 3
pawls on the circumference (Portion a) may not touch
the thin-walled portion on the carrier (Portion b). Take
care, however, that the thin walled portion can be on the
opposite side of the carrier, depending on actual individ-
ual items. Be sure that the pin pawl does not contact the
slender side of the carrier.

v. After inserting the pin, stake 2 places (h) around the pin.

vi. Check that all the gears rotate smoothly.

5. Set No. 2 carrier assembly (13) and tighten mounting bolt (12).

Thread of mounting bolt: Adhesive (LT-2)

Mounting bolt: 343 - 427 Nm (253 - 314 lbf ft)

6. No.2 sun gear.

Install No. 2 sun gear (11).

PC300LC/HD-8 50-50 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Install the No. 2 sun gear with press-fit plate (P) down.

7. Ring gear.
Install the O-ring to ring gear (10) using eyebolt attached to case
(29).
★ Degrease the mating faces of ring gear (10) and case (29).

★ Align the convex portion on the case flange (Portion c) and the
counter mark on the ring gear (Portion d) in the position
illustrated in the following figure, and then install it.

Final drive assembly mounting bolt:

245 - 309 Nm (181 - 227 lbf ft)

50-51 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
8. No.1 carrier assembly.

A. Assemble No. 1 carrier assembly as follows.

i. Press-fit shaft (5) into the carrier in the direction of the

arrow until the snap ring groove becomes visible.

ii. After installing snap ring (4), push it back from the opposite
side until it is fitted to face (P) of the carrier.
★ At this time, take care not to push back the snap ring too
much.

iii. Install plate (9).

iv. Install thrust washer (8), bearing (7), gear (6), and snap ring
(4).

B. Install No.1 carrier assembly (3).

9. No.1 sun gear assembly.

Assemble No. 1 sun gear (2).

PC300LC/HD-8 50-52 B
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
★ Install the No. 1 sun gear with press-fit plate (P) down.

10. Swing motor assembly.

A. Set swing machinery assembly (33) to block [1].

B. Install swing motor assembly (1).

C. Install ring gear (10) and swing motor assembly (1) to the
following positions.

Swing motor mounting face: Gasket sealant (LG-6)

Mounting bolt: 98 - 123 Nm (73 - 90 lbf ft)

11. Refilling with oil.

Tighten the drain plug and add oil through the oil filler to the specified level.

Swing machinery: 13.4 L (3.5 gal)

50-53 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
12
SWING CIRCLE

Removal
1. Disassemble the revolving frame assembly referring to the "Removal
and installation of revolving frame assembly" section in this manual.

2. Sling swing circle assembly (1) at 3 points and remove the mounting
bolt to remove the assembly. [*1]

Swing circle assembly: 500 kg (1,103 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]

Threads of swing circle mounting bolt: Adhesive (LT-2)

Swing circle mounting bolt:

926.7 ± 103 Nm (683.4 ± 75.9 lbf ft)

★ Set the soft zone S mark on the inside ring of the inner race facing
the right side as shown in the diagram. Then install to the track
frame.

Volume charged to grease bath: Grease (G2-LI) 33 L (8.71 gal)

PC300LC/HD-8 50-54 B
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
12
CARRIER ROLLER

Disassembly
★ Disassemble according to the following figure.
Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below.

• Floating seal.
★ Before installing floating seals (7) and (8), completely degrease
both contact surfaces of the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take care so that no dust
will stick to the contact surface of the floating seal.
★ After inserting the floating seal with tool F1, check that its slant
is less than 1 mm and its projection (a) is 5 - 7 mm.

• Carrier roller.
★ Check the amount of air leakage from the seal with tool F2 by
applying the standard pressure to the oil filler port.
★ Check that the gauge needle does not go down, when the
following standard pressure is applied for 10 seconds.
Standard pressure:. . . . . . . . . . . . . . . . . . . . . . 1 kg/cm2 (14.2 psi)

50-55 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
★ Fill the carrier roller assembly with oil, using tool F2, and then
tighten the plug.

Carrier roller: 145 - 155 cc (4.9 - 5.2 oz) (EO30)

PC300LC/HD-8 50-56 B
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
TRACK ROLLER

Disassembly
• Disassemble according to the following figure.
Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below.

• Floating seal.
★ Before installing floating seals (5) and (6), completely degrease
both contact surfaces of the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take care so that no dust
will stick to the contact surface of the floating seal.
★ After inserting the floating seal with tool F1, check that its slant
is less than 1 mm and its projection (a) is 5 - 7 mm.
• Mounting roller cover mounting bolt.

Track roller cover mounting bolt:

44.12 - 53.93 Nm (32.5 - 39.7 lbf ft)

50-57 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
• Track roller.
★ Check the amount of air leakage from the seal with tool G2 by
applying the standard pressure to the oil filler port.
★ Check that the gauge needle does not go down, when the
following standard pressure is applied for 10 seconds.
Standard pressure:. . . . . . . . . . . . . . . . . . . . . . 1 kg/cm2 (14.2 psi)

★ Fill the track roller assembly with oil, using tool G2, and tighten
the plug.

Track roller: 250 - 280 cc (8.45 - 9.46 oz) (EO30)

Plug: 10 - 20 Nm (7.3 - 14.7 lbf ft)

PC300LC/HD-8 50-58 B
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
12
IDLER ASSEMBLY

Disassembly

1. Remove dowel pin (1) to remove support (2).

2. Remove floating seal (3) from support (2) and idler (4).

3. Remove idler (4) from shaft (5) and support assembly (7).

Oil in the idler: 230 ± 10 cc (7.7 ± 0.33 oz.).

Drain it at this time or spread cloths to absorb it.

4. Remove floating seal (6) on the opposite side from idler (4), shaft (5)
and support assembly (7).

5. Remove dowel pin (8) to remove support (7) from shaft (5).

6. Remove bushings (9) and (10) from idler (4).

50-59 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
12
Assembly
1. Press fit bushings (9) and (10) to idler (4).

2. Fit O-ring and install support (7) to shaft (5) using dowel pin (8).

★ Be sure to assemble shaft (5) with the UP marking facing

upward.

3. Using tool H1, install floating seal (6) to idler (4), shaft (5) and
support (7) assembly.

★ Before installing the floating seal, completely degrease both

contact surfaces of the O-ring and the floating seal (hatched area
in the illustration). Furthermore, make sure there is no dust or
oil on contact surface of the floating seal.
★ After inserting the floating seal, check that inclination of the
seal is less than 1 mm and that protrusion (a) of the seal remains
within the range of 5 - 7 mm.

PC300LC/HD-8 50-60 B
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY

4. Assemble shaft (5) and support (7) assembly to idler (4).

5. Using tool H1, install floating seal (3) to idler (4), shaft (2) and
support (7) assembly.

★ Coat the sliding surface of the floating seal with oil, and be
careful not to let any dirt or dust get stuck to it.
★ Remove all grease and oil from the contact surfaces of the
O-ring and the floating seal.

50-61 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY
6. Install O-ring, then install support (2) using dowel pin (1).
★ Stake the pin of the support after insertion.

7. Using tool H2, fill the idler assembly with oil and tighten the plug.

Idler: 230 ± 10 cc (7.7 ± 0.33 oz) (EO30)

Plug: 130 - 180 Nm (95.8 - 132.7 lbf ft)

PC300LC/HD-8 50-62 B
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
RECOIL SPRING

Disassembly

1. Remove piston assembly (2) from recoil spring assembly (1).

2. Disassembly of recoil spring assembly.

A. Set recoil spring assembly (1) to tool. J1

WARNING! The spring is under large installed load,

so be very sure to set the tool properly.
Failure to do this is dangerous.

Installed load of spring: . . . . . . . . . . . . . . . 208.74 kN (46,926 lbf)

B. Apply hydraulic pressure gradually to remove lock plate (3)

then nut (4).
★ Compress the spring until the nut becomes loose.
★ Release the hydraulic pressure slowly and release the tension of the spring.
Free length of spring: . . . . . . . . . . . . . . . . . . .811.5 mm (31.94 in)

C. Remove yoke (6), cylinder (7), collar (8) and dust seal (9) from spring (5).

3. Disassembly of piston assembly.

A. Remove lock plate (11) from piston (10), then remove valve (12).

B. Remove snap ring (13), then remove U-packing (14) and ring (15).

50-63 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
12
Assembly

1. Disassembly of piston assembly.

A. Assemble ring (15) and U-packing (14) to piston (10) and secure
with snap ring (13).

B. Tighten valve (12) temporarily, and secure with lock plate (11).

2. Disassembly of recoil spring assembly.

A. Using tool J2, install dust seal (9) to cylinder (7).

B. Assemble cylinder (7), collar (8) and yoke (6) to spring (5), and
set it on tool J1.

Cylinder sliding part: Grease (G2-LI)

PC300LC/HD-8 50-64 B
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
C. Apply hydraulic pressure slowly to compress the spring, and
then tighten nut (4) so that the installed length of the spring is
dimension (a) and secure it with lock plate (3).
Installed length (a) of spring: . . . . . . . . . . . . . . 655 mm (25.78 in)

D. Remove recoil spring assembly (1) from tool J1.

3. Assemble piston assembly (2) to recoil spring assembly (1).

Sliding part of piston: Grease (G2-LI)

Wear ring: Grease (G2-LI)

★ Install the piston assembly so the valve position is on the outside.

★ Fill the inside of the cylinder with 180 cc (6.08 oz.) of grease (G2-LI), then bleed the air and check that grease comes
out of the grease hole.

50-65 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY SPROCKET
12
SPROCKET

Removal
1. Expand the track shoe assembly referencing “Expansion and installation of track shoe assembly”.

2. Swing work equipment 90°, push up chassis with work equipment

and place blocks [1] between track frame and track shoe.

3. Remove the mounting bolt and then lift off sprocket (1). [*1]

Sprocket: 65 kg (143.3 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]

Threads of sprocket mounting bolt: Adhesive (LT-2)

Sprocket mounting bolt: 640 - 785 Nm (472 - 578 lbf ft)

PC300LC/HD-8 50-66 B
DISASSEMBLY AND ASSEMBLY TRACK SHOE
12
TRACK SHOE

Expansion
1. Set the master pin position.
★ Start the engine and rotate tracks so the master pin position is on
the front side of the idler.
★ Set block [1] in front of the idler.

2. Lower the work equipment to the ground, and loosen lubricator (1)
in order to loosen track shoe tension. [*1]

WARNING! Inner pressure of the adjustment cylinder

is extremely high. Never loosen the
lubricator more than one turn. If the
grease does not come out, move the
machine backwards and forwards.

3. Remove track shoe (3) on master pin (2). [*2]

4. Use tool K and remove nut (2). [*3]

5. Drive the machine slowly in reverse to expand the track shoe.

Installation
• Installation is done in the reverse order of expansion.
[*1]
★ Refer to the “Checking and adjusting track shoe tension” section in
the Testing and adjusting chapter of this manual.
[*2]

Mounting bolt: Seizure prevention agent (Maruzen

Morimax No.2 or equivalent)

Mounting bolt: 393 ± 39 Nm (289 ± 28.7 lbf ft)

[*3]
★ Press-fit the master pin, using tool K in such that the master pin
protrusion becomes (a).
Master pin protrusion amount (a): . 4.2 ± 2 mm (0.165 ± 0.078 in)

50-67 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
12
REVOLVING FRAME

Removal

WARNING! Extend the arm and bucket fully, lower the

work equipment to the ground and then
move the work equipment lock lever to
the LOCK position.

1. Remove the work equipment assembly.

For details, see “Removal and installation of work equipment
assembly”.

2. Remove the counterweight assembly.

For details, see “Removal and installation of counterweight
assembly”.

3. Disconnect 4 boom cylinder hoses (1).

★ Plug the hose to stop oil flow-out.

4. Sling boom cylinder assembly (2).

5. Remove plate (3) and pin (4), and then lift boom cylinder assembly
(2) to remove.
★ Remove the boom cylinder assembly on the opposite side in the
same manner.

Boom cylinder assembly: 260 kg (573.2 lb)

6. Sling engine hood (5) temporarily.

★ When slinging the engine hood, take care not to damage the
rubber seal.

PC300LC/HD-8 50-68 B
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
7. Remove the engine hood mounting bolt and then remove pin (6).

8. Lift off work equipment assembly (5).

9. Remove plates (7) and (8).

10. Remove aftercooler tube (9).

★ When other parts can interfere with the lifting hook in removal
of the revolving frame, such parts must be removed beforehand.

11. Disconnect 8 hoses (12) through (18).

• (12): Center swivel joint (D port) – Swing motor (T port)
• (13): Center swivel joint (D port) – Hydraulic oil tank
• (14): Center swivel joint (E port) – Solenoid valve
• (15): Center swivel joint (B port) – Control valve LH travel (B2
port)
• (16): Center swivel joint (D port) – Control valve RH travel (B5
port)
• (17): Center swivel joint (A port) – Control valve LH travel (A2
port)
• (18): Center swivel joint (C port) – Control valve RH travel (A5
port)

12. Pull out pin (19) on the side of center swivel joint and remove the
jam plate from the center swivel joint.

13. Remove 40 mounting bolts and then lift off revolving frame
assembly (20). [*1]
★ Using the lever block, adjust fore and aft as well as right and left
balance of the revolving frame assembly, with only 2 mounting
bolts being left in the front and rear side of the assembly. After
the adjustment, remove the remaining two bolts.

WARNING! When removing the revolving frame

assembly, take care so that it does not hit
the swivel joint assembly.

Revolving frame assembly: 6,000 kg (13,228 lb)

50-69 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

Installation
• Installation is done in the reverse order of removal.
[*1]

Mating face of swing circle: Gasket sealant (LG-6)

Threads of revolving frame mounting bolt: Adhesive (LT-2)

Revolving frame mounting bolt: 926.7 ± 103 Nm (683.4 ± 75.9 lbf ft)

• Refilling with oil (Hydraulic tank)

Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding
Bleed air from the travel motor referencing the “Bleeding air from various parts” section in the Testing and adjusting
chapter of this manual.

PC300LC/HD-8 50-70 B
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
COUNTERWEIGHT

Removal
1. Remove the accessories on the counterweight according to the
following procedure.
(Mirror specification)

A. Remove mirror (1).

B. Sling counterweight assembly (2).

(1-rear camera specification)

A. Disconnect connector A40 (3) of camera 1 (RC1).

B. Disconnect connector CN-L09 (5) and wiring harness clamps

(6) from rear working lamp (4). (If equipped)

C. Sling counterweight assembly (2).

(2-rear camera specification)

A. Disconnect connector A40 (3) of camera 1 (RC1).

B. Disconnect connector CN-L09 (5) and wiring harness clamps

(6) from rear working lamp (4). (If equipped)

C. Remove cover (7).

D. Disconnect coaxial cable connector (8) of camera 2 (RC2).

2. Install eyebolt [1] to counterweight assembly (2), and sling.

3. Remove 4 mounting bolts (9). [*1]

★ Record the locations where the shims were used.

4. Lift off counterweight assembly (2) horizontally using wire or chain

block. [*2]
★ Be careful not to bump it against the engine or radiator or cooler
assembly.

Counterweight: 7,370 kg (16,249 lb)

50-71 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
Installation
• Install in reverse order of removal.
[*1]

Counterweight mounting bolt: 1,715 - 1,911 Nm (1,264.9 - 1,409.4 lbf ft)

[*2]
★ Installing and adjusting counterweight.

A. Adjust the level difference from the exterior part (vertical clearance) with the shim between the counterweight and
revolving frame.
Set shim thickness: . . . . . . . . . . . . . . . . . . . . . . .1.0 mm, 2.0 mm

B. Install counterweight in such a way that clearance between the door and counterweight as well as clearance between
the revolving frame and counterweight is 10 ± 5 mm.

PC300LC/HD-8 50-72 B
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
CENTER SWIVEL JOINT

Removal

WARNING! Release the remaining pressure in the

hydraulic circuit. For details, see Testing
and adjusting, “Releasing remaining
pressure in hydraulic circuit”.

★ Attach an identification tag to each piping to avoid a mistake in the

position of installation later.

1. Disconnect 8 hoses (1) through (8) of the travel motor center swivel
joint.
• (1): Center swivel joint (T port) – LH travel motor (T port)
• (2): Center swivel joint (T port) – RH travel motor (T port)
• (3): Center swivel joint (B port) – LH travel motor (PA port)
• (4): Center swivel joint (D port) – RH travel motor (PB port)
• (5): Center swivel joint (A port) – LH travel motor (PB port)
• (6): Center swivel joint (C port) – RH travel motor (PA port)
• (7): Center swivel joint (E port) – LH travel motor (P port)
• (8): Center swivel joint (E port) – RH travel motor (P port)

2. Disconnect 7 hoses (9) through (15).

• (9): Center swivel joint (D port) – Swing motor (T port)
• (10): Center swivel joint (D port) – Hydraulic oil tank
• (11): Center swivel joint (E port) – Solenoid valve
• (12): Center swivel joint (B port) – Control valve LH travel (B2 port)
• (13): Center swivel joint (D port) – Control valve RH travel (B5 port)
• (14): Center swivel joint (A port) – Control valve LH travel (A2 port)
• (15): Center swivel joint (C port) – Control valve RH travel (A5 port)

3. Pull out pin (16) on the side of center swivel joint and remove the jam plate from the center swivel joint.

4. Remove 4 mounting bolts (17).

50-73 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
5. Lift and remove center swivel joint assembly (18). [*1]

Center swivel joint assembly: 40 kg (89 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]
★ Install the center swivel joint assembly (18) with ports (B) and
(D) directed to the front of the machine (in the direction of the
arrow).
(Part (19) in the following figure is the sprocket.)
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level.
Let the oil circulate in the hydraulic system by starting the engine.
Then check the oil level again.
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic
cylinder. For details, see Testing and adjusting, “Bleeding air from
various parts”.

PC300LC/HD-8 50-74 B
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
Disassembly

1. Remove cover (1).

2. Remove snap ring (2).

3. Using tool L, pull out swivel rotor (4) and ring (3) from swivel shaft
(5).

4. Remove dust seal (6) from cover (7).

5. Remove O-ring (8) and slipper seal (9) from swivel rotor (4).

50-75 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
12
Assembly
1. Assemble slipper seal (9) and O-ring (8) to swivel rotor (4).

2. Install cover (7) to swivel shaft (5).

Inside of cover: Grease (G2-LI) (Apply 2 – 3 cc)

3. Install dust seal (6) to cover (7).

Lip of dust seal: Grease (G2-LI) (Apply 2 – 3 cc)

4. Set swivel shaft (5) to block, then using push tool, tap swivel rotor
(4) with a plastic hammer to install.

Contact surface of rotor and shaft: Grease (G2-LI)

★ When installing the rotor, take care not to damage the slipper
seal and the O-ring.

5. Install ring (3) and secure it with snap ring (2).

6. Fit O-ring and install cover (1).

Mounting bolt: 31.4 ± 2.9 Nm (23.1 ± 2.13 lbf ft)

PC300LC/HD-8 50-76 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK

Removal
1. Remove covers (1) and (2).

2. Drain oil from the hydraulic tank

Hydraulic tank: 248 L (65.5 gal)

3. Open the engine hood.

4. Remove control valve top cover (3).

5. Disconnect hoses (4), (5), (6) and (7).

6. Disconnect hoses (8) and (9).

50-77 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
7. Disconnect hoses (10), (11) and (12).

8. Remove 4 mounting bolts to remove suction tube (13).

9. Sling the hydraulic oil tank assembly and remove 6 mounting bolts
(14).

10. Lift and remove hydraulic oil tank assembly (15).

Hydraulic oil tank assembly: 200 kg (441 lb)

PC300LC/HD-8 50-78 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
Installation
• Installation is done in the reverse order of removal.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.

Hydraulic tank: 248 L (65.5 gal)

• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting,
“Bleeding air from various parts”.

50-79 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
CONTROL VALVE

Removal

WARNING! Lower the work equipment to the ground

for safety and stop the engine. Unscrew
the oil filler cap on the hydraulic tank
slowly to release pressure inside the tank.
Then move the work equipment lock lever
to the LOCK position.

★ Attach an identification tag to each piping to avoid a mistake in the

position of installation later.

1. Open up engine hood and remove top control valve cover (1).

2. Remove partition covers (3) and (4) provided between the engine
and control valve.

3. Disconnect 4 boom hoses (5).

4. Remove boom tube mounting clamps (6) and (7).

5. Remove plate (8).

PC300LC/HD-8 50-80 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
6. Disconnect 8 hoses and 8 tubes on the control valve.
• (9): TSW port hose (Swing motor S port)
• (10): T1 port hose (connected to the tank)
• (11): From the top:
A1 port tube (boom Hi bottom side)
A1 port tube (bucket bottom side),
A2 port hose (swivel joint A port)
A3 port tube (boom bottom side),
A4 port hose (swing motor MB port)
A5 port hose (swivel joint C port),
A6 port tube (arm head side)
• (12): From the top: B1 port tube (arm Hi bottom side)
A1 port tube (bucket head side)
A2 port hose (swivel joint B port)
B3 port tube (boom head side)
B4 port hose (swing motor MA port)
B5 port hose (swivel joint D port)
B6 port tube (arm bottom side)

7. Disconnect the 6 PPC hoses at right.

• (13): Bucket dump (Hose band: Black)
(14): LH forward (Hose band: Red)
(15): Boom (Hose band: Brown)
(16): Right swing
(17): RH forward (Hose band: Green)
(18): Arm digging (Hose band: Blue)

8. Disconnect 2 hoses and 8 tubes on the control valve.

• (19): Bucket dump (Hose band: Yellow -Blue)
• (20): PST port hose (Hose band: Brown)

9. Disconnect drain hoses (21).

50-81 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
10. Disconnect 7 left side PPC hoses and 5 control valve hoses.
• (22): PLS2 port hose (Hose band: Red)
• (23): PLS1 port hose
• (24): PLS2 port hose (Hose band: Blue)
• (25): From the top: Bucket digging (Hose band: White)
LH reverse
Boom RAISE (Hose band: Green)
Swing LS separator valve
BP5 port hose (to solenoid)
Left swing (Hose band: Red)
RH reverse (Hose band: Blue)
Arm dump (Hose band: Yellow)
• (26): PX2 port hose

11. Disconnect the 7 hoses and the wiring connectors (2 locations).

• (27): PPS1 port hose (Front pump)
• (28): PPS2 port hose (Rear pump)
• (29): PR port hose (Solenoid)
• (30): PR port hose (Pump)
• (31): PP1 port hose (Front pump)
• (32): PP2 port hose (Rear pump)
• (33): T port hose (Oil cooler)
• (34): A51 (Front pump pressure sensor)

• (35): A52 (Rear pump pressure sensor)

12. Remove the 3 mounting bolts, and then lift and remove control valve
assembly (36).

Control valve assembly: 250 kg (552 lb)

PC300LC/HD-8 50-82 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
Installation
• Installation is done in the reverse order of removal.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting, “
Bleeding air from various parts”.

Disassembly
★ This section deals with only precautions to be followed when reassembling the control valve assembly.

Assembly
Procedures for replacing pressure compensation valve seal

1. Remove the seal from the pressure compensation valve.

★ Clean the pressure compensation valve thoroughly, and then assemble the seal using the tool, as indicated in the
diagram.

2. Install the O-ring to piston (1).

3. Set tool M1 to piston (1) and push it in slowly by hand so that seal
(2) may spread out evenly.
★ The seal may be also fitted by pushing it down to the flat surface
of the tool and then pushing it in with the tool fitted to the
piston.

4. Likewise, set tool M2 to piston (1) in the same direction and push it
slowly by hand so that seal (3) may be spread out evenly.
★ The seal may be also fitted by pushing it down to the flat surface
of the tool and then pushing it in with the tool fitted to the
piston.

50-83 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
5. Set correction tool M3 to piston (1) for about one minute in order to
make seals (2) and (3) securely adhered to the piston.
★ Check that there is no protrusion or cut on the seal.

6. Assemble the piston in the sleeve.

★ If it is difficult to install the piston, do not push it in forcibly but
install it to correcting tool M3 again to fit the seal and then
install it to the sleeve.
★ After the installation, push the piston by hand and check that the
piston reacts only with spring force.

Assembly of control valve assembly

• Coat the sliding surface with engine oil and then reassemble the control valve assembly.
• Upper and lower control valve covers.

Mating face of the upper and lower control valve cover: Seal End 242 or equivalent

• Tighten the mounting bolts for the upper and lower control covers in
the sequence of A, D, C, B below.

Mounting bolt for the upper and lower control valve

covers: 156.9 - 176.5 Nm (115.7 - 130.1 lbf ft)

• The filter installed on the valve assembly should be assembled in the

direction shown in the following figure.
• Pump merge-divider valve.

Mating face of the merge-divider valve:

Seal End 242 or equivalent

• Tighten the mounting bolts for the merge divider valve in the same
sequence as that for the control valve cover mounting bolts.

Merge-divider valve mounting bolt:

156.9 - 176.5 Nm (115.7 - 130.1 lbf ft)

• Back pressure valve.

Back pressure valve mounting bolt: 58.8 - 73.8 Nm (43.3 - 54.4 lbf ft)

PC300LC/HD-8 50-84 B
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
• Tighten the mounting bolts for the boom Hi check valve, quick return valve, lock valve and arm plate in the same
sequence as that for the control valve cover mounting bolts.

Boom Hi check valve mounting bolt: 58.8 - 73.8 Nm (43.3 - 54.4 lbf ft)

Mounting bolt for quick return valve, lock valve and arm plate: 58.8 – 73.8 Nm (43.3 - 54.4 lbf ft)

• Pressure compensation valve.

★ Install each pressure compensation valve, paying attention to the counter mark that was put when removing it.
Main relief valve assembly

Assemble the main relief valve assembly with the control valve and install them to the machine. Then, test and adjust the main
relief pressure. For details, see Testing and adjusting, “Testing and adjusting oil pressure in work equipment, swing, and travel
circuit”.

50-85 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP

Removal

WARNING! Disconnect the cable from the negative

(–) terminal of the battery.

WARNING! Lower the work equipment to the ground

and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.

★ Attach an identification tag to each piping to avoid a mistake in the

position of installation later.

1. Remove the hydraulic tank strainer and stop the flow of oil using
tool C.
★ When not using tool C, remove the drain plug to drain oil from
the hydraulic tank and piping.

Hydraulic tank: 248 L (65.5 gal)

2. Drain oil from the damper case.

Damper case: 1.07 L (0.282 gal)

3. Open cover (1) and remove covers (2) - (4).

4. Remove cover (5).

5. Remove covers (6) and (7).

PC300LC/HD-8 50-86 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
6. Disconnect the pump wiring connectors at the following two
locations.
• (8): V19 (LS-EPC solenoid valve)
• (9): V11 (PC-EPC solenoid valve)

7. Disconnect 8 hoses and a tube.

• (12): Drain port hose
• (13): Front load pressure input port hose
• (14): Front load pressure input port hose (Color band: Red)
• (15): EPC source pressure port hose (Color band: Yellow)
• (16): Rear pressure input port hose (Color band: Yellow)
• (17): Front pressure input port hose
• (18): Rear pump delivery port hose
• (19): Front pump delivery port hose
• (20): Pump suction port tube

8. Remove muffler drain tube (21).

9. Disconnect wiring clamp (22) at two locations.

10. Remove muffler clamp (23) and two U-bolts (24) to remove muffler
(25).

11. Remove muffler bracket (26).

12. Lift and remove hydraulic pump assembly (27). [*1]

Hydraulic pump assembly: 220 kg (485 lb)

50-87 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
Installation
• Installation is done in the reverse order of removal.
[*1]

Hydraulic pump involute spline: Molybdenum disulfide grease (LM-G)

Mating face of hydraulic pump case: Gasket sealant (LG-6)

• Refilling with oil (damper case).

Refill hydraulic oil through the oil filler port to the specified level.

Damper case: 1.07 L (0.282 gal)

• Refilling with oil (hydraulic tank).

Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.

Hydraulic tank: 248 L (65.5 gal)

• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see Testing and adjusting,
“Bleeding air from various parts”.

Oil Seal In Hydraulic Pump Input Shaft

Removal

1. Remove the hydraulic pump assembly. For details, see “Removal

and installation of hydraulic pump”.

2. Remove snap ring (1) and then remove spacer (2).

3. Pry off oil seal (3) with a screwdriver. [*1]

★ Take care in removing the oil seal so that the shaft may not be
damaged.
Installation
• Installation is done in the reverse order of removal.
[*1]

Oil seal lip portion and outer circumference:

Grease (G2-LI)

★ Coat the oil seal outer circumference thinly with grease.

★ Press-fit oil seal (3), using tool [1].

PC300LC/HD-8 50-88 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE
12
WORK EQUIPMENT PPC VALVE

Disassembly
★ Disassemble according to the following figure.
Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below.
• Work equipment PPC valve reassembly.
★ When assembling spring (11), be sure to face its smaller end turn
(inner diameter) side toward shim (12).
★ Springs (10) in use differ in the number of turns according to
hydraulic ports as classified in the table below. Hence take care when
installing one.
★ The location of each port is stamped in the lower part of the valve
body.
Port position Spring free length
P1 and P2 44.45 mm
P3 and P4 42.48 mm

★ When assembling piston (8), coat the piston outer periphery and
body hole inner periphery with grease.

Piston body: Grease (G2-LI)

★ Tighten plate (15) with the following torque.

Mounting bolt: 11.8 - 14.7 Nm (8.7 - 10.8 lbf ft)

★ When installing joint (4), apply a drop (0.02 g) of adhesive each to 2

places of the female threads of its body.

Body female screw: Adhesive (Loctite No. 262)

Joint (4): 39 - 49 Nm (28.7 - 36.1 lbf ft)

Joint (4) sliding part: Grease 2 – 4 cc (G2-LI)

★ Apply grease to the mating faces of piston (8) and disc (2).

Contact surface of piston and disc (2): Grease 0.3 - 0.8 cc (G2-LI)

★ Tighten nut (1) to the following torque.

Nut (1): 98 - 127 Nm (72.2 - 93.6 lbf ft)

★ After installing the disc, adjust the play of the lever. For details, see Testing and adjusting, “Adjusting play of work equip-
ment and swing PPC valve”.

50-89 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE

TRAVEL PPC VALVE

Disassembly
★ Disassemble according to the following figure.

Assembly
★ Assemble according to the following figure.
★ Only the precautions for assembly are described below
★ Clean and check the parts so that they are free of dirt, rust, flaws, etc.
and then assemble them with extreme care.
★ When installing piston (1), apply grease (G2- LI) to its outside and
the inside of the hole of the body.
★ Install spring (2) with the small diameter seat end on shim (3) side.
Seat diameters of spring (inside diameter)
Small diameter end: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9 mm
Large diameter end: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.55 mm

★ Do not drive in bushing (4) and pin (5) directly with a hammer, etc.
Use follwing pin and bushing tools to insert the pins anbushings.

PC300LC/HD-8 50-90 B
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE

★ Apply grease (G2-LI) to the sliding parts of shaft (6), contact parts of
lever (7) and piston (1), and pin contact parts of plate (8) and lever
(9).

Quantity of grease
Sliding parts of shaft (6): 6 - 8 cc/all periphery
Contact parts of lever (7) and piston (1): 0.3 - 0.8 cc/
part
Pin contact parts of plate (8) and lever (9): 0.3 - 0.8 cc/
part

★ After washer (10) (t = 1.6) is installed, if the difference between the

strokes of the right and left levers is larger than 0.7°, replace the
washer to reduce the difference to 0.7° or less.
(If the washer thickness is reduced by 0.3 mm, the stroke angle is
increased by 0.39°.)
Set washer thickness (t) = . . . . . . . . . . . . . . . . . .1.0, 1.3, 1.6 mm
★ Tighten the parts according to the following torque.

Plug (11): 6 - 11 Nm (4.4 - 8.1 lbf ft)

Bolt (12): 3.9 - 4.9 Nm (2.8 - 3.6 lbf ft)
(Apply LOCTITE #262)
Screw (13): 7.8 - 9.8 Nm (5.7 - 7.2 lbf ft)
Plug (14): 4 - 9 Nm (3.6 - 6.6 lbf ft)
Bolt (15): 25 - 31 Nm (18.4 - 22.8 lbf ft)
Bolt (16): 27 - 34 Nm (19.9 - 25.0 lbf ft)

50-91 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER

Disassembly
1. Piston rod assembly

A. Remove piping from the cylinder assembly.

B. Remove the mounting bolts and then disconnect head assembly

(1).

C. Pull out piston rod assembly (2).

★ Place a container under the cylinder to catch the oil.

D. Disassemble the piston rod assembly as follows.

i. Set piston rod assembly (2) on tool N1.

ii. Remove stopper screw (3) of piston assembly.

★ Common to the boom, arm and bucket cylinder.
Screw size:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 × Pitch 1.75

★ If the staking of screw (3) is too strong and it cannot be removed,

tighten the screw fully, then fit a tap to the thread and remove the
screw.

PC300LC/HD-8 50-92 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
iii. Use tool N2 to remove piston assembly (4).
• When not using tool N2, use the drill holes (∅10 at 4
locations) to loosen the piston assembly.

iv. Remove plunger.

• Boom and arm cylinder only.

v. Remove collar (6).

• Boom and arm cylinder only.

vi. Remove head assembly (7).

vii. Remove cap (8), pull 12 balls (9) and then remove plunger
(10).
• Arm cylinder only.

2. Disassembly of piston assembly.

A. Remove ring (11).

B. Remove wear ring (12).

C. Remove piston ring (13).

D. Remove O-ring and backup ring (14).

50-93 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3. Disassembly of cylinder head assembly.

A. Remove O-ring and backup ring (15).

B. Remove snap ring (16) and then remove dust seal (17).

C. Remove rod packing (18).

D. Remove buffer ring (19).

E. Remove busing (20).

Assembly
★ Be careful not to damage the packing, dust seal and O-ring.
★ Clean each part, then cover the piping ports and pin-inserting hole to
prevent dust from entering them.
★ Do not try to force the backup ring into position. Warm it in warm
water 50 - 60°C (122 - 140°F) before installing it.

1. Recoil spring assembly.

A. Press-fit oil seal (20), using tool N5.

B. Assemble buffer ring (19).

C. Assemble rod packing (18).

D. Using tool N6, install dust seal (17) and then secure it with snap
ring (16).

E. Install backup ring and O-ring (15).

2. Piston assembly.

A. Press-fit oil seal (13), using tool N3.

★ Set the piston ring on tool N3, and turn the handle 8 - 10
times to expand the ring.

B. Tighten piston ring (13) by setting tool N4.

PC300LC/HD-8 50-94 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
C. Install backup ring and O-ring (14).

D. Assemble wear ring (12).

E. Assemble ring (11).

★ Be careful not to open the end gap of the ring too wide.

Ring groove: Grease (G2-LI)

3. Piston rod assembly.

A. Set piston rod assembly (2) on tool.

B. Assemble head assembly (7).

C. Assemble collar (6) after installing O-ring and backup ring to it.
• Boom and arm cylinder only

D. Assemble plunger (5).

• Boom and arm cylinder only.

E. Set plunger (10) on the piston rod, assemble 12 balls (9) to it and
secure with cap (8).
★ Check that there is a small amount of play at the tip of the
plunger.
• Arm cylinder only.

50-95 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
F. Assemble piston assembly (4) as follows.
• When using rod and piston assembly (2) again
★ Wash thoroughly to eliminate metal particles and dirt.

i. Screw in piston assembly (4), then using tool N2, tighten

piston assembly (2) until the position of the screw thread
hole matches.
★ Remove all burrs and flashes using a file.

ii. Tighten screw (3).

Screw thread: Loctite No.262

Screw: 58.9 - 73.6 Nm (43.4 - 54.2 lbf ft)

iii. Stake 4 places of threaded part (a) with a punch.

• When the rod and/or piston assembly (2) is a new part.

★ For the rod with bottom cushion, mark the cushion plug
position on the end of the rod.
• Arm cylinder only.

i. Screw in piston assembly (4) until rod (2) is contacted

against end face (b) and then tighten the assembly using the
tool.

Piston assembly: 294 ± 29.4 Nm (216.8 ± 21.6 lbf ft)

★ After tightening the piston, check that there is play in

plunger (5).

PC300LC/HD-8 50-96 B
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12 • Boom and arm cylinder only.

ii. Machine one of the holes used to install screw (3).

★ Using a drill, level off V-groove between piston (4) and rod
(3).
★ Machining of the cylinder with bottom cushion (arm
cylinder) must not be done at the cushion plug position.
• Screw machining dimension (mm).

Prepared hole Depth of prepared Tap used Tapping depth

drilling diameter hole
10.3 27 12 x 1.75 20

iii. After machining, wash thoroughly to eliminate metal particles and dust.

iv. Tighten screw (3).

Screw: 58.9 - 73.6 Nm (43.4 - 54.2 lbf ft)

v. Stake thread at 4 places using a punch.

G. Assemble piston rod assembly (2).

★ Set the ring end gap (C) horizontally (sideways), and then
insert it aligning the axial center of cylinder tube.
★ After inserting, make sure that the ring is not broken and is
present in its place. Then push in the assembly fully.

H. Tighten head assembly (1) with mounting bolts.

Mounting bolt:

Cylinder name Torque

Bucket 373 ± 54 Nm (275 ± 39.8 lbf ft)

Arm 490 ± 49 Nm (361 ± 36.1 lbf ft)

Boom 373 ± 54 Nm (275 ± 39.8 lbf ft)

I. Install piping.

50-97 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT

Removal

WARNING! Extend the arm and bucket fully. Lower

the work equipment to the ground and set
the work equipment lock lever to the lock
position.

WARNING! Release the residual pressure. For

details, see Testing and adjusting,
“Releasing residual pressure from
hydraulic circuit”.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2), and remove lock bolt and nut (3).
[*1]

3. Remove plate (4), then remove head pin (5).[*2]

★ Check the number as well as locations of the shims used.

4. Start the engine and then retract the piston rod.

★ Fasten the piston rod with wire and place it on the stand so that
it may not slip out, or place a support to prevent the cylinder
from hanging toward the bottom.
★ In the latter case, remove the bottom side grease nipple.
★ Remove the boom cylinder on the other side in the same
manner.
★ When the work equipment assembly is lifted up, if the sling
touches the working lamp, remove the working lamp.

5. Disconnect intermediate connector A42 (6) for the working lamp.

6. Disconnect 3 arm cylinder hoses (7) and 2 bucket cylinder hoses (8).
★ Apply the oil restraining plug and then fix the hoses to the valve
side by use of ropes.

7. Lift the work equipment, and then remove plate (9).

8. Using tool P, remove foot pin (10). [*3]

★ Check the number as well as locations of the shims used.

PC300LC/HD-8 50-98 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
9. Remove work assembly (11).

Work equipment assembly: 5,800 kg (12,787 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]
★ When tightening the locknut, make sure that 0.5 - 1.5 mm clearance
(a) is maintained between the plate and nut after the tightening.

[*2]

Inside surface of bushing when assembling pin:

Anti-friction agent (LM-P)

Fill with grease after assembling pin: Grease (LM-G)

WARNING! When aligning the position of the pin hole,

never insert your fingers into the pin hole.

★ Adjust the clearance (b) between cylinder rod (12) and plate (4) to
1.5 mm or less using shims.
Thickness of standard shim: . . . . . . . . . . . . . . . . 1.0 and 2.0 mm

50-99 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
[*3]

Inside surface of bushing when assembling pin:

Anti-friction agent (LM-P)

Fill with grease after assembling pin: Grease (LM-G)

★ Adjust the clearance (c) between the foot's end face of boom (13)
and bracket (14) to 1 mm or less by use of shims.
Thickness of standard shim: . . . . . . . . . 2.0, 2.5, 3.0 and 3.5 mm
• Air bleeding.
Bleed the air from the circuit between the valve and the hydraulic
cylinder. For details, see Testing and adjusting, “Bleeding air from various parts”.
• Refilling with oil (hydraulic tank).
Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.

PC300LC/HD-8 50-100 B
DISASSEMBLY AND ASSEMBLY CAB
12
CAB

Removal

WARNING! Disconnect the negative terminal (–) of

the battery before starting the work.

1. Remove front window (1).

2. Remove step plate (2).

3. Remove floor mat (3).

4. Refer to “Removal and installation of monitor assembly”, and

remove monitor assembly (4).

5. Remove covers (5) and (6).

6. Remove cover duct assembly (7).

7. Insert key (8), turn it right, and open the outside-air filter cover.

8. Remove outside-air filter (9).

9. Remove rear covers (10) to (13).

10. Remove duct (14).

11. Remove cover (15).

★ Disconnect connector H15 fixed on the back from the clip.

12. Remove plate (16).

50-101 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
13. Remove plate (17).

14. Remove lock pin (18) and remove duct (19).

15. Remove duct (20).

16. Disconnect connector (21).

17. Remove plates (22) and (23) from the cab.

18. Pass over and disconnect antenna (24) from KOMTRAX

communication modem.

19. Disconnect connectors K01(25) and CK02 (26).

20. Disconnect connector M10(27) from the cab. (If equipped)

21. Disconnect cab wiring intermediate connectors H09(28), H08(29),

and H16(30).
★ Cut tie-wrap (T).

22. Disconnect radio antenna (31).

★ (23) is removed plate.

23. Remove ducts (32) and (33).

★ Cut tie-wrap.

24. Disconnect wiper motor connector M05(34).

25. Remove harness (35) and antenna (36) from the cab wall.
★ Cut 2 points of tie-wrap.

PC300LC/HD-8 50-102 B
DISASSEMBLY AND ASSEMBLY CAB
26. Remove duct (37).

27. Remove duct (38) upper and lower.

28. Disconnect window washer hose (39).

29. Disconnect harness clamp (40).

30. Haul in antenna (36).

31. Detach harness clamp (41) from the right back side of cab.

32. Remove bolt (42) under the cab and remove lock plate (43). [*1]

33. Remove bolt (44). [*2]

50-103 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
34. Dismount 6 mounting bolts (45) and 4 mounting nuts (46).
★ Check the bolt length beforehand.

35. Lift off and remove cab assembly (47).

Cab assembly: 470 kg (1,037 lb)

Installation
• Installation is done in the reverse order of removal.
[*1]

Mounting bolt of lock plate (43):

98 - 123 Nm (72.2 - 90.7 lbf ft)

[*2]

Bolt (44): 245 - 309 Nm (180.7 - 227.9 lbf ft)

PC300LC/HD-8 50-104 B
DISASSEMBLY AND ASSEMBLY CAB
12
Cab Glass (Stuck Glass)

5. Front window assembly (Front window glass + Front

1. Right side window glass
frame)

2. Left side rear window glass 6. Dam rubber

3. Door lower window glass 17. Center trim seal

4. Front window glass 18. Rear glass

★ Among the panes of window glass on the 4 sides of the cab, 5 panes (1) to (4) and (18) are stuck.
★ In this section, the procedure for replacing the stuck glasses is explained.
★ When replacing front window glass (4), remove front window assembly (5). (It is impossible to replace only the front
window glass while the front window assembly is installed to the cab.)
★ For the procedure for replacing the front window assembly, see “Removal and installation of front window assembly”.

50-105 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Removal
★ Remove the window glass to be replaced according to the following
procedure.

1. Using seal cutter [1], cut the adhesive between broken window glass
(7) and cab (metal sheet)(8).

(The figure shows the cab of a wheel loader.)

★ If a seal cutter is not available, make holes on the adhesive and
dam rubber with a drill and pass a fine wire (piano wire, etc.) [2]
through the holes. Then, grip the both ends of the wire with
plyers [3], etc. (or hold them by winding them onto something)
and move the wire to the right and left to cut the adhesive and
dam rubber. Since the wire may break by the frictional heat,
apply lubricant to the wire.

(The figure shows the cab of a wheel loader.)

★ If the window glass is broken finely, it may be removed with a
knife [4] and a screwdriver.
★ Widening the cut with a flat blade screwdriver, cut the dam
rubber and adhesive with knife [4].

2. Remove the window glass.

PC300LC/HD-8 50-106 B
DISASSEMBLY AND ASSEMBLY CAB
12
Installation

1. Using a knife and scraper [5], remove the remaining adhesive and
dam rubber from the metal sheets (glass sticking surfaces) of the cab.
★ Remove the adhesive and dam rubber to a degree that they will
not affect adhesion of the new adhesive. Take care not to scratch
the painted surfaces.
(If the painted surfaces are scratched, adhesion will be lowered.)
(The figure shows the cab of a wheel loader.)

2. Remove oil, dust, and dirt, etc. form the sticking surfaces of cab (8)
and window glass (9) with white gasoline.
★ If the sticking surfaces are not cleaned well, the glass may not
be stick correctly.
★ Clean the all black part on the back side of the window glass.
★ After cleaning the sticking surfaces, leave them for at least 5
minutes to dry.
(The figure shows the cab of a wheel loader.)

3. Apply primer (10).

★ The maximum age of primer is 4 months after the date of
manufacture. Do not use the primer after this limit.
★ Use the primer within 2 hours after unpacking it.
★ Even if the primer is packed again just after it is unpacked, use it
within 24 hours after it is unpacked for the first time.
(Discard the primer 24 hours after it is unpacked.)

A. Stir the primers for both of paint and glass sufficiently before
using them.
★ If the primer has been stored in a refrigerator, leave it at the
room temperature for at least half a day before stirring it.
(If the primer is unpacked just after taken out of the
refrigerator, water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient
time.)

B. When reusing primer brush (11), wash it in white gasoline.

★ After washing the brush, check it again for dirt and foreign matter.
★ Prepare respective brushes for the paint primer and glass primer.

50-107 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
C. Evenly apply the paint primer to the surfaces to stick dam rubber
to on cab (8).

Paint primer: Sunstar primer for painting plane 580

super or equivalent

★ Do not apply the primer more than 2 times.

(If it is applied more than 2 times, its performance will be
lowered.)

★ Parts to be coated with primer; Apply the primer all over

dimension (a).
Dimension to apply primer (a): . . . . . . . . . . . . . . . . . . . . . . 25 mm

★ In addition to the above parts, additionally apply the primer

to right side window glass (1) and door lower window glass
(3).
Range to apply primer additionally for right side window glass (1):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (b)
Range to apply primer additionally for door lower window glass (3):
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (c)
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.

PC300LC/HD-8 50-108 B
DISASSEMBLY AND ASSEMBLY CAB
★ Never apply the wrong primer.
If the glass primer, etc. is applied by mistake, wipe it off
with white gasoline.

D. Apply the glass primer to the sticking surfaces of window glass

(9).

Glass primer: Sunstar primer for glass 580 super or

equivalent

★ Do not apply the primer more than 2 times.

(If it is applied more than 2 times, its performance will be
lowered.)
★ Parts to be coated with primer; Apply the primer to all
around of sticking surface (d) of window glass (9) for dam
rubber (6) installation position and cab (8).
★ Leave a 5 mm border between the black and transparent
area of the glass.
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
★ Never apply the wrong primer.
If the paint primer, etc. is applied by mistake, wipe it off
with white gasoline.

4. Stick dam rubber (both-sided adhesive tape)(6) along the inside edge
of the glass sticking section.
★ Do not remove the release tape of dam rubber on the glass
sticking side before sticking the glass.
★ When sticking the dam rubber, do not touch the cleaned surface.
★ Care should be taken not to float the dam rubber of each sticking
corner.

★ When sticking dam rubber (6) around a frame, leave a 5 mm gap

between the finished end and the starting end (e).

A. Stick dam rubber (6) for right side window glass (1) to the
position as shown in the figure.

50-109 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
★ Stick dam rubber (6a) additionally to right side window
glass (1).
• Positions to stick additional dam rubber to the right side
window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm

B. Stick dam rubber (6) for left side window glass (2) to the
position as shown in the figure.

C. Stick dam rubber (6) for door lower window glass (3) to the
position as shown in the figure.

★ Stick dam rubber (6b) additionally to door lower window

glass (3).
• Positions to stick additional dam rubber to the door lower
window class:
(j) : 110 mm
(k) : 90 mm
(m) : 200 mm

PC300LC/HD-8 50-110 B
DISASSEMBLY AND ASSEMBLY CAB
D. Stick dam rubber (6) for front window glass (4) to the position
as shown in the figure.

★ Stick dam rubber (6c) of the lower side of the front window
glass along the outside edge of the lower line, differently
from other dam rubbers (6). (If it is stuck along the inside, it
will be seen through the transparent part of the glass.)

5. Position the new window glass.

A. Check the clearance between the window glass and the cab on
the right, left, upper, and lower sides, and then position the
window glass to be the clearances evenly.

B. Stick tapes [6] between window glass (9) and cab (8) and draw
positioning line (n).
★ Stick tapes [6] for positioning to 3 points, that is, right, left
and lower parts of the right side window glass, left side rear
window glass, and door lower window glass for accurate
positioning.

C. Cut the tape between window glass (9) and cab (8) with a knife,
etc. and then remove the window glass.
★ Do not remove the tapes left on the window glass and the
cab before installing the window glass.

50-111 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12 ★ When positioning front window glass (4), set its horizontal
position to the frame width.
And set its vertical position to make the height difference
(p) between the frame top and the front window glass 3
mm.

6. Apply adhesive.
★ Use either of two types of adhesives according to the season.

Adhesive (Apr. to Oct.):

Sunstar penguine seal 580 super “S” or equivalent

Adhesive (Oct. to Apr.):

Sunstar penguine seal 580 super “W” or equivalent

★ The maximum age of the adhesive is 4 months after the date of

manufacture. Do not use the adhesive after this limit.
★ Keep the adhesive in a dark place where the temperature is
below 25°C (77°F).
★ Never heat the adhesive higher than 30°C (86°F).
★ When reusing the adhesive, remove the all hardened part form the nozzle tip.

A. Break aluminum seal (13) of the outlet of adhesive cartridge (12) and install the nozzle.

B. Cut the tip of the adhesive nozzle (14) so that dimensions (q)
and (r) will be as follows.
Dimension (q): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm
Dimension (r): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm

PC300LC/HD-8 50-112 B
DISASSEMBLY AND ASSEMBLY CAB
C. Set adhesive cartridge (12) to caulking gun [7].
★ An electric caulking gun is more efficient.

D. Remove the release tape of dam rubber on the glass adhesive

side.

E. Apply adhesive (15) to the outside of dam rubber (6) of the cab.

★ Apply adhesive (15) with dimensions (s) and (t) for dam
rubber (6) of cab (8).
Dimension (s): 10 mm
Dimension (t): 15 mm
★ Apply adhesive (15) higher than dam rubber (6).
★ Apply the adhesive evenly with same height level.

50-113 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12 ★ Apply adhesive (15) additionally to additional dam rubber
(6a) of right side window glass and additional dam rubber
(6b) of door lower window glass.

7. Install the window glass.

A. Install window glass (9), matching it to the lines of the

positioning tapes drawn in step E.
★ Since the window glass cannot be removed and stuck again,
stick it with utmost caution.
★ Stick the glass within 5 minutes after applying the adhesive.

B. After sticking window glass (9), press all the way around until it
sticks to the dam rubber.
★ Press the corners of the window glass firmly.

★ You can perform this work efficiently by pulling window

glass (9) from inside of the cab with suction cup X2.

PC300LC/HD-8 50-114 B
DISASSEMBLY AND ASSEMBLY CAB
★ After installing front window glass (4), fill the clearances
between it and center trim seal (16) with caulking material
in range (s) with dimensions (t) and (u).
After applying the primer to glass (4) of section A-A, apply
the adhesive as caulking material.
Caulking dimension (t): 2 mm
Caulking dimension (u): 5 mm
★ When caulking, mask the glass side and form the adhesive
with a rubber spatula as shown in the figure.
★ Wipe off the projected adhesive.

Glass primer:
Sunstar primer for glass 580 super or equivalent

Adhesive:
SUNSTAR penguine seal 580 super “S” or “W” or
equivalent

8. Fix the window glass.

A. After installing right window glass (1) to the cab, insert stopper
rubbers X3 to 2 places (v) at the bottom of the glass to fix the
glass.

50-115 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
B. By using styrene foam blocks [9] and rubber bands [10], fix the
window glass and the dam rubber to fit them completely.

9. After installing the window glass, remove any excess of the primer
and adhesive from the cab and window glass.
★ By using the white gasoline, wipe off the adhesive before it is
dried up.
★ When cleaning the glass, do not give an impact on it.

10. Protect the stuck window glass.

A. Keep the stopper rubbers, styrene foam blocks, and rubber

bands installed for 10 hours. (at temperature of 20°C (68°F) and
humidity of 60%)

B. After removing the stopper rubbers, styrene foam blokes, and rubber bands, wait at least 14 hours, that is, at least 24
hours in total, before operating the machine actually.

PC300LC/HD-8 50-116 B
DISASSEMBLY AND ASSEMBLY CAB
12
Front Window

WARNING! Lower the work equipment completely to

the ground and stop the engine.

★ To replace the front window glass, the front window assembly must
be removed from the cab. The procedure for removing and installing
the front window assembly (front frame and front window glass) is
explained below.

Removal

1. Raise the front window assembly to the ceiling and fix it with the
rear locks (on both sides).

2. Remove left corner block (1) and right corner block (2). [*1]
★ Mounting bolt (4) and washer (3) for left corner block are used
to hang the pull-up assist cable in the following step 6.

3. Release the rear lock of the cab.

4. Lower the front window assembly carefully. Put rollers (5) and (6)
under both sides of the front window through the
portion from which the corner blocks were removed in the above
step 2. (the portion where the rail is open) and hold them.

5. Remove rollers (5) and (6) under the both sides of the front window.

6. Remove left lower pin (7). [*2]

★ By removing left lower pin (7), plate (8) at the end of pull-up
assist cable (9) comes off.
★ Hang plate (8) on the mounting bolt of left corner block (use
washer) and set in place.

WARNING! The return load of 58.8 N {6 kg} is applied

to the rear of the cab. Accordingly, take
care when removing left lower pin (7) to
disconnect pull-up assist cable (9).

50-117 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12

7. Pull out the bottom of front window assembly (10) though the rail
opening portion and lower it gradually.

8. Lower front window assembly (10) completely.

★ Do not let the front window assembly touch the monitor.

PC300LC/HD-8 50-118 B
DISASSEMBLY AND ASSEMBLY CAB
12
9. Twist front window assembly (10) to the right and left to remove
both upper rollers (11) and (12) from the rails, and then remove front
window assembly (10).

50-119 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
Installation
• Carry out installation in the reverse order to removal.
[*1]
• Adjust opening and closing of the front window assembly according
to the following procedure.

1. Open and close the front window to check that it does not interfere
with the rails and that the rollers are not hitched.

2. If there is any problem in opening and closing of the front window,

loosen the mounting bolt of roller adjustment bracket (13) and adjust
the condition of the front window, and then tighten the mounting bolt
again.
★ Make sure that bracket (13) is not mounted on the angle.

Mounting bolt: 34.3 Nm (25.2 lbf ft)

3. Raise the front window assembly and fix it with the rear locks (on
both sides).
★ Check that the locks in the rear of the cab are securely fastened.

4. Install right corner block (2).

★ Fully tighten the block after adjusting the “Close” position in the
following step 6.
★ Install the right corner block so that clearance (a) between the
rail and right corner block (2) becomes 0 - 2.0 mm.
★ Install the right corner block so that there is no level difference
at the rolling surface (R) of the roller.

PC300LC/HD-8 50-120 B
DISASSEMBLY AND ASSEMBLY CAB
5. Install left corner block (1).
★ Fully tighten the block after adjusting the “Close” position in the
following step 6.
★ Install the left corner block so that clearance (b) between the rail
and left corner block (1) becomes 0 - 2.0 mm.
★ Install the left corner block so that there is no level difference at
the rolling surface (R) of the roller.

6. Adjust the “Close” position of the front window assembly lock

according to the following procedure.

A. Tighten left and right corner blocks (1) and (2) at roughly right
positions so that front window glass (14) is attached firmly to
cab-side trim seal (15).

B. Check the working condition of right and left locks (16) and
(17) when opening and closing the front window assembly.
• If right and left locks (16) and (17) do not work normally.

i. Loosen lock fitting bolt (18), move lock (16) forward, and
then tighten the bolt again.
★ The same applies to the right side.

ii. After moving the lock, recheck the fit of front window glass
(14) and cab-side trim seal (15) which was checked in step
i.

iii. Repeat the work in i and ii until the fit of the front window
glass and the working condition of locks (16) and (17) are
both acceptable, and then tighten the mounting bolts of the
right and left corner blocks.

7. After the adjustment, splash water over the front window glass and
check that the water does not leak into the cab.

50-121 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
12
8. Adjust the “Open” position of the front window assembly lock.

A. After adjusting the “Close” position of the front window

assembly lock in steps 6 and 7, raise the front window assembly
to the ceiling.

B. Set the front window assembly locks at the both sides of rear of
the cab to the “Open” position, and then check the following
items.
• Check the working condition of right and left locks (16) and
(17) (as explained above).
• Front window assembly must be in contact with the right
and left rubber stoppers (18) and furthermore, must be
pushing them backward for 1.5 - 3.0 mm.
• The front window assembly must be pushing the limit switch backward for 4 - 7 mm.
★ The position of limit switch (19) cannot be adjusted. Therefore, the “Open” position of the front window
assembly is decided within the range where this switch works.
★ Limit switch (19) is used to prevent the windshield wiper from moving when turning the wiper switch on by
mistake when the front window assembly is in “Open” position. If the wiper operates when there is no glass in
the front, the wiper falls down inside the cab and causes trouble. To check whether limit switch (19) is working,
turn the key switch on and see that, even if the wiper switch is turned on, the wiper does not operate when the
front window assembly is in “Open” position.
• After checking the above items, adjust if necessary.

C. Close front window assembly (10).

D. Loosen locknut (20) of right and left side of rubber stoppers

(18), and then pull back both rubber stoppers (18) so that they
won't contact with the front window assembly when it is in
“Open” position.

E. Loosen both sides of locknuts (22), and adjust the position of

striker bolt (21).
Striker bolt (21): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10
Inner diameter of plate (23):. . . . . . . . . . . . . . . . . . . . . ø 14.5 mm

PC300LC/HD-8 50-122 B
DISASSEMBLY AND ASSEMBLY CAB
i. Front window assembly (10) must be pushing the limit
switch backward for 4 - 7 mm (at “Open” position).

ii. Working condition of lock (17).

F. Adjustment of right and left rubber stoppers (18).

i. Bring front window assembly (10) (the lock should be in

“Open” position) into contact with right and left rubber
stoppers (18).

ii. Close front window assembly (10).

iii. Turn right and left rubber stoppers (18) to the left for one
and a half rotations.
★ One turn of rubber stopper (18) to the left is equivalent
to squashing the rubber for approximately 1.5 mm.
★ When the front window assembly is in “Open” position,
the front window assembly must be pushing right and
left rubber stoppers (18) 1.5 - 3.0 mm.

iv. Tighten locknuts (20) of the both sides of rubber stopper

(18).

50-123 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
9. Adjust stopper (24) of the front window assembly.

A. Adjust and lock both sides of stopper (24) so that when pulling
up the front window assembly, surface (d) of stopper (D) of
front window assembly (10) is in contact with surface (c) of
stopper (24).

10. Check the operating effort of the lock of the front window assembly.

A. After finishing the adjustment of steps 6 - 9, check that latching

efforts of both right and left locks (16) and (17) are even.
★ Check the latching efforts on both “Close” side (in the front
of the cab) and “Open” side (in the rear of the cab).
[*2]

Left lower pin: 27 - 34 Nm (19.9 - 25.0 lbf ft)

Mounting bolt: Adhesive (LT-2)

PC300LC/HD-8 50-124 B
DISASSEMBLY AND ASSEMBLY CAB
12
Floor Frame
Removal
WARNING! Disconnect the negative terminal (–) of the battery before starting the work.

WARNING! In the case that you do not drain the coolant, if you disconnect the heater hose when the
coolant temperature in the radiator is high, you may be scalded. In this case, wait until
the coolant temperature lowers and then disconnect the heater hose.

WARNING! Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance.

★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on
protective goggles while you are collecting the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant (R134a). Collecting and filling work must be
conducted by a qualified person.

1. Turn the upper structure by 90°.

2. Drain the engine coolant.

Coolant: 36 L (9.5 gal)

3. Remove the cab assembly by referring to “Removal and installation

of cab assembly”.

4. Remove cover (1).

5. Disconnect ground (2).

50-125 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
6. Disconnect the following PPC hoses from the travel PPC valve. The
color of the band is;
• (3): Red
• (4): No color
• (5): Green
• (6): Blue
★ Prepare an oil sump.

7. Disconnect top and bottom of connector (7).

Top: P09
Bottom: P10

• Step 8 - 10 is optional (for breaker).

8. Disconnect the following PPC hoses from the PPC valve. The color
of the band is;
• (8): Yellow
• (9): No color
★ Plug the hose to stop oil flow-out.

9. Disconnect connectors S11 (10) and S10 (11).

10. Disconnect connectors P13 (12) and V30 (13).

11. Disconnect ground (14). From the left, T04, T05, T06, T07, T09,
T10.

12. Disconnect clamp (15).

13. Disconnect connector A08 (16) from the clip.

14. Disconnect connector P17 (17) from the air conditioner tube.

15. Remove the clamp and disconnect spacer (18).

16. Disconnect hose (19).

★ Mark the connecting point.
★ Plug the hose to stop oil flow-out.
★ Disconnect the work equipment PPC at joint box side. (See item 33.)

17. Disconnect hose (20).

★ Mark the connecting point.
★ Plug the hose to stop oil flow-out.

18. Disconnect heater hose (21).

★ Mark the connecting point.

19. Remove mounting bolt (22) and disconnect air conditioner tube (23).
[*1]

20. Remove clamps (24) and (25). [*2]

21. Disconnect clamp (26). (If equipped)

PC300LC/HD-8 50-126 B
DISASSEMBLY AND ASSEMBLY CAB
12
22. Disconnect connectors N10 (27) and AC01 (28).

23. Disconnect connectors ECU10 and ECU11 (29) from the air
conditioner controller (ACCONT).

24. Cut tie-wrap (30) and draw in wiring harness (31).

25. Disconnect the clamp of wiring harness (32).

26. Disconnect connector H15 (33).

27. Remove grommet (34).

28. Move wiring harness (35) to the outside of the floor frame.
★ (SP) is made of sponge.

29. Disconnect the clamp of wiring harness (35).

30. Move plates (36) and (37) together with wiring harness (35) to the
boom side.

31. Open the engine hood and remove cover (38).

50-127 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY CAB
32. Disconnect clamp (39).

33. Disconnect PPC hose (40) of the work equipment. From the top, the
color of the band is:
White
Brown
None
Blue
Black
Green
Red
Yellow
★ Prepare an oil sump.

34. Pull out PPC hose assembly (41) of the work equipment.

35. Sling floor frame assembly (42) and remove it.

★ Make sure that the hoses, connectors, clamps, etc. are
disconnected.

Floor frame assembly: 250 kg (552 lb)

PC300LC/HD-8 50-128 B
DISASSEMBLY AND ASSEMBLY CAB
12
Installation
• Installation is done in the reverse order of removal.
[*1]
★ When installing the air conditioner circuit hoses, take care so that dirt, water, may not enter.
★ Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose.
★ Check that there is no defect or deterioration on the O-ring.
★ When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: ND-
OIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)).

Mounting bolt: 8 - 12 Nm (5.9 - 8.8 lbf ft)

[*2]
★ Make sure that the hoses do not overlap.
• Fill air conditioner circuit with refrigerant (R134a).

Filling quantity: 870 ± 50 g

• Refilling with coolant.

Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.

Coolant: 36 L (9.5 gal)

50-129 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM

Air Conditioner Unit

Removal
WARNING! Disconnect the negative terminal (–) of the battery before starting the work.

WARNING! In the case that you do not drain the coolant, if you disconnect the heater hose when the
coolant temperature in the radiator is high, you may be scalded. In this case, wait until
the coolant temperature lowers and then disconnect the heater hose.

WARNING! Collect the air conditioner refrigerant (R134a) from air conditioner circuit in advance.

★ Never release the refrigerant (R134a) to the atmosphere.

WARNING! If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on
protective goggles while you are collecting the refrigerant (R134a) or filling the air condi-
tioner circuit with the refrigerant (R134a). Collecting and filling work must be conducted
by a qualified person.

1. Turn the upper structure by 90°.

2. Drain the engine coolant.

Coolant: 36 L (9.5 gal)

3. Remove front window (1).

4. Remove step plate (2).

5. Remove floor mat (3).

6. Remove covers (5) and (6).

7. Pull down opening and closing lever (8) of the outside air filter
cover.

8. Remove outside air filter (9).

PC300LC/HD-8 50-130 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
9. Remove rear covers (10) to (13).

10. Remove duct (14).

11. Remove cover (15).

★ Disconnect connector H15 fixed on the back from the clip.

12. Remove plate (16).

13. Remove plate (17).

14. Remove lock pin (18) and remove duct (19).

15. Remove ducts (20) and (21).

★ Cut tie-wrap.

50-131 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

16. Remove ducts (22) and (23).

★ Cut tie-wrap.

17. Remove duct (24) upper and lower.

18. Remove duct (25) upper and lower.

19. Disconnect plate (26) from the cab wall.

20. Disconnect connectors N10 (27) and AC01 (28).

21. Disconnect connectors ECU10 and ECU11 (29) from the air
conditioner controller (ACCONT).

22. Loosen tie-wrap (30) and draw in wiring harness (31).

23. Remove cover (32).

PC300LC/HD-8 50-132 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
24. Remove mounting bolt (33) and disconnect air conditioner tube (34).
[*1]

25. Disconnect heater hose (35).

★ Mark the connecting point.

26. Remove the 7 mounting bolts and air conditioner unit assembly (36).

Installation
• Installation is done in the reverse order of removal.
[*1]
★ When installing the air conditioner circuit hoses, take care so that dirt, water, may not enter.
★ Make sure before the installation that there is O-ring at the piping connector of the air conditioner hose.
★ Check that there is no defect or deterioration on the O-ring.
★ When connecting the refrigerant piping, coat the O-ring with compressor oil for new refrigerant (R134a) (Denso: ND-
OIL8, Zexcel: ZXL100PG (PAG 46 or equivalent)).

Mounting bolt: 8 - 12 Nm (5.9 - 8.8 lbf ft)

[*2]
★ Make sure that the hoses do not overlap.
• Fill air conditioner circuit with refrigerant (R134a).

Filling quantity: 870 ± 50 g

• Refilling with coolant.

Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.

Coolant: 36 L (9.5 gal)

50-133 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Komtrax Communication Modem
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.

1. Remove covers (1) - (4).

2. Twist antenna wire (5) to disconnect it.

3. Disconnect connectors K01(6) and CK02 (7).

4. Remove the 4 mounting bolts and KOMTRAX communication

modem assembly (8).

Installation
• Installation is done in the reverse order of removal.

PC300LC/HD-8 50-134 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Monitor
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.

1. Remove cap (1).

2. Remove cover (2) and then disconnect wiring connector P31 (3) for
air conditioner sunlight sensor (S).

3. Remove duct (4).

4. Remove cover (5) as follows. [*1]

A. Insert flat-head screwdriver inside slit (SL) and push it upward.

B. Release lock (L) and remove the cover.

C. Disconnect wiring connector M04 of the cigarette lighter from

the back of cover (5).

5. Remove the 4 mounting bolts and lift monitor assembly (6). [*2]

6. Disconnect connectors CM01 (7), CM02 (8) and CM03 (9).

★ Since CM02 (8) and CM03 (9) can be installed in reverse, be
careful to install correctly.
CM 03 (9) is a green connector.

7. In the case of rear camera specification, disconnect connector CN-5

(11).

8. Disconnect connector (10).

50-135 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM

Installation
[*1], [*2]

A. Temporarily install monitor assembly (6) with 4 mounting bolts, and then install cover (5).

B. With cover (5) installed, tighten the mounting bolts of monitor assembly.
• Carry out the rest of installation in the reverse order to removal.

PC300LC/HD-8 50-136 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Pump Controller
Removal
WARNING! Disconnect the negative terminal (–) of
the battery before starting the work.

1. Remove cover (1).

2. Disconnect relay R08 (4) from the clip.

3. Disconnect bracket (5) and put it to the right side.

4. Disconnect wiring connectors C01 (6) and C02 (7) as follows.

• Tilt lock (L12) inside while pressing lock (L1).
★ Bar (B) comes out and the lock is released.

5. Remove the 4 mounting bolts and pump controller assembly (8).

50-137 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Installation
• Installation is done in the reverse order of removal.
★ Reference

1. Procedure for removing connector cover (1).

A. Cut and remove cable tie (2).

B. Move lever (3) up.

C. Lightly push part (A) of connector cover (1) from both sides to
unfasten claw (B).

D. Remove connector cover (1) around claw (C).

★ Connector without connector cover (1)

2. Procedure for installing connector cover.

A. Push in right and left sliders (4) as far as possible.

PC300LC/HD-8 50-138 B
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
★ Right and left sliders (4) pushed in as far as possible (Left
figure)

B. Move lever (3) of connector cover (1) from the upper position to
the left position (lock position) in the figure.
★ (B), (C): Claws
★ If the sliders and lever are not set as shown in the following
figure, the connector is not disconnected or locked securely
with the lever. Accordingly, check their positions again.

C. Set claw (C) to the connector and place connector cover (1).
★ Take care that wiring harness (5) will not be caught.

D. Set claw (B) and install connector cover (1).

E. Bind connector cover (1) and wiring harness with a new cable
tie.

50-139 B PC300LC/HD-8
DISASSEMBLY AND ASSEMBLY ELECTRICAL SYSTEM
12
Engine Controller
Removal
WARNING! Disconnect the cable from the negative (–) terminal of the battery.

1. Open the engine hood.

2. Disconnect connectors EC01 (1), ENG (2), and CE03 (3).

3. Remove engine controller (4).

Installation
• Carry out installation in the reverse order to removal.

50-140 B PC300LC/HD-8
 90 OTHERS

HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5

PC300LC/HD-8 90-1
 Electrical
Electrical circuit diagram

PC300LC/HD-8 90-5
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